Page 2 A CAUTION indicates special precautions that NOTICE must be taken to avoid damage to the snowmo- This manual was written by the Yamaha Motor bile. Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible NOTE: to put an entire mechanic’s education into one...
Page 3 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 content. POWR 1 General information CHAS 2 Periodic inspections and adjustments 3 Chassis 4 Power train 5 Engine COOL 6 Cooling system...
Page 4 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTIONS AND INSP ADJUSTMENTS CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 5: Table Of Contents
... . . (SXV70SJ) ......
Page 6 DETONATION CONTROL SYSTEM (SXV70SJ) ......CIRCUIT DIAGRAM ....
Page 7: Periodic Inspections And Adjustments
Drive track and idler Check deflection, and for wear and damage. wheels *Adjust / replace if necessary. Check for wear and damage. Slide runners Slide runners *Replace if necessary. *It is recommended that these items be serviced by a Yamaha dealer. –1–...
Page 8 Tool kit and recom- Check for proper placement. mended equipment *It is recommended that these items be serviced by a Yamaha dealer. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required.
Page 9: Engine
INSP COOLING SYSTEM ENGINE COOLING SYSTEM Coolant replacement (VT70J) NOTE: The coolant should be changed at least every season. 1. Place the machine on a level surface. 2. Remove: S Exhaust pipe S Exhaust joint Refer to “EXHAUST ASSEMBLY” in CHAP- TER 5.
Page 10 INSP COOLING SYSTEM 5. Place an open container under the coolant drain bolt 1 . 6. Remove: S Coolant drain bolt S Gasket (coolant drain bolt) 7. Drain the coolant. NOTE: Lift up the tail of the machine to drain the cool- ant.
Page 11 High quality silicate – free ethylene glycol antifreeze containing corrosion inhibitors Coolant mixing ratio (coolant : water) 3 : 2 (60% : 40%) Total amount: SXV70SJ 4.7 L (4.14 Imp qt, 4.97 US qt) VT70J 5.0 L (4.40 Imp qt, 5.29 US qt) –5–...
Page 12 INSP COOLING SYSTEM CAUTION: S Hard water or salt water is harmful to en- gine parts. If soft water is not available, use boiled or distilled water. S Do not use water containing impurities or oil. 19. Bleed the air from the cooling system. 20.
Page 13: Throttle Cable Free Play Adjustment
COOLING SYSTEM/ INSP THROTTLE CABLE FREE PLAY ADJUSTMENT S Add coolant to the coolant cold level a . S Loosen the bleed bolt 2 . S Drain the coolant until no more air bubbles ap- pear. S Tighten the bleed bolt 2 . Bleed bolt: 3.5 Nm (0.35 mSkg, 2.5 ftSlb) S Install the coolant filler cap.
Page 14: Oil Pump Cable Adjustment
THROTTLE CABLE FREE PLAY ADJUSTMENT/ INSP OIL PUMP CABLE ADJUSTMENT 2. Adjust: S Throttle cable free play Adjustment steps: S Loosen the locknut 1 . S Turn the adjusting nut 2 in or out until the spe- cified free play is obtained. Turning in ! Free play is increased.
Page 15: 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.: S Be sure the parking brake is applied. S Be sure the throttle lever moves smoothly. S Do not run the engine up to the clutch en- gagement speed.
Page 16: Power Train
INSP BRAKE FLUID LEVEL INSPECTION POWER TRAIN BRAKE FLUID LEVEL INSPECTION 1. Place the machine on a level surface. 2. Check: S Fluid level Fluid level is under the “LOWER” level line a ! Fill to the proper level. Recommended brake fluid: DOT 4 NOTE: For a correct reading of the brake fluid level,...
Page 17: Chassis
Ski runner wear limit: 8 mm (0.31 in) Plastic ski wear limit: VT70J: 13 mm (0.51 in) SXV70SJ: 25 mm (0.98 in) CAUTION: To avoid scratching, wearing and damaging the plastic skis, be careful when loading and unloading the snowmobile and avoid riding...
Page 18: Tuning
INSP CLUTCH TUNING R Red CLUTCH W White High altitude Y Yellow Specifications Model: SXV70SJ X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft)
Page 19 INSP CLUTCH CLUTCH G Green High altitude L Blue P Pink Specifications Model: VT70J for U.S.A, CAN X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft)
Page 20 1.0 mm (0.04 in) NOTE: S Confer in Yamaha dealer when you use in more than 4,500 ft (1,400 m). S Do not use specification of VT70J (for U.S.A, CAN) when you use in more than 4,500 ft (1,400 m).
Page 21 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the de- sired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the en- gine speed at which the machine first begins to move from a complete stop.
Page 22: Gear Selection
19 teeth 8DW-17682-90 20 teeth 8DW-17682-00 VT70J (EUR) Drive sprocket Drive s rocket 21 teeth 8DW-17682-10 22 teeth 8DW-17682-20 SXV70SJ/VT70J (U.S.A, CAN) 23 teeth 8DW-17682-30 37 teeth 8DW-47587-70 38 teeth 8DW-47587-80 SXV70SJ Driven sprocket Driven s rocket 39 teeth 8FB-47587-90...
Page 23 INSP GEAR SELECTION 5 Torque cam (secondary spring seat) Identification mark Effects Part no. Cam angle Identification mark Standard Quicker upshifting 8BV-17604-71 8BV71 SXV70SJ during acceleration VT70J 8BV-17604-51 8BV51 (U.S.A, CAN) 8BV-17604-31 8BV31 8BV-17604-11 8BV11 Quicker backshifting 8BV-17604-91 8BV91 VT70J (EUR) under load –17–...
Page 24 6.0 (0.236) 60 (2.36) 4.82 86.7 (3.41) 90501-603L2 24.5 (2.50) 441 (45) Yellow-White-Yellow 6.0 (0.236) 60 (2.36) 5.39 91.4 (3.60) SXV70SJ 90501-603L3 27.0 (2.75) 441 (45) Green-White-Green 6.0 (0.236) 60 (2.36) 5.08 89.8 (3.54) 90501-624L8 31.9 (3.25) 343 (35) Orange-Silver-Orange 6.2 (0.244)
Page 25 Weight g (oz) Shape & ID mark Standard without bush and rivets 35.32 8CH-17605-10 (1.247) 38.09 8CR-17605-10 (1.345) 34.26 8DG-17605-00 (1.209) 37.77 8DJ-17605-00 (1.333) 42.09 8DN-17605-20 (1.486) SXV70SJ 39.00 8EK-17605-00 VT70J (1.376) (U.S.A, CAN) 45.41 8BU-17605-10 VT70J (EUR) (1.602) –19–...
Page 26 8 Weight rivets Parts No. Material Length Weight Standard Effects mm (in) g (oz) 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) SXV70SJ (out)/VT70J (in, out) Increased Force 90261-06034 Steel 13.9 (0.547) 3.6 (0.127) SXV70SJ (in) 90261-06019 Steel 13.3 (0.524) 3.1 (0.109) 90261-06017 Steel 11.3 (0.445)
Page 27: Front Suspension
INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload (SXV70SJ) 1. Adjust: S Spring preload Adjustment steps: S Turn the spring seat 1 in or out. Spring seat Standard Shorter z ! Longer distance Harder z ! Softer Preload Min. Max. Length...
Page 28 INSP FRONT SUSPENSION/REAR SUSPENSION Compression damping force (SXV70SJ for U.S.A, CAN) 1. Adjust: S Compression damping force. Adjustment steps: S Turn the adjuster 1 in or out. 15 clicks 10 clicks 1 click Damping force adj ster force adjuster Minim m...
Page 29: Rear Suspension
Less weight transfer Shorter Less weight on skis; More weight transfer S Tighten the locknut 1 . Locknut: 16 Nm (1.6 mSkg, 11 ftSlb) A SXV70SJ B VT70J ESS00102 Spring preload 1. Adjust: S Spring preload Adjustment steps: S Turn the adjusting ring 1 to the proper posi- tion.
Page 30 INSP REAR SUSPENSION Spring adjuster position Softer z ! Harder Preload SXV70SJ: 4 Rear Standard VT70J: 2 A SXV70SJ B VT70J WARNING This shock absorber contains highly pres- surized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly.
Page 31: Chassis
CHAS STEERING CHASSIS STEERING 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Thumb warmer lead coupler Disconnect.
Page 32 CHAS STEERING 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) Order Job name/Part name Q’ty Remarks Master cylinder assembly NOTE: Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” in CHAPTER 9, to check the Handlebar cable, lead and hose routings.
Page 33: Ski
CHAS SXV70SJ 11 Nm (1.1 mSkg, 8.0 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 21 Nm (2.1 mSkg, 15 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below.
Page 34 CHAS VT70J 11 Nm (1.1 mSkg, 8.0 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 21 Nm (2.1 mSkg, 15 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below.
Page 35: Front Suspension
CHAS FRONT SUSPENSION FRONT SUSPENSION ESSO beacon 325 grease or Aeroshell grease #7A 23 Nm (2.3 mSkg, 17 ftSlb) 42 Nm (4.2 mSkg, 30 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) 56 Nm (5.6 mSkg, 40 ftSlb) 78 Nm (7.8 mSkg, 56 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) Order...
Page 36: Installation
CHAS FRONT SUSPENSION INSTALLATION Stabilizer part number Size length Part number ID color bar diameter 8CR-2386E-00 16 mm Purple (SXV70SJ) (35.2755 0.6299 in) 8CW-2386E-00 18 mm Light green (VT70J) (35.2755 0.7087 in) –30–...
Page 37: Power Train
POWR BRAKE POWER TRAIN BRAKE 10 Nm (1.0 mSkg, 7.2 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Brake master cylinder removal Remove the parts in the order listed below. Brake fluid Drain.
Page 38: Inspection
POWR BRAKE INSPECTION 1. Inspect: S Master cylinder 1 Wear/scratches ! Replace the master cyl- inder assembly. S Master cylinder body 2 Cracks/damage ! Replace. S Oil delivery passage (master cylinder body) Blow out with compressed air. 2. Inspect: S Master cylinder kit 1 Scratches/wear/damage ! Replace as a set.
Page 39: Slide Rail Suspension
Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Blind cap Suspension rear plate Slide rail suspension Collar (SXV70SJ) For installation, reverse the removal procedure. –33–...
Page 40 Job name/Part name Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below. Stopper band Hook Bushing Collar Front shock absorber Bracket (SXV70SJ) Front suspension bracket Shaft (VT70J) Rubber damper (SXV70SJ) Front pivot arm Bushing Shaft Bushing Collar...
Page 41 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Suspension wheel Collar Wheel bracket Circlip Suspension wheel Collar...
Page 42 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear shock absorber Collar Bushing Pull rod Collar Bushing Rear bracket (VT70J) Collar (VT70J)
Page 43 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear pivot arm Bushing Shaft Shaft Rear pivot arm bracket...
Page 44: Installation
(in) Length mm (in) Length mm (in) Control rod 1 2.5P 3 = 7.5 153.5 (6.04) SXV70SJ (U.S.A, CAN) (0.098P 3 = 0.295) 303 5 (11 95) 303.5 (11.95) Control rod 1 2.5P 3 = 7.5 148.5 (5.85) SXV70SJ (EUR) (0.098P...
Page 45: Engine
Exhaust assembly Refer to “EXHAUST ASSEMBLY” in CHAPTER 5. Carburetors Refer to “CARBURETORS” in CHAPTER 7. Y.P.V.S. Refer to “YAMAHA POWER VALVE SYSTEM (Y.P.V.S.)” in CHAPTER 5. Recoil starter Refer to “RECOIL STARTER” in CHAPTER 5. AC magneto Refer to “AC MAGNETO” in CHAPTER 5.
Page 46 ENGINE ASSEMBLY 33 Nm (3.3 mSkg, 24 ftSlb) 57 Nm (5.7 mSkg, 41 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job name/Part name Q’ty Remarks Oil hose Disconnect. Vacuum hose Disconnect. Oil pump cable Knock sensor lead Disconnect. Starter motor (For model with starter motor) Starter motor lead (For model with starter motor)
Page 47 CYLINDER HEAD AND CYLINDER CYLINDER HEAD AND CYLINDER 10 Nm (1.0 mSkg, 7.2 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) Order Job name/Part name Q’ty Remarks Cylinder head and cylinder removal Remove the parts in the order listed below. Spark plug cap Clamp Sub-wire harness 2 Bracket...
Page 48: Cylinder Head And Cylinder
CYLINDER HEAD AND CYLINDER 14 Nm (1.4 mSkg, 10 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 33 Nm (3.3 mSkg, 24 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) Order Job name/Part name Q’ty Remarks Spark plug Cylinder head Gasket...
Page 49: Heat Exchanger
COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER 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 CHAPTER 2. Coolant filler cap Coolant reservoir tank Thermostat assembly Coolant hose 1 Coolant hose 2 Joint pipe...
Page 50: Thermostat
COOL THERMOSTAT THERMOSTAT 10 Nm (1.0 mSkg, 7.2 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 3.5 Nm (0.35 mSkg, 2.5 ftSlb) Order Job name/Part name Q’ty Remarks Thermostat disassembly Remove the parts in the order listed below. Washer Carburetor heating knob O-ring...
Page 51: Carburetion
CARB CARBURETORS CARBURETION CARBURETORS Order Job name/Part name Q’ty Remarks Carburetors removal Remove the parts in the order listed below. Throttle cable Refer to “FUEL PUMP” in CHAPTER 7. Intake silencer Carburetor heating knob Before removing the carburetors, make sure that the carburetor heating knob is turned to “OFF”.
Page 52 CARB CARBURETORS –46–...
Page 53: Electrical
ELEC GRIP WARMER SYSTEM (SXV70J) ELECTRICAL –47–...
Page 54: Grip Warmer System (Vt70J)
ELEC GRIP WARMER SYSTEM (VT70J) –48–...
Page 55: Troubleshooting
Check the tail/brake light bulb and lighting system. Refer to “LIGHTING SYSTEM”. FAULTY Replace the tail/brake light bulb and/or repair the “LIGHTING SYSTEM”. For SXV70SJ: Check the condenser. Refer to “IGNITION SYSTEM”. OUT OF SPECIFICATION Replace the condenser. Check the stator coil and pickup coil.
Page 56 ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER DOES NOT OPERATE. (VT70J) Check the “IGNITION” fuse and “TAIL” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the “IGNITION” fuse and/or “TAIL” fuse. Check the stator coil and pickup coil. Refer to “IGNITION SYSTEM”.
Page 57: Grip And Thumb Warmer Coil
ELEC GRIP WARMER SYSTEM GRIP AND THUMB WARMER COIL 1. Disconnect: S Grip warmer leads 1 S Thumb warmer coupler 2 2. Connect: S Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads) 3. Inspect: S Grip warmer 1 continuity S Thumb warmer 2 continuity No continuity ! Replace both grips together or separately and/or the handlebar switch.
Page 58: Grip Warmer Switch
ELEC GRIP WARMER SYSTEM GRIP WARMER SWITCH 1. Disconnect: S Grip warmer switch coupler 1 2. Connect: S Pocket tester (to the switch coupler) 3. Inspect: S Grip warmer switch continuity Switch is operated. Faulty ! Replace the handlebar switch (left).
Page 59: Passenger Grip Warmer Switch (Vt70J)
ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER SWITCH (VT70J) 1. Disconnect: S Passenger grip warmer switch coupler 1 2. Connect: S Pocket tester (to the passenger grip warmer switch cou- pler) 3. Inspect: S Passenger grip warmer switch continuity Faulty ! Replace. Continuity RESISTOR (VT70J) 1.
Page 60: Passenger Grip Warmer Relay (Vt70J)
ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER RELAY (VT70J) 1. Inspect: S Passenger grip warmer relay 1 Inspection steps: S Disconnect the passenger grip warmer relay from the coupler. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the passenger grip warmer relay terminals as shown.
Page 61: Detonation Control System (Sxv70Sj)
ELEC DETONATION CONTROL SYSTEM (SXV70SJ) –55–...
Page 62: Detonation Control System (Vt70J)
ELEC DETONATION CONTROL SYSTEM (VT70J) –56–...
Page 63: Troubleshooting
FAULTY Replace the knock sensor. Check the main switch. NO CONTINUITY Replace the main switch. Check for voltage on the smoothing condenser coupler (SXV70SJ). OUT OF SPECIFICATION Correct connection and/or replace the rectifire/regulator. Check the stator coil and/or connection. NO CONTINUITY Replace the A.C.
Page 64: Knock Sensor
ELEC DETONATION CONTROL SYSTEM KNOCK SENSOR 1. Disconnect: S Knock sensor coupler 1 2. Connect: S Pocket tester (to the knock sensor coupler) 3. Measure: S Knock sensor resistance Out of specification ! Replace the knock sensor. Knock sensor resistance: (Black –...
Page 65: Combination Meter Function
ELEC COMBINATION METER FUNCTION COMBINATION METER FUNCTION Switch the “kilometers” to “miles” To switch the speedometer, odometer, and trip- meter displays between kilometers and miles, select the odometer mode “ODO”, and then push the select/reset button 1 for at least 10 seconds.
Page 66: Self-Diagnosis
ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS This model features a self-diagnosing system for following displays. 1. Fuel meter, fuel level warning indicator 1 and the warning light 6 2. Coolant temperature warning indicator 2 and the warning light 6 3. Self-diagnosis warning indicator 3 and the warning light 6 4.
Page 67: Self-Diagnosis Warning Indicator And The Warning Light
ELEC SELF-DIAGNOSIS 3. SELF-DIAGNOSIS WARNING INDICATOR AND THE WARNING LIGHT The self-diagnosis warning indicator and the warning light faults are displayed as follows S Throttle position sensor (T.P.S.) S Grip and thumb warmer switch S Grip and thumb warmer S Voltage S Knock sensor Item T.P.S.
Page 68 ELEC SELF-DIAGNOSIS Item Thumb warmer switch Condition Disconnected Item Thumb warmer Condition Short-circuit Item Voltage Condition Wrong Item Knock sensor Condition Disconnected Short-circuit Warning light ON Warning light OFF s Time (second) –62–...
Page 69: Detonation Control System Indicator Light
ELEC ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS 4. DETONATION CONTROL SYSTEM INDICATOR LIGHT The detonation control system indicator light flashes to inform the rider that the detonation control sys- tem has been activated. If a detonation is detected by the knock sensor, the system automatically ad- justs the ignition timing for optimal firing, and the detonation control system indicator light flashes as follows.
Page 70 ELEC SELF-DIAGNOSIS –64–...
Page 71: Specifications
Gear oil API “GL-3” SAE #75 or #80 Capacity 0.25 L (8.8 Imp oz, 8.5 US oz) Coolant: Total amount 4.7 L (4.14 Imp qt, 4.97 US qt) (SXV70SJ) 5.0 L (4.40 Imp qt, 5.29 US qt) (VT70J) Fuel: R + M Type Regular unleaded gasoline (Pump Octane ;...
Page 72 Track type Internal drive type Track width 381 mm (15.0 in) Length on ground 752 mm (29.6 in) (SXV70SJ) 944 mm (37.2 in) (VT70J) 25 X 30 mm (0.98 X 1.18 in) Track deflection mm/10 kg (22 lb) Brake: Brake type...
Page 73: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model SXV70SJ/VT70J Cylinder head: #1: 24.55 X 24.85 cm (1.50 X 1.52 cu.in) Volume (with spark plug) #2, #3: 21.35 X 21.65 cm (1.30 X 1.32 cu.in) <Warp limit> <0.03 mm (0.0012 in)> *Lines indicate straight edge measurement.
Page 74 SPEC MAINTENANCE SPECIFICATIONS Model SXV70SJ/VT70J Crankshaft: 56.95 X 57.00 mm (2.242 X 2.244 in) Crank width “A” 292.75 X 293.30 mm (11.526 X 11.547 in) Crank width “B” Maximum runout “C”: C 0.03 mm (0.0012 in) 0.04 mm (0.0016 in) 0.03 mm (0.0012 in)
Page 75 High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors Coolant mixing ratio 3 : 2 (60% : 40%) (coolant: water) Coolant total amount 4.7 L (4.14 Imp qt, 4.97 US qt) (SXV70SJ) 5.0 L (4.40 Imp qt, 5.29 US qt) (VT70J) –69–...
Page 76: Power Train
V-belt automatic 3.8 X 1.0 : 1 Range of ratio 3,900 ± 200 r/min (3,700 X 4,100 r/min) (SXV70SJ) Engagement speed r/min 3,500 ± 200 r/min (3,300 X 3,700 r/min) (VT70J for U.S.A, CAN) 3,100 ± 200 r/min (2,900 X 3,300 r/min) (VT70J for EUR) 8,400 ±...
Page 77 Hole position Sheave side-spring side (twist angle) 1-6 (70_) (SXV70SJ/VT70J for U.S.A, CAN) 2-6 (80_) (VT70J for EUR) Spring rate 7.3 N/mm (0.74 kg/mm, 41.44 lb/in) (SXV70SJ) 8.5 N/mm (0.87 kg/mm, 48.72 lb/in) (VT70J) Number of coils 5.53 Free length 75 mm (2.95 in)
Page 78 11.5 mm (0.452 in) (VT70J for U.S.A, CAN) 12.0 mm (0.472 in) (VT70J for EUR) Suspension setting position: 25 ± 0.5 mm (0.98 ± 0.02 in) (SXV70SJ) Hook setting length *(Standard) 20 ± 0.5 mm (0.79 ± 0.02 in) (VT70J for U.S.A, CAN) 30 ±...
Page 79 Shock absorber damping force: Front Extension 490 N/0.3 m/s (50 kg/0.3 m/s, 110 lb/0.3 m/s) (SXV70SJ for U.S.A, CAN) 1,830 N/0.3 m/s (187 kg/0.3 m/s, 412 lb/0.3 m/s) (SXV70SJ for EUR) 450 N/0.3 m/s (46 kg/0.3 m/s, 101 lb/0.3 m/s) (VT70J for U.S.A, CAN)
Page 80 SPEC MAINTENANCE SPECIFICATIONS Model SXV70SJ/VT70J 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) Pad wear limit 4.7 mm (0.19 in) 0.025 X 0.115 mm (0.001 X 0.005 in)
Page 81: Chassis
12.7-23.5-27.4 N/mm (1.3-24-27 kg/mm, 72.8-134-151 lb/in) (SXV70SJ for EUR) 22.5 N/mm (2.3 kg/mm, 128.8 lb/in) (VT70J) Wire diameter 7.5 mm (0.295 in) (SXV70SJ for U.S.A, CAN) 7.8 mm (0.307 in) (SXV70SJ for EUR) 8.2 mm (0.323 in) (VT70J) Shock absorber:...
Page 82: Electrical
(color code) (White/Red – White/Green) 0.36 X 0.44 Ω at 20_C (68_F) Stator coil resistance (color code) (White – White) CDI unit model/Manufacturer F8T37574 /MITSUBISHI (SXV70SJ) F8T40171 /MITSUBISHI (VT70J) Rectifier/regulator: Type Short circuit type Model/Manufacturer SH650D-11/SHINDENGEN 14.1 X 14.9 V...
Page 83 SPEC MAINTENANCE SPECIFICATIONS Model SXV70SJ/VT70J Starter motor (VT70J): Model/Manufacturer DB4XF/DENSO Output 12 V – 0.6 kW Armature coil resistance 0.014 X 0.018 Ω at 20_C (68_F) Continuity check Insulation check More than 100 kΩ at 20_C (68_F) Brush Overall length 12 mm (0.47 in)
Page 84: High Altitude Settings
SPEC HIGH ALTITUDE SETTINGS HIGH ALTITUDE SETTINGS SXV70SJ/VT70J Tempera- – 40_C – 29_C – 18_C – 7_C 16_C ture (– 40_F) (– 20_F) (0_F) (20_F) (40_F) (60_F) Altitude MJ #160 MJ #158.8 MJ #157.5 MJ #156.3 MJ #155 MJ #153.8...
Page 85: Tightening Torque
SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Crankcase (M8 80) (1st) Tighten the bolts in two Crankcase (M8 (2nd) stages. Crankcase (M8 Engine bracket (front) and frame Engine bracket damper Engine bracket (front) and engine Engine bracket right (rear) and engine...
Page 86: Power Train
SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Primary sheave (1st) 12.0 Tighten the bolts in two Primary sheave (2nd) stages. See NOTE. Spider and sliding sheave 20.0 Left-hand thread. Primary sheave cap and sliding sheave Roller and weight (primary sheave) Starter motor driven gear...
Page 87 SPEC TIGHTENING TORQUE Tightening torque Parts be tightened Parts be tightened Remarks Remarks mSkg ftSlb  Wheel bracket shaft and sliding frame Apply LOCTITE  Set bolt (front axle) Apply LOCTITE Speed sensor Gear unit (speed sensor) Knock sensor NOTE: Tightening steps: 1.
Page 88: Chassis
Tie rod and steering arm Relay arm  Locknut (relay rod / tie rod) Apply LOCTITE Ski runner Ski column lower bracket (SXV70SJ) Ski and ski handle (upper) Ski and ski handle (lower)  Shock absorber (upper) Apply LOCTITE ...
Page 89: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (nut) (bolt) (bolt) This chart specifies torque for standard fasteners mSkg ftSlb 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 90 SPEC –84–...
Page 91: Cable Routing
SPEC CABLE ROUTING –85–...
Page 92 SPEC CABLE ROUTING CABLE ROUTING Frame directly attached clamp Coolant temperature sensor Knock sensor coupler Clamp coolant hose, T.O.R.S. lead connector, ignition coil lead and detonation control system lead. S Clamp them in front of the igni- tion coil lead connector and T.O.R.S.
Page 93 SPEC CABLE ROUTING –87–...
Page 94 SPEC CABLE ROUTING Clamp the side frame reinforce- ment with the harness wire, starter relay lead, gear position switch lead and main harness. Pass the coupler under the fuel and oil reserve hose and the coupler has to be hidden in the inner panel.
Page 95 SPEC CABLE ROUTING –89–...
Page 96 SPEC CABLE ROUTING Frame directly attached clamp Clamp so that the oil tank cap and oil tank breather hose do not interfere with each other. Band them beside the instru- ment panel attaching bolt. Lay the fuel tank breather hose along the steering gate.
Page 97 SPEC CABLE ROUTING –91–...
Page 98 SPEC CABLE ROUTING Attach the hexagon bolt to the Y.P.V.S. bracket. Oil level switch coupler Fuel hose Pulser hose Oil delivery hose Situate the CDI unit coupler in the footrest. CDI unit Headlight dimmer relay (black) Passenger grip warmer relay (VT70J) Load control relay (white) Back buzzer...
Page 99 SPEC CABLE ROUTING –93–...
Page 100 SPEC CABLE ROUTING Headlight harness Align the clamp with the tape on the headlight harness. Clamp the headlight harness. Route it behind the shroud stop- per. Fit the rubber boot into the speedometer coupler securely. Hook Stay –94–...
Page 101 SPEC CABLE ROUTING –95–...
Page 102 SPEC CABLE ROUTING Handlebar holder Thumb warmer coupler Engine stop switch coupler Thumb warmer switch coupler Clamp the connectors. Grip warmer connector Grip warmer switch coupler High beam switch coupler Tail / brake light switch coupler Parking brake cable Clamp the tail / brake light switch lead, high beam switch lead, grip warmer lead and grip warmer switch lead.
Page 103 SPEC CABLE ROUTING –97–...
Page 104 SPEC CABLE ROUTING Clamp the fuel tank breather hose, CDI unit lead and Y.P.V.S. lead aligning with the positioning tape on the main harness. Clamp the CDI unit lead and speed sensor lead. Speed sensor lead Connecter joint Care should be taken about the direction of the fuel hose.
Page 105 SPEC CABLE ROUTING –99–...
Page 106 SPEC CABLE ROUTING Hose To the Coolant reservoir tank Clamp the main harness Clamp the tail / brake light lead, harness, rectifier / regulator and gear position switch lead. (For model with reverse) Fold back the gear position switch lead, and clamp it. (For model without reverse) Brake hose Do not kink.
Page 107 SPEC CABLE ROUTING –101–...
Page 108 SPEC CABLE ROUTING Clamp the main wire harness, coolant hose and throttle posi- tion sensor behind the throttle position sensor coupler. Point the tip of the clamp to the intake silencer side. Throttle position sensor Joint connecter Starter cable Throttle cable Pass the oil pump cable through the outside of the starter cable.
Page 109 SPEC CABLE ROUTING –103–...
Page 110 SPEC CABLE ROUTING Do not catch the CDI magneto lead between the main harness and coolant hose. Point the tip of the clamp to the inner side of the vehicle. Follow the direction of spark plug caps as shown in the illustration. Position of the clamp should be at the identification tape position of the spark plug lead.
Page 111 SPEC CABLE ROUTING –105–...
Page 112 SPEC CABLE ROUTING Coolant reservoir tank Joint Main wire harness This is the main wire harness to the headlight unit. Main harness from the starter relay to the starter motor. Pass the main harness under the coolant pipe. Main harness from the starter relay to the starter motor.
Page 113 SXV70SJ WIRING DIAGRAM A.C. Magneto Rectifier / regulator Smoothing condenser Main switch Engine stop switch Throttle switch Carburetor switch CDI unit Throttle position sensor Y.P.V.S. Servo motor Ignition coil Spark plug Engine ground Body ground Grip warmer switch Thumb warmer switch...
Page 114 SXV70SJ WIRING DIAGRAM O Gy R/Y G/Y R/W R L/R - G/B Sb B/G Y/B G L/Y Lg/B Lg/B Y/G Gy/B Gy/B W Ch G/Y B G/Y B B R/B GR L/W Y W Br/W Lg/B Br/L Lg/L Lg/W MAIN HARNESS...
Page 115 VT70J WIRING DIAGRAM A.C. Magneto Rectifier / regulator Main switch Engine stop switch Throttle switch Carburetor switch CDI unit Throttle position sensor Y.P.V.S. Servo motor Ignition coil Spark plug Engine ground Body ground Grip warmer switch Thumb warmer switch Water temperature sensor Knock sensor Thumb warmer Grip warmer...
Page 116 VT70J WIRING DIAGRAM O Gy R/Y G/Y L/R O/B L/R O/B G/B Sb B/G Y/B G L/Y Lg/B Lg/B Y/G Gy/B Gy/B W Ch B R/B GR L/W Y W G/Y B G/Y B Br/W Lg/B Br/L Lg/L Lg/W MAIN HARNESS CORD HEAD LIGHT 1 MAIN HARNESS CORD HEAD LIGHT 2...
Page 120 SERVICE MANUAL VX700F VX700DXF SX700F MM700F VT700F LIT-12618-02-17 8CH-28197-10 981050...
Page 121 NOTICE HOW TO USE THIS MANUAL This manual was written by the Yamaha Motor Com- pany primarily for use by Yamaha dealers and their Particularly important information is distinguished in qualified mechanics. It is not possible to put an entire this manual by the following notations: mechanic’s education into one manual, so it is as-...
Page 122 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 content. 1 General information POWR 2 Periodic inspection and adjustment CHAS 3 Chassis 4 Power train 5 Engine 6 Cooling system 7 Carburetion...
Page 123 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 124 CHAPTER 1. POWER TRAIN ..........2-16 GENERAL INFORMATION SHEAVE DISTANCE AND OFFSET ADJUSTMENT ......... 2-16 DRIVE V-BELT ......... 2-18 MACHINE IDENTIFICATION ......1-1 ENGAGEMENT SPEED CHECK ..... 2-20 FRAME SERIAL NUMBER ......1-1 PARKING BRAKE PAD INSPECTION ..2-20 ENGINE SERIAL NUMBER ....... 1-1 PARKING BRAKE ADJUSTMENT ...
Page 125 SKI ..............3-8 BRAKE MASTER CYLINDER VX700/VX700DX/VT700 ......3-8 ASSEMBLY ..........4-37 SX700/MM700 ..........3-9 INSTALLATION ........4-37 INSPECTION ..........3-10 INSTALLATION SLIDE RAIL SUSPENSION ......4-38 (VX700/VX700DX/VT700) ......3-10 VX700/VX700DX/SX700 ......4-38 VT700 ............4-39 FRONT SUSPENSION ........3-11 MM700 ............
Page 126 CHAPTER 6. HANDLEBAR SWITCH (RIGHT) ....8-8 CARBURETOR SWITCH ......8-9 COOLING SYSTEM MAIN SWITCH ........... 8-9 LOAD CONTROL RELAY ......8-10 HEAT EXCHANGER ........6-1 EMERGENCY ENGINE STARTING VX700/VX700DX/SX700/VT700 ....6-1 (VX700/SX700/MM700) ......8-10 MM700 ............6-2 INSPECTION ..........6-3 ELECTRICAL STARTING SYSTEM INSTALLATION ..........
Page 127 PASSENGER GRIP WARMER SWITCH (VT700) ........8-42 RESISTOR (VT700) ......... 8-42 PASSENGER GRIP WARMER RELAY (VT700) ............. 8-43 FAULT LOCATION TABLE ......8-44 CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS ......9-1 MAINTENANCE SPECIFICATIONS ....9-4 ENGINE ............9-4 POWER TRAIN .......... 9-7 CHASSIS ..........
Page 128: 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 frame (just SCH1010 below the front of the seat). ENGINE SERIAL NUMBER The engine serial number is located on the right-hand side of the crankcase.
Page 129: Important Information
SCH1070 ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments. SCH1080...
Page 130: 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 131: 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 132: 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. SCH1170 • 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. SCH1180 •...
Page 133: For Carburetion Service
SPECIAL TOOLS INFO • Clutch bushing press P/N: YS-42424 This tool is used for removing and installing the post bushings (primary sheave cap bush, sliding sheave bush and torque cam bush). SCH1250 • Track clip installer P/N: YS-91045-A (for U.S.A./Canada) 90890-01721 (for Europe) This tool is used for installing the track clip.
Page 134: 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 135 INSP PERIODIC MAINTENANCE TABLE Every Initial Pre- 1 month Seasonally operation Item Remarks check 800 km 3,200 km (Daily) (500 mi) (2,000 mi) (40 hr) (160 hr) Check operation and fluid leakage. Brake and parking brake Adjust free play and/or replace pads if necessary. Replace brake fluid.
Page 136: 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 SCH2010 3. Measure: • Spark plug gap a Out of specification → Regap. Use a wire thickness gauge.
Page 137: 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 138 INSP OIL PUMP 14. Install: • Gasket (bleed bolt) • Bleed bolt 15. Install: • Rear bracket (right) M8 mounting bolt (rear): 33 Nm (3.3 m · kg, 24 ft · lb) M10 mounting bolt (rear): 57 Nm (5.7 m · kg, 41 ft · lb) 16.
Page 139: Fuel Line Inspection
INSP FUEL LINE INSPECTION/COOLING SYSTEM FUEL LINE INSPECTION 1. Remove: • Intake silencer Refer to “FUEL PUMP” in CHAPTER 7. 2. Inspect: • Fuel hose 1 • Fuel delivery hoses 2 Cracks/damage → Replace. 3. Install: SCH2090 • Intake silencer Refer to “FUEL PUMP”...
Page 140 INSP COOLING SYSTEM 4. Remove: • Coolant filler cap 1 WARNING Do not remove the coolant filler cap 1 when the engine is hot. Pressurized scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, place a thick rag or a towel over the coolant filler cap.
Page 141 INSP COOLING SYSTEM 9. Disconnect: • Coolant hoses 1 Å VX700/VX700DX/SX700/VT700 ı MM700 10. Drain the coolant. NOTE: Lift up the front of the machine to drain the coolant completely. SCH2150 WARNING Coolant is poisonous. It is harmful or fatal if swallowed.
Page 142 INSP COOLING SYSTEM 18. Inspect: • Gasket (coolant drain bolt) Damage → Replace. 19. Install: • Gasket • Coolant drain bolt 1 Coolant drain bolt 1: 13 Nm (1.3 m · kg, 9.4 ft · lb) SCH2130 20. Install: • Exhaust joint •...
Page 143 INSP COOLING SYSTEM 22. Bleed the air from the cooling system. 23. Inspect: • Cooling system Decrease of pressure (leaks) → Repair as required. Inspection steps: • Attach the cooling system tester 1 to the coolant filler 2. Cooling system tester: 90890-01325, YU-24460-01 •...
Page 144 INSP COOLING SYSTEM Air bleeding steps: • Lift up the tail of the machine. • Remove the bleed bolt 1 on the heat exchanger. • While slowly adding coolant to the coolant filler, drain the coolant until no more air bubbles ap- pear.
Page 145: Carburetor Synchronization
COOLING SYSTEM/ INSP CARBURETOR SYNCHRONIZATION • Remove the coolant filler cap and bleed the cooling system again, as described above. No air bubbles → OK. • Add coolant to the specified level. • Pour coolant into the coolant reservoir 3 until the coolant level reaches the “FULL”...
Page 146: Engine Idle Speed Adjustment
ENGINE IDLE SPEED ADJUSTMENT/ INSP THROTTLE CABLE FREE PLAY ADJUSTMENT ENGINE IDLE SPEED ADJUSTMENT 1. Adjust: • Engine idle speed Adjustment steps: • Start the engine and let it warm up. • Turn the throttle stop screw 1 in or out until the specified engine idle speed is obtained.
Page 147: Throttle Override System (T.o.r.s.) Check
THROTTLE CABLE FREE PLAY ADJUSTMENT/ INSP THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK 2. Adjust: • Throttle cable free play Adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 in or out until the specified free play is obtained. Turning in →...
Page 148: Starter (Choke) Cable Free Play Adjustment
STARTER (CHOKE) CABLE FREE PLAY ADJUSTMENT/ INSP EXHAUST SYSTEM INSPECTION STARTER (CHOKE) CABLE FREE PLAY ADJUSTMENT 1. Measure: • Starter cable free play a Out of specification → Adjust. Starter cable free play a: 0.5 ~ 1.5 mm (0.02 ~ 0.06 in) SCH2340 2.
Page 149: 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. Measure: • Sheave distance a Use the distance gauge. Out of specification → Adjust. Sheave distance a: 267 ~ 270 mm (10.52 ~ 10.62 in) Distance gauge:...
Page 150 INSP SHEAVE DISTANCE AND OFFSET ADJUSTMENT 6. Measure: • Secondary sheave free play (clearance) a Use a thickness gauge. Out of specification → Adjust. Secondary sheave free play (clearance) a: 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) SCH2400 7. Adjust: •...
Page 151: 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 (–0.02 in) below the edge a. If the V-belt is not positioned correctly, the clutch engagement speed will be changed.
Page 152 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 Not necessary –0.5 mm (–0.02 in)
Page 153: 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 154: Brake Lever Adjustment (Vx700Dx/Sx700/Vt700)
BRAKE LEVER ADJUSTMENT (VX700DX/SX700/VT700)/ INSP BRAKE FLUID LEVEL INSPECTION BRAKE LEVER ADJUSTMENT (VX700DX/SX700/VT700) 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 direction a, turn the adjusting bolt 2 by fingers to set the brake SCH2510 lever to the desired position.
Page 155: Brake Pad Inspection
BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Inspect: • Brake pad Wear indicator 1 nearly contacts the brake disc → Replace as a set. Wear limit a: 4.7 mm (0.19 in) SCH2530 BRAKE HOSE INSPECTION...
Page 156: Drive Chain
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP DRIVE CHAIN d. Tighten the bleed screws when the brake lever limit has been reached, then release the lever. • Repeat steps (a) to (d) until all of the air bubbles have disappeared from the fluid. •...
Page 157 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 158 INSP DRIVE CHAIN Oil replacement Oil replacement steps: • Place the oil pan under the drain hole. • Remove the oil drain bolt 1 and drain the oil. CAUTION: Be sure to remove any oil from the heat protec- tor. SCH2590 •...
Page 159: Track Tension Adjustment
DRIVE CHAIN/ INSP TRACK TENSION ADJUSTMENT 3. Install: • Battery bracket (VX700DX/VT700) • Battery (VX700DX/VT700) CAUTION: • Connect the positive lead to the battery termi- nal first. • Make sure the battery leads are connected properly. Reversing the leads can seriously damage the electrical system.
Page 160 INSP TRACK TENSION ADJUSTMENT 3. Adjust: • Track deflection Adjustment steps: • Place the machine onto a suitable stand to raise the track off of the ground. • Loosen the rear axle nut 1. NOTE: It is not necessary to remove the cotter pin 2. SCH2630 a.
Page 161: Slide Runner Inspection
INSP SLIDE RUNNER INSPECTION SLIDE RUNNER INSPECTION 1. Inspect: • Slide runner 1 Cracks/damage/wear → Replace. 2. Measure: • Slide runner thickness a Out of specification → Replace. Slide runner wear limit a: SCH2680 10 mm (0.39 in) 2-28...
Page 162: Maximizing Drive Track Life
Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible damage, consult your stud manu- facturer for installation and stud pattern recommen- dations. Yamaha does not recommend track studding. 2-29...
Page 163: Chassis
INSP SKI/SKI RUNNER CHASSIS SKI/SKI RUNNER 1. Inspect: • • Ski runner Damage/wear → Replace. SCH2690 Ski runner wear limit a: 8 mm (0.31 in) Plastic ski wear limit b: VX700/VX700DX/VT700: 13 mm (0.51 in) SX700/MM700: 8 mm (0.31 in) SCH2695 CAUTION: To avoid scratching, wearing and damaging the...
Page 164: Steering System
INSP STEERING SYSTEM STEERING SYSTEM Free play check 1. Check: • Steering system free play Move the handlebar up and down and back and forth. Turn the handlebar slightly to the right and left. Excessive free play → Check that the handle- bar, tie rod ends and relay rod ends are in- SCH2710 stalled securely in position.
Page 165 INSP STEERING SYSTEM/LUBRICATION 3. Adjust: • Ski toe-out Adjustment steps: • Loosen the locknuts (tie-rod) 1. • Turn the tie rods 2 in or out until the specified toe- out is obtained. • Tighten the locknuts (tie-rod) 1. SCH2720 Locknut (rod end) 1: 25 Nm (2.5 m ·...
Page 166: Lubrication
INSP LUBRICATION Relay arm (steering) 1. Use a grease gun to inject grease into the nipples 1. Recommended lubricant: ESSO Beacon 325 Grease or Aeroshell Grease #7A SCH2740 Front and rear suspension 1. Use a grease gun to inject grease into the nipples 1.
Page 167: 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 recom- mended distance D. Refer to the table below. 3. Measure the distance H from the floor to the center of the headlight and place a mark on the SCH2765 wall at that height.
Page 168: Battery Inspection (Vx700Dx/Vt700)
INSP BATTERY INSPECTION (VX700DX/VT700) BATTERY INSPECTION (VX700DX/VT700) WARNING Battery fluid is poisonous and dangerous, causes severe burns, etc. Contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL – Flush with water. INTERNAL – Drink large quantities of water or milk.
Page 169 INSP BATTERY INSPECTION (VX700DX/VT700) Replace the battery if: • Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging. • Sulfation of one or more cells occurs, as indicated by the plates turning white, or an accumulation of material exists in the bottom of the cell.
Page 170: Battery Charging (Vx700Dx/Vt700)
INSP BATTERY CHARGING (VX700DX/VT700) BATTERY CHARGING (VX700DX/VT700) The battery must be charged properly before using for the first time. This initial charge will prolong the life of the battery. 1. Remove: • Battery WARNING When removing the battery, disconnect the nega- tive lead first.
Page 171: Fuse Inspection (Vx700Dx/Vt700)
BATTERY CHARGING (VX700DX/VT700)/ INSP FUSE INSPECTION (VX700DX/VT700) 2. Install: • Battery CAUTION: • Connect the positive lead to the battery termi- nal first. • Make sure the battery leads are connected properly. Reversing the leads can seriously damage the electrical system. •...
Page 172 INSP FUSE INSPECTION (VX700DX/VT700) 2. Replace: • Blown fuse Replacing steps: • Set the main switch to “OFF”. • Install a new fuse of the correct amperage. • Set the main switch to “ON” and verify if the electrical circuit is operational. •...
Page 173: 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 174 Use the chart in CHAPTER 9 to select main jets according to variations in elevation and temperature. 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...
Page 175 INSP CARBURETOR TUNING Guide for carburetion SCH2815 2-42...
Page 176 INSP CARBURETOR TUNING Standard main jet Main jet whose diameter is 10% smaller than standard Main jet whose diameter is 10% larger than standard SCH2820 position position position SCH2825 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 177 INSP CARBURETOR TUNING Low-speed tuning The carburetors are built so that low speed tuning can be done by adjusting the pilot mixture screw 2 and throttle stop screw 1. CAUTION: Never run the engine without the air intake si- lencer installed. Severe engine damage may re- sult.
Page 178 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 size. deposits White or light gray Mixture is too lean.
Page 179 INSP CARBURETOR TUNING Trouble Diagnosis Adjustment • Remove the pilot jet, clean it with compressed air, and Poor performance at Clogged or loose pilot jet mid-range speeds: then install it. • Momentary slow re- • Make sure that the pilot jet is fully tightened. sponse to the throttle •...
Page 180: Clutch
INSP CLUTCH CLUTCH G Green Silver High altitude Pink W White R Red Specifications Model: VX700 ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) 1,600 ±...
Page 181 INSP CLUTCH G Green R Red O Orange Silver Pink W White Specifications Model: VX700DX ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) 1,600 ±...
Page 182 INSP CLUTCH G Green R Red Yellow Specifications Model: SX700 ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) 1,600 ±...
Page 183 INSP CLUTCH G Green W White Yellow Specifications Model: MM700 ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) 1,600 ±...
Page 184 INSP CLUTCH G Green O Orange Pink Specifications Model: VT700 ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) 1,600 ±...
Page 185 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the desired han- dling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the machine first begins to move from a complete stop.
Page 186: Gear Selection
INSP GEAR SELECTION 1 Chain and sprocket part number Å Part name ı Teeth & links Ç Part no. Î Standard 18 teeth 89J-17682-80 19 teeth 89J-17682-91 20 teeth 89J-17682-00 VT700 for Europe ‰ Drive sprocket 21 teeth MM700 89J-17682-10 VX700DX/SX700 22 teeth 89J-17682-20...
Page 187 INSP GEAR SELECTION 5 Torque cam (secondary sheave spring seat) SCH2850 ı Effects Ç Part no. Î Cam angle ‰ Identification mark Ï Standard 8BV-17604-71 47° 8BV71 VX700/VX700DX/SX700 8BV-17604-51 45° 8BV51 VT700 for U.S.A./Canada MM700 8BV-17604-31 43° 8BV31 VT700 for Europe 8BV-17604-11 41°...
Page 188 INSP GEAR SELECTION 6 Primary sheave spring SCH2855 ‰ Ó È Ï Ô Î Spring rate Wire Outside Free Ò Standard Ì Color Preload No. of Parts No. N/mm gauge diameter length coils (kg/mm) N (kg) mm (in) mm (in) mm (in) 90501-551L3 19.6 (2.00)
Page 189 INSP GEAR SELECTION 7 Clutch weights Å Standard 8CH-17605-10 35.32 g VX700/ VX700DX VT700 for U.S.A./Canada SCH2860 8CR-17605-10 38.09 g MM700 VT700 for Europe SCH2861 8DF-17605-10 37.84 g SX700 SCH2863 8DG-17605-00 39.26 g SCH2865 8DJ-17605-00 37.77 g SCH2867 8DN-17605-20 42.09 g SCH2869 2-56...
Page 190 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 DIAMETER TYPE (P/N) MARK (Width) PART NUMBER 8CR-17624-00-00 14.5 mm Duralon VX700/ (0.57 in) VX700DX/ MM700/ VT700/ 90380-09245-00 8CR-17624-10-00...
Page 191: 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 192: Front Suspension
INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload (VX700/VX700DX/MM700/VT700) 1. Adjust: • Spring preload Adjustment steps: • Turn the adjusting ring 1 to the proper position. Spring adjuster SCH2880 position Softer ← → Harder Preload VX700/VX700DX/VT700: 1 Standard MM700: 3 CAUTION: Be sure that the left and right spring preload is the same.
Page 193: 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 characteristics of the machine. Adjustment steps: •...
Page 194 INSP REAR SUSPENSION Spring preload (VX700/VX700DX/MM700/VT700) 1. Adjust: • Spring preload Adjustment steps: • Turn the adjusting ring 1 to the proper position. Spring adjuster SCH2900 position Softer ← → Harder Preload VX700: 1 Å Front Standard VX700DX/MM700/VT700: 3 Spring adjuster position Softer ←...
Page 195 INSP REAR SUSPENSION Rear suspension-full rate 1. Adjust: • Full rate adjuster Adjustment steps: Installation position Spring rate Soft Medium Hard and damping SCH2920 Standard NOTE: Be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile. •...
Page 196 INSP REAR SUSPENSION Rear suspension position (MM700) 1. Adjust: • Rear suspension position NOTE: Select the rear suspension position according to the snow conditions: a standard; b deep new snow. Bolt (slide rail suspension): 72 Nm (7.2 m · kg, 52 ft · lb) SCH2935 2-63...
Page 197: Steering
CHAS STEERING CHASSIS STEERING VX700/VX700DX/SX700/VT700 Å 10 Nm (1.0 m · kg, 7.2 ft · lb) ı 23 Nm (2.3 m · kg, 17 ft · lb) SCH3010 Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Oil tank breather hose...
Page 198: Mm700
CHAS STEERING MM700 Å 10 Nm (1.0 m · kg, 7.2 ft · lb) ı 23 Nm (2.3 m · kg, 17 ft · lb) SCH3020 Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Oil tank breather hose...
Page 199 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 43 Nm (4.3 m · kg, 31 ft · lb) ‰...
Page 200: Inspection
CHAS STEERING INSPECTION 1. Inspect: • Handlebar 1 (VX700/VX700DX/SX700/VT700) • Handlebar 2 (MM700) • Steering column 3 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent column. SCH3040 This may dangerously weaken the column. 2. Inspect: • Bearings (steering column) 1 •...
Page 201: 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) SCH3090 2. Install: • Tie rod 1 • Locknut 2 • Joints 3 Å...
Page 202 CHAS STEERING 4. Install: • Relay rod 1 NOTE: Make sure that the end of the relay rod with the indentation a is connected to the relay arm. CAUTION: Always use new cotter pins. SCH3130 Nut (relay rod): 35 Nm (3.5 m · kg, 25 ft · lb) 5.
Page 203 CHAS STEERING 6. Install: • Handlebar CAUTION: • For SX700/MM700: Be sure the projection on the handlebar is not installed into the area a shown. • Be sure the side of the holder with the small gap b faces forward. SCH3150 •...
Page 204: Ski
CHAS VX700/VX700DX/VT700 Å 11 Nm (1.1 m · kg, 8.0 ft · lb) ı 17 Nm (1.7 m · kg, 12 ft · lb) Ç 21 Nm (2.1 m · kg, 15 ft · lb) Î 48 Nm (4.8 m · kg, 35 ft · lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A...
Page 205 CHAS SX700/MM700 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 SCH3200...
Page 206: 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 • Collars 9 Wear/damage →...
Page 207: Front Suspension
CHAS FRONT SUSPENSION FRONT SUSPENSION Å 23 Nm (2.3 m · kg, 17 ft · lb) ı 43 Nm (4.3 m · kg, 31 ft · lb) Ç 48 Nm (4.8 m · kg, 35 ft · lb) Î 50 Nm (5.0 m · kg, 36 ft · lb) ‰...
Page 208: Handling Notes (Sx700)
CHAS FRONT SUSPENSION HANDLING NOTES (SX700) 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 209 CHAS FRONT SUSPENSION 4. Inspect: • Connecting rod 1 • Stabilizer 2 Cracks/bends/damage → Replace. • Collar 3 Wear/scratches/damage → Replace. SCH3280 5. Inspect: • Front arm 1 Cracks/bends/damage → Replace. SCH3290 3-13...
Page 210: Installation
CHAS FRONT SUSPENSION INSTALLATION 1. Install: • Control rod 1 • Nut 2 • Joint 3 a Set length Å Left hand Ç Ì color ı SCH3300 Set length a angle ‰ Upper 475.5 ± 0.5 mm 93 ± 1° (VX700/VX700DX/ (18.7204 ±...
Page 211 CHAS FRONT SUSPENSION 2. Install: • Steering arm 1 NOTE: • Align the punch mark a on the ski column with the punch mark b on the steering arm. • Install sections c without any gaps. Nut (steering arm): 56 Nm (5.6 m · kg, 40 ft · lb) SCH3310 Å...
Page 212 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 213 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. SCH3370 CAUTION: When tightening the ball joint locknut, be sure to keep the ball joint outer housing centered with the ball to prevent binding.
Page 214 CHAS FRONT SUSPENSION Front arm part number SCH3390 ı Caster Ç Control rod Î Shock absorber ‰ ID Å Part number bracket angle b bracket angle c mark d 8DM-2382E-10 (L/H) VX700/VX700DX 25.5° 3° 10° 8DM-2382F-10 (R/H) 8CR-2382E-20 (L/H) SX700 25.5°...
Page 215 CHAS FRONT SUSPENSION Control rod part number SCH3410 Ç Part Number Î Length a ‰ Angle b 439.5 ± 1 mm (17.3031 ± 0.0394 in) 10.8 ± 0.5° Å Upper 8CR-2384E-20 VX700/VX700DX/ 431.6 ± 1 mm (16.9921 ± 0.0394 in) 10.8 ±...
Page 216: 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) SCH4010 Order Job name/Part name Q’ty Remarks Primary sheave removal...
Page 217 POWR PRIMARY SHEAVE AND DRIVE V-BELT Å 6 Nm (0.6 m · kg, 4.3 ft · lb) ı 14 Nm (1.4 m · kg, 10 ft · lb) Ç 19 Nm (1.9 m · kg, 13 ft · lb) Î 200 Nm (20.0 m ·...
Page 218: 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: SCH4030 90890-01701, YS-01880 Primary sheave puller: YS-01881-1, YS-01882-1...
Page 219: Disassembly
POWR PRIMARY SHEAVE AND DRIVE V-BELT DISASSEMBLY 1. Remove: • Fixed sheave 1 • Stopper 2 • Sliding sheave 3 • Bushing 4 • Spider 5 SCH4040 Removal steps: • Immerse the primary sheave assembly in 80° ~ 100°C (176° ~ 212°F) water for several minutes. •...
Page 220: Inspection
POWR PRIMARY SHEAVE AND DRIVE V-BELT INSPECTION 1. Inspect: • Spider 1 • Sliding sheave 2 • Fixed sheave 3 • Primary sheave cap 4 Cracks/damage → Replace. SCH4080 2. Inspect: • Primary sheave spring 1 Cracks/damage → Replace. 3. Measure: •...
Page 221 POWR PRIMARY SHEAVE AND DRIVE V-BELT 5. Inspect: • Weight 1 • Roller 2 • Bushing 3 • Slider 4 • Rivet 5 • Collar Wear/scratches/damage → Replace. SCH4110 Slider inside clearance Min. 0 mm (0 in) Max. 0.3 mm (0.0118 in) Rivet replacement steps: •...
Page 222: 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). SCH4150 2. Install: • Fixed sheave (onto the spider) NOTE: •...
Page 223 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. SCH4190 WARNING • Do not operate the primary sheave until the LOCTITE ®...
Page 224 POWR PRIMARY SHEAVE AND DRIVE V-BELT 7. Tighten: • Bolts Tightening steps: • Temporarity tighten the bolts 1 ~ 6 in the order shown. Bolt (starter motor driven gear) 1 ~ 6: 19 Nm (1.9 m · kg, 13 ft · lb) SCH4220 NOTE: •...
Page 225: 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 us- ing a cloth dampened with thinner. SCH4230 2. Apply: •...
Page 226: Secondary Sheave
POWR SECONDARY SHEAVE SECONDARY SHEAVE Å 64 Nm (6.4 m · kg, 46 ft · lb) SCH4260 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 227 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 SCH4270...
Page 228: 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 229: Assembly
POWR SECONDARY SHEAVE 5. Measure: • Ramp shoe thickness Out of specification → Replace the ramp shoe. Wear limit a: 1.0 mm (0.04 in) SCH4320 ASSEMBLY 1. Install: • Stopper • Sliding sheave Screw (stopper): 6.5 Nm (0.65 m · kg, 4.6 ft · lb) 2.
Page 230 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. a = (sheave hole number + spring seat hole SCH4350 number) ×...
Page 231: Installation
• Measure the secondary sheave clearance again. Repeat these steps until the clearance is within specification. SCH4380 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 232 POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL 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 233: 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. SCH4400 •...
Page 234 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 lb) of force b. Out of specification →...
Page 235: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the following. Å Make sure that the bearing seals face towards the drive chain as shown. ı Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. Be sure to install the spacers in their original positions, otherwise the brake disc and jackshaft will stick.
Page 236: With Reverse Model
POWR DRIVE CHAIN HOUSING WITH REVERSE MODEL Å 10 Nm (1.0 m · kg, 7.2 ft · lb) ı 13 Nm (1.3 m · kg, 9.4 ft · lb) Ç 16 Nm (1.6 m · kg, 11 ft · lb) Î...
Page 237 POWR DRIVE CHAIN HOUSING Å 10 Nm (1.0 m · kg, 7.2 ft · lb) ı 13 Nm (1.3 m · kg, 9.4 ft · lb) Ç 16 Nm (1.6 m · kg, 11 ft · lb) Î 24 Nm (2.4 m · kg, 17 ft · lb) ‰...
Page 238: Inspection
POWR DRIVE CHAIN HOUSING INSPECTION 1. Inspect: • Drive chain housing 1 • Drive chain housing cover 2 Cracks/damage → Replace. • Shift fork 3 Pitting/wear/damage → Replace. • Oil seals (drive chain housing) Wear/damage → Replace. SCH4480 • Bearings (drive chain housing and cover) 4 Pitting/damage →...
Page 239: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the following. Å Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. ı Make sure that the bearing seals face towards the drive chain as shown.
Page 240 POWR DRIVE CHAIN HOUSING 4. Install: • Shift rod 1 5. Adjust: • Shift rod length a Adjustment steps: • Move the shift lever to the “FWD.” position. • Loosen the locknuts 2. • Turn the shift rod 1 so that shift rod free play is SCH4520 0 mm (in direction where a can be shortened appropriately) and then turn back the shift rod...
Page 241: 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) SCH4530 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 242: 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. SCH4540 2. Inspect: • Bearing holder 1 Cracks/damage → Replace. •...
Page 243: 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 244: 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) SCH4580 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 245: 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 246 POWR BRAKE 2. Install: • Brake pads • Pad spring Installation steps: • Connect a suitable hose 1 tightly to the caliper bleed screw 2. Put the other end of this hose into an open container. • Loosen the caliper bleed screw and push the SCH4610 pistons into the caliper with your finger.
Page 247 POWR BRAKE Å 30 Nm (3.0 m · kg, 22 ft · lb) ı 48 Nm (4.8 m · kg, 35 ft · lb) SCH4620 Order Job name/Part name Q’ty Remarks Brake caliper and parking brake re- Remove the parts in the order listed below. moval Brake fluid Drain.
Page 248 POWR BRAKE SCH4630 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 proce- dure.
Page 249: 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 SCH4640 • Piston oil seals 1 Removal steps: • Using a wood of piece 2, lock the right piston.
Page 250: 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. SCH4670 • Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and dust seals when- ever a caliper is disassembled.
Page 251 POWR BRAKE Å 14 Nm (1.4 m · kg, 10 ft · lb) ı 30 Nm (3.0 m · kg, 22 ft · lb) SCH4690 Order Job name/Part name Q’ty Remarks Brake master cylinder removal Remove the parts in the order listed below. Brake fluid Drain.
Page 252: Inspection
POWR BRAKE INSPECTION 1. Inspect: • Master cylinder 1 Wear/scratches → Replace the master cylin- der assembly. • Master cylinder body 2 Cracks/damage → Replace. • Oil delivery passage (master cylinder body) Blow out with compressed air. SCH4700 2. Inspect: •...
Page 253 POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION VX700/VX700DX/SX700 Å 72 Nm (7.2 m · kg, 52 ft · lb) SCH4730 Job name/Part name Order Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen.
Page 254: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION VT700 Å 24 Nm (2.4 m · kg, 17 ft · lb) ı : 72 Nm (7.2 m · kg, 52 ft · lb) SCH4740 Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen.
Page 255 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 256 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) å : For SX700 : 1 ESSO beacon 325 grease or Aeroshell grease #7A SCH4760...
Page 257 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 SCH4770 Job name/Part name Order Q’ty Remarks...
Page 258 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) å For SX700/VT700 : 1 ESSO beacon 325 grease or Aeroshell grease #7A SCH4780...
Page 259 POWR SLIDE RAIL SUSPENSION MM700 Å 72 Nm (7.2 m · kg, 52 ft · lb) SCH4790 Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen.
Page 260 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 261 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 SCH4810 Order...
Page 262 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 SCH4820 Job name/Part name Order Q’ty Remarks...
Page 263 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 SCH4830 Job name/Part name...
Page 264: Inspection
POWR SLIDE RAIL SUSPENSION INSPECTION 1. Inspect: • Suspension wheel • Guide wheel Cracks/damage → Replace. • Wheel bearing Wheel turns roughly → Replace. SCH4840 2. Inspect: • Stopper band 1 Frayed/damage → Replace. • Pull rod 2 Bends/damage → Replace. •...
Page 265: Assembly
POWR SLIDE RAIL SUSPENSION ASSEMBLY 1. Install: • Shaft 1 (MM700) NOTE: Ensure the rubber collars 2 are not pinched between the shaft and sliding frames 3. Bolt (shaft) 1: SCH4870 72 Nm (7.2 m · kg, 52 ft · lb) 2.
Page 266 POWR SLIDE RAIL SUSPENSION Control rod parts number SCH4890 ı Parts number Ç Length a Î Length b Å Control rod 1 8CR-4745A-01 310.5 mm (12.2244 in) 200.0 mm(7.8740 in) Å Control rod 1 8ED-4745A-00 262.5 mm (10.3346 in) 146.0 mm(5.7480 in) Ì...
Page 267 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) SCH4900 Order Job name/Part name Q’ty Remarks Front axle and track removal Remove the parts in the order listed below.
Page 268: Inspection
POWR FRONT AXLE AND TRACK INSPECTION 1. Inspect: • Track 1 • Slide metal 2 Wear/cracks/damage → Replace. SCH4910 2. Inspect: • Sprocket wheel 1 Wear/break/damage → Replace. • Front axle 2 Bends/scratches (excessive)/damage → Replace. SCH4920 INSTALLATION 102 mm 123 mm 102 mm (4.02 in)
Page 269 POWR FRONT AXLE AND TRACK 2. Place the track in the chassis. NOTE: • For VX700/VX700DX/SX700/MM700: For track with a direction of rotation mark a: Install the track with the mark pointing in the direc- tion of track rotation. • For VT700: Be sure it is positioned as shown in the illustration.
Page 270: Engine
EXHAUST ASSEMBLY ENGINE EXHAUST ASSEMBLY Å 18 Nm (1.8 m · kg, 13 ft · lb) 2nd 27 Nm (2.7 m · kg, 19 ft · lb) SCH5010 Order Job name/Part name Q’ty Remarks Exhaust assembly removal Remove the parts in the order listed below. Shroud Open.
Page 271: Installation
EXHAUST ASSEMBLY INSTALLATION 1. Install: • Gasket 3 • Exhaust joint NOTE: • Install the gasket 3 with its projection a facing the primary sheave side. • Tighten the bolts 1 ~ 6 in a crisscross pattern. SCH5020 Bolt (exhaust joint) 1 ~ 6: 1st: 18 Nm (1.8 m ·...
Page 272: Engine Assembly
ENGINE ASSEMBLY ENGINE ASSEMBLY Å 15 Nm (1.5 m · kg, 11 ft · lb) ı 23 Nm (2.3 m · kg, 17 ft · lb) Ç 33 Nm (3.3 m · kg, 24 ft · lb) Î 57 Nm (5.7 m · kg, 41 ft · lb) ‰...
Page 273: Inspection
ENGINE ASSEMBLY INSPECTION 1. Inspect: • Rear bracket (right) 1 Cracks/damage → Replace. SCH5050 INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUTING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Fasten: SCH5060 • Plastic band 1 NOTE: •...
Page 274 ENGINE ASSEMBLY 3. Bleed: • Oil system Refer to “OIL PUMP” in CHAPTER 2. • Cooling system Refer to “COOLING SYSTEM” in CHAPTER 2. 4. Adjust: • Oil pump cable distance a Refer to “OIL PUMP” in CHAPTER 2. Distance a: ±...
Page 275: Cylinder Head And Cylinder
CYLINDER HEAD AND CYLINDER CYLINDER HEAD AND CYLINDER Å : 10 Nm (1.0 m · kg, 7.2 ft · lb) ı : 14 Nm (1.4 m · kg, 10 ft · lb) SCH5080 Order Job name/Part name Q’ty Remarks Cylinder head and cylinder removal Remove the parts in the order listed below.
Page 276 CYLINDER HEAD AND CYLINDER Å 14 Nm (1.4 m · kg, 10 ft · lb) ı 11 Nm (1.1 m · kg, 8.0 ft · lb) 23 Nm (2.3 m · kg, 17 ft · lb) Ç 20 Nm (2.0 m · kg, 14 ft · lb) Î...
Page 277: 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 SCH5100 crankcase with a clean rag so that you will not accidentally drop the clip into the crankcase.
Page 278: 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. SCH5120 2. Inspect: • Cylinder head water jacket Crust of minerals/rust →...
Page 279 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. SCH5160 8. Measure: • Piston-to-cylinder clearance Measurement steps: 1st step: •...
Page 280 CYLINDER HEAD AND CYLINDER 2nd step: • Measure the piston skirt diameter (P) with a micrometer. a 15 mm (0.59 in) from the bottom edge of the piston Piston size (standard) (P): 70.427 ~ 70.430 mm (2.7727 ~ 2.7728 in) •...
Page 281 CYLINDER HEAD AND CYLINDER 10. Install: • Piston ring (into the cylinder) Push in the ring with the piston crown. NOTE: Insert the ring into the cylinder, and push it approxi- mately 20 mm (0.8 in) into the cylinder. Push in the ring with the piston crown so that the ring is at right SCH5210 angles to the cylinder bore.
Page 282 CYLINDER HEAD AND CYLINDER 14. Inspect: • Reed valves 1 Bends/cracks/damage → Replace. SCH5250 15. Measure: • Valve stopper height a Out of specification → Replace the valve stop- per. Valve stopper height a: 10.3 ~ 10.7 mm (0.41 ~ 0.42 in) SCH5260 16.
Page 283: 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 284 CYLINDER HEAD AND CYLINDER 4. Check: • Piston ring position CAUTION: • Make sure that the ring ends are properly fitted around the ring locating pins in the piston grooves. • Be sure to check that the manufacturer’s marks or numbers stamped on the rings face upward. SCH5320 5.
Page 285 CYLINDER HEAD AND CYLINDER 9. Tighten: • Nuts (cylinder head) Tightening steps: • Temporarily tighten the cylinder head nuts 1 ~ E as follows. 1st step: • Tighten the nuts 1 ~ E. Nut (cylinder head) 1 ~ E: 11 Nm (1.1 m · kg, 8.0 ft · lb) 2nd step: •...
Page 286: 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 287: 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 SCH5400 Maximum runout: : 0.03 mm (0.0012 in) : 0.04 mm (0.0016 in) : 0.03 mm (0.0012 in) 90 mm (3.54 in) 85 mm (3.35 in)
Page 288 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. SCH5430 5. Inspect: SCH5440 • Impeller driven gear teeth 1 Wear/damage →...
Page 289: Installation
OIL PUMP, CRANKCASE AND CRANKSHAFT INSTALLATION 1. Install: • Stopper ring 1 [onto the crankshaft bearing 2 (primary sheave side) as shown] 3 Knock pin SCH5460 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 290 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) SCH5490 CAUTION: Before installing and torquing the crankcase bolts, be sure to check that the crankshaft turns smoothly.
Page 291 OIL PUMP, CRANKCASE AND CRANKSHAFT 6. Install: • Oil hose 1 NOTE: Install so that the mark a on the check valve faces the crankcase. SCH5530 5-22...
Page 292: Ac Magneto
AC MAGNETO AC MAGNETO Å 23 Nm (2.3 m · kg, 17 ft · lb) ı 48 Nm (4.8 m · kg, 35 ft · lb) Ç 110 Nm (11 m · kg, 80 ft · lb) SCH5540 Order Job name/Part name Q’ty Remarks AC magneto removal...
Page 293: Removal
AC MAGNETO REMOVAL 1. Remove: • Bolts 1 • Starter pulley 2 • Nut 3 NOTE: Attach the primary sheave holder to hold the primary sheave. SCH5550 Primary sheave holder: 90890-01701, YS-01880 2. Remove: • Magneto rotor 1 NOTE: • Remove the magneto rotor using the rotor puller 2.
Page 294: Installation
AC MAGNETO INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUTING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Install: • Stator coil NOTE: Route the pickup coil lead 1 under and behind the pickup coil 2 as shown. SCH5570 2.
Page 295 AC MAGNETO 4. Tighten: • Bolts 1 • Nut 2 Bolt (starter pulley) 1: 23 Nm (2.3 m · kg, 17 ft · lb) Nut (magneto rotor) 2: 110 Nm (11 m · kg, 80 ft · lb) SCH5590 NOTE: Attach the primary sheave holder to hold the primary sheave.
Page 296: Recoil Starter
RECOIL STARTER RECOIL STARTER Å 12 Nm (1.2 m · kg, 8.7 ft · lb) ı 18 Nm (1.8 m · kg, 13 ft · lb) SCH5600 Order Job name/Part name Q’ty Remarks Recoil starter removal Remove the parts in the order listed below. Exhaust silencer Refer to “EXHAUST ASSEMBLY”.
Page 297: 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. SCH5610 SCH5620 INSPECTION...
Page 298: 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 299: Chapter 6. Cooling System
COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER VX700/VX700DX/SX700/VT700 Å 7 Nm (0.7 m · kg, 5.1 ft · lb) SCH6010 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.
Page 300: Mm700
COOL HEAT EXCHANGER MM700 Å 7 Nm (0.7 m · kg, 5.1 ft · lb) SCH6020 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.
Page 301: Inspection
COOL HEAT EXCHANGER INSPECTION 1. Inspect: • Coolant hoses 1 • Heat exchangers 2 • Filler cap body 3 • Carburetor heating lever assembly 4 • Carburetor heating hoses 5 Cracks/damage → Replace. Å VX700/VX700DX/SX700/VT700 ı MM700 SCH6030 SCH6040...
Page 302: Installation
COOL HEAT EXCHANGER 2. Measure: • Filler cap opening pressure Cap opens with a pressure below the specified pressure → Replace. Cap opening pressure: 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm , 14 ~ 18 psi) SCH6050 Measurement steps: •...
Page 303: 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) Ç 33 Nm (3.3 m · kg, 24 ft · lb) Î 90 Nm (9.0 m · kg, 65 ft · lb) SCH6060 Order Job name/Part name...
Page 304: Removal
COOL WATER PUMP REMOVAL 1. Remove: • Impeller 1 NOTE: Attach the primary sheave holder to hold the primary sheave. Primary sheave holder: SCH6070 90890-01701, YS-01880 INSPECTION 1. Inspect: • Impeller 1 • Water pump cover 2 • Thermostatic cover 3 Cracks/damage →...
Page 305: Chapter 7. Carburetion
CARB CARBURETORS CARBURETION CARBURETORS SCH7010 Q’ty Remarks Order Job name/Part name Carburetors removal Remove the parts in the order listed below. Intake silencer Refer to “FUEL PUMP”. Carburetor heating lever Before removing the carburetors, make sure that the carburetor heating lever is turned to “OFF”. Carburetor switch (T.O.R.S.) lead Throttle cable Starter cable...
Page 306 CARB CARBURETORS : 1 ESSO beacon 325 grease or Aeroshell grease #7A SCH7020 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 Breather hose...
Page 307 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) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SCH7030...
Page 308 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) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SCH7030...
Page 309: 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 SCH7040 air. 2. Inspect: • Rubber seals 1 •...
Page 310: Assembly
CARB CARBURETORS 5. Inspect: • Throttle valve 1 Wear/damage → Replace. 6. Check: • Throttle valve movement Sticks → Replace carburetor body assembly. SCH7080 ASSEMBLY NOTE: • Before reassembling, wash all parts in clean gaso- line. • Always use new gaskets and O-rings. 1.
Page 311 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 312: Fuel Level Adjustment
CARB CARBURETORS FUEL LEVEL ADJUSTMENT 1. Measure: • Fuel level a 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 313: Installation
CARB CARBURETORS INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUTING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Fasten: • Carburetor heating hose 1 NOTE: Fasten the carburetor heating hose with a clamp 2 at the white mark a.
Page 314: Fuel Pump
CARB FUEL PUMP FUEL PUMP VX700/VX700DX/VT700 Å 5 Nm (0.5 m · kg, 3.6 ft · lb) ı 10 Nm (1.0 m · kg, 7.2 ft · lb) SCH7160 Order Job name/Part name Q’ty Remarks Fuel pump removal Remove the parts in the order listed below. Carburetor heating lever assembly Air filter element Screw...
Page 315: Sx700/Mm700
CARB FUEL PUMP SX700/MM700 Å 5 Nm (0.5 m · kg, 3.6 ft · lb) ı 10 Nm (1.0 m · kg, 7.2 ft · lb) SCH7170 Q’ty Remarks Order Job name/Part name Fuel pump removal Remove the parts in the order listed below. Carburetor heating lever assembly Air filter element Screw...
Page 316: Inspection
CARB FUEL PUMP INSPECTION SCH7180 1. Inspect: • Fuel hose 1 • Fuel delivery hoses 2 • Vacuum hose 3 • Oil delivery hose 4 Clogs/damage → Replace. 2. Check: • Fuel pump operation Checking steps: • Connect the Mity vac 1 to the vacuum hose 2. Mity vac: 90890-06756, YB-35956 SCH7190...
Page 317: Chapter 8. Electrical
– ELEC SWITCH INSPECTION ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for conti- nuity. If the continuity is faulty at any point, replace the switch. Pocket tester: 90890-03112, YU-03112 NOTE: • Set the pocket tester to “0” before starting a test. •...
Page 318: Ignition System
– ELEC IGNITION SYSTEM SCH8180...
Page 319 – ELEC IGNITION SYSTEM 1 AC magneto 2 Rectifier/regulator ∗1 3 Condenser ∗2 4 Main fuse ∗2 6 Battery 8 Main switch 9 Engine stop switch 0 Throttle switch C Carburetor switch E CDI unit H Ignition coil I Spark plug J Engine ground K Frame ground S Brake light switch...
Page 320: Troubleshooting
– ELEC IGNITION SYSTEM TROUBLESHOOTING NO SPARK OR WEAK SPARK. For VX700DX/VT700: Check the main fuse and “IGNITION” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or “IGNITION” fuse. For VX700DX/VT700: Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2.
Page 321 – ELEC IGNITION SYSTEM For VX700/SX700/MM700: Check the lighting, signal and meter system. Refer to “LIGHTING SYSTEM” and “SIGNAL SYSTEM”. FAULTY Repair the lighting system and/or signal system and/or meter system. Correct the connection and/or replace the rectifier/regulator and/or CDI unit. NOTE: For VX700/SX700/MM700: If a short circuit occurred in the lighting system, the...
Page 322: Condenser (Vx700/Sx700/Mm700)
– ELEC IGNITION SYSTEM CONDENSER (VX700/SX700/MM700) 1. Disconnect: • Condenser 1 SCH8190 2. Connect: • Condenser (to the LCR meter) 3. Measure: • Condenser capacity Out of specification → Replace. Condenser capacity: µ 6,800 F at 20˚C (68˚F) AC MAGNETO 1.
Page 323: Spark Plug
– ELEC IGNITION SYSTEM SPARK PLUG 1. Remove: • Spark plugs 2. Measure: • Spark plug gap Standard spark plug: BR9ES (NGK) Spark plug gap: SCH8220 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) SPARK PLUG CAP 1. Remove: • Spark plug cap 2.
Page 324: Throttle Override System (T.o.r.s.)
– ELEC IGNITION SYSTEM THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should malfunction during operation, T.O.R.S. will operate when the throttle lever is released. T.O.R.S. is designed to interrupt the ignition and keep the engine revolutions between 2,800 and 3,000 r/min if the carburetor fails to return to idle when the lever is released.
Page 325: Carburetor Switch
– ELEC IGNITION SYSTEM 4. Check: • Throttle switch continuity Faulty → Replace the handlebar switch (right). Ω × 1 Throttle switch Continuity position – B/Y B/W Throttle lever is operated. Throttle lever is not operated. SCH8310 CARBURETOR SWITCH SCH8320 1.
Page 326: Load Control Relay
– ELEC IGNITION SYSTEM LOAD CONTROL RELAY 1. Inspect: • Load control relay (black) 1 Inspection steps: • Disconnect the load control relay from the cou- pler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the load control relay terminals as SCH8340 shown.
Page 327: Electrical Starting System (Vx700Dx/Vt700)
– ELEC ELECTRICAL STARTING SYSTEM (VX700DX/VT700) SCH8030 8-11...
Page 328: Troubleshooting
– ELEC ELECTRICAL STARTING SYSTEM (VX700DX/VT700) TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. WARNING Before starter motor operation, push the engine stop switch to “OFF”. 1. Connect: • Starter relay terminals (battery side and starter motor side) Check the battery and connectors. Refer to “BATTERY INSPECTION”...
Page 329: Main Switch
– ELEC ELECTRICAL STARTING SYSTEM (VX700DX/VT700) FAULTY Check the main fuse and “IGNITION” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or “IGNITION” fuse. FAULTY Check the main switch. Replace the main switch. Correct the connection. MAIN SWITCH 1.
Page 330: Starter Motor
– ELEC ELECTRICAL STARTING SYSTEM (VX700DX/VT700) STARTER MOTOR Å : 7 Nm (0.7 m · kg, 5.1 ft · lb) SCH8070 Order Job name/Part name Q’ty Remarks Starter motor disassembly Remove the parts in the order listed below. Starter motor removal Refer to “ENGINE REMOVAL”...
Page 331 – ELEC ELECTRICAL STARTING SYSTEM (VX700DX/VT700) Inspection 1. Inspect: • Commutator (outer surface) Dirty → Clean with #600 grit sandpaper 1. Hold the armature in a vise 2 and copper or aluminium plate 3. CAUTION: Lightly grip the armature with a vise. SCH8080 2.
Page 332 – ELEC ELECTRICAL STARTING SYSTEM (VX700DX/VT700) 5. Measure: • Brush length a Out of specification → Replace the starter motor. Brush wear limit a: 8.5 mm (0.33 in) SCH8120 6. Measure: • Brush spring pressure Fatigue/out of specification → Replace as a set.
Page 333: Charging System (Vx700Dx/Vt700)
– ELEC CHARGING SYSTEM (VX700DX/VT700) SCH8150 8-17...
Page 334: Troubleshooting
– ELEC CHARGING SYSTEM (VX700DX/VT700) TROUBLESHOOTING BATTERY IS NOT CHARGED. 1. Connect: • Pocket tester (to the battery terminals) OUT OF SPECIFICATIONS 2. Measure: • Battery voltage • Fluid gravity • Check the battery. Battery voltage: more than 12 V at 20 ˚C (68˚F) Refer to “BATTERY INSPECTION”...
Page 335: Battery
– ELEC CHARGING SYSTEM (VX700DX/VT700) BATTERY Inspection 1. Inspect: • Battery fluid level Refer to “BATTERY INSPECTION” in CHAP- TER 2. 2. Check: • Specific gravity Less than 1.280 → Recharge battery. Battery Storage The battery should be stored if the vehicle is not going to be used for a long period.
Page 336: Lighting System
– ELEC LIGHTING SYSTEM SCH8370 8-20...
Page 337 – ELEC LIGHTING SYSTEM 1 AC magneto 2 Rectifier/regulator ∗1 3 Condenser ∗2 4 Main fuse ∗2 6 Battery 8 Main switch E CDI unit K Frame ground T Tail/brake light Z High beam indicator light [ Speedometer light \ Tachometer light a Headlight b Headlight beam switch c Headlight relay (blue)
Page 338: Troubleshooting
– ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT AND/OR METER LIGHT DO NOT COME ON. Check the bulb(s). NO CONTINUITY Replace the bulb(s). For VX700DX/VT700: Check the main fuse, “IGNITION” fuse and “HEAD” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION”...
Page 339 – ELEC LIGHTING SYSTEM TAIL LIGHT DOES NOT COME ON. Check the bulb(s). NO CONTINUITY Replace the bulb(s). For VX700DX/VT700: Check the main fuse, “IGNITION” fuse and “TAIL” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION” fuse and/or “TAIL” fuse.
Page 340: Bulb(S)
– ELEC LIGHTING SYSTEM BULB(S) SCH8380 1. Remove: • Headlight bulb a • Tail/brake light bulb b • Meter light bulb c 2. Connect: • Pocket tester (to the bulb terminals) WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot. Do not touch the bulb until it cools down.
Page 341: Headlight Relay
– ELEC LIGHTING SYSTEM HEADLIGHT RELAY 1. Inspect: • Headlight relay (blue) 1 Inspection steps: • Disconnect the headlight relay from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay terminals as shown. SCH8410 Positive battery terminal →...
Page 342: Signal System
– ELEC SIGNAL SYSTEM SCH8430 8-26...
Page 343 – ELEC SIGNAL SYSTEM 1 AC Magneto 2 Rectifier/regulator ∗1 3 Condenser ∗2 4 Main fuse ∗2 6 Battery 8 Main switch D Water temperature sensor E CDI unit K Frame ground ∗2 Q DC back buzzer ∗2 R Gear position switch S Brake light switch T Tail/brake light U Fuel sender...
Page 344: Troubleshooting
– ELEC SIGNAL SYSTEM TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. Check the tail/brake light bulb. Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb. For VX700DX/VT700: Check the main fuse, “IGNITION” fuse and “TAIL” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION”...
Page 345 – 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). Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb(s). For VX700DX/VT700: Check the main fuse, “IGNITION”...
Page 346 – ELEC SIGNAL SYSTEM FUEL METER DOES NOT OPERATE. For VX700DX/VT700: Check the main fuse, “IGNITION” fuse and “HEAD” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION” fuse and/or “HEAD” fuse. For VX700DX/VT700: Check the battery. Refer to “BATTERY INSPECTION”...
Page 347 – ELEC SIGNAL SYSTEM BACK BUZZER DOES NOT SOUND. (VX700DX/VT700) Check the main fuse, “IGNITION” fuse and “TAIL” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION” fuse and/or “TAIL” fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 348: Brake Light Switch
– ELEC SIGNAL SYSTEM BRAKE LIGHT SWITCH SCH8440 1. Disconnect: • Brake light switch coupler 1 2. Check: • Brake light switch continuity Faulty → Replace. Switch position Continuity Brake lever operates Brake lever does not operate GEAR POSITION SWITCH (VX700DX/VT700) 1.
Page 349: Water Temperature Sensor
– ELEC SIGNAL SYSTEM WATER TEMPERATURE SENSOR 1. Disconnect the water temperature sensor cou- pler 1 and remove the water temperature sen- sor. CAUTION: Handle the water temperature sensor with spe- cial care. Never subject it to shock or allow it to be dropped.
Page 350: Oil Level Switch
– ELEC SIGNAL SYSTEM OIL LEVEL SWITCH 1. Remove: • Intake silencer Refer to “FUEL PUMP” in CHAPTER 7. • Oil level gauge 1 SCH8470 2. Connect: • Pocket tester (to the oil level switch coupler) 3. Check: • Oil level switch continuity Faulty →...
Page 351 – ELEC 8-35...
Page 352: Grip Warmer System
– ELEC GRIP WARMER SYSTEM SCH8540 8-36...
Page 353 – ELEC GRIP WARMER SYSTEM 1 AC magneto 2 Rectifier/regulator ∗1 3 Condenser ∗2 4 Main fuse ∗2 6 Battery 8 Main switch A Grip warmer B Thumb warmer E CDI unit F Variable resistor (thumb warmer) G Variable resistor (grip warmer) K Frame ground ∗3 L Passenger grip warmer switch...
Page 354: Troubleshooting
– ELEC GRIP WARMER SYSTEM TROUBLESHOOTING GRIP WARMER AND THUMB WARMER DO NOT OPERATE. For VX700DX/VT700: Check the main fuse and “IGNITION” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or “IGNITION” fuse. For VX700DX/VT700: Check the battery.
Page 355 – ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER DOES NOT OPERATE. (VT700) Check the main fuse, “IGNITION” fuse and “TAIL” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION” fuse and/or “TAIL” fuse. Check the battery. Refer to “BATTERY INSPECTION”...
Page 356: Grip And Thumb Warmer Coil
– ELEC GRIP WARMER SYSTEM GRIP AND THUMB WARMER COIL SCH8550 1. Disconnect: • Grip warmer leads 1 • Thumb warmer coupler 2 2. Connect: • Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads) 3. Check: •...
Page 357: Variable Resistor (Grip Warmer)
– ELEC GRIP WARMER SYSTEM VARIABLE RESISTOR (GRIP WARMER) 1. Disconnect: • Variable resistor coupler 1 2. Connect: • Pocket tester (to the variable resistor coupler) SCH8590 3. Check: • Variable resistor resistance When pulley is turned once. Ω × 1 Out of specification →...
Page 358: Passenger Grip Warmer Switch (Vt700)
– ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER SWITCH (VT700) 1. Disconnect: • Passenger grip warmer switch coupler 1 2. Connect: • Pocket tester (to the passenger grip warmer switch coupler) SCH8630 3. Check: • Passenger grip warmer switch continuity Faulty →...
Page 359: Passenger Grip Warmer Relay (Vt700)
– ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER RELAY (VT700) SCH8680 1. Inspect: • Passenger grip warmer relay 1 Inspection steps: • Disconnect the passenger grip warmer relay from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the passenger grip warmer relay termi- nals as shown.
Page 360: 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 361 – ELEC FAULT LOCATION TABLE Patterns Condition Reference Shorting of grip warmer is Refer to “GRIP Repeats detected. WARMER SYSTEM”. 0.75 s 0.25 s 3.5 s SCH8740 Discontinuity of the Refer to “VARI- Repeats variable resistor (thumb ABLE RESIS- warmer) is detected. TOR (THUMB WARMER)”.
Page 362: Chapter 9. Specifications
Maximum torque r/min 8,250 r/min Starting system Recoil hand starter (VX700/SX700/MM700) Electric and recoil hand starter (VX700DX/VT700) Lubrication system Separate lubrication (YAMAHA AUTOLUBE) Engine oil: Type YAMALUBE 2-cycle oil Tank capacity 3.0 L (2.6 Imp qt, 3.2 US qt) Drive chain housing oil: Type Gear oil API “GL-3”...
Page 363 SPEC GENERAL SPECIFICATIONS Model VX700/VX700DX/SX700/MM700/VT700 Fuel: R + M Type Regular unleaded gasoline (Pump Octane ; 88) Research Octane; 93 (for Europe) 44.3 L (9.7 Imp gal, 11.7 US gal) Tank capacity Carburetor: TM33/3 Type/Quantity MIKUNI Manufacturer Spark plug: BR9ES Type Manufacturer 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Page 364 SPEC GENERAL SPECIFICATIONS Model VX700/VX700DX/SX700/MM700/VT700 Bulb wattage × Quantity: 12 V, 60 W/55 W × 2 Headlight 12 V, 8 W/23 W × 1 Tail/Brake light 12 V, 1.7 W × 1 Tachometer light 12 V, 1.7 W × 1 Speedometer light 12 V, 1.7 W ×...
Page 365: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model VX700/VX700DX/SX700/MM700/VT700 Cylinder head: 22.9 ~ 23.5 cm Volume (with spark plug) (1.40 ~ 1.43 cu.in) <0.03 mm (0.0012 in)> <Warp limit> ∗Lines indicate straight edge measurement. Cylinder: Aluminum alloy with dispersion coating Material 70.500 ~ 70.520 mm Bore size (2.7756 ~ 2.7764 in)
Page 366 SPEC MAINTENANCE SPECIFICATIONS Model VX700/VX700DX/SX700/MM700/VT700 Crankshaft: Crank width “A” 55.95 ~ 56.00 mm (2.203 ~ 2.205 in) 291.75 ~ 292.30 mm (11.486 ~ 11.508 in) Crank width “B” Maximum runout “C” : C 0.03 mm (0.0012 in) 0.04 mm (0.0016 in) 0.03 mm (0.0012 in) Measuring points: 90 mm (3.54 in)
Page 367 SPEC MAINTENANCE SPECIFICATIONS Model VX700/VX700DX/SX700/MM700/VT700 Carburetor: Type/Quantity TM33/3 MIKUNI Manufacturer I.D. mark 8CH10 #1: 145 Main jet (M.J) #2, #3: 143.8 Pilot jet (P.J) 6DGM05-3 Jet needle (J.N) Needle jet (N.J) #1: Q-8 #2, #3: Q-4 Pilot air jet (P.A.J) Pilot outlet (P.O) ø0.8...
Page 368: Power Train
SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model VX700/VX700DX/SX700/MM700/VT700 Transmission: V-belt automatic Type 3.8 ~ 1.0 :1 Range of ratio 4,000 ± 200 r/min (3,800 ~ 4,200 r/min) (VX700/VX700DX) Engagement speed r/min 3,900 ± 200 r/min (3,700 ~ 4,100 r/min) (SX700/VT700) 4,700 ± 200 r/min (4,500 ~ 4,900 r/min) (MM700) 8,300 ±...
Page 369 SPEC MAINTENANCE SPECIFICATIONS VX700/VX700DX/SX700/MM700/VT700 Model Primary sheave weight arm: 8CH-17605-10 (VX700/VX700DX) (VT700 for U.S.A./Canada) Part number (with bushing) 8DF-17605-10 (SX700) 8CR-17605-10 (MM700) (VT700 for Europe) 35.32 g (1.246 oz) (VX700/VX700DX) (VT700 for U.S.A./Canada) Weight 37.84 g (1.334 oz) (SX700) 38.09 g (1.345 oz) (MM700) (VT700 for Europe) Rivet: Outer 90261-06015 (VX700/VX700DX)
Page 370 SPEC MAINTENANCE SPECIFICATIONS VX700/VX700DX/SX700/MM700/VT700 Model Drive chain: REXNORD S37TNB13 Type 70 L (VX700/VX700DX/SX700/MM700) (VT700 for U.S.A./Canada) Number of links 68 L (VT700 for Europe) Track: 8EA-47110-10 (VX700/VX700DX/SX700) Part number 8ED-47110-00 (MM700) 8BN-47110-00 (VT700) 381 mm (15.0 in) Width 3,072 mm (120.9 in) (VX700/VX700DX/SX700) Length 3,584 mm (141.1 in) (MM700) 3,456 mm (136.1 in) (VT700)
Page 371 SPEC MAINTENANCE SPECIFICATIONS Model VX700/VX700DX/SX700/MM700/VT700 Suspension setting position: Hook setting length ∗ 10 ± 0.5 mm (0.39 ± 0.02 in) (VX700/MM700) 15 ± 0.5 mm (0.59 ± 0.02 in) (VX700DX) 25 ± 0.5 mm (0.98 ± 0.02 in) (SX700/VT700) Full rate adjusting position ∗∗ Shock absorber: Damping force Front 451 N/0.3 m/s (46 kg/0.3 m/s, 101 lb/0.3 m/s) (VX700)
Page 372: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model VX700/VX700DX/SX700/MM700/VT700 Frame: Aluminum Frame material 730 mm (28.7 in) (VX700/VX700DX/SX700/VT700) Seat height 700 mm (27.6 in) (MM700) Rear side of seat Luggage box location Steering: 29.4° (R ski) 34.7° (L ski) (VX700/VX700DX/SX700/VT700) Lock-to-lock angle (left) 34.7°...
Page 373: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model VX700/VX700DX/SX700/MM700/VT700 12 V Voltage Ignition system: 18° at 1,500 r/min Ignition timing (B.T.D.C.) Advanced type Digital type Ignition coil: F6T535/MITSUBISHI Model/Manufacturer 6 mm (0.236 in) or more Minimum spark gap 0.36 ~ 0.48 Ω at 20°C (68°F) Primary coil resistance 5.4 ~ 7.4 kΩ...
Page 374 SPEC MAINTENANCE SPECIFICATIONS VX700/VX700DX/SX700/MM700/VT700 Model Starter motor (VX700DX/VT700): Model/Manufacturer DB4XF/DENSO Output 12 V-0.6 kW Armature coil resistance 0.014 ~ 0.018 Ω at 20°C (68°F) Continuity check Insulation check More than 100 kΩ at 20°C (68°F) Brush Overall length 12 mm (0.47 in) Wear limit 8.5 mm (0.33 in) Spring pressure...
Page 375: High Altitude Settings
SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS VX700/SX700 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 #148.8 MJ #1 #147.5 MJ #1 #146.3 MJ #1 #145 MJ #1 #143.8 MJ #2#3 #147.5 MJ #2#3 #146.3 MJ #2#3 #143.8 MJ #2#3 #145...
Page 376 SPEC MAINTENANCE SPECIFICATIONS VX700DX 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 #148.8 MJ #1 #147.5 MJ #1 #146.3 MJ #1 #145 MJ #1 #143.8 MJ #2#3 #147.5 MJ #2#3 #146.3 MJ #2#3 #145 MJ #2#3 #143.8 MJ #2#3 #142.5...
Page 377 SPEC MAINTENANCE SPECIFICATIONS MM700/VT700 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 #148.8 MJ #1 #147.5 MJ #1 #146.3 MJ #1 #145 MJ #1 #143.8 MJ #2#3 #147.5 MJ #2#3 #146.3 MJ #2#3 #145 MJ #2#3 #143.8 MJ #2#3 #142.5...
Page 378: Tightening Torque
SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m · kg ft · lb Crankcase (M8 × 80) (1st) Tighten the bolts in two (2nd) stages. Crankcase (M8 × 35) Engine bracket (front) and frame Engine bracket damper (front/rear) Engine bracket (front) and engine Engine bracket right (rear) and engine...
Page 379 SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Tightening torque Parts to be tightened Remarks m · kg ft · lb Primary sheave (1st) 12.0 Tighten the bolts in two (2nd) stages. See NOTE. Spider and fixed sheave 20.0 Left-hand thread. Apply LOCTITE ®...
Page 380 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Parts to be tightened Remarks m · kg ft · lb ® Wheel bracket shaft and sliding frame Apply LOCTITE 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 381 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 ®...
Page 382: 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 specifica- 10 mm 6 mm tions for special components or assemblies are in- 12 mm 8 mm cluded in the applicable sections of this book.
Page 383 SPEC 9-22...
Page 384: Cable Routing
SPEC CABLE ROUTING SCH9010 9-23...
Page 385 SPEC CABLE ROUTING CABLE ROUTING 1 Water temperature sensor coupler 2 Fasten the carburetor switch leads and water temperature sensor leads and ignition coil leads to the coolant hose with a plastic band. For VX700DX/ VT700, include the starter motor and battery negative leads.
Page 386 SPEC CABLE ROUTING SCH9010 9-25...
Page 387 SPEC CABLE ROUTING D Connectors of the gear position switch (VX700DX/VT700) E Route the main switch wire harness under the oil tank breather hose and fuel tank breather hose. F Install the main switch coupler behind the instrument panel. G Make sure that the main switch wire harness is on the inside of the instrument panel screw (away from the engine).
Page 388 SPEC CABLE ROUTING SCH9020 9-27...
Page 389 SPEC CABLE ROUTING 1 Brake hose 2 Oil pump cable 3 Throttle cable 4 Wire harness 5 Starter cable 9-28...
Page 390 SPEC CABLE ROUTING SCH9030 9-29...
Page 391 SPEC CABLE ROUTING 1 Wire harness 2 Ensure this is not kink. 3 50 mm (1.97 in) 4 Make sure that the oil tank cap and oil tank breather hose do not touch each other. 5 Route the fuel tank breather hose over the main switch wire harness.
Page 392 SPEC CABLE ROUTING SCH9030 9-31...
Page 393 SPEC CABLE ROUTING K Fuel tank breather hose L Ground lead M Install the clamp so that it does not come into contact with the ground lead terminal. N Route the fuel tank breather hose behind the condenser. (VX700/ SX700/MM700) O Condenser (VX700/SX700/ MM700) P Fasten the condenser leads and...
Page 394 SPEC CABLE ROUTING SCH9040 9-33...
Page 395 SPEC CABLE ROUTING 1 Speedometer coupler 2 Tachometer coupler 3 Plastic band 4 Clamp 5 Headlight leads 6 Speedometer cable 7 Fasten the headlight leads and speedometer cable at the white tape mark, with a plastic band. 8 Route the wire harness and speedometer cable under the shroud’s stopper wire.
Page 396 SPEC CABLE ROUTING SCH9050 9-35...
Page 397 SPEC CABLE ROUTING 1 Oil pump cable 2 Throttle cable 3 Do not fasten the throttle cable and oil pump cable. 4 Pass only the throttle, and oil pump cables through the inside of the cable holder. 5 Thumb warmer coupler 6 Engine stop switch coupler 7 Connectors of the grip warmer 8 Brake light switch coupler...
Page 398 SPEC CABLE ROUTING SCH9050 9-37...
Page 399 SPEC CABLE ROUTING S When fastening the wire harness with the attached clamp, bend the clamp inward to fasten. T Do not fasten. U Fasten the wire harness at the white tape mark, with a clamp. V Oil hose W Coolant reservoir hose X To filler cap body Y Passenger grip warmer relay coupler (VX700/VX700DX/...
Page 400 SPEC CABLE ROUTING SCH9060 9-39...
Page 401 SPEC CABLE ROUTING 1 Make sure a plastic band is routed through the projection located on the silencer, when fastening it around the wire harness and the starter cable. (VX700/VX700DX/VT700) 2 Starter cable 3 Make sure the plastic bands are routed through the projection located on the silencer, when fastening them around the wire...
Page 402 AC magneto COLOR CODE Rectifier/regulator B ....Black Br ....Brown ∗1 Condenser Ch ....Chocolate ∗2 Main fuse G ....Green ∗2 Gy ....Gray Starter relay L ....Blue ∗2 Battary Lg ....Light green ∗2 O ....Orange Starter motor P ....
Page 403 WIRING DIAGRAM VX700/VX700DX/SX700/MM700/VT700 B/W Y Br/W B Y/R Lg G/R (WHITE) (BLACK) W W W W W W (BLACK) (BLACK) OPEN B/Y B/W B/W B/Y IDLE START Br/W Y/B G/R Br R Å (30A) Br/W (BLACK) Å Br/W G/B B (BLACK) R/B G/R (BLACK)
Page 404 00 06 × 0.8.E. PRINTED ON RECYCLED PAPER...

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Vt70j

Yamaha SXV70SJ Supplementary Service Manual

Index 1 Gen Info Periodic Inspections and

Chapter 2 Periodic Inspections and Adjustments

Chapter 3 Chassis

Chapter 5 Engine

. General Information

Chapter 1. General Information

Chapter 4. Power Train

Chapter 6. Cooling System

Chapter 7. Carburetion

Chapter 8. Electrical

Chapter 9. Specifications

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha SXV70SJ