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#1
Руководство пользователя (русский язык)
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7,2 MB
Просмотры: 9.830
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#2
Yamaha Phazer FX (Help)
Ребят куплю (или возьму на 3 дня за 3 
) руководство по ремонту. Книжку, которая идет в комплекте, или если кто знает, где ее можно найти в Интернете на данный снегоход.
Заранее спасибо!
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#3
Re: Yamaha Phazer FX (Help)
+1, ищу мануалку на PHAZER MTX, поделитесь плз 
…..
С Уважением,
eLoX.
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#4
Re: Yamaha Phazer FX (Help)
Вот нашел, может кому понадобится 
….
З.Ы. по SERVICE и OWNERS мануалам для PZ50MW 8GP1, вопрос остается открытым….
C Уважением,
eLoX.
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1,8 MB
Просмотры: 2.262
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#5
Re: Yamaha Phazer FX (Help)
service manual для Фазиков 2007….
+ дополнение для моделей 2008….
З.Ы. осталась мануалка …..
С Уважением,
eLoX.
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15,5 MB
Просмотры: 2.680 -
9,1 MB
Просмотры: 1.396
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#6
Re: Yamaha Phazer FX (Help)
Ну и ,собственно, мануал …
С Уважением,
eLoX.
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5,9 MB
Просмотры: 2.292
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#7
Re: Руководство пользователя Yamaha venture MP и вся платформа
Сервисное Руководство. PZ50 07-08
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9,1 MB
Просмотры: 7.713
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#8
Re: Руководство пользователя Yamaha venture MP и вся платформа
Полный cервис мануал Yamaha Multi Purpose и Yamaha Phazer
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22,9 MB
Просмотры: 5.030
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#9
MAD написал(а):
Руководство пользователя (русский язык)
Не получается скачать, выдает:
Вы не авторизованы для скачивания этого вложения.
Что это значит?
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#10
Надоели лишние страницы в мануале.
Удалил из сервис мануала Фазера и Мультика французский и норвежский, оставил только английский язык
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14,8 MB
Просмотры: 861
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#11
Бюллетень про проблемы с задней передачей
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1,3 MB
Просмотры: 396
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#12
Чтоб не забылось, парни меняли
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SERVICE MANUAL
MANUEL D’ATELIER
INSTRUKTIONSBOK
VX700F
VX700DXF
SX700F
MM700F
VT700F
8CH-28197-J0
(981051)
Related Manuals for Yamaha VT700F
Summary of Contents for Yamaha VT700F
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Page 1
SERVICE MANUAL MANUEL D’ATELIER INSTRUKTIONSBOK VX700F VX700DXF SX700F MM700F VT700F 8CH-28197-J0 (981051) -
Page 3
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 4
AVERTISSEMENT COMMENT UTILISER Ce manuel a été écrit par la Yamaha Motor Company CE MANUEL à l’intention des concessionnaires Yamaha et de leurs mécaniciens qualifiés. Il n’est pas possible de mettre Les informations particulièrement importantes sont toute la formation d’un mécanicien dans un seul repérées par les notations suivantes. -
Page 5
ANMÄRKNING ANVÄNDNING AV Denna handbok som är skriven av Yamaha Motor INSTRUKTIONSBOKEN Company är främst avsedd för Yamaha auktoriserade återförsäljare och reparatörer. En utbildad mekanik- Särskilt viktig information i instruktionsboken har ers erfarenhet kan inte ersättas med instruktioner — märkts på följande sätt: hur fullständiga de än är — i en verkstadshandbok av… -
Page 6
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 7
SYMBOLES GRAPHIQUES ILLUSTRERADE SYMBOLER (Voir l’illustration) (Se illustrationen) Les symboles graphiques à servent à repérer De illustrerade symbolerna 1 till 9 har utformats les différents chapitres et à indiquer leur contenu. som ett index för att indikera kapitlets nummer och Renseignements généraux innehåll. -
Page 9
INDEX INDEX INNEHÅLLSFÖRTECKNING GENERAL INFORMATION RENSEIGNEMENTS GENERAUX ALLMÄN INFORMATION INFO PERIODIC INSPECTIONS AND ADJUSTMENT INSPECTIONS ET REGLAGES PERIODIQUES INSP PERIODISK INSPEKTION OCH JUSTERING CHASSIS CHASSIS CHAS CHASSI POWER TRAIN TRAIN DE ROULEMENT POWR DRIVENHET ENGINE MOTEUR MOTOR COOLING SYSTEM SYSTEME DE REFROIDISSEMENT COOL KYLSYSTEM CARBURETION… -
Page 10
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 11
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 12
CHAPTER 6. HANDLEBAR SWITCH (RIGHT) ….8-7 CARBURETOR SWITCH ……8-8 COOLING SYSTEM MAIN SWITCH ……….. 8-8 LOAD CONTROL RELAY ……8-9 HEAT EXCHANGER ……..6-1 EMERGENCY ENGINE STARTING VX700/VX700DX/SX700/VT700 ….6-1 (VX700/SX700/MM700) ……8-9 MM700 …………6-2 INSPECTION ……….6-3 ELECTRICAL STARTING SYSTEM INSTALLATION ………. -
Page 13
PASSENGER GRIP WARMER RELAY (VT700) …………. 8-38 FAULT LOCATION TABLE ……8-39 CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS ……9-1 MAINTENANCE SPECIFICATIONS ….9-4 ENGINE …………9-4 POWER TRAIN ………. 9-7 CHASSIS ……….9-11 ELECTRICAL ……….. 9-12 HIGH ALTITUDE SETTINGS ….9-14 TIGHTENING TORQUE …… -
Page 14
CHAPITRE 1. CONTROLE DU SYSTEME D’ARRET DU MOTEUR PRIORITAIRE (T.O.R.S.) ..2-14 RENSEIGNEMENTS GENERAUX REGLAGE DU JEU DU CABLE DE STARTER (CHOKE) … 2-15 NUMEROS D’IDENTIFICATION ….1-1 CONTROLE DU SYSTEME NUMERO DE SERIE DU CHASSIS ..1-1 D’ECHAPPEMENT ……… 2-15 NUMERO DE SERIE DU MOTEUR .. -
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REGLAGE …………. 2-40 CARTER DE CHAINE DE REGLAGE DES CARBURATEURS ..2-40 TRANSMISSION ………. 4-17 REGLAGE DE L’EMBRAYAGE…. 2-47 MODELES SANS MARCHE SELECTION DES PIGNONS ….2-52 ARRIERE ……….4-17 REGLAGE POUR HAUTE ALTITUDE .. 2-58 INSPECTION ……….. 4-18 SUSPENSION AVANT ……2-59 MONTAGE ………. -
Page 16
MOTEUR …………5-3 POMPE A CARBURANT ……7-10 INSPECTION ……….5-4 VX700/VX700DX/VT700 ……7-10 MONTAGE ……….5-4 SX700/MM700 ……… 7-11 INSPECTION ……….. 7-12 CULASSE ET CYLINDRES ……5-6 MONTAGE ……….7-12 DEPOSE …………. 5-8 CHAPITRE 8. INSPECTION ……….5-9 PARTIE ELECTRIQUE MONTAGE ………. -
Page 17
SYSTEME D’ECLAIRAGE ……8-19 PARTIE ELECTRIQUE ……9-12 SCHEMA DE CIRCUIT ……8-19 REGLAGE POUR HAUTE ALTITUDE . 9-14 GUIDE DE DEPANNAGE …… 8-20 COUPLE DE SERRAGE ……9-17 AMPOULE(S) ………. 8-22 CONTACTEUR DE FEU DE ROUTE ..8-22 SPECIFICATIONS GENERALES RELAIS DE PHARE …….. -
Page 18
KAPITEL 1. DRIVENHET ……….. 2-16 INSTÄLLNING AV SKIVAVSTÅND OCH ALLMÄN INFORMATION SIDOFÖRSKJUTNING ……2-16 DRIVREM ……….2-18 MASKINENS IDENTIFIERING ……1-1 KONTROLL AV RAMENS SERIENUMMER ……1-1 INKOPPLINGSHASTIGHETEN ….2-20 MOTORNS SERIENUMMER ….. 1-1 INSPEKTION AV PARKERINGSBROMSENS BROMSKLOTS ……… 2-20 VIKTIG INFORMATION …….. -
Page 19
KAPITEL 3. BROMS …………4-29 BYTE AV BROMKLOTSAR …… 4-30 CHASSI ISÄRTAGNING AV BROMSOK ….4-34 INSPEKTION OCH REPARATION AV STYRNING …………3-1 BROMSOKET ……….. 4-34 VX700/VX700DX/SX700/VT700 ….3-1 BROMSOK ……….4-35 MM700 …………3-2 MONTERING AV BROMSOK ….4-35 INSPEKTION ………. -
Page 20
REKYLSTARTARE ……..5-27 TÄNDSTIFT ……….8-6 DEMONTERING ……..5-28 TÄNDSTIFTSGAP ……..8-6 INSPEKTION ……….5-28 TÄNDSPOLE ……….8-6 INSTALLATION ……..5-29 GASLÅSNINGSSYSTEM (T.O.R.S.) ..8-7 STYRETS OMKOPPLARE (HÖGER) ..8-7 FÖRGASAROMKOPPLARE …… 8-8 KAPITEL 6. HUVUDOMKOPPLARE ……8-8 KYLSYSTEM DRIFTRELÄT ……….8-9 NÖDSTART AV MOTORN VÄRMEVÄXLARE ………. -
Page 21
VARIABELT MOTSTÅND (HANDTAGSVÄRMARE) ……8-36 PASSAGERARHANDTAGETS VÄRMARE (VT700) …………. 8-36 PASSAGERARHANDTAGETS VÄRMAROMKOPPLARE (VT700) … 8-37 MOTSTÅND (VT700) ……. 8-37 RELÄ FÖR PASSAGERARSÄTETS GREPPVÄRMARE (VT700) ….. 8-38 FELUNDERSÖKNINGSTABELL ….8-39 KAPITEL 9. SPECIFIKATIONER ALLMÄNNA SPECIFIKATIONER ….9-1 UNDERHÅLLSSPECIFIKATIONER ….9-4 MOTOR …………9-4 DRIVENHET ………. -
Page 22: 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.
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Page 23
NUMEROS D’IDENTIFICATION MASKINENS IDENTIFIERING INFO RENSEIGNEMENTS ALLMÄN INFORMATION GENERAUX MASKINENS IDENTIFIERING RAMENS SERIENUMMER NUMEROS D’IDENTIFICATION Chassits serienummer 1 är beläget på chassits NUMERO DE SERIE DU CHASSIS högra sida (strax nedanför sitsens framdel). Le numéro de série du châssis est estampé du côté MOTORNS SERIENUMMER droit de ce dernier, (juste sous l’avant du siège). -
Page 24: 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…
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Page 25: Viktig Information
Vi rekommenderar användning av Yamaha original- d’origine pour tous les remplacements. Utiliser les delar för alla byten. Använd olja och fett som rekom- huiles recommandées par Yamaha lors des remonta- menderas av Yamaha vid hopsättning och justering. ges et réglages.
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Page 26
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 27
INFORMATIONS IMPORTANTES VIKTIG INFORMATION INFO JOINTS, BAGUES D’ETANCHEITE ET PACKNINGAR, OLJEPACKNINGAR JOINTS TORIQUES OCH O-RINGAR 1. Lorsqu’un moteur est révisé, tous les joints, ba- 1. Alla packningar, oljepackningar och O-ringar skall gues d’étanchéité et joints toriques doivent être bytas när motorn repareras. Alla ytor för changés. -
Page 28: 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.
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Page 29
OUTILS SPECIAUX SPECIALVERKTYG INFO OUTILS SPECIAUX SPECIALVERKTYG Les outils spéciaux convenables sont nécessaires pour Vissa specialverktyg är nödvändiga för fullkomlig jus- un assemblage et une mise au point complets et précis. tering och hopsättning. Användning av korrekt speci- L’utilisation des outils spéciaux convenables permet- alverktyg hjälper till att förhindra skada som kan upp- tra d’éviter les dommages dus à… -
Page 30
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 31
OUTILS SPECIAUX SPECIALVERKTYG INFO POUR LA REPARATION DU MOTEUR FÖR MOTORSERVICE • • Extracteur d’axe de piston Kolvbultsavdragare P/N YU-01304 (E.-U. et Canada) P/N YU-01304 (för USA/Canada) 90890-01304 (Europe) 90890-01304 (för Europa) Cet outil est utilisé pour enlever les axes de piston. Detta verktyg används för att demontera kolvbulten. -
Page 32
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 33
OUTILS SPECIAUX SPECIALVERKTYG INFO • • Poussoir de douille d’embrayage Kopplingsbussningspress P/N YS-42424 P/N YS-42424 Cet outil permet de déposer et de reposer les douilles Detta verktyg används för demontering och montering (poulies primaire et mobile, came de torsion). av postbussningarna (primärremskivans kåpbussning, glidremskivans bussning och vridmomentkammens bussning). -
Page 34
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 35
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 36
INSP INTRODUCTION/ENTRETIENS PERIODIQUES INSPECTIONS ET REGLAGES PERIODIQUES INTRODUCTION Ce chapitre traite de toutes les procédures nécessaires pour effectuer les inspections et réglages préconisés. Si l’on respecte ces procédures d’entretien préventif, on sera assuré d’un fonctionnement satisfaisant et d’une plus longue durée de service de la machine. La nécessité de révisions générales sera ainsi réduite dans une large mesure. -
Page 37
INSP ENTRETIENS PERIODIQUES Chaque Après le Vérifications premier mois Saison ou tous avant Désignation Remarques ou 800 km les 3.200 km utilisation (500 mi) (2.000 mi) (quotidiennes) (40 h) (160 h) Vérifier le fonctionnement et l’étanchéité. Frein et frein de stationne- Ajuster le jeu et/ou remplacer les plaquettes de ment frein si nécessaire. -
Page 38
INSP INLEDNING/TABELL FÖR PERIODISKT UNDERHÅLL PERIODISK INSPEKTION OCH JUSTERING INLEDNING Det här kapitlet innehåller all information som behövs för att utföra de rekommenderade inspektionerna och justeringarna. Dessa skyddande underhållsåtgärder, om de följs, kommer att tillförsäkra tillförlitligare maskin- funktion och ett längre brukbart liv hos maskinen. Behovet av dyra reparationsarbeten kommer dessutom att reduceras kraftigt. -
Page 39
INSP TABELL FÖR PERIODISKT UNDERHÅLL Första månaden eller Varje säsong Kontroll före första eller 3.200 km Detalj Anmärkningar användning 800 km (2.000 miles) (dagligen) (500 miles) (160 timmar) (40 timmar) Kontrollera funktionen och vätskeläckage. Justera spelrummet och/eller byt ut bromsklotsarna Broms/parkeringsbroms om nödvändigt. -
Page 40
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 41
BOUGIES INSP TÄNDSTIFT MOTEUR MOTOR BOUGIES TÄNDSTIFTET 1. Déposer: 1. Demontera: • • Capuchons de bougie Tändstiftshattar • • Bougies Tändstiftet 2. Inspecter: 2. Inspektera: • • Electrodes Elektroderna 1 Usure/endommagement → Remplacer. Skada/slitage → Byt tändstiften. • • Teinte de la porcelaine Isolatorns färg 2 3. -
Page 42
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 43
POMPE A HUILE INSP OLJEPUMP POMPE A HUILE OLJEPUMP Purge Avluftning ATTENTION: VIKTIGT: Purger la pompe à huile et les conduits d’huile Oljepumpen och oljetilloppsledningen måste quand: avluftas i följande fall: • • une partie quelconque du circuit d’huile a été När någon del av oljesystemet har kopplats ur. -
Page 44
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 45
POMPE A HUILE INSP OLJEPUMP 14. Installer: 14. Installera: • • Joint (boulon de purge) Packningen (avluftningsskruv) • • Boulon de purge Avluftningsskruven 15.Installer: 15. Installera: • • Support arrière (droit) Bakre fästet (höger) M8 boulon de fixation (arrière): M8 fästbult (bak): 33 Nm (3,3 m ·… -
Page 46
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 47
VERIFICATION DES CONDUITS DE CARBURANT/SYSTEME DE REFROIDISSEMENT INSP INSPEKTION AV BRÄNSLELEDNING/KYLSYSTEM VERIFICATION DES CONDUITS DE INSPEKTION AV BRÄNSLELEDNING CARBURANT 1. Demontera: • 1. Déposer: Insugningsljuddämpare • Silencieux d’admission Vi hänvisar till “BRÄNSLEPUMP” i kapitel 7. Se reporter à “POMPE A CARBURANT” au 2. -
Page 48
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 49
SYSTEME DE REFROIDISSEMENT INSP KYLSYSTEM 4. Déposer: 4. Demontera: • • Bouchon de l’orifice de remplissage du liquide Kylmedlets påfyllningslock 1 de refroidissement VARNING AVERTISSEMENT Tag inte av kylmedlets påfyllningslock 1 när Ne jamais enlever le bouchon de remplissage de motorn är het. -
Page 50
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 51
SYSTEME DE REFROIDISSEMENT INSP KYLSYSTEM 9. Déconnecter: 9. Koppla ur: • • Flexibles de liquide de refroidissement Kylmedelsslangarna 1 Å VX700/VX700DX/SX700/VT700 Å VX700/VX700DX/SX700/VT700 ı MM700 ı MM700 10. Vidanger le liquide de refroidissement. 10.Tappa ur kylmedlet. OBS: N.B.: Soulever l’avant de la motoneige pour vidanger com- Lyft upp maskinens framdel för att tappa ur kylmedlet plètement. -
Page 52
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 53
SYSTEME DE REFROIDISSEMENT INSP KYLSYSTEM 18. Inspecter: 18. Inspektera: • • Joint (boulon de vidange) Packning (kylmedlets urtappningsbult) Endommagement → Remplacer. Skada → Byt. 19. Installer: 19. Installera: • • Joint Packning • • Kylmedlets urtappningsbult 1 Boulon de vidange Kylmedlets urtappningsbult 1: Boulon de vidange 13 Nm (1,3 m ·… -
Page 54
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 55
SYSTEME DE REFROIDISSEMENT INSP KYLSYSTEM 22. Purger d’air le système de refroidissement. 22. Avlufta kylsystemet. 23. Inspecter: 23. Inspektera: • • Système de refroidissement Kylsystemet Perte de pression (fuites) → Réparer. Minskning i trycket (läckage) → Reparera efter behov. Marche à suivre: Inspektionsåtgärder: •… -
Page 56
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 57
SYSTEME DE REFROIDISSEMENT INSP KYLSYSTEM Marche à suivre: Avluftningsåtgärder: • • Soulever l’arrière de la machine. Lyft upp maskinens baksida. • • Retirer le boulon de purge de l’échangeur de Tag ut avluftningsbulten 1 på värmeväxlaren. • chaleur. Fyll sakta på kylmedel i kylartanken och tillåt •… -
Page 58
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 59
INSP SYSTEME DE REFROIDISSEMENT/SYNCHRONISATION DES CARBURATEURS KYLSYSTEM/SYNKRONISERING AV FÖRGASARE • • Démonter le bouchon de remplissage de liquide Tag av kylmedlets påfyllningslock och avlufta de refroidissement et purger à nouveau le sys- kylsystemet igen, på det sätt som visas i åtgär- tème de refroidissement en suivant les étapes derna ovan. -
Page 60
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 61
INSP REGLAGE DU REGIME DE RALENTI/REGLAGE DU JEU DE CABLE D’ACCELERATION JUSTERING AV MOTORNS TOMGÅNGSHASTIGHET/JUSTERING AV GASVAJERN REGLAGE DU REGIME DE RALENTI JUSTERING AV MOTORNS 1. Régler: TOMGÅNGSHASTIGHET • Régime de ralenti 1. Justera: • Motorns tomgångshastighet Marche à suivre: •… -
Page 62
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 63
INSP REGLAGE DU JEU DE CABLE D’ACCELERATION/CONTROLE DU SYSTEME D’ARRET DU MOTEUR PRIORITAIRE (T.O.R.S.) JUSTERING AV GASVAJERN/KONTROLL AV GASLÅSNINGSSYSTEMET (T.O.R.S.) 2. Régler: 2. Justera: • • Jeu de câble d’accélération Gasvajerns spelrum Marche à suivre: Justeringsåtgärder: • • Desserrer le contre-écrou Lossa på… -
Page 64
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 65
INSP REGLAGE DU JEU DU CABLE DE STARTER (CHOKE)/CONTROLE DU SYSTEME D’ECHAPPEMENT JUSTERING AV STARTKABELNS (CHOKENS) SPELRUM/INSPEKTION AV AVGASSYSTEMET REGLAGE DU JEU DU CABLE DE JUSTERING AV STARTKABELNS STARTER (CHOKE) (CHOKENS) SPELRUM 1. Mesurer: 1. Mät: • • Jeu du câble de starter Chokevajerns spelrum a Hors spécifications →… -
Page 66
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 67
ECARTEMENT DES POULIES ET REGLAGE DU DECALAGE INSP INSTÄLLNING AV SKIVAVSTÅND OCH SIDOFÖRSKJUTNING TRAIN DU ROULEMENT DRIVENHET ECARTEMENT DES POULIES ET INSTÄLLNING AV SKIVAVSTÅND OCH REGLAGE DU DECALAGE SIDOFÖRSKJUTNING 1. Ouvrir le capot. 1. Öppna motorhuven. 2. Déposer: 2. Demontera: •… -
Page 68
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 69
ECARTEMENT DES POULIES ET REGLAGE DU DECALAGE INSP INSTÄLLNING AV SKIVAVSTÅND OCH SIDOFÖRSKJUTNING 6. Mät: 6. Mesurer: • • Sekundärskivans frigång (rörelsemarginal) a Jeu de la poulie secondaire (écartement) Använd ett tjockleksmätare. Utiliser une jauge d’épaisseur. Motsvarar ej specifikation → Justera. →… -
Page 70
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 71
COURROIE TRAPEZOIDALE INSP DRIVREM COURROIE TRAPEZOIDALE DRIVREM AVERTISSEMENT VARNING Veiller à placer la nouvelle courroie trapézoïdale Var vid montering av en ny kilrem noga med att de 1,5 mm (0,06 in) au-dessus à –0,5 mm (–0,02 in) remmen placeras mellan 1,5 mm (0,06 in) ovanför en dessous du bord de la poulie secondaire. -
Page 72
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 73
COURROIE TRAPEZOIDALE INSP DRIVREM 2. Ajuster la position de la courroie trapézoïdale en 2. Justera kilremmens läge genom att ta bort eller ajoutant ou en retirant une entretoise au niveau lägga till ett mellanlägg 1 på var och en av de chacun des boulons de réglage justeringsbultarna 2. -
Page 74
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 75
VERIFICATION DU REGIME D’EMBRAYAGE/CONTROLE DES PLAQUETTES DE FREIN DE STATIONNEMENT/REGLAGE DU FREIN DE INSP STATIONNEMENT KONTROLL AV INKOPPLINGSHASTIGHETEN/INSPEKTION AV PARKERINGSBROMSENS BROMSKLOTS/JUSTERING AV PARKERINGSBROMSEN VERIFICATION DU REGIME KONTROLL AV D’EMBRAYAGE INKOPPLINGSHASTIGHETEN 1. Placer la motoneige sur une surface plane de 1. Placera maskinen på en plan yta av hårt packad neige dure. -
Page 76
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 77
REGLAGE DU LEVIER DE FREIN AVANT (VX700DX/SX700/VT700)/ INSP CONTROLE DU NIVEAU DE LIQUIDE DE FREIN JUSTERING AV HANDBROMS (VX700DX/SX700/VT700)/INSPEKTION AV BROMSVÄTSKANS NIVÅ REGLAGE DU LEVIER DE FREIN AVANT JUSTERING AV HANDBROMS (VX700DX/SX700/VT700) (VX700DX/SX700/VT700) 1. Régler: 1. Justera: • • Position du levier de frein Bromsspakens läge (distance entre la manette des gaz et le levier de (avståndet från gashandtaget till bromsspaken) -
Page 78
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 79
CONTROLE DES PLAQUETTES DE FREIN/CONTROLE DE FLEXIBLE DE FREIN/ INSP PURGE D’AIR (CIRCUIT DE FREINAGE HYDRAULIQUE) INSPEKTION AV BROMSKLOTSARNA/INSPEKTION AV BROMSSLANGEN/AVLUFTNING (HYDRAULISKT BROMSSYSTEM) CONTROLE DES PLAQUETTES DE FREIN INSPEKTION AV BROMSKLOTSARNA 1. Actionner le levier de frein. 1. Drag till bromsspaken. 2. -
Page 80
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. •… -
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PURGE D’AIR (CIRCUIT DE FREINAGE HYDRAULIQUE)/ INSP CHAINE DE TRANSMISSION AVLUFTNING (HYDRAULISKT BROMSSYSTEM)/DRIVKEDJAN d. Serrer les vis de purge quand le levier a atteint d. Drag fast avluftningsskruvarna när bromsspak- la limite de sa course, puis relâcher le levier. ens gräns har nåtts och släpp sedan spaken. •… -
Page 82
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 83
CHAINE DE TRANSMISSION INSP DRIVKEDJAN VIKTIGT: ATTENTION: L’extrémité de la jauge est munie d’un aimant. Det sitter en magnet i änden på oljestickan. Den är till för att avlägsna eventuella metallpartiklar Celui-ci permet d’éliminer toutes les particules métalliques qui pourraient s’accumuler dans le som samlats i drivkedjehuset. -
Page 84
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 85
CHAINE DE TRANSMISSION INSP DRIVKEDJAN Changement d’huile Oljebyte Åtgärder för oljebyte: Marche à suivre: • • Placera ett oljetråg under urtappningshålet. Placer un bac à vidange sous l’orifice de vi- • Tag ur oljeurtappningsbulten 1 och tappa ur dange. • oljan. -
Page 86
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 87
CHAINE DE TRANSMISSION/REGLAGE DE LA TENSION DE LA CHENILLE INSP DRIVKEDJAN/JUSTERING AV BANDSPÄNNINGEN 3. Installer: 3. Installera: • • Support de batterie (VX700DX/VT700) Batterifäste (VX700DX/VT700) • • Batterie (VX700DX/VT700) Batteriet (VX700DX/VT700) ATTENTION: VIKTIGT: • • Connecter d’abord le câble positif à la borne de Anslut pluskabeln till batteripolen först. -
Page 88: Track Tension Adjustment
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 89
REGLAGE DE LA TENSION DE LA CHENILLE INSP JUSTERING AV BANDSPÄNNINGEN 3. Régler: 3. Justera: • • Flèche de la chenille Bandets avböjning Marche à suivre: Justeringsåtgärder: • • Placer la motoneige sur un support adéquat, de Placera maskinen på att lämpligt stag så att façon à… -
Page 90
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 91
VERIFICATION DES PATINS INSP INSPEKTION AV GLIDSKENAN VERIFICATION DES PATINS INSPEKTION AV GLIDSKENAN 1. Inspecter: 1. Inspektera: • • Patin Glidskenan 1 → Sprickor/skada/slitage → Byt. Craquelures/endommagement/usure Rem- placer. 2. Mät: • 2. Mesurer: Glidskenans tjocklek a • Motsvarar ej specifikation → Byt. Epaisseur de patin →… -
Page 92
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 93
à la mönster. mise en place et l’emplacement correctes des clous. Yamaha rekommenderar inte dubbning av band. Yamaha ne recommande pas l’utilisation de clous. 2-29… -
Page 94
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 95
SKIS/LONGERONS DE SKI INSP SKIDAN/SKIDSKENAN CHASSIS CHASSI SKIS/LONGERONS DE SKI SKIDAN/SKIDSKENAN 1. Inspecter: 1. Inspektera: • • Skis Skidan • • Longerons de ski Skidskenan → Skada/slitage → Byt. Usure/endommagement Remplacer. Skidskenans slitagegräns a: Limite d’usure du longeron de ski 8 mm (0,31 in) 8 mm (0,31 in) Plastskidans slitagegräns b:… -
Page 96
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 97
DIRECTION INSP STYRSYSTEMET DIRECTION STYRSYSTEMET Inspection du jeu Kontroll av spelrum 1. Vérifier: 1. Kontrollera: • • Jeu du système de direction Styrsystemets spelrum Pousser le guidon en avant, en arrière et vers För styret uppåt och nedåt och fram och till- le haut et le bas. -
Page 98
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 99
DIRECTION/GRAISSAGE INSP STYRSYSTEMET/SMÖRJNING 3. Régler: 3. Justera: • • Ouverture des skis Skidornas skränkning Marche à suivre: Justeringsåtgärder: • • Desserrer les contre-écrous (barre d’accouple- Lossa på låsmuttrarna (parallellstag) 1. • ment) Vrid parallellstagen 2 inåt eller utåt tills specifice- •… -
Page 100
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 101
GRAISSAGE INSP SMÖRJNING Bras relais (direction) Reläarm (styrning) 1. Injecter de la graisse à travers les graisseurs à 1. Använd en fettpistol för att spruta in fett i nipplarna l’aide d’un pistolet graisseur. Lubrifiant recommandé: Rekommenderat smörjmedel: Graisse ESSO Beacon 325 ou ESSO:s Fett Beacon 325 eller Aeroshell n°7A Aeroshell Fett #7A… -
Page 102
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 103
REGLAGE DU FAISCEAU DU PHARE INSP JUSTERING AV STRÅLKASTAREN PARTIE ELECTRIQUE ELEKTRISKT REGLAGE DU FAISCEAU DU PHARE JUSTERING AV STRÅLKASTAREN 1. Placer la machine sur une surface plane. 1. Placera maskinen på en plan yta. 2. Placer le véhicule face à un mur à la distance 2. -
Page 104
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 105
INSPECTION DE LA BATTERIE (VX700DX/VT700) INSP INSPEKTION AV BATTERI (VX700DX/VT700) INSPECTION DE LA BATTERIE INSPEKTION AV BATTERI (VX700DX/VT700) (VX700DX/VT700) VARNING AVERTISSEMENT Batterivätska är giftigt och farligt och kan orsaka L’électrolyte de batterie est extrêmement toxique svåra brännskador m.m. Vätskan innehåller sva- et peut causer de graves brûlures. -
Page 106
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 107
INSPECTION DE LA BATTERIE (VX700DX/VT700) INSP INSPEKTION AV BATTERI (VX700DX/VT700) Remplacer la batterie dans les cas suivants: Byt ut batteriet i följande fall: • • Après plusieurs heures de charge, la tension de Om batterispänningen inte vill stiga till specifice- la batterie n’atteint pas la valeur spécifiée ou il rat värde eller om bubblorna inte stiger ens efter ne se dégage pas de bulles de gaz. -
Page 108
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 109
CHARGE DE LA BATTERIE (VX700DX/VT700) INSP LADDNING AV BATTERI (VX700DX/VT700) CHARGE DE LA BATTERIE LADDNING AV BATTERI (VX700DX/VT700) (VX700DX/VT700) Batteriet måsta laddas upp på korrekt sätt innan det Il convient de charger correctement une nouvelle tas i bruk för första gången. Denna inledande ladd- batterie avant sa première utilisation. -
Page 110
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 111
CHARGE DE LA BATTERIE (VX700DX/VT700)/ INSP VERIFICATION DES FUSIBLES (VX700DX/VT700) LADDNING AV BATTERI (VX700DX/VT700)/INSPEKTION AV SÄKRINGAR (VX700DX/VT700) 2. Installer: 2. Installera: • • Batterie Batteriet VIKTIGT: ATTENTION: • • Connecter d’abord le câble positif à la borne de Anslut pluskabeln till batteripolen först. •… -
Page 112
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 113
VERIFICATION DES FUSIBLES (VX700DX/VT700) INSP INSPEKTION AV SÄKRINGAR (VX700DX/VT700) 2. Remplacer: 2. Byt: • • Säkring som har gått Fusible grillé Etapes du remplacement: Åtgärder vid byte: • • Ställ huvudomkopplaren i läget “OFF”. Placer le contacteur à clé sur “OFF”. •… -
Page 114
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 115
REGLAGE DES CARBURATEURS INSP INSTÄLLNING AV FÖRGASARE REGLAGE INSTÄLLNING REGLAGE DES CARBURATEURS INSTÄLLNING AV FÖRGASARE Les carburateurs ont été réglés à l’usine pour fonc- Förgasarna är fabriksinställda för att användas vid en tionner à des températures allant de 0°C ~ –20°C temperatur på… -
Page 116
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 117
OBS: données figurant au CHAPITRE 9. Dessa munstycksspecifikationer kan ändras. Slå upp den senaste tekniska informationen från Yamaha för N.B.: Ces spécifications sont sujettes à modification. Con- att se till att Du har de allra nyaste munstycks- sulter la documentation technique Yamaha pour être… -
Page 118
INSP CARBURETOR TUNING Guide for carburetion SCH2815 2-42… -
Page 119
REGLAGE DES CARBURATEURS INSP INSTÄLLNING AV FÖRGASARE Guide pour la carburation Förgasningsguide Å Å Ouverture du papillon d’accélération Gasspällets öppning ı Réglage de moyen régime ı Inställning för medelhastighet Ç Réglage de haut régime Ç Inställning för hög hastighet Î Î… -
Page 120
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 121
REGLAGE DES CARBURATEURS INSP INSTÄLLNING AV FÖRGASARE Å Débit du gicleur principal (1/hr) Å Huvudmunstyckets bränsleflöde (1/timmen) ı Ouverture du papillon d’accélération ı Gasspällets öppning Ç Ouvert à fond Ç Helt öppet A Gicleur standard Standard huvudmunstycke B Gicleur dont le diamètre est inférieur de 10% au Huvudmunstycke vars diameter är 10% mindre än diamètre standard standard… -
Page 122
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 123
REGLAGE DES CARBURATEURS INSP INSTÄLLNING AV FÖRGASARE Réglage de bas régime Inställning för låg hastighet La mise au point des carburateurs pour la marche à Förgasarna är byggda så att inställningen för låg bas régime s’effectue au moyen de la vis de mélange hastighet kan göras genom att justera tomgångs- de ralenti et de la vis de butée de papillon… -
Page 124
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 125
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 126
INSP REGLAGE DES CARBURATEURS Tableau de sélection de gicleur principal Couleur de bougie Diagnostic Remède Jaune foncé ou gris Carburateurs bien réglés Dépôts noirs secs ou Mélange trop riche Remplacer le gicleur principal par un d’une taille pelucheux plus petite. Blanc ou gris clair Mélange trop pauvre Remplacer le gicleur principal par un d’une taille… -
Page 127
INSP REGLAGE DES CARBURATEURS Problème Diagnostic Réglage • Mauvais rendement à Gicleur de ralenti bouché Retirer le gicleur de ralenti, le nettoyer à l’air com- moyen régime: ou desserré primé, puis le remettre en place. • • Réponse lente aux Veiller à… -
Page 128
INSP INSTÄLLNING AV FÖRGASARE Tabell för val av huvudmunstycke Tändstiftsfärg Diagnos Åtgärd Ljus brunt eller grått Förgasaren är rätt inställd. Torra svarta eller fjuniga Blandningen är för rik. Byt ut huvudmunstycket mot ett som har ett nummer avlagringar lägre. Vitt eller ljus grått Blandningen är för mager. -
Page 129
INSP INSTÄLLNING AV FÖRGASARE Diagnos Justering • Dålig prestanda vid Tilltäppt eller löst sittande Demontera tomgångsmunstycket, rengör det med tryck- medelhastigheter: tomgångsmunstycke luft och installera det. • • Tillfälligt dålig reaktion Se till att tomgångsmunstycket dras fast ordentligt. vid gasning •… -
Page 130
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 131
REGLAGE DE L’EMBRAYAGE INSP KOPPLING REGLAGE DE L’EMBRAYAGE KOPPLING Haute altitude På hög höjd Caractéristiques Specifikationer Modèle: VX700 Modell: VX700 Å Altitude Å Höjd över havet ı Régime de ralenti ı Motorns tomgångsvarvtal Ç Régime d’embrayage (tr/mn) Ç Inkopplingsvarvtal (varv/min) Î… -
Page 132
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 133
REGLAGE DE L’EMBRAYAGE INSP KOPPLING Caractéristiques Specifikationer Modèle: VX700DX Modell: VX700DX Å Altitude Å Höjd över havet ı Régime de ralenti ı Motorns tomgångsvarvtal Ç Régime d’embrayage (tr/mn) Ç Inkopplingsvarvtal (varv/min) Î Régime de variation de rapport (tr/mn) Î Växlingsvarvtal (varv/min) ‰… -
Page 134
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 135
REGLAGE DE L’EMBRAYAGE INSP KOPPLING Caractéristiques Specifikationer Modèle: SX700 Modell: SX700 Å Altitude Å Höjd över havet ı Régime de ralenti ı Motorns tomgångsvarvtal Ç Régime d’embrayage (tr/mn) Ç Inkopplingsvarvtal (varv/min) Î Régime de variation de rapport (tr/mn) Î Växlingsvarvtal (varv/min) ‰… -
Page 136
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 ±… -
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REGLAGE DE L’EMBRAYAGE INSP KOPPLING Caractéristiques Specifikationer Modèle: MM700 Modell: MM700 Å Altitude Å Höjd över havet ı Régime de ralenti ı Motorns tomgångsvarvtal Ç Régime d’embrayage (tr/mn) Ç Inkopplingsvarvtal (varv/min) Î Régime de variation de rapport (tr/mn) Î Växlingsvarvtal (varv/min) ‰… -
Page 138
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 ±… -
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REGLAGE DE L’EMBRAYAGE INSP KOPPLING Caractéristiques Specifikationer Modèle: VT700 Modell: VT700 Å Altitude Å Höjd över havet ı Régime de ralenti ı Motorns tomgångsvarvtal Ç Régime d’embrayage (tr/mn) Ç Inkopplingsvarvtal (varv/min) Î Régime de variation de rapport (tr/mn) Î Växlingsvarvtal (varv/min) ‰… -
Page 140
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 141
REGLAGE DE L’EMBRAYAGE/SELECTION DES PIGNONS INSP KOPPLING/VAL AV VÄXEL Il pourrait s’avérer nécessaire de reprendre le réglage Det kan hända att kopplingen måste ställas in, de l’embrayage en fonction de la région d’utilisation, beorende på det område där maskinen används och des habitudes du pilote, etc. -
Page 142
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 143
SELECTION DES PIGNONS INSP VAL AV VÄXEL 1 N° de pièce de la chaîne et des pignons Detaljnummer på kedjor och kedjehjul Å Nom de pièce Å Detaljnamn ı Dents et maillons ı Kuggar & länkar Ç N° de pièce Ç… -
Page 144
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 145
SELECTION DES PIGNONS INSP VAL AV VÄXEL 5 Came de torsion (siège de ressort de poulie Momentkam (sekundärremskivans fjädersätet) Å secondaire) Identifieringsmärke Å Marque d’identification ı Effekter ı Effets Ç Detaljnummer Ç N° de pièce Î Kamvinkel Î Angle de came ‰… -
Page 146
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 147
SELECTION DES PIGNONS INSP VAL AV VÄXEL 6 Ressort de poulie primaire Primärremskivans fjäder Å Code de couleur des ressorts Å Färgkod för fjäderidentifiering ı Couleur de la raideur de ressort ı Färg för fjädervärde Ç Couleur de la précharge Ç… -
Page 148
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 149
INSP SELECTION DES PIGNONS VAL AV VÄXEL 7 Poids d’embrayage Kopplingsvikter Å Standard Å Standard 2-56… -
Page 150
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 151
SELECTION DES PIGNONS INSP VAL AV VÄXEL 8 Rouleaux Rullar Å N°/PIECE de ROULEAU et BAGUE Å RULLE med BUSSNING DETALJNUMMER ı DIAMETRE EXTERIEUR ı YTTRE DIAMETER Ç TYPE DE BAGUE (N°/P) Ç BUSSNINGSTYP (P/N) Î MARQUE D’IDENTIFICATION (largeur) Î IDENTIFIERINGSMÄRKE (bredd) ‰… -
Page 152
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 153: Reglage Pour Haute Altitude
INSP REGLAGE POUR HAUTE ALTITUDE REGLAGE POUR HAUTE ALTITUDE Pour obtenir le meilleur rendement à haute altitude, régler la motoneige comme indiqué ci-dessous. Vérifier les réglages standard. • Carburateurs • Bougies Déterminer la taille de gicleur principal selon le tableau. Tester gicleur principal (rendement et Incorrect Déterminer la taille de gicleur principal.
-
Page 154
INSTÄLLNING FÖR ANVÄNDNING PÅ HÖG HÖJD ÖVER INSP HAVSNIVÅ INSTÄLLNING FÖR ANVÄNDNING PÅ HÖG HÖJD ÖVER HAVSNIVÅ För att få bästa möjliga prestanda på platser som ligger högt över havsnivån skall Du varsamt ställa in snöskotern på det sätt som visas nedan. Kontrollera standardinställningarna •… -
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INSP… -
Page 156
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 157
SUSPENSION AVANT INSP FRÄMRE UPPHÄNGNING SUSPENSION AVANT FRÄMRE UPPHÄNGNING Précontrainte de ressort Fjäderförbelastning (VX700/VX700DX/MM700/VT700) (VX700/VX700DX/MM700/VT700) 1. Régler: 1. Justera: • • Précontrainte de ressort Fjäderförbelastningen Marche à suivre: Justeringsåtgärder: • • Tourner la bague de réglage jusqu’à la posi- Vrid justeringsringen 1 till lämpligt läge. tion désirée. -
Page 158
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 159
SUSPENSION ARRIERE INSP BAKRE UPPHÄNGNING SUSPENSION ARRIERE BAKRE UPPHÄNGNING Sangle d’arrêt Stoppband 1. Régler: 1. Justera: • • Tension de sangle d’arrêt Stoppbandets spänning ATTENTION: VIKTIGT: Veiller à régler de façon identique les côtés gauche Se till att vänster och höger sida på bakre et droite de la sangle d’arrêt de la suspension. -
Page 160
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 161
SUSPENSION ARRIERE INSP BAKRE UPPHÄNGNING Précontrainte de ressort Fjäderförbelastning (VX700/VX700DX/MM700/VT700) (VX700/VX700DX/MM700/VT700) 1. Régler: 1. Justera: • • Précontrainte de ressort Fjäderförbelastningen Marche à suivre: Justeringsåtgärder: • • Tourner la bague de réglage jusqu’à la position Vrid justeringsringen 1 till lämpligt läge. désirée. -
Page 162
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. •… -
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SUSPENSION ARRIERE INSP BAKRE UPPHÄNGNING Réglage général de la suspension arrière Bakre upphängningens fulla värde 1. Régler: 1. Justera: • • Dispositif de réglage de la suspension arrière Fullvärdesjusteraren Marche à suivre: Justeringsåtgärder: Position de Installations- montage läge Constante de Fjädervärde Mjuk Medel… -
Page 164
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 165
SUSPENSION ARRIERE INSP BAKRE UPPHÄNGNING Position de la suspension arrière (MM700) Bakre upphängningens läge (MM700) 1. Régler: 1. Justera: • • Position de la suspension arrière Bakre upphängningens läge N.B.: OBS: Sélectionner la position de la suspension arrière en Välj bakre upphängningens läge enligt gällande snö- förhållande: a normalt;… -
Page 166
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 167
DIRECTION CHAS STYRNING CHASSIS DIRECTION VX700/VX700DX/SX700/VT700 Ordre Travail/pièces Qté Remarques Dépose du guidon Déposer les pièces dans l’ordre indiqué ci-contre. Cache-guidon Attache réutilisable Reniflard de réservoir d’huile Coupleur de chauffe-pouce Déconnecter. Coupleur de coupe-circuit du moteur Déconnecter. Coupleur de contacteur de frein Déconnecter. -
Page 168
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 Remove the parts in the order listed below. Handlebar removal Handlebar cover Plastic band… -
Page 169
DIRECTION CHAS STYRNING MM700 Ordre Travail/pièces Qté Remarques Dépose du guidon Déposer les pièces dans l’ordre indiqué ci-con- tre. Cache-guidon Attache réutilisable Reniflard de réservoir d’huile Coupleur de chauffe-pouce Déconnecter. Coupleur de coupe-circuit du moteur Déconnecter. Coupleur de contacteur de frein Déconnecter. -
Page 170
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 171
DIRECTION CHAS STYRNING Ordre Travail/pièces Qté Remarques Dépose de la colonne de direction et de Déposer les pièces dans l’ordre indiqué ci-con- la barre d’accouplement tre. Moteur Se reporter à “MOTEUR” au CHAPITRE 5. Guidon Goupille fendue Agrafe Biellette intermédiaire Rondelle-frein Support de roulement Roulement… -
Page 172
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 173
DIRECTION CHAS STYRNING INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Guidon (VX700/VX700DX/SX700/VT700) Styret 1 (VX700/VX700DX/SX700/VT700) • • Guidon (MM700) Styret 2 (MM700) • • Colonne de direction Styrstången 3 Cintrage/craquelures/endommagement → Böjning/sprickor/skada → Byt. Remplacer. VARNING AVERTISSEMENT Gör inga försök att räta ut en böjd styrstång, Ne jamais essayer de redresser une colonne cin- eftersom detta kan försvaga styrstången på… -
Page 174
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 175
DIRECTION CHAS STYRNING MONTAGE INSTALLATION 1. Installer: 1. Installera: • • Bagues Bussningar 1 N.B.: OBS: Fäst bussningen med spelrummet a till änden på Monter la bague en veillant à laisser du jeu à l’extrémité du bras relais reläarmen 2. a Environ 1 mm (0‚04 in) Ca 1 mm (0,04 in) 2. -
Page 176
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 177
DIRECTION CHAS STYRNING 4. Installer: 4. Installera: • • Biellette intermédiaire Relästången 1 OBS: N.B.: Installer la biellette intermédiaire en veillant à con- Se till att stångänden på reläarmen med inbuktningen a ansluts till reläarmen. necter son extrémité porteuse de l’indentation bras relais. -
Page 178
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 179
DIRECTION CHAS STYRNING 6. Installer: 6. Installera: • • Guidon Styret VIKTIGT: ATTENTION: • • SX700/MM700: För SX700/MM700: S’assurer que la saillie du guidon ne vienne pas Se noga till att utbuktningen på styret inte monteras inom område a på illustrationen. s’insérer dans la zone illustrée. -
Page 180
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 181
SKIS CHAS SKIDA SKIS VX700/VX700DX/VT700 Ordre Travail/pièces Qté Remarques Dépose des skis Déposer les pièces dans l’ordre indiqué ci-con- tre. Goupille fendue Butée de ski Collerette Rondelle Support inférieur de colonne de ski Longeron de ski Collerette Couleur: Noir Collerette Couleur: Or Rondelle Levier de ski… -
Page 182
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 183
SKIS CHAS SKIDA SX700/MM700 Ordre Travail/pièces Qté Remarques Dépose des skis Déposer les pièces dans l’ordre indiqué ci-con- tre. Goupille fendue Support inférieur de colonne de ski Butée de ski Collerette Rondelle Longeron de ski Rondelle Poignée de ski Reposer les pièces dans l’ordre inverse de leur dépose. -
Page 184
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 185
SKIS CHAS SKIDA INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Skida 1 • • Longeron de ski Skidskena 2 • • Butée de ski Skidstoppare 3 • • Support inférieur de colonne de ski Skidstångens nedre fäste 4 • •… -
Page 186
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 187
SUSPENSION AVANT CHAS FRÄMRE UPPHÄNGNING SUSPENSION AVANT Ordre Travail/pièces Qté Remarques Dépose de la suspension avant Déposer les pièces dans l’ordre indiqué ci-con- tre. Se reporter à “SKIS”. Barre d’accouplement Amortisseur Capuchon Bras de direction Colonne de ski Douille Rondelle Barres de commande Collerette Douille… -
Page 188
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 189
SUSPENSION AVANT CHAS FRÄMRE UPPHÄNGNING REMARQUES AU SUJET DE LA ANMÄRKNINGAR BETRÄFFANDE MANIPULATION (SX700) HANTERING (SX700) AVERTISSEMENT VARNING Cet amortisseur contient de l’azote fortement com- Den här stötdämparen innehåller kraftigt kompri- primé. Lire et se conformer à ce qui suit avant de merad kvävgas. -
Page 190
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 191
SUSPENSION AVANT CHAS FRÄMRE UPPHÄNGNING 4. Inspecter: 4. Inspektera: • • Bielle Vevstaken 1 • • Stabilisateur Stabilisatorn 2 Craquelures/déformation/endommagement → Sprickor/böjning/skada → Byt. • Remplacer. Flänsarna 3 • Slitage/sprickor/skada → Byt. Collerette Usure/griffes/endommagement → Remplacer. 5. Inspecter: 5. Inspektera: •… -
Page 192
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 193
SUSPENSION AVANT CHAS FRÄMRE UPPHÄNGNING MONTAGE INSTALLATION 1. Installer: 1. Installera: • • Barre de commande Styrstaget 1 • • Ecrou Muttern 2 • • Raccord Leden 3 a Longueur Ställ in längd Å Gauche Å Vänster hand ı Longueur a ı… -
Page 194
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 195
SUSPENSION AVANT CHAS FRÄMRE UPPHÄNGNING 2. Installer: 2. Installera: • • Bras de direction Styrarmen 1 N.B.: OBS: • • Aligner le repère poinçonné de la colonne de ski Anpassa punsmärket a på skidstången med puns- et le repère poinçonné du bras de direction. -
Page 196
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 197
SUSPENSION AVANT CHAS FRÄMRE UPPHÄNGNING Carrossage de ski Skidspindellutning Vérifier le carrossage de ski en veillant à ce que la Kontrollera skidspindellutningen med snöskotern pla- motoneige soit installée sur une surface de niveau. cerad på en plan yta. Lyft INTE upp framändan. NE JAMAIS surélever l’avant du véhicule. -
Page 198
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 199
SUSPENSION AVANT CHAS FRÄMRE UPPHÄNGNING Fixer la barre intermédiaire de direction au bras 4 Installera styrstången på bogserarmen och dra åt traînant, puis serrer le boulon. Serrer le contre- bulten. Dra åt kulledens låsmutter och stryk fett écrou de la rotule, puis enduire la rotule de på… -
Page 200
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 201
SUSPENSION AVANT CHAS FRÄMRE UPPHÄNGNING N° de pièce de bras avant Främre arm, detaljnummer Å N°de pièce Å Detaljnummer ı Angle de chasse a ı Spindelbultens lutning bakåt a Ç Angle du support de barre de commande b Ç Styrstagsfästets vinkel b Î… -
Page 202
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 203
SUSPENSION AVANT CHAS FRÄMRE UPPHÄNGNING N° de pièce de barre de commande Styrstag, detaljnummer Å Haut Å Övre ı Bas ı Undre Ç N° de pièce Ç Detaljnummer Î Longueur a Î Längd a ‰ Angle b ‰ Vinkel b 3-19… -
Page 204
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 205
POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM TRAIN DE ROULEMENT POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE Ordre Travail/pièces Qté Remarques Dépose de poulie primaire Déposer les pièces dans l’ordre indiqué ci-con- tre. Courroie trapézoïdale Capuchon borgne Ens. poulie primaire Reposer les pièces dans l’ordre inverse de leur dépose. -
Page 206
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 207
POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM Ordre Travail/pièces Qté Remarques Démontage de poulie primaire Démonter les pièces dans l’ordre donné ci-contre. Cache de poulie primaire Ressort de poulie primaire Collerette Rouleau Rondelle Collerette Masselotte Rondelle Poulie fixe Pignon mené… -
Page 208
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 209
POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM DEPOSE DEMONTERING 1. Déposer: 1. Demontera: • • Ens. poulie primaire Primärremskivan 1 N.B.: OBS: Utiliser l’outil de maintien de poulie primaire Använd primärremskivans hållare 2 och primärrem- l’extracteur de poulie primaire skivans avdragare 3. -
Page 210
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°C ~ 100°C (176°F ~ 212°F) water for several minutes. •… -
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POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM DEMONTAGE ISÄRTAGNING 1. Déposer: 1. Demontera: • • Poulie fixe Den fasta remskivan 1 • • Butée Stopparen 2 • • Poulie mobile Glidremskivan 3 • • Douille Bussningen 4 • •… -
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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: •… -
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POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Croisillon Spindeln 1 • • Poulie mobile Glidremskivan 2 • • Poulie fixe Den fasta remskivan 3 • • Cache de poulie primaire Primärremskivans kåpa 4 Craquelures/endommagement →… -
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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: •… -
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POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM 5. Inspecter: 5. Inspektera: • • Masselotte Vikten 1 • • Rouleau Rullen 2 • • Douille Bussningarna 3 • • Coulisse Glidstyckena 4 • • Nitarna 5 Rivet • • Collerette Flänsen Usure/griffes/endommagement →… -
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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: •… -
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POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM ASSEMBLAGE MONTERING 1. Installer: 1. Installera: • • Poulie mobile Glidremskivan (sur le croisillon) (på spindeln) N.B.: OBS: Veiller à ce que le repère (X) sur la poulie mobile soit Se till att glidremskivans anpassningsmärke (X) an- aligné… -
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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 ®… -
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POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM • • Serrer le croisillon au couple spécifié au moyen Drag fast spindeln till det specificerade de la clé spéciale åtdragningsmomentet med skruvnyckeln 3. Croisillon: Spindel: 200 Nm (20 m · kg, 145 ft · lb) 200 Nm (20 m ·… -
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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: •… -
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POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM 7. Serrer: 7. Drag fast: • • Boulons Bultarna Marche à suivre: Åtgärder för åtdragning: • • Serrer provisoirement les boulons comme Drag fast bultarna 1 ~ 6 temporärt i den ord- illustré. -
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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: •… -
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POULIE PRIMAIRE ET COURROIE TRAPEZOIDALE POWR PRIMÄRREMSKIVA OCH DRIVREM MONTAGE INSTALLATION 1. Installer: 1. Installera: • • Ens. poulie primaire Primärremskivan ATTENTION: VIKTIGT: Veiller à éliminer tout résidu d’huile ou de graisse Se till att avlägsna all olja och/eller fett från de de la partie conique du vilebrequin et du croisillon koniska delarna på… -
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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”… -
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POULIE SECONDAIRE POWR SEKUNDÄR REMSKIVA POULIE SECONDAIRE Ordre Travail/pièces Qté Remarques Dépose de la poulie secondaire Déposer les pièces dans l’ordre indiqué ci-con- tre. Courroie trapézoïdale Rondelle Cale – Se reporter à “ECARTEMENT DES POULIES ET REGLAGE DU DECALAGE” au CHAPI- TRE 2. -
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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… -
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POULIE SECONDAIRE POWR SEKUNDÄR REMSKIVA Ordre Travail/pièces Qté Remarques Démontage de la poulie secondaire Déposer les pièces dans l’ordre indiqué ci-con- tre. Siège de ressort Ressort de poulie secondaire Plateau de poulie secondaire 1 (SX700) Poulie fixe Butée Poulie mobile Plateau de poulie secondaire 2 (SX700) Remonter les pièces dans l’ordre inverse de leur… -
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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). -
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POULIE SECONDAIRE POWR SEKUNDÄR REMSKIVA DEMONTAGE ISÄRTAGNING AVERTISSEMENT VARNING • • Faire très ATTENTION lors du démontage de VIKTIGT: Var ytterst försiktig när Du tar isär den la poulie secondaire, car le ressort, en se déten- sekundära remskivan, eftersom Du kan skada dant soudainement, pourrait occasionner une Dig svårt när fjädern frigörs plötsligt. -
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POWR SECONDARY SHEAVE 5. Measure: • Ramp shoe thickness a Out of specification → Replace the ramp shoe. Wear limit a: 1.0 mm (0.04 in) SCH4320 ASSEMBLY 1. Install: • Stopper • Sliding sheave Screw (stopper): 6.5 Nm (0.65 m · kg, 4.6 ft · lb) 2. -
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POULIE SECONDAIRE POWR SEKUNDÄR REMSKIVA 5. Mesurer: 5. Mät: • • Rampskons tjocklek a Epaisseur de butée en plastique Hors spécifications → Remplacer. Motsvarar ej specifikation → Byt ut rampskon. Slitagegräns a: Limite d’usure 1,0 mm (0,04 in) 1,0 mm (0,04 in) ASSEMBLAGE MONTERING 1. -
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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) ×… -
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POULIE SECONDAIRE POWR SEKUNDÄR REMSKIVA Marche à suivre: Installationsåtgärder: • • Maintenir le siège de ressort et tourner la Håll fast fjädersätet 1 och vrid samtidigt de fasta remskivan 2 moturs tills specificerad vinkel a poulie fixe dans le sens inverse des aiguilles d’une montre jusqu’à… -
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• 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. -
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Répéter ces étapes jusqu’à ce que l’écartement OBS: soit conforme aux spécifications. Vi på Yamaha rekommenderar att originalmellan- N.B.: läggen behålls. Yamaha recommande de conserver les cales d’ori- gine. Mellanlägg: Detaljnummer Tjocklek Cales: 90201-061H1 0,5 mm (0,02 in) N°… -
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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… -
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CARTER DE CHAINE DE TRANSMISSION POWR DRIVKEDJEHUS CARTER DE CHAINE DE TRANSMISSION MODELES SANS MARCHE ARRIERE Ordre Travail/pièces Qté Remarques Dépose du carter de chaîne de trans- Déposer les pièces dans l’ordre indiqué ci-con- mission tre. Etrier de frein Se reporter à “FREINS”. Frein de stationnement Se reporter à… -
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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 •… -
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CARTER DE CHAINE DE TRANSMISSION POWR DRIVKEDJEHUS INSPEKTION INSPECTION 1. Inspektera: 1. Inspecter: • • Drivkedjehuset 1 Carter de chaîne de transmission • • Kåpa för drivkedjan 2 Couvercle du carter de chaîne de transmission Craquelures/endommagement → Remplacer. Sprickor/skada → Byt. •… -
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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 →… -
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CARTER DE CHAINE DE TRANSMISSION POWR DRIVKEDJEHUS 3. Mesurer: 3. Mät: • • Drivkedjans 14-länkarssektion a Longueur de 14 maillons de la chaîne de transmission Använd en fjädervåg till att dra i drivkedjan med en kraft b på 36 kg (80 lb). Tendre la chaîne en appliquant une force de Motsvarar ej specifikation →… -
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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. -
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CARTER DE CHAINE DE TRANSMISSION POWR DRIVKEDJEHUS MONTAGE MONTERING 1. Respecter les points suivants lors du montage. 1. Observera följande punkter vid montering. Å Diriger les joints de roulement du côté de la chaîne de Å Kontrollera att bärlagerpackningarna är vända mot transmission. -
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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… -
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CARTER DE CHAINE DE TRANSMISSION POWR DRIVKEDJEHUS MODELE A MARCHE ARRIERE Ordre Travail/pièces Qté Remarques Dépose du carter de chaîne de trans- Déposer les pièces dans l’ordre indiqué ci-con- mission tre. Batterie Support de batterie Etrier de frein Se reporter à “FREINS”. Frein de stationnement Se reporter à… -
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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) ‰… -
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CARTER DE CHAINE DE TRANSMISSION POWR DRIVKEDJEHUS Travail/pièces Ordre Qté Remarques Tendeur de chaîne Rouleau Collerette Ressort Palier Pignon mené de marche arrière Rondelle Pignon mené de marche avant Collerette Pignon de renvoi Pignon menant Chaîne de transmission Collerette Rondelle Plaque Arbre Carter de chaîne de transmission… -
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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 →… -
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CARTER DE CHAINE DE TRANSMISSION POWR DRIVKEDJEHUS INSPEKTION INSPECTION 1. Inspecter: 1. Inspektera: • • Carter de chaîne de transmission Drivkedjehuset 1 • • Drivkedjehuskåpa 2 Couvercle du carter de chaîne de transmission Sprickor/skada → Byt ut. • → Craquelures/endommagement Remplacer. -
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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. -
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CARTER DE CHAINE DE TRANSMISSION POWR DRIVKEDJEHUS MONTAGE MONTERING 1. Respecter les points suivants lors du montage. 1. Observera följande punkter vid montering. Å Monter les joints en caoutchouc sur le carter de chaîne Å Montera gummipackningen på korrekt sätt på de transmission en veillant à… -
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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… -
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CARTER DE CHAINE DE TRANSMISSION POWR DRIVKEDJEHUS 4. Installer: 4. Installera: • • Tige de sélecteur Växelstången 1 5. Régler: 5. Justera: • • Longueur de tige de sélecteur Växelstångens längd a Marche à suivre: Justeringsåtgärder: • • Placer le levier de sélecteur à la position “FWD”. Flytta växelspaken till läget “FWD”. -
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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”. -
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ARBRE DE RENVOI SECONDAIRE POWR MELLANAXEL ARBRE DE RENVOI SECONDAIRE Ordre Travail/pièces Qté Remarques Dépose de l’arbre de renvoi secon- Déposer les pièces dans l’ordre indiqué ci-con- daire tre. Poulie secondaire Se reporter à “POULIE SECONDAIRE”. Silencieux Se reporter à “POMPE A CARBURANT” au CHAPITRE 7. -
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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. •… -
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ARBRE DE RENVOI SECONDAIRE POWR MELLANAXEL INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Arbre de renvoi secondaire Mellanaxeln 1 Griffes (profondes)/endommagement → Rem- Sprickor (för stora)/skada → Byt. • placer. Räfflorna 2 • Slitage/skada → Byt ut mellanaxeln. Cannelures Usure/endommagement →… -
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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) •… -
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ARBRE DE RENVOI SECONDAIRE POWR MELLANAXEL MONTAGE DU CARTER DE CHAINE DE MONTERING AV DRIVKEDJEHUS OCH TRANSMISSION ET DE L’ARBRE DE MELLANAXEL RENVOI SECONDAIRE 1. Installera: • 1. Installer: Drivkedjehus • • Carter de chaîne de transmission Mellanaxel • Arbre de renvoi secondaire Monteringssteg: •… -
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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… -
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FREINS POWR BROMS FREINS Ordre Travail/pièces Qté Remarques Dépose de plaquette de frein Déposer les pièces dans l’ordre indiqué ci-con- tre. Boulon capuchon Goupille de retenue Ressort de plaquette Plaquette de frein Cale 1 Cale 2 Reposer les pièces dans l’ordre inverse de leur dépose. -
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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. -
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FREINS POWR BROMS VIKTIGT: ATTENTION: Det är mycket sällan som skivbromskom- Il est rarement nécessaire de démonter les compo- ponenterna behöver tas isär. OBSERVERA FÖL- sants du disque de frein. NE JAMAIS: • Démonter les composants, sauf en cas de néces- JANDE: •… -
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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. -
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FREINS POWR BROMS 2. Installer: 2. Installera: • • Plaquettes de frein Bromsklotsarna • • Ressort de plaquette Bromsklotsfjädern Marche à suivre: Installationsåtgärder: • • Brancher fermement un flexible adéquat sur la Anslut en lämplig slang 1 ordentligt till bromsokets vis de purge de l’étrier . -
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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. -
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FREINS POWR BROMS Ordre Travail/pièces Qté Remarques Dépose d’étrier de frein et de frein de Déposer les pièces dans l’ordre indiqué ci-con- stationnement tre. Liquide de frein Vidanger. Flexible de frein Ens. étrier de frein Goupille fendue Câble de frein de stationnement Goupille Goupille Collerette… -
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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. -
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FREINS POWR BROMS Ordre Travail/pièces Qté Remarques Démontage d’étrier de frein Déposer les pièces dans l’ordre indiqué ci-con- tre. Boulon capuchon Goupille de retenue Ressort de plaquette Plaquette de frein Cale 1 Cale 2 Vis de purge Bague d’étanchéité Piston Remonter les pièces dans l’ordre inverse de leur démontage. -
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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. -
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FREINS POWR BROMS DEMONTAGE D’ETRIER DE FREIN ISÄRTAGNING AV BROMSOK N.B.: OBS: Avant de démonter un étrier de frein, vidanger le Innan Du tar isär ett bromsok skall Du tappa ur flexible de frein, le maître cylindre, l’étrier de frein et bromsvätskan från bromsslangen, huvudcylindern, le réservoir de frein. -
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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. -
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FREINS POWR BROMS 1. Inspecter: 1. Inspektera: • • Piston d’étrier Bromsokskolvarna 1 Rayures/rouille/usure → Remplacer l’ensem- Repor/rost/slitage → Byt ut bromsoket. • ble étrier. Bromsokscylindern 2 • Slitage/repor → Byt ut bromsoket. Cylindre d’étrier • Usure/rayures → Remplacer l’ensemble étrier. Bromsoket 3 •… -
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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. -
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FREINS POWR BROMS Ordre Travail/pièces Qté Remarques Dépose de maître cylindre de frein Déposer les pièces dans l’ordre indiqué ci-con- tre. Liquide de frein Vidanger. Câble de frein de stationnement Contacteur de frein Levier de frein Levier de frein de stationnement Raccord de flexible de frein Support Ens. -
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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: •… -
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FREINS POWR BROMS INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Maître cylindre Huvudcylindern 1 Usure/rayures → Remplacer l’ensemble maî- Slitage/repor → Byt ut huvudcylindern. • tre cylindre. Huvudcylinderenheten 2 • Sprickor/skada → Byt. Corps de maître cylindre Craquelures/endommagement → Remplacer. •… -
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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. -
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SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING SUSPENSION A RAIL DE COULISSEMENT VX700/VX700DX/SX700 Travail/pièces Ordre Qté Remarques Dépose de la suspension à rail de Déposer les pièces dans l’ordre indiqué ci-con- coulissement tre. Ecrou d’axe arrière Desserrer. Dispositif de réglage de la tension Desserrer. -
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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. -
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SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING VT700 Travail/pièces Qté Remarques Ordre Dépose de la suspension à rail de cou- Déposer les pièces dans l’ordre indiqué ci-con- lissement tre. Ecrou d’axe arrière Desserrer. Dispositif de réglage de tension Desserrer. Capuchon borgne Plaquette arrière de suspension Suspension à… -
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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) ‰… -
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SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING Travail/pièces Ordre Qté Remarques Démontage de la suspension à rail de Déposer les pièces dans l’ordre indiqué ci-con- coulissement tre. Sangle d’arrêt Crochet Douille Collerette Amortisseur avant Galet de suspension Collerette Arceau de galet Arbre (VT700) Caoutchouc amortisseur… -
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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… -
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SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING Travail/pièces Ordre Qté Remarques Galet de suspension Collerette Arceau de galet Circlip Galet de suspension Entretoise Douille Collerette Support de la suspension arrière Entretoise Douille (VX700/VX700DX/VT700) Collerette å: SX700 1 Graisse ESSO beacon 325 ou Aeroshell n°7A Ordningsföljd Arbetsnamn/detaljnamn Kvantitet… -
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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 287
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING Ordre Travail/pièces Qté Remarques Amortisseur arrière Douille (VX700/VX700DX/VT700) Collerette Tige de traction Collerette Douille (VX700/VX700DX/VT700) Support arrière (VT700) Collerette (VT700) Galet de suspension Barre de commande Douille Douille 1 Graisse ESSO beacon 325 ou Aeroshell n°7A Arbetsnamn/detaljnamn Kvantitet Anmärkningar… -
Page 288
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 289
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING Travail/pièces Qté Remarques Ordre Bras-pivot arrière Douille Collerette Collerette Arceau de bras-pivot arrière Collerette Circlip Galet de suspension Arceau de galet Axe arrière Galet de guidage 3 (4) Collerette Dispositif de réglage de tension Collerette 1 (2) Collerette… -
Page 290
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 291
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING MM700 Ordre Travail/pièces Qté Remarques Dépose de la suspension à rail de cou- Déposer les pièces dans l’ordre indiqué ci-con- lissement tre. Ecrou d’axe arrière Desserrer. Dispositif de réglage de tension Desserrer. Suspension à… -
Page 292
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 293
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING Ordre Travail/pièces Qté Remarques Démontage de la suspension à rail de Déposer les pièces dans l’ordre indiqué ci-con- coulissement tre. Sangle d’arrêt Crochet Collerette en caoutchouc Collerette en caoutchouc Arbre Douille Collerette Amortisseur avant Bras-pivot avant Douille… -
Page 294
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 295
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING Ordre Travail/pièces Qté Remarques Galet de suspension Collerette Arceau de galet Arceau de bras-pivot avant Circlip Galet de suspension Collerette Douille Collerette Support de la suspension arrière Entretoise Douille Collerette 1 Graisse ESSO beacon 325 ou Aeroshell n°7A Arbetsnamn/detaljnamn Ordningsföljd Kvantitet… -
Page 296
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 297
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING Ordre Travail/pièces Qté Remarques Amortisseur arrière Douille Collerette Tige de traction Collerette Douille Galet de suspension Barre de commande Douille Douille Arbre 1 Graisse ESSO beacon 325 ou Aeroshell n°7A Ordningsföljd Arbetsnamn/detaljnamn Kvantitet Anmärkningar Bakre stötdämpare… -
Page 298
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 299
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING Ordre Travail/pièces Qté Remarques Bras-pivot arrière Douille Collerette Collerette Arceau de bras-pivot arrière Collerette Circlip Galet de suspension Arbre-support de roue Axe arrière Galet de guidage Collerette Dispositif de réglage de tension Collerette Collerette Cadre coulissant… -
Page 300
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 301
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING INSPECTION INSPEKTION 1. Inspecter: 1. Inpektera: • • Galet de suspension Upphängningshjulet • • Galet de guidage Styrhjulet Craquelures/endommagement → Remplacer. Sprickor/skada → Byt. • • Roulement Hjullagret Le galet ne tourne pas de manière régulière → Hjulet roterar inte mjukt och smidigt →… -
Page 302
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 303
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING ASSEMBLAGE MONTERING 1. Installer: 1. Installera: • • Arbre (MM700) Axel 1 (MM700) N.B.: OBS: Veiller à ce que les collerettes en caoutchouc Se till att gummiflänsarna 2 inte kläms mellan axeln soient pas pincées entre l’arbre et les cadres coulis- och glidramarna 3. -
Page 304
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 305
SUSPENSION A RAIL DE COULISSEMENT POWR GLIDSKENANS UPPHÄNGNING Styrstag, detaljnummer N° de pièce de barre de commande Å Barre de commande 1 Å Styrstag 1 ı N° de pièce ı Detaljnummer Ç Longueur a Ç Längd a Î Longueur b Î… -
Page 306
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 307
AXE AVANT ET CHENILLE POWR FRAMAXEL OCH DRIVBAND AXE AVANT ET CHENILLE Ordre Travail/pièces Qté Remarques Dépose de l’axe avant et de la chenille Déposer les pièces dans l’ordre indiqué ci-con- tre. Carter de chaîne de transmission Se reporter à “CARTER DE CHAINE DE TRANSMISSION”. -
Page 308
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 309
AXE AVANT ET CHENILLE POWR FRAMAXEL OCH DRIVBAND INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Chenille Drivbandet 1 • • Métal coulissant Glidmetallen 2 Usure/craquelures/endommagement → Rem- Slitage/sprickor/skada → Byt. placer. 2. Inspecter: 2. Inspektera: • • Pignon d’entraînement Kedjehjulet 1 Usure/fissure/endommagement →… -
Page 310
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 311
AXE AVANT ET CHENILLE POWR FRAMAXEL OCH DRIVBAND 2. Placer la chenille sur le châssis. 2. Placera drivbandet på chassit. N.B.: OBS: • • VX700/VX700DX/SX700/MM700: För VX700/VX700DX/SX700/MM700: Pour les chenilles où figure un repère de direction Gäller drivband märkta med en rotationsriktnings- pil a: de rotation Monter la chenille en veillant à… -
Page 312
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 313
ENSEMBLE ECHAPPEMENT AVGASSYSTEM MOTEUR ENSEMBLE ECHAPPEMENT Ordre Travail/pièces Qté Remarques Dépose de l’ensemble échappement Déposer les pièces dans l’ordre indiqué ci-contre. Capot Ouvrir. Câble d’arrêt du capot Ressort 1 Ressort 2 Ressort 3 Tuyau d’échappement Joint 1 Joint 2 Raccord d’échappement Joint 3 Ressort 4 Ressort 5… -
Page 314
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 315
ENSEMBLE ECHAPPEMENT AVGASSYSTEM MONTAGE INSTALLATION 1. Installer: 1. Installera: • • Joint 3 Packningen 3 • • Raccord d’échappement Avgasleden N.B.: OBS: • • Installer le joint 3 en veillant à ce que sa saillie Installera packningen 3 med dess utbuktning a soit orientée vers le côté… -
Page 316: 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 317
MOTEUR MOTORPAKET MOTEUR Ordre Travail/pièces Qté Remarques Dépose du moteur Déposer les pièces dans l’ordre indiqué ci-contre. Ensemble échappement Se reporter à “ENSEMBLE ECHAPPEMENT”. Carburateurs Se reporter à “CARBURATEURS” au CHAPITRE 7. Lanceur à réenroulement Se reporter à “LANCEUR A REENROULEMENT”. Rotor de magnéto AC Se reporter à… -
Page 318
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 319
MOTEUR MOTORPAKET INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Support arrière (droit) Bakre fästet (höger) 1 → Sprickor/skada → Byt. Craquelures/endommagement Remplacer. MONTAGE INSTALLATION N.B.: OBS: Une fois toutes les pièces installées, se reporter à Vi hänvisar till “KABELDRAGNINGSSCHEMA” i ka- “CHEMINEMENT DES CABLES”… -
Page 320
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: 22 ±… -
Page 321
MOTEUR MOTORPAKET 3. Purger: 3. Avlufta: • • Circuit d’huile Oljesystemet Se reporter à “POMPE A HUILE” au CHAPI- Vi hänvisar till “OLJEPUMP” i kapitel 2. • TRE 2. Kylsystemet • Circuit de refroidissement Vi hänvisar till “KYLSYSTEM” i kapitel 2. Se reporter à… -
Page 322
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 323
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER CULASSE ET CYLINDRES Ordre Travail/pièces Qté Remarques Dépose de la culasse et des cylindres Déposer les pièces dans l’ordre indiqué ci-con- tre. Capuchon de bougie Bride Faisceau de fils secondaire 2 Support Attache réutilisable Bobine d’allumage n°3 Entretoise 1 Bobine d’allumage n°2… -
Page 324
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 325
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER Ordre Travail/pièces Qté Remarques Bougie Capteur de température d’eau Culasse Joint Cylindre Joint Bride Tubulure d’admission Entretoise Siège de clapet flexible Butée de clapet flexible Clapet flexible Joint Segment Axe de piston Piston Roulement Reposer les pièces dans l’ordre inverse de leur dépose. -
Page 326
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 327
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER DEPOSE DEMONTERING 1. Déposer: 1. Demontera: • • Circlip d’axe de piston Kolvbultsringen • • Axe de piston Kolvbulten • • Piston Kolven • • Coussinet de pied de bielle Kolvbultslagret N.B.: OBS: • •… -
Page 328
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 329
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER INSPECTION INSPEKTION 1. Eliminer: 1. Avlägsna: • • Calamine Sotavlagringar (de la chambre de combustion) (från förbränningskammaren) Utiliser un grattoir arrondi Använd en rundad skrapare 1. ATTENTION: VIKTIGT: Ne pas utiliser d’outil tranchant. Eviter d’endom- Använd inte ett skarpt instrument och undvik att mager ou de rayer la surface. -
Page 330
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 331
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER 7. Eliminer: 7. Avlägsna: • • Entailles et dépôts d’émail Märken och lackavlagringar (sur les parois du piston) (från kolvväggen) Se servir de toile émeri humide de 600 ~ 800. Använd 600 ~ 800 korns vått sandpapper. OBS: N.B.: Opérer le ponçage suivant une forme croisée. -
Page 332
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 333
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER Deuxième étape: Andra åtgärd: • • Mesurer le diamètre (P) de la jupe de piston à Mät kolvens skörtdiameter (P) med en mikrome- l’aide d’un palmer. ter. a 15 mm (0,59 in) à partir du bord inférieur du piston a 15 mm (0,59 in) från kolvens nedre kant Taille (standard) de piston (P): Kolvstorlek (standard) (P):… -
Page 334
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 335
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER 10. Installer: 10. Installera: • • Segment Kolvringen (dans le cylindre) (i cylindern) Pousser le segment avec la couronne du piston. Tryck in kolvringen med kolvkronan. OBS: N.B.: Insérer le segment dans le cylindre, et l’enfoncer de Sätt i kolvringen i cylindern och tryck in den ca. -
Page 336
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 337
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER 14. Inspecter: 14. Inspektera: • • Clapets flexibles Tungventilerna 1 Déformations/craquelures/endommagement → Böjning/sprickor/skada → Byt. Remplacer. 15. Mesurer: 15. Mät: • • Ventilstopparens höjd a Hauteur de butée de clapet flexible Hors spécifications → Remplacer la butée de Motsvarar ej specifikation →… -
Page 338
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 339
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER MONTAGE INSTALLATION 1. Installera: 1. Installer: • • Tungventilerna Clapets flexibles • • Tungventilsstopparna Butées de clapet flexible OBS: N.B.: • • Placera tungventilen 1 med dess konkava yta Installer les clapets flexibles en veillant à diriger riktad mot tungventilssätet 2. -
Page 340
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 341
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER 4. Vérifier: 4. Kontrollera: • • Position du segment de piston Kolvringens läge VIKTIGT: ATTENTION: • • S’assurer que les becs de segments sont disposés Se till att ringändarna passas in runt ring- correctement par rapport aux goupilles de posi- placeringsbultarna i kolvskårorna. -
Page 342
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 343
CULASSE ET CYLINDRES TOPPLOCK OCH CYLINDER 9. Serrer: 9. Drag fast: • • Ecrous (culasse) Muttrarna (topplock) Marche à suivre: Åtdragningsåtgärder: • • Serrer provisoirement les écrous de culasse Drag temporärt fast topplocksmuttrarna 1 ~ E dans l’ordre numérique. på följande sätt. Pré-serrage: Första åtgärd: •… -
Page 344
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 345
POMPE A HUILE, CARTER ET VILEBREQUIN OLJEPUMP, VEVHUS OCH VEVAXEL POMPE A HUILE, CARTER ET VILEBREQUIN Ordre Travail/pièces Qté Remarques Dépose de la pompe à huile, du carter Déposer les pièces dans l’ordre indiqué ci-con- et du vilebrequin tre. Pompe à huile Flexible d’huile 1 Support arrière (gauche) Support inférieur avant… -
Page 346
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 347
POMPE A HUILE, CARTER ET VILEBREQUIN OLJEPUMP, VEVHUS OCH VEVAXEL INSPECTION INSPEKTION 1. Mesurer: 1. Mät: • • Cintrage Kastning Utiliser des vés de mécanicien et un comparateur Använd V-klotsarna och en mätklocka. Motsvarar ej specifikation → Byt ut eller repa- à… -
Page 348
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 349
POMPE A HUILE, CARTER ET VILEBREQUIN OLJEPUMP, VEVHUS OCH VEVAXEL 4. Inspecter: 4. Inspektera: • • Demi-carter inférieur Det nedre vevhuset 1 • • Det övre vevhuset 2 Demi-carter supérieur • • Supports inférieurs avant De främre nedre fästena 3 •… -
Page 350
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 351
POMPE A HUILE, CARTER ET VILEBREQUIN OLJEPUMP, VEVHUS OCH VEVAXEL MONTAGE INSTALLATION 1. Installer: 1. Installera: • • Bague d’arrêt Stoppringen 1 [sur le roulement de vilebrequin (côté poulie [på vevaxelns lager 2 (primärremskivans sida) primaire) comme indiqué] så som visas] Ergot de chasse 3 Slagbult 2. -
Page 352
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 353
POMPE A HUILE, CARTER ET VILEBREQUIN OLJEPUMP, VEVHUS OCH VEVAXEL 3. Remplir: 3. Fyll på: • • Cavité de pignon Drevkammaren 1 Huile recommandée: Rekommenderad olja: YAMALUBE 2 temps YAMALUBE 2-takts Capacité de cavité de pignon: Drevkammarens kapacitet: 25 cm (0,81 lmp oz, 0,77 US oz) 25 cm (0,81 lmp oz, 0,77 US oz) -
Page 354
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 355
POMPE A HUILE, CARTER ET VILEBREQUIN OLJEPUMP, VEVHUS OCH VEVAXEL 6. Installer: 6. Installera: • • Flexible d’huile 1 Oljeslang 1 N.B.: OBS: Utför monteringen så att märket a på kontrollventilen Monter de sorte que le repère du clapet antiretour soit dirigé… -
Page 356
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 357
MAGNETO AC AC-MAGNET MAGNETO AC Ordre Travail/pièces Qté Remarques Dépose de la magnéto AC Déposer les pièces dans l’ordre indiqué ci-con- tre. Lanceur à réenroulement Se reporter à “LANCEUR A REENROULEMENT”. Traverse Coupleur de magnéto AC Déconnecter. Attache réutilisable Poulie de lanceur Entretoise Rotor de magnéto Clavette demi-lune… -
Page 358
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 359
MAGNETO AC AC-MAGNET DEPOSE DEMONTERING 1. Déposer: 1. Demontera: • • Boulon Bultarna 1 • • Poulie de lanceur Startremskivan 2 • • Ecrou Muttern 3 N.B.: OBS: Fixer l’outil de maintien de poulie primaire afin de Sätt på den primära remskivans hållare för att hålla maintenir la poulie primaire. -
Page 360
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 361
MAGNETO AC AC-MAGNET MONTAGE INSTALLATION N.B.: OBS: Après avoir installé toutes les pièces, se reporter à Vi hänvisar till “KABELDRAGNINGSSCHEMA” i ka- “CHEMINEMENT DES CABLES” au CHAPITRE pitel 9 angående kontroll av vajrarnas, ledningarnas 9 afin de contrôler le cheminement des câbles, fils et och slangarnas dragningar, efter att alla delar instal- flexibles. -
Page 362
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 363
MAGNETO AC AC-MAGNET 4. Serrer: 4. Drag fast: • • Boulons Bultarna 1 • • Ecrou Mutter 2 Boulon (poulie de lanceur) Bult (startremskiva) 1: 23 Nm (2,3 m · kg, 17 ft · lb) 23 Nm (2,3 m · kg, 17 ft · lb) Ecrou (rotor de magnéto) Mutter (magnetrotor) 2: 110 Nm (11 m ·… -
Page 364: 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”.
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Page 365
LANCEUR A REENROULEMENT REKYLSTARTARE LANCEUR A REENROULEMENT Ordre Travail/pièces Qté Remarques Dépose de lanceur à réenroulement Déposer les pièces dans l’ordre indiqué ci-con- tre. Silencieux Se reporter à “ENSEMBLE ECHAPPEMENT”. Poignée de lanceur Boîtier de lanceur à réenroulement Plateau d’entraînement Guide de came Ressort de plateau d’entraînement Rondelle… -
Page 366
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 367
LANCEUR A REENROULEMENT REKYLSTARTARE DEPOSE DEMONTERING 1. Déposer: 1. Demontera: • • Poignée de lanceur Starthandtaget 1 N.B.: OBS: Pour séparer la poignée de lanceur du cordon, défaire För att demontera starthandtaget skall Du lossa på le nœud du cordon et faire un nœud au cordon knuten 2 i startrepet och göra en ny knut 3 på… -
Page 368
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 369
LANCEUR A REENROULEMENT REKYLSTARTARE MONTAGE INSTALLATION 1. Enrouler: 1. Linda upp: • • Cordon de lanceur (de 2-1/2 tours dans le sens Startrepet (2-1/2 gånger i moturs riktning) inverse des aiguilles d’une montre) (dans l’en- (i remskivstrumman) rouleur) 2. Installer: 2. -
Page 370
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 371
ECHANGEUR DE CHALEUR COOL VÄRMEVÄXLARE SYSTEME DE REFROIDISSEMENT ECHANGEUR DE CHALEUR VX700/VX700DX/SX700/VT700 Ordre Travail/pièces Qté Remarques Dépose de l’échangeur de chaleur Déposer les pièces dans l’ordre indiqué ci-contre. Liquide de refroidissement Vidanger. Se reporter à “SYSTEME DE RE- FROIDISSEMENT” au CHAPITRE 2. Bouchon de remplissage de liquide de refroidissement Flexible de liquide de refroidissement 1… -
Page 372
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 373
ECHANGEUR DE CHALEUR COOL VÄRMEVÄXLARE MM700 Qté Remarques Ordre Travail/pièces Dépose de l’échangeur de chaleur Déposer les pièces dans l’ordre indiqué ci-contre. Liquide de refroidissement Vidanger. Se reporter à “SYSTEME DE RE- FROIDISSEMENT” au CHAPITRE 2. Bouchon de remplissage de liquide de refroidissement Flexible de liquide de refroidissement 1 Ressort 1… -
Page 374
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 375
ECHANGEUR DE CHALEUR COOL VÄRMEVÄXLARE INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Flexibles de liquide de refroidissement Kylmedelsslangarna 1 • • Echangeurs de chaleur Värmeväxlarna 2 • • Corps de bouchon de remplissage Påfyllningsröret 3 • • Ens. levier de réchauffeur de carburateur Förgasvärmarspaken 4 •… -
Page 376
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 377
ECHANGEUR DE CHALEUR COOL VÄRMEVÄXLARE 2. Mesurer: 2. Mät: • • Pression d’ouverture du bouchon de remplis- Påfyllningslockets öppningstryck sage Locket öppnas vid ett tryck som är lägre än det specificerade trycket → Byt. Le bouchon s’ouvre à une pression inférieure à celle spécifiée →… -
Page 378: 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…
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Page 379
POMPE A EAU COOL VATTENPUMP POMPE A EAU Ordre Travail/pièces Qté Remarques Dépose de la pompe à eau et de la Déposer les pièces dans l’ordre indiqué ci-con- soupape thermostatique tre. Raccord d’échappement Se reporter à “ENSEMBLE ECHAPPEMENT” au CHAPITRE 5. Liquide de refroidissement Vidanger. -
Page 380
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 381
POMPE A EAU COOL VATTENPUMP DEPOSE DEMONTERING 1. Déposer: 1. Demontera: • • Rotor Skovelhjulet 1 N.B.: OBS: Fixer l’outil de maintien de poulie primaire afin de Sätt på den primäraremskivans hållare för att hålla maintenir la poulie primaire. fast den primära remskivan. Outil de maintien de poulie primaire: Hållare för primärremskiva: 90890-01701, YU-01880… -
Page 382
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 383
CARBURATEURS CARB FÖRGASARE CARBURATION CARBURATEURS Ordre Travail/pièces Qté Remarques Dépose des carburateurs Déposer les pièces dans l’ordre indiqué ci-contre. Silencieux d’admission Se reporter à “POMPE A CARBURANT”. Levier de réchauffeur de carburateur Avant de déposer les carburateurs, s’assurer d’avoir placé le bouton de réchauffeur de carburateur sur “OFF”. -
Page 384
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 385
CARBURATEURS CARB FÖRGASARE Ordre Travail/pièces Qté Remarques Séparation des carburateurs Déposer les pièces dans l’ordre indiqué ci-con- tre. Flexible de réchauffeur de carburateur Support de câble de starter Collerette Ressort Desserrer. Tige de starter Ressort Levier de starter Reniflard Cache supérieur Joint Vis de connexion d’arbre d’accélérateur Bride… -
Page 386
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 387
CARBURATEURS CARB FÖRGASARE Ordre Travail/pièces Qté Remarques Démontage d’un carburateur Déposer les pièces dans l’ordre indiqué ci-con- tre. Vis de butée des gaz Tourner dans le sens des aiguilles d’une montre. Contacteur de carburateur (T.O.R.S.) Support de câble d’accélération Ens. papillon d’accélération Ens. -
Page 388
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 389
CARBURATEURS CARB FÖRGASARE Ordre Travail/pièces Qté Remarques Joint Gicleur principal Anneau de gicleur principal Diffuseur Gicleur de ralenti Manchon de gicleur de ralenti Axe de flotteur Flotteur Pointeau Vis (siège de pointeau) Ens. siège de pointeau Joint torique Remonter les pièces dans l’ordre inverse de leur démontage. -
Page 390
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 391
CARBURATEURS CARB FÖRGASARE INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Corps du carburateur Förgasarkroppen • • Passage de carburant Bränslepassagen Encrassement → Nettoyer. Förorening → Rengör. N.B.: OBS: • • Utiliser du solvant à base de pétrole pour nettoyer. Använd ett bensinbaserat lösningsmedel för ren- •… -
Page 392
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 393
CARBURATEURS CARB FÖRGASARE 5. Inspecter: 5. Inspektera: • • Papillon d’accélération Gasspjällsventilen 1 Usure/endommagement → Remplacer. Slitage/skada → Byt. 6. Vérifier: 6. Kontrollera: • • Mobilité du papillon d’accélération Gasspjällsventilens rörelse Raideur → Remplacer le corps de carburateur. Kärvar → Byt ut förgasaren. ASSEMBLAGE MONTERING N.B:… -
Page 394
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 395
CARBURATEURS CARB FÖRGASARE Marche à suivre: Åtgärder för mätning och justering: • • Retourner le carburateur. Håll förgasaren upp och ned. • • Mesurer la distance entre le corps de carburateur Mät avståndet mellan förgasarkroppen och et le sommet des flotteurs. flottörernas övre del. -
Page 396
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 397
CARBURATEURS CARB FÖRGASARE REGLAGE DU NIVEAU DE CARBURANT JUSTERING AV BRÄNSLENIVÅ 1. Mesurer: 1. Mät: • • Bränslenivån a Niveau de carburant Hors spécifications → Régler. Motsvarar ej specifikation → Justera. Niveau de carburant (à partir du Bränslenivå (från cylinderns mitt) a: centre d’alésage) 36 ~ 38 mm (1,42 ~ 1,50 in) 36 ~ 38 mm (1,42 ~ 1,50 in) -
Page 398
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 399
CARBURATEURS CARB FÖRGASARE MONTAGE INSTALLATION N.B.: OBS: Après avoir installé toutes les pièces, se reporter à Vi hänvisar till “KABELDRAGNINGSSCHEMA” i ka- “CHEMINEMENT DES CABLES” au CHAPITRE pitel 9 angående kontroll av vajrarnas, ledningarnas 9 afin de contrôler le cheminement des câbles, fils et och slangarnas dragningar, efter att alla delar instal- flexibles. -
Page 400: 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…
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Page 401
POMPE A CARBURANT CARB BRÄNSLEPUMP POMPE A CARBURANT VX700/VX700DX/VT700 Ordre Travail/pièces Qté Remarques Dépose de la pompe à carburant Déposer les pièces dans l’ordre indiqué ci-contre. Ens. levier de réchauffeur de carburateur Elément de filtre à air Desserrer. Attache réutilisable Faisceau de fils Câble d’accélérateur N.B.:… -
Page 402
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 403
POMPE A CARBURANT CARB BRÄNSLEPUMP SX700/MM700 Ordre Travail/pièces Qté Remarques Dépose de la pompe à carburant Déposer les pièces dans l’ordre indiqué ci-contre. Ens. levier de réchauffeur de carburateur Elément de filtre à air Desserrer. Attache réutilisable Faisceau de fils Silencieux d’admission Flexible de carburant Déconnecter. -
Page 404
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 405
POMPE A CARBURANT CARB BRÄNSLEPUMP INSPECTION INSPEKTION 1. Inspecter: 1. Inspektera: • • Flexible de carburant Bränsleslangen 1 • • Flexibles d’arrivée de carburant Bränsletillförselslangarna 2 • • Flexible de dépression Vakuumslangen 3 • • Flexible d’arrivée d’huile Oljetillförselslangen 4 Obstruction/endommagement →… -
Page 406: Switch Inspection
– 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. •…
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Page 407
VERIFICATION DES CONTACTEURS – ELEC INSPEKTION AV OMKOPPLARE PARTIE ELECTRIQUE ELSYSTEM VERIFICATION DES CONTACTEURS INSPEKTION AV OMKOPPLARE VERIFICATION DES CONTACTEURS INSPEKTION AV OMKOPPLARE Vérifier la continuité des bornes à l’aide d’un multi- Använd en fickprovare för att kontrollera att det finns mètre. -
Page 408
– ELEC IGNITION SYSTEM SCH8180… -
Page 409: Ignition System
SYSTEME D’ALLUMAGE – ELEC TÄNDSYSTEM SYSTEME D’ALLUMAGE TÄNDSYSTEM IGNITION SYSTEM SCHEMA DE CIRCUIT KOPPLINGSSCHEMA CIRCUIT DIAGRAM 1 Magnéto AC 1 AC-magnet 1 AC magneto 2 Redresseur/régulateur 2 Likriktare/regulator 2 Rectifier/regulator ∗1 ∗1 ∗1 3 Condensateur 3 Kondensator 3 Condenser ∗2 ∗2 ∗2 4 Fusible principal…
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Page 410
– 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 411
– 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 412
– ELEC SYSTEME D’ALLUMAGE GUIDE DE DEPANNAGE ABSENCE D’ETINCELLE OU ETINCELLE FAIBLE. VX700DX/VT700: Contrôler le fusible principal et le fusible d’allumage “IGNITION”. Se reporter à “VERIFICATION DES FUSIBLES” au CHAPITRE 2. DEFECTUEUX Remplacer le fusible principal et/ou le fusible d’allu- mage “IGNITION”. -
Page 413
– ELEC SYSTEME D’ALLUMAGE VX700/SX700/MM700: Vérifier le système d’éclairage, de signalisation et des compteurs. Se reporter à “SYSTEME D’ECLAIRAGE” et “SYSTEME DE SIGNALISATION”. DEFECTUEUX Réparer le système d’éclairage et/ou le système de signalisation et/ou le système des compteurs. Corriger les connexions et/ou remplacer le bloc CDI et/ou le redresseur/régulateur. -
Page 414
– ELEC TÄNDSYSTEM FELSÖKNING INGEN GNISTA ELLER SVAG GNISTA. För VX700DX/VT700: Kontrollera huvudsäkringen och tändningssäkringen “IGNITION”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. Byt ut huvudsäkringen och/eller tändningssäkringen “IGNITION”. För VX700DX/VT700: Kontrollera batteriet. Vi hänvisar till “INSPEKTION AV BATTERI” i kapitel 2. -
Page 415
– ELEC TÄNDSYSTEM För VX700/SX700/MM700: Kontrollera ljus-, signal- och mätarsystemet. Vi hänvisar till “LJUSSYSTEM” och “SIGNALSYSTEM”. Reparera ljussystemet och/eller signalsystemet och/ eller mätarsystemet. Rätta till anslutningen och/eller byt ut Likriktaren/regulatorn och/eller CDI-enheten. OBS: För VX700/SX700/MM700: Om ljussystemet, signalsystemet eller mätarsystemet skulle kortslutas, går det att starta motorn och köra fordonet i nödfall genom att koppla ifrån driftrelät. -
Page 416
– 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: 6,800 µF at 20°C (68°F) AC MAGNETO 1. Disconnect: •… -
Page 417
SYSTEME D’ALLUMAGE – ELEC TÄNDSYSTEM CONDENSATEUR (VX700/SX700/MM700) KONDENSATOR (VX700/SX700/MM700) 1. Déconnecter: 1. Koppla ur: • • Condensateur Kondensatorn 1 2. Connector: 2. Anslut: • • Condensateur Kondensatorn (au multimètre LCR) (till LCR-mätaren) 3. Mesurer: 3. Mät: • • Capacité du condensateur Kondensatorns kapacitet Hors spécifications →… -
Page 418
– 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 419
SYSTEME D’ALLUMAGE – ELEC TÄNDSYSTEM BOUGIES TÄNDSTIFT 1. Déposer: 1. Tag ur: • Bougies • Tändstiften 2. Mesurer: 2. Mät: • Ecartement des électrodes • Tändstiftsgap Bougie standard: Standardtändstift: BR9ES (NGK) BR9ES (NGK) Ecartement des électrodes: Tändstiftsgap: 0,7 ~ 0,8 mm (0,028 ~ 0,031 in) 0,7 ~ 0,8 mm (0,028 ~ 0,031 in) CAPUCHON DE BOUGIE TÄNDSTIFTSGAP… -
Page 420
– 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 421
SYSTEME D’ALLUMAGE – ELEC TÄNDSYSTEM SYSTEME D’ARRET DU MOTEUR GASLÅSNINGSSYSTEM (T.O.R.S.) PRIORITAIRE (T.O.R.S.) Om förgasaren eller gasvajern inte skulle fungera när Lorsqu’un mauvais fonctionnement des câbles d’ac- maskinen körs, kommer T.O.R.S. att aktiveras när célération et de carburateur est détecté pendant la gashandtaget släpps. -
Page 422
– 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 423
SYSTEME D’ALLUMAGE – ELEC TÄNDSYSTEM 4. Vérifier: 4. Kontrollera: • • Continuité du contacteur d’accélérateur. Gasspjällsomkopplarens kontinuitet Défectueux → Remplacer le contacteur au Bristfällig → Byt ut styrets omkopplare (höger). guidon (droit). Gasspjällsomkopplarens Kontinuitet Position du contacteur läge Continuité d’accélérateur Gashandtaget manövreras. -
Page 424
– 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 425
SYSTEME D’ALLUMAGE – ELEC TÄNDSYSTEM RELAIS DE COMMANDE DE CHARGE DRIFTRELÄT 1. Inspecter: 1. Inspektera: • • Relais de commande de charge (noir) Driftrelät (svart) 1 Marche à suivre: Inspektionsåtgärder: • • Déconnecter le relais de commande de charge du Koppla ifrån driftrelät från kopplaren. -
Page 426
– ELEC ELECTRICAL STARTING SYSTEM (VX700DX/VT700) SCH8030 8-10… -
Page 427
SYSTEME DE DEMARRAGE ELECTRIQUE (VX700DX/VT700) – ELEC ELEKTRISKT STARTSYSTEM (VX700DX/VT700) ELEKTRISKT STARTSYSTEM SYSTEME DE DEMARRAGE (VX700DX/VT700) ELECTRIQUE (VX700DX/VT700) KOPPLINGSSCHEMA SCHEMA DE CIRCUIT ∗2 ∗2 4 Fusible principal Huvudsäkring ∗2 ∗2 5 Relais de démarreur Startrelä ∗2 ∗2 6 Batterie Batteri ∗2 ∗2 7 Démarreur… -
Page 428
– 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 429
– 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 430
– ELEC SYSTEME DE DEMARRAGE ELECTRIQUE (VX700DX/VT700) GUIDE DE DEPANNAGE LE DEMARREUR NE FONCTIONNE PAS. AVERTISSEMENT Avant de faire fonctionner le démarreur, mettre le coupe-circuit du moteur sur “OFF”. INCORRECT 1. Connecter: • Bornes de relais de démarreur (côté batterie et côté démarreur) Vérifier la batterie et les connecteurs. -
Page 431
– ELEC SYSTEME DE DEMARRAGE ELECTRIQUE (VX700DX/VT700) DEFECTUEUX Contrôler le fusible principal et le fusible d’allu- mage “IGNITION”. Se reporter à “VERIFICATION DES FUSIBLES” au CHAPITRE 2. Remplacer le fusible principal et/ou le fusible d’allumage “IGNITION”. DEFECTUEUX Vérifier le contacteur à clé. Remplacer le contacteur à… -
Page 432
– ELEC ELEKTRISKT STARTSYSTEM (VX700DX/VT700) FELSÖKNING STARTMOTORN FUNGERAR INTE. VARNING Innan Du manövrerar startmotorn skall Du trycka in motorns stoppomkopplare till läget “OFF”. 1. Anslut: • Startreläpolerna (batterisidan och startmotorsidan) Kontrollera batteriet och kontakterna. Vi hänvisar till “INSPEKTION AV BATTERI” i kapi- tel 2. -
Page 433
– ELEC ELEKTRISKT STARTSYSTEM (VX700DX/VT700) Kontrollera huvudsäkringen och tändningssäk- ringen “IGNITION”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. Byt ut huvudsäkringen och/eller tändningssäk- ringen “IGNITION”. Kontrollera huvudomkopplaren. Byt ut huvudomkopplaren. Rätta till anslutningen. HUVUDOMKOPPLARE 1. Koppla ur: • Huvudomkopplarens koppling 1 2. -
Page 434
– 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 435
SYSTEME DE DEMARRAGE ELECTRIQUE (VX700DX/VT700) – ELEC ELEKTRISKT STARTSYSTEM (VX700DX/VT700) DEMARREUR Ordre Travail/pièces Qté Remarques Démontage du démarreur Déposer les pièces dans l’ordre indiqué ci-con- tre. Dépose du démarreur Se reporter à “DEPOSE DU MOTEUR” au CHAPITRE 5. Support arrière Joint torique Plaquette de balais Balai 1… -
Page 436
– 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 437
SYSTEME DE DEMARRAGE ELECTRIQUE (VX700DX/VT700) – ELEC ELEKTRISKT STARTSYSTEM (VX700DX/VT700) Inspection Inspektion 1. Inspecter: 1. Inspektera: • • Collecteur (surface extérieure) Kommutatorn (yttre yta) Encrassée → Nettoyer avec du papier de verre Smutsig → Rengör med #600 sandpapper 1. de grain n°600 Sätt fast armaturen i ett skruvstäd 2 försett Serrer l’induit dans un étau et une plaque de… -
Page 438
– 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 439
SYSTEME DE DEMARRAGE ELECTRIQUE (VX700DX/VT700) – ELEC ELEKTRISKT STARTSYSTEM (VX700DX/VT700) 5. Mät: 5. Mesurer: • • Borstens längd a Longueur de balai Motsvarar inte specifikationen → Byt ut start- Hors spécifications → Remplacer le démar- motorn. reur. Borstens slitagegräns a: Limite d’usure de balai 8,5 mm (0,33 in) 8,5 mm (0,33 in) -
Page 440
– ELEC CHARGING SYSTEM (VX700DX/VT700) SCH8150 8-16… -
Page 441
SYSTEME DE CHARGE (VX700DX/VT700) – ELEC LADDNINGSSYSTEM (VX700DX/VT700) SYSTEME DE CHARGE LADDNINGSSYSTEM (VX700DX/VT700) (VX700DX/VT700) SCHEMA DE CIRCUIT KOPPLINGSSCHEMA 1 Magnéto AC AC-magnet 2 Redresseur/régulateur Likriktare/regulator ∗2 4 Fusible principal ∗2 Huvudsäkring 6 Batterie Batteri ∗2 VX700DX/VT700 ∗2 VX700DX/VT700 8-16… -
Page 442
– 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 443
– ELEC SYSTEME DE CHARGE (VX700DX/VT700) GUIDE DE DEPANNAGE LA BATTERIE N’EST PAS CHARGEE. 1. Connecter: • Testeur de poche (aux bornes de batterie) HORS SPECIFICATIONS 2. Mesurer: • Voltage de batterie • Densité • Vérifier la batterie. Voltage de batterie: plus de 12 V à… -
Page 444
– ELEC LADDNINGSSYSTEM (VX700DX/VT700) FELSÖKNING BATTERIET ÄR INTE LADDAT. 1. Anslut: • Fickprovaren (till batteripolerna) MOTSVARAR INTE SPECIFIKATIONERNA 2. Mät: • Batteriets spänning • Vätskans vikt • Kontrollera batteriet. Batterispänning: mer än 12 V vid 20°C (68°F) Vi hänvisar till “INSPEKTION AV BATTERI” i kapitel 2. -
Page 445
– ELEC 8-19… -
Page 446
– 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 447
SYSTEME DE CHARGE (VX700DX/VT700) – ELEC LADDNINGSSYSTEM (VX700DX/VT700) BATTERIE BATTERI Inspection Inspektion 1. Inspecter: 1. Inspektera: • • Niveau d’électrolyte Batterivätskans nivå Se reporter à “INSPECTION DE LA BATTE- Vi hänvisar till “INSPEKTION AV BATTERI” i RIE” au CHAPITRE 2. kapitel 2. -
Page 448
– ELEC LIGHTING SYSTEM SCH8370 8-19… -
Page 449: Lighting System
SYSTEME D’ECLAIRAGE – ELEC LJUSSYSTEM SYSTEME D’ECLAIRAGE LJUSSYSTEM LIGHTING SYSTEM SCHEMA DE CIRCUIT KOPPLINGSSCHEMA CIRCUIT DIAGRAM 1 Magnéto AC 1 AC-magnet 1 AC magneto 2 Redresseur/régulateur 2 Likriktare/regulator 2 Rectifier/regulator ∗1 ∗1 ∗1 3 Condensateur 3 Kondensator 3 Condenser ∗2 ∗2 ∗2 4 Fusible principal…
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Page 450
– 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 451
– 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 452
– ELEC SYSTEME D’ECLAIRAGE GUIDE DE DEPANNAGE PHARE ET/OU ECLAIRAGE DES INSTRUMENTS DE BORD NE S’ALLUMENT PAS. Vérifier l’ampoule ou les ampoules. DISCONTINUITE Remplacer l’ampoule ou les ampoules. VX700DX/VT700: Contrôler le fusible principal, le fusible d’allumage “IGNITION” et le fusible de phare “HEAD”. Se reporter à… -
Page 453
– ELEC SYSTEME D’ECLAIRAGE LE FEU ARRIERE NE S’ALLUME PAS. Vérifier l’ampoule ou les ampoules. DISCONTINUITE Remplacer l’ampoule ou les ampoules. VX700DX/VT700: Contrôler le fusible principal, le fusible d’allumage “IGNITION” et le fusible de feu arrière “TAIL”. Se reporter à “VERIFICATION DES FUSIBLES” au CHAPITRE 2. -
Page 454
– ELEC LJUSSYSTEM FELSÖKNING STRÅLKASTAREN OCH/ELLER MÄTARBELYSNINGEN TÄNDS INTE. Kontrollera glödlampan/lamporna. INGEN KONTINUITET Byt ut glödlampan/lamporna. För VX700DX/VT700: Kontrollera huvudsäkringen, tändningssäkringen “IGNITION” och strålkastarsäkringen “HEAD”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. Byt ut huvudsäkringen , tändningssäkringen “IGNITION” och/eller strålkastarsäkringen “HEAD”. För VX700DX/VT700: Kontrollera batteriet. -
Page 455
– ELEC LJUSSYSTEM BAKLJUSET TÄNDS INTE. Kontrollera glödlampan/lamporna. INGEN KONTINUITET Byt ut glödlampan/lamporna. För VX700DX/VT700: Kontrollera huvudsäkringen, tändningssäkringen “IGNITION” och bakljussäkringen “TAIL”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. Byt ut huvudsäkringen , tändningssäkringen “IGNITION” och/eller bakljussäkringen “TAIL”. För VX700DX/VT700: Kontrollera batteriet. -
Page 456
– 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 457
SYSTEME D’ECLAIRAGE – ELEC LJUSSYSTEM AMPOULE(S) GLÖDLAMPA/LAMPOR 1. Déposer: 1. Demontera: • • Strålkastarlampan a Ampoule de phare • • Ampoule de feu arrière/stop Bak/bromsljuslampan b • • Mätarbelysningens lampa c Ampoule d’éclairage des instruments 2. Connecter: 2. Anslut: • •… -
Page 458
– 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 459
SYSTEME D’ECLAIRAGE – ELEC LJUSSYSTEM RELAIS DE PHARE STRÅLKASTARELÄT 1. Inspecter: 1. Inspektera: • • Relais de phare (bleu) Strålkastarelät (blå) 1 Marche à suivre: Inspektionsåtgärder: • • Déconnecter le relais de phare du coupleur. Koppla ifrån strålkastarrelät från kopplaren. •… -
Page 460
– ELEC SIGNAL SYSTEM SCH8430 8-24… -
Page 461: Signal System
SYSTEME DE SIGNALISATION – ELEC SIGNALSYSTEM SYSTEME DE SIGNALSYSTEM SIGNAL SYSTEM SIGNALISATION KOPPLINGSSCHEMA CIRCUIT DIAGRAM 1 AC-magnet 1 AC Magneto SCHEMA DE CIRCUIT 1 Magnéto AC 2 Likriktare/regulator 2 Rectifier/regulator ∗1 ∗1 3 Kondensator 3 Condenser 2 Redresseur/régulateur ∗2 ∗2 ∗1 4 Huvudsäkring 4 Main fuse…
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Page 462
– 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 463
– 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 464
– 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 465
– 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 466
– ELEC SYSTEME DE SIGNALISATION GUIDE DE DEPANNAGE LE FEU STOP NE S’ALLUME PAS. Vérifier l’ampoule de feu arrière/stop. Se reporter à “SYSTEME D’ECLAIRAGE”. DISCONTINUITE Remplacer l’ampoule. VX700DX/VT700: Contrôler le fusible principal, le fusible d’allumage “IGNITION” et le fusible de feu arrière “TAIL”. Se reporter à… -
Page 467
– ELEC SYSTEME DE SIGNALISATION LES TEMOINS DE TEMPERATURE D’EAU ET/OU DE NIVEAU D’HUILE NE S’ALLUMENT PAS. Vérifier l’ampoule des témoins de température d’eau et/ou de niveau d’huile. Se reporter à “SYSTEME D’ECLAIRAGE”. DISCONTINUITE Remplacer l’ampoule ou les ampoules. VX700DX/VT700: Contrôler le fusible principal, le fusible d’allumage “IGNITION”… -
Page 468
– ELEC SYSTEME DE SIGNALISATION LA JAUGE DE CARBURANT NE FONCTIONNE PAS. VX700DX/VT700: Contrôler le fusible principal, le fusible d’allumage “IGNITION” et le fusible de phare “HEAD”. Se reporter à “VERIFICATION DES FUSIBLES” au CHAPITRE 2. DEFECTUEUX Remplacer le fusible principal, le fusible d’allumage “IGNITION”… -
Page 469
– ELEC SYSTEME DE SIGNALISATION L’AVERTISSEUR DE MARCHE ARRIERE NE FONCTIONNE PAS. (VX700DX/VT700) Contrôler le fusible principal, le fusible d’allumage “IGNITION” et le fusible de feu arrière “TAIL”. Se reporter à “VERIFICATION DES FUSIBLES” au CHAPITRE 2. DEFECTUEUX Remplacer le fusible principal, le fusible d’allumage “IGNITION”… -
Page 470
– ELEC SIGNALSYSTEM FELSÖKNING BROMSLJUSET TÄNDS INTE. Kontrollera bak/bromsljusets lampa. Vi hänvisar till “LJUSSYSTEM”. INGEN KONTINUITET Byt ut glödlampan. För VX700DX/VT700: Kontrollera huvudsäkringen, tändningssäkringen “IGNITION” och bakljussäkringen “TAIL”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. Byt ut huvudsäkringen , tändningssäkringen “IGNITION”… -
Page 471
– ELEC SIGNALSYSTEM INDIKATORLAMPAN FÖR VATTENTEMPERATUREN OCH/ELLER OLJENIVÅN TÄNDS INTE. Kontrollera indikeringslampan/lamporna för vattentemperaturen och/eller oljenivån. Vi hänvisar till “LJUSSYSTEM”. INGEN KONTINUITET Byt ut glödlampan/lamporna. För VX700DX/VT700: Kontrollera huvudsäkringen, tändningssäkringen “IGNITION” och strålkastarsäkringen “HEAD”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. -
Page 472
– ELEC SIGNALSYSTEM BRÄNSLEMÄTAREN FUNGERAR INTE. För VX700DX/VT700: Kontrollera huvudsäkringen, tändningssäkringen “IGNITION” och strålkastarsäkringen “HEAD”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. Byt ut huvudsäkringen , tändningssäkringen “IGNITION” och/eller strålkastarsäkringen “HEAD”. För VX700DX/VT700: Kontrollera batteriet. Vi hänvisar till “INSPEKTION AV BATTERI” i kapitel 2. -
Page 473
– ELEC SIGNALSYSTEM BACKSIGNALEN LJUDER INTE. (VX700DX/VT700) Kontrollera huvudsäkringen, tändningssäkringen “IGNITION” och bakljussäkringen “TAIL”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. Byt ut huvudsäkringen , tändningssäkringen “IGNITION” och/eller bakljussäkringen “TAIL”. Kontrollera batteriet. Vi hänvisar till “INSPEKTION AV BATTERI” i kapitel 2. -
Page 474
– 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 475
SYSTEME DE SIGNALISATION – ELEC SIGNALSYSTEM CONTACTEUR DE FREIN BROMSLAMPANS OMKOPPLARE 1. Déconnecter: 1. Koppla ur: • • Coupleur de contacteur de feu stop Bromslampans omkopplare koppling 1 2. Kontrollera: 2. Vérifier: • • Kontinuiteten i bromslampans omkopplare Continuité du contacteur de frein Bristfällig →… -
Page 476
– 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 477
SYSTEME DE SIGNALISATION – ELEC SIGNALSYSTEM CAPTEUR DE TEMPERATURE D’EAU VATTENTEMPERATURSENSOR 1. Déconnecter le coupleur du capteur de tempéra- 1. Koppla ur vattentemperatursensorns kontakt 1 ture d’eau et déposer le capteur de température och demontera vattentemperatursensorn. d’eau. VIKTIGT: ATTENTION: Hantera vattentemperatursensorn med varsam- Manipuler le capteur de température d’eau avec het. -
Page 478
– 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 479
SYSTEME DE SIGNALISATION – ELEC SIGNALSYSTEM CONTACTEUR DE NIVEAU D’HUILE OLJENIVÅOMKOPPLARE 1. Déposer: 1. Demontera: • • Silencieux d’admission Insugningsljuddämparen Se reporter à “POMPE A CARBURANT” au Vi hänvisar till “BRÄNSLEPUMP” i kapitel 7. • CHAPITRE 7. Oljenivåmätaren 1 • Jauge de niveau d’huile 2. -
Page 480
– ELEC GRIP WARMER SYSTEM SCH8540 8-32… -
Page 481: Grip Warmer System
SYSTEME DES CHAUFFE-POIGNEES – ELEC HANDTAGSVÄRMARSYSTEM HANDTAGSVÄRMARSYSTEM SYSTEME DES GRIP WARMER SYSTEM KOPPLINGSSCHEMA CHAUFFE-POIGNEES CIRCUIT DIAGRAM 1 AC-magnet SCHEMA DE CIRCUIT 1 AC magneto 2 Likriktare/regulator 1 Magnéto AC 2 Rectifier/regulator ∗1 3 Kondensator 2 Redresseur/régulateur ∗1 3 Condenser ∗2 4 Huvudsäkring ∗1 3 Condensateur…
-
Page 482
– 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 483
– 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 484
– ELEC SYSTEME DES CHAUFFE-POIGNEES GUIDE DE DEPANNAGE LE CHAUFFE-POIGNEES ET LE CHAUFFE-POUCE NE FONCTIONNENT PAS. VX700DX/VT700: Contrôler le fusible principal et le fusible d’allumage “IGNITION”. Se reporter à “VERIFICATION DES FUSIBLES” au CHAPITRE 2. DEFECTUEUX Remplacer le fusible principal et/ou le fusible d’allu- mage “IGNITION”. -
Page 485
– ELEC SYSTEME DES CHAUFFE-POIGNEES LE CHAUFFE-POIGNEE DE PASSAGER NE FONCTIONNE PAS. (VT700) Contrôler le fusible principal, le fusible d’allumage “IGNITION” et le fusible de feu arrière “TAIL”. Se reporter à “VERIFICATION DES FUSIBLES” au CHAPITRE 2. DEFECTUEUX Remplacer le fusible principal, le fusible d’allumage “IGNITION”… -
Page 486
– ELEC HANDTAGSVÄRMARSYSTEM FELSÖKNING HANDTAGSVÄRMAREN OCH TUMVÄRMAREN FUNGERAR INTE. För VX700DX/VT700: Kontrollera huvudsäkringen och tändningssäkringen “IGNITION”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. Byt ut huvudsäkringen och/eller tändningssäkringen “IGNITION”. För VX700DX/VT700: Kontrollera batteriet. Vi hänvisar till “INSPEKTION AV BATTERI” i kapitel 2. -
Page 487
– ELEC HANDTAGSVÄRMARSYSTEM PASSAGERARSÄTETS GREPPVÄRMARE FUNGERAR INTE. (VT700) Kontrollera huvudsäkringen, tändningssäkringen “IGNITION” och bakljussäkringen “TAIL”. Vi hänvisar till “INSPEKTION AV SÄKRINGAR” i kapitel 2. Byt ut huvudsäkringen , tändningssäkringen “IGNITION” och/eller bakljussäkringen “TAIL”. Kontrollera batteriet. Vi hänvisar till “INSPEKTION AV BATTERI” i kapitel 2. -
Page 488
– 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 489
SYSTEME DES CHAUFFE-POIGNEES – ELEC HANDTAGSVÄRMARSYSTEM BOBINE DE CHAUFFE-POIGNEES ET DE HANDTAGS- OCH TUMVÄRMARSPOLE CHAUFFE-POUCE 1. Koppla ur: • 1. Déconnecter: Handtagsvärmarens ledningar 1 • • Fils de chauffe-poignées Tumvärmarens koppling 2 • Coupleur du chauffe-pouce 2. Anslut: • 2. Connecter: Fickprovaren •… -
Page 490
– 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 491
SYSTEME DES CHAUFFE-POIGNEES – ELEC HANDTAGSVÄRMARSYSTEM RESISTANCE VARIABLE (CHAUFFE- VARIABELT MOTSTÅND POIGNEES) (HANDTAGSVÄRMARE) 1. Déconnecter: 1. Koppla ur: • Coupleur de résistance variable • Det variabla motståndets koppling 1 2. Connecter: 2. Anslut: • • Multimètre Fickprovaren (au coupleur de résistance variable) (till det variabla motståndets koppling) 3. -
Page 492
– 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 493
SYSTEME DES CHAUFFE-POIGNEES – ELEC HANDTAGSVÄRMARSYSTEM PASSAGERARHANDTAGETS CONTACTEUR DE CHAUFFE-POIGNEES DE PASSAGER (VT700) VÄRMAROMKOPPLARE (VT700) 1. Koppla ur: 1. Déconnecter: • • Coupleur du contacteur de chauffe-poignées Kopplingen för passagerarhandtagets värma- romkopplare 1 de passager 2. Anslut: 2. Connecter: • Fickprovaren •… -
Page 494
– 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 495
SYSTEME DES CHAUFFE-POIGNEES – ELEC HANDTAGSVÄRMARSYSTEM RELAIS DE CHAUFFE-POIGNEES DE RELÄ FÖR PASSAGERARSÄTETS PASSAGER (VT700) GREPPVÄRMARE (VT700) 1. Inspecter: 1. Inspektera: • • Relais de chauffe-poignées de passager Relä för passagerarsätets greppvärmare 1 Marche à suivre: Inspektionsåtgärder: • • Déconnecter le relais de chauffe-poignées de Koppla ifrån relät för passagerarsätets grepp- passager du coupleur. -
Page 496
– 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 497
– 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 498
– ELEC TABLEAU D’ORIGINE DES PANNES TABLEAU D’ORIGINE DES PANNES N.B.: Lorsque plusieurs problèmes sont détectés, le type de clignotement du témoin de température d’eau sera celui du numéro de panne le plus petit. Une fois cette panne réparée, le clignotement du témoin sera celui du type du numéro de la panne suivante, et ainsi de suite jusqu’à… -
Page 499
– ELEC TABLEAU D’ORIGINE DES PANNES N° Types de clignotement Problèmes Référence Court-circuit du réchauf- Se reporter à Repeats feur de griffe. “SYSTEME DES CHAUFFE- POIGNEES”. 0.75 s 0.25 s 3.5 s SCH8740 Discontinuité de la Se reporter à Repeats résistance variable “RESISTANCE (chauffe-pouce). -
Page 500
– ELEC FELUNDERSÖKNINGSTABELL FELUNDERSÖKNINGSTABELL OBS: När fler än ett problem upptäcks blinkar vattentemperatursindikatorn i mönstret för det lägst numrerade problemet. Efter att det problemet har korrigerats blinkar vattentemperatursindikatorn i mönstret för det näst lägst numrerade problemet. Detta fortgår tills alla problem har upptäckts och åtgärdats. Mönster Förhållande Referens… -
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– ELEC FELUNDERSÖKNINGSTABELL Mönster Förhållande Referens Kortslutning i handtag- Vi hänvisar till Repeats svärmaren har upptäckts. “HANDTAGS- VÄRMAR- SYSTEM”. 0.75 s 0.25 s 3.5 s SCH8740 Kortslutning i det variabla Vi hänvisar till Repeats motståndet (tomvärmar). “VARIABELT MOTSTÅND (TUM- VÄRMARE)”. 0.75 s 0.25 s 4.5 s… -
Page 502
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 503
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 504
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 505
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 506
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 507
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 508
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 509
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 510
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) -
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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) -
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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 513
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 514
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 515
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 #145 MJ #2#3 #143.8… -
Page 516
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 517
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 518
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 519
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 520
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 521
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 522
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. -
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SPEC 9-22… -
Page 524
8.250 tr/mn Couple maximal tr/mn Lanceur manuel à réenroulement (VX700/SX700/MM700) Système de démarrage Démarreur électrique et lanceur manuel à réenroulement (VX700DX/VT700) Indépendant (AUTOLUBE YAMAHA) Système de lubrification Huile moteur: Huile deux temps YAMALUBE 2 Type Contenance 3,0 L (2,6 Imp qt, 3,2 US qt) Huile du carter de chaîne de transmission:… -
Page 525
SPEC CARACTERISTIQUES GENERALES Modèle VX700/VX700DX/SX700/MM700/VT700 Carburant: R + M Type Essence sans plomb (indice d’octane à la pompe: : 88) Indice d’octane de recherche: 93 (Europe) Contenance du réservoir 44,3 L (9,7 Imp gal, 11,7 US gal) Carburateur: Type/quantité TM33/3 Fabricant MIKUNI Bougie:… -
Page 526
SPEC CARACTERISTIQUES GENERALES Modèle VX700/VX700DX/SX700/MM700/VT700 Wattage d’ampoule × quantité: 12 V, 60 W/55 W × 2 Phare 12 V, 8 W/23 W × 1 Feu arrière/stop 12 V, 1,7 W × 1 Eclairage de compte-tours 12 V, 1,7 W × 1 Eclairage de compteur de vitesse 12 V, 1,7 W ×… -
Page 527
SPEC CARACTERISTIQUES D’ENTRETIEN CARACTERISTIQUES D’ENTRETIEN MOTEUR Modèle VX700/VX700DX/SX700/MM700/VT700 Culasse: 22,9 ~ 23,5 cm Volume (avec bougie) (1,40 ~ 1,43 cu.in) <0,03 mm (0,0012 in)> <Limite de déformation> ∗Les lignes indiquent où il faut placer la règle pour les mesures. Cylindre: Matériau Alliage d’aluminium avec recouvrement par dispersion Alésage… -
Page 528
SPEC CARACTERISTIQUES D’ENTRETIEN Modèle VX700/VX700DX/SX700/MM700/VT700 Vilebrequin: 55,95 ~ 56,00 mm (2,203 ~ 2,205 in) Largeur du vilebrequin “A” Largeur du vilebrequin “B” 291,75 ~ 292,30 mm (11,486 ~ 11,508 in) 0,03 mm (0,0012 in) Déflexion de vilebrequin “C” : C 0,04 mm (0,0016 in) 0,03 mm (0,0012 in) 90 mm (3,54 in) -
Page 529
SPEC CARACTERISTIQUES D’ENTRETIEN Modèle VX700/VX700DX/SX700/MM700/VT700 Carburateur: TM33/3 Type/quantité Fabricant MIKUNI 8CH10 Code d’identification #1: 145 Gicleur principal (M.J) #2, #3: 143,8 Gicleur de ralenti (P.J) Aiguille (J.N) 6DGM05-3 #1: Q-8 Puits d’aiguille (N.J) #2, #3: Q-4 Gicleur d’air de ralenti (P.A.J) ø0,8 Sortie de ralenti (P.O.) -
Page 530
SPEC CARACTERISTIQUES D’ENTRETIEN TRAIN DE ROULEMENT Modèle VX700/VX700DX/SX700/MM700/VT700 Transmission: Automatique, à courroie trapézoïdale Type 3,8 ~ 1,0 :1 Plage de démultiplication 4.000 ± 200 tr/mn (3.800 ~ 4.200 tr/mn) (VX700/VX700DX) Régime d’embrayage tr/mn 3.900 ± 200 tr/mn (3.700 ~ 4.100 tr/mn) (SX700/VT700) 4.700 ±… -
Page 531
SPEC CARACTERISTIQUES D’ENTRETIEN Modèle VX700/VX700DX/SX700/MM700/VT700 Bras de masselotte de poulie primaire: Numéro de pièce (avec douille) 8CH-17605-10 (VX700/VX700DX) (VT700, E.-U. et Canada) 8DF-17605-10 (SX700) 8CR-17605-10 (MM700) (VT700, Europe) 35,32 g (1,246 oz) (VX700/VX700DX) (VT700, E,-U, et Canada) Poids 37,84 g (1,334 oz) (SX700) 38,09 g (1,345 oz) (MM700) (VT700, Europe) Rivet: Extérieur… -
Page 532
SPEC CARACTERISTIQUES D’ENTRETIEN Modèle VX700/VX700DX/SX700/MM700/VT700 Chaîne de transmission: REXNORD S37TNB13 Type 70 L (VX700/VX700DX/SX700/MM700) (VT700, E.-U. et Canada) Nombre de maillons 68 L (VT700, Europe) Chenille: 8EA-47110-10 (VX700/VX700DX/SX700) Numéro de pièce 8ED-47110-00 (MM700) 8BN-47110-00 (VT700) 381 mm (15,0 in) Largeur 3.072 mm (120,9 in) (VX700/VX700DX/SX700) Longueur 3.584 mm (141,1 in) (MM700) -
Page 533
SPEC CARACTERISTIQUES D’ENTRETIEN Modèle VX700/VX700DX/SX700/MM700/VT700 Position de réglage de la suspension: 10 ± 0,5 mm (0,39 ± 0,02 in) (VX700/MM700) Longueur de réglage du crochet ∗ 15 ± 0,5 mm (0,59 ± 0,02 in) (VX700DX) 25 ± 0,5 mm (0,98 ± 0,02 in) (SX700/VT700) Position de réglage général ∗∗… -
Page 534
SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE CYCLE Modèle VX700/VX700DX/SX700/MM700/VT700 Cadre: Aluminium Matériau du cadre 730 mm (28,7 in) (VX700/VX700DX/SX700/VT700) Hauteur du siège 700 mm (27,6 in) (MM700) Arrière du siège Emplacement du coffre à bagage Direction: 29,4° (Ski D) 34,7° (Ski G) (VX700/VX700DX/SX700/VT700) Angle de braquage (gauche) 34,7°… -
Page 535
SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE ELECTRIQUE Modèle VX700/VX700DX/SX700/MM700/VT700 Tension 12 V Système d’allumage: Avance à l’allumage (av. P.M.H.) 18° à 1.500 tr/mn Numérique Dispositif d’avance Bobine d’allumage: F6T535/MITSUBISHI Modèle/fabricant Longueur d’étincelle minimum 6 mm (0,236 in) ou plus 0,36 ~ 0,48 Ω à 20°C (68°F) Résistance de l’enroulement primaire Résistance de l’enroulement secondaire 5,4 ~ 7,4 kΩ… -
Page 536
SPEC CARACTERISTIQUES D’ENTRETIEN Modèle VX700/VX700DX/SX700/MM700/VT700 Démarreur: (VX700DX/VT700): DB4XF/DENSO Modèle/fabricant 12 V-0,6 kW Puissance Résistance de bobine d’induit 0,014 ~ 0,018 Ω à 20°C (68°F) Contrôle de la continuité Plus de 100 kΩ à 20°C (68°F) Contrôle de l’isolation Balais 12 mm (0,47 in) Longueur hors tout 8,5 mm (0,33 in) Limite d’usure… -
Page 537
SPEC CARACTERISTIQUES D’ENTRETIEN REGLAGE POUR HAUTE ALTITUDE VX700/SX700 Tempéra- –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… -
Page 538
SPEC CARACTERISTIQUES D’ENTRETIEN VX700DX Tempéra- –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 539
SPEC CARACTERISTIQUES D’ENTRETIEN MM700/VT700 Tempéra- –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 540
SPEC CARACTERISTIQUES D’ENTRETIEN COUPLE DE SERRAGE MOTEUR Couple de serrage Pièce à serrer Remarques m · kg ft · lb Carter (M8 × 80) (1re) Serrer les boulons en (2e) deux passes. Carter (M8 × 35) Support de moteur (avant) et cadre Amortisseur de support de moteur (avant/arrière) Support de moteur (avant) et moteur Support de moteur droit (arrière) et moteur… -
Page 541
SPEC CARACTERISTIQUES D’ENTRETIEN TRAIN DE ROULEMENT Couple de serrage Pièce à serrer Remarques m · kg ft · lb Poulie primaire (1re) 12,0 Serrer les boulons en (2e) deux passes. Voir N.B.: Croisillon et poulie fixe 20,0 Filet à pas à gauche. ®… -
Page 542
SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Pièce à serrer Remarques m · kg ft · lb ® Arbre de support de galet et cadre coulissant Appliquer du LOCTITE Boulon sans tête (axe avant) Ensemble entraînement de compteur de vitesse N.B.: Etapes de serrage: 1. -
Page 543
SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE CYCLE Couple de serrage Pièce à serrer Remarques m · kg ft · lb Support de guidon Colonne de direction Supérieur Inférieur Colonne de direction et biellette intermédiaire Biellette intermédiaire et bras relais Bras relais et barre d’accouplement Barre d’accouplement et bras de direction Bras relais ®… -
Page 544
SPECIFICATIONS GENERALES DE COUPLE/ SPEC DEFINITION DES UNITES SPECIFICATIONS GENERALES DE Spécifications générales COUPLE de couple (Ecrou) (Boulon) Ce tableau spécifie les couples de serrage les attaches m · kg ft · lb standard avec filetage à pas I.S.O. standard. Les 10 mm 6 mm spécifications de couple pour les composants ou… -
Page 545
SPEC 9-22… -
Page 546
8.500 varv/min Max. vridmoment varv/min 8.250 varv/min Startsystem Rekylhandstart (VX700/SX700/MM700) Elektrisk start och rekylhandstart (VX700DX/VT700) Smörjsystem Separat smörjning (YAMAHA AUTOLUBE) Motorolja: YAMALUBE 2-taktsolja Tankkapacitet 3,0 L (2,6 Imp qt, 3,2 US qt) Drivkejdehusolja: Växellådsolja API GL-3 SAE #75 eller #80… -
Page 547
SPEC ALLMÄNNA SPECIFIKATIONER Modell VX700/VX700DX/SX700/MM700/VT700 Bränsle: R + M Blyfri bensin (pumpoktanvärde : 88) Forskat oktanvärde: 93 (för Europa) Tankkapacitet 44,3 L (9,7 Imp gal, 11,7 US gal) Förgasare: Typ/kvantitet TM33/3 Tillverkare MIKUNI Tändstift: BR9ES Tillverkare 0,7 ~ 0,8 mm (0,028 ~ 0,031 in) Växellåda: Primärt reduktionssystem Kilrem… -
Page 548
SPEC ALLMÄNNA SPECIFIKATIONER Modell VX700/VX700DX/SX700/MM700/VT700 Lampornas wattförbrukning × antal: 12 V, 60 W/55 W × 2 Strålkastare 12 V, 8 W/23 W × 1 Bak/bromsljus 12 V, 1,7 W × 1 Varvräknarljus 12 V, 1,7 W × 1 Hastighetsmätarens ljus 12 V, 1,7 W ×… -
Page 549
SPEC UNDERHÅLLSSPECIFIKATIONER UNDERHÅLLSSPECIFIKATIONER MOTOR Modell VX700/VX700DX/SX700/MM700/VT700 Topplock: 22,9 ~ 23,5 cm Volym (med tändstift) (1,40 ~ 1,43 cu.in) <Skevningsgräns> <0,03 mm (0,0012 in)> ∗Linjerna indikerar riktskenans mått. Cylinder: Material Aluminiumlegering med dispersionsbeläggning Cylinderstorlek 70,500 ~ 70,520 mm (2,7756 ~ 2,7764 in) <Slitagegräns>… -
Page 550
SPEC UNDERHÅLLSSPECIFIKATIONER Modell VX700/VX700DX/SX700/MM700/VT700 Vevaxel: Vevbredd “A” 55,95 ~ 56,00 mm (2,203 ~ 2,205 in) 291,75 ~ 292,30 mm (11,486 ~ 11,508 in) Vevbredd “B” Maximal kastning “C”: C 0,03 mm (0,0012 in) 0,04 mm (0,0016 in) 0,03 mm (0,0012 in) Mätpunkter: 90 mm (3,54 in) 85 mm (3,35 in) -
Page 551
SPEC UNDERHÅLLSSPECIFIKATIONER Modell VX700/VX700DX/SX700/MM700/VT700 Förgasare: Typ/kvantitet TM33/3 MIKUNI Tillverkare Identifieringsmärke 8CH10 #1: 145 Huvudmunstycke (M.J) #2, #3: 143,8 Tomgångsmunstycke (P.J) 6DGM05-3 Munstycksnål (J.N) Nålmunstycke (N.J) #1: Q-8 #2, #3: Q-4 Tomgångsluftmunstycke (P.A.J) Tomgångsuttag (P.O) ø0,8 ø0,8 Förbiledningskanal (B.P.1) Tomgångsskruv (P.S) 1-1/2 varv utåt C,A 3,5 Gasspjällsventil… -
Page 552
SPEC UNDERHÅLLSSPECIFIKATIONER DRIVENHET Modell VX700/VX700DX/SX700/MM700/VT700 Växellåda: Kilrem, automatisk 3,8 ~ 1,0 :1 Verkningsgrad 4.000 ± 200 varv/min (3.800 ~ 4.200 varv/min) (VX700/VX700DX) Inkopplingsvarvtal varv/min 3.900 ± 200 varv/min (3.700 ~ 4.100 varv/min) (SX700/VT700) 4.700 ± 200 varv/min (4.500 ~ 4.900 varv/min) (MM700) 8.300 ±… -
Page 553
SPEC UNDERHÅLLSSPECIFIKATIONER VX700/VX700DX/SX700/MM700/VT700 Modell Primärskivans viktarm: 8CH-17605-10 (VX700/VX700DX) (VT700 för USA/Canada) Detaljnummer (med bussning) 8DF-17605-10 (SX700) 8CR-17605-10 (MM700) (VT700 för Europa) 35,32 g (1,246 oz) (VX700/VX700DX) (VT700 för USA/Canada) Vikt 37,84 g (1,334 oz) (SX700) 38,09 g (1,345 oz) (MM700) (VT700 för Europa) Nit: Yttre 90261-06015 (VX700/VX700DX) -
Page 554
SPEC UNDERHÅLLSSPECIFIKATIONER VX700/VX700DX/SX700/MM700/VT700 Modell Drivkedja: REXNORD S37TNB13 70 L (VX700/VX700DX/SX700/MM700) (VT700 för USA/Canada) Antal länkar 68 L (VT700 för Europa) Drivband: 8EA-47110-10 (VX700/VX700DX/SX700) Detaljnummer 8ED-47110-00 (MM700) 8BN-47110-00 (VT700) 381 mm (15,0 in) Bredd 3.072 mm (120,9 in) (VX700/VX700DX/SX700) Längd 3.584 mm (141,1 in) (MM700) 3.456 mm (136,1 in) (VT700) 64 mm (2,52 in) Stigning… -
Page 555
SPEC UNDERHÅLLSSPECIFIKATIONER Modell VX700/VX700DX/SX700/MM700/VT700 Upphängningens inställningsläge: Krokinställningslängd ∗ 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) Hela justeringsområdet ∗∗ Stötdämpare: Dämningskraft Fram 451 N/0,3 m/s (46 kg/0,3 m/s, 101 lb/0,3 m/s) (VX700) Förlängning… -
Page 556
SPEC UNDERHÅLLSSPECIFIKATIONER CHASSI Modell VX700/VX700DX/SX700/MM700/VT700 Ram: Rammaterial Aluminium Sitshöjd 730 mm (28,7 in) (VX700/VX700DX/SX700/VT700) 700 mm (27,6 in) (MM700) Bagageutrymmets placering Bakom sitsen Styrning: Låsningsvinkel (vänster) 29,4° (höger skida) 34,7° (vänster skida) (VX700/VX700DX/SX700/VT700) (höger) 34,7° (höger skida) 29,4° (vänster skida) (VX700/VX700DX/SX700/VT700) (vänster) 26,7°… -
Page 557
SPEC UNDERHÅLLSSPECIFIKATIONER ELEKTRISKT Modell VX700/VX700DX/SX700/MM700/VT700 12 V Spänning Tändningssystem: 18° vid 1.500 varv/min Tändningsinställning (före övre död- punkten) Digital typ Förinställd typ Tändspole: F6T535/MITSUBISHI Modell/Tillverkare Minimalt tändstiftsgap 6 mm (0,236 in) eller mer 0,36 ~ 0,48 Ω vid 20°C (68°F) Primärspolens resistans Sekundärspolens resistans 5,4 ~ 7,4 kΩ… -
Page 558
SPEC UNDERHÅLLSSPECIFIKATIONER VX700/VX700DX/SX700/MM700/VT700 Modell Startmotor (VX700DX/VT700): Modell/Tillverkare DB4XF/DENSO Uteffekt 12 V-0,6 kW Armaturspolens resistans 0,014 ~ 0,018 Ω vid 20°C (68°F) Kontroll av kontinuitet Isolationsprov Mer än 100 kΩ vid 20°C (68°F) Borste Total längd 12 mm (0,47 in) Slitagegräns 8,5 mm (0,33 in) Fjädertryck 6,38 ~ 9,32 N (650 ~ 950 g, 22,9 ~ 33,5 oz) -
Page 559
SPEC UNDERHÅLLSSPECIFIKATIONER INSTÄLLNINGAR FÖR HÖG HÖJD VX700/SX700 Tempera- –40°C –29°C –18°C –7°C 4°C 16°C Höjd (–40°F) (–20°F) (0°F) (20°F) (40°F) (60°F) över havet 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… -
Page 560
SPEC UNDERHÅLLSSPECIFIKATIONER VX700DX Tempera- –40°C –29°C –18°C –7°C 4°C 16°C Höjd (–40°F) (–20°F) (0°F) (20°F) (40°F) (60°F) över havet 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 561
SPEC UNDERHÅLLSSPECIFIKATIONER MM700/VT700 Tempera- –40°C –29°C –18°C –7°C 4°C 16°C Höjd (–40°F) (–20°F) (0°F) (20°F) (40°F) (60°F) över havet 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 562
SPEC UNDERHÅLLSSPECIFIKATIONER ÅTDRAGNINGSMOMENT MOTOR Åtdragningsmoment Delar som skall dras fast Anmärkningar m · kg ft · lb Vevhus (M8 × 80) (1:a) Drag fast bultarna i två (2:a) omgångar. Vevhus (M8 × 35) Motorfäste (fram) och ram Motorfästets dämpare (fram/bak) Motorfäste (fram) och motor Motorfäste, höger (bak) och motor Motorfäste, vänster (bak) och motor… -
Page 563
SPEC UNDERHÅLLSSPECIFIKATIONER DRIVENHET Åtdragningsmoment Delar som skall dras fast Anmärkningar m · kg ft · lb Primärremskiva (1:a) 12,0 Dra åt bultarna i två steg. (2:a) Se OBS. Spindel och fast remskiva 20,0 Vänstergängad. Stryk på LOCTITE ® Primärremskivans kåpa och glidremskiva Rulle och vikt (primärremskiva) Startmotorns drivna drev (VX700DX/VT700) -
Page 564
SPEC UNDERHÅLLSSPECIFIKATIONER Åtdragningsmoment Delar som skall dras fast Anmärkningar m · kg ft · lb Stryk på LOCTITE ® Hjulfästets axel och glidram Inställningsbult (framaxel) Hastighetsmätardrev OBS: Åtdragningsåtgärder: 1. Dra åt bulten till åtdragningsmomentet 120 Nm (12 m · kg, 85 ft · lb). 2. -
Page 565
SPEC UNDERHÅLLSSPECIFIKATIONER CHASSI Åtdragningsmoment Delar som skall dras fast Anmärkningar m · kg ft · lb Styrets hållare Styrstång Övre Nedre Styrstång och relästång Relästång och reläarm Reläarm och parallellstag Parallellstag och styrarm Reläarm ® Låsmutter (relästång och stagbult) Stryk på LOCTITE Skida Skidskena Nedre fäste för skidstång… -
Page 566
ALLMÄN VÄGLEDNING FÖR ÅTDRAGNINGSMOMENT/ SPEC DEFINITION AV ENHETER ALLMÄN VÄGLEDNING FÖR Allmänna åtdragnings- ÅTDRAGNINGSMOMENT specifikationer (mutter) (bult) Den här tabellen specificerar åtdragningsmomenten m · kg ft · lb för standardskruvar/muttrar med standard ISO- 10 mm 6 mm gängor. Åtdragningsspecifikationerna för special- 12 mm 8 mm komponenter eller enheter finns angivna i de berörda… -
Page 567
SPEC 9-22… -
Page 568
SPEC CABLE ROUTING SCH9010 9-23… -
Page 569: Cable Routing
CHEMINEMENT DES CABLES SPEC KABELDRAGNINGSSCHEMA CABLE ROUTING CHEMINEMENT DES KABELDRAG- CABLES NINGSSCHEMA 1 Water temperature sensor coupler 1 Coupleur du capteur de température 1 Koppling, 2 Fasten the carburetor switch d’eau vattentemperatursensor leads and water temperature 2 Attacher les fils de contacteur de 2 Fäst förgasaromkopplarens sensor leads and ignition coil carburateur, les fils du capteur de…
-
Page 570
SPEC CABLE ROUTING SCH9010 9-25… -
Page 571
CHEMINEMENT DES CABLES SPEC KABELDRAGNINGSSCHEMA D Connectors of the gear position D Connecteurs du contacteur de D Anslutningar för switch (VX700DX/VT700) position de rapport (VX700DX/ växellägesomkopplaren (VX700DX/VT700) VT700) E Route the main switch wire harness under the oil tank E Acheminer le faisceau de fil du E Dra startlåsets kabelstam under breather hose and fuel tank contacteur à… -
Page 572
SPEC CABLE ROUTING SCH9020 9-27… -
Page 573
CHEMINEMENT DES CABLES SPEC KABELDRAGNINGSSCHEMA 1 Brake hose 1 Flexible de frein 1 Bromsslang 2 Oil pump cable 2 Câble de la pompe à huile 2 Oljepumpskabel 3 Throttle cable 3 Câble d’accélérateur 3 Gasvajer 4 Wire harness 4 Faisceau de fils 4 Kabelstam 5 Starter cable 5 Câble de démarreur… -
Page 574
SPEC CABLE ROUTING SCH9030 9-29… -
Page 575
CHEMINEMENT DES CABLES SPEC KABELDRAGNINGSSCHEMA 1 Wire harness 1 Faisceau de fils 1 Kabelstam 2 Ensure this is not kink. 2 Ne pas plier. 2 Snor sig inte. 3 50 mm (1.97 in) 3 50 mm (1,97 in) 3 50 mm (1,97 in) 4 Make sure that the oil tank cap 4 S’assurer que le bouchon du 4 Kontrollera att oljetankens lock… -
Page 576
SPEC CABLE ROUTING SCH9030 9-31… -
Page 577
CHEMINEMENT DES CABLES SPEC KABELDRAGNINGSSCHEMA K Fuel tank breather hose K Reniflard du réservoir de carburant K Bränsleventilationsslang L Ground lead L Fil de mise à la terre L Jordledning M Install the clamp so that it does M Placer la bride de sorte qu’elle ne M Montera klämman så… -
Page 578
SPEC CABLE ROUTING SCH9040 9-33… -
Page 579
CHEMINEMENT DES CABLES SPEC KABELDRAGNINGSSCHEMA 1 Speedometer coupler 1 Coupleur du compteur de vitesse 1 Koppling, hastighetsmätare 2 Tachometer coupler 2 Coupleur du compte-tours 2 Koppling, varvräknare 3 Plastic band 3 Attache en plastique 3 Plastband 4 Clamp 4 Bride 4 Klämma 5 Headlight leads 5 Fils de phare… -
Page 580
SPEC CABLE ROUTING SCH9050 9-35… -
Page 581
CHEMINEMENT DES CABLES SPEC KABELDRAGNINGSSCHEMA 1 Oil pump cable 1 Câble de pompe à huile 1 Oljepumpskabel 2 Throttle cable 2 Câble d’accélérateur 2 Gasvajer 3 Do not fasten the throttle cable 3 Ne pas attacher le câble d’accélérateur 3 Fäst inte gasvajern och and oil pump cable. -
Page 582
SPEC CABLE ROUTING SCH9050 9-37… -
Page 583
CHEMINEMENT DES CABLES SPEC KABELDRAGNINGSSCHEMA S When fastening the wire harness S Pour attacher le faisceau de fils à S Böj klämman inåt för att fästa with the attaches clamp, bend the l’aide de la bride, il convient de kabelstammen med den clamp inward to fasten. -
Page 584
SPEC CABLE ROUTING SCH9060 9-39… -
Page 585
CHEMINEMENT DES CABLES SPEC KABELDRAGNINGSSCHEMA 1 Make sure a plastic band is 1 En attachant la bride en plastique 1 Se till att plastbandet, som dras routed through the projection autour du faisceau de fils et du câble runt kabelstammen och located on the silencer, when startkabeln, också… -
Page 586
AC magneto AC-magnet Magnéto AC COLOR CODE Rectifier/regulator Redresseur/régulateur Likriktare/regulator B ….. Black Br ….Brown ∗1 ∗1 ∗1 Condenser Kondensator Condensateur Ch ….Chocolate ∗2 ∗2 ∗2 G ….Green Main fuse Fusible principal Huvudsäkring Gy ….Gray ∗2 ∗2 ∗2 Starter relay… -
Page 587
WIRING DIAGRAM KOPPLINGSSCHEMA FÖR WIRING DIARAM 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… -
Page 589
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 • 8 — 0.7 × 1 CR IMPRIME SUR PAPIER RECYCLE TRYCKT PÅ ÅTERVUNNIT PAPPER…
Описание конструкции снегохода Yamaha.
- Год издания: —
- Страниц: 65
- Формат: PDF
- Размер: 6,9 Mb
Руководство на английском языке по техническому обслуживанию и ремонту снегохода Yamaha BR250F.
- Год издания: 1981
- Страниц: 191
- Формат: PDF
- Размер: 8,7 Mb
Руководство по эксплуатации и техническому обслуживанию снегоходов Yamaha BR250TG и Yamaha VK540EG.
- Год издания: 2001
- Страниц: 88
- Формат: PDF
- Размер: 8,7 Mb
Дополнение к руководству по техническому обслуживанию и ремонту снегохода Yamaha ET300E.
- Год издания: 1980
- Страниц: 8
- Формат: PDF
- Размер: 790 Kb
Сборник руководств по эксплуатации и техническому обслуживанию снегоходов Yamaha FX Nytro моделей FX10/RFX10 различных модификаций.
- Год издания: 2007-2012
- Страниц: 94/118/122
- Формат: PDF
- Размер: 32,0 Mb
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha FX Nytro модели FX10 различных модификаций.
- Год издания: 2007-2011
- Страниц: 92/104
- Формат: PDF
- Размер: 18,5 Mb
Руководство на английском языке по техническому обслуживанию и ремонту снегохода Yamaha FX Nytro модели FX10 различных модификаций.
- Год издания: 2007
- Страниц: 410
- Формат: PDF
- Размер: 13,5 Mb
Руководство по эксплуатации и техническому обслуживанию снегоходов Yamaha MM700/VT700/VX700ER.
- Год издания: 2001
- Страниц: 100
- Формат: PDF
- Размер: 9,2 Mb
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha MM600/MM700/SX600/VT600/VT700/VX600/VX700 различных модификаций.
- Год издания: 1998-2002
- Страниц: —
- Формат: PDF
- Размер: 32,0 Mb
Сборник руководств по эксплуатации и техническому обслуживанию снегоходов Yamaha PZ50/RPZ50 Venture различных модификаций.
- Год издания: 2006/2012
- Страниц: 110/120
- Формат: PDF
- Размер: 11,7 Mb
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha PZ50 Phazer, Venture различных модификаций.
- Год издания: 2006-2009
- Страниц: 88/92/98/104
- Формат: PDF
- Размер: 21,6 Mb
Сборник руководств на английском языке по техническому обслуживанию и ремонту снегохода Yamaha PZ50 Phazer, Venture различных модификаций.
- Год издания: 2006-2007
- Страниц: 424/114
- Формат: PDF
- Размер: 21,2 Mb
Руководство на английском языке по техническому обслуживанию и ремонту снегоходов Yamaha PZ500C и Yamaha VT500XLC.
- Год издания: 1998
- Страниц: 209
- Формат: PDF
- Размер: 6,0 Mb
Руководство на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha PZ 500D/PZ500MLD/VT500XLD.
- Год издания: 1999
- Страниц: 83
- Формат: PDF
- Размер: 2,4 Mb
Сборник руководств по эксплуатации и техническому обслуживанию снегоходов Yamaha RS10/RS90/RSG90/RST90 RS Vecror, RS Venture различных модификаций.
- Год издания: 2004/2011/2012
- Страниц: 100/108/162
- Формат: PDF
- Размер: 31,0 Mb
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha RS90/RSG90/RST90 RS Vector, RS Venture различных модификаций.
- Год издания: 2004-2011
- Страниц: —
- Формат: PDF
- Размер: 63,5 Mb
Сборник руководств на английском языке по техническому обслуживанию и ремонту снегоходов Yamaha RS90/RSG90/RST90 RS Venture различных модификаций.
- Год издания: 2004/2006/2008
- Страниц: 414/202/299
- Формат: PDF
- Размер: 37,1 Mb
Сборник руководств по эксплуатации и техническому обслуживанию снегоходов Yamaha RX10/RXW10 Apex различных модификаций.
- Год издания: 2001-2012
- Страниц: —
- Формат: PDF
- Размер: 28,6 Mb
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha RX90/RXW90 Apex различных модификаций.
- Год издания: 2002-2010
- Страниц: —
- Формат: PDF
- Размер: 48,2 Mb
Руководство на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha SRX700G.
- Год издания: 2001
- Страниц: 84
- Формат: PDF
- Размер: 6,6 Mb
Сборник руководств по эксплуатации и техническому обслуживанию снегоходов Yamaha SXV60/SXV70/VT60/VT70 различных модификаций.
- Год издания: 2003
- Страниц: 113/127
- Формат: PDF
- Размер: 10,5 Mb
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha SXV60/SXV70/VT60/VT70 различных модификаций.
- Год издания: 2001-2005
- Страниц: —
- Формат: PDF
- Размер: 48,3 Mb
Сборник руководств по эксплуатации и техническому обслуживанию снегоходов Yamaha VK10/VK10D RS Viking.
- Год издания: 2007/2012
- Страниц: 98/108
- Формат: PDF
- Размер: 15,6 Mb
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha VK10L и Yamaha VK10X.
- Год издания: 2005/2007
- Страниц: 98/88
- Формат: PDF
- Размер: 7,9 Mb
Дополнение к руководству по техническому обслуживанию и ремонту снегоходов Yamaha VK10L/VK10W.
- Год издания: 2005-2006
- Страниц: 360/103
- Формат: PDF
- Размер: 12,2 Mb
Руководство по эксплуатации и техническому обслуживанию снегоходов Yamaha VK540E/VK540EC.
- Год издания: 2012
- Страниц: 82
- Формат: PDF
- Размер: 3,2 Mb
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha VK540EG/VK540EK.
- Год издания: 2001/2004
- Страниц: 76
- Формат: PDF
- Размер: 4,8 Mb
Руководство на английском языке по техническому обслуживанию и ремонту снегохода Yamaha VK540EK.
- Год издания: 2000
- Страниц: 211
- Формат: PDF
- Размер: 4,9 Mb
Руководство по эксплуатации и техническому обслуживанию снегохода Yamaha VT500XL.
- Год издания: 2001
- Страниц: 84
- Формат: PDF
- Размер: 8,2 Mb
Коды неисправностей Yamaha.
- Год издания: —
- Страниц: 11
- Формат: JPG
- Размер: 1,7 Mb
Руководства по эксплуатации, обслуживанию и ремонту снегоходов Yamaha
Описание конструкции снегохода Yamaha.
- Год издания: —
- Страниц: 65
- Формат: PDF
- Размер: 6,9 Mb
Service Manual Yamaha BR250F.
Руководство на английском языке по техническому обслуживанию и ремонту снегохода Yamaha BR250F.
- Год издания: 1981
- Страниц: 191
- Формат: PDF
- Размер: 8,7 Mb
Руководство пользователя Yamaha BR250TG/VK540EG.
Руководство по эксплуатации и техническому обслуживанию снегоходов Yamaha BR250TG и Yamaha VK540EG.
- Год издания: 2001
- Страниц: 88
- Формат: PDF
- Размер: 8,7 Mb
Supplementary Service Manual Yamaha ET300E.
Дополнение к руководству по техническому обслуживанию и ремонту снегохода Yamaha ET300E.
- Год издания: 1980
- Страниц: 8
- Формат: PDF
- Размер: 790 Kb
Руководство пользователя Yamaha FX Nytro.
Сборник руководств по эксплуатации и техническому обслуживанию снегоходов Yamaha FX Nytro моделей FX10/RFX10 различных модификаций.
- Год издания: 2007-2012
- Страниц: 94/118/122
- Формат: PDF
- Размер: 32,0 Mb
Owner`s Manual Yamaha FX Nytro.
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha FX Nytro модели FX10 различных модификаций.
- Год издания: 2007-2011
- Страниц: 92/104
- Формат: PDF
- Размер: 18,5 Mb
Service Manual Yamaha FX Nytro.
Руководство на английском языке по техническому обслуживанию и ремонту снегохода Yamaha FX Nytro модели FX10 различных модификаций.
- Год издания: 2007
- Страниц: 410
- Формат: PDF
- Размер: 13,5 Mb
Руководство пользователя Yamaha MM700/VT700/VX700ER.
Руководство по эксплуатации и техническому обслуживанию снегоходов Yamaha MM700/VT700/VX700ER.
- Год издания: 2001
- Страниц: 100
- Формат: PDF
- Размер: 9,2 Mb
Owner`s Manual Yamaha MM/SX/VT/VX 600/700.
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию снегоходов Yamaha MM600/MM700/SX600/VT600/VT700/VX600/VX700 различных модификаций.
- Год издания: 1998-2002
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Коды неисправностей Yamaha.
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Источник
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Page 1
E115A 115B 140B SERVICE MANUAL 61U-28197-5H-11… -
Page 2: Important Information
NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
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Page 3: Table Of Contents
Contents General information INFO Specification SPEC Periodic check and adjustment Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Electrical system ELEC Troubleshooting TRBL SHTG Index…
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Page 5: General Information
INFO General information How to use this manual …………….1-1 Manual format ………………1-1 Symbol ………………… 1-2 Safety while working ………………. 1-3 Fire prevention ………………1-3 Ventilation ………………..1-3 Self-protection ………………1-3 Parts, lubricant, and sealant …………..1-3 Good working practice …………….1-4 Disassembly and assembly …………..
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Page 6: How To Use This Manual
INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 9 Parts are shown and detailed in an exploded diagram and are listed in the components list (see in the figure below for an example page).
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Page 7: Symbol
7 Apply Yamaha 2-stroke outboard motor oil q Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) w Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)
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Page 8: Safety While Working
Parts, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the out- board motor. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous.
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Page 9: Good Working Practice
Safety while working 6. Keep a supply of clean, lint-free cloths for Disassembly and assembly wiping up spills, etc. 1. Use compressed air to remove dust and dirt during disassembly. Good working practice 2. Apply engine oil to the contact surfaces Special service tool of moving parts before assembly.
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Page 10: Identification
115BE, 115BET, 140BET Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. 6G410010 YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D’ORIGINE JAPON 6B410020 1 Model name 2 Approved model code…
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Page 11: Special Service Tool
Identification/Special service tool Special service tool Digital tachometer Compression gauge 90890-06760 90890-03160 Timing light Flywheel holder 90890-03141 90890-06522 Leakage tester Flywheel puller 90890-06840 90890-06521 Ball bearing attachment Digital caliper 90890-06704 90890-06663 Driver rod LS Vacuum/pressure pump gauge set 90890-06606 90890-06756 61U5H11…
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Page 12
INFO General information Needle bearing attachment Gear puller 90890-06609, 90890-06610, 90890-06611, 90890-06612, 90890-06653, 90890-06654 90890-06540 Bearing separator Driver rod L3 90890-06534 90890-06652 Cylinder gauge Ball bearing attachment 90890-06759 90890-06633, 90890-06636 90890-06637, 90890-06656 Support Bearing outer race attachment 90890-02394 90890-06620, 90890-06624 Bearing inner race attachment Small end bearing installer 90890-06640, 90890-06662… -
Page 13
Special service tool Piston slider Stopper guide plate 90890-06530 90890-06501 Dial gauge set Bearing housing puller claw L 90890-01252 90890-06502 Shift rod push arm Center bolt 90890-06052 90890-06504 Ring nut wrench 3 Stopper guide stand 90890-06511 90890-06538 Bearing puller assembly Ring nut wrench extension 90890-06535 90890-06513… -
Page 14
INFO General information Bearing outer race puller assembly Driver rod SS 90890-06523 90890-06604 Bearing depth plate Driver rod SL 90890-06603 90890-06602 Pinion height gauge Drive shaft holder 6 90890-06710 90890-06520 Pinion nut holder Shimming plate 90890-06715 90890-06701 Backlash indicator Driver rod LL 90890-06706 90890-06605 61U5H11… -
Page 15
Special service tool Magnet base plate Test harness (4 pins) 90890-07003 90890-06878 Magnet base B Trim and tilt wrench 90890-06844 90890-06587 Digital circuit tester Ignition tester 90890-03174 90890-06754 Up relief fitting 90890-06773 Peak voltage adaptor B Down relief fitting 90890-03172 90890-06774 Test harness (4 pins) Hydraulic pressure gauge… -
Page 16: Propeller Selection
INFO General information Propeller selection Selection When the engine speed is at the full throttle The performance of a boat and outboard operating range (4,500–5,500 r/min), the motor will be critically affected by the size and ideal propeller for the boat is one that pro- type of propeller you choose.
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Page 17: Predelivery Check
Propeller selection Checking the battery Predelivery check (E, ET, WH) To make the delivery process smooth and 1. Check the capacity, electrolyte level, and efficient, the predelivery checks should be specified gravity of the battery. completed as explained below. Recommended battery capacity: Checking the fuel system CCA/EN: 430 A 1.
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Page 18: Checking The Remote Control Cable (Remote Control Model)
INFO General information Checking the remote control cable 4. Check that the remote control lever is in the neutral position, and check that the (Remote control model) center of the set pin 5 is aligned with the 1. Set the remote control lever to the neutral alignment mark a on the bottom cowling.
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Page 19: Checking The Steering System
Predelivery check Checking the steering system Checking the gear shift and throttle 1. Check the steering friction for proper operation adjustment. 1. Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from neutral to for- ward or reverse.
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Page 20: Checking The Ptt System (Et)
INFO General information 3. Check that the choke solenoid operates Checking the PTT system when the engine start switch is pushed (ET) in. (E, ET) 1. Check that the outboard motor tilts up and down smoothly when operating the PTT unit. 2.
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Page 21: Checking The Cooling Water Pilot Hole
Predelivery check Checking the cooling water pilot hole Break-in 1. Start the engine, then check that the During the test run, perform the break-in cooling water is discharged from the operation in the following 5 stages. 1. 10 minutes a at the lowest possible cooling water pilot hole.
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Page 22: After Test Run
INFO General information After test run 1. Check for water in the gear oil. 2. Check for fuel leakage in the cowling. 3. Flush the cooling water passage with fresh water using the flushing kit 1 and with the engine running at idle. 6S310070 Be sure to supply sufficient water when flushing the cooling water passage, other-…
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Page 23: Specification
SPEC Specification General specification ………………2-1 Maintenance specification …………….2-5 Power unit (E115A models) ……………2-5 Lower unit (E115A models)…………….2-7 Electrical (E115A models)…………….2-7 Power unit (115B, 140B models) ………….2-10 Lower unit (115B, 140B models) ………….2-12 Electrical (115B, 140B models) ……………2-12 Dimension ………………..2-15 Tightening torque………………2-19 Specified torque………………2-19…
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Page 24: General Specification
SPEC Specification General specification Model Item Unit E115AMH E115AWH E115AE E115AET Dimension Overall length mm (in) 1,458 (57.4) 828 (32.6) Overall width mm (in) 600 (23.6) Overall height mm (in) 1,558 (61.3) 1,435 (56.5) mm (in) 1,611 (63.4) — mm (in) 1,684 (66.3) 1,561 (61.5) Boat transom height…
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Page 25
General specification Model Item Unit E115AMH E115AWH E115AE E115AET Cooling system Water Exhaust system Propeller boss Lubrication system Pre-mixed fuel and oil Fuel and oil Fuel type Regular unleaded gasoline Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3 Gear oil type Hypoid gear oil Gear oil grade (*1) -
Page 26
SPEC Specification Model Item Unit 115BE 115BET 140BET Dimension Overall length mm (in) 828 (32.6) Overall width mm (in) 600 (23.6) Overall height mm (in) 1,435 (56.5) mm (in) 1,561 (61.5) Boat transom height mm (in) 508 (20.0) mm (in) 635 (25.0) Weight (with aluminum propeller) -
Page 27
General specification Model Item Unit 115BE 115BET 140BET Cooling system Water Exhaust system Propeller boss Lubrication system Pre-mixed fuel and oil Fuel and oil Fuel type Regular unleaded gasoline Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3 Gear oil type Hypoid gear oil Gear oil grade (*1) -
Page 28: Maintenance Specification
SPEC Specification Maintenance specification Power unit (E115A models) Model Item Unit E115AMH E115AWH E115AE E115AET Power unit Minimum compression — 450 (4.5, 64) pressure (*1) at electric starter (kgf/cm , psi) at manual starter 400 (4.0, 57) — Cylinder head…
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Page 29
Maintenance specification Model Item Unit E115AMH E115AWH E115AE E115AET Piston ring Top ring Dimension B mm (in) 1.970–1.990 (0.0776–0.0783) Dimension T mm (in) 2.700–2.900 (0.1063–0.1142) End gap mm (in) 0.30–0.40 (0.0118–0.0157) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024) Oversize outside diameter mm (in) 90.25 (3.5531) mm (in) -
Page 30: Lower Unit (E115A Models)
SPEC Specification Lower unit (E115A models) Model Item Unit E115AMH E115AWH E115AE E115AET Gear backlash Pinion-to-forward mm (in) 0.32–0.50 (0.0126–0.0197) Pinion-to-reverse mm (in) 0.80–1.17 (0.0315–0.0461) Pinion gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50…
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Page 31
Maintenance specification Model Item Unit E115AMH E115AWH E115AE E115AET Charge coil output peak voltage (B/R–L: High-speed) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) (R–Br: Low-speed) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Charge coil resistance at 20°C (68°F) -
Page 32
SPEC Specification Model Item Unit E115AMH E115AWH E115AE E115AET PTT system Trim sensor resistance Ω — 239–379 at 20°C (68°F) (P–B) Fluid type — Dexron 2 Motor type — 64E00 Output — 0.40 Brushes Standard length mm (in) — 9.8 (0.39) Wear limit mm (in) —… -
Page 33: Power Unit (115B, 140B Models)
Maintenance specification Power unit (115B, 140B models) Model Item Unit 115BE 115BET 140BET Power unit Minimum compression 450 (4.5, 64) pressure (*1) (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.10 (0.0039) (lines indicate straightedge position) Cylinder Bore size mm (in) 90.000–90.020 (3.5433–3.5441) Piston…
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Page 34
SPEC Specification Model Item Unit 115BE 115BET 140BET Piston ring Top ring Dimension B mm (in) 1.970–1.990 (0.0776–0.0783) Dimension T mm (in) 2.700–2.900 (0.1063–0.1142) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024) Oversize outside diameter mm (in) 90.25 (3.5531) mm (in) 90.50 (3.5630) -
Page 35: Lower Unit (115B, 140B Models)
Maintenance specification Lower unit (115B, 140B models) Model Item Unit 115BE 115BET 140BET Gear backlash Pinion-to-forward mm (in) 0.32–0.50 (0.0126–0.0197) Pinion-to-reverse mm (in) 0.80–1.17 (0.0315–0.0461) Pinion gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Electrical (115B, 140B models)
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Page 36
SPEC Specification Model Item Unit 115BE 115BET 140BET Charge coil output peak voltage (B/R–L: High-speed) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) (R–Br: Low-speed) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Charge coil resistance at 20°C (68°F) -
Page 37
Maintenance specification Model Item Unit 115BE 115BET 140BET PTT system Trim sensor resistance Ω — 239–379 at 20°C (68°F) (P–B) ATF Dexron 2 Fluid type — Motor type — 64E00 Output — 0.40 Brushes Standard length mm (in) — 9.8 (0.39) Wear limit mm (in) —… -
Page 38: Dimension
SPEC Specification Dimension Exterior E115A mm (in) 325 (12.8) 539 (21.2) 845 (33.3) L: 1,005 (39.6) Y: 1,055 (41.5) 570 (22.4) X: 1,120 (44.1) 270 (10.6) 64 (2.5) MH, WH 616 (24.3) 61U2001M 2-15 61U5H11…
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Page 39
Maintenance specification E115A, 115B, 140B mm (in) 539 (21.2) L: 1,005 (39.6) 482 (19.0) X: 1,120 (44.1) 214 (8.4) 64 (2.5) 616 (24.3) ** ET 6IU2002M 61U5H11 2-16… -
Page 40
SPEC Specification Clamp bracket mm (in) 182 (7.2) 182 (7.2) 163.5 (6.4) 163.5 (6.4) 62 (2.4) 13 (0.5) 13 (0.5) 125.4 (4.9) 125.4 (4.9) 6IU2003M 2-17 61U5H11… -
Page 41
Maintenance specification mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 82 (3.2) 13 (0.5) 13 (0.5) 6G42003M 101.5 (4.0) 101.5 (4.0) 125.4 (4.9) 125.4 (4.9) 61U5H11 2-18… -
Page 42: Tightening Torque
SPEC Specification Tightening torque Specified torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Intake silencer cover bolt Manual injection cable end bolt Screw (carburetor) — Plug (carburetor) — Plug (float chamber) — Fuel pump screw —…
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Page 43
Thread size N·m kgf·m ft·lb Lower unit Check screw — Drain screw — Lower case mount bolt 28.8 Lower case mount nut (E115A: Y-transom) — 28.8 Trim tab bolt 28.8 Water pump housing bolt 13.3 Ring nut — 10.3 76.0 Pinion nut —… -
Page 44: General Torque
SPEC Specification General torque General torque specifications This chart specifies tightening torques for Nut (A) Bolt (B) standard fasteners with a standard ISO N·m kgf·m ft·lb thread pitch. Tightening torque specification 8 mm for special components or assemblies are 10 mm provided in applicable sections of this manu- 12 mm 14 mm…
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Page 45
Periodic check and adjustment Maintenance interval chart …………….3-1 Top cowling ………………..3-2 Checking the top cowling …………….. 3-2 Fuel system ………………..3-2 Checking the fuel joint and fuel hose (fuel joint-to-carburetor) ….3-2 Checking the fuel filter …………….3-2 Power unit ………………… -
Page 46: Periodic Check And Adjustment
Check / charge 3-14 Cooling water passages Clean Cowling clamp Check Fuel filter (can be dis- Check / clean assembled) Fuel system Check Fuel tank (Yamaha por- Check / clean — table tank) Gear oil Change 3-12 Lubrication points Lubricate 3-14…
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Page 47: Top Cowling
Maintenance interval chart/Top cowling/Fuel system Top cowling Fuel system Checking the top cowling Checking the fuel joint and fuel 1. Check the fitting by pushing the cowling hose (fuel joint-to-carburetor) with both hands. Adjust the fittings if nec- 1. Check the fuel hose connections and fuel essary.
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Page 48: Periodic Check And Adjustment
Periodic check and adjustment 5. Install the spark plug temporary tight, Power unit then to the specified torque with a spark Checking the spark plug plug wrench. 1. Disconnect the spark plug caps, and then remove the spark plugs. Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) 2.
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Page 49: Checking The Cooling Water Passage
Power unit/Control system 3. Check for water flow at the cooling water Water pilot hole. If there is no water flow, check Valve lift a temperature the cooling water passage inside of the 48–52°C 0.05 mm (0.002 in) outboard motor. (118.4–125.6°F) (valve begins to tilt) above…
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Page 50: Checking The Control Link And Throttle Link Position
Periodic check and adjustment NOTE: Checking the control link and throt- Make a note that how many times you turn tle link position out the throttle stop screw. 1. Remove the throttle cable. 3. Loosen the throttle lever tightening 2. Measure the length of control link rod 1. screws 3 and 4 clockwise.
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Page 51: Checking The Engine Idle Speed
Control system 3. Turn the throttle stop screw 3 in direc- 8. Tighten the throttle lever tightening screw 4 counterclockwise on the lower carbu- tion a or b until the specified engine idle retor. speed is obtained. NOTE: The screw 4 is left hand thread. 9.
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Page 52: Checking The Gear Shift Operation
Periodic check and adjustment 4. Connect the cable joint 3, install the nut 2. Set the throttle grip or remote control 2, and then tighten the lock nut 1. lever to the fully closed position. 61U30095 61U30085 3. Adjust the position of the throttle cable 5.
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Page 53: Checking The Ignition Timing
Control system 6. Install the shift cable joint 3, install the 4. Make sure to align the center of the set pin a on the shift lever with the align- clip 2, and then tighten the locknut 1. ment mark b on the bottom cowling. 61U30100 7.
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Page 54: Checking The Choke Solenoid (E, Et)
61U30250 Engine speed (throttle fully opened): 5,500 r/min Engine idle speed: 700–800 r/min Timing plate position: E115A: Timing light 3: 90890-03141 BTDC 22–24° 115B: 4. Check that the ATDC 5° scale a on the BTDC 24–26° flywheel magnet is aligned with the point-…
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Page 55: Bracket
Control system/Bracket Checking the PTT fluid level Bracket (ET) Checking the PTT operation 1. Fully tilt the outboard motor up, and then (ET) support it with the tilt stop lever 1. 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation.
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Page 56: Lower Unit
Periodic check and adjustment 3. If necessary, add sufficient fluid of the 3. Fully tilt the outboard motor up, then sup- port it with the tilt stop lever 2 to check recommended type until it overflows out of the filler hole. the lock mechanism of the lever.
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Page 57: Changing The Gear Oil
Bracket/Lower unit Changing the gear oil 1. Tilt the outboard motor so that the gear oil drain screw at the lowest point possi- ble. 2. Place a drain pan under the drain screw 1, remove the drain screw, then the check screw 2 and let the oil drain com- pletely.
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Page 58: Checking The Lower Unit For Air Leakage
Periodic check and adjustment Checking the lower unit for air leak- General Checking the anode 1. Check the anode and trim tab. Clean if there are scales, grease, or oil. Do not over pressurize the lower unit, oth- erwise the oil seals may be damaged. 1.
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Page 59: Checking The Battery (Wh, E, Et)
Lower unit/General Checking the battery (WH, E, ET) NOTE: 9 Batteries vary per manufacturer. The proce- 1. Check the battery electrolyte level. If the dures mentioned in this manual may not level is at or below the minimum level always apply, therefore, consult the instruc- mark a, add distilled water until the level tion manual of the battery.
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Page 60
Periodic check and adjustment 61U30170 6G430530 NOTE: 6G430500 Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown. 6G430510 6G430540 3. Apply corrosion resistant grease to the area shown. -
Page 61
FUEL Fuel system Hose routing ………………..4-1 Fuel hose and breather hose …………..4-1 Fuel line ………………….4-3 Carburetor ………………… 4-6 Disassembling the carburetor …………..4-12 Checking the carburetor ……………. 4-12 Assembling the carburetor …………..4-13 Fuel pump ………………..4-15 Checking the fuel pump …………….. -
Page 62: Fuel System
FUEL Fuel system Hose routing Fuel hose and breather hose 61U4001A 1 Fuel hose (fuel joint-to-fuel filter) 2 Fuel hose (fuel filter-to-manual injection : MH, WH) 3 Fuel hose (fuel filter-to-fuel pump) 4 Manual injection pump : MH, WH 5 Fuel hose (manual injection-to-upper carburetor : MH, WH) 6 Fuel hose (fuel pump-to-carburetor) 61U5H11…
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Page 63
Hose routing PORT STBD MH, WH E, ET 61U4001B 1 Breather hose (manifold-to-cylinder body #2) 2 Breather hose (manifold-to-cylinder body #4) 3 Breather hose (breather hose-to-manual injection) 4 Breather hose (manifold-to-manual injection) 5 Breather hose (breather hose-to-manual injection hose) 6 Breather hose (manifold-to-cylinder body #1) 7 Breather hose (cylinder body #3-to-manual injection hose) 8 Breather hose (manifold-to-intake silencer) 9 Breather hose (manifold-to-cylinder body #3) -
Page 64: Fuel Line
FUEL Fuel system Fuel line 4 N·m (0.4 kgf·m, 3.0 ft·lb) 61U4040E Part name Q’ty Remarks M6 × 16 mm Bolt Fuel filter assembly Lock tie MH, WH Not reusable Lock tie Not reusable E, ET Fuel hose Fuel hose MH, WH Fuel hose Joint…
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Page 65
Fuel line 4 N·m (0.4 kgf·m, 3.0 ft·lb) 61U4040E Part name Q’ty Remarks Fuel pump assembly Gasket Not reusable Fuel hose Joint Fuel hose Fuel hose M6 × 10 mm MH, WH Bolt Start-in-gear protection cable MH, WH M6 × 12 mm MH, WH Bolt M5 ×… -
Page 66
FUEL Fuel system 6G44040E Part name Q’ty Remarks M6 × 16 mm Bolt Washer Holder M6 × 14 mm Bolt Bracket Fuel filter assembly O-ring Not reusable Fuel filter element Fuel filter cup 61U5H11… -
Page 67: Carburetor
Fuel line/Carburetor Carburetor E, ET 6 N·m (0.6 kgf·m, 4.4 ft·lb) 61U4060E Part name Q’ty Remarks M6 × 20 mm Bolt Cover Gasket Not reusable M6 × 20 mm Bolt Intake silencer M6 × 20 mm Bolt Breather hose Gasket Not reusable Upper carburetor assembly Lower carburetor assembly…
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Page 68
FUEL Fuel system E, ET 6 N·m (0.6 kgf·m, 4.4 ft·lb) 61U4060E Part name Q’ty Remarks M6 × 16 mm Bolt Choke solenoid Intake silencer Grommet 61U5H11… -
Page 69
Carburetor MH, WH 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 61U4070E Part name Q’ty Remarks Plug Gasket Screw Plate Gasket Not reusable Main air bleed Pilot screw Spring Screw Gasket Air bleed plug Pilot air jet… -
Page 70
FUEL Fuel system 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 61U4070E Part name Q’ty Remarks Gasket Not reusable Plug Gasket Main jet Drain plug Gasket Float chamber Plug Gasket Pilot jet ø5 ×… -
Page 71
Carburetor E, ET 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 61U4065E Part name Q’ty Remarks Plug Gasket Screw Plate Pilot screw Spring Screw Gasket Air bleed plug Pilot air jet Carburetor body Needle valve Clip… -
Page 72
FUEL Fuel system 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 61U4065E Part name Q’ty Remarks Gasket Main jet Float chamber Plug Gasket Pilot jet ø5 × 16 mm Screw Throttle stop screw Spring Lower carburetor assembly… -
Page 73: Disassembling The Carburetor
Carburetor Disassembling the carburetor 4. Check the pilot screw and needle valve for bends or wear. Replace the pilot NOTE: screw and needle valve if necessary. 9 Before disassembling the carburetors, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.
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Page 74: Assembling The Carburetor
FUEL Fuel system Assembling the carburetor ∫ 1. Install the gaskets 1, plugs 2, pilot air jets 3, and air bleed plugs 4, main air bleed 5 onto the carburetor body. å 6G440110 å MH, WH ∫ E, ET 61U40100 4.
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Page 75
Carburetor NOTE: When disassemble the carburetor, be sure to set the pilot screw by the specified times. Pilot screw turns out: E115A : 1–1 1/2 115B : 3/8–7/8 140B : 5/8–1 1/8 7. Install the carburetor assembly. 61U5H11 4-14… -
Page 76: Fuel Pump
FUEL Fuel system Fuel pump 3.5 N·m (0.35 kgf·m, 2.6 ft·lb) 6G44030E Part name Q’ty Remarks Base Gasket Not reusable Diaphragm Body assembly ø5 × 28 mm Screw Washer Check valve Body Gasket Not reusable Diaphragm Collar O-ring Not reusable Cover Plate Spring…
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Page 77: Checking The Fuel Pump
Fuel pump Checking the fuel pump 6. Apply the specified positive pressure and check that there is no air leakage. 1. Place a drain pan under the fuel hose Disassemble the fuel pump if necessary. connections, and then disconnect the fuel hoses from the fuel pump.
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Page 78: Assembling The Fuel Pump
FUEL Fuel system NOTE: Assembling the fuel pump Make sure that the gaskets and diaphragms NOTE: are kept in place through the assembly Clean the parts and soak the valves and the process. diaphragms in gasoline before assembly to obtain prompt operation of the fuel pump when starting the engine.
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Page 79
— MEMO — 61U5H11 4-18… -
Page 80: Powr
POWR Power unit Power unit ………………… 5-1 Checking the compression pressure …………5-1 Disassembling the manual starter (MH, WH) ……..5-14 Checking the spiral spring (MH, WH) ………… 5-15 Checking the drive pawl (MH, WH) …………5-15 Checking the starter rope (MH, WH) …………. 5-15 Assembling the manual starter (MH, WH) ……….
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Page 81
Checking the piston ring ……………. 5-37 Checking the piston ring side clearance ……….5-38 Checking the piston pin boss bore …………5-38 Checking the piston pin …………….. 5-38 Checking the internal anode …………..5-38 Checking the connecting rod small end axial play …….. 5-39 Checking the connecting rod big end side clearance …… -
Page 82: Power Unit
POWR Power unit Power unit 5. If the compression pressure is below specification and the compression pres- Checking the compression pressure sure for each cylinder is unbalanced, add 1. Start the engine, warm it up for 5 min- a small amount of engine oil to the cylin- utes, and then turn it off.
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Page 83
Power unit E,ET 25 N·m (2.5 kgf·m, 18.4 ft·lb) 61U5010E 8 N·m (0.8 kgf·m, 5.9 ft·lb) Part name Q’ty Remarks M8 × 35 mm MH, WH Bolt Grommet MH, WH Manual starter assembly MH, WH Collar MH, WH M6 × 20 mm MH, WH Bolt Power unit Dowel… -
Page 84
POWR Power unit E,ET 25 N·m (2.5 kgf·m, 18.4 ft·lb) 61U5010E 8 N·m (0.8 kgf·m, 5.9 ft·lb) Part name Q’ty Remarks M8 × 135 mm Bolt Apron Apron M6 × 25 mm E, ET Bolt Grommet E, ET Collar E, ET Grommet E, ET Flywheel cover… -
Page 85
Power unit 186 N·m (18.6 kgf·m, 137 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 61U5020E Part name Q’ty Remarks Washer Starter pulley MH, WH M8 × 25 mm MH, WH Bolt Flywheel magnet M6 × 60 mm Bolt Stator assembly Pulser coil assembly ø5 ×… -
Page 86
POWR Power unit 186 N·m (18.6 kgf·m, 137 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 61U5020E Part name Q’ty Remarks Washer Rectifier Regulator M6 × 12 mm Bolt Main harness Control link If equipped ø5 × 20 mm Screw Hour meter If equipped Case If equipped… -
Page 87
Power unit 61U5030E Part name Q’ty Remarks Joint Lock nut Control link rod Throttle link rod M6 × 25 mm Bolt Collar Wave washer Lock nut Screw Spring Screw M8 × 45 mm Bolt Washer Collar Bushing 61U5H11… -
Page 88
POWR Power unit 61U5030E Part name Q’ty Remarks Bushing Spring Control lever 1 Plastic washer Washer Bracket M8 × 30 mm Bolt Bushing Control lever 2 61U5H11… -
Page 89
Power unit 6IU5060E Part name Q’ty Remarks ø6 × 16 mm Screw Cover ø6 × 40 mm Screw CDI unit Charge coil coupler M6 × 12 mm Bolt Spark plug cap M6 × 20 mm Bolt Ignition coil M6 × 12 mm Bolt M6 ×… -
Page 90
POWR Power unit WH, E 30 N·m (3.0 kgf·m, 22.1 ft·lb) 29 N·m (2.9 kgf·m, 21.4 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 61U5050E Part name Q’ty Remarks M8 × 45 mm Bolt Starter motor Washer M8 ×… -
Page 91
Power unit WH, E 30 N·m (3.0 kgf·m, 22.1 ft·lb) 29 N·m (2.9 kgf·m, 21.4 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 61U5050E Part name Q’ty Remarks M6 × 12 mm Bolt Clamp Holder PTT relay (up) Holder PTT relay (down) -
Page 92
POWR Power unit MH, WH 61U5040E Part name Q’ty Remarks Manual starter case Plastic washer Spiral spring Collar Sheave drum Washer Clip Collar Drive pawl Spring Spring Drive plate Washer M6 × 16 mm Bolt M6 × 12 mm Bolt Washer M6 ×… -
Page 93
Power unit MH, WH 61U5040E Part name Q’ty Remarks Rope guide Roller Bushing M6 × 30 mm Bolt Grommet Collar M6 × 20 mm Bolt Bracket Damper Starter handle Bracket M6 × 12 mm Bolt Cotter pin Washer Start-in-gear protection cable 61U5H11 5-12… -
Page 94
POWR Power unit MH, WH 61U5040E Part name Q’ty Remarks Spring Guide Bolt Stopper Spring Starter rope 5-13 61U5H11… -
Page 95: Disassembling The Manual Starter (Mh, Wh)
Power unit Disassembling the manual starter 3. Remove the bolt, drive plate 6, spring (MH, WH) 7, drive pawl 8, spring 9, clip 0, wash- er q and collar w. 9 The sheave drum can pop out. Hold the sheave drum with your hand, then pull it out.
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Page 96: Checking The Spiral Spring (Mh, Wh)
POWR Power unit Assembling the manual starter 6. Remove the plastic washers r, spiral spring t from the manual starter case. (MH, WH) 1. Install the starter rope 1 into the sheave drum 2. 2. Install the manual starter handle 3. 61U50040 7.
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Page 97
Power unit 4. Install the plastic washer 4 and spiral 6. Install the collar 8, washer 9, clip 0, spring 5 into the manual starter case 6. drive pawl q, spring w, spring e, and drive plate r. 61U50520 61U50060 NOTE: Install the outer end c of the spiral spring onto the pin d of the starter case. -
Page 98: Removing The Power Unit
POWR Power unit 1. Remove the CDI unit cover, start-in-gear 9. Pull the manual starter handle several protection cable 1, then remove the times in the direction of the arrow to manual starter and starter pully (MH, check that the sheave drum turns WH).
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Page 99
Power unit 8. Remove the bracket bolt w 3. Disconnect the 10-pin main harness cou- manual pler 5. injection pump cable end e and start-in- gear protection cable end r. 61U50470 61U50460 4. Disconnect the fuel hose 6. 61U50461 61U50560 5. -
Page 100: Removing The Flywheel Magnet
POWR Power unit 11. Remove the power unit by removing the 2. Remove the flywheel magnet. bolts i, bolts o and nuts p. 61U50590 6B450090 Removing the flywheel magnet 1. Loosen the flywheel magnet nut. To prevent damage to the engine or tools, screw in the flywheel puller set bolts evenly and completely so that the fly- wheel puller is parallel to the flywheel…
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Page 101: Removing The Electrical Component
Power unit Removing the electrical component 1. Remove the cover 1 and disconnect the coupler. 61U50630 4. Remove the starter relay 8 and the PTT relay assembly 9. 61U50600 61U50600 61U50610 2. Remove the hour meter 2. 61U50650 61U50615 5. Remove the starter motor 0. 3.
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Page 102
POWR Power unit 6. Disconnect the ignition coil leads, and then remove the CDI unit q and case w. 61U50600 5-21 61U5H11… -
Page 103
Power unit/Intake manifold Intake manifold 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) MH, WH E, ET 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 61U5070E Part name Q’ty Remarks Gasket Not reusable Reed valve Gasket Not reusable… -
Page 104
POWR Power unit 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) MH, WH E, ET 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 61U5070E Part name Q’ty Remarks Bracket Bracket Intake manifold Bracket MH, WH M6 ×… -
Page 105: Intake Manifold
Intake manifold Removing the intake manifold Checking the reed valve 1. Check the reed valves for bends a. 1. Remove the carburetor assemblies and the fuel hoses. Replace the reed valves if above specifi- cation. 2. Disconnect the breather hoses 1. 6G450180 61U50370 Valve bending limit a:…
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Page 106: Exhaust Cover
POWR Power unit Exhaust cover 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 61U5080E Part name Q’ty…
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Page 107: Removing The Exhaust Cover
Exhaust cover Removing the exhaust cover Checking the PCV 1. Remove the exhaust cover bolts in the 1. Remove the PCV. sequence shown. 2. Check the PCV for wear or deformation. Replace the PCV if necessary. 3. Check the grommet for deformation. Replace the grommet if necessary.
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Page 108: Cylinder Head
POWR Power unit Cylinder head MH, WH 25 N·m (2.5 kgf·m, 18.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) E, ET 4 N·m (0.4 kgf·m, 3.0 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 61U5090E Part name…
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Page 109
Cylinder head MH, WH 25 N·m (2.5 kgf·m, 18.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) E, ET 4 N·m (0.4 kgf·m, 3.0 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 61U5090E Part name… -
Page 110: Removing The Cylinder Head
POWR Power unit Removing the cylinder head 5. Remove the cylinder head bolts in the sequence shown. 1. Remove the spark plugs. 2. Remove the thermostat cover bolts in the PORT STBD sequence as shown, and then remove the thermostat. 61U50170 61U50210 3.
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Page 111
Cylinder head 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in 4 directions as shown. Replace the cylinder head if above specification. 61U50240 61U50250 Cylinder head warpage limit: 0.10 mm (0.0039 in) 61U5H11 5-30… -
Page 112: Crankcase
POWR Power unit Crankcase 12 N·m (1.2 kgf·m, 8.9 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 37 N·m (3.7 kgf·m, 27.3 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 61U5100E Part name Q’ty Remarks M6 × 25 mm Bolt Oil seal Not reusable…
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Page 113
Crankcase 19 N·m (1.9 kgf·m, 14.0 ft·lb) 36 N·m (3.6 kgf·m, 26.6 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 36 N·m (3.6 kgf·m, 26.6 ft·lb) 61U5110E Part name Q’ty Remarks M8 × 22 mm Bolt Piston and connecting rod assembly Roller bearing… -
Page 114
POWR Power unit 61U5120E Part name Q’ty Remarks Connecting rod Piston (starboard side) Washer Needle bearing Clip Not reusable Piston pin Piston ring set Piston (port side) 5-33 61U5H11… -
Page 115: Removing The Crankcase
Crankcase Removing the crankcase 1. Remove the bearing housing bolts. 6G450270 61U50280 2. Remove the oil seal housing bolts. NOTE: Insert a flat-head screw driver between the pry tabs to pry off the crankcase. Disassembling the bearing housing 1. Remove the oil seal 1 and O-rings 2. 6G450280 3.
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Page 116: Disassembling The Oil Seal Housing
POWR Power unit Disassembling the oil seal housing NOTE: 9 Mark each piston with the identification 1. Remove the oil seals and O-ring. number a of the corresponding cylinder. Also, mark each connecting rod and con- necting rod cap with an identification num- ber b as shown.
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Page 117: Disassembling The Crankshaft
Crankcase Disassembling the crankshaft Checking the piston diameter 1. Remove the seal rings 1. 1. Measure the piston outside diameter at the specified measuring point. Replace the piston and piston rings as a set if out of specification. 61U50290 NOTE: To remove the seal rings 1, widen the seal 6G450410 ring end gap a, and then remove the ring…
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Page 118: Checking The Cylinder Bore
6F650430 NOTE: Be sure to rebore the cylinder for matching Piston ring end gap a: the replacement oversize pistons, when E115A: using the specified oversize pistons. 0.30–0.40 mm (0.0118–0.0157 in) 115B, 140B: Top: Piston clearance: 0.30–0.50 mm (0.0118–0.0197 in) 0.080–0.085 mm…
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Page 119: Checking The Piston Ring Side Clearance
Replace the piston and piston rings as a set if out of specification. 6S350110 6G450420 Piston pin diameter: Piston ring side clearance: E115A: Top ring and 2nd piston ring: 21.495–21.500 mm 0.02–0.06 mm (0.8463–0.8465 in) (0.0008–0.0024 in) 115B, 140B: 23.065–23.070 mm…
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Page 120: Checking The Connecting Rod Small End Axial Play
POWR Power unit Checking the connecting rod small Checking the crankshaft 1. Measure the crankshaft journal diameter end axial play a and crankpin diameter b. Replace the 1. Measure the connecting rod small end crankshaft if out of specification. axial play. Replace the bearing and con- necting rod if above specification.
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Page 121: Assembling The Crankshaft
Crankcase 2. Install the seal rings 4. 2. Measure the crankshaft runout. Replace the crankshaft if above specification. 61U50700 NOTE: First pass the seal ring 4 over the crankpin a, and then widen the seal ring end gap b 61U50430 to install the ring into the crankshaft groove.
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Page 122: Assembling The Bearing Housing
POWR Power unit Assembling the bearing housing Assembling the oil seal housing 1. Install the needle bearing. 1. Apply grease to the new oil seals, new O- ring and then install them into the oil seal housing. 6G450620 6G450640 Do not reuse the needle bearing, always replace it with a new one.
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Page 123: Assembling The Piston And Connecting Rod Assembly
1. Set the crankshaft in the cylinder block. 61U50720 NOTE: 9 Face the embossed “YAMAHA” mark a on the connecting rod in the same direction as the “UP” mark b on the piston. 9 Use the small end bearing installer 7 to install the needle bearings.
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Page 124
POWR Power unit 2. Install the pistons into the cylinders with Piston slider 3: the “UP” mark on the piston crown facing 90890-06530 towards the flywheel magnet. 3. Install the connecting rod bearings and connecting rod caps onto the connecting rods, and then tighten the connecting rod bolts 4 to the specified torques in 5 stages. -
Page 125
Crankcase NOTE: 4. Install the bearing housing onto the cylin- Do not get any sealant on the journals. der block. 7. Install the dowels, crankcase onto the cylinder block, and then temporarily tight- en the crankcase bolts. 61U50760 NOTE: Install the bearing housing with the arrow mark facing toward the cylinder block. -
Page 126
POWR Power unit 12. Install the new gasket 5, exhaust inner 10. Tighten the crankcase bolts to the speci- cover 6, new gasket 7, exhaust outer fied torques in 2 stages and in the cover 8, and then tighten the exhaust sequence shown. -
Page 127
Crankcase 13. Install the new gaskets 9 and the cylin- 15. Install the new gaskets e and the cylin- der head 0, and then tighten the cylinder der head covers r, and then tighten the head bolts to the specified torques in 2 cylinder head cover bolts to the specified stages and in the sequence shown. -
Page 128
POWR Power unit 16. Install the new gaskets, thermostats and the thermostat covers, and then tighten MH, WH the thermostat cover bolts to the speci- fied torques in 2 stages and in the sequence shown. 61U50810 61U50160 Intake manifold bolt u: 1st: 4 N·m (0.4 kgf·m, 3.0 ft·lb) NOTE: 2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb) -
Page 129
Crankcase 61U50835 å MH, WH ∫ E, ET 20. Install the starter motor i, pulser coil 61U50605 assembly o and stator assembly p onto 22. Install the starter relay f, the PTT relay the power unit. assembly g and Rectifier Regulator h onto the power unit. -
Page 130: Installing The Power Unit
POWR Power unit Installing the power unit 23. Install the hour meter into the case, and 1. Clean the power unit matching surface, and then onto the power unit. install the dowels 1 and a new gasket 2. 61U50850 2. Install the power unit 3, and then tighten 61U50636 the power unit bolts 4, bolts 5 and nut 6 to the specified torque.
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Page 131
Crankcase 3. Install the apron 7, and then tighten the 6. Install the bushing w and clip e. apron bolt 8 to specified torque. 6G450905 7. Connect the choke link rod. 8. Connect the 10-pin main harness coupler 61U50585 Apron bolt 8: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 4. -
Page 132
POWR Power unit 15. Connect the negative battery cable o, 10. Install the Woodruff key and flywheel positive battery cable p, and PTT motor magnet. lead a. å 11. Tighten the flywheel magnet nut to the specified torque. 61U50355 Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. -
Page 133: Adjusting The Timing Plate
Crankcase Adjusting the timing plate Cylinder #1 piston position (BTDC): E115A, 115B: NOTE: 3.33 mm (0.1311 in) Remove the all spark plugs and lock plate 140B: before adjusting the timing plate. 3.91 mm (0.1539 in) 1. Remove the manual starter or flywheel 5.
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Page 134: Adjusting The Ignition Timing Stopper
2. 61U50905 61U50910 Timing plate position: Specified length c : E115A: BTDC 23° (Reference data) E115A, 115B: 115B: 24.5 mm (0.96 in) BTDC 25° 140B: 140B: 22.0 mm (0.87 in) BTDC 22° 2. Set the control lever 1 to the full 5.
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Page 135
Crankcase Timing plate position: ATDC 5° 6. Set the control lever 1 to the full retard position, and check that the adjusting screw 2 contact with the stopper. 61U10045 7. Check that the mark 3 on the flywheel magnet aligned with the pointer 4 on the pulser coil assembly. -
Page 136
POWR Power unit — MEMO — 5-55 61U5H11… -
Page 137: Lowr
LOWR Lower unit Lower unit …………………..6-1 Removing the lower unit …………….6-4 Removing the water pump and shift rod ………..6-5 Checking the water pump and shift rod………….6-5 Propeller shaft housing ……………..6-6 Removing the propeller shaft housing assembly……..6-8 Disassembling the propeller shaft assembly ……….6-8 Disassembling the propeller shaft housing……….6-8 Checking the propeller shaft housing …………6-9 Checking the propeller shaft…………..6-9…
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Page 138: Lower Unit
M10 × 45 mm Bolt M10 × 70 mm Bolt Trim tab Spacer Propeller Washer Washer Cotter pin Not reusable Dowel E115A: Y-transom M10 × 45 mm Bolt Grommet E115A: Y-transom Spring washer E115A: Y-transom Washer E115A: Y-transom Extension E115A: Y-transom 61U5H11…
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Page 139
Lower unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 61U6020E Part name Q’ty Remarks Shift rod Oil seal Not reusable Cover O-ring Not reusable Spring Circlip M6 × 20 mm Bolt Joint Woodruff key M8 × 45 mm Bolt Cover Seal… -
Page 140
LOWR Lower unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 61U6020E Part name Q’ty Remarks Spacer Washer Wave washer Impeller Outer plate cartridge Gasket Not reusable Dowel Rubber seal Plate Check screw Gasket Not reusable Drain screw Dowel Lock tie… -
Page 141: Removing The Lower Unit
å vent the propeller from turning, and then remove the propeller nut and propeller. 61U60040 å E115A: Y-transom 6. Remove the stud bolts. (E115A: Y-transom) 61U60010 9 Do not hold the propeller with your hands when loosening or tightening it.
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Page 142: Removing The Water Pump And Shift Rod
LOWR Lower unit Removing the water pump and shift Checking the water pump and shift 1. Remove the water pump housing 1, col- 1. Check the water pump housing. Replace lar 2, spacer 3, washer 4, wave wash- if there is deformation. er 5, washer 6 and impeller 7.
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Page 143: Propeller Shaft Housing
Propeller shaft housing Propeller shaft housing 103 N·m (10.3 kgf·m, 76.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 61U6030E Part name Q’ty Remarks Shift rod joint Ball Shift slider Ball Ball Spring Dog clutch Crosspin Spring Propeller shaft Reverse gear shim —…
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Page 144
LOWR Lower unit 103 N·m (10.3 kgf·m, 76.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 61U6030E Part name Q’ty Remarks Straight key Needle bearing Oil seal Not reusable Claw washer Ring nut Cooling water inlet cover ø5 × 45 mm Screw 61U5H11… -
Page 145: Removing The Propeller Shaft Housing Assembly
Propeller shaft housing Removing the propeller shaft hous- Stopper guide plate 4: ing assembly 90890-06501 1. Remove the ring nut from the lower case, Bearing housing puller claw L 5: use the special service tools. 90890-06502 Center bolt 6: 90890-06504 Disassembling the propeller shaft assembly 1.
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Page 146: Checking The Propeller Shaft Housing
LOWR Lower unit Checking the propeller shaft 2. Remove the ball bearing. 1. Check the propeller shaft. Replace if bent or worn. 2. Measure the propeller shaft runout. Do not reuse the bearing, always replace S6P26200 it with a new one. Stopper guide plate 2: Runout limit: 0.02 mm (0.0008 in) 90890-06501…
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Page 147: Assembling The Propeller Shaft Housing
Propeller shaft housing 2. Install the dog clutch 5 onto the propeller 6. The hole in the dog clutch align with the shaft 6. 2 holes (propeller shaft and shift slider). NOTE: 7. Install the cross pin 0 and spring q. Face the marking side to original direction, and then install the dog clutch 5.
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Page 148
LOWR Lower unit 2. Apply grease to new oil seals, and then 4. Install the reverse gear assembly into the install them into the propeller shaft hous- propeller shaft housing using a press. ing to the specified depth. 61U60080 NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal. -
Page 149: Drive Shaft And Lower Case
Drive shaft and lower case Drive shaft and lower case 93 N·m (9.3 kgf·m, 68.6 ft·lb) 61U6040E Part name Q’ty Remarks Drive shaft Sleeve Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing O-ring Not reusable Pinion shim —…
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Page 150: Removing The Drive Shaft
LOWR Lower unit Removing the drive shaft Disassembling the drive shaft 1. Loosen the pinion nut. housing 1. Remove the cover, oil seals, and needle bearing. 6F660190 S6P26070E Drive shaft holder 6 1: 90890-06520 Needle bearing attachment 1: Pinion nut holder 2: 90890-06610 90890-06715 Driver rod L3 2: 90890-06652…
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Page 151: Disassembling The Lower Case
Drive shaft and lower case 2. Remove the needle bearing from the for- 2. Remove the taper roller bearing outer ward gear using a chisel. race and shim(s). 61U60030 6G460100 Bearing outer race puller assembly 3: 90890-06523 Do not reuse the bearing, always replace NOTE: it with a new one.
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Page 152: Checking The Lower Case
LOWR Lower unit Checking the lower case Needle bearing attachment 3: 1. Check the skeg and torpedo. Replace the 90890-06609 lower case if cracked or damaged. Driver rod SL 4: 90890-06602 Assembling the lower case Bearing depth plate 5: 1. Install the original shim(s) and taper roller 90890-06603 bearing outer race.
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Page 153: Assembling The Drive Shaft Housing
Drive shaft and lower case Assembling the drive shaft housing Installing the drive shaft 1. Install the new needle bearing into the 1. Install the forward gear into the lower drive shaft housing to the specified case. depth. 2. Install the thrust bearing 1 and original shim(s) 2 onto the drive shaft 3.
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Page 154: Installing The Propeller Shaft Housing
LOWR Lower unit 6F660310 61U60130 NOTE: Drive shaft holder 6 7: Face the shift rod joint connect part to 90890-06520 upward. Pinion nut holder 8: 90890-06715 4. Install the original shim(s) 4 and pro- peller shaft housing assembly 5 into the Pinion nut: lower case, and then install the straight 93 N·m (9.3 kgf·m, 68.6 ft·lb)
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Page 155: Installing The Water Pump And Shift Rod
Drive shaft and lower case 2. Install a new gasket 2, the outer plate cartridge 3, and dowels 4. 6F600065 NOTE: 9 To secure the ring nut, bend one tab q of the claw washer into a slot in the ring nut. 9 Bend all other tabs toward the propeller shaft housing assembly.
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Page 156: Installing The Lower Unit
LOWR Lower unit NOTE: 6. Install the new O-ring q and insert car- 9 When installing the pump housing, apply tridge w into the pump housing e. grease to the inside of the housing, and then turn the drive shaft clockwise while pushing down the pump housing.
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Page 157
Shift rod push arm: 90890-06052 3. Install the 2 dowels 1 into the lower unit and extension 2 (E115A: Y-transom). 4. Connect the speedometer hose 3. 5. Install the lower unit into the upper case, and then tighten the lower case mount bolts 4 or nuts to the specified torque. -
Page 158
LOWR Lower unit 9. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. 69D10050 Recommended gear oil: Hypoid gear oil API: GL-4 SAE: 90… -
Page 159: Shimming
Shimming Shimming 6G46090E 61U5H11 6-22…
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Page 160: Selecting The Pinion Shim
LOWR Lower unit Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: 9 Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 93 N·m (9.3 kgf·m, 68.6 ft·lb) 9 Shimming is required when assembling the 3.
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Page 161: Selecting The Forward Gear Shim
Shimming 5. Calculate the pinion shim thickness (T3) Example: as shown in the examples below. If “T3” is 0.70 mm, then the pinion shim is 0.68 mm. If “T3” is 0.74 mm, then the pinion shim is 0.72 mm. Selecting the forward gear shim 1.
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Page 162: Selecting The Reverse Gear Shim
LOWR Lower unit 2. Calculate the forward gear shim thick- Available shim thicknesses: ness (T1) as shown in the examples 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and below. 0.50 mm Example: If “T1” is 0.85 mm, then the forward gear shim is 0.82 mm.
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Page 163: Backlash
Shimming/Backlash NOTE: 4. Select the reverse gear shim(s) (T2) as 9 Without the O-ring, when measuring the follows. reverse gear height. Calculated numeral 9 Select the shim thickness (T2) by using the Rounded numeral at 1/100th place specified measurement(s) and the calcula- 1, 2 tion formula.
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Page 164
LOWR Lower unit 3. Install the special service tools so that it 5. Set the lower unit upside down. pushes against the propeller shaft. 6S360190 NOTE: Install the dial gauge so that the plunger a NOTE: contacts the mark b on the backlash indica- While turning the drive shaft clockwise 5–6 times to contact the gear evenly it tightens tor. -
Page 165
Backlash 8. Remove the special service tools from 10. Slowly turn the drive shaft clockwise and the propeller shaft. counterclockwise, and measure the backlash when the drive shaft stops in 9. Apply a load to the reverse gear by each direction. installing the propeller 8, the spacer 9 (without the washer 0), then the washer q as shown. -
Page 166: Brkt
BRKT Bracket unit Tiller handle ………………..7-1 Checking the throttle cable and shift cable ……….7-4 Assembling the tiller handle……………7-4 Lubricating the throttle gear……………7-4 Bottom cowling ………………..7-5 Upper case, steering arm …………….7-8 Disassembling the upper case …………..7-12 Checking the upper case……………..7-13 Assembling the upper case …………..7-13 Removing the steering arm …………..7-17 Removing the oil seal of swivel bracket (MH, WH, E)……7-17 Installing the oil seal of swivel bracket (MH, WH, E)…….7-17…
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Page 167
Tilt cylinder and trim cylinder…………..7-48 Disassembling the tilt cylinder and trim cylinder ……..7-50 Checking the tilt cylinder and trim cylinder ……….7-51 Assembling the tilt piston and trim piston ……….7-51 Assembling the PTT unit ……………..7-52 Bleeding the PTT unit …………….7-55 Bleeding the PTT unit (built-in) …………..7-56 PTT electrical system ………………7-57 Checking the fuse ………………7-57 Checking the PTT relay …………….7-57… -
Page 168
BRKT Bracket unit Tiller handle 11 N·m (1.1 kgf·m, 8.1 ft·lb) 37 N·m (3.7 kgf·m, 27.3 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 61U7010E 37 N·m (3.7 kgf·m, 27.3 ft·lb) Part name Q’ty Remarks Throttle cable M6 ×… -
Page 169
Tiller handle 11 N·m (1.1 kgf·m, 8.1 ft·lb) 37 N·m (3.7 kgf·m, 27.3 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 61U7010E 37 N·m (3.7 kgf·m, 27.3 ft·lb) Part name Q’ty Remarks Washer Bushing Collar Ball Spring Shift lever… -
Page 170
BRKT Bracket unit 11 N·m (1.1 kgf·m, 8.1 ft·lb) 37 N·m (3.7 kgf·m, 27.3 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 61U7010E 37 N·m (3.7 kgf·m, 27.3 ft·lb) Part name Q’ty Remarks ø6 × 8 mm Screw ø5 ×… -
Page 171: Tiller Handle
Tiller handle Checking the throttle cable and shift cable 1. Check that the operation of the throttle cable and shift cable. 2. Check the inner wire, outer wire of the throttle cable and shift cable. Replace if the outer wire is bent or damaged and the rubber seals are damaged.
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Page 172: Bottom Cowling
BRKT Bracket unit Bottom cowling 24 N·m (2.4 kgf·m, 17.7 ft·lb) 61U7030E Part name Q’ty Remarks Clip Shift rod Bushing Washer Shift lever O-ring Not reusable Washer Bushing Bracket Grease nipple Not reusable Circlip Grommet Ball Spring Bolt 61U5H11…
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Page 173
Bottom cowling 61U7040E Part name Q’ty Remarks Clamp M6 × 20 mm Bolt Plate M8 × 20 mm Bolt Bracket Holder Holder M6 × 12 mm Bolt Wave washer Clamp lever M6 × 12 mm Bolt Collar Pilot hole Lock lever M8 ×… -
Page 174
BRKT Bracket unit 61U7040E Part name Q’ty Remarks M6 × 28 mm Bolt Grommet M8 × 35 mm Bolt Ground lead Grommet Collar Washer Grommet Hose Screw E, ET Bracket E, ET Bracket E, ET 61U5H11… -
Page 175: Upper Case, Steering Arm
Bottom cowling/Upper case, steering arm Upper case, steering arm 51 N·m (5.1 kgf·m, 37.6 ft·lb) 71 N·m (7.1 kgf·m, 52.4 ft·lb) 61U7060E Part name Q’ty Remarks Grommet Upper mount Bracket Washer Rubber washer Washer Bolt Damper Washer M10 × 45 mm Bolt Mount housing Spring…
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Page 176
BRKT Bracket unit 51 N·m (5.1 kgf·m, 37.6 ft·lb) 71 N·m (7.1 kgf·m, 52.4 ft·lb) 61U7060E Part name Q’ty Remarks Washer Ground lead M14 × 180 mm Bolt Upper case assembly Ground lead Hose M10 × 45 mm Bolt M6 × 10 mm Bolt Cover Screw… -
Page 177
Upper case, steering arm 21 N·m (2.1 kgf·m, 15.5 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 61U7070E Part name Q’ty Remarks M8 × 45 mm Bolt M8 × 30 mm Bolt Gasket Not reusable… -
Page 178
BRKT Bracket unit 21 N·m (2.1 kgf·m, 15.5 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 61U7070E Part name Q’ty Remarks Dowel Upper case Rubber seal Pipe Rubber seal Bushing Circlip Hose… -
Page 179: Disassembling The Upper Case
Upper case, steering arm 3. Remove the bolts q, exhaust manifold Disassembling the upper case w and gasket e. 1. Remove the bolts 1, 2, muffler assem- bly 3 and rubber seal 4 from the upper case 5. 61U70040 4. Remove the bolts r, lower exhaust guide t and gasket y from the upper exhaust guide u.
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Page 180: Checking The Upper Case
BRKT Bracket unit 2. Install a new gasket 3, the lower exhaust 5. Remove the circlip, and then remove guide 4, and bolts 5, and then tighten drive shaft bushing. the bolts to the specified torque. 61U70220 Bearing puller assembly i: 90890-06535 Stopper guide stand o: 90890-06538…
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Page 181
Upper case, steering arm 4. Install the rubber damper 9 and clip 0 onto the muffler q. 5. Install the cooling water pipe w onto the muffler q. 6. Install the new gasket, muffler q onto the exhaust guide assembly e, and then tighten the bolts r to the specified torque. -
Page 182
BRKT Bracket unit 10. Install the upper mounts a and bracket 12. Install the lower mounts f and mount s into the upper case assembly, and housings j and tighten the bolts k. then tighten it with the bolts d. 61U70240 S60V7230 NOTE:… -
Page 183
Upper case, steering arm MH, WH, E 36 N·m (3.6 kgf·m, 26.6 ft·lb) 61U7080E Part name Q’ty Remarks Steering arm Washer Bushing Bracket assembly O-ring Not reusable Bushing Washer Steering yoke Circlip Trim stopper Damper Not reusable Oil seal 61U5H11 7-16… -
Page 184: Removing The Steering Arm
BRKT Bracket unit Removing the steering arm Installing the oil seal of swivel 1. Remove the circlip 1. bracket (MH, WH, E) 1. Install the bushing 1 and oil seal 2. S69J7075 61U70250 2. Remove the steering yoke 2 as shown. Needle bearing attachment 3: 90890-06654 Driver rod L3 4: 90890-06652…
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Page 185: Installing The Steering Arm
Upper case, steering arm 4. Install the steering yoke 9 to the steer- Installing the steering arm ing arm 3 by aligning the center a of the 1. Install the washer 1 and bushing 2 onto yoke with the center b of the steering the steering arm 3.
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Page 186: Installing The Upper Case
BRKT Bracket unit Installing the upper case 1. Install the upper and lower mount assem- bly into the bracket assembly 1 simulta- neously. 2. Install the upper mount nuts 2 and lower mount nuts 3, and then tighten them to the specified torques.
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Page 187: Clamp Bracket And Swivel Bracket
Upper case, steering arm/Clamp bracket and swivel bracket Clamp bracket and swivel bracket 15 N·m (1.5 kgf·m, 11.1 ft·lb) 61U7035E Part name Q’ty Remarks Self-locking nut M10 × 45 mm Bolt Clamp bracket Grease nipple Ground lead Washer Bushing Swivel bracket Bushing Shock absorber Bushing…
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Page 188
BRKT Bracket unit 15 N·m (1.5 kgf·m, 11.1 ft·lb) 61U7035E Part name Q’ty Remarks Anode M6 × 30 mm Bolt Tilt pin Circlip 7-21 61U5H11… -
Page 189
Clamp bracket and swivel bracket 61U7140E Part name Q’ty Remarks Tilt stop lever Bushing Tilt lock lever Spring Plate M6 × 10 mm Bolt Distance collar Collar Cotter pin Lever Cotter pin Washer Bracket 61U5H11 7-22… -
Page 190
BRKT Bracket unit 61U7140E Part name Q’ty Remarks M6 × 16 mm Bolt Spring Lever Lever Washer Cotter pin Spring Washer Tilt lock lever Tilt stop lever 7-23 61U5H11… -
Page 191: Removing The Clamp Bracket (Mh, Wh, E)
Clamp bracket and swivel bracket Removing the clamp bracket (MH, WH, E) 9 Do not tamper or attempt to open the shock absorber. 9 Do not subject the shock absorber to an open flame or any other source of high heat.
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Page 192: Disassembling The Swivel Bracket (Mh, Wh, E)
BRKT Bracket unit Disassembling the swivel bracket Assembling the swivel bracket (MH, WH, E) (MH, WH, E) 1. Remove the 2 large springs 1 and 2 cot- 1. Install the rod 1 and rod 2 into the tilt ter pins 2. lock lever 3, and then install the tilt lock lever to the swivel bracket 4.
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Page 193: Assembling The Clamp Bracket (Mh, Wh, E)
Clamp bracket and swivel bracket 6. Install the lever y to the swivel bracket 4 with the cotter pin u. 7. Install the lever i to the lever y with the 2 cotter pins o. 8. Install the 2 large springs p. 9.
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Page 194
BRKT Bracket unit 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 61U7020E Part name Q’ty Remarks Swivel bracket Clamp bracket Clamp bracket Self-locking nut Grease nipple Ground lead ø6 × 12 mm Screw Washer Bushing Trim sensor ø6 ×… -
Page 195
Clamp bracket and swivel bracket 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 61U7020E Part name Q’ty Remarks Through tube M8 × 20 mm Bolt Tilt stop lever Bushing Collar Distance collar Spring pin Spring Spring hook M6 ×… -
Page 196
BRKT Bracket unit 61U7090E Part name Q’ty Remarks PTT unit PTT motor lead Lock tie Not reusable Circlip M8 × 16 mm Bolt Washer Shaft Bushing M6 × 10 mm Bolt Ground lead Trim sensor lead 7-29 61U5H11… -
Page 197: Removing The Ptt Unit (Et)
Clamp bracket and swivel bracket Removing the PTT unit (ET) 1. Fully tilt the outboard motor up, and then Do not remove the tilt stop lever 1 from support it with the tilt stop lever 1. the clamp brackets. 5. Remove the lock ties 6, and then pull out the PTT motor lead 7.
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Page 198: Installing The Clamp Bracket (Et)
BRKT Bracket unit 3. Assemble the clamp brackets, washers, swivel bracket, trim sensor, and then install the through tube. 6G470765 NOTE: 9 Align the projection inside of the trim sensor cam with the through tube hole a, and then 61U70360 install it.
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Page 199: Installing The Ptt Unit (Et)
Clamp bracket and swivel bracket Installing the PTT unit (ET) 7. Fasten the PTT motor lead and trim sen- sor lead with the lock ties 9. 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. 6G470720 61U70280 9 When installing the PTT unit without…
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Page 200: Adjusting The Trim Sensor Cam (Et)
BRKT Bracket unit 5. If the trim sensor voltage is out of specifi- Adjusting the trim sensor cam (ET) cation, adjust the trim sensor cam 2 until 1. Fully retract the PTT unit. the specified trim sensor setting voltage is obtained. 2.
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Page 201: Ptt Unit
Clamp bracket and swivel bracket/PTT unit PTT unit 7 N·m (0.7 kgf·m, 5.2 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 61U7100E Part name Q’ty Remarks PTT motor Reservoir Reservoir cap Not reusable O-ring O-ring Not reusable M6 ×…
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Page 202: Checking The Hydraulic Pressure
BRKT Bracket unit Checking the hydraulic pressure 1. Fully extend the trim and tilt rams. 2. Remove the reservoir cap, and then check the fluid level in the reservoir. 6G470240 NOTE: 6G470250 If the fluid is at the correct level, the fluid NOTE: should overflow out of the filler hole when the Quickly install the special service tools before…
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Page 203
PTT unit 8. Reverse the PTT motor leads between 10. Remove the reservoir cap, and then the battery terminals to fully extend the check the fluid level. trim and tilt rams, and then measure the hydraulic pressure. 6G470240 NOTE: 6G470270 If the fluid is at the correct level, the fluid should overflow out of the filler hole when the Battery… -
Page 204
BRKT Bracket unit 13. Connect the PTT motor leads to the bat- 15. Remove the special service tools, and tery terminals to fully retract the trim and then install the manual valve and circlip. tilt rams, and then measure the hydraulic NOTE: pressure. -
Page 205
PTT unit/PTT motor PTT motor 61U7110E Part name Q’ty Remarks ø4 × 15 mm Screw Stator Armature O-ring Not reusable ø4 × 12 mm Screw Brush holder Brush 1 Brush 2 Brush holder Brush spring PTT motor base Oil seal Not reusable Bearing ø4 ×… -
Page 206: Ptt Motor
BRKT Bracket unit 4. Remove the armature from the PTT Disassembling the PTT motor motor base. 1. Loosen the bolts 1, remove the PTT motor 2, O-ring 3, gear pump filter 4, and joint 5 from the gear pump housing. Do not allow grease or oil to contact the commutator.
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Page 207: Checking The Ptt Motor
PTT motor 3. Measure the commutator undercut b. Replace the armature if below specifica- 9 Do not pull the PTT motor leads out from tion limit. the stator. 9 Do not touch the bimetal a, otherwise the operation of the circuit breaker can be affected.
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Page 208: Checking The Filter
BRKT Bracket unit 5. Measure the brush length. Replace if Assembling the PTT motor below specification limit. 1. Connect the PTT motor leads 1, and then tighten the screws 2. 6S370150 6G470370 Brush standard length: 9.8 mm (0.39 in) 2. Install the spring and push the brushes 3 Wear limit f: into the brush holder, and then install the 4.8 mm (0.19 in)
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Page 209
PTT motor/Gear pump Gear pump 6 N·m (0.6 kgf·m, 4.4 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 61U7120E Part name Q’ty Remarks M5 × 16 mm Bolt Gear pump assembly Ball Shuttle piston O-ring… -
Page 210
BRKT Bracket unit 6 N·m (0.6 kgf·m, 4.4 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 61U7120E Part name Q’ty Remarks Up-relief valve seat O-ring Not reusable Filter O-ring Not reusable Down-relief valve Valve pin… -
Page 211: Gear Pump
Gear pump 3. Remove the bolts 9, gear pump cover Disassembling the gear pump hous- 0, drive gear q and driven gear w. 1. Remove the bolts 1 and gear pump housing 2. 61U70170 NOTE: 61U70180 Make sure that the O-rings 3, valve pin 4, NOTE: and valve seat assembly 5 are removed.
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Page 212: Checking The Main Valve
BRKT Bracket unit 5. Cover the pump housing with a clean Checking the main valve cloth, and then blow compressed air 1. Check the main valve 1. Clean if there is through holes a and b while holding the dirt or residue. cloth down.
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Page 213: Assembling The Gear Pump Housing
Gear pump 4. Install the balls 0, shuttle pistons q, and Assembling the gear pump housing balls w into the gear pump cover. 1. Install a new O-ring 1, up-relief valve seat 2, ball 3, absorber valve pin 4, and spring 5 into the gear pump hous- ing.
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Page 214
BRKT Bracket unit 7. Install a new O-ring r onto the down- relief valve t. 8. Install the filter y, down-relief valve t, and filter u into the gear pump housing 6G470500 9. Install a new O-ring o, p onto the man- ual valve a. -
Page 215
Gear pump/Tilt cylinder and trim cylinder Tilt cylinder and trim cylinder 127 N·m (12.7 kgf·m, 93.7 ft·lb) 132 N·m (13.2 kgf·m, 97.4 ft·lb) 96 N·m (9.6 kgf·m, 70.8 ft·lb) 61U7130E Part name Q’ty Remarks Tilt ram Trim ram Cylinder body Free piston Backup ring O-ring… -
Page 216
BRKT Bracket unit 127 N·m (12.7 kgf·m, 93.7 ft·lb) 132 N·m (13.2 kgf·m, 97.4 ft·lb) 96 N·m (9.6 kgf·m, 70.8 ft·lb) 61U7130E Part name Q’ty Remarks O-ring Not reusable O-ring Not reusable Washer Ball Valve Spring 7-49 61U5H11… -
Page 217: Tilt Cylinder And Trim Cylinder
Tilt cylinder and trim cylinder Disassembling the tilt cylinder and 5. Drain the fluid. trim cylinder 6. Install the trim piston assemblies, and 1. Hold the PTT body in a vise using alu- then temporarily tighten the trim cylinder minum plates on the both sides. end screws.
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Page 218: Checking The Tilt Cylinder And Trim Cylinder
BRKT Bracket unit Checking the tilt cylinder and trim Assembling the tilt piston and trim cylinder piston 1. Install the new dust seal 1 and new O- 1. Disassemble the tilt piston assembly. rings 2 and 3 onto the tilt cylinder end screw.
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Page 219: Assembling The Ptt Unit
Tilt cylinder and trim cylinder 6. Install a new backup ring w and a new Recommended PTT fluid: O-ring e onto the free piston r. ATF Dexron II Fluid quantity: 30 cm (1.0 US oz, 1.1 Imp oz) 2. Push the free piston 1 into the tilt cylin- der until it bottoms out.
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Page 220
BRKT Bracket unit 4. Install the trim piston assemblies into the Gear pump housing mounting bolt 8: trim cylinders, and then tighten the trim 8 N·m (0.8 kgf·m, 5.9 ft·lb) cylinder end screws to the specified torque. 7. Install the O-ring into the reservoir cap. 8. -
Page 221
Tilt cylinder and trim cylinder 13. Remove all of the air bubble using a syringe or suitable tool. NOTE: Turn the joint with a screwdriver to bleed the gear pump. 14. Install a new O-ring w and the PTT motor e, and then tighten the bolts r to the 6G470650 specified torque. -
Page 222: Bleeding The Ptt Unit
BRKT Bracket unit 6. Connect the PTT motor leads to the bat- Bleeding the PTT unit tery terminals to fully retract the trim and 1. Tighten the manual valve 1 clockwise. tilt rams. 6G470830 Battery Rams PTT motor lead terminal 2.
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Page 223: Bleeding The Ptt Unit (Built-In)
Tilt cylinder and trim cylinder 8. Check the fluid level when the tilt ram is 3. Support the outboard motor with the tilt stop lever 1. fully extended. Add sufficient fluid if nec- essary. Bleeding the PTT unit (built-in) 1. Check the manual valve is fully tightened, and then connect the battery to the bat- tery leads.
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Page 224: Ptt Electrical System
BRKT Bracket unit 7. Install the reservoir cap, and then tighten 3. Connect the sky blue (Sb) lead or the it to the specified torque. light green (Lg) lead to the positive bat- tery terminal and the black (B) lead to the NOTE: negative battery terminal as shown.
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Page 225: Elec
ELEC Electrical system Checking the electrical component…………..8-1 Measuring the peak voltage …………..8-1 Electrical component ………………8-2 Port view ………………..8-2 Starboard view……………….8-3 Aft view ………………….8-4 Top view …………………8-5 Ignition and ignition control system …………8-6 Checking the ignition spark gap …………..8-6 Checking the spark plug cap …………..8-6 Checking the ignition coil…………….8-7 Checking the CDI unit…………….8-7 Checking the pulser coil …………….8-8…
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Page 226: Electrical System
ELEC Electrical system Checking the electrical NOTE: 9 Before measuring the peak voltage, check component all wiring for proper connection and corro- Measuring the peak voltage sion, and check that the battery is fully To check the electrical components or mea- charged.
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Page 227: Electrical Component
Checking the electrical component/Electrical component Electrical component Port view 61U80040D 1 Starter motor (WH, E, ET) 2 Starter relay (WH, E, ET) 3 PTT relay (ET) 4 Ignition coil 5 Fuse holder (20A: WH, E, ET) 61U5H11…
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Page 228: Starboard View
ELEC Electrical system Starboard view å ç ∫ ∫ 61U80020B 1 Choke solenoid (E, ET) å To pulser coil assembly. 2 Rectifier Regulator ∫ To CDI unit. ç To wire harness. 3 Hour meter (if equipped) 61U5H11…
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Page 229
Electrical component Aft view å ∫ ∫ å BOTTOM 61U80030C 1 Ignition coil #1 2 Ignition coil #2 3 Ignition coil #3 4 Ignition coil #4 5 Spark plug 6 Spark plug cap 7 Thermoswitch 8 CDI unit 9 PCV 61U5H11… -
Page 230: Top View
ELEC Electrical system Top view å å 61U80010A 1 Spark plug 2 Thermoswitch 3 Ignition coil #1 4 Ignition coil #2 5 Rectifier Regulator 6 Starter motor (WH, E, ET) 7 Stator assembly 8 Pulser coil assembly 9 Neutral switch (WH) 61U5H11…
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Page 231: Ignition And Ignition Control System
Ignition and ignition control system Ignition and ignition control Checking the spark plug cap 1. Check the spark plug caps. Replace if system cracked or damaged. Checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. 2.
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Page 232: Checking The Ignition Coil
ELEC Electrical system Checking the ignition coil Checking the CDI unit 1. Remove the spark plug cap from the 1. Remove the CDI unit cover. spark plug. 2. Connect the digital circuit tester with 2. Disconnect the ignition coil connectors. peak voltage adaptor B to the ignition coil lead and the ground.
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Page 233: Checking The Pulser Coil
Ignition and ignition control system Checking the pulser coil 1. Remove the CDI unit cover. 2. Connect the test harness to the pulser coil. 3. Measure the pulser coil output peak volt- age. Replace the pulser coil if less than specification.
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Page 234: Checking The Thermoswitch
ELEC Electrical system Checking the thermoswitch Test harness 1: 90890-06871 1. Place the thermoswitches in a container of water and slowly heat the water. Charge coil output peak voltage: (low-speed) Red (R) – Brown (Br) Unloaded Loaded r/min Cranking 1,500 3,500 DC V (100)
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Page 235: Checking The Engine Start Switch (Wh, E, Et)
Ignition and ignition control system/Starting system Checking the engine start switch Checking the engine stop lanyard (WH, E, ET) switch 1. Disconnect the 10-pin main harness cou- 1. Check the engine stop lanyard switch for pler. continuity. Replace if there is no continu- ity.
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Page 236: Checking The Starter Relay (Wh, E, Et)
ELEC Electrical system Checking the starter relay Checking the neutral switch (WH) 1. Check the neutral switch for continuity. (WH, E, ET) Replace if there is no continuity. 1. Remove the starter relay 1. 6F680140 61U80030 2. Connect the digital circuit tester leads to Switch Lead color the starter relay terminals.
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Page 237
Starting system/Starter motor (WH, E, ET) Starter motor (WH, E, ET) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 61U8010E Part name Q’ty Remarks M8 × 25 mm Bolt Starter motor bracket Clip Pinion stopper Spring… -
Page 238
ELEC Electrical system 30 N·m (3.0 kgf·m, 22.1 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 61U8010E Part name Q’ty Remarks Screw M6 × 115 mm Bolt 8-13 61U5H11… -
Page 239: Removing The Starter Motor Pinion
Starter motor (WH, E, ET) Removing the starter motor pinion 1. Slide the pinion stopper 1 down using the box wrench, and then remove the clips 2. 6G480220 2. Measure the commutator diameter a. Replace the armature if below specifica- tion limit.
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Page 240: Checking The Brush
ELEC Electrical system 4. Check the armature for continuity. 2. Check the brush holder assembly for Replace the armature if not shown as continuity. Replace the brush holder if not below chart. shown as below chart. 6G480270 Brush continuity: 6G480256 Brush 1 –…
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Page 241: Charging System
Starter motor (WH, E, ET)/Charging system Charging system Checking the Rectifier Regulator 1. Disconnect the Rectifier Regulator (R) Checking the lighting coil connector, then connect the digital circuit 1. Disconnect the lighting coil connector. tester to Rectifier Regulator (R) connec- tor and ground 2.
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Page 242: Checking The Hour Meter
ELEC Electrical system Checking the hour meter 1. Disconnect the hour meter coupler from the wiring harness. 2. Connect the positive battery lead to the yellow (Y) terminal a, also connect the negative battery lead to the black (B) ter- minal b, and then check that the hour meter displayed the all segments which has been illuminated for 2 seconds.
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Page 243: Trbl Shtg
TRBL TRBL SHTG SHTG Troubleshooting Troubleshooting the power unit …………..9-1 Troubleshooting the power unit…………..9-1 Troubleshooting the PTT unit…………..9-6 Troubleshooting the lower unit …………..9-7 61U5H11…
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Page 244
TRBL TRBL SHTG SHTG Troubleshooting Troubleshooting the power unit Troubleshooting the power unit (trouble code not available) The trouble shooting when a trouble code is not available consists of the following 4 items. Symptom 1: Specific trouble conditions. Symptom 2: Trouble conditions of an area or individual part. Cause 1: The content considered as the trouble factors of symptom 2. -
Page 245
Troubleshooting the power unit Refer Symptom 2 Cause 1 Cause 2 Checking step page Stuck piston Manual starter Disassemble and — 5-17 Piston lock due to check the power unit. or starter motor water or oil in the com- operates, but bustion chamber the engine does not crank… -
Page 246
TRBL SHTG Troubleshooting Refer Symptom 2 Cause 1 Cause 2 Checking step page Measure the pulser coil Pulser coil out- resistance. put peak volt- Pulser coil malfunction age less than Change the pulser coil specifications and check the ignition spark. Spark plug does not spark Measure the charge… -
Page 247
Trouble shooting the power unit Refer Symptom 2 Cause 1 Cause 2 Checking step page Fuel not sup- Float height Disassemble and Carburetor malfunction 4-12 plied properly improperly check the carburetor. Spark plug gap Check the spark plug Spark plug malfunction improperly gap and condition. -
Page 248
TRBL SHTG Troubleshooting Symptom 1: Limited engine speed (below 2,000 r/min) Refer Symptom 2 Cause 1 Cause 2 Checking step page Clogged cooling water Check the cooling — inlet water inlet. Check the impeller. Water pump impeller Check the Woodruff malfunction 9Buzzer comes key. -
Page 249
Troubleshooting the power unit Troubleshooting the PTT unit Symptom 1: PTT unit does not operate Refer Symptom 2 Cause 1 Cause 2 Checking step page Short, open, or loose Check the wiring har- connection of the — PTT relay does ness continuity. -
Page 250
TRBL SHTG Troubleshooting Symptom 1: PTT unit does not hold the outboard motor up Refer Symptom 2 Cause 1 Cause 2 Checking step page Manual valve Check the manual Manual valve opened — malfunction valve for open. Insufficient PTT fluid —… -
Page 251
Checking the PTT fluid level (ET) ….3-10 Checking the PTT motor……7-40 Adjusting the ignition timing stopper..5-53 Checking the PTT operation (ET)….3-10 Adjusting the start-in-gear protection Checking the PTT relay ……7-57 (MH, WH) ……….3-4 Checking the PTT system (ET) ….1-15 Adjusting the throttle cable ……3-6 Checking the Rectifier Regulator …..8-16 Adjusting the timing plate ……5-52 Checking the anode………3-13… -
Page 252
Checking the reservoir……7-45 Checking the spark plug ……3-3 Electrical (115B, 140B models) ….2-12 Checking the spark plug cap …..8-6 Electrical (E115A models) ……2-7 Checking the spiral spring (MH, WH) ..5-15 Electrical component ………8-2 Checking the starter motor operation ..8-15 Exhaust cover ……….5-25 Checking the starter motor pinion …8-14… -
Page 253
Selecting the forward gear shim ….6-24 Lower unit ………3-11, 6-1 Selecting the pinion shim……6-23 Lower unit (115B, 140B models) …..2-12 Selecting the reverse gear shim ….6-25 Lower unit (E115A models) …….2-7 Selection ……….1-11 Lubricating the outboard motor….3-14 Self-protection……….1-3 Lubricating the throttle gear…….7-4 Serial number ……….1-5… -
Page 254
WIRING DIAGRAM E115AMH Color code : Black 1 Thermoswitch : Brown 2 Spark plug : Green 3 Ignition coil : Gray 4 CDI unit 5 Charge coil : Blue : Pink 6 Lighting coil : Red 7 Pulser coil : White 8 Rectifier Regulator B/R : Black/red 9 Engine stop lanyard switch… -
Page 256
YAMAHA MOTOR CO., LTD. Printed in Japan Oct. 2005 – 1.2 × 1 ! Printed on recycled paper (E_1) -
Page 257
E115AMH 1 2 3 4 1 2 3 4 1 2 3 4… -
Page 258
WIRING DIAGRAM E115AE, E115AWH, 115BE Color code 1 Starter motor : Black 2 Starter relay : Brown 3 Battery : Green : Gray 4 Fuse (20A) 5 Thermoswitch : Blue 6 Spark plug : Light green 7 Ignition coil : Pink : Red 8 CDI unit 9 Charge coil… -
Page 259
E115AE,E115AWH,115BE Gy/B Gy/B 1 2 3 4 1 2 3 4 1 2 3 4 Gy/B… -
Page 260
Pulser coil Gy/B : Gray/black t Rectifier Regulator G/W : Green/white W/B : White/black y Choke solenoid u Hour meter (E115A) W/G : White/green i Trim sender W/L : White/blue o Over revolution W/R : White/red W/Y : White/yellow å… -
Page 261
E115AET,115BET,140BET Gy/B Gy/B 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 Gy/B Gy/B…