Yamaha VX600ERG User manual

VX600ERG
SX600G
MM600G
VT600G
SERVICE MANUAL
LIT-12618-02-20 8EA-28197-10
981059

HOWTO USE THIS MANUAL
Particularly important information is distinguished in
this manual by the following notations:
The Safety Alert Symbol means ATTENTION!
BE ALERT! YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result
insevereinjuryordeathtothesnowmobileoperator,
a bystander, or a person inspecting or repairing the
snowmobile.
CAUTION:
A CAUTION indicates special precautions that must
be taken to avoid damage to the snowmobile.
NOTE:
A NOTE provides key information that can make
procedures easier or clearer.
MANUAL FORMAT
All of the procedures in this manual are organized in
a sequential, step-by-step format. The information
has been compiled to provide the mechanic with an
easytoread, handy reference that containscompre-
hensiveexplanationsofallinspection,repair,assem-
bly, and disassembly operations.
Inthisrevisedformat,theconditionofafaultycompo-
nent will precede an arrow symbol and the course of
action required to correct the problem will follow the
symbol, e.g.,
•Bearings
Pitting/damage →Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before
each disassembly section to facilitate correct disas-
sembly and assembly procedures.
NOTICE
ThismanualwaswrittenbytheYamahaMotorCom-
pany primarily for use by Yamaha dealers and their
qualifiedmechanics.Itisnotpossibleto putanentire
mechanic’s education into one manual, so it is as-
sumedthat personsusingthisbook toperformmain-
tenance and repairs on Yamaha snowmobiles have
a basic understanding of the mechanical concepts
andprocedures inherentinsnowmobilerepair. With-
out such knowledge, attempted repairs or service to
this model may render it unfit and/or unsafe to use.
Yamaha Motor Company, Ltd. is continually striving
to improve all models manufactured by Yamaha.
Modifications and significant changes in specifica-
tionsorprocedureswillbeforwardedtoallauthorized
Yamaha dealers and will, where applicable, appear
in future editions of this manual.
VX600ER, SX600, MM600, VT600
SERVICE MANUAL
2001 by Yamaha Motor
Corporation, U.S.A.
1st Edition, June 2001
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N.LIT-12618-02-20

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1to 9are designed as thumb
tabs to indicate the chapter’s number and content.
1General information
2Periodic inspection and adjustment
3Chassis
4Power train
5Engine
6Cooling system
7Carburetion
8Electrical
9Specifications
Illustrated symbols 0to Fare used to identify the
specifications which appear.
0Filling fluid
ALubricant
BTightening
CWear limit, clearance
DEngine speed
ESpecial tool
FΩ, V, A
Illustrated symbols Gto Oin the exploded diagram
indicate grade of lubricant and location of lubrication
point.
GApply locking agent (LOCTITE®)
HApply Yamabond No.5®
IApply engine oil
JApply gear oil
KApply molybdenum disulfide oil
LApply wheel bearing grease
MApply low-temperature lithium-soap base grease
NApply molybdenum disulfide grease
OUse new one
1
3
5
7
9
0
F
I
L
4
6
8
G
K
MN
CHAS
POWR
TR
ENG
COOL
–+
ELEC
GEN
INFO
SPEC
H
J
B
M
G
E
5
LT
M
CARB
INSP
ADJ
2
A
CDE
B
O
New
T
R
.
.
LS

–+
GENERAL INFORMATION
PERIODIC INSPECTION AND
ADJUSTMENT
CHASSIS
POWERTRAIN
ENGINE
COOLING SYSTEM
CARBURETION
ELECTRICAL
SPECIFICATIONS
INDEX
GEN
INFO
CHAS
ENG
POWR
TR
CARB
ELEC
SPEC
COOL
1
INSP
ADJ 2
3
4
5
6
7
8
9

CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION............................ 1-1
FRAME SERIAL NUMBER......................... 1-1
ENGINE SERIAL NUMBER ....................... 1-1
IMPORTANT INFORMATION .......................... 1-2
PREPARATION FOR REMOVAL AND
DISASSEMBLY .......................................... 1-2
ALL REPLACEMENT PARTS .................... 1-2
GASKETS, OIL SEALS, AND O-RINGS .... 1-3
LOCK WASHERS/PLATES AND COTTER
PINS ........................................................... 1-3
BEARINGS AND OIL SEALS ..................... 1-3
CIRCLIPS ................................................... 1-3
LOCTITE®................................................... 1-3
SPECIAL TOOLS ............................................. 1-4
FOR TUNE UP ........................................... 1-4
FOR ENGINE SERVICE ............................ 1-5
FOR POWER TRAIN SERVICE................. 1-5
FOR CARBURETION SERVICE ................ 1-6
FOR ELECTRICAL SERVICE .................... 1-6
CHAPTER 2.
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION............................................... 2-1
PERIODIC MAINTENANCE TABLE ................ 2-1
ENGINE ............................................................ 2-3
SPARK PLUGS .......................................... 2-3
OIL PUMP .................................................. 2-4
FUEL LINE INSPECTION .......................... 2-6
COOLING SYSTEM ................................... 2-6
CARBURETOR SYNCHRONIZATION..... 2-12
ENGINE IDLE SPEED ADJUSTMENT .... 2-13
THROTTLE CABLE FREE PLAY
ADJUSTMENT ......................................... 2-13
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK.................................... 2-14
STARTER (CHOKE) CABLE FREE PLAY
ADJUSTMENT ......................................... 2-15
EXHAUST SYSTEM INSPECTION.......... 2-15
POWER TRAIN............................................... 2-16
SHEAVE DISTANCE AND OFFSET
ADJUSTMENT ......................................... 2-16
DRIVE V-BELT ......................................... 2-18
ENGAGEMENT SPEED CHECK ............. 2-20
PARKING BRAKE PAD INSPECTION..... 2-20
PARKING BRAKE ADJUSTMENT ........... 2-21
BRAKE LEVER ADJUSTMENT
(VX600ER/SX600/VT600) ........................ 2-21
BRAKE FLUID LEVEL INSPECTION....... 2-22
BRAKE PAD INSPECTION ...................... 2-22
BRAKE HOSE INSPECTION ................... 2-23
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM) ............. 2-23
DRIVE CHAIN .......................................... 2-24
TRACK TENSION ADJUSTMENT ........... 2-27
SLIDE RUNNER INSPECTION................ 2-29
MAXIMIZING DRIVE TRACK LIFE .......... 2-30
CHASSIS ........................................................ 2-31
SKI/SKI RUNNER..................................... 2-31
STEERING SYSTEM ............................... 2-32
LUBRICATION ......................................... 2-33
ELECTRICAL ................................................. 2-35
HEADLIGHT BEAM ADJUSTMENT......... 2-35
BATTERY INSPECTION
(VX600ER/VT600).................................... 2-36
BATTERY CHARGING
(VX600ER/VT600).................................... 2-38
FUSE INSPECTION (VX600ER/VT600) .. 2-39
TUNING .......................................................... 2-41
CARBURETOR TUNING.......................... 2-41
CLUTCH ................................................... 2-48
GEAR SELECTION .................................. 2-53
HIGH ALTITUDE TUNING ....................... 2-59
FRONT SUSPENSION............................. 2-60
REAR SUSPENSION ............................... 2-61
CHAPTER 3.
CHASSIS
STEERING........................................................ 3-1
VX600ER/SX600/VT600 ............................ 3-1
MM600........................................................ 3-2
INSPECTION.............................................. 3-4
INSTALLATION .......................................... 3-5

SKI .................................................................... 3-8
VX600ER/VT600 ........................................ 3-8
SX600/MM600............................................ 3-9
INSPECTION............................................ 3-10
INSTALLATION
(VX600ER/VT600).................................... 3-10
FRONT SUSPENSION ................................... 3-11
HANDLING NOTES (SX600) ................... 3-12
INSPECTION............................................ 3-12
INSTALLATION ........................................ 3-14
CHAPTER 4.
POWERTRAIN
PRIMARY SHEAVE AND DRIVE V-BELT ....... 4-1
REMOVAL .................................................. 4-3
DISASSEMBLY .......................................... 4-4
INSPECTION.............................................. 4-5
ASSEMBLY ................................................ 4-7
INSTALLATION ........................................ 4-10
SECONDARY SHEAVE ................................. 4-11
DISASSEMBLY ........................................ 4-13
INSPECTION............................................ 4-13
ASSEMBLY .............................................. 4-14
INSTALLATION ........................................ 4-16
DRIVE CHAIN HOUSING ............................... 4-17
WITHOUT REVERSE MODEL................. 4-17
INSPECTION............................................ 4-18
INSTALLATION ........................................ 4-20
WITH REVERSE MODEL ........................ 4-21
INSPECTION............................................ 4-23
INSTALLATION ........................................ 4-24
JACKSHAFT .................................................. 4-26
INSPECTION............................................ 4-27
JACKSHAFT AND DRIVE CHAIN
HOUSING INSTALLATION ...................... 4-28
BRAKE ........................................................... 4-29
BRAKE PAD REPLACEMENT ................. 4-30
BRAKE CALIPER DISASSEMBLY........... 4-34
BRAKE CALIPER INSPECTION AND
REPAIR .................................................... 4-34
BRAKE CALIPER ASSEMBLY................. 4-35
BRAKE CALIPER INSTALLATION .......... 4-35
INSPECTION............................................ 4-37
BRAKE MASTER CYLINDER
ASSEMBLY .............................................. 4-37
INSTALLATION ........................................ 4-37
SLIDE RAIL SUSPENSION............................ 4-38
VX600ER/SX600 ...................................... 4-38
VT600 ....................................................... 4-39
MM600...................................................... 4-44
INSPECTION............................................ 4-49
ASSEMBLY .............................................. 4-50
INSTALLATION ........................................ 4-50
FRONT AXLE AND TRACK........................... 4-52
INSPECTION............................................ 4-53
INSTALLATION ........................................ 4-53
CHAPTER 5.
ENGINE
EXHAUST ASSEMBLY .................................... 5-1
INSTALLATION .......................................... 5-2
ENGINE ASSEMBLY ....................................... 5-3
INSPECTION.............................................. 5-4
INSTALLATION .......................................... 5-4
CYLINDER HEAD AND CYLINDER ................ 5-6
REMOVAL .................................................. 5-8
INSPECTION.............................................. 5-9
INSTALLATION ........................................ 5-14
OIL PUMP, CRANKCASE AND
CRANKSHAFT ............................................... 5-17
INSPECTION............................................ 5-18
INSTALLATION ........................................ 5-20
AC MAGNETO................................................ 5-23
REMOVAL ................................................ 5-24
INSTALLATION ........................................ 5-25
RECOIL STARTER......................................... 5-27
REMOVAL ................................................ 5-28
INSPECTION............................................ 5-28
INSTALLATION ........................................ 5-29

CHAPTER 6.
COOLING SYSTEM
HEAT EXCHANGER ........................................ 6-1
VX600ER/SX600/VT600 ............................ 6-1
MM600........................................................ 6-2
INSPECTION.............................................. 6-3
INSTALLATION .......................................... 6-4
WATER PUMP.................................................. 6-5
REMOVAL .................................................. 6-6
INSPECTION.............................................. 6-6
INSTALLATION .......................................... 6-6
CHAPTER 7.
CARBURETION
CARBURETORS .............................................. 7-1
INSPECTION.............................................. 7-5
ASSEMBLY ................................................ 7-6
CARBURETOR SYNCHRONIZATION....... 7-7
FUEL LEVEL ADJUSTMENT ..................... 7-8
INSTALLATION .......................................... 7-9
FUEL PUMP ................................................... 7-10
VX600ER/VT600 ...................................... 7-10
SX600/MM600.......................................... 7-11
INSPECTION............................................ 7-12
INSTALLATION ........................................ 7-12
CHAPTER 8.
ELECTRICAL
SWITCH INSPECTION ..................................... 8-1
SWITCH INSPECTION .............................. 8-1
INSPECTING A SWITCH SHOWN IN THE
MANUAL..................................................... 8-1
IGNITION SYSTEM .......................................... 8-2
CIRCUIT DIAGRAM ................................... 8-2
TROUBLESHOOTING ............................... 8-4
CONDENSER (SX600/MM600) ................. 8-6
AC MAGNETO ........................................... 8-6
SPARK PLUG............................................. 8-7
SPARK PLUG CAP .................................... 8-7
IGNITION COIL .......................................... 8-7
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) ................................................... 8-8
HANDLEBAR SWITCH (RIGHT)................ 8-8
CARBURETOR SWITCH ........................... 8-9
MAIN SWITCH ........................................... 8-9
LOAD CONTROL RELAY ........................ 8-10
EMERGENCY ENGINE STARTING
(SX600/MM600) ....................................... 8-10
ELECTRICAL STARTING SYSTEM
(VX600ER/VT600) .......................................... 8-11
CIRCUIT DIAGRAM ................................. 8-11
TROUBLESHOOTING ............................. 8-12
MAIN SWITCH ......................................... 8-13
STARTER MOTOR .................................. 8-14
CHARGING SYSTEM (VX600ER/VT600) ...... 8-18
CIRCUIT DIAGRAM ................................. 8-18
TROUBLESHOOTING ............................. 8-19
BATTERY ................................................. 8-20
STATOR COIL.......................................... 8-20
LIGHTING SYSTEM ....................................... 8-22
CIRCUIT DIAGRAM ................................. 8-22
TROUBLESHOOTING ............................. 8-24
BULB(S) ................................................... 8-26
HEADLIGHT BEAM SWITCH................... 8-26
HEADLIGHT RELAY ................................ 8-27
SIGNAL SYSTEM........................................... 8-28
CIRCUIT DIAGRAM ................................. 8-28
TROUBLESHOOTING ............................. 8-30
BRAKE LIGHT SWITCH........................... 8-34
GEAR POSITION SWITCH
(VX600ER/VT600).................................... 8-34
DC BACK BUZZER (VX600ER/VT600) ... 8-34
WATER TEMPERATURE SENSOR ........ 8-35
OIL LEVEL SWITCH ................................ 8-36
FUEL SENDER ........................................ 8-36
GRIP WARMER SYSTEM .............................. 8-38
CIRCUIT DIAGRAM ................................. 8-38
TROUBLESHOOTING ............................. 8-40
GRIP AND THUMB WARMER COIL........ 8-42
VARIABLE RESISTOR
(THUMB WARMER) ................................. 8-42
VARIABLE RESISTOR
(GRIP WARMER) ..................................... 8-43

PASSENGER GRIP WARMER (VT600) .. 8-43
PASSENGER GRIP WARMER
SWITCH (VT600) .................................... 8-44
RESISTOR (VT600) ................................. 8-44
PASSENGER GRIP WARMER RELAY
(VT600)..................................................... 8-45
FAULT LOCATION TABLE............................ 8-46
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 ........................... 9-15
GENERAL TORQUE SPECIFICATIONS ....... 9-19
DEFINITION OF UNITS .................................. 9-19
CABLE ROUTING .......................................... 9-21

1-1
GEN
INFO
MACHINE IDENTIFICATION
GENERAL INFORMATION
MACHINE IDENTIFICATION
FRAME SERIAL NUMBER
Theframeserialnumber1islocatedontheright-handsideoftheframe(just
below the front of the seat).
ENGINE SERIAL NUMBER
The engine serial number 1is located on the right-hand side of the
crankcase.
NOTE:
Designs and specifications are subject to change without notice.
SEA1010
SEA1020

1-2
GEN
INFO
IMPORTANT INFORMATION
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
1.Remove all dirt, mud, dust, and foreign material before removal and
disassembly.
While cleaning, take care to protect the electrical parts, such as relays,
switches, motor, resistors, controllers, etc., from high pressure water
splashes.
2.Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS”.
3.When disassembling the machine, keep mated parts together. This
includes gears, cylinders, pistons, and other parts that have been
“mated” through normal wear. Mated parts must be reused or replaced
as an assembly.
4.During disassembly of the machine, clean all parts and place them in
trays in the order of disassembly. This will speed up assembly time and
help ensure that all parts are reinstalled correctly.
5.Keep all parts away from any source of fire.
6.Be sureto keep tothe tightening torquespecifications. When tightening
bolts, nuts, and screws, start with those that have larger diameters, and
proceed from the inside to the outside in a crisscross pattern.
ALL REPLACEMENT PARTS
We recommend using genuine Yamaha parts for all replacements. Use oil
and grease recommended by Yamaha for assembly and adjustments.
SEA1030
SEA1040
SEA1050
SEA1060
SEA1070
SEA1080
1

1-3
GEN
INFO
IMPORTANT INFORMATION
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.
LOCK WASHERS/PLATES AND COTTER PINS
All lock washers/plates 1and cotter pins must be replaced if they are
removed.Locktab(s)shouldbebentalongtheboltornutflat(s)afterthebolt
or nut has been properly tightened.
BEARINGS AND OIL SEALS
Install the bearings 1and oil seals 2with their manufacturer’s marks or
numbers facing outwards. (In other words, the stamped letters must be on
the side exposed to view.) When installing oil seals, apply a light coating of
lightweightlithiumbasegreasetotheseallips.Oilthebearingsliberallywhen
installing.
CAUTION:
Do not use compressed air to spin the bearings dry. This causes
damage to the surface of the bearings.
CIRCLIPS
Allcirclipsshouldbeinspectedcarefullybeforereassembly.Alwaysreplace
piston pin clips after one use. Replace misshapen circlips. When installing
acirclip1, make sure thatthesharpedgedcorner2is positioned opposite
to the thrust 3it receives. See the sectional view.
4Shaft
LOCTITE®
After installing fasteners that have LOCTITE®applied, wait 24 hours before
using the machine. This will give the LOCTITE®time to dry properly.
SEA1090
SEA1100
SEA1110
SEA1120

1-4
GEN
INFO
SPECIALTOOLS
SPECIALTOOLS
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:
Besuretousethecorrectpartnumberwhenorderingthetool,sincethepart
number may differ according to country.
FOR TUNE UP
•Sheave gauge
P/N: YS-42421-1 (15 mm offset) 1
YS-42421-2 (20 mm offset) 2
This gauge is used to measure the sheave distance and for offset adjust-
ment.
•Dial gauge
P/N: YU-03097 (for U.S.A./Canada)
90890-03097 (for Europe)
This gauge is used for run out measurement.
•Fuel level gauge
P/N: YM-01312-A (for U.S.A./Canada)
90890-01312 (for Europe)
This gauge is used to measure the fuel level in the float chamber.
•Distance gauge
P/N: YS-91047-3 (for U.S.A./Canada)
90890-01702 (for Europe)
This gauge is used to measure the distance between the center of the
primary sheave and the center of the secondary sheave.
SEA1130
SEA1160
SEA1150
SEA1140

1-5
GEN
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.
•Rotor holding puller
P/N: YU-33270 1(for U.S.A./Canada)
90890-01362 2(for Europe)
This tool is used to remove the magneto rotor.
•Cooling system tester
P/N: YU-24460-01 (for U.S.A./Canada)
90890-01325 (for Europe)
This tester is used for checking the cooling system.
FOR POWER TRAIN SERVICE
•Primary sheave holder
P/N: YS-01880 (for U.S.A./Canada)
90890-01701 (for Europe)
This tool is used to hold the primary sheave.
•Primary sheave puller (18 mm)
P/N: YS-01881-1 1, YS-01859-1 2
This tool is used for removing the primary sheave.
•Clutch spider separator
P/N: YS-28890-C
This tool is used when disassembling and assembling the primary sheave.
•Clutch separator adapter
P/N: YS-34480
This tool is used when disassembling and assembling the primary sheave.
SPECIALTOOLS
SEA1170
SEA1180
SEA1190
SEA1200
SEA1210
SEA1220
SEA1230
SEA1240
1
2

1-6
GEN
INFO
SPECIALTOOLS
•YXR clutch bushing jig kit
P/N: YS-39752
This tool is used for removal and installation of primary clutch weight and
roller bushings.
•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).
•Track clip installer
P/N: YS-91045-A
This tool is used for installing the track clip.
•Angle finder
P/N: YS-42422
This tool is used for checking and adjusting the ski spindle camber.
FOR CARBURETION SERVICE
•Mity vac
P/N: YS-42423 (for U.S.A./Canada)
90890-06756 (for Europe)
This tool is used to check the fuel pump.
FOR ELECTRICAL SERVICE
•Pocket tester
P/N: YU-03112 (for U.S.A./Canada)
90890-03112 (for Europe)
This instrument is necessary for checking the electrical components.
•Electro tester
P/N: YU-33260-A
This instrument is invaluable for checking the electrical system.
SEA1260
SEA1270
SEA1280
SEA1290
SEA1300
SEA1310
SEA1250

2-1
INSP
ADJ
Spark plugs
Engine oil
Fuel
Fuel filter
Fuel line
Oil line
Engine coolant
Carburetors
Recoil starter
Engine stop switch
Throttle override system
(T.O.R.S.)
Throttle lever
Exhaust system
Decarbonization
Drive guard
V-belt
Drive track and idler wheels
Slide runners
Brake and parking brake
Check condition.
Adjust gap and clean.
Replace if necessary.
Check oil level.
Air bleed the oil pump if necessary.
Check fuel level.
Check condition.
Replace if necessary.
Check fuel hose for cracks or damage.
Replace if necessary.
Check oil hose for cracks or damage.
Replace if necessary.
Check coolant level.
Air bleed the cooling system if necessary.
Check throttle lever operation.
Adjust the jets.
Check operation and rope damage.
Replace if necessary.
Check operation.
Repair if necessary.
Check operation.
Repair if necessary.
Check operation.
Repair if necessary.
Check for leakage.
Tighten or replace gasket if necessary.
More frequently if necessary.
Check for cracks, bends or damage.
Replace if necessary.
Check for wear and damage.
Replace if necessary.
Check deflection, and for wear and damage.
Adjust/replace if necessary.
Check for wear and damage.
Replace if necessary.
Check operation and fluid leakage.
Adjust free play and/or replace pads if necessary.
Replace brake fluid.
INTRODUCTION/PERIODIC MAINTENANCE TABLE
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These
preventivemaintenanceprocedures,iffollowed,willensuremorereliablemachineoperationandalongerservice
life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines
already in service as well as new machines that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE
Item Remarks Pre-
operation
check
(Daily)
Initial
1 month
or
800 km
(500 mi)
(40 hr)
Every
Seasonally
or
3,200 km
(2,000 mi)
(160 hr)
Whenever operating condition
(elevation/temperature) is changed.
See NOTE on page 2-2.

2-2
INSP
ADJ
PERIODIC MAINTENANCE TABLE
Check oil level.
Replace.
Check deflection.
Adjust if necessary.
Check for wear and damage.
Replace if necessary.
Check operation.
Adjust toe-out if necessary.
Check for damage.
Replace if necessary.
Check operation.
Replace bulbs if necessary.
Check fluid level.
Add only distilled water if necessary.
Check specific gravity and breather hose operation.
Charge/correct if necessary.
Check engagement and shift speed.
Adjust if necessary.
Inspect sheaves for wear/damage.
Inspect weights/rollers and bushings for wear-for pri-
mary.
Inspectrampshoes/bushingsforwear-forsecondary.
Replace if necessary.
Lubricate with specified grease.
Lubricate with specified grease.
Lubricate with specified grease.
Lubricate with specified grease.
Lubricate with specified grease.
Check cable damage.
Replace if necessary.
Make sure that the shroud latches are hooked.
Check tightness.
Repair if necessary.
Check for proper placement.
Whenever operating elevation is changed.
Initial at 500 km (300 mi) and every 800 km
(500 mi) thereafter.
Drive chain oil
Drive chain
Skis and ski runners
Steering system
Strap (MM600)
Lights
Battery
(VT600/VX600ER)
NOTE:
Brake fluid replacement:
1. Whendisassembling the master cylinderorcalipercylinder,replacethe brake fluid. Normallycheckthebrake
fluid level and add the fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Item Remarks Pre-
operation
check
(Daily)
Initial
1 month
or
800 km
(500 mi)
(40 hr)
Every
Seasonally
or
3,200 km
(2,000 mi)
(160 hr)
Primary and secondary
clutches
Steering column bearing
Ski and front suspension
Suspension component
Parking brake cable end
and lever end/throttle cable
end
Shroud latches
Fittings and fasteners
Tool kit and recommended
equipment
2

2-3
INSP
ADJ
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
3.Measure:
•Spark plug gap a
Out of specification → Regap.
Use a wire thickness gauge.
Spark plug gap:
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
If necessary, clean the spark plugs with a spark plug
cleaner.
Standard spark plug:
BR9ES (NGK)
Before installing a spark plug, clean the gasket sur-
face and spark plug surface.
4.Install:
•Spark plugs
Spark plug:
20 Nm (2.0 m · kg, 14 ft · lb)
NOTE:
Finger-tighten athe spark plug before torquing bit
to specification.
T
R
.
.
SEA2010
SEA2020
SEA2030

2-4
INSP
ADJ
1
1
1
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.
•The oil tank has been run empty.
•As part of the pre-delivery service.
1.Fill:
•Oil tank 1
Recommended oil:
YAMALUBE 2-cycle oil
Oil tank capacity:
3.0 L (2.6 Imp qt, 3.2 US qt)
2.Remove:
•Carburetors
Refer to “CARBURETORS” in CHAPTER 7.
3.Remove:
•Rear bracket (right) 1
4.Place a ragunderthe oil pump assembly tosoak
up any spilled oil.
5.Disconnect:
•Oil hose
6.Drain the oil until no more air bubbles appear in
the oil hose.
7.Connect:
•Oil hose
8.Disconnect:
•Oil delivery hose
9.Feed the “YAMALUBE 2-cycle oil” into the oil
delivery hose using an oil can for complete air
bleeding.
10.Connect:
•Oil delivery hose
11.Remove:
•Bleed bolt 1
•Gasket (bleed bolt)
12.Draintheoiluntilnomoreairbubblesappearfrom
the bleed hole.
13.Inspect:
•Gasket (bleed bolt)
Damage/wear →Replace.
SEA2050
SEA2060
SEA2040

2-5
INSP
ADJ
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.Install:
•Carburetors
Refer to “CARBURETORS” in CHAPTER 7.
Cable adjustment
NOTE:
Beforeadjustingtheoilpumpcable,thethrottlecable
free play should be adjusted.
Adjustment steps:
•Slide back the adjuster cover.
•Loosen the locknut 1.
•Turn the adjuster 2in or out until the specified
distance ais obtained.
Distance:
23 ±1 mm (0.906 ±0.039 in)
Turning in →Distance ais increased.
Turning out →Distance ais decreased.
•Tighten the locknut and push in the adjuster
cover.
SEA2070
SEA2080
T
R
.
.

2-6
INSP
ADJ
1
2
2
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:
•Intake silencer
Refer to “FUEL PUMP” in CHAPTER 7.
COOLING SYSTEM
Coolant replacement
NOTE:
The coolant should be changed at least every sea-
son.
1.Place the machine on a level surface.
2.Remove:
•Exhaust pipe
•Exhaust joint
Refer to “EXHAUST ASSEMBLY” in CHAP-
TER 5.
3.Make sure that the carburetor heating lever 1is
turned to “ON” a.
SEA2090
SEA2100
SEA2110