Yamaha MM600D User manual

MM600D
MM700D
SERVICE MANUAL
LIT-12618-02-12 8EJ-28197-10
(981033)

HOW TO 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 in severe injury or death to the snowmobile
operator, 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 snowmo-
bile.
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 informa-
tion has been compiled to provide the mechanic
with an easy to read, handy reference that con-
tains comprehensive explanations of all inspec-
tion, repair, assembly, and disassembly opera-
tions.
In this revised format, the condition of a faulty
component 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 dis-
assembly and assembly procedures.
NOTICE
This manual was written by the Yamaha Motor
Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to
put an entire mechanic’s education into one
manual, so it is assumed that persons using this
book to perform maintenance and repairs on
Yamaha snowmobiles have a basic understand-
ing of the mechanical concepts and procedures
inherent in snowmobile repair. Without such
knowledge, attempted repairs or service to this
model may render it unfit and/or unsafe to use.
Yamaha Motor Company, Ltd. is continually striv-
ing to improve all models manufactured by
Yamaha. Modifications and significant changes
in specifications or procedures will be forwarded
to all authorized Yamaha dealers and will, where
applicable, appear in future editions of this manual.
MM600, MM700
SERVICE MANUAL
1999 by Yamaha Motor Corporation, U.S.A.
1st Edition, June 1999
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.

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1to 9are designed as thumb
tabs to indicate the chapter’s number and con-
tent.
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 dia-
gram 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 .... 2-12
THROTTLE CABLE FREEPLAY
ADJUSTMENT ........................................ 2-13
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK .................................... 2-14
STARTER (CHOKE) CABLE FREEPLAY
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 .......... 2-20
BRAKE FLUID LEVEL INSPECTION ........ 2-21
BRAKE PAD INSPECTION ...................... 2-21
BRAKE HOSE INSPECTION .................... 2-22
AIR BLEEDING (HYDRAULIC BRAKE
SYSTEM) ................................................. 2-22
DRIVE CHAIN ........................................... 2-23
TRACK TENSION ADJUSTMENT .......... 2-25
SLIDE RUNNER INSPECTION ................ 2-27
CHASSIS ........................................................ 2-28
SKI/SKI RUNNER ..................................... 2-28
STEERING SYSTEM ................................ 2-28
LUBRICATION ......................................... 2-30
ELECTRICAL ................................................... 2-31
HEADLIGHT BEAM ADJUSTMENT ....... 2-31
TUNING .......................................................... 2-32
CARBURETOR TUNING .......................... 2-32
CLUTCH ................................................... 2-39
GEAR SELECTION ................................... 2-41
HIGH ALTITUDE TUNING ....................... 2-47
FRONT SUSPENSION ............................. 2-48
REAR SUSPENSION ............................... 2-49
CHAPTER 3.
CHASSIS
STEERING ........................................................ 3-1
INSPECTION .............................................. 3-3
INSTALLATION ......................................... 3-4
SKI .................................................................... 3-6
INSPECTION .............................................. 3-7
FRONT SUSPENSION ..................................... 3-8
INSPECTION .............................................. 3-9
INSTALLATION ....................................... 3-10

CHAPTER 4.
POWER TRAIN
PRIMARY SHEAVE AND DRIVE V-BELT ........ 4-1
REMOVAL .................................................. 4-3
DISASSEMBLY .......................................... 4-3
INSPECTION .............................................. 4-4
ASSEMBLY ................................................ 4-6
INSTALLATION ......................................... 4-8
SECONDARY SHEAVE .................................... 4-9
DISASSEMBLY ........................................ 4-11
INSPECTION ............................................ 4-11
ASSEMBLY .............................................. 4-12
INSTALLATION ....................................... 4-14
DRIVE CHAIN HOUSING ............................... 4-15
INSPECTION ............................................ 4-16
INSTALLATION ....................................... 4-18
JACKSHAFT ................................................... 4-19
INSPECTION ............................................ 4-20
JACKSHAFT AND DRIVE CHAIN
HOUSING INSTALLATION ..................... 4-21
BRAKE ............................................................ 4-22
BRAKE PAD REPLACEMENT .................. 4-23
BRAKE CALIPER DISASSEMBLY ........... 4-27
BRAKE CALIPER INSPECTION AND
REPAIR ..................................................... 4-27
BRAKE CALIPER ASSEMBLY ................. 4-28
BRAKE CALIPER INSTALLATION .......... 4-28
INSPECTION ............................................ 4-30
BRAKE MASTER CYLINDER
ASSEMBLY .............................................. 4-30
INSTALLATION ....................................... 4-30
SLIDE RAIL SUSPENSION ............................ 4-31
INSPECTION ............................................ 4-36
ASSEMBLY .............................................. 4-37
INSTALLATION ....................................... 4-37
FRONT AXLE AND TRACK ............................ 4-38
INSPECTION ............................................ 4-39
INSTALLATION ....................................... 4-39
CHAPTER 5.
ENGINE
EXHAUST ASSEMBLY .................................... 5-1
INSTALLATION ......................................... 5-2
ENGINE ASSEMBLY ........................................ 5-3
INSPECTION .............................................. 5-4
INSTALLATION ......................................... 5-4
CYLINDER HEAD AND CYLINDER.................. 5-5
REMOVAL .................................................. 5-6
INSPECTION .............................................. 5-7
INSTALLATION ....................................... 5-12
OIL PUMP, CRANKCASE AND
CRANKSHAFT ................................................ 5-15
INSPECTION ............................................ 5-16
INSTALLATION ....................................... 5-18
CDI MAGNETO .............................................. 5-21
REMOVAL ................................................ 5-22
INSTALLATION ....................................... 5-23
RECOIL STARTER .......................................... 5-25
REMOVAL ................................................ 5-26
INSPECTION ............................................ 5-26
INSTALLATION ....................................... 5-27
CHAPTER 6.
COOLING SYSTEM
HEAT EXCHANGER ......................................... 6-1
INSPECTION .............................................. 6-2
INSTALLATION ......................................... 6-2
WATER PUMP .................................................. 6-3
REMOVAL .................................................. 6-4
INSPECTION .............................................. 6-4
INSTALLATION ......................................... 6-4

CHAPTER 7.
CARBURETION
CARBURETORS ............................................... 7-1
INSPECTION .............................................. 7-5
ASSEMBLY ................................................ 7-6
FUEL LEVEL ADJUSTMENT ..................... 7-8
INSTALLATION ......................................... 7-9
FUEL PUMP.................................................... 7-10
INSPECTION ............................................ 7-11
INSTALLATION ....................................... 7-11
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 ............................... 8-3
SPARK PLUG CAP ..................................... 8-4
IGNITION COIL .......................................... 8-4
CDI MAGNETO .......................................... 8-4
SPARK PLUG ............................................. 8-5
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) ................................................... 8-5
HANDLEBAR SWITCH (RIGHT) ................ 8-6
CARBURETOR SWITCH ............................ 8-6
MAIN SWITCH ........................................... 8-7
LIGHTING SYSTEM ......................................... 8-8
CIRCUIT DIAGRAM ................................... 8-8
TROUBLESHOOTING ............................... 8-9
BULB(S) ................................................... 8-10
HEADLIGHT BEAM SWITCH .................. 8-10
CDI MAGNETO ........................................ 8-11
SIGNAL SYSTEM........................................... 8-12
CIRCUIT DIAGRAM ................................. 8-12
TROUBLESHOOTING ............................. 8-13
TAIL/BRAKE LIGHT BULB ....................... 8-15
BRAKE LIGHT SWITCH ........................... 8-15
WATER TEMPERATURE SENSOR ......... 8-16
OIL LEVEL SWITCH ................................. 8-17
FUEL SENDER ......................................... 8-17
CONDENSER ........................................... 8-18
GRIP WARMER SYSTEM .............................. 8-19
CIRCUIT DIAGRAM ................................. 8-19
TROUBLESHOOTING ............................. 8-20
GRIP AND THUMB WARMER COIL ....... 8-21
VARIABLE RESISTOR ............................. 8-21
CDI MAGNETO ........................................ 8-22
CHAPTER 9.
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................... 9-1
MAINTENANCE SPECIFICATIONS ................. 9-3
ENGINE ...................................................... 9-3
POWER TRAIN .......................................... 9-6
CHASSIS .................................................... 9-9
ELECTRICAL ............................................ 9-10
HIGH ALTITUDE SETTINGS ................... 9-11
TIGHTENING TORQUE ........................... 9-13
GENERAL TORQUE SPECIFICATIONS......... 9-17
DEFINITION OF UNITS .................................. 9-17
CABLE ROUTING ........................................... 9-19

1-1
GEN
INFO
MACHINE IDENTIFICATION
GENERAL INFORMATION
MACHINE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number 1is located on the right-hand side of the
frame (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.
SEJ1010
SEJ1020
1

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 pres-
sure 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 sure to keep to the tightening torque specifications. 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 adjust-
ments.
SEJ1030
SEJ1040
SEJ1050
SEJ1060
SEJ1070
SEJ1080

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. Lock tab(s) should be bent along the bolt or nut flat(s) after the
bolt 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 lightweight lithium base grease to the seal lips. Oil the
bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the bearings dry. This causes
damage to the surface of the bearings.
CIRCLIPS
All circlips should be inspected carefully before reassembly. Always
replace piston pin clips after one use. Replace misshapen circlips.
When installing a circlip 1, make sure that the sharp edged corner 2
is 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.
SEJ1090
SEJ1100
SEJ1110
SEJ1120

1-4
GEN
INFO
SPECIAL TOOLS
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.
FOR TUNE UP
•Sheave gauge
P/N: YS-42421-1 (15 mm offset)
This gauge is used to measure the sheave distance and for offset
adjustment.
•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.
SEJ1130
SEJ1160
SEJ1150
SEJ1140

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 (for U.S.A./Canada)
90890-01362 (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-39962
This tool is used for removing the primary sheave.
•Clutch spider separator
P/N: YS-28890-B (for U.S.A./Canada)
90890-01711 (for Europe)
This tool is used when disassembling and assembling the primary
sheave.
•Clutch separator adapter
P/N: YS-34480 (for U.S.A./Canada)
90890-01740 (for Europe)
This tool is used when disassembling and assembling the primary
sheave.
•YXR clutch bushing jig kit
P/N: YS-39752
This tool is used for removal and installation of primary clutch weight
and roller bushings.
SPECIAL TOOLS
SEJ1170
SEJ1180
SEJ1190
SEJ1200
SEJ1210
SEJ1220
SEJ1230
SEJ1240

1-6
GEN
INFO
SPECIAL TOOLS
•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 (for U.S.A./Canada)
90890-01721 (for Europe)
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: YB-35956 (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 (for U.S.A./Canada)
90890-03021 (for Europe)
This instrument is invaluable for checking the electrical system.
SEJ1250
SEJ1260
SEJ1280
SEJ1290
SEJ1300
SEJ1310

2-1
INSP
ADJ
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. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE
Item Remarks
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
Drive V-belt
Drive track/idler wheels
Slide runners
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)
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.
Retighten or replace gasket if necessary.
More frequently if necessary.
Check cracks, bends or damage.
Replace if necessary.
Check wear and damage.
Replace if necessary.
Check deflection, wear and damage.
Adjust/replace if necessary.
Check wear and damage.
Replace if necessary.
Whenever operating condition
(elevation/temperature) is changed.

2-2
INSP
ADJ
PERIODIC MAINTENANCE TABLE
Check operation and fluid leakage.
Adjust free play and/or replace pads if necessary.
Replace brake fluid.
Check oil level.
Replace.
Check deflection.
Adjust if necessary.
Check wear and damage.
Replace if necessary.
Check operation.
Adjust toe-out if necessary.
Check damage.
Replace if necessary.
Check operation.
Replace bulbs if necessary.
Check engagement and shift speed.
Adjust if necessary.
Check wear and damage.
Replace if necessary.
Lubricate with specified grease.
Lubricate with specified grease.
Adjust if necessary.
Lubricate with specified grease.
Lubricate with specified grease.
Lubricate with specified grease.
Lubricate with specified grease.
Check cable damage.
Replace if necessary.
Make sure the shroud latches are hooked.
Check tightness.
Repair if necessary.
Check proper placement.
Whenever operating elevation is changed.
Whenever operating elevation is changed.
Initial at 80 km (50 mi) and every 800 km
(500 mi) thereafter.
See NOTE.
Brake/
parking brake
Drive chain oil
Drive chain
Skis and ski runners
Steering system
Strap
Lights
Primary sheave
Secondary sheave
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
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the
brake fluid level and add the fluid as required.
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)
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 a:
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
surface 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
.
.
SEJ2010
SEJ2020
SEJ2030

2-4
INSP
ADJ
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. Place a rag under the oil pump assembly to
soak up any spilled oil.
4. Disconnect:
•Oil hose
5. Drain the oil until no more air bubbles appear
in the oil hose.
6. Connect:
•Oil hose
7. Disconnect:
•Oil delivery hose
8. Feed the “YAMALUBE 2-cycle oil” into the oil
delivery hose using an oil can for complete air
bleeding.
9. Connect:
•Oil delivery hose
10. Remove:
•Bleed bolt 1
•Gasket (bleed bolt)
11. Drain the oil until no more air bubbles appear
from the bleed hole.
12. Inspect:
•Gasket (bleed bolt)
Damage/wear →Replace.
SEJ2040
SEJ2050

2-5
INSP
ADJ
OIL PUMP
13. Install:
•Gasket (bleed bolt)
•Bleed bolt
14. Install:
•Carburetors
Refer to “CARBURETORS” in CHAPTER 7.
Cable adjustment
NOTE:
Before adjusting the oil pump cable, the throttle
cable distance should be adjusted.
Adjustment steps:
•Slide back the adjuster cover.
•Loosen the locknut 1.
•Turn the adjuster 2in or out until the specified
distance ais obtained.
Distance a:
MM600:
23 ±1 mm (0.906 ±0.04 in)
MM700:
22 ±1 mm (0.866 ±0.04 in)
Turning in →Distance ais increased.
Turning out →Distance ais decreased.
•Tighten the locknut and push in the adjuster
cover.
SEJ2060
SEJ2070

2-6
INSP
ADJ
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
season.
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 1
is turned to “ON” a.
SEJ2080
SEJ2090
SEJ2100

2-7
INSP
ADJ
1
1
4. Remove:
•Coolant filler cap 1
WARNING
Do not remove the coolant filler cap 1when 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.
Slowly turn the cap counterclockwise until it
stop. This allows any residual pressure to escape.
When the hissing sound has stopped, press down
on the cap while turning it counterclockwise to
remove it.
5. Place an open container under the coolant
drain bolt 1.
6. Remove:
•Coolant drain bolt
•Gasket (coolant drain bolt)
7. Drain the coolant.
NOTE:
Lift up the tail of the machine to drain the coolant.
8. Remove:
•Right side cover 1
9. Disconnect:
•Coolant hose 3 1
10. Drain the coolant.
NOTE:
Lift up the tail of the machine to drain the coolant
completely.
COOLING SYSTEM
SEJ2110
SEJ2120
SEJ2130
SEJ2140