Yamaha MM700A User manual

General Information
Troubleshooting
Lubrication, Maintenanceand Tune
- up
Engine
Fuel and Exhaust Systems
Electrical System
Oil InjectionSystem
CoolingSystem
Recoil Starter
Drive System
Brakes
Chaincase, Jackshaftand Front Axle
Front Suspensionand Steering
Track and Rear Suspension
Off
- season Storage
Index
Wiring Diagrams

Contents
CHAPTER ONE
........................................
GENERAL INFORMATION . . . . . . . 1
.................
Manualorganization ..................... 1 Precisionmeasuringtools 12
............
Warnings. cautionsand notes. ............. 2 Electricalsystem fundamentals 22
...........................
Safety 2 Special tools 24
...................
Serial numbers 3 Basic service methods 24
...................
Fasteners 4 Snowmobileoperation 29
.....................
Shopsupplies 6 Snowmobilesafety . 31
................
Basictools 8 Snowmobilecode of ethics 31
CHAPTER TWO
TROUBLESHOOTiNG 39
Operatingrequirements 39
Fuel system . 48
Testing electrica1components 39
Engine 49
...............
Ignition system troubleshooting 40 Two - strokepressure testing 53
............................
Batterycharging system Power train 56
(Modelswith electricstart) 44 Skis and steering 57
Lightingsystem 46 Track assembly
57
...................
Electricstartingsystem 46
CHAPTER THREE
....................
LUBRICATION. MAINTENANCE AND TUNE-UP
59
................
Prc - ride checks . 59 Unscheduledmaintenance 73
...........................
Fluid checks 59 Engine tune - up 74
................
Break - in procedure 59 High - altitude clutch tuning 84
.............
Maintenanceschedules 60 Chaincasesprocketadjustment 84
Lubrication
60 Suspensionadjustments . 84
.................
Scheduledmaintenance . 63

CHAPTER FOUR
........................................................... ENGINE 94
..............................
Engine number identification 94 Cylinder 102
..........
Engine lubrication 95 Piston. piston pin,and piston rings 104
....................
Service precautions . 95 Reed valve assembly 111
.................
Servicing enginein frame . 96 Crankcase and crankshaft
112
Engine removal 96 Coolant pumpand oil injection
......................
Engine installation 97 pump drive shaft 122
Engine top end 99
CHAPTER FIVE
...............................
.........
FUEL AND EXHAUST SYSTEMS 125
................
Air box 125 Carburetorheating system 136
.............................
Intake tubes 126 Fuel pump 137
..............................
Carburetor 126 Fuel tank 139
.........................
Carburetor operation 126 Exhaust system 139
....................
Carburetor service 127 Exhaust system repair 141
Carburetor adjustments 136
CHAPTER SIX
ELECTRICALSYSTEM
........
Battery 144 Instrument panelwarning lightcheck 159
........................
Capacitordischarge ignition (CDI) 148 Fuel level sender 159
..................
CDI box 150 Oil level sendertesting. 160
...................
Ignition coils 15 1 Thermoswitchtesting. 160
..................
Voltage regulator 151 Throttleoverride system 161
...........................
Electric startingsystem 15 1 Handwarmer 162
........................
Switches 156 Lighting system 163
CHAPTER SEVEN
..............................................
OIL INJECTIONSYSTEM 166
..............................
Oil pump service 166 Oil pump 169
Component replacement 167
CHAPTER EIGHT
COOLING SYSTEM 170
CHAPTER NINE
....................................................
RE C O I L STARTER 75
CHAPTER TEN
.....................................................
DRIVE SYSTEM 181
.............................
Drive unit 181 Drive belt 186
Primary sheave assembly 182 Primarysheave service 190
.................
Secondarysheave 183 Secondarysheave service 195

CHAPTER ELEVEN
BRAKES
202
Hydraulic brake pad replacement 203 Brake hose replacement 212
Brake caliper 203 Brakedisc 212
Brake master cylinder 207 Bleeding the brake system 213
Parking brake 210
CHAPTER TWELVE
CHAINCASE, JACKSHAFTAND FRONT AXLE 215
Drive chain and sprockets Chaincase 219
(Except VT6OO, VT700, VX6OOER and Jackshaft 219
VX7OOXTCD models) 215 Front axle 226
Drive chain. sprockets and gears
(VT6OO, VT7OO, VX600ER and
X700XTCD models) 2
1 8
CHAPTER THIRTEEN
FRONT SUSPENSION AND STEERING
. 233
.........................
Skis 233 Steering system 244
Shockabsorber 241 Steeringadjustment 247
Handlebarand grips 242
CHAPTER FOURTEEN
TRACK AND REAR SUSPENSION 251
Rear suspension 251 Shockabsorbers 254
..................... Wear strips 252 Suspension overhaul 255
.................................
End caps 253 Track 255
CHAPTER FIFTEEN
O FF - S E A S O N S T O RA G E . 264
INDEX 267
WlRING DIAGRAMS 271

Chapter One
General Information
This shop manual covers the
1997 - 2002
Yamaha models.
The text provides complete information on mainte
-
nance, tune - up, repair and overhaul. Hundreds of photos
and drawings guide the reader throughevery job.
A shop manual is a reference tool and as in all
manuals, the chaptersare thumb tabbed. Important items
are indexed at the end of the book. All procedures, tables
and figuresaredesignedforthereader who may bework
-
ing on the snowmobilefor the firsttime. Frequently used
specifications and capacitiesfromindividual chaptersare
summarized
in the Quick Reference Data at the front of
the book.
Tables 1 - 11 are at the end of this chapter.
Table 1 lists the Yamaha models covered in this man -
ual.
Table 2 listsvehiclelength.
Table 3 lists vehicle width.
Table 4 lists vehicle height.
Table 5 lists vehicle weight.
Table 6 lists conversion formulas.
Table 7 lists general torque specifications.
Table 8 liststechnicalabbreviations.
Table 9 listsmetric tap and drill sizes.
Table 10 listsdecimaland metric equivalents.
MANUALORGANIZATION
All dimensions and capacitiesare expressed in metric
and U.S. standard unitsof measurement.
This chapter provides general information on shop
safety, tool use, service fundamentals and shop supplies.
Thetablesat the endofthe chapterincludegeneralvehicle
information.
Chapter Two provides methods and suggestions for
quick and accuratediagnosis and repairing of problems.
Troubleshooting procedures discuss typical symptoms
and logicalmethodsto pinpointthe trouble.
ChapterThree explains all routine maintenance neces
-
sary to keep the snowmobile operating well. Chapter
Three also includes recommended tune
- up procedures,
eliminatingthe need to frequently consult other chapters
on the variousassemblies.
Subsequentchapters describespecificsystems, provid
-
ing disassembly, repair, assembly and adjustment proce -
dures in simple step - by - stepform.
Some of the procedures in this manual specify special
tools. In most cases, the tool is illustrated in use.

2 CHAPTER ONE
Well - equippedmechanicsmay be able to substitutesimi -
lar tools or fabricatea suitable replacement.However, in
some cases, the specialized equipment or expertise
required may make it impracticalfor the home mechanic
to attempt the procedure. When necessary, such opera
-
tionsarc identifiedin the textwith therecommendationto
have a dealershipor specialistperform the task.
It may be
less expensiveto havea professionalperform these jobs,
especiallywhen consideringthe cost of the equipment.
WARNINGS. CAUTIONS AND NOTES
The terms WARNING, CAUTION and NOTE have
specific meaningsin this manual.
A WARNING emphasizes areas where injury or even
death could result from negligence.Mechanical damage
may alsooccur. WARNINGS
are to be taken seriously.
ACAUTION emphasizesareas whereequipmentdam -
age could result. Disregarding a CAUTION could cause
permanentmechanicaldamage, though injuryisunlikely.
ANOTEprovidesadditionalinformation to makea step
or procedure easier or clearer. Disregarding a NOTE
could cause inconvenience, but would not cause equip
-
ment damage or injury.
SAFETY
Professional mechanics can work for years and never
sustain a serious injury or mishap. Follow these guide
-
lines and practicecommonsense to safelyservice the ve-
hicle.
1. Do notoperatethe vehiclein an enclosed area.Theex -
haustgassescontaincarbonmonoxide, anodorless,color -
less,andtastelesspoisonousgas. Carbon monoxidelevels
build quickly in small enclosed areas and can cause
un -
consciousness and death in a short time. Make sure the
workareaisproperly ventilatedoroperatethevehicleout
-
side.
2. Never use gasolineor any extremely flammableliquid
tocleanparts. Referto
CleaningParts and Handling Gas -
oline Safely in thischapter.
3. Never smoke or use a torch in the vicinity of flamma -
ble liquids, such as gasolineor cleaningsolvent.
4. If welding or brazing on the vehicle, remove the fuel
tank,carburetorandshocksto asafedistanceat least
50 ft.
(1 5 m) away.
5. Use the correct type and size of tools to avoid damag -
ing fasteners.
6. Keeptools cleanand in goodcondition.Replaceorre -
pair worn or damagedequipment.
7. When loosening a tight fastener, be guided by what
would happen if the tool slips.
8. When replacingfasteners,make surethe newfasteners
are the same size and strength as the original ones.
9. Keep the work area clean and organized.
10. Wear eyeprotection anytime thesafetyofyoureyesis
in question. This includes procedures involving drilling,
grinding, hammering, compressedair and chemicals.
11. Wear the correctclothing for the job. Tie up or cover
long hair so it cannot get caught in moving equipment.
12. Do notcarry sharp toolsin clothingpockets.
13. Alwayshavean approved fire extinguisheravailable.
Make sure it is rated for gasoline (Class
B) and electrical
(Class
C) fires.
14. Do not use compressedair to clean clothes, the vehi
-
cle or the work area. Debris may be blown into eyes or
skin.
Never direct compressedair at yourself or someone
else. Do not allow children to use or play with any com
-
pressed air equipment.
15. Whenusingcompressedair to dryrotatingparts,hold
thepartso it cannotrotate.Do notallow theforceof theair
to spin the part. The air jet is capable of rotating parts at
extreme speed. The
part may damage or disintegrate,
causing serious injury.
16. Donotinhalethe dustcreatedby brakepad and clutch
wear. These particles may contain asbestos. In addition,
some types of insulating materials and gaskets may con
-
tain asbestos. Inhaling asbestos particles is hazardous to
people's health.
17. Never workon the vehiclewhilesomeoneis working
under it.
18. When placing the vehicle on a stand, make sure it is
secure beforewalking away.
Handling Gasoline Safely
Gasolineisa volatileflammableliquid and is one ofthe
most dangerous items in the shop.

GENERAL INFORMATION 3
Because gasoline is used so often, many people forget
that it is hazardous.Only use gasoline as fuelfor gasoline
internal combustion engines. Keep in mind, when work
-
ing on a vehicle, gasoline is always present in the fuel
tank, fuel line and carburetor. To avoid a disastrous acci
-
dent when working around the fuelsystem, carefully ob-
serve the followingprecautions:
1. Never use gasoline to clean parts. See Cleaning Parts
in thischapter.
2. Whenworkingon the fuelsystem,work outsideor in a
well
- ventilatedarea.
3. Do not add fuel to the fuel tank or service the fuel sys -
tem whilethe vehicleis nearopenflames,sparksorwhere
someoneis smoking.Gasolinevapor is heavierthanair. It
collectsin low areasand is moreeasilyignitedthan liquid
gasoline.
4. Allow the engine to cool completely before working
on any fuel system component.
5. When draining the carburetor, catch the fuel in a plas -
tic container and then pour it into an approved gasoline
storage devise.
6. Do not store gasoline in glass containers.If the glass
breaks, a seriousexplosionor fire may occur.
7. Immediatelywipe up spilledgasoline with rags. Store
the rags in a metal container with a lid until they can be
properlydisposedof,or placethem outsidein a safeplace
for the fuel to evaporate.
8. Do not pour water onto a gasoline fire. Water spreads
the fire and makes it more difficult to extinguish. Use a
class B. BC or ABC fire extinguisher to extinguish the
fire.
9. Always turn off the engine before refueling. Do not
spill fuelonto the engine or exhaustsystem. Do not over
-
fill the fuel tank. Leave an air spaceat the top of the tank
to allow room for the fuel to expand due to temperature
fluctuations.
Cleaning Parts
Cleaning parts is one of the more tedious and difficult
service jobs performed in the home garage. There are
many types of chemical cleaners and solvents available
for shop use. Most are poisonousand extremelyflamma
-
ble.To preventchemicalexposure,vaporbuildup,fireand
serious injury, observe each product warning label and
note the following:
1. Read and observethe entireproductlabelbeforeusing
any chemical. Always know what type of chemical is be
-
ing used and whetherit is poisonousand/orflammable.
2. Do not use more thanone type of cleaningsolventat a
time.If mixing chemicalsiscalledfor,measuretheproper
amountsaccordingto the manufacturer.
3. Work in a well - ventilatedarea.
4. Wear chemical - resistantgloves.
5. Wear safetyglasses.
6. Wear a vapor respiratorif the instructionscall for it.
7. Wash hands and arms thoroughly aftercleaning parts.
8. Keepchemicalproductsawayfromchildrenandpets.
9. Thoroughly clean all oil, grease and cleaner residue
from any part that must be heated.
10. Usea nylonbrushwhencleaningparts.Metal brushes
may cause a spark.
11. When using a parts washer, only use the solvent rec -
ommended by the manufacturer. Make sure the parts
washer isequippedwitha metal lidthatwilllowerin case
of fire.
Warning Labels
Mostmanufacturersattach informationand warning la -
bels to the vehicle. These labels contain instructionsthat
are important to personal safety when operating, servic
-
ing, transporting and storing the vehicle. Refer to the
owner's manual for the descriptionand locationoflabels.
Order replacement labels from the manufacturer if they
are missingor damaged.
SERIAL NUMBERS
Serial numbers are stamped onto the frame and engine.
Record these numbers in the
Quick Reference Data sec -
tionatthefrontof the book.Havethesenumbersavailable
when ordering parts.
The frame number
(Figure 1) or vehicleidentification
number
(VIN) is located on the side of the tunnel.
The engine number
(Figure 2) is stampedinto the right
end of the engine crankcase.

4 CHAPTER ONE
FASTENERS
Properfastenerselectionandinstallation is importantto
ensure that the vehicle operates as designed, and can be
servicedefficiently.Thechoiceoforiginalequipmentfas
-
tenersis not arrivedat by chance.Make sure replacement
fastenersmeetallthesamerequirementsastheoriginals.
Threaded Fasteners
Threaded fasteners secure most of the components on
thevehicle.Most are tightened byturningthemclockwise
(right
- handthreads). If the normalrotationof the compo -
nent being tightened loosens the fastener, it may have
left
- hand threads.If a left - hand threaded fastenerisused,
it is noted in the text.
Two dimensions are required to match the size of the
fastener: the number of threadsin a givendistanceand the
outside diameterof the threads.
Two systemsare currentlyused to specifythreadedfas
-
tenerdimensions:the U.S. Standardsystemandthemetric
system. Although fastenersmay appear similar, close in
-
spection shows that the thread designs are not the same
(Figure
3). Pay particular attention when working with
unidentified fasteners; mismatching thread types can
damagethreads.
NOTE
To ensure the fastener threads are not mis -
matched or cross - threaded, start allfasten-
em by hand. If a fasteneris hard to start or
turn, determinethe cause before tightening
with a wrench.
Thelength (L, Figure 4), diameter (D) and distancebe -
tween threadcrests(pitch)(T) classify metric screws and
bolts.
A typical bolt may be identified by the numbers
8 - 1.25 X 130. This indicatesthe bolt has diameter of 8
mm. The distance between thread crests is 1.25 mm and
the length is
130 mm. Always measure bolt length as
shown in Figure
5 to avoid purchasing replacements of
the wrong length.
The numbers locatedon the top of the fastener(Figure
4) indicate the strength of metric screws and bolts. The
higher the number, the stronger the fastener is. Unnum
-
beredfastenersare the weakest.
Manyscrews,boltsandstudsare combined with nutsto
secure particular components. To indicate the size of a
nut, manufacturersspecify the internal diameter and the
thread pitch.
The measurementacross two flatson a nut or bolt indi
-
cates the wrench size.
Grade marking
WARNING
Do notinstallfastenerswith astrength clas -
sificationlowerthan what wasoriginallyin -
stalled by the manufacturer. Doing so may
cause equipment failure and/ordamage.
TorqueSpecifications
The materials used in the manufacture of the vehicle
may be subjectedto uneven stresses if the fastenersof the
various subassembliesarenotinstalledand tightenedcor-
rectly. Fasteners that are improperly installed or work
loose
can causeextensivedamage.It is essential to usean
accuratetorquewrench, describedin thischapter, withthe
torquespecificationsin this manual.

GENERAL INFORMATION 5
Correct installation
Specifications for torque are provided in New -
ton - meters (N•m), foot - pounds (ft.-lb.) and inch - pounds
(in.-lb.).Refer to Table 6 for torqueconversions and Ta -
ble 7 for general torque specifications. To use Table 7,
firstdeterminethe sizeofthefastenerasdescribedin
Fas -
teners in this chapter. Torque specificationsfor specific
components are at the end of the appropriate chapters.
Torque wrenchesare covered in the
Basic Tools section.
Self
- Locking Fasteners
Several types of bolts, screws and nuts incorporate a
system that creates interference between the two fasten
-
ers. Interference is achieved in various ways. The most
common type is the nylon insert nut and a
dry adhesive
coatingon the threads of a bolt.
Self
- locking fasteners offer greater holding strength
than standard fasteners, which improves their resistance
tovibration.Most self
- lockingfastenerscannotbe reused.
Thematerialsusedtoform the lockbecomedistortedafter
the initialinstallationand removal. It is
a good practiceto
discard and replace self
- locking fasteners after their re -
moval. Do not replace self - locking fasteners with stan -
dard fasteners.
Washers
There are two basic types of washers: flat washersand
lockwashers.Flat washersare simple discs with a hole to
fit a screw or bolt. Lockwashers prevent a fastener from
working loose. Washers can be used as spacersandseals,
or to help distribute fastener load and to prevent the fas
-
tenerfrom damagingthe component.
As with fasteners, when replacing washers make sure
the replacementwashersare of the samedesign andqual
-
ity.
CotterPins
A cotter pin is a split metal pin inserted into a hole or
slot to preventa fastenerfrom loosening.
In certainappli -
cations,thefastenermustbesecuredin thisway. Forthese
applications, a cotter pin and castellated (slotted) nut is
used.
To use a cotter pin, first make sure the diameter is cor
-
rect for the hole in the fastener.After correctly tightening
the fastener and aligning the holes, insert the cotter pin
throughthe holeand bend theendsoverthe fastener(Fig
-
ure 6). Unless instructedto do so, never loosena torqued
fastenertoaligntheholes. If theholesdonotalign,tighten
the fastener just enough to achieve alignment.
Cotter pins are available in various diameters and
lengths.Measurelengthfromthebottomof theheadtothe
tip of the shortest pin.
Snap Rings and E
- rings
Snap rings(Figure 7) are circular
- shapedmetal retain -
ingclips.They helpsecurepartsandgearsin placesuchas
shafts, pins or rods. External type snap rings retain items
on shafts. Internal type snap rings secure parts within
housingbores. In some applications,in addition to secur
-
ingthecomponent(s),snapringsofvaryingthicknessalso
determineendplay.Theseareusuallycalledselectivesnap
rings.
Two basic types of snap rings are used: machined and
stamped snap rings. Machinedsnap rings (Figure
8) can

6 CHAPTER ONE
beinstalledineitherdirection,sincebothfaces havesharp
edges. Stamped snap rings
(Figure 9) have a sharp edge
and a roundedge. When installinga stamped snap ring in
a thrust application, install the sharp edge facing away
from the part producingthe thrust.
Observethe followingwhen installingsnap rings:
1. Remove and install snap rings with snap ring pliers.
See
Snap Ring Pliers in thischapter.
2.
In some applications, it may be necessary to replace
snap rings after removingthem.
3. Compressor expand snap ringsonly enough to install
them.Ifoverlyexpanded, theylosetheirretainingability.
4. After installing a snap ring, make sure it seats com -
pletely.
5. Wear eye protection when removing and installing
snap rings.
E
- ringsare used when it is not practical to use a snap
ring. Remove E
- rings with a flat blade screwdriver by
pryingbetweenthe shaft and E
- ring.To install an E - ring,
centerit overtheshaftgrooveandpushortapitintoplace.
SHOPSUPPLIES
Lubricants and Fluids
Periodiclubricationhelps ensure a long service life for
any type ofequipment.Usingthe correcttype of lubricant
is as important as performing the lubrication service, al
-
though in an emergency the wrong type is better than
none. The following section describes the types of lubri
-
cants most often required.Makesure to followthe manu -
facturer's recommendationsfor lubricanttypes.
Two - strokeengineoil
Lubricationfor a 2 - strokeengine is provided either by
oil mixedwith the incomingfuel
- air mixtureor by oil in -
jected into the fuel - air mixture. The models included in
this manual are equipped with an oil injection system.
Someof theoilsettlesoutin thecrankcase,lubricatingthe
crankshaftand lower end of the connectingrods.The rest
of the oil enters the combustion chamber to lubricate the
piston rings and cylinderwalls. This oil is burned during
the combustion process, then expelled with the engine's
exhaust.
Engine oil must have several special qualities to work
well in a 2
- strokesnowmobileengine.The oil must func -
tionproperlyin the highoperatingtemperatureassociated
with 2
- stroke engines,as well as flow freely in cold tem -
peratures. The oil must lubricate the engine sufficiently
and bum completely during combustion. The oil should
Internal snap ring
External clip
Plain clip
not leave behind excessivedeposits. Refer to Engine Lu -
brication in ChapterThree.
NOTE
The injection oil used by Yamahasnowmo-
bile engines must also be able to flow at
temperaturesof
-40º C (-40º F). See Chap -
ter Three under Lubrication for additional
information.
Four-strokeengine oil
CAUTION
Four - stroke oils are only discussed to pro -
vide a comparison. The engines used in
these models of Yamaha snowmobiles are
2
- stroke engines. Only use 2 - stroke oil.
Four - stroke (cycle) oil for ATV, motorcycle and auto -
motive engines is classified by the American Petroleum
Institute (API) and the Society of Automotive Engineers
(SAE) in several categories. Oil containers display these
ratingson the top or label.The APIclassificationis not
an
indicationof oil quality.
APIoil classificationis indicatedby letters;oilsforgas
-
olineenginesare identifiedby an S, suchasSF, SG, SH or
SJ. Using the type recommended by the manufactureris
important, but some earlier classifications of oil may be
difficult to find.
Viscosityisan indicationof the oil's thicknessorability
to flow at a specific temperature.The SAE uses numbers
to indicate viscosity; thin oils have low numbers while
thick oils have high numbers. AW after the number indi-

GENERAL INFORMATION 7
support
areas
cates that the viscosity testing was done at low tempera-
ture to simulate cold - weatheroperation. Engine oils fall
into the
5 to 50 range.
Multigrade oils (for example 5W
- 20) have been
changedby additivesthatmodifythe oil tobeless viscous
(thinner) at low temperatures and more viscous (thicker)
at high temperatures.This allows the oil to perform effi
-
ciently across a wide range of engine operating condi -
tions. The lower the number, the easier the engine will
start in cold climates. Highernumbersare usuallyrecom
-
mended for engines running in hot weatherconditions.
Greases
Grease is lubricatingoil with thickening agents added
to it. The National Lubricating Grease Institute (NLGI)
grades grease. Grades range from No. 000 to No.
6, with
No.
6 being the thickest. Typical multipurpose grease is
NLGI No.
2. For specific applications, manufacturers
may recommend water
- resistant type grease or one with
an additive such as molybdenum disulfide (MoS2).
Brake fluid
Brake fluid is the hydraulic fluid used to transmit hy -
draulicpressure(force)tothe wheel brakes.Brakefluidis
classified by the Department of Transportation (DOT).
Current designations for brake fluid are DOT
3, DOT 4
and DOT 5. This classificationappears on the fluid con -
tainer.
Each type of brake fluid has its own definite character
-
istics.Do not intermixdifferenttypesofbrakefluid.DOT
5 fluid is silicone
- based.DOT 5 is not compatible with
other fluids or in systems for which it was not designed.
Mixing DOT
5 fluid with other fluids may cause brake
system failure. When adding brake fluid,
only use the
fluid recommended by the manufacturer.
Brake fluid will damage any plastic, painted or plated
surface
it contacts. Use extreme care when working with
brake fluid and removeany spills immediatelywith soap
and water.
Hydraulic brake systems require clean and moisture
freebrakefluid.Neverreuse brakefluid. Keep containers
and reservoirsproperly sealed.
WA RNING
Never pour a mineral - based(petroleum) oil
into the brake system. Mineral oil causes
rubber parts in the system to swell and
break apart, resulting
in complete brake
failure.
Cleaners, Degreasers
and Solvents
Manychemicalsareavailableto removeoil, greaseand
other residuefrom the vehicle.
Before using cleaningsolvents,consider how they
will
be used and disposed of, particularly if they are not wa -
ter - soluble. Local ordinances may require special proce -
dures for the disposal of many types of cleaning
chemicals. Refer to
Safety and Cleaning Parts in this
chapter for more informationon their use.
Use brake parts cleaner to clean brake system compo
-
nents when using petroleum - based products will damage
seals.Brakepartscleanerleavesno residue. Useelectrical
contact cleaner to clean electrical connections and com
-
ponents without leaving any residue. Carburetor cleaner
is a powerful solvent used to remove fuel deposits and
varnish from
fad system components. Use this cleaner
carefully, as it may damagefinishes.
Generally, degreasers are strong cleaners used to re
-
move heavy accumulations of grease from engine and
frame components.

8 CHAPTER ONE
Mostsolventsareusedina partswashingcabinetfor in -
dividual component cleaning. For safety, use only non -
flammableor high flash point solvents.
GasketSealant
Sealants are used in combination with a gasket or seal
and are occasionally alone. Follow the manufacturer's
recommendation when using sealants. Use extreme care
when choosinga sealantdifferentfrom the typeoriginally
recommended.Choose sealants based on their resistance
to heat, various fluids and their scalingcapabilities.
Oneofthe mostcommonsealantsisRTV, or room tem
-
perature vulcanizing sealant. This sealant cures at room
temperatureover a specific time period. This allows the
repositioningof components without damaginggaskets.
Moisturein the air causes the
RTV sealant to cure. Al -
waysinstall thetubecapassoonaspossibleafterapplying
RTV sealant.
RTV sealant has a limited shelf life and will
notcureproperlyif theshelflifehas expired.Keep partial
tubes sealed and discard them if they have surpassed the
expirationdate.
Applying RTV sealant
Clean all old gasket residue from the mating surfaces.
Remove all gasket material from blind threaded holes; it
can cause inaccurate bolt torque. Spray the mating sur
-
faces with aerosol parts cleaner and then wipe with a
lint
- free cloth. The area must be clean for the sealant to
adhere.
Apply
RTV sealant in a continuous bead 2 - 3 mm
(0.08 - 0.12 in.) thick. Circle all the fastener holes unless
otherwise specified. Do not allow any sealant to enter
these holes. Assemble and tighten the fasteners to the
specified torque within the time frame recommended by
the RTV sealant manufacturer.
Gasket Remover
Aerosolgasket removercan helpremovestubborn gas -
kets. This product can speed up the removal process and
preventdamagetothe matingsurfacethat may be caused
by using a scraping tool. Most of these types of products
are very caustic. Follow the gasket remover manufac-
turer's instructionsfor use.
ThreadlockingCompound
A threadlocking compound is a fluid applied to the
threadsoffasteners.Aftertighteningthefastener,thefluid
dries and becomesa solid filler between the threads.This
makes
it difficult for the fastener to work loose from vi -
bration, or heat expansion and contraction. Some
threadlockingcompoundsalsoprovideasealagainstQuid
leakage.
Before applying threadlockingcompound remove any
old compoundfromboth threadareasandcleanthemwith
aerosol parts cleaner. Use the compound sparingly.
Ex -
cess fluid can run into adjoining parts.
Threadlockingcompoundscome in differentstrengths.
Follow the particular manufacturer's recommendations
regarding compound selection. Two manufacturers of
threadlocking compound are ThreeBond and Loctite
which offer a wide range of compounds for various
strength, temperatureand repair applications.
BASIC TOOLS
Mostof theproceduresin thismanual can becarriedout
with simple hand tools and test equipment familiar to the
homemechanic.Alwaysusethecorrecttoolsforthejobat
hand. Keeptoolsorganizedandclean.Storethem in a tool
chest with related tools organizedtogether.
Quality tools are essential. The best are constructed of
high
- strengthalloy steel. Thesetoolsare light, easy touse

GENERAL INFORMATION 9
and resistant to wear. Their working surface is devoid of
sharpedges and the tool is carefully polished.They have
an easy
- to - clean finish and are comfortableto use. Qual -
ity toolsare a good investment.
When purchasing toolsto perform the procedurescov
-
ered in this manual, consider the potential frequency of
use. Ifstartinga tool kit, consider purchasinga basictool
set from a large tool supplier. These sets are available in
many tool combinations and offer substantial savings
whencompared to individuallypurchasedtools. As work
experience grows and tasks become more complicated,
specialized tools can be added.
Screwdrivers
Screwdriversof various lengths and types are manda -
tory for the simplest tool kit. The two basic types are the
slottedtip (flatblade)and the Phillipstip.These areavail
-
able in sets that often include an assortment of tip sizes
and shaftlengths.
Aswithalltools,useascrewdriverdesignedforthejob.
Make sure the size of the tip conforms to the size and
shape of the fastener. Use them only for driving screws.
Neverusea screwdriverforpryingor chiselingmetal. Re
-
pairor replaceworn or damagedscrewdrivers.Aworn tip
may damage the fastener, making it difficulttoremove.
Wrenches
Box - end,open - end and combinationwrenches (Figure
10) come in a varietyof types and sizes.
The number stamped on the wrench refers to the dis
-
tance between the work areas. This size must match the
size of the fastener head.
Thebox
- end wrench isanexcellenttoolbecauseitgrips
the fastener on all sides. This reduces the chance of the
tool slipping.The box
- endwrenchisdesigned with either
a 6 or 12
- pointopening. For stubbornor damagedfasten -
ers, the 6 - point providessuperior holdingability by con -
tactingthefasteneracrossa widerareaatallsixedges. For
generaluse, the 12
- point workswell.Itallows thewrench
to be removed and reinstalledwithoutmoving the handle
oversuch a wide arc.
Anopen
- endwrenchisfast and worksbest inareaswith
limited overhead access. It contacts the fastener at only
twopoints,and canslip under heavyforce,or ifthetool or
fastener is worn. A box
- end wrench is preferred in most
instances, especially when breaking loose and applying
the final tightness to a fastener.
Thecombinationwrenchhasa box
- endon oneend,and
an open
- end on the other. This combination makes it a
very convenient tool.
Adjustable Wrenches
An adjustable wrench or Crescent wrench (Figure 11)
can fit nearly any nut or bolt head that has clear access
around its entire perimeter. Adjustablewrenchesare best
used as a backup wrench to keep a large nut or bolt from
turningwhilethe other end is beingloosened or tightened
with a box
- end or socket wrench.
Adjustable wrenches contact the fastener at only two
points,which makesthemmore subjecttoslippingoffthe
fastener. The fact that one jaw is adjustable and may
loosen only aggravates this shortcoming. Make certain
the solidjaw is the one transmitting the force.
SocketWrenches,Ratchets and Handles
Sockets that attach to a ratchet handle (Figure 12) are
available with 6
- point (A, Figure 13) or 12 - point (B)
openings and different drive sizes. The drive size indi -
cates the size of the square hole that accepts the ratchet
handle. The number stamped on the socket is the size of
the workarea and must match the fastener head.

10 CHAPTER ONE
As with wrenches, a 6-point socket provides supe-
rior - holding ability, while a 12 - point socket needs to be
moved only half as far to repositionit on the fastener.
Sockets are designated for either hand or impact use.
Impact socketsare made of thicker material for more du
-
rability. Comparethe size and wall thicknessof a 19-mm
hand socket(A, Figure 14) and the 19 - mmimpactsocket
(B). Use impact sockets when using an impact driver or
airtools. Use handsocketswith hand
- drivenattachments.
WARNING
Do not use hand sockets with air
or impact
tools, as they may shatter
and cause injury.
Always weareyeprotectionwhen using
im -
pact or air tools.
Various handles are available for sockets. The speed
handleis used for fastoperation.Flexibleratchet headsin
varyinglengthsallowthe socketto be turned withvarying
force, and at odd angles. Extensionbars allow the socket
setup to reach difficult areas. The ratchet is the most ver
-
satile.It allows the user to installor remove the nut with -
out removingthe socket.
Sockets combined with any number of drivers make
themundoubtedlythe fastest,safest and most convenient
tool for fastenerremoval
and installation.
ImpactDriver
Animpactdriver provides extra forcefor removingfas -
teners,by convertingthe impactof a hammer intoa turn -
ing motion. This makes it possible to remove stubborn
fasteners without damagingthem. Impact drivers and in
-
terchangeable bits (Figure 15) are available from most
toolsuppliers.When using a socket with an impactdriver
make sure the socket is designedfor impact use. Refer to
Socket Wrenches, Ratchets and Handles in thissection.
WARNING
Do not use hand sockets with air or impact
tools as they
may shatter and cause injury.
Always wear eye protectionwhen using im -
pact or air tools,
Allen Wrenches
Allenorsetscrewwrenches (Figure 16) areusedonfas -
tenerswithhexagonalrecessesinthefastenerhead.These
wrenches come
in L - shaped bar, socket and T-handle
types. Use a metric set when working on most vehicles.
Allen bolts are sometimescalled socket bolts.
Torque Wrenches
Atorquewrenchisused witha socket,torqueadapteror
similar extension to tighten a fastener to a measured
torque.Torquewrenchescomein severaldrivesizes
(1/4,
3/8, 12 and 3⁄4 and have various methods of reading the
torque value. The drivesizeis the sizeof the square drive
that accepts the socket, adapter or extension. Common
methods of reading the torque value are the deflecting
beam
(A, Figure 17), the dial indicator (B) and the audi -
ble click (C).

GENERAL INFORMATION
When choosing a torque wrench, consider the torque
range, drive size and accuracy. The torque specifications
in thismanualprovideanindication oftherangerequired.
A torque wrench is a precision tool that must be prop -
erlycaredfortoremainaccurate.Store torquewrenchesin
cases or separate padded drawers within a toolbox. Fol
-
lowthe manufacturer's instructionsfor theircareand cali -
bration.
To recalculate a torque reading when using a torque
adapter, use thefollowingformula,and referto
Figure 18.
TW is the torque setting or dial reading on the
is the torque specification and the actual
amount of torque that will be applied to the fastener.
A is
theamountthat theadapterincreases(or in somecases re
-
duces) the effective lever length as measured along the
centerlineof the torquewrench
(Figure 19). L is the lever
length of the wrench as measured from the center of the
drive to the center of the grip. The effectivelength of the
torquewrench measured alongthe centerlineofthetorque
wrench is the sum of
L and A (Figure 19).
Example:
TA 20
A= 3 in.
14 in.
TW
20 x 14 = 16.5 ft. Lb.
= 17
In this example, the torque wrench would be set to the
recalculatedtorquevalue
(TW = 16.5 ft.-lb.). When using
a beam
- type wrench, tighten the fasteneruntil the pointer
aligns with 16.5 ft.-lb. In this example, although the
torquewrench is pre
- set to 16.5 ft.-lb., theactualtorqueis
20 ft.-lb.
Pliers
Torque Adapters
Torque adapters or extensions extend or reduce the
reach of a torque wrench. The torque adapter shown in
Figure 18 is used to tighten a fastener that cannot be
reached due to the size of the torque wrench head, drive,
and socket. If a torqueadapterchanges the effectivelever
length
(Figure 191), the torquereadingon the wrench will
not equal the actual torque applied to the fastener. It is
necessary to recalibratethe torque setting on the wrench
tocompensatefor the changeof lever length. When using
a torqueadapterat a right angle to thedrivehead. calibra
-
tion is not required, since the effective length has not
changed.
Plierscomein awide rangeoftypesandsizes.Pliersare
useful forholding,cutting,bending,and crimping.Do not
use themto turnfasteners.
Figure 20 and Figure 21 show
several types of useful pliers. Each design has a special
-
ized function. Slip - jointpliers are general - purposepliers
used forgrippingand bending.Diagonalcuttingpliersare
neededto cut wireand can be used to removecotter pins.
Needlenosepliers are used to hold or bend small objects.
Locking pliers
(Figure 21), sometimescalled vise - grips,
are used to holdobjectsvery tightly. Theyhave manyuses
ranging from holding two parts together, to gripping the
end ofa broken stud. Use cautionwhen using lockingpli
-
ers, as the sharp jaws will damage the objects they hold.

12 CHAPTER ONE
HOW TO MEASURE TORQUE WRENCH EFFECTIVELENGTH
L A Effectivelength (E)
Effectivelength (E)
No calculationneeded
Snap Ring Pliers
Snapringorsnapringpliers(Figure
22) arespecialized
pliers with tips that fit into the ends of snap rings to re
-
move and install them.
Snap ringpliersare availablewith a fixedaction(either
internal or external) or convertible (one tool works on
both internal and external snap rings). They may have
fixedtips or interchangeableonesofvarioussizes and an
-
gles. For general use, select a convertibletype plier with
interchangeabletips.
WARNING
Snap ringscan slip and fly off whenremov -
ing and installingthem. Also, the snap ring
plier tips may break. Always wear eye pro-
tection when using snap ring pliers.
Hammers
Various types of hammers(Figure
23) are availableto
fit a numberof applications. A ball - peenhammer is used
tostrikeanothertool,suchas apunchorchisel.Soft
- faced
hammersarerequiredwhen a metal object mustbe struck
withoutdamaging
it. Never usea metal - faced hammeron
engineandsuspensioncomponents, asdamage will occur
in mostcases.
Always wear eye protection when using hammers.
Make sure the hammer face is in good condition and the
handle is not cracked. Select the correct hammer for the
job and makesure tostrike theobjectsquarely.Do notuse
the handle or the side of the hammerto strike an object.
PRECISIONMEASURINGTOOLS
The ability to accuratelymeasurecomponentsis essen -
tialtosuccessfullyrebuild an engine.Equipmentis manu-

GENERALINFORMATION 13
factured to close tolerances, and obtaining consistently
accurate measurements is essential to determiningwhich
componentsrequire replacementor furtherservice.
Each type of measuringinstrumentis designed to mea
-
sure a dimension with a certain degree of accuracy and
withinacertainrange.When selectingthe measuringtool,
make sure it is applicableto the task.
As with all tools, measuring tools provide the best re
-
sults if cared for properly. Improper use can damage the
tooland resultin inaccurateresults.If any measurementis
questionable,verify the measurementusing another tool.
A standard gauge is usually provided with measuring
toolsto check accuracy and calibratethe tool ifnecessary.
Precision measurementscan vary according to the ex
-
perience of the person performing the procedure. Accu -
rate results are only possibleif the mechanicpossessesa
feel for using the tool. Heavy
- handed use of measuring
tools produces less accurate results than if the tool is
grasped gently by the fingertips so the point at which the
tool contacts the object is easily felt. This feel for the
equipmentproducesmore accuratemeasurementsand re
-
duces the risk of damaging the tool or component. Refer
to the followingsections for specific measuring tools.
Feeler Gauge
The feeler or thickness gauge (Figure
24) is used for
measuringthe distance between two surfaces.
A feeler gauge set consists of an assortment of steel
strips of graduated thickness.Each blade is marked with
its thickness.Blades can be of variouslengthsand angles
for differentprocedures.
A common use for a feeler gauge is to measure valve
clearance. Wire (round) type gauges are used to measure
spark plug gap.

14 CHAPTER ONE
Calipers
Calipers (Figure 25) are excellent tools for obtaining
inside, outsideand depth measurements.Although not as
precise
as a micrometer, they allow reasonable precision,
typically to within 0.05 mm (0.001 in.). Most calipers
have a rangeup to 150 mm
(6 in.).
Calipersareavailablein dial,vernierordigitalversions.
Dial calipershave a dialreadoutthat providesconvenient
reading. Vernier calipershave markedscales that must be
compared todeterminethemeasurement.The digitalcali
-
per uses an LCD to show the measurement.
Properlymaintain themeasuringsurfacesofthecaliper.
There must not be any dirt or burrs between the tool and
the objectbeingmeasured.Never force the caliperclosed
around an object: close the caliper around the highest
point so it can be removed with a slight drag. Some cali
-
pers require calibration. Always refer to the manufac-
turer's instructions when using a new or unfamiliar
caliper.
To read a verniercaliper refer to
Figure 26. The fixed
scale is marked
in 1 mm increments.Ten individual lines
on the fixed scale equal 1 cm. The movable scale is
marked in 0.05 mm (hundredth) increments.To obtain a
reading, establishthe first numberby the locationof the0
lineon the movablescale in relationto the first line to the
left on the fixed scale. In this example, the number is
10
mm. To determine the next number, note which of the
lineson the movablescale align with a mark on the fixed
scale.Anumber oflineswillseem close,but onlyone will
alignexactly.In thiscase,0.50 mm isthereadingto add to
thefirstnumber.Theresultofadding10mm and0.50 mm
is a measurementof 10.50 mm.
Micrometers
A micrometer (Figure 27) isaninstrumentdesignedfor
linear measurement using the decimal divisions of the
inch or meter. While there are many types and styles of
micrometers, most of the procedures in this manual call
foranoutsidemicrometer.Theoutsidemicrometerisused
to measure the outside diameter of cylindricalforms and
the thicknessof materials.
A micrometer's size indicatesthe minimum and maxi -
mum size of a part that it can measure. The usual sizes
(Figure 27) are0 - 1 in.(0 - 25mm),1 - 2in. (25 - 50mm),2 - 3
in. (50
- 75mm) and 3 - 4 in. (75 - 100 mm).
Micrometersthat cover a wider range of measurement
are available. These use a large frame with interchange
-
ableanvilsof variouslengths.This typeof micrometerof -
fers a cost savings;however,its overall size may make it
less convenient.
Readinga Micrometer
When reading a micrometer, numbers are taken from
different scales and added together. The following sec
-
tions describe how to read the measurements of various
typesof outside micrometers.
For accurate results, properly maintain the measuring
surfaces of the micrometer. There cannot be any dirt or
burrs between the tool and the measured object. Never
force the micrometerclosed around an object. Close the
micrometeraroundthehighest pointso it can he removed
with a slight drag.
Figure 28 shows the markings and
parts of a standard inch micrometer. Be familiar with
these terms before using a micrometer in the follow sec
-
tions.
Standard inch micrometer
The standard inch micrometer is accurate to
one
- thousandthof an inch or 0.001. The sleeve is marked
in 0.025 in. increments.Every fourth sleevemarkis num
-
bered 1,2,3,4,5,6,7,8,9.Thesenumbersindicate0.100
in., 0.200 in.,0.300 in., and so on.
The tapered end of the thimble has twenty
- five lines
marked around it. Each mark equals 0.001 in. One com
-
plete turn of the thimble will align its zero mark with the
first mark on the sleeve or 0.025 in.
When reading a standardinch micrometer, performthe
following steps while referring to
Figure 29.
1. Read the sleeve and find the largest number visible.
Each sleeve number equals 0.100 in.
2. Count the number of lines between the numbered
sleevemark
and theedgeofthethimble.Eachsleevemark
equals 0.025 in.
3. Read the thimblemark that aligns with thesleeve line.
Each thimblemark equals0.001 in.