Yamaha VT600G Service manual

SERVICE MANUAL
VX600ERG
SX600G
MM600G
VT600G
LIT-12618-02-20
8EA-28197-10
981059
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 understanding 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 striving
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.
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 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
easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations.
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
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
Each chapter provides exploded diagrams before
each disassembly section to facilitate correct disassembly and assembly procedures.
1
ILLUSTRATED SYMBOLS
2
GEN
INFO
(Refer to the illustration)
INSP
ADJ
3
Illustrated symbols 1 to 9 are designed as thumb
tabs to indicate the chapter’s number and content.
4
CHAS
POWR
TR
5
6
1
2
3
4
5
6
7
8
9
COOL
ENG
7
8
CARB
ELEC
–
General information
Periodic inspection and adjustment
Chassis
Power train
Engine
Cooling system
Carburetion
Electrical
Specifications
+
9
SPEC
0
Illustrated symbols 0 to F are used to identify the
specifications which appear.
B
A
T.
R.
C
D
E
F
G
H
I
J
L
K
G
E
M
B
O
New
M
N
LS
Filling fluid
Lubricant
Tightening
Wear limit, clearance
Engine speed
Special tool
Ω, V, A
Illustrated symbols G to O in the exploded diagram
indicate grade of lubricant and location of lubrication
point.
5
LT
0
A
B
C
D
E
F
M
G
H
I
J
K
L
M
N
O
Apply locking agent (LOCTITE®)
Apply Yamabond No.5®
Apply engine oil
Apply gear oil
Apply molybdenum disulfide oil
Apply wheel bearing grease
Apply low-temperature lithium-soap base grease
Apply molybdenum disulfide grease
Use new one
INDEX
GENERAL INFORMATION
PERIODIC INSPECTION AND
ADJUSTMENT
CHASSIS
POWER TRAIN
ENGINE
COOLING SYSTEM
CARBURETION
GEN
INFO
1
INSP
ADJ
2
CHAS
3
POWR
TR
4
ENG
5
COOL
6
CARB
7
–
ELECTRICAL
SPECIFICATIONS
+
ELEC
8
SPEC
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 .............................................
FOR TUNE UP ...........................................
FOR ENGINE SERVICE ............................
FOR POWER TRAIN SERVICE .................
FOR CARBURETION SERVICE ................
FOR ELECTRICAL SERVICE ....................
1-4
1-4
1-5
1-5
1-6
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 ...............................................
SHEAVE DISTANCE AND OFFSET
ADJUSTMENT .........................................
DRIVE V-BELT .........................................
ENGAGEMENT SPEED CHECK .............
PARKING BRAKE PAD INSPECTION .....
PARKING BRAKE ADJUSTMENT ...........
BRAKE LEVER ADJUSTMENT
(VX600ER/SX600/VT600) ........................
BRAKE FLUID LEVEL INSPECTION .......
BRAKE PAD INSPECTION ......................
BRAKE HOSE INSPECTION ...................
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM) .............
DRIVE CHAIN ..........................................
TRACK TENSION ADJUSTMENT ...........
SLIDE RUNNER INSPECTION ................
MAXIMIZING DRIVE TRACK LIFE ..........
2-16
2-16
2-18
2-20
2-20
2-21
2-21
2-22
2-22
2-23
2-23
2-24
2-27
2-29
2-30
CHASSIS ........................................................
SKI/SKI RUNNER .....................................
STEERING SYSTEM ...............................
LUBRICATION .........................................
2-31
2-31
2-32
2-33
ELECTRICAL .................................................
HEADLIGHT BEAM ADJUSTMENT .........
BATTERY INSPECTION
(VX600ER/VT600) ....................................
BATTERY CHARGING
(VX600ER/VT600) ....................................
FUSE INSPECTION (VX600ER/VT600) ..
2-35
2-35
2-36
TUNING ..........................................................
CARBURETOR TUNING ..........................
CLUTCH ...................................................
GEAR SELECTION ..................................
HIGH ALTITUDE TUNING .......................
FRONT SUSPENSION .............................
REAR SUSPENSION ...............................
2-41
2-41
2-48
2-53
2-59
2-60
2-61
2-38
2-39
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 ...................................
HANDLING NOTES (SX600) ...................
INSPECTION ............................................
INSTALLATION ........................................
3-11
3-12
3-12
3-14
BRAKE MASTER CYLINDER
ASSEMBLY .............................................. 4-37
INSTALLATION ........................................ 4-37
SLIDE RAIL SUSPENSION ............................
VX600ER/SX600 ......................................
VT600 .......................................................
MM600 ......................................................
INSPECTION ............................................
ASSEMBLY ..............................................
INSTALLATION ........................................
4-38
4-38
4-39
4-44
4-49
4-50
4-50
FRONT AXLE AND TRACK ........................... 4-52
INSPECTION ............................................ 4-53
INSTALLATION ........................................ 4-53
CHAPTER 4.
POWER TRAIN
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 .................................
DISASSEMBLY ........................................
INSPECTION ............................................
ASSEMBLY ..............................................
INSTALLATION ........................................
4-11
4-13
4-13
4-14
4-16
DRIVE CHAIN HOUSING ...............................
WITHOUT REVERSE MODEL .................
INSPECTION ............................................
INSTALLATION ........................................
WITH REVERSE MODEL ........................
INSPECTION ............................................
INSTALLATION ........................................
4-17
4-17
4-18
4-20
4-21
4-23
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
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 .........................................
REMOVAL ................................................
INSPECTION ............................................
INSTALLATION ........................................
5-27
5-28
5-28
5-29
CHAPTER 6.
COOLING SYSTEM
HEAT EXCHANGER ........................................ 6-1
VX600ER/SX600/VT600 ............................ 6-1
MM600 ........................................................ 6-2
INSPECTION .............................................. 6-3
INSTALLATION .......................................... 6-4
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) ..........................................
CIRCUIT DIAGRAM .................................
TROUBLESHOOTING .............................
MAIN SWITCH .........................................
STARTER MOTOR ..................................
8-11
8-11
8-12
8-13
8-14
CHARGING SYSTEM (VX600ER/VT600) ......
CIRCUIT DIAGRAM .................................
TROUBLESHOOTING .............................
BATTERY .................................................
STATOR COIL ..........................................
8-18
8-18
8-19
8-20
8-20
LIGHTING SYSTEM .......................................
CIRCUIT DIAGRAM .................................
TROUBLESHOOTING .............................
BULB(S) ...................................................
HEADLIGHT BEAM SWITCH ...................
HEADLIGHT RELAY ................................
8-22
8-22
8-24
8-26
8-26
8-27
8-28
8-28
8-30
8-34
SWITCH INSPECTION ..................................... 8-1
SWITCH INSPECTION .............................. 8-1
INSPECTING A SWITCH SHOWN IN THE
MANUAL ..................................................... 8-1
SIGNAL SYSTEM ...........................................
CIRCUIT DIAGRAM .................................
TROUBLESHOOTING .............................
BRAKE LIGHT SWITCH ...........................
GEAR POSITION SWITCH
(VX600ER/VT600) ....................................
DC BACK BUZZER (VX600ER/VT600) ...
WATER TEMPERATURE SENSOR ........
OIL LEVEL SWITCH ................................
FUEL SENDER ........................................
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
GRIP WARMER SYSTEM ..............................
CIRCUIT DIAGRAM .................................
TROUBLESHOOTING .............................
GRIP AND THUMB WARMER COIL ........
VARIABLE RESISTOR
(THUMB WARMER) .................................
VARIABLE RESISTOR
(GRIP WARMER) .....................................
WATER PUMP ..................................................
REMOVAL ..................................................
INSPECTION ..............................................
INSTALLATION ..........................................
6-5
6-6
6-6
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
8-34
8-34
8-35
8-36
8-36
8-38
8-38
8-40
8-42
8-42
8-43
PASSENGER GRIP WARMER (VT600) ..
PASSENGER GRIP WARMER
SWITCH (VT600) ....................................
RESISTOR (VT600) .................................
PASSENGER GRIP WARMER RELAY
(VT600) .....................................................
8-43
8-44
8-44
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
MACHINE IDENTIFICATION
GEN
INFO
GENERAL INFORMATION
MACHINE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number 1 is located on the right-hand side of the frame (just
SEA1010
below the front of the seat).
ENGINE SERIAL NUMBER
The engine serial number 1 is located on the right-hand side of the
crankcase.
NOTE:
SEA1020
Designs and specifications are subject to change without notice.
1-1
IMPORTANT INFORMATION
GEN
INFO
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.
SEA1030
2. Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS”.
SEA1040
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.
SEA1050
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.
SEA1060
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.
SEA1070
ALL REPLACEMENT PARTS
We recommend using genuine Yamaha parts for all replacements. Use oil
and grease recommended by Yamaha for assembly and adjustments.
SEA1080
1-2
1
IMPORTANT INFORMATION
GEN
INFO
GASKETS, OIL SEALS, AND O-RINGS
1. All gaskets, seals, and O-rings should be replaced when an engine is
overhauled. All gasket surfaces, oil seal lips, and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply
grease to the oil seal lips.
LOCK WASHERS/PLATES AND COTTER PINS
All lock washers/plates 1 and 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.
SEA1090
BEARINGS AND OIL SEALS
SEA1100
Install the bearings 1 and oil seals 2 with 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.
SEA1110
CIRCLIPS
SEA1120
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 3 it receives. See the sectional view.
4 Shaft
LOCTITE®
After installing fasteners that have LOCTITE® applied, wait 24 hours before
using the machine. This will give the LOCTITE® time to dry properly.
1-3
SPECIAL TOOLS
GEN
INFO
SPECIAL TOOLS
Some special tools are necessary for a completely accurate tune-up and
assembly. Using the correct special tool will help prevent damage that can
be caused by the use of improper tools or improvised techniques.
NOTE:
Be sure to use the correct part number when ordering the tool, since the part
number may differ according to country.
FOR TUNE UP
• Sheave gauge
SEA1130
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 adjustment.
• Dial gauge
P/N: YU-03097 (for U.S.A./Canada)
90890-03097 (for Europe)
This gauge is used for run out measurement.
SEA1140
• 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.
SEA1150
• 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.
SEA1160
1-4
SPECIAL TOOLS
GEN
INFO
FOR ENGINE SERVICE
• Piston pin puller
SEA1170
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
1
P/N: YU-33270 1 (for U.S.A./Canada)
90890-01362 2 (for Europe)
This tool is used to remove the magneto rotor.
SEA1180
2
SEA1190
• 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.
SEA1200
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.
SEA1210
• Primary sheave puller (18 mm)
P/N: YS-01881-1 1, YS-01859-1 2
This tool is used for removing the primary sheave.
SEA1220
• Clutch spider separator
P/N: YS-28890-C
This tool is used when disassembling and assembling the primary sheave.
SEA1230
• Clutch separator adapter
P/N: YS-34480
This tool is used when disassembling and assembling the primary sheave.
SEA1240
1-5
SPECIAL TOOLS
GEN
INFO
• YXR clutch bushing jig kit
P/N: YS-39752
This tool is used for removal and installation of primary clutch weight and
roller bushings.
SEA1250
• 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).
SEA1260
• Track clip installer
P/N: YS-91045-A
This tool is used for installing the track clip.
SEA1270
• Angle finder
P/N: YS-42422
This tool is used for checking and adjusting the ski spindle camber.
SEA1280
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.
SEA1290
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.
SEA1300
• Electro tester
P/N: YU-33260-A
This instrument is invaluable for checking the electrical system.
SEA1310
1-6
INTRODUCTION/PERIODIC MAINTENANCE TABLE
INSP
ADJ
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
Spark plugs
Preoperation
check
(Daily)
Remarks
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.
Engine oil
Air bleed the oil pump if necessary.
Fuel
Check fuel level.
Fuel filter
Check condition.
Replace if necessary.
Fuel line
Check fuel hose for cracks or damage.
Replace if necessary.
Oil line
Check oil hose for cracks or damage.
Replace if necessary.
Engine coolant
Check coolant level.
Air bleed the cooling system if necessary.
Check throttle lever operation.
Carburetors
Whenever operating condition
(elevation/temperature) is changed.
Adjust the jets.
Recoil starter
Check operation and rope damage.
Replace if necessary.
Engine stop switch
Check operation.
Repair if necessary.
Throttle override system
(T.O.R.S.)
Check operation.
Repair if necessary.
Throttle lever
Check operation.
Repair if necessary.
Exhaust system
Check for leakage.
Tighten or replace gasket if necessary.
Decarbonization
More frequently if necessary.
Drive guard
Check for cracks, bends or damage.
Replace if necessary.
V-belt
Check for wear and damage.
Replace if necessary.
Drive track and idler wheels
Check deflection, and for wear and damage.
Adjust/replace if necessary.
Slide runners
Check for wear and damage.
Replace if necessary.
Check operation and fluid leakage.
Brake and parking brake
Adjust free play and/or replace pads if necessary.
See NOTE on page 2-2.
Replace brake fluid.
2-1
PERIODIC MAINTENANCE TABLE
Item
Preoperation
check
(Daily)
Remarks
INSP
ADJ
Initial
1 month
or
800 km
(500 mi)
(40 hr)
Every
Seasonally
or
3,200 km
(2,000 mi)
(160 hr)
Check oil level.
Drive chain oil
Drive chain
Skis and ski runners
Steering system
Replace.
Check deflection.
Adjust if necessary.
Check for wear and damage.
Replace if necessary.
2
Check operation.
Adjust toe-out if necessary.
Strap (MM600)
Check for damage.
Replace if necessary.
Lights
Check operation.
Replace bulbs if necessary.
Battery
(VT600/VX600ER)
Initial at 500 km (300 mi) and every 800 km
(500 mi) thereafter.
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.
Primary and secondary
clutches
Whenever operating elevation is changed.
Inspect sheaves for wear/damage.
Inspect weights/rollers and bushings for wear-for primary.
Inspect ramp shoes/bushings for wear-for secondary.
Replace if necessary.
Lubricate with specified grease.
Steering column bearing
Lubricate with specified grease.
Ski and front suspension
Lubricate with specified grease.
Suspension component
Lubricate with specified grease.
Parking brake cable end
and lever end/throttle cable
end
Lubricate with specified grease.
Shroud latches
Make sure that the shroud latches are hooked.
Fittings and fasteners
Check tightness.
Repair if necessary.
Tool kit and recommended
equipment
Check for proper placement.
Check cable damage.
Replace if necessary.
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.
2-2
SPARK PLUGS
INSP
ADJ
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.
SEA2010
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 surface and spark plug surface.
SEA2020
4. Install:
• Spark plugs
T.
R.
Spark plug:
20 Nm (2.0 m · kg, 14 ft · lb)
NOTE:
Finger-tighten a the spark plug before torquing b it
to specification.
SEA2030
2-3
OIL PUMP
INSP
ADJ
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
1
Recommended oil:
YAMALUBE 2-cycle oil
Oil tank capacity:
3.0 L (2.6 Imp qt, 3.2 US qt)
SEA2040
2. Remove:
• Carburetors
Refer to “CARBURETORS” in CHAPTER 7.
3. Remove:
• Rear bracket (right) 1
4. Place a rag under the oil pump assembly to soak
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
1
SEA2050
11. Remove:
• Bleed bolt 1
• Gasket (bleed bolt)
12. Drain the oil until no more air bubbles appear from
the bleed hole.
13. Inspect:
• Gasket (bleed bolt)
Damage/wear → Replace.
1
SEA2060
2-4
OIL PUMP
INSP
ADJ
14. Install:
• Gasket (bleed bolt)
• Bleed bolt
15. Install:
• Rear bracket (right)
T.
R.
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
SEA2070
NOTE:
Before adjusting the oil pump cable, the throttle cable
free play should be adjusted.
Adjustment steps:
• Slide back the adjuster cover.
• Loosen the locknut 1.
• Turn the adjuster 2 in or out until the specified
distance a is obtained.
Distance:
23 ± 1 mm (0.906 ± 0.039 in)
SEA2080
Turning in → Distance a is increased.
Turning out → Distance a is decreased.
• Tighten the locknut and push in the adjuster
cover.
2-5
FUEL LINE INSPECTION/COOLING SYSTEM
INSP
ADJ
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.
1
SEA2090
2
2
SEA2100
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 CHAPTER 5.
3. Make sure that the carburetor heating lever 1 is
turned to “ON” a.
SEA2110
2-6
COOLING SYSTEM
INSP
ADJ
4. Remove:
• Coolant filler cap 1
1
WARNING
Do not remove the coolant filler cap 1 when the
engine is hot. Pressurized scalding hot fluid and
steam may be blown out, which could cause
serious injury. When the engine has cooled, place
a thick rag or a towel over the coolant filler cap.
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.
SEA2120
5. Place an open container under the coolant drain
bolt 1.
6. Remove:
• Coolant drain bolt 1
• Gasket (coolant drain bolt)
7. Drain the coolant.
NOTE:
Lift up the tail of the machine to drain the coolant.
SEA2130
8. Remove:
• Right side cover 1 (MM600)
1
SEA2140
2-7
COOLING SYSTEM
INSP
ADJ
9. Disconnect:
• Coolant hoses 1
A
Å VX600ER/SX600/VT600
ı MM600
10. Drain the coolant.
NOTE:
Lift up the front of the machine to drain the coolant
completely.
SEA2150
WARNING
B
Coolant is poisonous. It is harmful or fatal if
swallowed.
• If coolant is swallowed, induce vomiting immediately and get immediate medical attention.
• If coolant splashes in your eyes, thoroughly
wash them with water and consult a doctor.
• If coolant splashes on your skin or clothes,
quickly wash it away with soap and water.
1
SEA2160
11. Connect:
• Coolant hoses
12. Install:
• Right side cover 1 (MM600)
T.
1
R.
Bolt (side cover):
3 Nm (0.3 m · kg, 2.2 ft · lb)
SEA2140
13. Disconnect:
• Coolant reservoir hose 1
1
SEA2170
14. Remove:
• Coolant reservoir cap 1
15. Drain the coolant from the coolant reservoir.
16. Install:
• Coolant reservoir cap
17. Connect:
• Coolant reservoir hose
1
SEA2180
2-8
COOLING SYSTEM
INSP
ADJ
18. Inspect:
• Gasket (coolant drain bolt)
Damage → Replace.
19. Install:
• Gasket
• Coolant drain bolt 1
T.
R.
SEA2130
Coolant drain bolt:
13 Nm (1.3 m · kg, 9.4 ft · lb)
20. Install:
• Exhaust joint
• Exhaust pipe
Refer to “EXHAUST ASSEMBLY” in CHAPTER 5.
T.
R.
Bolt (exhaust joint):
1st:
18 Nm (1.8 m · kg, 13 ft · lb)
2nd:
27 Nm (2.7 m · kg, 19 ft · lb)
21. Fill:
• Cooling system
Recommended coolant:
High quality ethylene glycol
antifreeze containing
corrosion inhibitors
Coolant mixing ratio (coolant:water)
3:2 (60%:40%)
Total amount:
VX600ER/SX600:
3.8 L (3.34 lmp qt, 4.02 US qt)
MM600:
4.0 L (3.52 lmp qt, 4.23 US qt)
VT600:
4.1 L (3.61 lmp qt, 4.33 US qt)
Reservoir tank capacity:
0.28 L (0.25 lmp qt, 0.30 US qt)
From LOW to FULL level:
0.13 L (0.11 lmp qt, 0.14 US qt)
CAUTION:
• Hard water or salt water is harmful to engine
•
2-9
parts. If soft water is not available, use boiled or
distilled water.
Do not use water containing impurities or oil.
COOLING SYSTEM
INSP
ADJ
22. Bleed the air from the cooling system.
23. Inspect:
• Cooling system
Decrease of pressure (leaks) → Repair as
required.
Inspection steps:
• Attach the cooling system tester 1 to the coolant
filler 2.
Cooling system tester:
90890-01325, YU-24460-01
2
1
• Apply 100 kPa (1.0 kg/cm2, 14 psi).
• Measure the pressure with the gauge.
SEA2220
A
Air bleeding
1. Remove:
• Seat (VX600ER/SX600/VT600)
• Rear bumper cover 1 (VT600)
• Bleed bolt cap 1 (MM600)
Å VT600
ı MM600
1
2 .Bleed air from the cooling system.
SEA2210
B
1
SEA2220
2-10
COOLING SYSTEM
INSP
ADJ
Air bleeding steps:
• Lift up the tail of the machine.
• Remove the bleed bolt 1 on the heat exchanger.
• While slowly adding coolant to the coolant filler,
drain the coolant until no more air bubbles appear.
• Tighten the bleed bolt 1.
A
SEA2230
T.
R.
B
Bleed bolt:
VX600ER/SX600/VT600:
13 Nm (1.3 m · kg, 9.4 ft · lb)
MM600:
4 Nm (0.4 m · kg, 2.9 ft · lb)
Å VX600ER/SX600/VT600
ı MM600
1
SEA2240
• Add coolant to the coolant cold level a.
• Loosen the bleed bolt 2 on the thermostatic
•
•
cover.
Drain the coolant until no more air bubbles appear.
Tighten the bleed bolt 2.
T.
R.
Bleed bolt:
7 Nm (0.7 m · kg, 5.1 ft · lb)
SEA2250
• Install the coolant filler cap.
Apply and lock the parking brake. Start the engine
and run it at approximately 2,500 ~ 3,000 r/min
until the coolant circulates (approximately 3 ~
5 minutes). The rear heat exchanger will be warm
to the touch.
WARNING
To avoid severe injury or death:
• Make sure the machine is securely supported with a suitable stand.
• Do not exceed 3,000 r/min. Drive line damage
and excessive V-belt wear could occur, or
the machine could unexpectedly move forward if the clutch engages.
• Operate the engine only in a well-ventilated
area.
2-11
COOLING SYSTEM/
CARBURETOR SYNCHRONIZATION
INSP
ADJ
• Remove the coolant filler cap and bleed the
•
•
3
cooling system again, as described above.
No air bubbles → OK.
Add coolant to the specified level.
Pour coolant into the coolant reservoir 3 until
the coolant level reaches the “FULL” level mark.
SEA2260
3. Install:
• Bleed bolt cap (MM600)
• Rear bumper cover (VT600)
• Seat (VX600ER/SX600/VT600)
CARBURETOR SYNCHRONIZATION
1. Remove:
• Carburetors
Refer to “CARBURETORS” in CHAPTER 7.
2. Adjust:
• Carburetor synchronization
Adjustment steps:
• Turn the throttle stop screw 1 of carburetor #2
until the specified throttle valve height a is obtained.
Throttle valve height:
1.2 mm (0.047 in)
• Adjust the throttle valve height a on carburetor
#1 2 and #3 3 with the adjusting screws 4.
SEA2270
• Move the throttle lever 2 ~ 3 times.
• Make sure that all of the carburetor throttle valves
are at the same height.
3. Install:
• Carburetors
Refer to “CARBURETORS” in CHAPTER 7.
SEA2280
2-12
ENGINE IDLE SPEED ADJUSTMENT/
THROTTLE CABLE FREE PLAY ADJUSTMENT
INSP
ADJ
ENGINE IDLE SPEED ADJUSTMENT
1. Adjust:
• Engine idle speed
Adjustment steps:
• Start the engine and let it warm up.
• Turn the throttle stop screw 1 in or out until the
specified engine idle speed is obtained.
SEA2290
Turning in → Idle speed is increased.
Turning out → Idle speed is decreased.
Engine idle speed:
1,600 ± 100 r/min
NOTE:
After adjusting the engine idle speed, the throttle
cable free play should be adjusted.
THROTTLE CABLE FREE PLAY
ADJUSTMENT
NOTE:
• Before adjusting the throttle cable free play, the
•
engine idle speed should be adjusted.
Adjust the throttle cable free play while the cable is
in the cable guide.
1. Measure:
• Throttle cable free play a
Out of specification → Adjust.
Throttle cable free play:
1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
SEA2300
2-13
THROTTLE CABLE FREE PLAY ADJUSTMENT/
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK
INSP
ADJ
2. Adjust:
• Throttle cable free play
Adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting nut 2 in or out until the
specified free play is obtained.
Turning in → Free play is increased.
SEA2310
Turning out → Free play is decreased.
• Tighten the locknut.
NOTE:
After adjusting the free play, turn the handlebar to
right and left, and make sure that the engine idling
does not run faster.
THROTTLE OVERRIDE SYSTEM (T.O.R.S.)
CHECK
WARNING
When checking T.O.R.S.:
• Be sure the parking brake is applied.
• Be sure the throttle lever moves smoothly.
• Do not run the engine up to the clutch engagement speed. Otherwise, the machine could start
moving forward unexpectedly, which could
cause an accident.
1. Start the engine.
2. Hold the pivot point of the throttle lever away from
the throttle switch by putting your thumb (above)
and forefinger (below) between the throttle lever
pivot 1 and stop switch housing 2.
While holding as described above, press the
throttle lever 3 gradually.
The T.O.R.S. will operate and the engine should
run between 2,800 and 3,000 r/min.
WARNING
2
3
If the engine does not run between 2,800 and
3,000 r/min, stop the engine by turning the main
switch to the “OFF” position and check the electrical system.
1
SEA2320
2-14
STARTER (CHOKE) CABLE FREE PLAY ADJUSTMENT/
EXHAUST SYSTEM INSPECTION
INSP
ADJ
STARTER (CHOKE) CABLE FREE PLAY
ADJUSTMENT
1. Measure:
• Starter cable free play a
Out of specification → Adjust.
Starter cable free play:
0.5 ~ 1.5 mm (0.02 ~ 0.06 in)
SEA2330
2. Adjust:
• Starter cable free play
Adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting nut 2 in or out until the
specified free play is obtained.
Turning in → Free play is increased.
Turning out → Free play is decreased.
• Tighten the locknut.
EXHAUST SYSTEM INSPECTION
1. Open the shroud.
2. Remove:
• Springs
Refer to “EXHAUST ASSEMBLY” in CHAPTER 5.
3. Inspect:
• Exhaust joint 1
• Exhaust pipe 2
• Exhaust silencer 3
Cracks/damage → Replace.
• Gasket 1 4
• Gasket 2 5
• Gasket 3 6
Exhaust gas leaks → Replace.
4. Check:
• Tightening torque 7
SEA2340
T.
R.
Bolt (exhaust joint):
1st:
18 Nm (1.8 m · kg, 13 ft · lb)
2nd:
27 Nm (2.7 m · kg, 19 ft · lb)
5. Install:
• Springs
Refer to “EXHAUST ASSEMBLY” in CHAPTER 5.
2-15
SHEAVE DISTANCE AND OFFSET ADJUSTMENT
INSP
ADJ
POWER TRAIN
SHEAVE DISTANCE AND OFFSET
ADJUSTMENT
1. Open the shroud.
2. Remove:
• Drive V-belt guard
• Drive V-belt
3. Measure:
• Sheave distance a
Use the distance gauge.
Out of specification → Adjust.
Sheave distance:
267 ~ 270 mm (10.52 ~ 10.62 in)
Distance gauge:
90890-01702, YS-91047-3
SEA2350
4. Measure:
• Sheave offset a
Use the sheave gauge.
Out of specification → Adjust.
Sheave offset:
VX600ER/VT600:
18.5 ~ 21.5 mm (0.73 ~ 0.85 in)
SX600/MM600:
13.5 ~ 16.5 mm (0.53 ~ 0.64 in)
SEA2360
Sheave gauge:
YS-42421-1 (15 mm offset)
YS-42421-2 (20 mm offset)
2-16
SHEAVE DISTANCE AND OFFSET ADJUSTMENT
INSP
ADJ
5. Adjust:
• Sheave distance
Adjustment steps:
• Loosen the mounting bolts (front) 1 and mounting bolts (rear) 2.
• Adjust the position of the engine so that the
sheave distance is within the specification.
• Tighten the mounting bolts (front) 1 and mounting bolts (rear) 2.
SEA2370
T.
R.
Mounting bolt (front):
90 Nm (9.0 m · kg, 65 ft · lb)
Mounting bolt (rear):
57 Nm (5.7 m · kg, 41 ft · lb)
2
SEA2380
6. Measure:
• Secondary sheave free play (clearance) a
Use a thickness gauge.
Out of specification → Adjust.
a
Secondary sheave free play
(clearance):
1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
SEA2390
7. Adjust:
• Secondary sheave free play (clearance)
3
Adjustment steps:
• Apply the brake to lock the secondary sheave.
• Remove the bolt 1 and washer 2.
• Adjust the secondary sheave free play (clearance) by adding or removing a shim(s) 3.
2
1
SEA2400
Shim size:
Part number
90201-222F0
90201-225A4
2-17
Thickness
0.5 mm (0.02 in)
1.0 mm (0.04 in)
DRIVE V-BELT
INSP
ADJ
DRIVE V-BELT
WARNING
When installing the new V-belt, make sure that it
is positioned from 1.5 mm (0.06 in) above the
edge of the secondary sheave to –0.5 mm
(–0.02 in) below the edge a.
If the V-belt is not positioned correctly, the clutch
engagement speed will be changed. The machine
may move unexpectedly when the engine is
started.
Adjust the V-belt position by removing or adding
a spacer 1 on each adjusting bolt 2.
CAUTION:
As the V-belt wears, adjustment may be necessary. To ensure proper clutch performance, the Vbelt position should be adjusted by adding a spacer
on each adjusting bolt when the V-belt position
reaches 1.5 mm (0.06 in) below the edge.
SEA2410
New belt width:
34.5 mm (1.36 in)
Belt wear limit width:
32.5 mm (1.28 in)
1. Measure:
• V-belt position a
NOTE:
Install the new V-belt onto the secondary sheave
only. Do not force the V-belt between the sheaves;
the sliding and fixed sheaves must touch each other.
V-belt position:
–0.5 ~ 1.5 mm (–0.02 ~ 0.06 in)
SEA2420
2-18
DRIVE V-BELT
INSP
ADJ
2. Adjust the position of the V-belt by removing or
adding a spacer 1 on each adjusting bolt 2.
V-belt position
More than 1.5 mm
(0.06 in) above the
edge
From 1.5 mm (0.06 in)
above the edge to
–0.5 mm (–0.02 in)
below the edge
More than –0.5 mm
(–0.02 in) below the
edge
Adjustment
Remove a spacer
Not necessary
(It is correct.)
Add spacer
3. Tighten:
• Adjusting bolt 2
T.
R.
Adjusting bolt:
10 Nm (1.0 m · kg, 7.2 ft · lb)
SEA2430
4. Inspect:
• Drive V-belt
Cracks/damage/wear → Replace.
Oil or grease on the V-belt → Check the primary and secondary sheaves.
SEA2440
5. Inspect:
• Primary sheave
• Secondary sheave
Oil or grease on the primary and secondary
sheaves → Use a rag soaked in lacquer thinner
or solvent to remove the oil or grease. Check
the primary and secondary sheaves.
SEA2450
6. Measure:
• V-belt circumference a
Out of specification → Replace.
V-belt circumference:
1,129 ~ 1,137 mm (44.4 ~ 44.7 in)
SEA2460
2-19
ENGAGEMENT SPEED CHECK/
PARKING BRAKE PAD INSPECTION
INSP
ADJ
ENGAGEMENT SPEED CHECK
1. Place the machine on a level surface of hardpacked snow.
2. Check:
• Clutch engagement speed
Checking steps:
• Start the engine, and open the throttle lever
gradually.
• Check the engine speed when the machine starts
moving forward.
Out of specification → Adjust the primary sheave.
Engagement speed:
VX600ER/VT600 for U.S.A./Canada:
4,000 ± 200 r/min
(3,800 ~ 4,200 r/min)
SX600:
4,200 ± 200 r/min
(4,000 ~ 4,400 r/min)
MM600:
4,600 ± 200 r/min
(4,400 ~ 4,800 r/min)
VT600 for Europe:
3,900 ± 200 r/min
(3,700 ~ 4,100 r/min)
PARKING BRAKE PAD INSPECTION
1. Measure:
• Parking brake pad thickness a
Out of specification → Replace as a set.
Wear limit:
1.0 mm (0.04 in)
SEA2470
2-20
PARKING BRAKE ADJUSTMENT/
BRAKE LEVER ADJUSTMENT (VX60ER/SX600/VT600)
INSP
ADJ
PARKING BRAKE ADJUSTMENT
1. Measure:
• Clearance a
Out of specification → Adjust.
Clearance:
1.2 ~ 1.3 mm (0.047 ~ 0.051 in)
2. Adjust:
• Clearance a
SEA2480
Adjustment steps:
• Loosen the locknuts 1.
• Turn the cable adjuster 2 in or out to until the
specified clearance between the brake pad 3
and disc 4 is obtained.
• Turn the brake pad adjusting bolt 5 in or out until
the specified clearance between the brake pad 6
and disc 4 is obtained.
• Tighten the locknuts.
SEA2490
BRAKE LEVER ADJUSTMENT
(VX600ER/SX600/VT600)
1. Adjust:
• Brake lever position
(distance from the grip to the brake lever)
Adjustment steps:
• Loosen the locknut 1.
• While lightly pushing the brake lever in direction a,
turn the adjusting bolt 2 by fingers to set the brake
lever to the desired position.
• Tighten the locknut securely after adjusting.
SEA2500
T.
R.
2-21
Locknut:
6 Nm (0.6 m · kg, 4.3 ft · lb)
BRAKE FLUID LEVEL INSPECTION/
BRAKE PAD INSPECTION
INSP
ADJ
BRAKE FLUID LEVEL INSPECTION
1. Place the machine on a level surface.
2. Check:
• Fluid level
Fluid level is under the “LOWER” level line a
→ Fill to the proper level.
Recommended brake fluid:
DOT 4
SEA2510
NOTE:
For a correct reading of the brake fluid level, make
sure that the top of the handlebar brake master
cylinder reservoir is horizontal.
CAUTION:
Brake fluid may corrode painted surfaces or plastic parts. Always clean up spilled fluid immediately.
WARNING
• Use only the designated brake fluid. Other
•
•
fluids may deteriorate the rubber seals, causing leakage and poor brake performance.
Refill with the same type of fluid. Mixing fluids
may result in a harmful chemical reaction leading to poor brake performance.
When refilling, be careful that water does not
enter the brake master cylinder reservoir. Water will significantly lower the boiling point of
the fluid and may cause vapor lock.
BRAKE PAD INSPECTION
1. Apply the brake lever.
2. Inspect:
• Brake pad wear limit a
Wear indicator 1 nearly contacts the brake
disc → Replace as a set.
Wear limit:
4.7 mm (0.19 in)
SEA2515
2-22
BRAKE HOSE INSPECTION
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
INSP
ADJ
BRAKE HOSE INSPECTION
1. Inspect:
• Brake hose
Cracks/damage/wear → Replace.
2. Check:
• Fluid leakage
Apply the brake lever several times.
Fluid leakage → Replace the defective parts.
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
WARNING
Bleed the brake system in the following cases:
• The system has been disassembled.
• A brake hose is loosened or removed.
• The brake fluid has been very low.
• Brake operation is faulty.
If the brake system is not properly bled a loss of
braking performance may occur.
1. Bleed:
• Brake system
Air bleeding steps:
• Fill the brake master cylinder reservoir with the
proper brake fluid.
• Install the diaphragm. Be careful not to spill any
fluid or allow the brake master cylinder reservoir
to overflow.
• Connect clear plastic hoses 1 tightly to the brake
caliper bleed screws 2.
• Place the other ends of the hoses in a container.
a. Slowly apply the brake lever several times.
b. Pull the lever in, then hold the lever in position.
c. Loosen the bleed screws and allow the brake
lever to travel towards its limit.
SEA2520
2-23
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/
DRIVE CHAIN
INSP
ADJ
d. Tighten the bleed screws when the brake lever
limit has been reached, then release the lever.
• Repeat steps (a) to (d) until all of the air bubbles
have disappeared from the fluid.
• Tighten the bleed screws.
T.
R.
Bleed screw:
6 Nm (0.6 m · kg, 4.3 ft · lb)
NOTE:
If bleeding is difficult, it may be necessary to let the
brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny bubbles
in the system have disappeared.
• Add brake fluid to the proper level.
Refer to “BRAKE FLUID LEVEL INSPECTION”.
WARNING
After bleeding the brake system, check the brake
operation.
DRIVE CHAIN
Oil level inspection
WARNING
The engine and muffler will be very hot after the
engine has run. Avoid touching a hot engine and
muffler while they are still hot with any part of
your body or clothing during inspection or repair.
1. Place the machine on a level surface.
2. Check:
• Oil level
1
Checking steps:
• Remove the dipstick 1 and wipe it off with a
clean rag.
Reinsert the dipstick.
SEA2525
2-24
DRIVE CHAIN
INSP
ADJ
CAUTION:
There is a magnet attached to the end of the
dipstick. It is used to remove any metal particles
that may accumulate in the drive chain housing.
Be sure to:
• Pull the dipstick out slowly and gently so the
metal particles do not fall off the magnet back
into the drive chain housing.
• Wipe off the magnet before reinserting the
dipstick into the drive chain housing.
A
B
• Remove the dipstick and check that the oil is
between the upper a and lower b levels. If not,
add oil to the upper level.
Å For models without reverse transmissions
(SX600/MM600)
ı For models with reverse transmissions
(VX600ER/VT600)
SEA2530
Recommended oil:
Gear oil API “GL-3”
SAE #75 or #80
CAUTION:
Make sure that no foreign material enters the gear
case.
SEA2535
• Reinsert the dipstick and fit the loop 2 of the
dipstick handle onto the projection 3 of the gear
case.
2
3
SEA2540
2-25
DRIVE CHAIN
INSP
ADJ
Oil replacement
A
Oil replacement steps:
• Place the oil pan under the drain hole.
• Remove the oil drain bolt 1 and drain the oil.
CAUTION:
Be sure to remove any oil from the heat protector.
SEA2545
• Install the oil drain bolt 1.
B
T.
1
R.
Oil drain bolt:
16 Nm (1.6 m · kg, 11 ft · lb)
Recommended oil:
Gear oil API “GL-3” SAE #75 or #80
Oil capacity:
0.25 L (8.8 Imp oz, 8.5 US oz)
SEA2550
Å VX600ER/SX600/VT600
ı MM600
Chain slack adjustment
1. Remove:
• Battery (VX600ER/VT600)
• Battery bracket (VX600ER/VT600)
WARNING
When removing the battery, disconnect the negative lead first.
2. Adjust:
• Drive chain slack
2
Adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting bolt 2 in until it is finger tight.
• Tighten the locknut 1.
1
SEA2555
T.
R.
2-26
Locknut (Chain tensioner):
24 Nm (2.4 m · kg, 17 ft · lb)
DRIVE CHAIN/
TRACK TENSION ADJUSTMENT
INSP
ADJ
3. Install:
• Battery bracket (VX600ER/VT600)
• Battery (VX600ER/VT600)
CAUTION:
• Connect the positive lead to the battery termi•
•
nal first.
Make sure the battery leads are connected
properly. Reversing the leads can seriously
damage the electrical system.
Make sure that the battery breather hose is
properly connected and is not obstructed.
TRACK TENSION ADJUSTMENT
WARNING
A broken track or track fittings, and debris thrown
by the track could be dangerous to an operator or
by standers. Observe the following precautions.
• Do not allow anyone to stand behind the
machine when the engine is running.
• When the rear of the machine is raised to allow
the track to spin, a suitable stand must be used
to support the rear of the machine. Never allow
anyone to hold the rear of the machine off the
ground to allow the track to spin. Never allow
anyone near a rotating track.
• Inspect the condition of the track frequently.
Replace the track if it is damaged to a level
where the fabric reinforcement material is
visible.
• Never install studs (cleats) closer than 76 mm
(3 in) to the edge of the track.
1. Lift the rear of the machine onto a suitable stand
to raise the track off the ground.
2. Measure:
• Track deflection a
Using a spring scale 1, pull down on the center
of the track with 10 kg (22 lb) of force.
Out of specification → Adjust.
Track deflection:
VX600ER/SX600/VT600:
25 ~ 30 mm (0.98 ~ 1.18 in)
MM600:
20 ~ 25 mm (0.79 ~ 0.98 in)
SEA2560
2-27
INSP
ADJ
TRACK TENSION ADJUSTMENT
3. Adjust:
• Track deflection
Adjustment steps:
• Place the machine onto a suitable stand to raise
the track off of the ground.
• Loosen the rear axle nut 1.
NOTE:
It is not necessary to remove the cotter pin 2.
SEA2565
a. Start the engine and rotate the track once or
twice. Stop the engine.
b. Check the track alignment with the slide runner 3.
If the alignment is incorrect, turn the left and right
adjusters to adjust.
SEA2570
A
Track alignment
6 Shifted
to right
7 Shifted
to left
Turn out
Turn in
Turn in
Turn out
4 Left adjuster
5 Right adjuster
8 Slide runner
0 Track metal
9 Track
A Gap
B Forward
Å VX600ER/SX600/VT600
ı MM600
SEA2575
c. Adjust the track deflection until the specified
amount is obtained.
B
Track deflection
4 Left adjuster
5 Right adjuster
4
More than
specified
Less than
specified
Turn in
Turn in
Turn out
Turn out
CAUTION:
5
SEA2580
The adjusters should be turned an equal amount.
6
7
• Recheck the alignment and deflection. If neces•
sary, repeat steps (a) to (c) until the specified
amount is obtained.
Tighten the rear axle nut.
T.
R.
SEA2585
2-28
Nut (rear axle):
75 Nm (7.5 m · kg, 54 ft · lb)
SLIDE RUNNER INSPECTION
INSP
ADJ
SLIDE RUNNER INSPECTION
1. Inspect:
• Slide runner 1
Cracks/damage/wear → Replace.
2. Measure:
• Slide runner thickness a
Out of specification → Replace.
Slide runner wear limit:
10 mm (0.39 in)
SEA2590
2-29
MAXIMIZING DRIVE TRACK LIFE
INSP
ADJ
MAXIMIZING DRIVE TRACK LIFE
Recommendations
Track tension
During initial break-in, the new drive track will tend to
stretch quickly as the track settles. Be sure to correct
the track tension and alignment frequently. (See
pages 2-27 ~ 2-28 for adjustment procedures.) A
loose track can slip (ratchet), derail or catch on
suspension parts causing severe damage. Do not
overtighten the drive track, otherwise it may increase
the friction between the track and the slide runnners,
resulting in the rapid wear of both components. Also,
this may put an excessive load on the suspension
components, resulting in component failure.
Marginal snow
The drive track and the slide runners are lubricated
and cooled by snow and water. To prevent the drive
track and slide runners from overheating, avoid sustained high-speed usage in areas such as icy trails,
frozen lakes and rivers that have minimal snow
coverage. An overheated track will be weakened
internally, which may cause failure or damage.
Off-trail riding
Avoid off-trail riding until there is sufficient snow
coverage. It generally takes several feet of snow to
provide a good overall base to properly cover debris,
such as rocks, logs, etc. If snow coverage is not
sufficient, stay on trails to avoid impact damage to the
drive track.
Studded track
In general, track life will be shortened when studs are
installed. Drilling stud holes into the drive track will cut
the internal fibers, which weakens the track. Avoid
spinning the drive track. Studs may catch on an
object and pull out of the track, leaving tears and
damage around the already weakened area. To
minimize possible damage, consult your stud manufacturer for installation and stud pattern recommendations.
Yamaha does not recommend track studding.
2-30
SKI/SKI RUNNER
INSP
ADJ
CHASSIS
A
SKI/SKI RUNNER
1. Inspect:
• Ski
• Ski runner
Damage/wear → Replace.
2. Measure:
• Ski runner wear limit a
• Plastic ski wear limit b
Out of specification → Replace.
a
SEA2595
A
Ski runner wear limit:
8 mm (0.31 in)
Plastic ski wear limit:
VX600ER/VT600:
13 mm (0.51 in)
SX600/MM600:
8 mm (0.31 in)
SEA2600
CAUTION:
B
To avoid scratching, wearing and damaging the
plastic skis, be careful when loading and unloading the snowmobile and avoid riding in areas with
little or no snow and on surfaces with sharp
edges such as concrete, curbs, etc.
Å VX600ER/VT600
ı SX600/MM600
SEA2605
B
SEA2610
2-31
STEERING SYSTEM
INSP
ADJ
STEERING SYSTEM
Free play check
1. Check:
• Steering system free play
Move the handlebar up and down and back
and forth.
Turn the handlebar slightly to the right and left.
Excessive free play → Check that the handlebar, tie rod ends and relay rod ends are installed securely in position. If free play still
exists, check the steering bearing, front suspension links and ski mounting area for wear.
Replace if necessary.
SEA2615
Toe-out adjustment
1. Place the machine on a level surface.
2. Check:
• Ski toe-out (a – c)
Point the skis forward.
Out of specification → Adjust.
• Ski stance (center to center) b
Ski toe-out:
0 ~ 15 mm (0 ~ 0.59 in)
Ski stance (center to center):
VX600ER/SX600/VT600:
1,070 mm (42.1 in)
MM600:
980 mm (38.6 in)
SEA2620
2-32
STEERING SYSTEM/LUBRICATION
INSP
ADJ
3. Adjust:
• Ski toe-out
A
Adjustment steps:
• Loosen the locknuts (tie rod) 1.
• Turn the tie rods 2 in or out until the specified toeout is obtained.
• Tighten the locknuts (tie rod) 1.
SEA2625
T.
R.
B
Locknut (tie rod):
25 Nm (2.5 m · kg, 18 ft · lb)
LOCTITE®
CAUTION:
After tightening the inside and outside ball joint
locknuts 1, make sure the tie rod 2 can be
rotated freely through the ball joint travel. If not,
loosen the locknut 1 and re-position the ball joint
so that the tie rod 2 can be rotated freely. Tighten
the locknuts to specification.
SEA2630
C
Å Left side
ı Right side
Ç Inside
SEA2635
LUBRICATION
Brake lever, throttle lever and throttle cable end
1. Lubricate the brake lever pivot, throttle lever and
the ends of the throttle cables.
Recommended lubricant:
ESSO Beacon 325 Grease
WARNING
SEA2640
Apply a dab of grease onto only the end of the
cables.
Do not grease the throttle cables.
They could freeze and cause a loss of control.
2-33
LUBRICATION
INSP
ADJ
Relay arm (steering)
1. Use a grease gun to inject grease into the
nipple 1.
Recommended lubricant:
ESSO Beacon 325 Grease or
Aeroshell Grease #7A
SEA2645
Front and rear suspension
1. Use a grease gun to inject grease into the
nipples 1.
Lubricate the ball joints 2, 3.
A
Recommended lubricant:
Esso Beacon 325 Grease or
Aeroshell Grease #7A
Å Front
ı Rear (VX600ER/SX600/VT600)
Ç Rear (MM600)
SEA2650
A
SEA2655
B
SEA2660
C
SEA2665
2-34
HEADLIGHT BEAM ADJUSTMENT
INSP
ADJ
ELECTRICAL
HEADLIGHT BEAM ADJUSTMENT
1. Place the machine on a level surface.
2. Place the machine in front of a wall at the recommended distance D. Refer to the table below.
3. Measure the distance H from the floor to the
center of the headlight and place a mark on the
wall at that height.
SEA2670
4. With a person sitting on the machine, apply the
parking brake, start the engine and let it idle.
5. Switch on the headlight’s high beam and check
the height of the projected beam on the wall. The
projection should be at the position marked in
step 3 or 1/2° lower (set range S).
D
3.0 m (10 ft)
7.6 m (25 ft)
S
26 mm (1.0 in)
66 mm (2.6 in)
D: Distance
S: Set range
6. Adjust:
• Headlight beam (vertically)
Vertical adjustment
Higher
Turn the adjusting screw 1 + 2
clockwise.
Lower
Turn the adjusting screw 1 + 2
counterclockwise.
SEA2675
7. Adjust:
• Headlight beam (horizontally)
Horizontal adjustment
To right Turn the adjusting screw 1
clockwise or turn the adjusting
screw 2 counterclockwise.
To left
Turn the adjusting screw 2
clockwise or turn the adjusting
screw 1 counterclockwise.
2-35
BATTERY INSPECTION (VX600ER/VT600)
INSP
ADJ
BATTERY INSPECTION (VX600ER/VT600)
WARNING
Battery fluid is poisonous and dangerous, causes
severe burns, etc. Contains sulfuric acid.
Avoid contact with skin, eyes or clothing.
Antidote:
EXTERNAL – Flush with water.
INTERNAL – Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg or
vegetable oil. Call a physician immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep sparks,
flames, cigarettes, etc. away. Ventilate when
charging or using in enclosed space. Always
shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
1. Remove:
• Battery
WARNING
When removing the battery, disconnect the negative lead first.
2. Inspect:
• Fluid level should be between “UPPER
LEVEL” a and “LOWER LEVEL” b marks.
Incorrect → Refill.
CAUTION:
Refill with distilled water only; tap water contains
minerals harmful to a battery.
SEA2680
3. Check:
• Specific gravity.
Less than 1.280 → Recharge battery.
Specific gravity:
1.280 at 20°C (68°F)
2-36
BATTERY INSPECTION (VX600ER/VT600)
INSP
ADJ
Replace the battery if:
• Battery voltage will not rise to a specific value or
bubbles fail to rise even after many hours of
charging.
• Sulfation of one or more cells occurs, as indicated
by the plates turning white, or an accumulation of
material exists in the bottom of the cell.
• Specific gravity readings after a long, slow charge
indicate one cell to be lower than the rest.
• Warpage or buckling of plates or insulators is
evident.
SEA2685
CAUTION:
Always charge a new battery before using it to
ensure maximum performance.
4. Inspect:
• Battery terminal
Dirty terminal → Clean with a wire brush.
Poor connection → Correct.
NOTE:
After cleaning the terminals, apply grease lightly to
the terminals.
SEA2690
5. Install:
• Battery
CAUTION:
• Connect the positive lead to the battery terminal first.
• Make sure the battery leads are connected
•
2-37
properly. Reversing the leads can seriously
damage the electrical system.
Make sure that the battery breather hose is
properly connected and is not obstructed.
BATTERY CHARGING (VX600ER/VT600)
INSP
ADJ
BATTERY CHARGING (VX600ER/VT600)
The battery must be charged properly before using
for the first time. This initial charge will prolong the life
of the battery.
1. Remove:
• Battery
WARNING
When removing the battery, disconnect the negative lead first.
Battery charging step:
• Remove all filler caps from the battery.
NOTE
Place the battery on a level place.
• Cool the electrolyte down to below 30°C (86°F).
• Pour electrolyte into each cell little by little up to the
upper level line, and leave it for a while. When the
battery fluid permeates the plates and separators,
the fluid level begins to lower. Add electrolyte and
bring back to upper level line.
NOTE:
Fill the battery with diluted sulfuric acid (electrolyte).
• Connect the battery to a battery charger 1.
• Set the battery charger rate at 1/10 the battery
capacity and charge the battery for 10 hours.
Charging Rate:
2.0 Ah × 10 hours
SEA2695
• Turn the battery charger off then disconnect it
•
•
2-38
from the battery.
Check the specific gravity of each cell with a
hydrometer. If the hydrometer reading is below
the specification, additional charging is necessary.
Install the filler caps, and thoroughly wipe off the
fluid around the filler caps.
BATTERY CHARGING (VX600ER/VT600)/
FUSE INSPECTION (VX600ER/VT600)
INSP
ADJ
2. Install:
• Battery
CAUTION:
• Connect the positive lead to the battery terminal first.
• Make sure the battery leads are connected
•
properly. Reversing the leads can seriously
damage the electrical system.
Make sure that the battery breather hose is
properly connected and is not obstructed.
FUSE INSPECTION (VX600ER/VT600)
The following procedure applies to all of the fuses.
CAUTION:
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing a
fuse.
1 .Check:
• Continuity
Checking steps:
• Connect the pocket tester to the fuse and check
the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester:
90890-03112, YU-03112
• If the pocket tester indicates “∞”, replace the fuse.
2-39
FUSE INSPECTION (VX600ER/VT600)
INSP
ADJ
2. Replace:
• Blown fuse
Replacing steps:
• Set the main switch to “OFF”.
• Install a new fuse of the correct amperage.
• Set the main switch to “ON” and verify if the
electrical circuit is operational.
• If the fuse immediately blows again, check the
electrical circuit.
Item
Amperage
Q’ty
1 Main fuse
30 A
1
2 “HEAD” fuse
20 A
1
3 “TAIL” fuse
10 A
1
4 “IGNITION” fuse
10 A
1
5 Reserve fuse
20 A
10 A
1
1
6 Reserve fuse
30 A
1
SEA2700
WARNING
Never use a fuse with an amperage other than
that specified. Improvising or using a fuse with
the wrong amperage rating may cause extensive
damage to the electrical system, cause the lighting, ignition, grip warmer, signal and meter systems to malfunction and could possibly cause a
fire.
SEA2705
2-40
CARBURETOR TUNING
INSP
ADJ
TUNING
CARBURETOR TUNING
The carburetors are set at the factory to run at
temperatures of 0°C ~ –20°C (32°F ~ –4°F) at
sea level. If the machine is to be operated under
conditions other than those specified above, the
carburetors must be properly adjusted. Special care
should be taken in carburetor setting so
that the pistons will not be damaged or will not seize.
CAUTION:
Engine oil is mixed with fuel just before the fuel
enters the carburetors. During initial fuel flow to
the carburetors, it is not always possible to supply the optimum fuel/oil mixture depending on
the throttle opening. Therefore, after the carburetors have been tuned or maintained, or after the
float chambers are removed for cleaning or jet
replacement, be sure to idle the engine for about
three minutes in order to avoid engine trouble.
CAUTION:
Before performing the carburetor tuning, make
sure that the following items are set to
specification.
• Engine idle speed
• Throttle cable free play
• Carburetor synchronization
• Starter cable free play
• Oil pump cable free play
Carburetor tuning data
1. Standard specifications
Å Type:
TM31
ı Manufacturer:
MIKUNI
Ç I.D. Mark:
8DG100
Î Main jet (M.J.):
#1:136.3, #2, #3:133.8
‰ Pilot jet (P.J.):
#42.5
Ï Pilot screw (P.S.): 2 turns out
2-41
Ì Float height:
11.3 ~ 15.3 mm
(0.44 ~ 0.60 in)
Ó Idle speed:
1,600 ± 100 r/min
CARBURETOR TUNING
INSP
ADJ
Mid-range and high speed tuning
Adjustments are normally not required, but may sometimes be necessary, depending on temperatures,
altitude or both.
Mid-range speed and high speed tuning (from
1/4 to full-throttle) can be done by adjusting the main
jet.
CAUTION:
Never run the engine without the air intake silencer installed. Severe engine damage may result.
1. Start the engine and operate the machine under
normal conditions to make sure that the engine
operates smoothly. Stop the engine.
2. Remove:
• Spark plugs
3. Check:
• Spark plug insulator 1 color
A medium to light tan color indicates normal
conditions.
Distinctly different color → Replace the main
jet.
4. The main jet should be adjusted on the basis of
the “Main jet selection chart”.
SEA2710
NOTE:
By checking the condition of the spark plugs, it is easy
to get some idea of the condition of the engine. This
may diagnose potential problems before engine damage occurs.
High altitude tuning
Use the chart in CHAPTER 9 to select main jets
according to variations in elevation and temperature.
NOTE:
These jetting specifications are subject to change.
Consult the latest technical information from Yamaha
to be sure you have the most up-to-date jetting
specifications.
1
2
3
4
SEA2715
2-42
Clip
Jet needle
Pilot mixture screw
Main jet
CARBURETOR TUNING
INSP
ADJ
Guide for carburetion
SEA2720
2-43
CARBURETOR TUNING
INSP
ADJ
A Standard main jet
B Main jet whose diameter is 10% smaller than
standard
C Main jet whose diameter is 10% larger than
standard
SEA2725
A No. 2 position
B No. 1 position
C No. 3 position
SEA2730
CAUTION:
If the intake silencer is removed from the carburetors, the change in pressure in the intake will
create a lean mixture that may cause severe
engine damage. The intake silencer has no effect
on performance characteristics and must be secured to the carburetors during carburetor tuning
and adjustment. Also, it must always be in place
when the engine is operated. Regularly clean the
silencer and keep it free from obstructions.
SEA2735
2-44
CARBURETOR TUNING
INSP
ADJ
Low-speed tuning
The carburetors are built so that low speed tuning can
be done by adjusting the pilot mixture screw 2 and
throttle stop screw 1.
CAUTION:
Never run the engine without the air intake silencer installed. Severe engine damage may result.
SEA2290
1. Tighten the pilot mixture screw 2 until it is lightly
seated and then back it out the specified number
of turns.
Pilot mixture screw 2:
2 turns out
Pilot mixture screw effects:
Turn in
←
STD setting
Leaner
Mixture
→ Turn out
Richer
Mixture
2. Set the engine idle speed by turning the throttle
stop screw in (to increase engine speed) or out (to
decrease engine speed).
SEA2740
Engine idle speed:
1,600 ± 100 r/min
3. If low-speed performance is still poor at higher
elevations under extreme conditions, the standard pilot jets may need to be replaced. In this
way, the proper air/fuel mixture is obtained.
NOTE:
In this case, use a larger numbered pilot jet to enrich
the air/fuel mixture.
Standard pilot jet:
#42.5
2-45
CARBURETOR TUNING
INSP
ADJ
Main jet selection chart
Spark plug color
Diagnosis
Remedy
Light tan or gray
Carburetors are tuned
properly.
Dry black or fluffy
deposits
Mixture is too rich.
Replace the main jet with the next smaller size.
White or light gray
Mixture is too lean.
Replace the main jet with the next larger size.
White or gray insulator Mixture is too lean. The piston
with small black or
is damaged or seized.
grayish brown spots
and electrodes having a
bluish-burnt
appearance
Replace the piston and spark plug.
Tune the carburetors again. Begin with lowspeed tuning.
Melted electrodes and
possibly a blistered
insulator
Metallic deposits on
insulator
Check the piston for holes or seizure.
Check the cooling system, gasoline octane
rating and ignition timing. After replacing the
spark plug with a colder type, tune the
carburetors again. Begin with low-speed tuning.
Mixture is too lean. The spark
plug melted.
Troubleshooting
Trouble
Hard starting
Adjustment
Diagnosis
Insufficient fuel
Add gasoline.
Excessive use of the Return the starter lever to its seated position so that the
starter valve is fully closed.
starter or choke
Fuel passage is clogged • Check and, if necessary, clean the fuel tank air vent, the
fuel filter and all of the fuel passages.
or frozen
• Check and, if necessary, clean the carburetor air vents,
fuel passages and the float valve.
• Clean the float chamber of any ice or water.
Overflow
Adjust the fuel level.
Improper idling speed Adjust the engine idle speed.
Refer to “Low speed tuning”.
• Poor performance at adjustment
Damaged pilot screw
Replace the pilot screw.
low speeds
Poor idling:
• Poor acceleration
Clogged bypass hole
Clean the bypass hole.
• Slow response to Clogged or loose pilot jet • Remove the pilot jet, clean it with compressed air and
then install it.
throttle
• Make sure that the pilot jet is fully tightened.
• Engine tends to stall
Air leaking into the carbu- Retighten the clamp screws on the carburetor joints.
retor joint
Defective starter valve Clean or replace the starter valve seat.
seat
Overflow
Adjust the fuel level.
2-46
CARBURETOR TUNING
Trouble
Diagnosis
INSP
ADJ
Adjustment
Poor performance at Clogged or loose pilot jet • Remove the pilot jet, clean it with compressed air, and
then install it.
mid-range speeds:
• Make sure that the pilot jet is fully tightened.
• Momentary slow response to the throttle
• Poor acceleration
Lean mixture
Overhaul the carburetors.
Remove the air vent hose and clean it.
Poor performance at Clogged air vent
normal speeds:
Clogged or loose main jet • Remove the main jet, clean it with compressed air, and
then install it.
• Excessive fuel consumption
• Make sure that the main jet is fully tightened.
• Poor acceleration
Check and, if necessary, clean the float and float valve.
Overflow
Poor performance at Starter valve is left open Return the starter lever to its seated position so that the
starter valve is fully closed.
high speeds:
• Power loss
Clogged air vent
• Poor acceleration
Clogged or loose main air • Remove the main jet, clean it with compressed air, and
then install it.
jet
Remove and clean the air vent.
• Make sure that the main jet is fully tightened.
Clogged fuel line
Clean or replace the fuel line.
Dirty fuel tank
Clean the fuel tank.
Air leaks into the fuel line Tighten or replace the fuel line joint.
Low fuel pump perfor- Repair or replace the fuel pump.
mance
Clogged fuel filter
Replace the fuel filter.
Clogged intake
Remove any obstructions (e.g., ice).
Abnormal combustion: Lean mixture
Clean and adjust the carburetors.
Dirty carburetors
Clean the carburetors.
• Backfiring
Dirty or clogged fuel line
Clean or replace the fuel line.
Overflow:
Clogged air vent
Clean the air vent.
• Poor idling
Clogged float valve
• Disassemble and clean the float valve.
• Poor performance at
low, mid-range, and Scratched or unevenly
high speeds
worn float valve or valve
• Excessive fuel con- seat
sumption
Broken float
• Hard starting
• Power loss
• Poor acceleration
Incorrect float level
• Do not scratch the valve seat.
• Clean or replace the float valve and valve seat.
• The valve seat and body must be replaced as a set.
Replace the float.
Check and, if necessary, replace the following parts:
• Float tang
• Float (entire assembly)
• Arm pin
2-47
CLUTCH
CLUTCH
High altitude
Specifications
INSP
ADJ
G
Green
R
Red
Y
Yellow
Model: VX600ER
Å Elevation
ı Engine idle speed
Ç Engagement r/min
Î Shift r/min
‰ Main jet
Ï Pilot jet
Ì Pilot screw
Ó Secondary reduction
ratio (number of links)
È Primary sheave spring
Ô Color
 Free length
Ò Preload
˜ Spring rate
ˆ Wire diameter
Ø Outside diameter
∏ Weight (ID)
ΠWeight rivet
 Weight bushing
Í Roller outer dia.
Ê Roller bushing
Ë Pri. clutch shim
◊ Secondary sheave spring
„ Color
Ù Free length
Á Preload rate
Û Wire diameter
å Outside diameter
∫ Sec. torque cam angle
Ç Sec. clutch shim
~ 1,000 m
(~ 3,500 ft)
1,600 ± 100 r/min
4,000 ± 200 r/min
8,500 ± 250 r/min
900 ~ 1,500 m
(3,000 ~ 5,000 ft)
←
4,100 ± 200 r/min
←
1,400 ~ 2,100 m
(4,500 ~ 7,000 ft)
←
4,200 ± 200 r/min
←
2,000 ~ 3,000 m
(6,500 ~ 10,000 ft)
←
←
←
∂ Refer to “HIGH ALTITUDE SETTINGS” in “MAINTENANCE SPECIFICATIONS”.
39/21 (68 L)
90501-582L7
Y-G-Y
89.4 mm (3.52 in)
392 N (40 kg, 88 lb)
24.5 N/mm (2.50 kg/mm,
140 lb/in)
5.8 mm (0.228 in)
60 mm (2.362 in)
8DG-17605-00 (8DG00)
39/20 (68 L)
←
←
←
←
←
←
←
←
Aluminum 10.3 (OUT) None (OUT)
Steel 13.9 (IN)
Steel 13.9 (IN)
Duralon
←
15.0 mm (0.59 in)
←
Duralon
←
None
←
90508-536A9
←
R
←
75 mm (2.95 in)
←
80° (2-6)
729 kg·mm/rad
5.3 mm (0.209 in)
69.5 mm (2.736 in)
47°
1.0 mm (0.04 in)
39/19 (68 L)
90501-602L8
G-G-G
87.9 mm (3.46 in)
←
27.0 N/mm (2.75 kg/mm,
154 lb/in)
6.0 mm (0.236 in)
←
←
None (OUT)
Steel 10.3 (IN)
←
←
←
←
←
←
←
39/18 (68 L)
←
←
←
←
←
←
←
←
Aluminum 10.3 (OUT)
None (IN)
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
2-48
CLUTCH
Specifications
INSP
ADJ
G
Green
S
Silver
P
Pink
Y
Yellow
R
Red
Model: SX600
Å Elevation
ı Engine idle speed
Ç Engagement r/min
Î Shift r/min
‰ Main jet
Ï Pilot jet
Ì Pilot screw
Ó Secondary reduction
ratio (number of links)
È Primary sheave spring
Ô Color
 Free length
Ò Preload
˜ Spring rate
ˆ Wire diameter
Ø Outside diameter
∏ Weight (ID)
ΠWeight rivet
 Weight bushing
Í Roller outer dia.
Ê Roller bushing
Ë Pri. clutch shim
◊ Secondary sheave spring
„ Color
Ù Free length
Á Preload rate
Û Wire diameter
å Outside diameter
∫ Sec. torque cam angle
Ç Sec. clutch shim
~ 1,000 m
(~ 3,500 ft)
1,600 ± 100 r/min
4,200 ± 200 r/min
8,500 ± 250 r/min
900 ~ 1,500 m
(3,000 ~ 5,000 ft)
←
←
←
1,400 ~ 2,100 m
(4,500 ~ 7,000 ft)
←
4,100 ± 200 r/min
←
2,000 ~ 3,000 m
(6,500 ~ 10,000 ft)
←
4,200 ± 200 r/min
←
∂ Refer to “HIGH ALTITUDE SETTINGS” in “MAINTENANCE SPECIFICATIONS”.
39/20 (68 L)
90501-582L7
Y-G-Y
89.4 mm (3.52 in)
392 N (40 kg, 88 lb)
24.5 N/mm (2.50 kg/mm,
140 lb/in)
5.8 mm (0.228 in)
60 mm (2.362 in)
8DG-17605-00 (8DG00)
Steel 10.3 (OUT)
Steel 13.9 (IN)
Duralon
14.5 mm (0.57 in)
Duralon
None
90508-536A9
R
75 mm (2.95 in)
80° (2-6)
729 kg·mm/rad
5.3 mm (0.209 in)
69.5 mm (2.736 in)
47°
1.0 mm (0.04 in)
39/19 (68 L)
←
←
←
←
←
←
←
←
39/18 (68 L)
←
90501-602L3
P-S-P
85.1 mm (3.35 in)
343 N (35 kg, 77 lb)
29.4 N/mm (3.00 kg/mm,
168 lb/in)
6.0 mm (0.236 in)
←
←
←
←
←
←
←
←
←
←
Aluminum 10.3 (OUT) Aluminum 10.3 (OUT) Aluminum 10.3 (OUT)
Steel 13.9 (IN)
Steel 10.3 (IN)
Aluminum 10.3 (IN)
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
2-49
90° (3-6)
729 kg·mm/rad
←
←
←
←
←
←
←
←
←
CLUTCH
INSP
ADJ
R
Red
W White
Y
Specifications
Yellow
Model: MM600
Å Elevation
ı Engine idle speed
Ç Engagement r/min
Î Shift r/min
‰ Main jet
Ï Pilot jet
Ì Pilot screw
Ó Secondary reduction
ratio (number of links)
È Primary sheave spring
Ô Color
 Free length
Ò Preload
˜ Spring rate
ˆ Wire diameter
Ø Outside diameter
∏ Weight (ID)
ΠWeight rivet
 Weight bushing
Í Roller outer dia.
Ê Roller bushing
Ë Pri. clutch shim
◊ Secondary sheave spring
„ Color
Ù Free length
Á Preload rate
Û Wire diameter
å Outside diameter
∫ Sec. torque cam angle
Ç Sec. clutch shim
~ 1,000 m
(~ 3,500 ft)
1,600 ± 100 r/min
4,400 ± 200 r/min
8,500 ± 250 r/min
900 ~ 1,500 m
(3,000 ~ 5,000 ft)
←
4,500 ± 200 r/min
←
1,400 ~ 2,100 m
(4,500 ~ 7,000 ft)
←
4,600 ± 200 r/min
←
2,000 ~ 3,000 m
(6,500 ~ 10,000 ft)
←
←
←
∂ Refer to “HIGH ALTITUDE SETTINGS” in “MAINTENANCE SPECIFICATIONS”.
39/21 (68 L)
←
90501-603L2
Y-W-Y
91.4 mm (3.60 in)
441 N (45 kg, 99 lb)
24.5 N/mm (2.50 kg/mm,
140 lb/in)
6.0 mm (0.236 in)
60 mm (2.362 in)
8DG-17605-00 (8DG00)
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
Steel 17.2 (OUT)
Steel 17.2 (IN)
Duralon
15.6 mm (0.61 in)
Duralon
None
90508-536A9
R
75 mm (2.95 in)
80° (2-6)
729 kg·mm/rad
5.3 mm (0.209 in)
69.5 mm (2.736 in)
43°
1.0 mm (0.04 in)
Steel 13.3 (OUT)
Steel 13.9 (IN)
←
←
←
←
←
←
←
39/19 (68 L)
Steel 13.3 (OUT)
Steel 10.3 (IN)
←
←
←
←
←
←
←
←
Aluminum 10.3 (OUT)
Steel 10.3 (IN)
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
2-50
CLUTCH
Specifications
INSP
ADJ
G
Green
P
Pink
S
Silver
R
Red
Model: VT600
Å Elevation
ı Engine idle speed
Ç Engagement r/min
Î Shift r/min
‰ Main jet
Ï Pilot jet
Ì Pilot screw
Ó Secondary reduction
ratio (number of links)
È Primary sheave spring
Ô Color
 Free length
Ò Preload
˜ Spring rate
ˆ Wire diameter
Ø Outside diameter
∏ Weight (ID)
ΠWeight rivet
 Weight bushing
~ 1,000 m
(~ 3,500 ft)
1,600 ± 100 r/min
4,000 ± 200 r/min
3,900 ± 200 r/min
(for Europe)
8,500 ± 250 r/min
900 ~ 1,500 m
(3,000 ~ 5,000 ft)
←
4,100 ± 200 r/min
4,000 ± 200 r/min
(for Europe)
←
1,400 ~ 2,100 m
(4,500 ~ 7,000 ft)
←
2,000 ~ 3,000 m
(6,500 ~ 10,000 ft)
←
4,200 ± 200 r/min
←
←
←
∂ Refer to “HIGH ALTITUDE SETTINGS” in “MAINTENANCE SPECIFICATIONS”.
39/20 (68 L)
39/19 (68 L)
39/18 (68 L)
39/18 (68 L)
(for Europe)
(for Europe)
90501-602L9
90501-582L2
←
(for Europe)
P-G-P
←
G-S-G (for Europe)
86.7 mm (3.41 in)
87.4 mm (3.44 in)
←
(for Europe)
392 N (40 kg, 88 lb)
343 N (35 kg, 77 lb)
←
(for Europe)
29.4 N/mm (3.00 kg/mm,
168 lb/in)
27.0 N/mm (2.75 kg/mm,
←
154 lb/in)
(for Europe)
6.0 mm (0.236 in)
5.8 mm (0.228 in)
←
(for Europe)
60 mm (2.362 in)
←
8DG-17605-00 (8DG00)
←
Steel 10.3 (OUT)
Steel 13.9 (OUT)
Steel 13.9 (IN)
Steel 17.2 (IN)
Steel 17.2 (IN)
(for Europe)
Duralon
←
2-51
39/18 (68 L)
←
90501-602L9
←
P-G-P
←
86.7 mm (3.41 in)
←
392 N (40 kg, 88 lb)
←
29.4 N/mm (3.00 kg/mm,
168 lb/in)
←
6.0 mm (0.236 in)
←
←
←
←
←
Aluminum 10.3 (OUT) None (OUT)
Steel 13.9 (IN)
Steel 13.3 (IN)
←
←
CLUTCH
Specifications
INSP
ADJ
G
Green
P
Pink
S
Silver
R
Red
Model: VT600
Å Elevation
ß Roller outer dia.
Ê Roller bushing
Ë Pri. clutch shim
√ Secondary sheave spring
∑ Color
≈ Free length
Á Preload rate
Ω Wire diameter
å Outside diameter
∫ Sec. torque cam angle
ç Sec. clutch shim
~ 1,000 m
(~ 3,500 ft)
14.5 mm (0.57 in)
Duralon
None
90508-536A9
90508-556A2
(for Europe)
R
G
(for Europe)
900 ~ 1,500 m
(3,000 ~ 5,000 ft)
←
←
←
75 mm (2.95 in)
70° (1-6)
729 kg·mm/rad
80° (2-6)
848 kg·mm/rad
5.3 mm (0.209 in)
5.5 mm (0.217 in)
(for Europe)
69.5 mm (2.736 in)
43°
1.0 mm (0.04 in)
←
1,400 ~ 2,100 m
(4,500 ~ 7,000 ft)
←
←
←
2,000 ~ 3,000 m
(6,500 ~ 10,000 ft)
←
←
←
←
90508-536A9
←
←
R
←
←
←
←
70° (1-6)
729 kg·mm/rad
←
←
5.3 mm (0.209 in)
←
←
←
←
2-52
←
←
←
←
←
←
CLUTCH/GEAR SELECTION
INSP
ADJ
The clutch may require tuning depending upon where
the machine will be operated and the desired handling characteristics. The clutch can be tuned by
changing the engagement and shifting speeds.
Clutch engagement speed is defined as the engine
speed at which the machine first begins to move from
a complete stop.
Clutch shifting speed is defined as the engine speed
reached when the machine has travelled 200 ~
300 m (650 ~ 1,000 ft) after being started at fullthrottle from a dead stop.
Normally, when a machine reaches shifting speed,
the vehicle speed increases but the engine speed
remains nearly constant. Under unfavorable conditions (wet snow, icy snow, hills, or rough terrain),
however, engine speed may decrease after the shifting speed has been reached.
Å Engine speed
ı Good condition
Ç Bad condition
Î Clutch shifting speed
‰ Clutch engagement speed
Ï Starting position
Ì 200 ~ 300 m (650 ~ 1,000 ft)
Ó Distance travelled
SEA2745
GEAR SELECTION
The reduction ratio of the driven gear to the drive gear
must be set according to the snow conditions. If there
are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased.
If the surfaces are fairly smooth or better snow
conditions exist, decrease the ratio.
Gear ratio chart
The drive and driven gears and the chains shown in
the gear ratio chart are available as options. The
figures containing a decimal point represent the drive/
driven gear ratios, while the bottom numbers designate the number of links in the chain.
2-53
GEAR SELECTION
INSP
ADJ
1 Chain and sprocket part number
Å Part name
ı Teeth & links
Ç Part no.
Î Standard
18 teeth
19 teeth
89J-17682-80
89J-17682-91
VT600 for Europe
MM600
20 teeth
89J-17682-00
SX600
VT600 for U.S.A./Canada
21 teeth
22 teeth
23 teeth
39 teeth
39 teeth
40 teeth
68 links
70 links
89J-17682-10
89J-17682-20
89J-17682-30
8CW-47587-90
89J-47587-90
89J-47587-00
94860-02068
94860-02070
‰ Drive sprocket
Ï Driven sprocket
Ì Chain
VX600ER
VX600ER/VT600
SX600/MM600
VX600ER/SX600/MM600/VT600
2 Gear ratio
Å Drive sprocket
18 teeth 19 teeth 20 teeth 21 teeth 22 teeth 23 teeth
ı Driven sprocket
2.053
1.950
1.857
1.773
1.696
2.167
68 links 68 links 68 links 68 links 70 links 70 links
2.105
2.000
1.905
1.818
1.739
2.222
68 links 68 links 68 links 70 links 70 links 70 links
39 teeth
40 teeth
3 Secondary sheave spring
Å Part no.
90508-500B1
90508-536A9
ı Spring rate
(torsion)
N·mm/rad
(kg·mm/rad)
N/mm (kg/mm) (lb/in)
6003 (613)
6.2 (0.63), 35.28
7147 (729)
Ç Spring rate
Î Color
(compression)
7.3 (0.74), 41.44
‰ Wire
Ï No. of
gauge
coils
mm (in)
Brown
Red
5.0 (0.196)
5.3 (0.209)
5.19
5.53
Ì Free
Ó Outside
length
diameter
mm (in)
mm (in)
75 (2.95)
69.5 (2.736)
75 (2.95)
69.5 (2.736)
È Standard
VX600ER/
SX600/
MM600
VT600 for
U.S.A/Canada
90508-556A2
8314 (848)
8.5 (0.87), 48.72
Green
5.5 (0.217)
5.53
75 (2.95)
69.5 (2.736)
90508-556A7
9460 (965)
10.21 (1.04), 58.24
Silver
5.5 (0.217)
4.86
75 (2.95)
69.5 (2.736)
VT600 for
Europe
4 Secondary spring twist angle
90508-500B1 (brown) / 90508-536A9 (red) / 90508-556A2 (green) / 90508-556A7 (silver)
Å Seat
ı Sheave
1
2
3
0
10°
20°
30°
3
40°
50°
60°
2-54
6
70°
80°
90°
9
100°
110°
120°
GEAR SELECTION
INSP
ADJ
5 Torque cam (secondary sheave spring seat)
SEA2750
ı Effects
Ç Part no.
Î Cam angle
‰ Identification mark
Ï Standard
8BV-17604-71
47°
8BV71
VX600ER/SX600
8BV-17604-51
45°
8BV51
8BV-17604-31
43°
8BV31
8BV-17604-11
41°
8BV11
8BV-17604-91
39°
8BV91
2-55
MM600/VT600
GEAR SELECTION
INSP
ADJ
6 Primary sheave spring
SEA2755
Î
‰
Ï
Ó
È
Ô

Parts No.
Spring rate
Preload
Ì Color
Wire
Outside
No. of
Free
N/mm
N (kg)
gauge
diameter
coils
length
mm (in)
mm (in)
(kg/mm)
mm (in)
Blue-Pink-Blue
5.5 (0.216) 60 (2.362)
4.91
88.4 (3.48)
90501-551L9 19.6 (2.00) 343 (35)
Blue-Silver-Blue
5.5 (0.216) 60 (2.362)
4.91
90.9 (3.58)
90501-552L5 19.6 (2.00) 392 (40)
Blue-Green-Blue
5.5 (0.216) 60 (2.362)
4.91
93.4 (3.68)
90501-581L5 24.5 (2.50) 294 (30)
Yellow-Pink-Yellow
5.8 (0.228) 60 (2.362)
4.92
85.4 (3.36)
90501-581L6 27.0 (2.75) 294 (30)
Green-Pink-Green
5.8 (0.228) 60 (2.362)
4.66
84.3 (3.32)
90501-582L1 24.5 (2.50) 343 (35)
Yellow-Gold-Yellow
5.8 (0.228) 60 (2.362)
4.92
87.4 (3.44)
90501-582L2 27.0 (2.75) 343 (35)
Green-Silver-Green
5.8 (0.228) 60 (2.362)
4.66
87.4 (3.44)
90501-582L6 22.1 (2.25) 392 (40)
White-Green-White
5.8 (0.228) 60 (2.362)
5.25
91.2 (3.59)
90501-582L7 24.5 (2.50) 392 (40)
Yellow-Green-Yellow
5.8 (0.228) 60 (2.362)
4.92
89.4 (3.52)
90501-583L0 19.6 (2.00) 441 (45)
Blue-White-Blue
5.8 (0.228) 60 (2.362)
5.65
95.9 (3.78)
90501-583L1 22.1 (2.25) 441 (45)
White-White-White
5.8 (0.228) 60 (2.362)
5.25
93.4 (3.68)
90501-583L4 22.1 (2.25) 343 (35)
White-Silver-White
5.8 (0.228) 60 (2.362)
5.25
89.0 (3.50)
90501-583L5 22.1 (2.25) 294 (30)
White-Pink-White
5.8 (0.228) 60 (2.362)
5.25
86.7 (3.41)
90501-601L7 29.4 (3.00) 294 (30)
Pink-Pink-Pink
6.0 (0.236) 60 (2.362)
4.82
83.4 (3.28)
90501-601L8 31.9 (3.25) 294 (30)
Orange-Pink-Orange
6.0 (0.236) 60 (2.362)
4.60
82.6 (3.25)
90501-602L3 29.4 (3.00) 343 (35)
Pink-Silver-Pink
6.0 (0.236) 60 (2.362)
4.82
85.1 (3.35)
90501-602L8 27.0 (2.75) 392 (40)
Green-Green-Green
6.0 (0.236) 60 (2.362)
5.08
87.9 (3.46)
90501-602L9 29.4 (3.00) 392 (40)
Pink-Green-Pink
6.0 (0.236) 60 (2.362)
4.82
86.7 (3.41)
90501-603L2 24.5 (2.50) 441 (45)
Yellow-White-Yellow
6.0 (0.236) 60 (2.362)
5.39
91.4 (3.60)
90501-603L3 27.0 (2.75) 441 (45)
Green-White-Green
6.0 (0.236) 60 (2.362)
5.08
89.8 (3.54)
90501-624L8 31.9 (3.25) 343 (35)
Orange-Silver-Orange
6.2 (0.244) 60 (2.362)
5.00
84.2 (3.31)
90501-551L3 19.6 (2.00) 294 (30)
Ò Standard
VT600 for Europe
VX600ER/SX600
VT600 for U.S.A/
2-56
Canada
MM600
GEAR SELECTION
7 Clutch weights
Å Standard
8CH-17605-10
35.32 g
SEA2760
8CR-17605-10
38.09 g
SEA2765
8DG-17605-00
34.30 g
VX600ER/
SX600/
MM600/
VT600
SEA2770
8DJ-17605-00
37.77 g
SEA2775
8DN-17605-20
42.09 g
SEA2780
8EK-17605-00
39.00 g
SEA2785
2-57
INSP
ADJ
GEAR SELECTION
INSP
ADJ
8 Rollers
Å ROLLER with
BUSHING
PART NUMBER
ı OUTSIDE
DIAMETER
8CR-17624-00
14.5 mm
(0.57 in)
Ç BUSHING Î IDENTIFICATION
TYPE (P/N)
MARK (Width)
COLLAR OUTSIDE
DIAMETER (P/N)
‰ Standard
Duralon
90380-09245
SX600/
VT600
8CR-17624-10
15.0 mm
(0.59 in)
9 mm (0.4 in)
90387-0514U
Duralon
90380-09245
SEA2790
VX600ER
8CR-17624-20
15.6 mm
(0.61 in)
9 mm (0.4 in)
90387-0514U
Duralon
90380-09245
SEA2795
MM600
8CR-17624-30
16.0 mm
(0.63 in)
9 mm (0.4 in)
90387-0514U
Duralon
90380-09245
SEA2800
9 mm (0.4 in)
90387-0514U
SEA2805
2-58
Ï EFFECTS
HIGH ALTITUDE TUNING
INSP
ADJ
HIGH ALTITUDE TUNING
To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below.
Check STD settings
Carburetors
•
•
Spark plugs
▼
Adjust the main jet size according to the
chart
▼
Not OK
Adjust the size of the main jet
▼
Test the main jet
(performance & plug color)
▼
OK
▼
OK
Check to see if the gearing is too high or low
▼
OK
▼
Not OK
▼
OK
Try high altitude settings
OK
▼
Not OK
Not OK
▼
Test the low speed setting
▼
Re-test
▼
Decide if the problem is with the
pilot jet and adjust accordingly
▼
▼
OK
Not OK
OK
▼
Check the engagement speed
and shift performance
High altitude
tuning OK
▼
▼
Adjust the primary clutch as required
Not OK
▼
Not OK
OK
Not OK
▼
Adjust the secondary clutch as required
2-59
OK
INSP
ADJ
FRONT SUSPENSION
FRONT SUSPENSION
Spring preload (VX600ER/MM600/VT600)
1. Adjust:
• Spring preload
Adjustment steps:
• Turn the adjusting ring 1 to the proper position.
Spring adjuster
position
SEA2810
1
2
3
Preload
Softer ←
Standard
VX600ER/VT600: 1
MM600: 3
4
5
→ Harder
CAUTION:
Be sure that the left and right spring preload is the
same.
Spring preload (SX600)
1. Adjust:
• Spring preload
Adjustment steps:
• Turn the spring seat 1 in or out.
SEA2815
Standard
Spring seat
distance
Shorter ←
→ Longer
Preload
Harder ←
→ Softer
Min.
Length a
251.5 mm
(9.90 in)
Max.
261.5 mm
(10.30 in)
261.5 mm
(10.30 in)
CAUTION:
Be sure that the left and right spring preloads are
the same.
WARNING
This shock absorber contains highly pressurized
nitrogen gas.
Do not tamper with or attempt to open the shock
absorber assembly.
Do not subject the shock absorber assembly to
flames or high heat, which could cause it to
explode.
2-60
REAR SUSPENSION
INSP
ADJ
REAR SUSPENSION
Stopper band
1. Adjust:
• Stopper band tension
CAUTION:
Make sure the left and right sides of the rear
suspension stopper band are adjusted evenly.
NOTE:
This adjustment affects the handling characteristics
of the machine.
A
Adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting nut 2 in or out to adjust the
stopper band tension.
SEA2820
B
Adjuster
thread
length a
VX600ER:
15 ± 0.5 mm (0.59 ± 0.02 in)
SX600/VT600:
25 ± 0.5 mm (0.98 ± 0.02 in)
MM600:
10 ± 0.5 mm (0.39 ± 0.02 in)
Longer
Shorter
(Maximum)
(Minimum)
Effects
More weight
on skis;
Less weight
transfer
SEA2825
1
a
2
Less weight
on skis;
More weight
transfer
• Tighten the locknut.
T.
R.
Locknut:
16 Nm (1.6 m · kg, 11 ft · lb)
Å VX600ER/SX600/VT600
ı MM600
2-61
INSP
ADJ
REAR SUSPENSION
Spring preload (VX600ER/MM600/VT600)
1. Adjust:
• Spring preload
A
Adjustment steps:
• Turn the adjusting ring 1 to the proper position.
Spring adjuster
position
SEA2830
B
1
2
3
4
5
Preload
Softer ←
Å Front Standard
VX600ER/MM600/VT600: 3
Spring adjuster
position
1
Preload
Softer ←
ı Rear Standard
VX600ER: 2
MM600/VT600: 4
2
→ Harder
3
4
5
6
7
→ Harder
SEA2835
Spring preload (SX600)
1. Adjust:
• Spring preload
A
Adjustment steps:
• Turn the spring seat 1 in or out.
Standard
Spring seat
SEA2840
B
distance
Shorter ←
→ Longer
Preload
Harder ←
→ Softer
Å Front:
length a
203 mm
(7.99 in)
ı Rear:
length b
358.5 mm
(14.11 in)
Min.
Max.
213 mm
(8.39 in)
213 mm
(8.39 in)
368.5 mm
(14.51 in)
378.5 mm
(14.90 in)
Min.
Max.
WARNING
This shock absorber contains highly pressurized
nitrogen gas.
Do not tamper with or attempt to open the shock
absorber assembly.
Do not subject the shock absorber assembly to
flames or high heat, which could cause it to
explode.
SEA2845
2-62
REAR SUSPENSION
INSP
ADJ
Rear suspension-full rate
1. Adjust:
• Full rate adjuster
Adjustment steps:
Installation
position
Spring rate
and damping
SEA2850
A
B
C
Soft
Medium
Hard
Standard
B
NOTE:
Be sure to make this adjustment when there is no load
(rider or cargo) on the snowmobile.
• Loosen the nut 1 1/2 or 3/4 turns, while holding
the adjusting bolt 2 securely with a wrench so it
does not move.
SEA2855
CAUTION:
Never allow the adjusting bolt 2 to move while
loosening the nut.
• Turn the adjusting bolt 2 to the desired position.
CAUTION:
Be sure the adjusting bolt ends are set at the
same position on each side.
• While holding the adjusting bolt securely, tighten
SEA2860
the nut 1.
T.
R.
Nut (shock absorber):
49 Nm (4.9 m · kg, 35 ft · lb)
CAUTION:
Never allow the adjusting bolt to move while
tightening the nut.
• This model has a “Easy adjust” system for the Full
rate adjuster. The bolt has teeth on it. So when the
bolt is turned, it rides up and down the bracket.
NOTE:
• The nut has to be loosen first, while the bolt is held
in place with a wrench.
• Then the bolt can be turned to adjust the shock
position up or down.
• If the bolt is turned with the nut tight, it is possible
to strip the teeth off the bolt.
2-63
REAR SUSPENSION
INSP
ADJ
Rear suspension position (MM600)
1. Adjust:
• Rear suspension position
NOTE:
Select the rear suspension position according to the
snow conditions: a standard; b deep new snow.
T.
R.
a
b
a
b
SEA2865
2-64
Bolt (slide rail suspension):
72 Nm (7.2 m · kg, 52 ft · lb)
LOCTITE®
REAR SUSPENSION
2-65
INSP
ADJ
STEERING
CHAS
CHASSIS
STEERING
VX600ER/SX600/VT600
Å: 10 Nm (1.0 m · kg, 7.2 ft · lb)
ı: 23 Nm (2.3 m · kg, 17 ft · lb)
3
SEA3010
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Job name/Part name
Handlebar removal
Handlebar cover
Plastic band
Oil tank breather hose
Thumb warmer coupler
Engine stop switch coupler
Brake light switch coupler
Headlight beam switch coupler
Grip warmer lead
Throttle cable holder
Throttle cable
Oil pump cable
Brake lever holder
Master cylinder assembly
Handlebar holder (upper)
Cable holder
Handlebar
Handlebar holder (lower)
Q’ty
Remarks
Remove the parts in the order listed below.
1
3
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
NOTE:
After installing all parts, refer to “CABLE ROUTING” in CHAPTER 9, to check the cable, lead
and hose routings.
For installation, reverse the removal procedure.
3-1
STEERING
CHAS
MM600
Å: 10 Nm (1.0 m · kg, 7.2 ft · lb)
ı: 23 Nm (2.3 m · kg, 17 ft · lb)
SEA3020
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Job name/Part name
Handlebar removal
Handlebar cover
Plastic band
Oil tank breather hose
Thumb warmer coupler
Engine stop switch coupler
Brake light switch coupler
Headlight beam switch coupler
Grip warmer lead
Throttle cable holder
Throttle cable
Oil pump cable
Brake lever holder
Master cylinder assembly
Handlebar holder (upper)
Cable holder
Handlebar
Handlebar holder (lower)
Q’ty
Remarks
Remove the parts in the order listed below.
1
3
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
NOTE:
After installing all parts, refer to “CABLE ROUTING” in CHAPTER 9, to check the cable, lead
and hose routings.
For installation, reverse the removal procedure.
3-2
STEERING
CHAS
Å: 23 Nm (2.3 m · kg, 17 ft · lb)
ı: 25 Nm (2.5 m · kg, 18 ft · lb)
Ç: 35 Nm (3.5 m · kg, 25 ft · lb)
Î: 43 Nm (4.3 m · kg, 31 ft · lb)
‰: 80 Nm (8.0 m · kg, 58 ft · lb)
å: For VX600ER/VT600
∫: For SX600/MM600
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
Order
Job name/Part name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Steering column and tie rod removal
Engine assembly
Handlebar
Cotter pin
Clip
Relay rod
Lock washer
Bearing holder
Bearing
Collar
Steering column
Cotter pin
Tie rod
Washer
Washer
Bushing
Collar
Relay arm
SEA3030
Q’ty
Remarks
Remove the parts in the order listed below.
Refer to “ENGINE ASSEMBLY” in CHAPTER 5.
1
1
1
2
3
4
4
1
4
2
2
2
2
1
1
For installation, reverse the removal procedure.
3-3
STEERING
CHAS
INSPECTION
1. Inspect:
• Handlebar 1 (VX600ER/SX600/VT600)
• Handlebar 2 (MM600)
• Steering column 3
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent column.
This may dangerously weaken the column.
SEA3040
2. Inspect:
• Bearings (steering column) 1
• Collars 2
Wear/damage → Replace.
• Steering column 3 (bearing contact surfaces)
Scratches/wear/damage → Replace.
SEA3050
3. Inspect:
• Relay rod 1
• Tie rods 2
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten bent rods. This may
dangerously weaken the rods.
SEA3060
4. Check:
• Rod end movement
Rod end free play exists → Replace the rod
end.
Rod end turns roughly → Replace the rod end.
SEA3070
5. Inspect:
• Relay arm
Cracks/damage → Replace.
SEA3080
3-4
STEERING
CHAS
INSTALLATION
2
1. Install:
• Bushings 1
a
1
NOTE:
Mount the bushing with clearance a to the end of the
relay arm 2.
a
a Approx. 1 mm (0.04 in)
SEA3090
2. Install:
• Tie rod 1
• Locknut 2
• Joints 3
a
b
3
2
1
2
Å Tie rod
part number
3
SEA3100
ı Set
length a
Ç Tie rod
length b
8CR-23831-00
(VX600ER/
SX600/VT600)
517.2 mm
(20.3622 in)
454.2 mm
(17.8819 in)
8CS-23831-00
(MM600)
474.5 mm
(18.6811 in)
411.5 mm
(16.2008 in)
3. Install:
• Tie rods 1
NOTE:
• Make sure that the indentation a on the tie rod
faces out.
• The threads on both rod ends must be the same
length.
SEA3110
CAUTION:
Always use new cotter pins.
T.
R.
SEA3120
3-5
Locknut (tie rod):
25 Nm (2.5 m · kg, 18 ft · lb)
LOCTITE®
Nut (tie rod-relay arm):
35 Nm (3.5 m · kg, 25 ft · lb)
Nut (tie rod-steering arm):
43 Nm (4.3 m · kg, 31 ft · lb)
STEERING
CHAS
4. Install:
• Relay rod 1
NOTE:
Make sure that the end of the relay rod with the
indentation a is connected to the relay arm.
CAUTION:
Always use new cotter pins.
SEA3130
T.
R.
Nut (relay rod):
35 Nm (3.5 m · kg, 25 ft · lb)
5. Adjust:
• Skis
Adjustment steps:
• Temporarily install the handlebar.
• Hold the handlebar straight and check that the
skis are at right angles to the handlebar.
• Loosen the locknuts (relay rod) 1.
• Position the skis parallel in the riding direction.
• With the skis in this position, turn the relay rod 2
in either direction until the handlebars at right
angles with respect to the direction of movement.
LT
LT
Turning the relay rod
in direction a
Turning the handlebar
in direction c
Turning the relay rod
in direction b
Turning the handlebar
in direction d
• Tighten the locknuts (relay rod) 1.
SEA3140
T.
R.
3-6
Locknut (relay rod):
25 Nm (2.5 m · kg, 18 ft · lb)
LOCTITE®
STEERING
CHAS
6. Install:
• Handlebar
CAUTION:
• For SX600/MM600:
•
SEA3150
•
Be sure the projection on the handlebar is not
installed into the area a shown.
Be sure the side of the holder with the small
gap b faces forward.
Center the match mark c on the handlebar 1
between the lower handlebar holders 2.
T.
R.
Bolt (handlebar holder):
23 Nm (2.3 m · kg, 17 ft · lb)
CAUTION:
• First tighten the bolts on the front side of the
SEA3160
•
SEA3170
8CH-10
8ED-10
SEA3180
3-7
handlebar holder, and then tighten the bolts
on the rear side.
For SX600/MM600:
The handlebar for the SX600 (8EA4) has “8CH10” stamped on one end for identification. The
handlebar for the MM600 (8EJ3) has “8ED-10”
stamped on one end. Since these handlebars
are specifically designed for the SX600 (8EA4)
and MM600 (8EJ3), do not use them on any
future models.
SKI
CHAS
SKI
VX600ER/VT600
Å: 11 Nm (1.1 m · kg, 8.0 ft · lb)
ı: 17 Nm (1.7 m · kg, 12 ft · lb)
Ç: 21 Nm (2.1 m · kg, 15 ft · lb)
Î: 48 Nm (4.8 m · kg, 35 ft · lb)
: 1 ESSO beacon 325
grease or Aeroshell
grease #7A
SEA3190
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Ski removal
Cotter pin
Ski stopper
Collar
Washer
Ski column lower bracket
Ski runner
Collar
Collar
Ski
Washer
Ski handle
Q’ty
Remarks
Remove the parts in the order listed below.
1
1
1
6
1
1
2
2
1
4
1
Color : Black
Color : Gold
For installation, reverse the removal procedure.
3-8
SKI
CHAS
SX600/MM600
Å: 11 Nm (1.1 m · kg, 8.0 ft · lb)
ı: 21 Nm (2.1 m · kg, 15 ft · lb)
ç: 48 Nm (4.8 m · kg, 35 ft · lb)
: 1 ESSO beacon 325
grease or Aeroshell
grease #7A
SEA3200
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Ski removal
Cotter pin
Ski stopper
Collar
Washer
Ski column lower bracket
Ski runner
Ski
Washer
Ski handle
Q’ty
Remarks
Remove the parts in the order listed below.
1
1
1
6
1
1
1
6
1
For installation, reverse the removal procedure.
3-9
SKI
CHAS
INSPECTION
A
1. Inspect:
• Ski 1
• Ski runner 2
• Ski stopper 3
• Ski column lower bracket 4
• Ski handle 5
Wear/cracks/damage → Replace.
• Mounting bolt 6
• Collar 7
• Bolts 8
• Collars 9
Wear/damage → Replace.
7
3
4
5
1
9
9
9
8
6
Å VX600ER/VT600
ı SX600/MM600
2
SEA3210
B
SEA3220
INSTALLATION (VX600ER/VT600)
1. Install:
• Ski column lower bracket 1
a
NOTE:
FW
D
Be sure to install the ski column lower bracket with the
arrow mark a pointing forward the tip of the ski.
1
SEA3230
3-10
FRONT SUSPENSION
CHAS
FRONT SUSPENSION
Å: 23 Nm (2.3 m · kg, 17 ft · lb)
ı: 43 Nm (4.3 m · kg, 31 ft · lb)
Ç: 48 Nm (4.8 m · kg, 35 ft · lb)
Î: 50 Nm (5.0 m · kg, 36 ft · lb)
‰: 56 Nm (5.6 m · kg, 40 ft · lb)
Ï: 78 Nm (7.8 m · kg, 56 ft · lb)
å: For SX600
∫: For VX600ER/MM600/VT600
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA3240
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job name/Part name
Front suspension removal
Ski
Tie rod
Shock absorber
Cap
Steering arm
Ski column
Bushing
Washer
Control rod
Collar
Bushing
Connecting rod
Collar
Front arm
Q’ty
Remarks
Remove the parts in the order listed below.
Refer to “SKI”.
1
1
1
1
1
2
1
2
2
4
1
2
1
For installation, reverse the removal procedure.
3-11
FRONT SUSPENSION
CHAS
HANDLING NOTES (SX600)
WARNING
This shock absorber contains highly compressed
nitrogen gas. Before handling the shock absorber
read and make sure that you understand the
following information. The manufacturer cannot
be held responsible for property damage or personal injury that may result from improper handling.
• Do not tamper or attempt to open the gas
chamber.
• Do not subject the shock absorber to flames or
any other source of high heat. This may cause
the unit to explode due to excessive gas pressure.
• Do not deform or damage the gas chamber in
any way. Gas chamber damage will result in
poor damping performance.
INSPECTION
1. Inspect:
• Shock absorber 1
Oil (gas) leaks/bends/damage → Replace.
SEA3250
2. Inspect:
• Ski column 1
• Steering arm 2
Cracks/bends/damage → Replace.
• Bushing 3
Wear/scratches/damage → Replace.
SEA3260
3. Inspect:
• Control rod 1
Cracks/bends/damage → Replace.
• Bushing 2
• Collar 3
Wear/scratches/damage → Replace.
SEA3270
3-12
FRONT SUSPENSION
CHAS
4. Inspect:
• Connecting rod 1
• Stabilizer 2
Cracks/bends/damage → Replace.
• Collar 3
Wear/scratches/damage → Replace.
SEA3280
5. Inspect:
• Front arm 1
Cracks/bends/damage → Replace.
SEA3290
3-13
FRONT SUSPENSION
CHAS
INSTALLATION
1. Install:
• Control rod 1
• Nut 2
• Joint 3
Å Left hand
Ç Set
ı Set length a
SEA3300
angle b
‰ Upper
(VX600ER/SX600/
VT600)
Ï Lower
(VX600ER/SX600/
VT600)
‰ Upper
(MM600)
475.5 ± 0.5 mm
(18.7204 ± 0.0197 in)
93 ± 1°
472.6 ± 0.5 mm
(18.6062 ± 0.0197 in)
93 ± 1°
429.7 ± 0.5 mm
(16.9173 ± 0.0197 in)
93 ± 1°
Ï Lower
(MM600)
428.7 ± 0.5 mm
(16.8779 ± 0.0197 in)
93 ± 1°
Ì color
c
Blue
Green
Î Right hand
ı Set length a
Ç Set
angle b
‰ Upper
(VX600ER/SX600/
VT600)
Ï Lower
(VX600ER/SX600/
VT600)
475.5 ± 0.5 mm
(18.7204 ± 0.0197 in)
87 ± 1°
472.6 ± 0.5 mm
(18.6062 ± 0.0197 in)
87 ± 1°
‰ Upper
(MM600)
429.7 ± 0.5 mm
(16.9173 ± 0.0197 in)
87 ± 1°
Ï Lower
(MM600)
428.7 ± 0.5 mm
(16.8779 ± 0.0197 in)
87 ± 1°
T.
R.
3-14
Ì color
c
Yellow
White
Locknut (control rod):
12 mm = 56 Nm (5.6 m · kg, 40 ft · lb)
14 mm = 73 Nm (7.3 m · kg, 53 ft · lb)
LOCTITE®
FRONT SUSPENSION
CHAS
2. Install:
• Steering arm 1
NOTE:
• Align the punch mark a on the ski column with the
punch mark b on the steering arm.
• Install sections c without any gaps.
T.
SEA3310
R.
Nut (steering arm):
56 Nm (5.6 m · kg, 40 ft · lb)
Å VX600ER/VT600
ı SX600/MM600
A
c
SEA3320
B
c
SEA3330
3-15
FRONT SUSPENSION
CHAS
Ski spindle camber
Place the unit on a level surface and check the ski spindle camber. DO NOT elevate the front end.
1 Using an angle finder, be sure that the unit sits parallel with the floor. Place the angle finder up against the
flat aluminum part of the belly pan.
Å USE AN ANGLE FINDER TO CHECK THAT THE
UNIT IS LEVEL.
Angle finder:
YS-42422
SEA3340
2 Place the angle finder up against the vertical flat surface on the trailing arm just behind the spindle weld and
check the spindle camber.
Ski spindle camber:
–0.5° to +0.5°
SEA3350
3 To adjust the camber, loosen the lower radius rod ball joint locknut and remove the bolt securing the radius
rod to the trailing arm. Turn the rod in or out as necessary until the proper camber angle is obtained.
SEA3360
3-16
FRONT SUSPENSION
CHAS
4 Install the radius rod onto the trailing arm and tighten the bolt. Tighten the ball joint locknut and apply grease
to the ball joint. Repeat the procedure for the other side.
SEA3370
CAUTION:
When tightening the ball joint locknut, be sure to keep the ball joint outer housing centered with the ball
to prevent binding.
Ski alignment
NOTE:
Be sure to verify the spring preload setting and the ski spindle camber before adjusting the ski toe out since either
of those adjustments may affect the ski toe out setting.
Point the skis straight forward and measure the amount of ski toe out.
Å Ski toe out:
0 ~ 15 mm (0 ~ 0.59 in)
a – b = Toe out
Refer to “STEERING SYSTEM” in CHAPTER 2.
SEA3380
3-17
FRONT SUSPENSION
CHAS
Front arm part number
a
d
b
c
R
SEA3390
Å Part number
ı Caster Ç Control rod Î Shock absorber
‰ ID
a
bracket angle b bracket angle c mark d
VX600ER/VT600
8DM-2382E-10 (L/H)
8DM-2382F-10 (R/H)
25.5°
3°
10°
M
SX600
8CR-2382E-20 (L/H)
8CR-2382F-20 (R/H)
25.5°
3°
10°
R
MM600
8CS-2382E-20 (L/H)
8CS-2382F-20 (R/H)
25.5°
3°
7°
S
Stabilizer part number
a
b
c
ı Size length a ×
bar diameter b
Å Part number
SEA3400
Ç ID color c
VX600ER/SX600
8CR-2386E-00
896 × 16 mm
(35.2755 × 0.6299 in)
Purple
MM600
8CS-2386E-00
832 × 16 mm
(32.7558 × 0.6299 in)
White
VT600
8CW-2386E-00
896 × 18 mm
(35.2755 × 0.7087 in)
Light green
3-18
FRONT SUSPENSION
CHAS
Control rod part number
a
b
SEA3410
Ç Part Number
Î Length a
‰ Angle b
VX600ER/SX600/
VT600
Å Upper
ı Lower
8CR-2384E-20
8CR-2384F-20
439.5 ± 1 mm (17.3031 ± 0.0394 in) 10.8 ± 0.5°
431.6 ± 1 mm (16.9921 ± 0.0394 in) 10.8 ± 0.5°
MM600
Å Upper
ı Lower
8CS-2384E-20
8CS-2384F-20
393.7 ± 1 mm (15.5000 ± 0.0394 in)
387.7 ± 1 mm (15.2637 ± 0.0394 in)
3-19
8.8 ± 0.5°
8.8 ± 0.5°
PRIMARY SHEAVE AND DRIVE V-BELT
POWR
TR
POWER TRAIN
PRIMARY SHEAVE AND DRIVE V-BELT
Å: 1st
2nd
120 Nm (12.0 m · kg, 85 ft · lb)
60 Nm (6.0 m · kg, 43 ft · lb)
SEA4010
Order
1
2
3
Job name/Part name
Primary sheave removal
V-belt
Blind cap
Primary sheave assembly
Q’ty
Remarks
Remove the parts in the order listed below.
1
1
1
For installation, reverse the removal procedure.
4-1
PRIMARY SHEAVE AND DRIVE V-BELT
POWR
TR
Å: 4 Nm (0.4 m · kg, 2.9 ft · lb)
ı: 6 Nm (0.6 m · kg, 4.3 ft · lb)
Ç: 14 Nm (1.4 m · kg, 10 ft · lb)
Î: 20 Nm (2.0 m · kg, 14 ft · lb)
‰: 200 Nm (20.0 m · kg, 145 ft · lb)
4
SEA4020
Order
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
Job name/Part name
Primary sheave disassembly
Primary sheave cap
Primary sheave spring
Collar
Roller
Washer
Collar
Weight
Washer
Fixed sheave
Starter motor driven gear
Fixed sheave stopper
Sliding sheave
Bushing
Spider
Slider
Q’ty
Remarks
Remove the parts in the order listed below.
1
1
3
3
6
3
3
6
1
1
1
1
1
1
6
(VX600ER/VT600)
For assembly, reverse the disassembly procedure.
4-2
PRIMARY SHEAVE AND DRIVE V-BELT
POWR
TR
REMOVAL
1. Remove:
• Primary sheave assembly 1
NOTE:
Use the primary sheave holder 2 and primary sheave
puller 3.
Primary sheave holder:
90890-01701, YS-01880
Primary sheave puller:
YS-01881-1, YS-01859-1
SEA4030
4-3
PRIMARY SHEAVE AND DRIVE V-BELT
POWR
TR
DISASSEMBLY
1. Remove:
• Fixed sheave 1
• Stopper 2
• Sliding sheave 3
• Bushing 4
• Spider 5
SEA4040
Removal steps:
• Immerse the primary sheave assembly in 80°C ~
100°C (176°F ~ 212°F) water for several minutes.
• Attach the lower piece of the clutch spider separator 6 onto a rigid table using suitable mounting
bolts.
Then, install the clutch separator adapter 7 onto
the separator.
Clutch spider separator:
YS-28890-C
Clutch separator adapter:
YS-34480
SEA4050
• Fit the primary sheave assembly onto the adapter
and secure the supporting plates 8.
NOTE:
Securely fit the projections on the adapter into the
fixed sheave holes.
• Set the bar wrench 9 onto the spider and turn the
SEA4060
special tool clockwise to loosen the spider.
Clutch spider separator (bar wrench):
YS-28890-C
CAUTION:
• The spider has a left-handed thread.
• Since a high torque is required to loosen the
spider, make sure that the spider, fixed sheave
and special tool are well secured. Loosen the
spider carefully to prevent cracks and damage
to the sheaves and spider.
SEA4070
• Remove the fixed sheave, fixed sheave stopper,
and sliding sheave from the spider.
4-4
PRIMARY SHEAVE AND DRIVE V-BELT
POWR
TR
INSPECTION
1. Inspect:
• Spider 1
• Sliding sheave 2
• Fixed sheave 3
• Primary sheave cap 4
Cracks/damage → Replace.
SEA4080
2. Inspect:
• Primary sheave spring 1
Cracks/damage → Replace.
3. Measure:
• Primary sheave spring free length a
Out of specification → Replace the primary
sheave spring.
Primary sheave spring free length:
VX600ER/SX600:
89.4 mm (3.52 in)
MM600:
91.4 mm (3.60 in)
VT600 for U.S.A./Canada:
86.7 mm (3.41 in)
VT600 for Europe:
87.4 mm (3.44 in)
SEA4090
NOTE:
When changing the primary sheave springs, refer to
“GEAR SELECTION” in CHAPTER 2.
4. Inspect:
• Primary sheave cap bush 1
• Sliding sheave bush 2
Cracks/damage → Replace.
Clutch bushing press:
YS-42424
SEA4100
4-5
PRIMARY SHEAVE AND DRIVE V-BELT
POWR
TR
5. Inspect:
• Weight 1
• Roller 2
• Bushing 3
• Slider 4
• Rivet 5
• Collar
Wear/scratches/damage → Replace.
• Slider inside clearance
Out of specification → Replace the slider.
SEA4110
Slider inside clearance = A1 + A2
Slider inside clearance:
Min. 0 mm (0 in)
Max. 0.3 mm (0.0118 in)
Rivet replacement steps:
• Remove old rivet with the appropriate drill.
• Insert the rivet 1 from the ID mark 2 side.
• Press or peen the rivet head so that the diameter
a of the rivet head measures 8.2 mm (0.32 in)
or larger .
SEA4120
A
6. Measure:
• Bushing inside diameter
Out of specification → Replace as a set.
B
Bushing inside diameter:
Å Roller
New: 9.077 mm (0.357 in)
Wear limit: 9.3 mm (0.366 in)
ı Weight
New: 8.077 mm (0.318 in)
Wear limit: 8.3 mm (0.327 in)
SEA4130
4-6
PRIMARY SHEAVE AND DRIVE V-BELT
C
POWR
TR
NOTE:
D
When replacing the weight and roller bushings, use
the YXR clutch bushing jig kit.
YXR clutch bushing jig kit:
YS-39752
Ç Removing
Î Installing
SEA4140
ASSEMBLY
1. Install:
• Sliding sheave
(onto the spider)
NOTE:
Be sure the sliding sheave match mark (X) is aligned
with the spider match mark (X).
SEA4150
2. Install:
• Fixed sheave
(onto the spider)
NOTE:
• Clean the threads.
• Apply LOCTITE® #648 to the fixed sheave as
a
b
shown.
LLT
T
SEA4160
CAUTION:
LOCTITE® should be applied only to the specified
area. Never apply it to the bushings and other
areas.
a 16 mm (0.63 in)
b 30 ~ 35 mm (1.18 ~ 1.38 in)
4-7
PRIMARY SHEAVE AND DRIVE V-BELT
POWR
TR
3. Install:
• Fixed sheave stoppers 1
NOTE:
Stopper tapered portion should face fixed sheave.
4. Tighten:
• Spider
Tightening steps:
• Finger-tighten the spider until it is stopped by the
fixed sheave stopper.
• Hold the fixed sheave with the clutch spider
separator 1.
SEA4170
Clutch spider separator:
YS-28890-C
NOTE:
Securely fit the projections on the clutch separator
adapter 2 into the fixed sheave holes.
SEA4180
• Tighten the spider to specification using the bar
wrench 3.
T.
R.
Spider:
200 Nm (20 m · kg, 145 ft · lb)
CAUTION:
The spider has a left-handed thread.
SEA4190
WARNING
• Do not operate the primary sheave until the
•
4-8
LOCTITE® has dried completely. Wait 24 hours
before operating the primary sheave.
Since a high torque is required to tighten the
spider, make sure the spider, fixed sheave, and
special tool are well secured. Tighten the spider carefully to prevent cracks and damage to
the sheaves and spider.
PRIMARY SHEAVE AND DRIVE V-BELT
POWR
TR
5. Install:
• Weight
• Nuts 1
T.
R.
Nut (weight):
6 Nm (0.6 m · kg, 4.3 ft · lb)
NOTE:
To maintain the primary sheave balance, the bolts 2
must be installed with their threaded portions pointing
in a counterclockwise direction, as illustrated.
SEA4200
6. Install:
• Primary sheave spring 1
• Primary sheave cap 2
NOTE:
Be sure the sheave cap match mark (X) is aligned
with the spider match mark (X).
SEA4210
T.
R.
Bolt (primary sheave cap):
14 Nm (1.4 m · kg, 10 ft · lb)
7. Tighten:
• Bolts (VX600ER/VT600)
1
3
Tightening steps:
• Temporarity tighten the bolts 1 ~ 6 in the order
shown.
4
5
Bolt (starter motor driven gear):
20 Nm (2.0 m · kg, 14 ft · lb)
T.
6
R.
2
SEA4220
NOTE:
• Clean the threads.
• Apply LOCTITE® #648.
4-9
PRIMARY SHEAVE AND DRIVE V-BELT
POWR
TR
INSTALLATION
1. Install:
• Primary sheave assembly
CAUTION:
Be sure to remove any oil or grease from the
tapered portion of the crankshaft and spider using a cloth dampened with thinner.
SEA4230
2. Apply:
• YAMALUBE 2-cycle oil or an equivalent grease
(to threads of primary sheave bolt)
SEA4240
3. Tighten:
• Bolt (primary sheave) 1
Tightening steps:
• Hold the primary sheave 3 using the primary
sheave holder 2 and tighten the bolt (primary
sheave) to specification.
Primary sheave holder:
90890-01701, YS-01880
SEA4250
T.
R.
Bolt (primary sheave):
(initial tightening)
120 Nm (12.0 m · kg, 85 ft · lb)
• Loosen the bolt (primary shave) completely.
• Retighten the bolt (primary sheave) to specification.
T.
R.
Bolt (primary sheave):
60 Nm (6.0 m · kg, 43 ft · lb)
4. Adjust:
• V-belt position
Refer to “DRIVE V-BELT” in CHAPTER 2.
• Sheave distance
• Sheave offset
• Secondary sheave free play (clearance)
Refer to “SHEAVE DISTANCE AND OFFSET
ADJUSTMENT” in CHAPTER 2.
4-10
SECONDARY SHEAVE
POWR
TR
SECONDARY SHEAVE
Å: 64 Nm (6.4 m · kg, 46 ft · lb)
SEA4260
Order
Job name/Part name
Q’ty
1
2
3
Secondary sheave removal
V-belt
Washer
Shim
1
1
–
4
5
Collar
Secondary sheave assembly
1
1
Remarks
Remove the parts in the order listed below.
Refer to “SHEAVE DISTANCE AND OFFSET
ADJUSTMENT” in CHAPTER 2.
For installation, reverse the removal procedure.
4-11
SECONDARY SHEAVE
POWR
TR
Å: 4 Nm (0.4 m · kg, 2.9 ft · lb)
ı: 6.5 Nm (0.65 m · kg, 4.6 ft · lb)
Ç: 10 Nm (1.0 m · kg, 7.2 ft · lb)
Î: 23 Nm (2.3 m · kg, 17 ft · lb)
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA4270
Order
1
2
3
4
5
6
7
Job name/Part name
Secondary sheave disassembly
Spring seat
Secondary sheave spring
Secondary sheave plate 1
Fixed sheave
Stopper
Sliding sheave
Secondary sheave plate 2
Q’ty
Remarks
Remove the parts in the order listed below.
1
1
1
1
1
1
1
4-12
(SX600)
(SX600)
For assembly, reverse the disassembly procedure.
SECONDARY SHEAVE
POWR
TR
DISASSEMBLY
WARNING
• Use extreme CAUTION when disassembling
the secondary sheave since serious injury can
occur due to the sudden release of spring tension. Use the sheave compressor to contain the
spring tension before removing the nuts (spring
seat).
• Do not attempt this procedure unless you have
the proper tools and understand the instructions thoroughly.
1. Remove:
• Nuts (spring seat)
SEA4280
INSPECTION
1. Inspect:
• Sliding sheave 1
• Fixed sheave 2
• Spring seat 3
Cracks/damage → Replace.
• Stopper 4
Wear/damage → Replace.
SEA4290
2. Inspect:
• Bushing (spring seat) 1
• Sliding sheave (V-belt contact surface) 2
Scratches/wear/damage → Replace.
• Sliding bushing 3
Unsymmetrical wear/damage → Replace.
SEA4300
3. Inspect:
• Secondary sheave spring 1
Cracks/damage → Replace.
4. Measure:
• Secondary sheave spring free length a
Below specification → Replace the secondary
sheave spring.
Secondary sheave spring free length:
75 mm (2.95 in)
SEA4310
4-13
SECONDARY SHEAVE
POWR
TR
5. Measure:
• Ramp shoe thickness a
Out of specification → Replace the ramp shoe.
Wear limit:
1.0 mm (0.04 in)
SEA4320
ASSEMBLY
1. Install:
• Stopper
• Sliding sheave
T.
R.
Screw (stopper):
6.5 Nm (0.65 m · kg, 4.6 ft · lb)
2. Install:
• Fixed sheave 1
• Bolts 2
(along with the shims)
T.
R.
Bolt:
10 Nm (1.0 m · kg, 7.2 ft · lb)
SEA4330
3. Install:
• Secondary sheave spring 1
• Spring seat 2
NOTE:
Hook the end of the secondary sheave spring into the
spring holes in the fixed sheave. Hook the other end
of the spring into the holes in the spring seat.
SEA4340
Standard spring position:
2-6 (VX600ER/SX600/MM600)
(VT600 for Europe)
1-6 (VT600 for U.S.A/Canada)
4-14
SECONDARY SHEAVE
POWR
TR
Installation steps:
• Hold the spring seat 1 and turn the fixed sheave
2 counterclockwise to the specified angle a.
NOTE:
The holes in the spring seat should align with the bolts
on the sliding sheave.
a = (sheave hole number + spring seat hole
number) × 10
SEA4350
Twist angle:
80° (VX600ER/SX600/MM600)
(VT600 for Europe)
70° (VT600 for U.S.A./Canada)
• Push down on the spring seat until the bolts come
•
through the holes.
While pushing down on the spring seat, install the
nuts and tighten them to the specified torque.
SEA4360
T.
R.
Nut (spring seat):
23 Nm (2.3 m · kg, 17 ft · lb)
4. Measure:
• Secondary sheave clearance a
Out of specification → Adjust.
Secondary sheave clearance:
35.0 ~ 35.8 mm (1.38 ~ 1.41 in)
a
5. Calculate:
• Shim thickness
SEA4370
NOTE:
For example, if the clearance is 36 mm (1.42 in),
install a 0.5-mm (0.02-in) shim on each bolt so the
clearance is 35.5 mm (1.40 in).
6. Adjust:
• Secondary sheave clearance
4-15
SECONDARY SHEAVE
POWR
TR
Adjustment steps:
• Disassemble the secondary sheave.
• Remove the bolts and original shims 1.
• Install new shims of the proper thickness and
reassemble the secondary sheave.
• Measure the secondary sheave clearance again.
Repeat these steps until the clearance is within
specification.
SEA4380
NOTE:
Yamaha recommends keeping the original shims.
Shims:
Part number
90201-061H1
90201-06037
Thickness
0.5 mm (0.02 in)
1.0 mm (0.04 in)
INSTALLATION
1. Lubricate:
• Splines (fixed sheave)
Recommended grease:
ESSO beacon 325 grease or
Aeroshell grease #7A
2. Tighten:
T.
R.
Bolt (secondary cheave):
64 Nm (6.4 m · kg, 46 ft · lb)
3. Adjust:
• V-belt position
Refer to “DRIVE V-BELT” in CHAPTER 2.
• Sheave distance
• Sheave offset
• Secondary sheave free play (clearance)
Refer to “SHEAVE DISTANCE AND OFFSET
ADJUSTMENT” in CHAPTER 2.
4-16
DRIVE CHAIN HOUSING
POWR
TR
DRIVE CHAIN HOUSING
WITHOUT REVERSE MODEL
Å: 16 Nm (1.6 m · kg, 11 ft · lb)
ı: 24 Nm (2.4 m · kg, 17 ft · lb)
Ç: 48 Nm (4.8 m · kg, 35 ft · lb)
Î: 60 Nm (6.0 m · kg, 43 ft · lb)
SEA4390
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Drive chain housing removal
Coolant hose bracket
Frame cross member bolt (M10 × 65)
Brake caliper
Parking brake
Chain tension adjuster
Bolt
Drive chain housing cover
Chain tensioner
Roller
Drive sprocket
Collar
Drive chain
Driven sprocket
Collar
Drive chain housing
Q’ty
1
1
1
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed below.
Refer to “HEAT EXCHANGER” in CHAPTER 6.
Refer to “AC MAGNETO” in CHAPTER 5.
Refer to “BRAKE”.
Refer to “BRAKE”.
Loosen.
Drain the oil.
For installation, reverse the removal procedure.
4-17
DRIVE CHAIN HOUSING
POWR
TR
INSPECTION
1. Inspect:
• Drive chain housing 1
• Drive chain housing cover 2
Cracks/damage → Replace.
• Oil seals (drive chain housing)
Wear/damage → Replace.
• Bearings (drive chain housing and cover) 3
Pitting/damage → Replace.
• Bearing (chain tensioner) 4
Pitting/damage → Replace the bearing and the
inner race holder as a set.
SEA4400
Replacement steps:
• Remove the circlip 5 (drive chain housing).
• Remove the bearing(s) 3 using a general bearing puller.
• Install the new bearing(s).
SEA4410
NOTE:
Use a socket 6 that is the same size as the outside
diameter of the bearing race.
CAUTION:
Do not strike the inner race 7 or ball bearings 8.
Contact only the outer race 9.
• Install a new circlip (drive chain housing).
SEA4420
CAUTION:
Always use new circlips.
2. Inspect:
• Drive sprocket 1
• Driven sprocket 2
• Chain tensioner 3
Pitting/wear/damage → Replace.
SEA4430
4-18
DRIVE CHAIN HOUSING
POWR
TR
3. Measure:
• 14 link section a of the drive chain
Using a spring scale, pull on the drive chain
with 36 kg (80 lb) of force b.
Out of specification → Replace the drive chain.
12 34 56 78 90 AB CD E
Maximum 14 link drive chain section
length:
133.35 mm (5.25 in)
Limit 137.35 mm (5.41 in)
a
NOTE:
• Measure the length between drive chain pin 1 and
E as shown.
• Perform this measurement at two or three different
places.
b
If replacement is necessary, always replace the chain
and the sprockets as a set.
SEA4440
4. Inspect:
• Drive chain 1
Stiffness → Clean and lubricate or replace.
• Drive chain plates 2
Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain.
SEA4450
4-19
DRIVE CHAIN HOUSING
POWR
TR
INSTALLATION
1. During installation, pay attention to the following.
Å Make sure that the bearing seals face towards the
drive chain as shown.
ı Properly install the rubber seal onto the drive chain
housing, making sure that there are no gaps.
C1 C2 Be sure to install the spacers in their original
positions, otherwise the brake disc and jackshaft
will stick.
Î 0.1 ~ 0.5 mm (0.004 ~ 0.020 in)
: ESSO beacon 325 grease or Aeroshell grease
#7A
For the jackshaft and drive chain housing installation,
refer to “JACKSHAFT”.
2. Fill:
• Drive chain housing oil
Refer to “DRIVE CHAIN” in CHAPTER 2.
3. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN” in CHAPTER 2.
SEA4460
4-20
DRIVE CHAIN HOUSING
POWR
TR
WITH REVERSE MODEL
Å: 10 Nm (1.0 m · kg, 7.2 ft · lb)
ı: 13 Nm (1.3 m · kg, 9.4 ft · lb)
Ç: 16 Nm (1.6 m · kg, 11 ft · lb)
Î: 24 Nm (2.4 m · kg, 17 ft · lb)
‰: 48 Nm (4.8 m · kg, 35 ft · lb)
Ï: 60 Nm (6.0 m · kg, 43 ft · lb)
SEA4470
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Drive chain housing removal
Battery
Battery bracket
Coolant hose bracket
Frame cross member bolt (M10 × 65)
Brake caliper
Parking brake
Chain tension adjuster
Joint
Shift rod
Shift lever assembly
Lever
Bolt
Drive chain housing cover
Joint
Lever rod
Washer
Reverse drive gear
Remarks
Q’ty
Remove the parts in the order listed below.
Refer to “HEAT EXCHANGER” in CHAPTER 6.
Refer to “AC MAGNETO” in CHAPTER 5.
Refer to “BRAKE”.
Refer to “BRAKE”.
Loosen.
2
1
1
1
1
1
2
1
1
1
4-21
Disconnect the gear position switch leads.
Drain the oil.
DRIVE CHAIN HOUSING
POWR
TR
Å: 10 Nm (1.0 m · kg, 7.2 ft · lb)
ı: 13 Nm (1.3 m · kg, 9.4 ft · lb)
Ç: 16 Nm (1.6 m · kg, 11 ft · lb)
Î: 24 Nm (2.4 m · kg, 17 ft · lb)
‰: 48 Nm (4.8 m · kg, 35 ft · lb)
Ï: 60 Nm (6.0 m · kg, 43 ft · lb)
SEA4470
Order
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Job name/Part name
Spring
Chain tensioner
Roller
Collar
Spring
Journal
Reverse driven gear
Washer
Forward driven sprocket
Collar
Counter gear
Drive sprocket
Drive chain
Collar
Washer
Plate
Shaft
Drive chain housing
Q’ty
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
4-22
DRIVE CHAIN HOUSING
POWR
TR
INSPECTION
1. Inspect:
• Drive chain housing 1
• Drive chain housing cover 2
Cracks/damage → Replace.
• Shift fork 3
Pitting/wear/damage → Replace.
• Oil seals (drive chain housing)
Wear/damage → Replace.
• Bearings (drive chain housing and cover) 4
Pitting/damage → Replace.
2. Inspect:
• Drive sprocket 1
• Forward driven sprocket 2
• Reverse driven gear 3
• Reverse drive gear 4
• Counter gear 5
• Journal 6
• Chain tensioner 7
Pitting/wear/damage → Replace.
• Drive chain 8
Wear/damage → Replace.
Stiff → Clean or replace.
• Shift lever assembly 9
• Bearing (chain tensioner) 0
Pitting/damage → Replace the bearing and the
inner race holder as a set.
SEA4480
For the bearing replacement and drive chain inspection, refer to “WITHOUT REVERSE MODEL”.
SEA4490
4-23
DRIVE CHAIN HOUSING
POWR
TR
INSTALLATION
1. During installation, pay attention to the following.
Å Properly install the rubber seal onto the drive chain
housing, making sure that there are no gaps.
ı Make sure that the bearing seals face towards the
drive chain as shown.
C1 C2 Be sure to install the spacers in their original
positions, otherwise the brake disc and jackshaft
will stick.
Î 0.1 ~ 0.5 mm (0.004 ~ 0.020 in)
: ESSO beacon 325 grease or Aeroshell grease
#7A
For the jackshaft and drive chain housing installation,
refer to “JACKSHAFT”.
SEA4500
2. Install:
• Lever rod 1
3. Adjust:
• Lever rod length a
Adjustment steps:
• Loosen the locknuts 2.
• Turn the lever rod 1 in or out until the specified
length is obtained.
Lever rod length:
139 ~ 141 mm (5.42 ~ 5.55 in)
• Tighten the locknuts.
SEA4510
4-24
DRIVE CHAIN HOUSING
POWR
TR
4. Install:
• Shift rod 1
5. Adjust:
• Shift rod length a
Adjustment steps:
• Move the shift lever to the “FWD.” position.
• Loosen the locknuts 2.
• Turn the shift rod 1 so that shift rod free play is
0 mm (in direction where a can be shortened
appropriately) and then turn back the shift rod
1/4 turns.
• Tighten the locknuts.
SEA4520
6. Fill:
• Drive chain housing oil
Refer to “DRIVE CHAIN” in CHAPTER 2.
7. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN” in CHAPTER 2.
4-25
JACKSHAFT
POWR
TR
JACKSHAFT
Å: 8.5 Nm (0.85 m · kg, 6.1 ft · lb)
ı: 23 Nm (2.3 m · kg, 17 ft · lb)
SEA4530
Order
1
2
3
4
5
6
7
8
Job name/Part name
Jackshaft removal
Secondary sheave
Silencer
Drive chain housing
Collar
Brake disc
Key
Washer
Circlip
Jackshaft
Bearing holder
Bearing
Q’ty
Remarks
Remove the parts in the order listed below.
Refer to “SECONDARY SHEAVE”.
Refer to “FUEL PUMP” in CHAPTER 7.
Refer to “DRIVE CHAIN HOUSING”.
1
1
1
1
1
1
2
1
For installation, reverse the removal procedure.
4-26
JACKSHAFT
POWR
TR
INSPECTION
1. Inspect:
• Jackshaft 1
Scratches (excessive)/damage → Replace.
• Splines 2
Wear/damage → Replace the jackshaft.
• Bearing contact surface 3
Scratches/wear/damage → Replace the
jackshaft.
SEA4540
2. Inspect:
• Bearing holder 1
Cracks/damage → Replace.
• Bearing 2
Pitting/damage → Replace.
SEA4550
3. Measure:
• Brake disc thickness a
Out of specification → Replace.
Brake disc thickness limit (minimun):
9.5 mm (0.37 in)
Measuring point: 1 ~ 3 mm (0.04 ~ 0.12 in) from the
edge of the brake disc.
SEA4560
4-27
JACKSHAFT
POWR
TR
JACKSHAFT AND DRIVE CHAIN HOUSING
INSTALLATION
1. Install:
• Drive chain housing
• Jackshaft
Installation steps:
• Install the drive chain housing 1.
• Tighten the bolts 2.
T.
R.
Bolt (drive chain housing):
48 Nm (4.8 m · kg, 35 ft · lb)
• Temporarily tighten the nuts 3.
• Tighten the nuts 4.
T.
R.
Nut (jackshaft):
60 Nm (6.0 m · kg, 43 ft · lb)
• Retighten the nuts 3.
T.
R.
Nut (bearing holder):
23 Nm (2.3 m · kg, 17 ft · lb)
• Tighten the set screws 5.
T.
R.
Set screw (bearing):
8.5 Nm (0.85 m · kg, 6.1 ft · lb)
LOCTITE®
• Install the drive chain housing cover 6.
Å Properly install the rubber seal onto the drive chain
housing, making sure that these are no gaps.
• Tighten the bolts 7.
T.
R.
SEA4570
4-28
Bolt (drive chain housing cover):
24 Nm (2.4 m · kg, 17 ft · lb)
BRAKE
POWR
TR
BRAKE
Å: 6 Nm (0.6 m · kg, 4.3 ft · lb)
ı: 48 Nm (4.8 m · kg, 35 ft · lb)
SEA4580
Order
1
2
3
4
5
6
Job name/Part name
Brake pad removal
Cap bolt
Retaining pin
Pad spring
Brake pad
Shim 1
Shim 2
Q’ty
Remarks
Remove the parts in the order listed below.
1
1
1
2
2
2
For installation, reverse the removal procedure.
4-29
BRAKE
POWR
TR
CAUTION:
Disc brake components rarely require disassembly. DO NOT:
• Do not disassemble components unless absolutely necessary.
• Do not use solvents on internal brake components.
• Do not use contaminated brake fluid for cleaning.
Use only clean brake fluid.
• Do not allow brake fluid to contact the eyes,
otherwise eye injury may occur.
• Do not allow brake fluid to contact painted
surfaces or plastic parts otherwise damage
may occur.
• Do not disconnect any hydraulic connection,
otherwise the entire system must be disassembled, drained, cleaned, and then properly
filled and bled after reassembly.
BRAKE PAD REPLACEMENT
NOTE:
It is not necessary to disassemble the brake caliper
and brake hose in order to replace the brake pads.
1. Remove:
• Brake pads 1
NOTE:
• Do not depress the brake lever when the caliper or
disc is off the machine otherwise the brake pads will
be forced shut.
• Install a new brake pad spring and shims when the
brake pads are replaced.
• Replace the pads as a set if either one is found to
be worn to the wear limit a.
SEA4590
Wear limit:
4.7 mm (0.19 in)
SEA4600
4-30
BRAKE
POWR
TR
2. Install:
• Brake pads
• Pad spring
Installation steps:
• Connect a suitable hose 1 tightly to the caliper
bleed screw 2. Put the other end of this hose into
an open container.
• Loosen the caliper bleed screw and push the
pistons into the caliper with your finger.
• Tighten the caliper bleed screw 2.
SEA4610
T.
R.
Bleed screw:
6 Nm (0.6 m · kg, 4.3 ft · lb)
• Install the brake pads and pad spring.
3. Inspect:
• Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPECTION”
in CHAPTER 2.
4. Check:
• Brake lever operation
A soft or spongy feeling → Bleed brake system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 2.
4-31
BRAKE
POWR
TR
Å: 30 Nm (3.0 m · kg, 22 ft · lb)
ı: 48 Nm (4.8 m · kg, 35 ft · lb)
SEA4620
Order
Job name/Part name
1
2
3
4
5
6
7
8
9
Brake caliper and parking brake removal
Brake fluid
Brake hose
Brake caliper assembly
Cotter pin
Parking brake cable
Pin
Pin
Collar
Spring
Brake shoe
Remarks
Q’ty
Remove the parts in the order listed below.
Drain.
1
1
2
1
1
1
2
2
2
For installation, reverse the removal procedure.
4-32
BRAKE
POWR
TR
SEA4630
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Brake caliper disassembly
Cap bolt
Retaining pin
Pad spring
Brake pad
Shim 1
Shim 2
Bleed screw
Piston seal
Piston
Q’ty
Remarks
Remove the parts in the order listed below.
1
1
1
2
2
2
2
4
2
For assembly, reverse the disassembly procedure.
4-33
BRAKE
POWR
TR
BRAKE CALIPER DISASSEMBLY
NOTE:
Before disassembling a caliper, drain brake fluid from
brake hose, master cylinder, brake caliper and brake
reservoir of their brake fluid.
1. Remove:
• Pistons
• Piston seals 1
SEA4640
Removal steps:
• Using a wood of piece 2, lock the right piston.
• Blow compressed air into the hose joint opening
a to force out the left piston from the caliper
body.
• Remove the piston seals and reinstall the piston.
• Repeat the previous steps to force out the right
piston from the caliper body.
SEA4650
WARNING
• Never try to pry out the pistons.
• Do not loosen the retaining pin 3.
SEA4660
BRAKE CALIPER INSPECTION AND REPAIR
Recommended brake component
replacement schedule
Brake pads
As required
Piston seals and
dust seals
Every two years
Brake hose
Every two years
Brake fluid
Only when brakes are
disassembled.
WARNING
All internal brake components should be cleaned
only with new brake fluid. Do not use solvents as
they will cause seals to swell and distort.
4-34
BRAKE
POWR
TR
1. Inspect:
• Caliper piston 1
Scratches/rust/wear → Replace the caliper
assembly.
• Caliper cylinder 2
Wear/scratches → Replace the caliper assembly.
• Caliper body 3
Cracks/damage → Replace.
• Oil delivery passage (caliper body)
Blow out with compressed air.
SEA4670
WARNING
Replace the piston seals and dust seals whenever a caliper is disassembled.
BRAKE CALIPER ASSEMBLY
WARNING
• All internal parts should be cleaned only with
new brake fluid.
• Internal parts should be lubricated with brake
fluid when installed.
Recommended brake fluid:
DOT 4
• Replace the piston seals and dust seals whenever a caliper is disassembled.
BRAKE CALIPER INSTALLATION
1. Install:
• Brake hose 1
CAUTION:
When installing the brake hose 1 onto the brake
caliper 2, make sure that the brake pipe touches
the projection 3 on the brake caliper.
SEA4680
4-35
BRAKE
POWR
TR
Å : 14 Nm (1.4 m · kg, 10 ft · lb)
ı : 30 Nm (3.0 m · kg, 22 ft · lb)
å: For VX600ER/SX600/VT600
∫: For MM600
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA4690
Order
1
2
3
4
5
6
7
Job name/Part name
Brake master cylinder removal
Brake fluid
Parking brake cable
Brake light switch
Brake lever
Parking brake lever
Brake hose joint
Holder
Master cylinder assembly
Q’ty
Remarks
Remove the parts in the order listed below.
Drain.
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
1
2
3
4
Brake master cylinder disassembly
Boot
Circlip
Master cylinder kit
Master cylinder body
Remove the parts in the order listed below.
1
1
1
1
For assembly, reverse the disassembly procedure.
4-36
BRAKE
POWR
TR
INSPECTION
1. Inspect:
• Master cylinder 1
Wear/scratches → Replace the master cylinder assembly.
• Master cylinder body 2
Cracks/damage → Replace.
• Oil delivery passage (master cylinder body)
Blow out with compressed air.
SEA4700
2. Inspect:
• Master cylinder kit 1
Scratches/wear/damage → Replace as a set.
SEA4710
BRAKE MASTER CYLINDER ASSEMBLY
WARNING
• All internal parts should be cleaned only with
new brake fluid.
• Internal parts should be lubricated with brake
fluid when installed.
Recommended brake fluid:
DOT 4
• Replace the piston seals and dust seals whenever a caliper is disassembled.
INSTALLATION
1. Connect:
• Brake hose
30˚
NOTE:
30˚
Install the brake hose with the mark a facing upwards, as shown in the diagram.
a
T.
R.
SEA4720
4-37
Brake hose joint:
Brake master cylinder side
14 Nm (1.4 m · kg, 10 ft · lb)
Brake hose side
30 Nm (3.0 m · kg, 22 ft · lb)
SLIDE RAIL SUSPENSION
POWR
TR
SLIDE RAIL SUSPENSION
VX600ER/SX600
Å: 72 Nm (7.2 m · kg, 52 ft · lb)
SEA4730
Order
1
2
3
4
Job name/Part name
Slide rail suspension removal
Rear axle nut
Tension adjuster
Blind cap
Suspension rear plate
Slide rail suspension
Collar
Q’ty
Remarks
Remove the parts in the order listed below.
Loosen.
Loosen.
2
2
1
2
For installation, reverse the removal procedure.
4-38
SLIDE RAIL SUSPENSION
POWR
TR
VT600
Å: 24 Nm (2.4 m · kg, 17 ft · lb)
ı: 72 Nm (7.2 m · kg, 52 ft · lb)
SEA4740
Order
1
2
3
Job name/Part name
Slide rail suspension removal
Rear axle nut
Tension adjuster
Blind cap
Suspension rear plate
Slide rail suspension
Q’ty
Remarks
Remove the parts in the order listed below.
Loosen.
Loosen.
2
2
1
For installation, reverse the removal procedure.
4-39
SLIDE RAIL SUSPENSION
POWR
TR
Å: 4 Nm (0.4 m · kg, 2.9 ft · lb)
ı: 16 Nm (1.6 m · kg, 11 ft · lb)
Ç: 24 Nm (2.4 m · kg, 17 ft · lb)
Î: 30 Nm (3.0 m · kg, 22 ft · lb)
‰: 49 Nm (4.9 m · kg, 35 ft · lb)
Ï: 72 Nm (7.2 m · kg, 52 ft · lb)
å: For VT600
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA4750
Order
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
Job name/Part name
Slide rail suspension disassembly
Stopper band
Hook
Bushing
Collar
Front shock absorber
Suspension wheel
Collar
Wheel bracket
Shaft
Rubber damper
Front pivot arm
Bushing
Collar
Bushing
Collar
Front pivot arm bracket
Bracket
Front suspension bracket
Q’ty
2
2
4
2
1
2
2
2
1
2
1
2
1
4
2
2
2
1
4-40
Remarks
Remove the parts in the order listed below.
(VT600)
(VX600ER/SX600)
(VX600ER/SX600)
SLIDE RAIL SUSPENSION
POWR
TR
Å: 24 Nm (2.4 m · kg, 17 ft · lb)
ı: 49 Nm (4.9 m · kg, 35 ft · lb)
Ç: 72 Nm (7.2 m · kg, 52 ft · lb)
å: For SX600
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA4760
Order
I
J
K
L
M
N
O
P
Q
R
S
T
Job name/Part name
Suspension wheel
Collar
Wheel bracket
Circlip
Suspension wheel
Spacer
Bushing
Collar
Rear suspension bracket
Spacer
Bushing
Collar
Q’ty
2
2
2
2
2
2
2
1
1
2
2
1
4-41
Remarks
(VX600ER/VT600)
SLIDE RAIL SUSPENSION
POWR
TR
Å: 49 Nm (4.9 m · kg, 35 ft · lb)
ı: 72 Nm (7.2 m · kg, 52 ft · lb)
å: For SX600
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA4770
Order
U
V
W
X
Y
Z
[
\
]
^
a
b
Job name/Part name
Rear shock absorber
Bushing
Collar
Pull rod
Collar
Bushing
Rear bracket
Collar
Suspension wheel
Control rod
Bushing
Bushing
Remarks
Q’ty
1
2
1
2
4
4
2
2
2
2
2
2
4-42
(VX600ER/VT600)
(VX600ER/VT600)
(VT600)
(VT600)
SLIDE RAIL SUSPENSION
POWR
TR
Å: 24 Nm (2.4 m · kg, 17 ft · lb)
ı: 72 Nm (7.2 m · kg, 52 ft · lb)
Ç: 75 Nm (7.5 m · kg, 54 ft · lb)
å: For SX600
∫: For VX600ER/VT600
ç: For SX600/VT600
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
Order
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
Job name/Part name
Rear pivot arm
Bushing
Collar
Collar
Rear pivot arm bracket
Collar
Circlip
Suspension wheel
Wheel bracket shaft
Rear axle
Guide wheel
Collar
Tension adjuster
Collar
Collar
Sliding frame
SEA4780
Q’ty
Remarks
1
2
1
1
1
1
2
2
1
1
3 (4)
2
2
1 (2)
1
2
For assembly, reverse the disassembly procedure.
4-43
SLIDE RAIL SUSPENSION
POWR
TR
MM600
Å: 72 Nm (7.2 m · kg, 52 ft · lb)
SEA4790
Order
1
2
3
Job name/Part name
Slide rail suspension removal
Rear axle nut
Tension adjuster
Suspension rear plate
Slide rail suspension
Collar
Q’ty
Remarks
Remove the parts in the order listed below.
Loosen.
Loosen.
2
1
2
For installation, reverse the removal procedure.
4-44
SLIDE RAIL SUSPENSION
POWR
TR
Å: 4 Nm (0.4 m · kg, 2.9 ft · lb)
ı: 16 Nm (1.6 m · kg, 11 ft · lb)
Ç: 24 Nm (2.4 m · kg, 17 ft · lb)
Î: 30 Nm (3.0 m · kg, 22 ft · lb)
‰: 49 Nm (4.9 m · kg, 35 ft · lb)
Ï: 72 Nm (7.2 m · kg, 52 ft · lb)
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA4800
Order
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
Job name/Part name
Slide rail suspension disassembly
Stopper band
Hook
Rubber collar
Rubber collar
Shaft
Bushing
Collar
Front shock absorber
Front pivot arm
Bushing
Collar
Bushing
Collar
Front suspension bracket
Suspension wheel
Collar
Wheel bracket
Q’ty
2
2
2
1
1
4
2
1
1
2
1
4
2
1
2
2
2
4-45
Remarks
Remove the parts in the order listed below.
SLIDE RAIL SUSPENSION
POWR
TR
Å: 24 Nm (2.4 m · kg, 17 ft · lb)
ı: 49 Nm (4.9 m · kg, 35 ft · lb)
Ç: 72 Nm (7.2 m · kg, 52 ft · lb)
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
Order
H
I
J
K
L
M
N
O
P
Q
R
S
T
Job name/Part name
Suspension wheel
Collar
Wheel bracket
Front pivot arm bracket
Circlip
Suspension wheel
Collar
Bushing
Collar
Rear suspension bracket
Spacer
Bushing
Collar
SEA4810
Q’ty
2
2
2
2
2
2
2
2
1
1
2
2
1
4-46
Remarks
SLIDE RAIL SUSPENSION
POWR
TR
Å: 49 Nm (4.9 m · kg, 35 ft · lb)
ı: 72 Nm (7.2 m · kg, 52 ft · lb)
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
Order
U
V
W
X
Y
Z
[
\
]
^
a
Job name/Part name
Rear shock absorber
Bushing
Collar
Pull rod
Collar
Bushing
Suspension wheel
Control rod
Bushing
Bushing
Shaft
SEA4820
Q’ty
1
2
1
2
4
4
2
2
2
2
1
4-47
Remarks
SLIDE RAIL SUSPENSION
POWR
TR
Å: 24 Nm (2.4 m · kg, 17 ft · lb)
ı: 72 Nm (7.2 m · kg, 52 ft · lb)
Ç: 75 Nm (7.5 m · kg, 54 ft · lb)
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
Order
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
Job name/Part name
Rear pivot arm
Bushing
Collar
Collar
Rear pivot arm bracket
Collar
Circlip
Suspension wheel
Wheel bracket shaft
Rear axle
Guide wheel
Collar
Tension adjuster
Collar
Collar
Sliding frame
SEA4830
Q’ty
Remarks
1
2
1
1
1
1
2
2
1
1
4
2
2
2
1
2
For assembly, reverse the disassembly procedure.
4-48
SLIDE RAIL SUSPENSION
POWR
TR
INSPECTION
1. Inspect:
• Suspension wheel
• Guide wheel
Cracks/damage → Replace.
• Wheel bearing
Wheel turns roughly → Replace.
SEA4840
2. Inspect:
• Stopper band 1
Frayed/damage → Replace.
• Pull rod 2
Bends/damage → Replace.
• Shock absorber 3
Oil leaks/damage → Replace.
• Bushings
Wear/cracks/damage → Replace.
• Front pivot arm 4
• Rear pivot arm 5
• Rear pivot arm bracket 6
• Rear suspension bracket 7
• Sliding frame 8
Cracks/damage → Replace.
• Slide runner 9
Wear/damage → Replace.
A
Å VX600ER/SX600/VT600
ı MM600
SEA4850
B
SEA4860
4-49
SLIDE RAIL SUSPENSION
POWR
TR
ASSEMBLY
3
2
1
2
1. Install:
• Shaft 1 (MM600)
3
NOTE:
Ensure the rubber collars 2 are not pinched between
the shaft and sliding frames 3.
SEA4870
T.
R.
Bolt (shaft):
72 Nm (7.2 m · kg, 52 ft · lb)
LOCTITE®
2. Install:
• Stopper band 1
1
a
NOTE:
b
• For VX600ER/SX600/VT600:
•
SEA4880
Install the stopper band with a toward the hook
and b toward the front suspension bracket.
For MM600:
Install the stopper band with a toward the hook
and b toward the shaft.
T.
R.
Nut (stopper band):
4 Nm (0.4 m · kg, 2.9 ft · lb)
INSTALLATION
1. Adjust:
• Slide rail suspension position (MM600)
Refer to “REAR SUSPENSION” in CHAPTER 2.
4-50
POWR
TR
SLIDE RAIL SUSPENSION
Control rod parts number
a
b
SEA4890
ı Parts number
Ç Length a
Î Length b
Å Control rod 1
8CR-4745A-01
310.5 mm (12.2244 in)
200.0 mm (7.8740 in)
Å Control rod 1
8ED-4745A-00
262.5 mm (10.3346 in)
146.0 mm (5.7480 in)
‰ Control rod 1
parts number
VX600ER/
SX600
8CR-4745A-01
MM600
8ED-4745A-00
VT600
8CR-4745A-01
Ï Control rod 2
parts number
8CR-4745B-00
4-51
Ì Washer plate parts number
Ó Washer plate thickness
È Upper
90202-16232
10.0 mm (0.3937 in)
90202-16229
2.5 mm (0.0984 in)
90202-16230
5.0 mm (0.1969 in)
Ô Lower
90202-16232
10.0 mm (0.3937 in)
90202-16231
7.5 mm (0.2953 in)
90202-16229
2.5 mm (0.0984 in)
FRONT AXLE AND TRACK
POWR
TR
FRONT AXLE AND TRACK
Å: 8.5 Nm (0.85 m · kg, 6.1 ft · lb)
ı: 20 Nm (2.0 m · kg, 14 ft · lb)
SEA4900
Order
1
2
3
4
5
6
Job name/Part name
Front axle and track removal
Drive chain housing
Slide rail suspension
Secondary sheave
Speedometer gear assembly
Cable joint
Set screw
Front axle assembly
Bearing
Track
Q’ty
Remarks
Remove the parts in the order listed below.
Refer to “DRIVE CHAIN HOUSING”.
Refer to “SLIDE RAIL SUSPENSION”.
Refer to “SECONDARY SHEAVE”.
1
1
2
1
1
1
For installation, reverse the removal procedure.
4-52
FRONT AXLE AND TRACK
POWR
TR
INSPECTION
1. Inspect:
• Track 1
• Slide metal 2
Wear/cracks/damage → Replace.
SEA4910
2. Inspect:
• Sprocket wheel 1
Wear/break/damage → Replace.
• Front axle 2
Bends/scratches (excessive)/damage →
Replace.
SEA4920
A
104 mm
(4.09 in)
43.1 mm
(1.70 in)
41 mm
(1.61 in)
123 mm
(4.84 in)
27 mm
(1.06 in)
INSTALLATION
104 mm
(4.09 in)
1. Install:
• Sprocket wheels
• Guide wheels
41 mm
(1.61 in)
NOTE:
60 mm
(2.36 in)
132.6 mm
(5.22 in)
164.1 mm
(6.46 in)
B
43.1 mm
(1.70 in)
axle, align the lugs on each sprocket wheel.
201.4 mm
(7.93 in)
• Position each sprocket wheel on the axle as shown
SEA4950
102 mm
(4.02 in)
123 mm
(4.84 in)
102 mm
(4.02 in)
39 mm
(1.54 in)
27 mm
(1.06 in)
39 mm
(1.54 in)
60 mm
(2.36 in)
in the illustration.
Å VX600ER/VT600
ı SX600
Ç MM600
111.9 mm
(4.41 in)
201.4 mm
(7.93 in)
132.6 mm
(5.22 in)
164.1 mm
(6.46 in)
SEA4930
C
102 mm
(4.02 in)
123 mm
(4.84 in)
102 mm
(4.02 in)
43.1 mm
(1.70 in)
37.5 mm
(1.48 in)
27 mm
(1.06 in)
37.5 mm
(1.48 in)
131.1 mm
(5.16 in)
164.1mm
(6.46 in)
• When pressing the sprocket wheels onto the front
111.9 mm
(4.41 in)
63 mm
(2.48 in)
111.9 mm
(4.41 in)
199.9 mm
(7.87 in)
SEA4940
4-53
FRONT AXLE AND TRACK
POWR
TR
2. Place the track in the chassis.
A
NOTE:
• For track with a direction of rotation mark a:
Install the track with the mark pointing in the direction of track rotation.
a
Å VX600ER, VT600 for U.S.A/Canada
ı SX600
Ç MM600
Î VT600 for Europe
SEA4960
B
a
SEA4970
C
a
SEA4980
D
a
SEA4990
4-54
EXHAUST ASSEMBLY
ENG
ENGINE
EXHAUST ASSEMBLY
Å: 1st 18 Nm (1.8 m · kg, 13 ft · lb)
2nd 27 Nm (2.7 m · kg, 19 ft · lb)
SEA5010
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Exhaust assembly removal
Shroud
Shroud’s stopper wire
Spring 1
Spring 2
Spring 3
Exhaust pipe
Gasket 1
Gasket 2
Exhaust joint
Gasket 3
Spring 4
Spring 5
Exhaust silencer
Q’ty
Remarks
Remove the parts in the order listed below.
Open.
2
2
1
1
1
1
1
1
2
1
1
For installation, reverse the removal procedure.
5-1
EXHAUST ASSEMBLY
ENG
INSTALLATION
4
5
1
1. Install:
• Gasket 3
• Exhaust joint
a
NOTE:
3
2
• Install the gasket 3 with its projection a facing the
6
primary sheave side.
• Tighten the bolts 1 ~ 6 in a crisscross pattern.
SEA5020
T.
R.
Bolt (exhaust joint):
1st:
18 Nm (1.8 m · kg, 13 ft · lb)
2nd:
27 Nm (2.7 m · kg, 19 ft · lb)
2. Install:
• Spring 5 1
• Springs 4 2
• Spring 3 3
• Springs 2 4
• Springs 1 5
3
2
5
NOTE:
Install the springs as shown.
5
4
1
2
1
SEA5030
5-2
ENGINE ASSEMBLY
ENG
ENGINE ASSEMBLY
Å: 15 Nm (1.5 m · kg, 11 ft · lb)
ı: 23 Nm (2.3 m · kg, 17 ft · lb)
Ç: 33 Nm (3.3 m · kg, 24 ft · lb)
Î: 57 Nm (5.7 m · kg, 41 ft · lb)
‰: 90 Nm (9.0 m · kg, 65 ft · lb)
SEA5040
Order
Job name/Part name
Q’ty
Engine removal
Exhaust assembly
Carburetors
Recoil starter
AC magneto rotor
Primary sheave
Coolant
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Coolant hose 1
Coolant hose 6
Carburetor heating hose 1
Plastic band
Carburetor heating hose 3
Battery negative lead
Water temperature sensor coupler
Ignition coil coupler
Rear bracket (right)
Oil pump cable
Oil delivery hose
Vacuum hose
Starter motor
Starter motor lead
Engine assembly
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
Remarks
Remove the parts in the order listed below.
Refer to “EXHAUST ASSEMBLY”.
Refer to “CARBURETORS” in CHAPTER 7.
Refer to “RECOIL STARTER”.
Refer to “AC MAGNETO”.
Refer to “PRIMARY SHEAVE AND DRIVE VBELT” in CHAPTER 4.
Drain. Refer to “COOLING SYSTEM” in CHAPTER 2.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
(VX600ER/VT600)
Disconnect.
Disconnect.
Disconnect.
Disconnect.
(VX600ER/VT600)
(VX600ER/VT600)
For installation, reverse the removal procedure.
5-3
ENGINE ASSEMBLY
ENG
INSPECTION
1. Inspect:
• Rear bracket (right) 1
Cracks/damage → Replace.
SEA5050
INSTALLATION
NOTE:
After installing all parts, refer to “CABLE ROUTING”
in CHAPTER 9, to check the cable, lead and hose
routings.
1. Fasten:
• Plastic band 1
SEA5060
NOTE:
• Fasten the carburetor heating hose 3 2 without
•
squashing it.
For VX600ER/VT600:
Clamp the starter motor lead 3 and carburetor
heating hose 3 2 together so that the white tape on
the starter motor lead 3 is positioned behind the
front bracket.
2 .Install:
• Starter motor lead 1 (VX600ER/VT600)
SEA5070
NOTE:
1
Route the starter motor lead as shown in the illustration.
5-4
ENGINE ASSEMBLY
ENG
3. Bleed:
• Oil system
Refer to “OIL PUMP” in CHAPTER 2.
• Cooling system
Refer to “COOLING SYSTEM” in CHAPTER 2.
4. Adjust:
• Oil pump cable distance a
Refer to “OIL PUMP” in CHAPTER 2.
Distance:
23 ± 1 mm (0.906 ± 0.039 in)
SEA5080
5-5
CYLINDER HEAD AND CYLINDER
ENG
CYLINDER HEAD AND CYLINDER
Å: 10 Nm (1.0 m · kg, 7.2 ft · lb)
ı: 14 Nm (1.4 m · kg, 10 ft · lb)
SEA5090
Order
Job name/Part name
1
2
3
4
5
6
7
8
9
10
Cylinder head and cylinder removal
Spark plug cap
Clamp
Sub-wire harness 2
Bracket
Plastic band
Ignition coil #3
Spacer 1
Ignition coil #2
Spacer 2
Ignition coil #1
Q’ty
Remarks
Remove the parts in the order listed below.
3
1
1
1
3
1
2
1
1
1
5-6
CYLINDER HEAD AND CYLINDER
ENG
Å: 14 Nm (1.4 m · kg, 10 ft · lb)
ı: 1st 11 Nm (1.1 m · kg, 8.0 ft · lb)
2nd
23 Nm (2.3 m · kg, 17 ft · lb)
Ç: 20 Nm (2.0 m · kg, 14 ft · lb)
Î: 23 Nm (2.3 m · kg, 17 ft · lb)
‰: 28 Nm (2.8 m · kg, 20 ft · lb)
SEA5100
Order
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Job name/Part name
Spark plug
Water temperature sensor
Cylinder head
Gasket
Cylinder
Gasket
Clamp
Intake manifold
Spacer
Reed valve seat
Reed valve stopper
Reed valve
Gasket
Piston ring
Piston pin
Piston
Bearing
Q’ty
Remarks
3
1
1
3
3
1
1
3
3
3
6
6
3
6
3
3
3
For installation, reverse the removal procedure.
5-7
CYLINDER HEAD AND CYLINDER
ENG
REMOVAL
1. Remove:
• Piston pin clip
• Piston pin
• Piston
• Small end bearing
NOTE:
• Before removing the piston pin clip, cover the
SEA5110
•
•
crankcase with a clean rag so that you will not
accidentally drop the clip into the crankcase.
Before removing the piston pin, deburr the clip
groove and pin hole area. If the piston pin groove
is deburred and the piston pin is still difficult to
remove, use the piston pin puller.
Put identification marks on each piston head for
reference during reinstallation.
Piston pin puller:
90890-01304, YU-01304
CAUTION:
Do not use a hammer to drive out the piston pin
out.
1 Piston pin
2 Piston
3 Piston pin puller
SEA5120
5-8
CYLINDER HEAD AND CYLINDER
ENG
INSPECTION
1. Eliminate:
• Carbon deposits
(from the combustion chamber)
Use the rounded scraper 1.
CAUTION:
Do not use a sharp instrument. Avoid damaging
or scratching the surface.
SEA5130
2. Inspect:
• Cylinder head water jacket
Crust of minerals/rust → Clean.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface.
Warpage limit:
0.03 mm (0.0012 in)
• Straight edge 1
• Thickness gauge 2
SEA5140
4. Eliminate:
• Carbon deposits
(from the cylinders)
Use the rounded scraper 1.
CAUTION:
Do not use a sharp instrument. Avoid damaging
or scratching the surface.
SEA5150
5. Eliminate:
• Carbon deposits
(from the piston crown and ring grooves)
6. Inspect:
• Piston crown
Burrs/nicks/damage → Replace.
SEA5160
5-9
ENG
CYLINDER HEAD AND CYLINDER
7. Eliminate:
• Score marks and lacquer deposits
(from the piston wall)
Use 600 ~ 800 grit wet sandpaper.
NOTE:
Sand in a crisscross pattern. Do not sand excessively.
SEA5170
8. Measure:
• Piston-to-cylinder clearance
Measurement steps:
1st step:
• Measure the cylinder bore (C) with a cylinder bore
gauge 1.
NOTE:
SEA5180
Measure the cylinder bore (C) parallel to and at right
angles to the crankshaft. Then find the average of the
measurements.
Standard
Cylinder bore
(C)
Wear limit
65.000 ~ 65.014 mm 65.100 mm
(2.5591 ~ 2.5596 in) (2.5630 in)
Taper (T)
_
0.05 mm
(0.002 in)
Out of round
(R)
_
0.01 mm
(0.0004 in)
C = Maximum D
T = (Maximum of D1 or D2) –
(Maximum of D5 or D6)
R = (Maximum of D1, D3 or D5) –
(Minimum of D2, D4 or D6)
• If out of specification, replace cylinder, and replace piston and piston rings as a set.
SEA5190
5-10
CYLINDER HEAD AND CYLINDER
ENG
2nd step:
• Measure the piston skirt diameter (P) with a
micrometer.
a 10 mm (0.39 in) from the bottom edge of the piston
Piston size (standard) (P):
64.932 ~ 64.935 mm
(2.5564 ~ 2.5565 in)
• If out of specification, replace the piston and
SEA5200
piston rings as a set.
3rd step:
• Calculate the piston-to-cylinder clearance with
the following formula:
Piston-to-cylinder clearance =
Cylinder bore (C) – Piston skirt diameter (P)
• If out of specification, rebore or replace cylinder,
and replace piston and piston rings as a set.
Piston-to-cylinder clearance:
0.065 ~ 0.070 mm
(0.0026 ~ 0.0028 in)
Limit 0.15 mm (0.006 in)
9. Measure:
• Side clearance (piston rings)
Use the thickness gauge 1.
Out of specification → Replace the piston
and/or rings.
NOTE:
Eliminate the carbon deposits from the piston ring
grooves and rings before measuring the side clearance.
SEA5210
Side clearance (top):
0.02 ~ 0.06 mm
(0.0008 ~ 0.0024 in)
Side clearance (2nd):
0.02 ~ 0.06 mm
(0.0008 ~ 0.0024 in)
5-11
CYLINDER HEAD AND CYLINDER
ENG
10. Install:
• Piston ring
(into the cylinder)
Push in the ring with the piston crown.
NOTE:
Insert the ring into the cylinder, and push it approximately 20 mm (0.8 in) into the cylinder. Push in the
ring with the piston crown so that the ring is at right
angles to the cylinder bore.
SEA5220
11. Measure:
• End gap (piston rings)
Use the thickness gauge 1.
Out of specification → Replace the rings as a
set.
End gap (top):
0.35 ~ 0.55 mm
(0.014 ~ 0.022 in)
End gap (2nd):
0.35 ~ 0.55 mm
(0.014 ~ 0.022 in)
SEA5230
a 20 mm (0.8 in)
12. Measure:
• Outside diameter (piston pin) a
Out of specification → Replace the piston pin.
Outside diameter (piston pin):
19.995 ~ 20.000 mm
(0.7872 ~ 0.7874 in)
SEA5240
13. Measure:
• Piston pin-to-piston clearance
Out of specification → Replace the piston.
Piston pin-to-piston clearance =
Bore size (piston pin) b –
Outside diameter (piston pin) a
Piston pin-to-piston clearance =
0.009 ~ 0.015 mm
(0.000354 ~ 0.000591 in)
SEA5250
5-12
CYLINDER HEAD AND CYLINDER
ENG
14. Inspect:
• Reed valves 1
Bends/cracks/damage → Replace.
SEA5260
15. Measure:
• Valve stopper height a
Out of specification → Replace the valve stopper.
Valve stopper height:
10.3 ~ 10.7 mm (0.41 ~ 0.42 in)
SEA5270
16. Measure:
• Reed valve bending limit a
Out of specification → Replace the reed valve.
Reed valve bending limit:
less than 1.5 mm (0.059 in)
SEA5280
5-13
CYLINDER HEAD AND CYLINDER
ENG
INSTALLATION
1. Install:
• Reed valves
• Reed valve stoppers
NOTE:
• Place the reed valve 1 with its concave surface
facing toward the reed valve seat 2.
• Fit the reed valve stopper cut a into the corresponding cut b on the reed valve.
SEA5290
2. Tighten:
• Screws 1
T.
R.
Screw (reed valve):
1 Nm (0.1 m · kg, 0.7 ft · lb)
LOCTITE®
NOTE:
Tighten each screw gradually to avoid warping.
SEA5300
3. Install:
• Small end bearing
• Piston
• Piston pin
• Piston pin clip
• Piston rings
NOTE:
• The arrow a on the piston must point toward to the
SEA5310
•
•
front of the engine.
Before installing the piston pin clip, cover the
crankcase with a clean rag so that you do not
accidentally drop the pin clip and other material into
the crankcase.
Position each piston very carefully in its original
place.
CAUTION:
• Always use new piston pin clips.
• Do not allow the clip gap to align with the piston
pin slot.
SEA5320
5-14
CYLINDER HEAD AND CYLINDER
ENG
4. Check:
• Piston ring position
CAUTION:
• Make sure that the ring ends are properly fitted
•
SEA5330
around the ring locating pins in the piston
grooves.
Be sure to check that the manufacturer’s marks
or numbers stamped on the rings face upward.
5. Install:
• Gasket (cylinder)
NOTE:
Install the gasket (cylinder) with its projection a
facing the AC magneto side.
CAUTION:
Always use new gasket.
SEA5340
6. Install:
• Cylinder
NOTE:
Install the cylinder with one hand while compressing
the piston rings with the other hand.
SEA5350
7. Tighten:
• Nuts (cylinder)
T.
R.
a
Nut (cylinder) :
28 Nm (2.8 m · kg, 20 ft · lb)
8. Install:
• Gaskets (cylinder head)
b
NOTE:
Install with the mark a facing upwards and the
projection b on the intake side.
SEA5360
5-15
CYLINDER HEAD AND CYLINDER
ENG
9. Tighten:
• Nuts (cylinder head)
Tightening steps:
• Temporarily tighten the cylinder head nuts 1 ~ E
as follows.
1st step:
• Tighten the nuts 1 ~ E.
T.
R.
Nut (cylinder head):
11 Nm (1.1 m · kg, 8.0 ft · lb)
2nd step:
• Retighten the nuts 1 ~ E.
T.
R.
Nut (cylinder head):
23 Nm (2.3 m · kg, 17 ft · lb)
SEA5370
1
2
10. Connect:
• Ignition coil leads
Ignition coil #1 Black/White lead →
Sub-wire harness Orange lead
Ignition coil #2 Black/White lead →
Sub-wire harness Gray lead
Ignition coil #3 Black/White lead →
Sub-wire harness White lead
Ignition coil #1, #2, #3 Black lead →
Sub-wire harness Black lead
3
B/W
B
B/W
B
O
B
Gy
B
B/W
B
W
B
B
NOTE:
Connect the black leads of the sub-wire harness to
the ignition coils as follows: the longest lead to
ignition coil #1, the medium-size lead to ignition coil
#2, and the shortest lead to ignition coil #3.
Gy O
B
W
SEA5380
11. Install:
• Plastic band
SEA5390
NOTE:
Pass the ignition coil leads as shown in the illustration.
5-16
OIL PUMP, CRANKCASE AND CRANKSHAFT
ENG
OIL PUMP, CRANKCASE AND CRANKSHAFT
Å: 8 Nm (0.8 m · kg, 5.8 ft · lb)
ı: 13 Nm (1.3 m · kg, 9.4 ft · lb)
Ç: 15 Nm (1.5 m · kg, 11 ft · lb)
Î: 33 Nm (3.3 m · kg, 24 ft · lb)
‰: 40 Nm (4.0 m · kg, 29 ft · lb)
Ï: 1st
2nd
13 Nm (1.3 m · kg, 9.4 ft · lb)
27 Nm (2.7 m · kg, 19 ft · lb)
SEA5400
Order
Job name/Part name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Oil pump, crankcase and crankshaft
removal
Oil pump
Oil hose 1
Rear bracket (left)
Front lower bracket
Damper
Clamp
Front upper bracket
Clamp
Water pump cover
Gasket
Oil hose 2
Lower crankcase
Crankshaft assembly
Oil seal
Upper crankcase
Q’ty
Remarks
Remove the parts in the order listed below.
1
1
1
2
2
1
2
1
1
1
1
1
1
1
1
(VX600ER/VT600)
(VX600ER/VT600)
For installation, reverse the removal procedure.
5-17
OIL PUMP, CRANKCASE AND CRANKSHAFT
ENG
INSPECTION
1. Measure:
• Runout
Use the V-blocks and a dial gauge.
Out of specification → Replace or repair the
crankshaft.
Dial gauge:
90890-03097, YU-03097
SEA5410
Maximum runout:
C1
: 0.03 mm (0.0012 in)
C2 ~ C5: 0.04 mm (0.0016 in)
C6
: 0.03 mm (0.0012 in)
a 90 mm (3.54 in)
b 85 mm (3.35 in)
2. Measure:
• Small end free play a
Use the dial gauge.
Out of specification → Replace the defective
parts.
Small end free play:
0.8 ~ 1.0 mm (0.03 ~ 0.04 in)
• Big end side clearance b
SEA5420
Use the thickness gauge.
Out of specification → Replace the defective
parts.
Big end side clearance:
0.25 ~ 0.75 mm (0.01 ~ 0.03 in)
• Big end radial clearance c
Use the dial gauge.
Out of specification → Replace the defective
parts.
Big end radial clearance:
0.026 ~ 0.040 mm
(0.0010 ~ 0.0016 in)
5-18
OIL PUMP, CRANKCASE AND CRANKSHAFT
ENG
3. Inspect:
• Crankshaft bearing 1
Pitting/damage → Replace.
• Stopper ring 2
Bends/damage → Replace.
• Crankshaft oil seals 3
• Impeller drive gear teeth 4
Wear/damage → Replace.
SEA5430
CAUTION:
Lubricate the bearings immediately after examining them in order to prevent rust.
4 .Inspect:
• Lower crankcase 1
• Upper crankcase 2
• Front lower brackets 3
• Front upper brackets 4
• Rear bracket (left) 5
• Dampers 6
Cracks/damage → Replace.
SEA5440
5. Inspect:
• Impeller driven gear teeth 1
Wear/damage → Replace the impeller shaft.
• Impeller shaft 2
• Bearing 3
Pitting/damage → Replace.
SEA5450
6. Inspect:
• Oil pump
Cracks/damage → Replace.
• Oil hoses
Clogs/damage → Replace.
SEA5460
5-19
OIL PUMP, CRANKCASE AND CRANKSHAFT
ENG
INSTALLATION
1. Install:
• Stopper ring 1
[onto the crankshaft bearing 2 (primary sheave
side) as shown]
3 Knock pin
SEA5470
2. Install:
• Crankshaft assembly
(onto the upper crankcase Å)
NOTE:
Turn the bearings and labyrinth seal to set the knock
pins 1 on the bearings and labyrinth seal into the pin
holes 2 in the upper crankcase Å.
SEA5480
3 Bearing (AC magneto side)
NOTE:
Turn bearing 3 to set the knock pin 4 on the upper
crankcase Å into the pin hole 5 in the bearing.
SEA5490
CAUTION:
The oil seal lip must fit into the crankcase groove.
SEA5500
5-20
OIL PUMP, CRANKCASE AND CRANKSHAFT
ENG
3. Fill:
• Gear room 1
Recommended oil:
YAMALUBE 2-cycle
Gear room capacity:
25 cm3 (0.81 Imp oz, 0.77 US oz)
SEA5510
CAUTION:
Before installing and torquing the crankcase
bolts, be sure to check that the crankshaft turns
smoothly.
SEA5520
4. Tighten:
• Crankcase bolts 1 ~ F (M8 × 80)
ED
6 4
2 7
0A
NOTE:
Tighten the bolts in order, starting with the lowest
number, and torque the bolts in two stages.
5 1
FC
9
3 8
B
T.
6
2
R.
SEA5530
Bolt (crankcase):
1st:
13 Nm (1.3 m · kg, 9.4 ft · lb)
2nd:
27 Nm (2.7 m · kg, 19 ft · lb)
5. Tighten:
• Crankcase bolts 1 ~ 6 (M8 × 35)
4
NOTE:
Tighten the bolts in order, starting with the lowest
number.
1
5
T.
3
R.
SEA5540
5-21
Bolt (crankcase):
15 Nm (1.5 m · kg, 11 ft · lb)
OIL PUMP, CRANKCASE AND CRANKSHAFT
ENG
6. Install:
• Oil hose 1
NOTE:
a
Install so that the mark a on the check valve faces
the crankcase.
SEA5550
5-22
AC MAGNETO
ENG
AC MAGNETO
Å: 23 Nm (2.3 m · kg, 17 ft · lb)
ı: 48 Nm (4.8 m · kg, 35 ft · lb)
Ç: 110 Nm (11 m · kg, 80 ft · lb)
SEA5560
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
AC magneto removal
Recoil starter
Frame cross member
AC magneto coupler
Plastic band
Starter pulley
Spacer
Magneto rotor
Woodruff key
Clamp
Plate
Stator coil assembly
Remarks
Q’ty
Remove the parts in the order listed below.
Refer to “RECOIL STARTER”.
1
2
1
1
1
1
1
1
1
1
Disconnect.
For installation, reverse the removal procedure.
5-23
AC MAGNETO
ENG
REMOVAL
1. Remove:
• Bolts 1
• Starter pulley 2
• Nut 3
NOTE:
Attach the primary sheave holder to hold the primary
sheave.
SEA5570
Primary sheave holder:
90890-01701, YS-01880
2. Remove:
• Magneto rotor 1
NOTE:
• Remove the magneto rotor using the rotor
•
SEA5580
puller 2.
Fully tighten the tool holding bolts, making sure the
tool body is parallel with the magneto rotor. If
necessary, one screw may be backed out slightly
to level the tool body.
Rotor holding puller:
90890-01362, YU-33270
5-24
AC MAGNETO
ENG
INSTALLATION
NOTE:
After installing all parts, refer to “CABLE ROUTING”
in CHAPTER 9, to check the cable, lead and hose
routings.
1. Install:
• Stator coil
NOTE:
Route the pickup coil lead 1 under and behind the
pickup coil 2 as shown.
1
2
SEA5590
2. Install:
• Woodruff key 1
CAUTION:
Be sure to remove any oil or grease from the
tapered portion of the crankshaft using a cloth
dampened with thinner.
NOTE:
SEA5600
Pass the magneto leads through the hole and install
the grommet in the crankcase.
3. Install:
• Magneto rotor
• Washer
• Nut
CAUTION:
Be sure to remove any oil or grease from the
tapered portion of the magneto rotor using a
cloth dampened with thinner.
NOTE:
When installing the magneto rotor, make sure the
woodruff key is properly seated in the keyway of the
crankshaft.
5-25
AC MAGNETO
ENG
4. Tighten:
• Bolts 1
• Nut 2
T.
R.
SEA5610
Bolt (starter pulley):
23 Nm (2.3 m · kg, 17 ft · lb)
Nut (magneto rotor):
110 Nm (11 m · kg, 80 ft · lb)
NOTE:
Attach the primary sheave holder to hold the primary
sheave.
Primary sheave holder:
90890-01701, YS-01880
5-26
RECOIL STARTER
ENG
RECOIL STARTER
Å: 12 Nm (1.2 m · kg, 8.7 ft · lb)
ı: 18 Nm (1.8 m · kg, 13 ft · lb)
SEA5620
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Recoil starter removal
Exhaust silencer
Starter handle
Recoil starter case
Drive plate
Cam guide
Drive plate spring
Washer
Drive pawl
Return spring
Sheave drum
Starter rope
Starter spring
Q’ty
Remarks
Remove the parts in the order listed below.
Refer to “EXHAUST ASSEMBLY”.
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
5-27
RECOIL STARTER
ENG
REMOVAL
1. Remove:
• Starter handle 1
NOTE:
To remove the starter handle, untie the knot 2 in the
starter rope and then re-tie a knot 3 in the rope end
so that it is not pulled into the recoil starter case 4.
SEA5630
SEA5640
INSPECTION
1. Inspect:
• Drive plate 1
Cracks/bends/damage → Replace.
• Drive pawl 2
• Return spring 3
• Cam guide 4
Wear/cracks/damage → Replace.
• Drive plate spring 5
Wear/damage → Replace.
• Sheave drum 6
Cracks/damage → Replace.
• Starter spring 7
Cracks/bends/damage → Replace.
• Starter rope 8
Wear/breaks/damage → Replace.
SEA5650
5-28
RECOIL STARTER
ENG
INSTALLATION
1. Wind:
• Starter rope (2-1/2 times counterclockwise)
(in the sheave drum)
2. Install:
• Starter spring 1
• Sheave drum assembly 2
NOTE:
• Mesh the spring hook 3 with the case slit, then
•
SEA5660
wind the spring counterclockwise into the case
from a larger to a smaller diameter.
Mesh the sheave drum hook 4 with the spring
hook 5.
3. Install:
• Drive pawl 1
• Cam guide 2
• Drive plate 3
NOTE:
The cam guide 2 should not be on top of the drive
pawl 1.
SEA5670
4. Pull about 102 mm (4 in) of starter rope out of the
cutout portion in the sheave drum and rotate the
sheave drum 4-1/2 times counterclockwise to
preload the starter spring.
SEA5680
NOTE:
Pass the rope through the case hole and make a
knot 1 in the rope so that the rope is not pulled into
the case.
SEA5690
5-29
HEAT EXCHANGER
COOL
COOLING SYSTEM
HEAT EXCHANGER
VX600ER/SX600/VT600
Å: 7 Nm (0.7 m · kg, 5.1 ft · lb)
SEA6010
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Job name/Part name
Heat exchanger removal
Coolant
Coolant filler cap
Coolant hose 1
Spring 1
Filler cap body
Carburetor heating hose 1
Carburetor heating lever assembly
Carburetor heating hose 2
Plastic band
Carburetor heating hose 3
Coolant hose bracket
Coolant hose 2
Spring 2
Coolant hose 3
Heat exchanger (right)
Coolant hose 4
Coolant hose 5
Heat exchanger (left)
Heat exchanger (rear)
Coolant hose 6
Spring 3
Q’ty
Remarks
Remove the parts in the order listed below.
Drain. Refer to “COOLING SYSTEM” in CHAPTER 2.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
6-1
6
HEAT EXCHANGER
COOL
MM600
Å: 7 Nm (0.7 m · kg, 5.1 ft · lb)
SEA6020
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Job name/Part name
Heat exchanger removal
Coolant
Coolant filler cap
Coolant hose 1
Spring 1
Filler cap body
Carburetor heating hose 1
Carburetor heating lever assembly
Carburetor heating hose 2
Plastic band
Carburetor heating hose 3
Coolant hose bracket
Coolant hose 2
Spring 2
Coolant hose 3
Heat exchanger (right)
Coolant hose 4
Coolant hose 5
Heat exchanger (left)
Heat exchanger (rear)
Coolant hose 6
Spring 3
Q’ty
Remarks
Remove the parts in the order listed below.
Drain. Refer to “COOLING SYSTEM” in CHAPTER 2.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
6-2
HEAT EXCHANGER
COOL
INSPECTION
A
1. Inspect:
• Coolant hoses 1
• Heat exchangers 2
• Filler cap body 3
• Carburetor heating lever assembly 4
• Carburetor heating hoses 5
Cracks/damage → Replace.
Å VX600ER/SX600/VT600
ı MM600
SEA6030
B
SEA6040
6-3
HEAT EXCHANGER
COOL
2. Measure:
• Filler cap opening pressure
Cap opens with a pressure below the specified
pressure → Replace.
Cap opening pressure:
95 ~ 125 kPa
(0.95 ~ 1.25 kg/cm2, 14 ~ 18 psi)
SEA6050
Measurement steps:
• Attach the cooling system tester 1 to the coolant
filler cap 2.
Cooling system tester:
90890-01325, YU-24460-01
• Apply the specified pressure for 10 seconds and
make sure there is no pressure drop.
INSTALLATION
1. Install:
• Heat exchangers
Use the rivet gun.
6-4
WATER PUMP
COOL
WATER PUMP
Å: 10 Nm (1.0 m · kg, 7.2 ft · lb)
ı: 13 Nm (1.3 m · kg, 9.4 ft · lb)
Ç: 33 Nm (3.3 m · kg, 24 ft · lb)
Î: 90 Nm (9.0 m · kg, 65 ft · lb)
SEA6060
Order
Job name/Part name
Q’ty
Water pump and thermostatic valve
removal
Exhaust joint
Coolant
1
2
3
4
5
6
7
8
9
10
11
Thermostatic cover
Plain washer
Gasket
Plastic band
Clamp
Engine bracket
Carburetor heating hose 3
Coolant hose 6
Water pump cover
Gasket
Impeller
Remarks
Remove the parts in the order listed below.
Refer to “EXHAUST ASSEMBLY” in CHAPTER 5.
Drain. Refer to “COOLING SYSTEM” in CHAPTER 2.
1
1
1
1
1
1
1
1
1
1
1
(VX600ER/VT600)
For installation, reverse the removal procedure.
6-5
WATER PUMP
COOL
REMOVAL
1. Remove:
• Impeller 1
NOTE:
Attach the primary sheave holder to hold the primary
sheave.
Primary sheave holder:
90890-01701, YS-01880
SEA6070
INSPECTION
1. Inspect:
• Impeller 1
• Water pump cover 2
• Thermostatic cover 3
Cracks/damage → Replace.
SEA6080
INSTALLATION
1. Install:
• Impeller 1
NOTE:
Attach the primary sheave holder to hold the primary
sheave.
Primary sheave holder:
90890-01701, YS-01880
SEA6090
T.
R.
Bolt (impeller):
10 Nm (1.0 m · kg, 7.2 ft · lb)
2. Fasten:
• Plastic band 1
NOTE:
• Fasten the carburetor heating hose 3 2 without
squashing it.
• For VX600ER/VT600:
Clamp the starter motor lead 3 and carburetor
heating hose 3 2 together so that the white tape on
the starter motor lead 3 is positioned behind the
front bracket.
SEA6100
6-6
CARBURETORS
CARB
CARBURETION
CARBURETORS
SEA7010
Order
Job name/Part name
Q’ty
1
Carburetors removal
Intake silencer
Carburetor heating lever
1
2
3
4
5
6
7
8
9
Carburetor switch (T.O.R.S.) lead
Throttle cable
Starter cable
Clamp
Carburetor heating hose
Clamp screw
Fuel delivery hose
Carburetor
2
1
1
1
2
3
3
3
Remarks
Remove the parts in the order listed below.
Refer to “FUEL PUMP”.
Before removing the carburetors, make sure that
the carburetor heating lever is turned to “OFF”.
Unfasten.
Loosen.
Disconnect.
For installation, reverse the removal procedure.
7-1
7
CARBURETORS
CARB
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA7020
Order
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
Job name/Part name
Carburetor separation
Carburetor heating hose
Starter cable holder
Collar
Spring
Screw
Starter rod
Spring
Starter lever
Breather hose
Top cover
Gasket
Throttle shaft connecting screw
Clamp
Connecting plate (upper)
Connecting plate (lower)
Q’ty
Remarks
Remove the parts in the order listed below.
2
1
1
1
3
1
1
3
6
3
3
3
1
1
1
Loosen.
For assembly, reverse the separation procedure.
7-2
CARBURETORS
CARB
Å: 0.7 Nm (0.07 m · kg, 0.51 ft · lb)
ı: 1 Nm (0.1 m · kg, 0.7 ft · lb)
Ç: 1.8 Nm (0.18 m · kg, 1.3 ft · lb)
Î: 2.5 Nm (0.25 m · kg, 1.8 ft · lb)
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA7030
Order
1
2
3
4
5
6
7
8
9
0
A
B
Job name/Part name
Carburetor disassembly
Throttle stop screw
Carburetor switch (T.O.R.S.)
Throttle cable holder
Throttle valve assembly
Inner throttle lever assembly
Boot
Starter plunger assembly
Pilot mixture screw
Spring
Washer
O-ring
Float chamber
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
7-3
Remarks
Remove the parts in the order listed below.
Turn clockwise.
CARBURETORS
CARB
Å: 0.7 Nm (0.07 m · kg, 0.51 ft · lb)
ı: 1 Nm (0.1 m · kg, 0.7 ft · lb)
Ç: 1.8 Nm (0.18 m · kg, 1.3 ft · lb)
Î: 2.5 Nm (0.25 m · kg, 1.8 ft · lb)
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
SEA7030
Order
C
D
E
F
G
H
I
J
K
L
M
N
O
Job name/Part name
Gasket
Main jet
Main jet ring
Main nozzle
Pilot jet
Pilot jet sleeve
Float pin
Float
Needle valve
Screw (valve seat)
Valve seat assembly
O-ring
Pilot air jet
Q’ty
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly procedure.
7-4
CARBURETORS
CARB
INSPECTION
1. Inspect:
• Carburetor body
• Fuel passage
Contamination → Clean.
NOTE:
• Use a petroleum based solvent for cleaning.
• Blow out all passages and jets with compressed
SEA7040
air.
2. Inspect:
• Rubber seals 1
• Bearing 2
Wear/damage → Replace.
SEA7050
3. Inspect:
• Float 1
Damage → Replace.
SEA7060
4. Inspect:
• Valve seat assembly 1
• Main nozzle 2
• Main jet 3
• Main jet ring 4
• Pilot jet 5
• Pilot jet sleeve 6
• Pilot mixture screw assembly 7
• Starter plunger assembly 8
• Jet needle 9
Bends/wear/damage → Replace.
Blockage → Blow out the jets with compressed
air.
SEA7070
7-5
CARBURETORS
CARB
5. Inspect:
• Throttle valve 1
Wear/damage → Replace.
6. Check:
• Throttle valve movement
Sticks → Replace carburetor body assembly.
SEA7080
ASSEMBLY
NOTE:
• Before reassembling, wash all parts in clean gaso•
line.
Always use new gaskets and O-rings.
1. Tighten:
• Inner parts
T.
R.
Pilot air jet:
0.7 Nm (0.07 m · kg, 0.51 ft · lb)
Screw (valve seat):
1 Nm (0.1 m · kg, 0.7 ft · lb)
Pilot jet:
0.7 Nm (0.07 m · kg, 0.51 ft · lb)
Main jet:
1.8 Nm (0.18 m · kg, 1.3 ft · lb)
Starter plunger assembly:
2.5 Nm (0.25 m · kg, 1.8 ft · lb)
2. Measure:
• Float height a
Out of specification → Adjust.
Float height:
11.3 ~ 15.3 mm (0.44 ~ 0.60 in)
SEA7090
7-6
CARBURETORS
CARB
Measurement and adjustment steps:
• Hold the carburetor upside down.
• Measure the distance between the carburetor
body and top of the floats.
NOTE:
The float arm should resting on the needle valve
without exerting pressure on it.
• If the float height is not within specification, in-
SEA7100
spect the valve seat and needle valve.
• If either is worn, replace them both.
• If both are fine, adjust the float height by bending
•
the float arm tang 1 on the float.
Recheck the float height.
3. Install:
• Return springs 1
• Carburetors (No.1, No.3)
NOTE:
Hook the spring hooks 2 to the projections on the
connecting lever 3 and carburetor body 4 while
twisting the spring clockwise approximately 315 degrees.
SEA7110
SEA7120
CARBURETOR SYNCHRONIZATION
1. Adjust:
• Carburetor synchronization
Refer to “CARBURETOR SYNCHRONIZATION” in CHAPTER 2.
7-7
CARBURETORS
CARB
FUEL LEVEL ADJUSTMENT
1. Measure:
• Fuel level a
Out of specification → Adjust.
Fuel level (from the bore center):
36 ~ 38 mm (1.42 ~ 1.50 in)
Measurement and adjustment steps:
• Place the machine on a level surface.
• Attach the fuel level gauge 1 to the float chamber
nozzle.
Fuel level gauge:
90890-01312, YM-01312-A
NOTE:
SEA7130
Use the adapter (outside diameter ø6 hose) 2 when
attaching the fuel level gauge.
• Loosen the drain screw 3 and start the engine.
• Place the tube along the seam line 4 of the
•
•
•
•
•
•
SEA7140
•
7-8
carburetor body.
Measure the fuel level a with the gauge.
If the fuel level is incorrect, adjust the fuel level.
Remove the carburetor.
Inspect the valve seat and needle valve.
If either is worn, replace them both.
If both are fine, adjust the float height by bending
the float tang 5 on the float.
Recheck the fuel level.
CARBURETORS
CARB
INSTALLATION
NOTE:
After installing all parts, refer to “CABLE ROUTING”
in CHAPTER 9, to check the cable, lead and hose
routings.
1. Fasten:
• Carburetor heating hose 2 1
NOTE:
Fasten the carburetor heating hose 2 with a clamp 2
at the white mark a.
1
a
2
SEA7150
2. Bleed:
• Cooling system
Refer to “COOLING SYSTEM” in CHAPTER 2.
3. Adjust:
• Starter cable free play
Refer to “STARTER (CHOKE) CABLE FREE
PLAY ADJUSTMENT” in CHAPTER 2.
4. Adjust:
• Throttle cable free play
Refer to “THROTTLE CABLE FREE PLAY
ADJUSTMENT” in CHAPTER 2.
7-9
FUEL PUMP
CARB
FUEL PUMP
VX600ER/VT600
Å: 5 Nm (0.5 m · kg, 3.6 ft · lb)
ı: 10 Nm (1.0 m · kg, 7.2 ft · lb)
SEA7160
Order
Job name/Part name
Remarks
Q’ty
1
2
3
4
5
6
7
Fuel pump removal
Carburetor heating lever assembly
Air filter element
Screw
Plastic band
Wire harness
Throttle cable
Oil pump cable
1
1
3
3
1
1
1
8
9
10
11
12
13
Intake silencer
Fuel hose
Fuel delivery hose
Vacuum hose
Oil delivery hose
Fuel pump assembly
1
1
3
1
1
1
Remove the parts in the order listed below.
Loosen.
NOTE:
• First, remove the throttle and oil pump cables
from the cable guide on the steering column.
• When removing the intake silencer, lift up the
throttle and oil pump cables.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
7-10
FUEL PUMP
CARB
SX600/MM600
Å: 5 Nm (0.5 m · kg, 3.6 ft · lb)
ı: 10 Nm (1.0 m · kg, 7.2 ft · lb)
SEA7170
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Fuel pump removal
Carburetor heating lever assembly
Air filter element
Screw
Plastic band
Wire harness
Intake silencer
Fuel hose
Fuel delivery hose
Vacuum hose
Oil delivery hose
Fuel pump assembly
Remarks
Q’ty
Remove the parts in the order listed below.
1
1
3
3
1
1
1
3
1
1
1
Loosen.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
7-11
FUEL PUMP
CARB
INSPECTION
SEA7180
1. Inspect:
• Fuel hose 1
• Fuel delivery hoses 2
• Vacuum hose 3
• Oil delivery hose 4
Clogs/damage → Replace.
2. Check:
• Fuel pump operation
Checking steps:
• Connect the Mity vac 1 to the vacuum hose 2.
Mity vac:
90890-06756, YS-42423
SEA7190
• Place a container 3 under the end of the fuel
delivery hoses 4.
• Operate the Mity vac 1 while checking that fuel
flows from the fuel delivery hoses 4.
• If fuel does not flow out, replace the fuel pump.
INSTALLATION
NOTE:
After installing all parts, refer to “CABLE ROUTING”
in CHAPTER 9, to check the cable, lead and hose
routings.
1. Bleed:
• Oil system
Refer to “OIL PUMP” in CHAPTER 2.
7-12
SWITCH INSPECTION
ELEC
–
+
ELECTRICAL
SWITCH INSPECTION
SWITCH INSPECTION
Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the
switch.
Pocket tester:
90890-03112, YU-03112
NOTE:
• Set the pocket tester to “0” before starting a test.
• When testing the switch for continuity the pocket
•
tester should be set to the “× 1” Ω range.
When checking the switch turn it on and off a few
times.
SEA8010
R
INSPECTING A SWITCH SHOWN IN THE
MANUAL
Br/L L/Y L/B
The terminal connections for switches (main switch,
handlebar switch, engine stop switch, light switch,
etc.) are shown in a chart similar to the one on the left.
This chart shows the switch positions in the column
and the switch lead colors in the top row.
For each switch position, “
” indicates the
terminals with continuity.
OFF
ON
R Br/L
L/Y L/B
SEA8020
The example chart shows that:
1 There is continuity between the “Blue/Yellow and
Blue/Black” leads when the switch is set to “OFF”.
2 There is continuity between the “Red and Brown/
Blue” leads when the switch is set to “ON”.
8
8-1
W
B
8-2
Y
Lg
(BLACK)
1
L
G
(10A)
c
L/W
L/W
Y
G
G
B
B
Lg L/W
L/R
G
R
R
L
b
Br
R
W/G
W/R
a
Y
A
B
Br/W
HI
LO
G
Y
B
G
B
Y
G
B
Lg
Y
L/W
Br/W
a
L
d
R Br
Y
R
B
F
R
B
R
B
B
B
6
R
Å
G
3
R
R
R
L
B
L/W
B
7
R
R
5
4
(30A)
R/W
B
B
F
L
Å
R/W
(BLACK)
B
R
R
B
R
B
Y
L
Y/B B Y/B Y/B
R
B
3
R
Br
R/W
W
Å
F
START
ON
OFF
8
B
Y R/B
L G/R
X
Y
Z
B
R/B Y
G/R L
R/B
G/R
B
R/B
B
G/B
A
G/R
A
A
V
R/B
B
A
B
G/B
B R/W
Br
B/W R/Y
B
L
G/B Y/B
R/W B
Br
R B/W
Br B
L G/B
\
B
[
]
`
R/W
R/Y
B/W
B
R/B
G/R
U
G/B
Br
R/B
B
(GREEN)
(GREEN)
Gy
B
G/B
B
B
G
B
G/B
A
Ch
B/Y
Lg
B
B
B
G/Y
B
C
B
B
D
B
B
L/R G/Y
D D
L/R G/Y
L/R G/Y
C C
L/R G/Y
L
G/Y
B
G/Y
L
S
B
Lg
RUN
IDLE
G/Y
L/R
Ch
B
G
W/G
B/Y W/R
L/R
G/Y
B
(BLACK)
L/R B
(BLACK)
B/Y
Y/B
L/W
L/R Y/W W/B
C
L/R G/Y
T
ON
OFF
L/R
B
W
Ch
B/W B/Y
B/W Y Br/W
Lg G/R
B/Y B/W
(WHITE)
Br
B Y/R
A
B
B
Y/R
OFF
OPEN
OFF
0
W
RUN
9
B/W
O
Gy
B
D
L/R
L/R
Y/R
Lg
W/G
W/R
Br
B/W
B/Y
B
L/R
P
Br/W Y/B
E
G/R
Br
P
R
P
B
P
Q
L/R
G
Y
Y
O/B
Y/W
L/R
L/R
P
Y/W
W/B
L/W
O
Gy
W
L/R
O/B
Y/R
O/B
Y/L
L
Y/W
B/R
LO
HI
(BLACK)
G/R
O
B
L
(BLACK)
B
R
R
G/R
O/B
O/B
D
O/B
G/R
N
C
O/B
Y/L
M
J
O/B
Y/L
Y/W
W/B
B
G/R
L
R
(BLACK) (BLACK)
Y/L
G/R
L/W
W/B
B
(BLACK) (BLACK)
OFF
Y/W
B/R
F
W/B
B
Y/L
B
G/R
(BLACK) (BLACK)
Y
G
G/R
O/B
Y/L
L/R
W/B
L/W
O E O
Gy E Gy
W E W
K
B
A
B
H
H
H
Y G
L Y/B
HEADLIGHT
SUB-WIRE
HARNESS
(BLACK)
B G/B
R/B G/R
B/W
B/W
B/W
L/R O/B
G/Y B
SUB-WIRE
HARNESS 1
O/B L/R
B G/Y
TAIL/BRAKE
SUB-WIRE
HARNESS 1 LIGHT SUB-WIRE
HARNESS
O/B L/R
B G/Y
D
WIRE HARNESS
L/R O/B
G/Y B
C
HEADLIGHT
WIRE HARNESS SUB-WIRE
HARNESS
G Y
Y/B L/W
WIRE HARNESS
(BLACK)
G/B B
G/R R/B
B
E
B
B
W
B
Gy
B
O
ı
Å
I
I
I
Gy
B
E
F
R
L L
Gy
B
O
W
(BLACK)
R/Y
L/W L/R
SUB-WIRE
HARNESS 3
(BLACK)
B
R/W R
SUB-WIRE
HARNESS 2
(BLACK)
WIRE HARNESS WIRE HARNESS
(BLACK)
G
WIRE HARNESS
(BLACK)
B
R R/W
WIRE HARNESS
(BLACK)
O
W
ELEC
B
B
G
L/ W Lg
R/Y
g f e
(10A)
B
2
W W W
L
W/G W/R
W W W
G
Ç (20A)
ı
W
L/W
Y
Lg G B
W
R
W
W W
W/R W/G
W
W W
CIRCUIT DIAGRAM
IGNITION SYSTEM
IGNITION SYSTEM
–
+
SEA8030
IGNITION SYSTEM
IGNITION SYSTEM
CIRCUIT DIAGRAM
1
2
3
4
6
8
9
0
C
E
H
I
J
K
S
T
U
V
W
X
Y
Z
[
\
]
_
a
b
c
d
e
∗1
∗2
AC magneto
Rectifier/regulator
Condenser∗1
Main fuse∗2
Battery∗2
Main switch
Engine stop switch
Throttle switch
Carburetor switch
CDI unit
Ignition coil
Spark plug
Engine ground
Frame ground
Brake light switch
Tail/brake light
Fuel sender
Oil level switch
Speedometer
Oil level indicator light
Water temperature
indicator light
High beam indicator light
Speedometer light
Tachometer light
Tachometer
Fuel meter
Headlight
Headlight beam switch
Headlight relay
(with the black coupler)
Load control relay
(with the white coupler)
“IGNITION” fuse∗2
SX600/MM600
VX600ER/VT600
ı SX600/MM600
Ç VX600ER/VT600
8-3
ELEC
–
+
IGNITION SYSTEM
ELEC
–
+
TROUBLESHOOTING
NO SPARK OR WEAK SPARK.
For VX600ER/VT600:
Check the main fuse and
“IGNITION” fuse.
Refer to “FUSE INSPECTION”
in CHAPTER 2.
OK
FAULTY
Replace the main fuse and/or “IGNITION” fuse.
For VX600ER/VT600:
Check the battery.
Refer to “BATTERY INSPECTION”
in CHAPTER 2.
OK
OUT OF SPECIFICATION
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
For SX600/MM600:
Check the condenser.
OK
OUT OF SPECIFICATION
Replace the condenser.
Check the stator coil and pickup coil.
OK
OUT OF SPECIFICATION
Replace the stator coil assembly.
Check the spark plug gap.
OK
OUT OF SPECIFICATION
Repair or replace the spark plug.
Check the spark plug cap resistance.
OK
OUT OF SPECIFICATION
Replace the spark plug cap.
Check the ignition coil resistance.
OK
OUT OF SPECIFICATION
Replace the ignition coil.
Check the engine stop switch, throttle
switch, carburetor switch and main
switch.
OK
FAULTY
Replace the handlebar switch (right), carburetor
switch, and/or main switch.
Check the load control relay.
OK
FAULTY
Replace the load cotrol relay.
*
8-4
IGNITION SYSTEM
ELEC
–
+
*
For SX600/MM600:
Check the lighting, signal and meter system.
Refer to “LIGHTING SYSTEM” and
“SIGNAL SYSTEM”.
OK
FAULTY
Repair the lighting system and/or signal system
and/or meter system.
Correct the connection and/or
replace the rectifier/regulator
and/or CDI unit.
NOTE:
For SX600/MM600:
If a short circuit occurred in the lighting system, the
signal system, or the meter system, the engine can
be started in an emergency by cutting off the load
control relay.
8-5
IGNITION SYSTEM
ELEC
CONDENSER (SX600/MM600)
1. Disconnect:
• Condenser 1
SEA8040
2. Connect:
• Condenser
(to the LCR meter)
3. Measure:
• Condenser capacity
Out of specification → Replace.
Condenser capacity:
6,800 µF at 20°C (68°F)
AC MAGNETO
1. Disconnect:
• AC magneto couplers 1
2. Connect:
• Pocket tester
(to the AC magneto coupler)
3. Measure:
• Pickup coil resistance a
• Stator coil resistance b
Out of specification → Replace.
SEA8050
b
Pickup coil resistance:
(White/Red – White/Green)
189 ~ 231 Ω at 20°C (68°F)
Stator coil resistance:
(White – White)
0.36 ~ 0.44 Ω at 20°C (68°F)
Ω×1
–
W
+
W
W
SEA8060
8-6
–
+
IGNITION SYSTEM
ELEC
–
SPARK PLUG
1. Remove:
• Spark plugs
2. Measure:
• Spark plug gap
Standard spark plug:
BR9ES (NGK)
Spark plug gap:
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
SEA8070
SPARK PLUG CAP
1. Remove:
• Spark plug cap
2. Connect:
• Pocket tester
(to the spark plug cap)
3. Measure:
• Spark plug cap resistance
Out of specification → Replace.
Spark plug cap resistance:
5 kΩ at 20°C (68°F)
SEA8080
IGNITION COIL
1. Disconnect:
• Ignition coil lead
• Spark plug lead
2. Connect:
• Pocket tester
(to the ignition coil and spark plug lead)
3. Measure:
• Primary coil resistance a
• Secondary coil resistance b
Out of specification → Replace.
SEA8090
Primary coil resistance:
0.36 ~ 0.48 Ω at 20°C (68°F)
Secondary coil resistance:
5.4 ~ 7.4 kΩ at 20°C (68°F)
SEA8100
8-7
+
IGNITION SYSTEM
ELEC
–
+
THROTTLE OVERRIDE SYSTEM (T.O.R.S.)
A
If the carburetor or throttle cable should malfunction
during operation, T.O.R.S. will operate when the
throttle lever is released.
T.O.R.S. is designed to interrupt the ignition and keep
the engine revolutions between 2,800 and 3,000
r/min if the carburetor fails to return to idle when the
lever is released.
SEA8110
WARNING
• If T.O.R.S. operates, make sure that the cause
B
•
of the malfunction is corrected and that the
engine can be operated without a problem
before restarting the engine.
Be sure to use the standard resistance-type
spark plug and spark plug cap. Otherwise,
T.O.R.S. will not work properly.
C
Status A Idling B
or
Running
Switch
starting
Throttle
OFF
ON
switch
SEA8120
C
Carburetor
switch
Engine
1
2
3
4
a
b
SEA8130
ON
Trouble
OFF
OFF
Running Running
OFF
T.O.R.S. operating
Carburetor switch
Throttle switch
Throttle cable
Throttle stop screw
ON
OFF
HANDLEBAR SWITCH (RIGHT)
SEA8140
Engine stop switch and throttle switch
1. Disconnect:
• Handlebar switch (right) coupler 1
2. Connect:
• Pocket tester
3. Check:
• Engine stop switch continuity
Faulty → Replace the handlebar switch (right).
Ω×1
–
+
Switch position
Continuity
B/Y B/W
RUN (pulled out)
No
B
OFF (pushed in)
Yes
SEA8150
8-8
IGNITION SYSTEM
ELEC
–
+
4. Check:
• Throttle switch continuity
Faulty → Replace the handlebar switch (right).
Ω×1
–
+
Throttle switch
position
B/Y B/W
B
SEA8160
Continuity
Throttle lever is
operated.
Yes
Throttle lever is not
operated.
No
CARBURETOR SWITCH
SEA8170
1. Disconnect:
• Carburetor switch lead 1
2. Connect:
• Pocket tester
3. Check:
• Carburetor switch continuity
Faulty → Replace.
Carburetor switch
position
Ω×1
–
+
B
B/Y
Continuity
Throttle lever is
operated.
No
Throttle lever is not
operated.
Yes
SEA8180
MAIN SWITCH
1. Disconnect:
• Main switch coupler 1
2. Connect:
• Pocket tester
3. Check:
• Main switch continuity
Faulty → Replace.
SEA8190
Switch position
Continuity
OFF
Yes
ON
No
Br
Color code
R
R/W
B
Switch
position
OFF
ON
START
Continuity
8-9
B/W
IGNITION SYSTEM
ELEC
–
+
LOAD CONTROL RELAY
1. Inspect:
• Load control relay (with the white coupler) 1
Inspection steps:
• Disconnect the load control relay from the coupler.
• Connect the pocket tester (Ω × 1) and battery
(12 V) to the load control relay terminals as
shown.
SEA8200
Positive battery terminal → Brown 1
Negative battery terminal → Brown/White 2
Positive tester probe → Red 3
Negative tester probe → Blue 4
3
4
R
L
Br
2
Br/W
• If load control relay does not have continuity
between the red and blue terminals, replace it.
1
SEA8210
EMERGENCY ENGINE STARTING
(SX600/MM600)
If a short circuit occurred in the lighting system, the
signal system, or the meter system, the engine can
be started in an emergency by cutting off the load
control relay.
1. Disconnect:
• Load control relay (with the white coupler) 1
2. Start the engine.
SEA8220
8-10
B
W
W
8-11
Ç
ı
W
R
W
W W
1
L
G
(10A)
L/W
L/R
G
R
R/Y
g f e
(10A)
B
2
W W W
L
W/G W/R
W W W
G
(20A)
W/R W/G
W
W W
Br
R
R
L
W/G
W/R
Br/W
L
L/W
Br/W
d
R Br
R
B
3
R
R
B
R
B
B
6
R
Å
F
CIRCUIT DIAGRAM (VX600ER/VT600)
R
R
L/W
B
7
R
R
ELECTRICAL STARTING SYSTEM
R
5
4
(30A)
B
3
R
R/W
B
B
F
Å
R/W
(BLACK)
B
R
R
B
R
B
Å
F
START
ON
OFF
8
R/W
R/Y
R/W
Br
B
Br
B/W
B
R/W B
Br
R B/W
B
L
B R/W
Br
B/W R/Y
OFF
RUN
9
B/W
W
A
Ch
B
B/Y
Lg
B
B
B
B
W
Ch
B/W B/Y
B/W Y Br/W
Lg G/R
B/Y B/W
(WHITE)
Br
B Y/R
A
B
B
Y/R
OPEN
OFF
0
O
Gy
B
Lg
IDLE
RUN
C
Ch
B
G
W/G
B/Y W/R
(BLACK)
L/R B
(BLACK)
B/Y
Y/B
L/W
L/R Y/W W/B
G/R
Main fuse∗2
Starter relay∗2
Battery∗2
Starter motor∗2
Main switch
“IGNITION” fuse∗2
VX600ER/VT600
Br/W Y/B
E
ELEC
–
Ç VX600ER/VT600
4
5
6
7
8
e
∗2
B
D
L/R
L/R
Y/R
Lg
W/G
W/R
Br
B/W
B/Y
B
ELECTRICAL STARTING SYSTEM
+
SCH8230
ELECTRICAL STARTING SYSTEM
ELEC
–
+
TROUBLESHOOTING (VX600ER/VT600)
STARTER MOTOR DOES NOT OPERATE.
WARNING
Before starter motor operation, push the engine stop switch to “OFF”.
NO
1. Connect:
• Starter relay terminals
(battery side and starter motor side)
Check the battery and connectors.
Refer to “BATTERY INSPECTION” in CHAPTER 2.
OK
NO
Charge and/or replace the battery.
Refer to “BATTERY CHARGING” in
CHAPTER 2.
SEA8240
Repair or replace the starter motor.
1 Jumper lead
2. Check:
• Starter motor operation
WARNING
A wire for the jumper lead 1 must have the
equivalent capacity as that of the battery lead or
more, otherwise it may cause the jumper lead to
be burned.
This check is likely to produce sparks, so be sure
that no flammable gas or fluid is in the vicinity.
OK
3. Disconnect:
• Starter relay coupler
4. Connect:
• Starter relay coupler terminals
NO
SEA8250
1 Jumper lead
5. Check:
• Starter motor operation
Replace the starter relay.
OK
*
8-12
ELECTRICAL STARTING SYSTEM
ELEC
–
+
*
FAULTY
Check the main fuse and “IGNITION” fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
OK
Replace the main fuse and/or “IGNITION” fuse.
FAULTY
Check the main switch.
OK
Replace the main switch.
Correct the connection.
MAIN SWITCH
1. Disconnect:
• Main switch coupler 1
2. Connect:
• Pocket tester
3. Check:
• Main switch continuity
Faulty → Replace.
SEA8190
Switch position
Continuity
OFF
Yes
ON
No
Switch
position
OFF
ON
START
Br
R
Continuity
8-13
Color code
R/W
B
B/W
ELECTRICAL STARTING SYSTEM
ELEC
–
+
STARTER MOTOR (VX600ER/VT600)
Å: 7 Nm (0.7 m · kg, 5.1 ft · lb)
SEA8260
Order
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
Job name/Part name
Starter motor disassembly
Starter motor removal
Rear bracket
O-ring
Brush plate
Brush 1
Brush 2
Brush spring
Washer
Yoke
Clip
Pinion stopper
Return spring
Washer
Pinion gear
Armature coil
Washer
Front bracket
Q’ty
Remarks
Remove the parts in the order listed below.
Refer to “ENGINE REMOVAL” in CHAPTER 5.
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly procedure.
8-14
ELECTRICAL STARTING SYSTEM
ELEC
–
+
Inspection
1. Inspect:
• Commutator (outer surface)
Dirty → Clean with #600 grit sandpaper 1.
Hold the armature in a vise 2 and copper or
aluminium plate 3.
CAUTION:
Lightly grip the armature with a vise.
SEA8270
2. Measure:
• Commutator diameter a
Measure the diameter a of the commutator at
points where the brush comes in contact.
Out of specification → Replace the starter
motor.
Commutator diameter wear limit:
27 mm (1.06 in)
SEA8280
3. Measure:
• Mica undercut (insulation depth) a
(between commutator segments)
Out of specification → Scrape mica 1 to
proper limits.
Use a hacksaw blade 2 that is ground to fit.
Mica undercut:
0.6 mm (0.024 in)
SEA8290
8-15
ELECTRICAL STARTING SYSTEM
ELEC
–
+
4. Measure:
• Armature coil resistance
(insulation/continuity)
Defect(s) → Replace the starter motor.
Inspecting steps:
• Connect the pocket tester for the continuity
check 1 and the insulation check 2.
• Measure the armature coil resistances.
SEA8300
Armature coil resistance:
Continuity check:
0.014 ~ 0.018 Ω at 20°C (68°F)
Insulation check:
More than 100 kΩ at 20°C (68°F)
• If the resistance is incorrect, replace the starter
motor.
5. Measure:
• Brush length a
Out of specification → Replace the starter
motor.
Brush length wear limit:
8.5 mm (0.33 in)
SEA8310
6. Measure:
• Brush spring pressure
Fatigue/out of specification → Replace as a
set.
Brush spring pressure:
6.38 ~ 9.32 N
(650 ~ 950 g, 22.9 ~ 33.5 oz)
8-16
ELECTRICAL STARTING SYSTEM
ELEC
–
+
Assembly
Reverse the “Disassembly” procedure.
Note the following points.
1. Before installing the front bracket and rear bracket,
apply bearing grease to the bearings of the front
bracket and rear bracket.
2. Make sure the front bracket and rear bracket
cover are fitted with O-rings.
SEA8320
3. When installing the rear bracket assembly, take
care not to scratch the brushes.
4. Install:
• Securing bolts (starter motor)
NOTE:
Align the match marks 1 on the bracket with the
match marks 2 on the yoke.
SEA8330
8-17
8-18
Ç
ı
R
W
W
B
W
W
W W
1
L
G
(10A)
L/W
L/R
G
R
R/Y
g f e
(10A)
B
2
W W W
L
W/G W/R
W W W
G
(20A)
W/R W/G
W
W W
Br
R
R
L
W/G
W/R
Br/W
L
L/W
Br/W
d
R Br
R
B
3
R
R
B
R
B
B
6
R
Å
F
CIRCUIT DIAGRAM (VX600ER/VT600)
CHARGING SYSTEM
R
R
L/W
B
7
R
R
R
5
4
(30A)
B
3
R
R/W
B
B
F
Å
R/W
(BLACK)
B
R
R
B
R
B
Å
F
START
ON
OFF
8
R/W
R/Y
R/W
Br
B
Br
B/W
B
R/W B
Br
R B/W
B
L
B R/W
Br
B/W R/Y
OFF
RUN
9
B/W
W
A
Ch
B
B/Y
Lg
B
B
B
B
W
Ch
B/W B/Y
B/W Y Br/W
Lg G/R
B/Y B/W
(WHITE)
Br
B Y/R
A
B
B
Y/R
OPEN
OFF
0
O
Gy
B
Lg
IDLE
RUN
C
Ch
B
L/R B
(BLACK)
B
D
Br/W Y/B
E
G/R
AC magneto
Rectifiler/regulator
Main Fuse∗2
Battery∗2
VX600ER/VT600
L/R
Y/R
Lg
W/G
W/R
Br
B/W
B/Y
B
L/R
1
2
4
6
∗2
G
W/G
B/Y W/R
(BLACK)
B/Y
Y/B
L/W
L/R Y/W W/B
CHARGING SYSTEM
ELEC
–
+
SEA8340
CHARGING SYSTEM
ELEC
–
+
TROUBLESHOOTING (VX600ER/VT600)
BATTERY IS NOT CHARGED.
1. Connect:
• Pocket tester
(to the battery terminals)
2. Measure:
• Battery voltage
• Fluid gravity
OUT OF SPECIFICATIONS
• Check the battery.
Battery voltage:
more than 12 V at 20°C (68°F)
•
OK
3. Start the engine and accelerate to 5,000
r/min.
4. Measure:
• Charging voltage
Refer to “BATTERY INSPECTION” in CHAPTER 2.
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
OUT OF SPECIFICATION
Charging voltage:
14 V/5,000 r/min
• Check the main fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
• Check the startor coil.
FAULTY
OK
Replace the main fuse and/or the startor
coil assembly.
SEA8350
WARNING
Replace the rectifier/regulator.
Be sure the V-belt is removed.
CAUTION:
Never disconnect battery cables while generator
is operating, otherwise, the rectifier/regulator will
be damaged.
OK
Correct connector.
8-19
CHARGING SYSTEM
ELEC
–
+
BATTERY
Inspection
1. Inspect:
• Battery fluid level
Refer to “BATTERY INSPECTION” in CHAPTER 2.
2. Check:
• Specific gravity
Less than 1.280 → Recharge battery.
Battery Storage
The battery should be stored if the vehicle is not going
to be used for a long period.
1. Remove:
• Battery
WARNING
When removing the battery, disconnect the negative lead first.
Battery storage and maintenance tips:
• Recharge the battery periodically.
• Store the battery in a cool, dry place.
• Recharge the battery before reinstalling.
Battery
Electrolyte
Specific gravity: 1.280
at 20°C (68°F)
Initial charging rate
2.0 Amp for 10 hours
(new battery)
Recharging
rate
10 hours (or until specific
gravity reaches 1.280)
Refill fluid
Distilled water
(to maximum level line)
Refill period
Check once per month
(or more often as required)
STATOR COIL
1. Measure:
• Stator coil resistance
Out of specification → Replace startor coil assembly.
Ω×1
–
W
+
W
Stator coil resistance:
(White – White)
0.36 ~ 0.44 Ω at 20°C (68°F)
W
SEA8360
8-20
CHARGING SYSTEM
8-21
ELEC
–
+
W
B
8-22
Y
Lg
(BLACK)
1
L
G
(10A)
c
L/W
L/W
Y
G
G
B
B
Lg L/W
L/R
G
R
R
L
b
Br
R
W/G
W/R
a
Y
B
A
Br/W
HI
LO
B
G
B
G
Y
G
B
Y
Lg
Y
L/W
Br/W
d
a
L
R Br
Y
R
B
F
R
B
R
B
B
B
6
R
Å
G
3
R
R
R
L
B
L/W
B
7
R
R
5
4
(30A)
R/W
B
B
F
L
Å
R/W
(BLACK)
B
R
R
B
R
B
Y
L
Y/B B Y/B Y/B
R
B
3
R
R/W
W
Å
F
START
ON
OFF
8
Br
B
Y R/B
L G/R
X
Y
Z
B
R/B Y
G/R L
R/B
G/R
B
R/B
B
G/B
A
G/R
A
A
V
R/B
B
A
B
G/B
B R/W
Br
B/W R/Y
B
L
G/B Y/B
R/W B
Br
R B/W
Br B
L G/B
\
B
[
]
`
R/W
R/Y
B/W
B
R/B
G/R
U
G/B
Br
Gy
B
R/B
B
(GREEN)
(GREEN)
A
A
Ch
B/Y
Lg
B
B
B
G/Y
B
C
B
B
D
B
B
L/R G/Y
D D
L/R G/Y
L/R G/Y
C C
L/R G/Y
L
G/Y
B
G/Y
L
S
B
Lg
RUN
IDLE
G/Y
L/R
Ch
B
G
W/G
B/Y W/R
L/R
G/Y
B
(BLACK)
L/R B
(BLACK)
B/Y
Y/B
L/W
L/R Y/W W/B
C
L/R G/Y
T
ON
OFF
L/R
B
W
Ch
B/W B/Y
B/W Y Br/W
Lg G/R
B/Y B/W
(WHITE)
Br
B Y/R
G/B
B
B
B
B
Y/R
OPEN
OFF
0
W
G
B
G/B
OFF
RUN
9
B/W
O
Gy
B
D
L/R
L/R
Y/R
Lg
W/G
W/R
Br
B/W
B/Y
B
L/R
P
Br/W Y/B
E
G/R
Br
P
R
P
B
P
Q
L/R
G
Y
Y
O/B
Y/W
L/R
L/R
P
Y/W
W/B
L/W
O
Gy
W
L/R
O/B
Y/R
O/B
Y/L
L
Y/W
B/R
LO
HI
Y/L
G/R
B
L
(BLACK)
O
B
R
R
N
G/R
G/R
G/R
O/B
O/B
D
O/B
Y/L
M
C
O/B
J
O/B
Y/L
Y/W
W/B
B
G/R
L
R
(BLACK) (BLACK)
(BLACK)
L/W
W/B
B
(BLACK) (BLACK)
OFF
Y/W
B/R
F
W/B
B
Y/L
B
G/R
(BLACK) (BLACK)
Y
G
G/R
O/B
Y/L
L/R
W/B
L/W
O E O
Gy E Gy
W E W
K
B
A
D
H
H
H
L/R O/B
G/Y B
SUB-WIRE
HARNESS 1
O/B L/R
B G/Y
HEADLIGHT
SUB-WIRE
HARNESS
Y G
L Y/B
HEADLIGHT
SUB-WIRE
HARNESS
(BLACK)
B G/B
R/B G/R
B/W
B/W
B/W
TAIL/BRAKE
SUB-WIRE
HARNESS 1 LIGHT SUB-WIRE
HARNESS
O/B L/R
B G/Y
WIRE HARNESS
L/R O/B
G/Y B
C
WIRE HARNESS
G Y
Y/B L/W
B
WIRE HARNESS
(BLACK)
G/B B
G/R R/B
B
E
B
B
W
B
Gy
B
O
ı
Å
I
I
I
Gy
B
E
B
R R/W
G
Gy
B
O
W
(BLACK)
R/Y
L/W L/R
SUB-WIRE
HARNESS 3
(BLACK)
B
R/W R
SUB-WIRE
HARNESS 2
(BLACK)
WIRE HARNESS WIRE HARNESS
(BLACK)
R
L L
WIRE HARNESS
(BLACK)
F
WIRE HARNESS
(BLACK)
O
W
ELEC
B
B
G
L/ W Lg
R/Y
g f e
(10A)
B
2
W W W
L
W/G W/R
W W W
G
Ç (20A)
ı
W
L/W
Y
Lg G B
W
R
W
W W
W/R W/G
W
W W
CIRCUIT DIAGRAM
LIGHTING SYSTEM
LIGHTING SYSTEM
–
+
SEA8370
LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM
1
2
3
4
6
8
E
K
T
Z
[
\
a
b
c
d
e
f
g
∗1
∗2
AC magneto
Rectifier/regulator
Condenser∗1
Main fuse∗2
Battery∗2
Main switch
CDI unit
Frame ground
Tail/brake light
High beam indicator light
Speedometer light
Tachometer light
Headlight
Headlight beam switch
Headlight relay (with the black coupler)
Load control relay (with the white coupler)
“IGNITION” fuse∗2
“TAIL” fuse∗2
“HEAD” fuse∗2
SX600/MM600
VX600ER/VT600
ı SX600/MM600
Ç VX600ER/VT600
8-23
ELEC
–
+
LIGHTING SYSTEM
ELEC
–
+
TROUBLESHOOTING
HEADLIGHT AND/OR METER LIGHT DO NOT COME ON.
Check the bulb(s).
OK
NO CONTINUITY
Replace the bulb(s).
For VX600ER/VT600:
Check the main fuse, “IGNITION” fuse and “HEAD” fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
OK
FAULTY
Replace the main fuse, “IGNITION” fuse and/or
“HEAD” fuse.
For VX600ER/VT600:
Check the battery.
Refer to “BATTERY INSPECTION” in CHAPTER 2.
OK
OUT OF SPECIFICATION
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
For SX600/MM600:
Check the condenser.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the condenser.
Check the stator coil and pickup coil.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the stator coil assembly.
Check the main switch.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the main switch.
Check the headlight beam switch.
OK
FAULTY
Replace the headlight beam switch.
Check the headlight relay.
OK
FAULTY
Replace the headlight relay.
Check the load control relay.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the load control relay.
Correct the connection and/or
replace the rectifier/regulator
and/or CDI unit.
8-24
LIGHTING SYSTEM
ELEC
–
+
TAIL LIGHT DOES NOT COME ON.
Check the bulb(s).
OK
NO CONTINUITY
Replace the bulb(s).
For VX600ER/VT600:
Check the main fuse,
“IGNITION” fuse and “TAIL” fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
OK
FAULTY
Replace the main fuse, “IGNITION” fuse and/or “TAIL”
fuse.
For VX600ER/VT600:
Check the battery.
Refer to “BATTERY INSPECTION” in CHAPTER 2.
OK
OUT OF SPECIFICATION
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
For SX600/MM600:
Check the condenser.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the condenser.
Check the stator coil and pickup coil.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the stator coil assembly.
Check the main switch.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the main switch.
Check the load control relay.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the load control relay.
Correct the connection and/or
replace the rectifier/regulator
and/or CDI unit.
8-25
LIGHTING SYSTEM
ELEC
–
+
BULB(S)
SEA8380
1. Remove:
• Headlight bulb a
• Tail/brake light bulb b
• Meter light bulb c
2. Connect:
• Pocket tester
(to the bulb terminals)
WARNING
Keep flammable products and your hands away
from the bulb while it is on; it will be hot. Do not
touch the bulb until it cools down.
3. Check:
• Bulb(s)
SEA8390
Terminal
Continuity
1–2
Yes
1–3
Yes
HEADLIGHT BEAM SWITCH
1. Disconnect:
• Headlight beam switch coupler
2. Connect:
• Pocket tester
(to the headlight beam switch coupler)
3. Check:
• Headlight beam switch continuity
Faulty → Replace.
L/ W Lg
SEA8400
8-26
Switch position
Continuity
HI
Yes
LO
No
LIGHTING SYSTEM
ELEC
–
+
HEADLIGHT RELAY
1. Inspect:
• Headlight relay (with the black coupler) 1
SEA8410
Inspection steps:
• Disconnect the headlight relay from the coupler.
• Connect the pocket tester (Ω × 1) to the headlight relay terminals as shown.
1
L/W
Y
Lg
G
Positive tester probe → Blue/White 1
Negative tester probe → Green 2
B
2
• If headlight relay does not have continuity be-
SEA8420
tween the blue/white and green terminals, replace it.
• Connect the pocket tester (Ω × 1) and battery
(12V) to the headlight relay terminals as shown.
5
6
Positive battery terminal → Light green 3
Negative battery terminal → Black 4
Positive tester probe → Blue/White 5
Negative tester probe → Yellow 6
L/W
Y
Lg
4
G
B
3
• If headlight relay does not have continuity be-
SEA8430
tween the blue/white and yellow terminals, replace it.
8-27
8-28
Y
Lg
(BLACK)
L/W
Y
Lg G B
1
L
G
(10A)
c
L/W
L/W
Y
G
G
B
B
Lg L/W
L/R
G
R
R
L
b
Br
R
W/G
W/R
a
Y
B
A
Br/W
HI
LO
B
G
B
G
Y
G
B
Y
Lg
Y
L/W
Br/W
a
L
d
R Br
Y
R
B
F
R
B
R
B
B
B
6
R
Å
G
3
R
R
R
L
B
L/W
B
7
R
R
5
4
(30A)
R/W
B
B
F
L
Å
R/W
(BLACK)
B
R
R
B
R
B
Y
L
Y/B B Y/B Y/B
R
B
3
R
R/W
W
Å
F
START
ON
OFF
8
Br
B
Y R/B
L G/R
X
Y
Z
B
R/B Y
G/R L
R/B
G/R
B
R/B
B
G/B
A
G/R
A
A
V
R/B
B
A
B
G/B
B R/W
Br
B/W R/Y
B
L
G/B Y/B
R/W B
Br
R B/W
Br B
L G/B
\
B
[
]
`
R/W
R/Y
B/W
B
R/B
G/R
U
G/B
Br
R/B
B
(GREEN)
(GREEN)
Gy
B
G/B
B
A
A
Ch
B/Y
Lg
B
B
B
G/Y
B
C
B
B
D
B
B
L/R G/Y
D D
L/R G/Y
L/R G/Y
C C
L/R G/Y
L
G/Y
B
G/Y
L
S
B
Lg
RUN
IDLE
G/Y
L/R
Ch
B
G
W/G
B/Y W/R
L/R
G/Y
B
(BLACK)
L/R B
(BLACK)
B/Y
Y/B
L/W
L/R Y/W W/B
C
L/R G/Y
T
ON
OFF
L/R
B
W
Ch
B/W B/Y
B/W Y Br/W
Lg G/R
B/Y B/W
(WHITE)
Br
B Y/R
G
B
G/B
B
B
B
Y/R
OFF
OPEN
OFF
0
W
RUN
9
B/W
O
Gy
B
D
L/R
L/R
Y/R
Lg
W/G
W/R
Br
B/W
B/Y
B
L/R
P
Br/W Y/B
E
G/R
Br
P
R
P
B
P
Q
L/R
G
Y
Y
O/B
Y/W
L/R
L/R
P
Y/W
W/B
L/W
O
Gy
W
L/R
O/B
Y/R
O/B
Y/L
L
Y/W
B/R
LO
HI
Y/L
G/R
G/R
B
L
(BLACK)
O
B
R
R
G/R
O/B
O/B
D
O/B
G/R
N
C
O/B
Y/L
M
J
O/B
Y/L
Y/W
W/B
B
G/R
L
R
(BLACK) (BLACK)
(BLACK)
L/W
W/B
B
(BLACK) (BLACK)
OFF
Y/W
B/R
F
W/B
B
Y/L
B
G/R
(BLACK) (BLACK)
Y
G
G/R
O/B
Y/L
L/R
W/B
L/W
O E O
Gy E Gy
W E W
K
B
A
D
H
H
H
L/R O/B
G/Y B
SUB-WIRE
HARNESS 1
O/B L/R
B G/Y
HEADLIGHT
SUB-WIRE
HARNESS
Y G
L Y/B
HEADLIGHT
SUB-WIRE
HARNESS
(BLACK)
B G/B
R/B G/R
B/W
B/W
B/W
TAIL/BRAKE
SUB-WIRE
HARNESS 1 LIGHT SUB-WIRE
HARNESS
O/B L/R
B G/Y
WIRE HARNESS
L/R O/B
G/Y B
C
WIRE HARNESS
G Y
Y/B L/W
B
WIRE HARNESS
(BLACK)
G/B B
G/R R/B
B
E
B
B
W
B
Gy
B
O
ı
Å
I
I
I
Gy
B
E
F
R
L L
Gy
B
O
W
(BLACK)
R/Y
L/W L/R
SUB-WIRE
HARNESS 3
(BLACK)
B
R/W R
SUB-WIRE
HARNESS 2
(BLACK)
WIRE HARNESS WIRE HARNESS
(BLACK)
G
WIRE HARNESS
(BLACK)
B
R R/W
WIRE HARNESS
(BLACK)
O
W
ELEC
B
B
G
L/ W Lg
R/Y
g f e
(10A)
B
2
W W W
L
W/G W/R
W W W
G
Ç (20A)
ı
W
W
W
R
B
W
W W
W/R W/G
W
W W
CIRCUIT DIAGRAM
SIGNAL SYSTEM
SIGNAL SYSTEM
–
+
SEA8440
SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM
1
2
3
4
6
8
D
E
K
Q
R
S
T
U
V
X
Y
`
d
e
f
g
∗1
∗2
AC Magneto
Rectifier/regulator
Condenser∗1
Main fuse∗2
Battery∗2
Main switch
Water temperature sensor
CDI unit
Frame ground
DC back buzzer∗2
Gear position switch∗2
Brake light switch
Tail/brake light
Fuel sender
Oil level switch
Oil level indicator light
Water temperature
indicator light
Fuel meter
Load control relay
(with the white coupler)
“IGNITION” fuse∗2
“TAIL” fuse∗2
“HEAD” fuse∗2
SX600/MM600
VX600ER/VT600
ı SX600/MM600
Ç VX600ER/VT600
8-29
ELEC
–
+
SIGNAL SYSTEM
ELEC
–
+
TROUBLESHOOTING
BRAKE LIGHT DOES NOT COME ON.
Check the tail/brake light bulb.
Refer to “LIGHTING SYSTEM”.
OK
NO CONTINUITY
Replace the bulb.
For VX600ER/VT600:
Check the main fuse,
“IGNITION” fuse and “TAIL” fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
OK
FAULTY
Replace the main fuse, “IGNITION” fuse and/or “TAIL”
fuse.
For VX600ER/VT600:
Check the battery.
Refer to “BATTERY INSPECTION” in CHAPTER 2.
OK
OUT OF SPECIFICATION
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
For SX600/MM600:
Check the condenser.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the condenser.
Check the stator coil and pickup coil.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the stator coil assembly.
Check the main switch.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the main switch.
Check the brake light switch.
OK
FAULTY
Replace the brake light switch.
Check the load control relay.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the load control relay.
Correct the connection and/or
replace the rectifier/regulator
and/or CDI unit.
8-30
SIGNAL SYSTEM
ELEC
–
+
WATER TEMPERATURE AND/OR OIL LEVEL INDICATOR LIGHTS DO NOT COME ON.
Check the water temperature and/or oil
level indicator light bulb(s).
Refer to “LIGHTING SYSTEM”.
OK
NO CONTINUITY
Replace the bulb(s).
For VX600ER/VT600:
Check the main fuse,
“IGNITION” fuse and “HEAD” fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
OK
FAULTY
Replace the main fuse, “IGNITION” fuse and/or
“HEAD” fuse.
For VX600ER/VT600:
Check the battery.
Refer to “BATTERY INSPECTION” in CHAPTER 2.
OK
OUT OF SPECIFICATION
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
For SX600/MM600:
Check the condenser.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the condenser.
Check the stator coil and pickup coil.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the stator coil assembly.
Check the main switch.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the main switch.
Check the water temperature
sensor or oil level switch.
OK
FAULTY
Replace the water temperature sensor or oil level
switch.
Check the load control relay.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the load control relay.
Correct the connection and/or
replace the rectifier/regulator
and/or CDI unit.
NOTE:
The water temperature indicator light come on for a
few seconds after the engine starts. If the light does
not come on, check the indicator light circuit and bulb.
8-31
SIGNAL SYSTEM
ELEC
–
+
FUEL METER DOES NOT OPERATE.
For VX600ER/VT600:
Check the main fuse,
“IGNITION” fuse and “HEAD” fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
OK
FAULTY
Replace the main fuse, “IGNITION” fuse and/or
“HEAD” fuse.
For VX600ER/VT600:
Check the battery.
Refer to “BATTERY INSPECTION” in CHAPTER 2.
OK
OUT OF SPECIFICATION
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
For SX600/MM600:
Check the condenser.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the condenser.
Check the stator coil and pickup coil.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the stator coil assembly.
Check the main switch.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the main switch.
FAULTY
Replace the fuel sender.
Check the fuel sender.
OK
Check the load control relay.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the load control relay.
DOES NOT MOVE
Replace the fuel meter.
Check the fuel meter.
OK
Correct the connection and/or
replace the rectifier/regulator
and/or CDI unit.
8-32
SIGNAL SYSTEM
ELEC
–
+
BACK BUZZER DOES NOT SOUND. (VX600ER/VT600)
Check the main fuse,
“IGNITION” fuse and “TAIL” fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
OK
FAULTY
Replace the main fuse, “IGNITION” fuse and/or “TAIL”
fuse.
Check the battery.
Refer to “BATTERY INSPECTION” in CHAPTER 2.
OK
OUT OF SPECIFICATION
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
Check the stator coil and pickup coil.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the stator coil assembly.
Check the main switch.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the main switch.
Check the gear position switch.
OK
FAULTY
Replace the gear position switch.
Check the load control relay.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the load control relay.
Check the DC back buzzer.
OK
DOES NOT SOUND
Replace the DC back buzzer.
Correct the connection and/or
replace the rectifier/regulator
and/or CDI unit.
8-33
SIGNAL SYSTEM
ELEC
–
+
BRAKE LIGHT SWITCH
SEA8450
1. Disconnect:
• Brake light switch coupler 1
2. Connect:
• Pocket tester
(to the brake light switch coupler)
3. Check:
• Brake light switch continuity
Faulty → Replace.
Switch position
Continuity
Brake lever
operates
Yes
Brake lever does
not operate
No
G/Y
L
SEA8460
GEAR POSITION SWITCH (VX600ER/VT600)
1. Check:
• Gear position switch 1 continuity
Faulty → Replace.
Shift lever position
Continuity
FORWARD
No
REVERSE
Yes
SEA8470
DC BACK BUZZER (VX600ER/VT600)
SEA8480
1. Disconnect:
• DC back buzzer coupler 1
2. Connect:
• Battery
3. Check:
• DC back buzzer
Does not sound → Replace.
SEA8490
8-34
SIGNAL SYSTEM
ELEC
–
+
WATER TEMPERATURE SENSOR
1. Disconnect the water temperature sensor coupler 1 and remove the water temperature sensor.
CAUTION:
Handle the water temperature sensor with special care. Never subject it to shock or allow it to be
dropped. If it is dropped, it must be replaced.
SEA8500
2. Connect:
• Pocket tester 1
(to the water temperature sensor)
NOTE:
Set the tester selector to the “Ω × 1” position.
3. Immerse the water temperature sensor 2 in
coolant 3 and check the water temperature
sensor operation.
Water temperature sensor resistance:
5.2 ~ 6.4 kΩ at 0°C (34°F)
0.300 ~ 0.364 kΩ at 80°C (176°F)
0.170 ~ 0.208 kΩ at 100°C (212°F)
4 Temperature gauge
CAUTION:
SEA8510
Never heat the coolant to a temperature of 120°C
(248.5°F) or more.
4. If the water temperature sensor operation is
defective, replace it.
5. Install the water temperature sensor and connect
the water temperature sensor lead.
T.
R.
Water temperature sensor:
23 Nm (2.3 m · kg, 17 ft · lb)
CAUTION:
Do not overtighten the water temperature sensor.
8-35
SIGNAL SYSTEM
–
ELEC
+
OIL LEVEL SWITCH
1. Remove:
• Intake silencer
Refer to “FUEL PUMP” in CHAPTER 7.
• Oil level switch 1
SEA8520
2. Connect:
• Pocket tester
(to the oil level switch coupler)
3. Check:
• Oil level switch continuity
Faulty → Replace.
Switch position
SEA8530
Good
condition
×
Å Down position
ı Up position
: Continuity
Bad condition
×
×
×
× : No continuity
FUEL SENDER
SEA8540
1. Remove:
• Intake silencer
Refer to “FUEL PUMP” in CHAPTER 7.
• Fuel sender 1
(from the fuel tank)
2. Connect:
• Pocket tester
(to the fuel sender coupler)
3. Measure:
• Fuel sender resistance (full a)
• Fuel sender resistance (empty b)
Out of specification → Replace.
Ω×1
a
b
–
G
+
Fuel sender resistance (full):
4 ~ 10 Ω at 20°C (68°F)
Fuel sender resistance (empty):
90 ~ 100 Ω at 20°C (68°F)
B
SEA8550
8-36
SIGNAL SYSTEM
8-37
ELEC
–
+
W
B
8-38
Y
Lg
(BLACK)
1
L
G
(10A)
c
L/W
L/W
Y
G
G
B
B
Lg L/W
L/R
G
R
R
L
b
Br
R
W/G
W/R
a
Y
A
B
Br/W
HI
LO
G
Y
B
G
B
Y
G
B
Lg
Y
L/W
Br/W
a
L
d
R Br
Y
R
B
F
R
B
R
B
B
B
6
R
Å
G
3
R
R
R
L
B
L/W
B
7
R
R
5
4
(30A)
R/W
B
B
F
L
Å
R/W
(BLACK)
B
R
R
B
R
B
Y
L
Y/B B Y/B Y/B
R
B
3
R
R/W
W
Å
F
START
ON
OFF
8
Br
B
Y R/B
L G/R
X
Y
Z
B
R/B Y
G/R L
R/B
G/R
B
R/B
B
G/B
A
G/R
A
A
V
R/B
B
A
B
G/B
B R/W
Br
B/W R/Y
B
L
G/B Y/B
R/W B
Br
R B/W
Br B
L G/B
\
B
[
]
`
R/W
R/Y
B/W
B
R/B
G/R
U
G/B
Br
R/B
B
(GREEN)
(GREEN)
Gy
B
G/B
B
B
G
B
G/B
A
Ch
B/Y
Lg
B
B
B
G/Y
B
C
B
B
D
B
B
L/R G/Y
D D
L/R G/Y
L/R G/Y
C C
L/R G/Y
L
G/Y
B
G/Y
L
S
B
Lg
RUN
IDLE
G/Y
L/R
Ch
B
G
W/G
B/Y W/R
L/R
G/Y
B
(BLACK)
L/R B
(BLACK)
B/Y
Y/B
L/W
L/R Y/W W/B
C
L/R G/Y
T
ON
OFF
L/R
B
W
Ch
B/W B/Y
B/W Y Br/W
Lg G/R
B/Y B/W
(WHITE)
Br
B Y/R
A
B
B
Y/R
OFF
OPEN
OFF
0
W
RUN
9
B/W
O
Gy
B
D
L/R
L/R
Y/R
Lg
W/G
W/R
Br
B/W
B/Y
B
L/R
P
Br/W Y/B
E
G/R
Br
P
R
P
B
P
Q
L/R
G
Y
Y
O/B
Y/W
L/R
L/R
P
Y/W
W/B
L/W
O
Gy
W
L/R
O/B
Y/R
O/B
Y/L
L
Y/W
B/R
LO
HI
(BLACK)
G/R
O
B
L
(BLACK)
B
R
R
G/R
O/B
O/B
D
O/B
G/R
N
C
O/B
Y/L
M
J
O/B
Y/L
Y/W
W/B
B
G/R
L
R
(BLACK) (BLACK)
Y/L
G/R
L/W
W/B
B
(BLACK) (BLACK)
OFF
Y/W
B/R
F
W/B
B
Y/L
B
G/R
(BLACK) (BLACK)
Y
G
G/R
O/B
Y/L
L/R
W/B
L/W
O E O
Gy E Gy
W E W
K
B
A
B
H
H
H
L/R O/B
G/Y B
SUB-WIRE
HARNESS 1
O/B L/R
B G/Y
HEADLIGHT
SUB-WIRE
HARNESS
Y G
L Y/B
HEADLIGHT
SUB-WIRE
HARNESS
(BLACK)
B G/B
R/B G/R
B/W
B/W
B/W
TAIL/BRAKE
SUB-WIRE
HARNESS 1 LIGHT SUB-WIRE
HARNESS
O/B L/R
B G/Y
D
WIRE HARNESS
L/R O/B
G/Y B
C
WIRE HARNESS
G Y
Y/B L/W
WIRE HARNESS
(BLACK)
G/B B
G/R R/B
B
E
B
B
W
B
Gy
B
O
ı
Å
I
I
I
Gy
B
E
F
R
L L
Gy
B
O
W
(BLACK)
R/Y
L/W L/R
SUB-WIRE
HARNESS 3
(BLACK)
B
R/W R
SUB-WIRE
HARNESS 2
(BLACK)
WIRE HARNESS WIRE HARNESS
(BLACK)
G
WIRE HARNESS
(BLACK)
B
R R/W
WIRE HARNESS
(BLACK)
O
W
ELEC
B
B
G
L/ W Lg
R/Y
g f e
(10A)
B
2
W W W
L
W/G W/R
W W W
G
Ç (20A)
ı
W
L/W
Y
Lg G B
W
R
W
W W
W/R W/G
W
W W
CIRCUIT DIAGRAM
GRIP WARMER SYSTEM
GRIP WARMER SYSTEM
–
+
SEA8560
GRIP WARMER SYSTEM
GRIP WARMER SYSTEM
CIRCUIT DIAGRAM
1
2
3
4
6
8
A
B
E
F
G
K
L
M
N
O
P
d
e
f
∗1
∗2
∗3
AC magneto
Rectifier/regulator
Condenser∗1
Main fuse∗2
Battery∗2
Main switch
Grip warmer
Thumb warmer
CDI unit
Variable resistor (thumb warmer)
Variable resistor (grip warmer)
Frame ground
Passenger grip warmer switch∗3
Resistor*3
Passenger grip warmer (left)∗3
Passenger grip warmer (right)∗3
Passenger grip warmer relay∗3
Load control relay
(with the white coupler)
“IGNITION” fuse∗2
“TAIL” fuse∗2
SX600/MM600
VX600ER/VT600
VT600
ı SX600/MM600
Ç VX600ER/VT600
8-39
ELEC
–
+
GRIP WARMER SYSTEM
ELEC
–
+
TROUBLESHOOTING
GRIP WARMER AND THUMB WARMER DO NOT OPERATE.
For VX600ER/VT600:
Check the main fuse and “IGNITION” fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
OK
FAULTY
Replace the main fuse and/or
“IGNITION” fuse.
For VX600ER/VT600:
Check the battery.
Refer to “BATTERY INSPECTION” in CHAPTER 2.
OK
OUT OF SPECIFICATION
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
For SX600/MM600:
Check the condenser.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the condenser.
Check the stator coil and pickup coil.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the stator coil assembly.
Check the main switch.
Refer to “IGNITION SYSTEM”.
OK
NO CONTINUITY
Replace the main switch.
Check the grip and thumb warmer.
OK
NO CONTINUITY
Replace the grip and/or thumb warmer.
Check the variable resistors.
CORRECT
INCORRECT
Replace the variable resistors.
Check the load control relay.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the load control relay.
Correct the connection and/or
replace the rectifier/regulator
and/or CDI unit.
8-40
GRIP WARMER SYSTEM
ELEC
–
+
PASSENGER GRIP WARMER DOES NOT OPERATE. (VT600)
Check the main fuse,
“IGNITION” fuse and “TAIL” fuse.
Refer to “FUSE INSPECTION” in CHAPTER 2.
OK
FAULTY
Replace the main fuse, “IGNITION” fuse and/or
“TAIL” fuse.
Check the battery.
Refer to “BATTERY INSPECTION” in CHAPTER 2.
OK
OUT OF SPECIFICATION
Replace and/or charge the battery.
Refer to “BATTERY CHARGING” in CHAPTER 2.
Check the stator coil and pickup coil.
Refer to “IGNITION SYSTEM”.
OK
OUT OF SPECIFICATION
Replace the stator coil assembly.
Check the main switch.
Refer to “IGNITION SYSTEM”.
OK
NO CONTINUITY
Replace the main switch.
Check the passenger grip warmer.
OK
NO CONTINUITY
Replace the passenger grip warmer.
Check the passenger grip warmer switch.
OK
NO CONTINUITY
Replace the passenger grip warmer switch.
INCORRECT
Replace the resistor.
Check the resistor.
CORRECT
Check the passenger grip warmer relay.
OK
FAULTY
Replace the passenger grip warmer relay.
Check the load control relay.
Refer to “IGNITION SYSTEM”.
OK
FAULTY
Replace the load control relay.
Correct the connection and/or
replace the rectifier/regulator
and/or CDI unit.
8-41
GRIP WARMER SYSTEM
ELEC
–
+
GRIP AND THUMB WARMER COIL
SEA8570
1. Disconnect:
• Grip warmer leads 1
• Thumb warmer coupler 2
2. Connect:
• Pocket tester
(to the grip warmer coil leads and/or thumb
warmer coil leads)
2
(L)
B
3. Check:
• Grip warmer 1 continuity
• Thumb warmer 2 continuity
No continuity → Replace both grips together or
separately and/or the handlebar switch.
1
(R)
W
Ω×1
+
–
SEA8580
VARIABLE RESISTOR (THUMB WARMER)
1. Disconnect:
• Variable resistor coupler 1
2. Connect:
• Pocket tester
(to the variable resistor coupler)
SEA8590
3. Check:
• Variable resistor resistance
When pulley is turned once.
Out of specification → Replace the variable
resistor.
Ω×1
–
+
Y/W B/R
Variable resistor resistance:
(Yellow/White – Black/Red)
400 ~ 600 Ω at 20°C (68°F)
SEA8600
8-42
GRIP WARMER SYSTEM
ELEC
–
+
VARIABLE RESISTOR (GRIP WARMER)
1. Disconnect:
• Variable resistor coupler 1
2. Connect:
• Pocket tester
(to the variable resistor coupler)
SEA8610
3. Check:
• Variable resistor resistance
When pulley is turned once.
Out of specification → Replace the variable
resistor.
Ω×1
–
+
Y/W B/R
Variable resistor resistance:
(Yellow/White – Black/Red)
400 ~ 600 Ω at 20°C (68°F)
SEA8620
PASSENGER GRIP WARMER (VT600)
1. Disconnect:
• Passenger grip warmer coupler 1
2. Connect:
• Pocket tester
(to the passenger grip warmer coupler)
SEA8630
3. Check:
• Passenger grip warmer continuity
No continuity → Replace both passenger grips
together or separately.
Ω×1
–
L
+
B
SEA8640
8-43
GRIP WARMER SYSTEM
ELEC
–
+
PASSENGER GRIP WARMER SWITCH
(VT600)
1. Disconnect:
• Passenger grip warmer switch coupler 1
2. Connect:
• Pocket tester
(to the passenger grip warmer switch coupler)
SEA8650
3. Check:
• Passenger grip warmer switch continuity
Faulty → Replace.
Ω×1
Y/L O/B Y/R
–
Y/L
+
O/B
Y/R
LO
OFF
HI
SEA8660
Continuity
Ω×1
Y/L O/B Y/R
–
+
SEA8670
RESISTOR (VT600)
SEA8680
1. Disconnect:
• Resistor coupler 1
2. Connect:
• Pocket tester
(to the resistor coupler)
3. Measure:
• Resistor resistance
Out of specification → Replace.
Ω×1
–
B
Resistor resistance:
(Black – Black)
1.4 ~ 1.7 Ω at 20°C (68°F)
+
B
SEA8690
8-44
GRIP WARMER SYSTEM
ELEC
–
+
PASSENGER GRIP WARMER RELAY (VT600)
SEA8700
1. Inspect:
• Passenger grip warmer relay 1
Inspection steps:
• Disconnect the passenger grip warmer relay
from the coupler.
• Connect the pocket tester (Ω × 1) and battery
(12 V) to the passenger grip warmer relay terminals as shown.
Positive battery terminal → Blue/Red 1
Negative battery terminal → Yellow 2
Positive tester probe → Blue/Red 3
Negative tester probe → Orange/Black 4
3
4
L/R
O/B
L/R
2
Y
• If load control relay does not have continuity
between the blue/red and orange/black terminals, replace it.
1
SEA8710
8-45
FAULT LOCATION TABLE
ELEC
–
+
FAULT LOCATION TABLE
NOTE:
When more than one problem is detected, the water temperature indicator light flashes in the pattern of the lowest
numbered problem. After that problem is corrected, the water temperature indicator light flashes in the pattern
of the next lowest numbered problem. This continues until all of the problems are detected and corrected.
No.
Patterns
Condition
• Water temperature
indicator light is good.
Reference
Refer to “SIGNAL
SYSTEM”.
• If the water temperature indicator light does
not come on replace it.
0
SEA8720
∗ If the CDI unit is working properly, the water temperature indicator light flashes in this pattern when
the engine is turned on.
Overheat.
1
SEA8730
Shorting of the water
temperature sensor is
detected.
Refer to “WATER
TEMPERATURE
SENSOR”.
Discontinuity of the
variable resistor (grip
warmer) is detected.
Refer to “VARIABLE RESISTOR
(GRIP
WARMER)”.
2
SEA8740
3
Repeats
0.75 s
2.5 s
SEA8750
ON
: Warning light is on
OFF :
Warning light is off
8-46
s : Second
FAULT LOCATION TABLE
No.
Patterns
ELEC
Condition
Repeats
–
+
Reference
Shorting of grip warmer is Refer to “GRIP
detected.
WARMER
SYSTEM”.
4
0.75 s
0.25 s
3.5 s
SEA8760
Repeats
Discontinuity of the
variable resistor (thumb
warmer) is detected.
Refer to “VARIABLE RESISTOR (THUMB
WARMER)”.
Shorting of thumb
warmer is detected.
Refer to “GRIP
WARMER
SYSTEM”.
Abnormal electric source
voltage
Refer to “GRIP
WARMER
SYSTEM”.
5
0.75 s
0.25 s
4.5 s
SEA8770
Repeats
6
0.75 s
0.25 s
5.5 s
SEA8780
Repeats
7
0.75 s
0.25 s
ON
: Warning light is on
6.5 s
SEA8790
OFF :
Warning light is off
8-47
s : Second
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
VX600ER/SX600/MM600/VT600
Model
Model code number
Dimensions:
Overall length
Overall width
Overall height
Dry weight
Minimum turning radius:
Clockwise
Counterclockwise
Engine:
Engine type
Induction system
Cylinder arrangement
Displacement
Bore × Stroke
Compression ratio
Maximum horse power r/min
Maximum torque r/min
Starting system
8DG4 (VX600ER)
8EA4 (SX600)
8EJ3 (MM600)
8EB4 (VT600)
2,780 mm (109.4 in) (VX600ER)
2,760 mm (108.7 in) (SX600)
2,990 mm (117.7 in) (MM600/VT600)
1,200 mm (47.2 in) (VX600ER/SX600/VT600)
1,115 mm (43.9 in) (MM600)
1,230 mm (48.4 in) (VX600ER/SX600)
1,215 mm (47.8 in) (MM600)
1,330 mm (52.4 in) (VT600)
229 kg (505 lb) (VX600ER)
222 kg (489 lb) (SX600)
234 kg (516 lb) (MM600)
257 kg (567 lb) (VT600)
4.0 m (13.1 ft)
4.0 m (13.1 ft)
Liquid cooled 2-stroke, 7-port
Crankcase reed valve
Forward inclined parallel 3-cylinder
593 cm3 (36.2 cu.in)
65.0 × 59.6 mm (2.56 × 2.35 in)
6.6 : 1
8,500 r/min
8,250 r/min
Recoil hand starter (SX600/MM600)
Electric and recoil hand starter (VX600ER/VT600)
Lubrication system
Separate lubrication (YAMAHA AUTOLUBE)
Engine oil:
Type
Tank capacity
YAMALUBE 2-cycle oil
3.0 L (2.6 Imp qt, 3.2 US qt)
Drive chain housing oil:
Type
Capacity
Gear oil API “GL-3” SAE #75 or #80
0.25 L (8.8 Imp oz, 8.5 US oz)
Coolant:
Total amount
Reservoir tank capacity
3.8 L (3.34 Imp qt, 4.02 US qt) (VX600ER/SX600)
4.0 L (3.52 Imp qt, 4.23 US qt) (MM600)
4.1 L (3.61 Imp qt, 4.33 US qt) (VT600)
0.28 L (0.25 Imp qt, 0.30 US qt)
9-1
GENERAL SPECIFICATIONS
Model
Fuel:
Type
Tank capacity
VX600ER/SX600/MM600/VT600
R+M
; 88 or higher)
2
Research Octane; 93 or higher (for Europe)
44.3 L (9.7 Imp gal, 11.7 US gal)
Regular unleaded gasoline (Pump Octane
Carburetor:
Type/Quantity
Manufacturer
TM31/3
MIKUNI
Spark plug:
Type
Manufacturer
Gap
BR9ES
NGK
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Transmission:
Primary reduction system
Primary reduction ratio
Clutch type
Secondary reduction system
Secondary reduction ratio
Reverse system
Chassis:
Frame type
Caster angle
Ski stance (center to center)
Suspension:
Front suspension type
Rear suspension type
Track:
Track type
Track width
Length on ground
Track deflection mm/10 kg (22 lb)
SPEC
V-Belt
3.8 ~ 1.0 : 1
Automatic centrifugal engagement
Chain
1.857 (39/21) (VX600ER)
1.950 (39/20) (SX600) (VT600 for U.S.A./Canada)
2.053 (39/19) (MM600)
2.167 (39/18) (VT600 for Europe)
No (SX600/MM600)
Yes (VX600ER/VT600)
Monocoque
25.5°
1,070 mm (42.1 in) (VX600ER/SX600/VT600)
980 mm (38.6 in) (MM600)
Leading arm
Slide rail suspension
Internal drive type
381 mm (15.0 in)
752 mm (29.6 in) (VX600ER/SX600)
887 mm (34.9 in) (MM600)
944 mm (37.2 in) (VT600)
25 ~ 30 mm (0.98 ~ 1.18 in) (VX600ER/SX600/VT600)
20 ~ 25 mm (0.79 ~ 0.98 in) (MM600)
Brake:
Brake type
Operation method
Caliper type disc brake
Handle lever, left hand operated
Electrical:
Ignition system/Manufacturer
Generator system
DC-CDI/MITSUBISHI
AC magneto
9
9-2
GENERAL SPECIFICATIONS
Model
Bulb wattage × Quantity:
Headlight
Tail/Brake light
Tachometer light
Speedometer light
High beam indicator light
Water temperature indicator light
Oil level indicator light
SPEC
VX600ER/SX600/MM600/VT600
12 V, 60 W/55 W × 2
12 V, 8 W/23 W × 1
12 V, 1.7 W × 1
12 V, 1.7 W × 1
12 V, 1.7 W × 1
12 V, 1.7 W × 1
12 V, 1.7 W × 1
9-3
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Model
VX600ER/SX600/MM600/VT600
Cylinder head:
Volume (with spark plug)
<Warp limit>
Cylinder:
Material
Bore size
Aluminum alloy with dispersion coating
65.000 ~ 65.014 mm
(2.5591 ~ 2.5596 in)
<65.100 mm (2.5630 in)>
<0.05 mm (0.002 in)>
<0.01 mm (0.0004 in)>
<Wear limit>
<Taper limit>
<Out-of-round limit>
Piston:
Piston size (D)
Measuring point a
Piston to-cylinder clearance
<Limit>
Piston offset
Piston offset direction
Piston pin bore inside diameter
Piston pin:
Piston pin outside diameter
Piston pin length
Piston ring:
Sectional sketch
Top Ring
Side clearance
(installed)
Plating/coating
64.932 ~ 64.935 mm
(2.5564 ~ 2.5565 in)
10 mm (0.39 in)
0.065 ~ 0.070 mm
(0.0026 ~ 0.0028 in)
<0.15 mm (0.006 in)>
0.5 mm (0.0197 in)
EX side
20.004 ~ 20.015 mm (0.7876 ~ 0.7880 in)
19.995 ~ 20.000 mm (0.7872 ~ 0.7874 in)
55.7 ~ 56.0 mm (2.193 ~ 2.205 in)
Keystone
B = 1.20 mm (0.047 in)
T = 2.55 mm (0.100 in)
2nd Ring
End gap (installed)
18.7 ~ 19.3 cm3
(1.14 ~ 1.18 cu.in)
<0.03 mm (0.0012 in)>
∗Lines indicate straight edge measurement.
Top Ring
2nd Ring
Top Ring
2nd Ring
Top Ring
2nd Ring
Keystone
B = 1.20 mm (0.047 in)
T = 2.55 mm (0.100 in)
0.35 ~ 0.55 mm (0.014 ~ 0.022 in)
0.35 ~ 0.55 mm (0.014 ~ 0.022 in)
0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in)
0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in)
Chrome plated/Parkerrizing
Chrome plated/Parkerrizing
9-4
MAINTENANCE SPECIFICATIONS
Model
Crankshaft:
Crank width “A”
Crank width “B”
Maximum runout “C” : C1
C2 ~ C5
C6
Measuring points: 1
2
Connecting rod big end side clearance
“D”
Connecting rod big end radial clearance “E”
Connecting rod small end free play “F”
VX600ER/SX600/MM600/VT600
55.95 ~ 56.00 mm (2.203 ~ 2.205 in)
291.75 ~ 292.30 mm (11.486 ~ 11.508 in)
0.03 mm (0.0012 in)
0.04 mm (0.0016 in)
0.03 mm (0.0012 in)
90 mm (3.54 in)
85 mm (3.35 in)
0.25 ~ 0.75 mm (0.01 ~ 0.03 in)
0.026 ~ 0.040 mm (0.0010 ~ 0.0016 in)
0.8 ~ 1.0 mm (0.03 ~ 0.04 in)
Big end bearing:
Type
Needle bearing
Small end bearing:
Type
Needle bearing
Crank pin:
Crank pin outside diameter
26.991 ~ 27.000 mm (1.0626 ~ 1.0630 in)
Connecting rod:
Small end diameter
Big end diameter
Read valve:
Material
Thickness
<Bending limit>
Stopper height
SPEC
24.995 ~ 25.005 mm
(0.9841 ~ 0.9844 in)
34.020 ~ 34.033 mm (1.3394 ~ 1.3399 in)
Resin
0.35 ~ 0.49 mm (0.014 ~ 0.019 in)
<1.5 mm (0.059 in)>
10.3 ~ 10.7 mm (0.41 ~ 0.42 in)
9-5
MAINTENANCE SPECIFICATIONS
Model
Carburetor:
Type/Quantity
Manufacturer
I.D. mark
Main jet
Pilot jet
Jet needle
Needle jet
(M.J)
(P.J)
(J.N)
(N.J)
Pilot air jet
(P.A.J)
Pilot outlet
(P.O)
Bypass
(B.P.1)
Pilot screw
(P.S)
Throttle valve
(Th.V)
Valve seat size
(V.S)
Starter jet
(G.S)
Float height
(F.H)
Fuel level (from the bore center)
Engine idle speed
VX600ER/SX600/MM600/VT600
TM31/3
MIKUNI
8DG100
#1: 136.3
#2, #3: 133.8
#42.5
6DHN50-3
#1: Q-4
#2, #3: Q-2
ø1.0
ø0.8
ø0.9
2 turns out
C.A 3
ø1.3
ø1.5
11.3 ~ 15.3 mm (0.44 ~ 0.60 in)
36 ~ 38 mm (1.42 ~ 1.50 in)
1,600 ± 100 r/min
Fuel pump:
Type
Manufacturer
Diaphragm
TAIYO GIKEN
Oil pump:
Pump cable adjusting distance
23 ± 1 mm (0.906 ± 0.039 in)
Cooling system:
Filler cap opening pressure
Water pump type
Coolant type
Coolant mixing ratio (coolant:water)
Coolant total amount
Reservoir tank capacity
SPEC
95 ~ 125 kPa (0.95 ~ 1.25 kg/cm2, 14 ~ 18 psi)
Impeller type
High quality ethylene glycol antifreeze containing corrosion
inhibitors
3:2 (60%:40%)
3.8 L (3.34 Imp qt, 4.02 US qt) (VX600ER/SX600)
4.0 L (3.52 Imp qt, 4.23 US qt) (MM600)
4.1 L (3.61 Imp qt, 4.33 US qt) (VT600)
0.28 L (0.25 Imp qt, 0.30 US qt)
9-6
MAINTENANCE SPECIFICATIONS
SPEC
POWER TRAIN
Model
Transmission:
Type
Range of ratio
Engagement speed r/min
Shift r/min
Sheave distance “A”
Sheave offset “B”
V-Belt:
Part number/Manufacturer
Circumference
Width “A”
<Wear limit “B”>
Primary sheave spring:
Part number
Color code
Diameter
Wire diameter
Preload
Spring rate
Number of coils
Free length
VX600ER/SX600/MM600/VT600
V-belt automatic
3.8 ~ 1.0 :1
4,000 ± 200 r/min (3,800 ~ 4,200 r/min) (VX600ER)
(VT600 for U.S.A./Canada)
4,200 ± 200 r/min (4,000 ~ 4,400 r/min) (SX600)
4,600 ± 200 r/min (4,400 ~ 4,800 r/min) (MM600)
3,900 ± 200 r/min (3,700 ~ 4,100 r/min) (VT600 for Europe)
8,500 ± 250 r/min (8,250 ~ 8,750 r/min)
267 ~ 270 mm (10.52 ~ 10.62 in)
13.5 ~ 16.5 mm (0.53 ~ 0.64 in) (SX600/MM600)
18.5 ~ 21.5 mm (0.73 ~ 0.85 in) (VX600ER/VT600)
8DN-17641-00/MITSUBOSHI
1,129 ~ 1,137 mm (44.4 ~ 44.7 in)
34.5 mm (1.36 in)
<32.5 mm (1.28 in)>
90501-582L7 (VX600ER/SX600)
90501-603L2 (MM600)
90501-602L9 (VT600 for U.S.A./Canada)
90501-582L2 (VT600 for Europe)
Yellow-Green-Yellow (VX600ER/SX600)
Yellow-White-Yellow (MM600)
Pink-Green-Pink (VT600 for U.S.A./Canada)
Green-Silver-Green (VT600 for Europe)
60 mm (2.362 in)
5.8 mm (0.228 in) (VX600ER/SX600) (VT600 for Europe)
6.0 mm (0.236 in) (MM600) (VT600 for U.S.A./Canada)
392 N (40 kg, 88 lb) (VX600ER/SX600)
(VT600 for U.S.A./Canada)
441 N (45 kg, 99 lb) (MM600)
343 N (35 kg, 77 lb) (VT600 for Europe)
24.5 N/mm (2.50 kg/mm, 140 lb/in) (VX600ER/SX600/MM600)
29.4 N/mm (3.00 kg/mm, 168 lb/in) (VT600 for U.S.A./Canada)
27.0 N/mm (2.75 kg/mm, 154 lb/in) (VT600 for Europe)
4.92 (VX600ER/SX600)
5.39 (MM600)
4.82 (VT600 for U.S.A./Canada)
4.66 (VT600 for Europe)
89.4 mm (3.52 in) (VX600ER/SX600)
91.4 mm (3.60 in) (MM600)
86.7 mm (3.41 in) (VT600 for U.S.A./Canada)
87.4 mm (3.44 in) (VT600 for Europe)
9-7
MAINTENANCE SPECIFICATIONS
VX600ER/SX600/MM600/VT600
Model
Primary sheave weight arm:
Part number (with bushing)
Weight
Rivet:
Outer
Part number
Material
Size
Quantity
Hole quantity
Inner
Part number
Material
Size
Quantity
Hole quantity
Secondary sheave spring:
Part number
Color code
Outside diameter
Wire diameter
Hole position
Sheave side-spring seat side (twist angle)
Spring rate
Number of coils
Free length
Torque cam angle
SPEC
8DG-17605-00
34.30 g (1.211 oz)
90261-06028 (VX600ER/MM600)
90261-06015 (SX600)
90261-06034 (VT600)
Aluminum (VX600ER/MM600)
Steel (SX600/VT600)
10.3 mm (0.41 in) (VX600ER/SX600/MM600)
13.9 mm (0.55 in) (VT600)
3
3
90261-06034 (VX600ER/SX600)
90261-06015 (MM600)
90261-06033 (VT600)
Steel
13.9 mm (0.55 in) (VX600ER/SX600)
10.3 mm (0.41 in) (MM600)
17.2 mm (0.68 in) (VT600)
3
3
90508-536A9 (VX600ER/SX600/MM600)
(VT600 for U.S.A./Canada)
90508-556A2 (VT600 for Europe)
Red (VX600ER/SX600/MM600) (VT600 for U.S.A./Canada)
Green (VT600 for Europe)
69.5 mm (2.736 in)
5.3 mm (0.209 in) (VX600ER/SX600/MM600)
(VT600 for U.S.A./Canada)
5.5 mm (0.217 in) (VT600 for Europe)
2-6 (80°) (VX600ER/SX600/MM600) (VT600 for Europe)
1-6 (70°) (VT600 for U.S.A./Canada)
7.3 N/mm (0.74kg/mm, 41.44 lb/in) (VX600ER/SX600/MM600)
(VT600 for U.S.A./Canada)
8.5 N/mm (0.87kg/mm, 48.72 lb/in) (VT600 for Europe)
5.53
75 mm (2.95 in)
47° (VX600ER/SX600)
43° (MM600/VT600)
9-8
MAINTENANCE SPECIFICATIONS
VX600ER/SX600/MM600/VT600
Model
Drive chain:
Type
Number of links
Track:
Part number
Width
Length
Pitch
Number of links
Thickness “A”
Height “B”
Track deflection at 10 kg (22 lb)
Slide rail suspension (Rear suspension):
Travel (Rear suspension stroke)
Front travel
Rear travel
Suspension spring rate
Front
Rear
Spring wire diameter
Front
Rear
SPEC
REXNORD S37TNB13
68 L
8DY-47110-00 (VX600ER)
8EA-47110-10 (SX600)
8ED-47110-01 (MM600)
8DM-47110-00 (VT600 for U.S.A./Canada)
8CC-47110-11 (VT600 for Europe)
381 mm (15.0 in)
3,072 mm (120.9 in) (VX600ER/SX600)
3,584 mm (141.1 in) (MM600)
3,456 mm (136.1 in) (VT600)
64 mm (2.52 in)
48 (VX600ER/SX600)
56 (MM600)
54 (VT600)
5.1 mm (0.20 in) (VX600ER) (VT600 for U.S.A./Canada))
5.5 mm (0.22 in) (SX600) (VT600 for Europe)
7.250 mm (0.29 in) (MM600)
30.50 mm (1.20 in) (VX600ER) (VT600 for U.S.A./Canada))
28.50 mm (1.12 in) (SX600)
58.05 mm (2.29 in) (MM600)
33.50 mm (1.32 in) (VT600 for Europe)
25 ~ 30 mm (0.98 ~ 1.18 in) (VX600ER/SX600/VT600)
20 ~ 25 mm (0.79 ~ 0.98 in) (MM600)
292 mm (11.5 in)
238 mm (9.37 in) (VX600ER/SX600)
205 mm (8.07 in) (MM600)
235 mm (9.25 in) (VT600)
273 mm (10.75 in) (VX600ER/SX600)
270 mm (10.63 in) (MM600/VT600)
19.6 N/mm (2.0 kg/mm, 112 lb/in) (VX600ER)
14.8 ~ 24.5 N/mm (1.5 ~ 2.5 kg/mm, 84 ~ 140 lb/in) (SX600)
29.4 N/mm (3.0 kg/mm, 168 lb/in) (MM600)
14.7 N/mm (1.5 kg/mm, 84 lb/in) (VT600)
29.4 ~ 44.1 N/mm (3.0 ~ 4.5 kg/mm, 168 ~ 252 lb/in) (VX600ER)
27.44 ~ 47.04 N/mm (2.8 ~ 4.8 kg/mm, 157 ~ 269 lb/in) (SX600)
22.54 ~ 42.14 N/mm (2.3 ~ 4.3 kg/mm, 129 ~ 241 lb/in) (MM600)
34.3 ~ 51.94 N/mm (3.5 ~ 5.3 kg/mm, 196 ~ 297 lb/in) (VT600)
7.8 mm (0.31 in) (VX600ER/SX600/VT600)
8.2 mm (0.32 in) (MM600)
11.5 mm (0.452 in) (VX600ER)
11.4 mm (0.448 in) (SX600)
10.8 mm (0.425 in) (MM600)
12.0 mm (0.472 in) (VT600)
9-9
MAINTENANCE SPECIFICATIONS
Model
Suspension setting position:
Hook setting length ∗
Full rate adjusting position ∗∗
Shock absorber: Damping force
Front
Extension
Compression
Rear
Extension
Compression
Slide runner:
Thickness
<Wear limit>
Track sprocket wheel:
Material
Number of teeth
SPEC
VX600ER/SX600/MM600/VT600
15 ± 0.5 mm (0.59 ± 0.02 in) (VX600ER)
25 ± 0.5 mm (0.98 ± 0.02 in) (SX600/VT600)
10 ± 0.5 mm (0.39 ± 0.02 in) (MM600)
B
720 N/0.3 m/s (73 kg/0.3 m/s, 161 lb/0.3 m/s) (VX600ER)
2,380 N/0.3 m/s (243 kg/0.3 m/s, 536 lb/0.3 m/s) (SX600)
1,570 N/0.3 m/s (160 kg/0.3 m/s, 357 lb/0.3 m/s) (MM600)
510 N/0.3 m/s (52 kg/0.3 m/s, 115 lb/0.3 m/s) (VT600)
1,020 N/0.3 m/s (104 kg/0.3 m/s, 229 lb/0.3 m/s) (VX600ER)
1,950 N/0.3 m/s (199 kg/0.3 m/s, 439 lb/0.3 m/s) (SX600)
860 N/0.3 m/s (88 kg/0.3 m/s, 194 lb/0.3 m/s) (MM600)
1,775 N/0.3 m/s (181 kg/0.3 m/s, 399 lb/0.3 m/s) (VT600)
2,206 N/0.3 m/s (225 kg/0.3 m/s, 496 lb/0.3 m/s) (VX600ER)
2,900 N/0.3 m/s (296 kg/0.3 m/s, 653 lb/0.3 m/s) (SX600)
1,570 N/0.3 m/s (160 kg/0.3 m/s, 357 lb/0.3 m/s) (MM600)
2,647 N/0.3 m/s (270 kg/0.3 m/s, 595 lb/0.3 m/s) (VT600)
726 N/0.3 m/s (74 kg/0.3 m/s, 163 lb/0.3 m/s) (VX600ER)
970 N/0.3 m/s (99 kg/0.3 m/s, 218 lb/0.3 m/s) (SX600)
860 N/0.3 m/s (88 kg/0.3 m/s, 194 lb/0.3 m/s) (MM600)
784 N/0.3 m/s (80 kg/0.3 m/s, 176 lb/0.3 m/s) (VT600)
17.8 mm (0.70 in)
<10 mm (0.39 in)>
Polyethylene
9 T (VX600ER/SX600/VT600)
8 T (MM600)
Rear guide wheel:
Material
Outside diameter
Aluminum with rubber
178 mm (7.01 in)
Brake:
Pad thickness
<Pad wear limit>
Pad to disk clearance
Disc outside diameter
Disc thickness
<Disc thickness limit>
10.2 mm (0.40 in)
<4.7 mm (0.19 in)>
0.025 ~ 0.115 mm (0.001 ~ 0.005 in)
220 mm (8.66 in)
10 mm (0.39 in)
<9.5 mm (0.37 in)>
9-10
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Model
Frame:
Frame material
Seat height
Aluminum
730 mm (28.7 in) (VX600ER/SX600/VT600)
700 mm (27.6 in) (MM600)
Rear side of seat
Luggage box location
Steering:
Lock-to-lock angle
(left)
(right)
(left)
(right)
Ski alignment
Toe-out size
Caster angle
Ski:
Ski material
Length
Width
Ski suspension (Front suspension):
Type
Travel (Front suspension stroke)
Spring type
Spring rate
Wire diameter
Shock absorber: damping force
Extension
Compression
VX600ER/SX600/MM600/VT600
29.4° (R ski) 34.7° (L ski) (VX600ER/SX600/VT600)
34.7° (R ski) 29.4° (L ski) (VX600ER/SX600/VT600)
26.7° (R ski) 32.0° (L ski) (MM600)
32.0° (R ski) 26.7° (L ski) (MM600)
Toe-out
0 ~ 15 mm (0 ~ 0.59 in)
25.5°
Plastic
1,020 mm (40.2 in) (VX600ER/VT600)
1,010 mm (39.8 in) (SX600/MM600)
132.0 mm (5.20 in) (VX600ER/VT600)
131.0 mm (5.16 in) (SX600)
139.7 mm (5.50 in) (MM600)
Proaction system
221 mm (9.0 in) (VX600ER/SX600/VT600)
170 mm (6.7 in) (MM600)
Coil spring
22.54 N/mm (2.3 kg/mm, 128.8 lb/in) (VX600ER/VT600)
12.74 ~ 20.58 ~ 24.50 N/mm (1.3 ~ 2.1 ~ 2.5 kg/mm,
72.8 ~ 117.6 ~ 140 lb/in) (SX600)
20.58 N/mm (2.1 kg/mm, 117.6 lb/in) (MM600)
8.2 mm (0.323 in) (VX600ER/VT600)
7.8 mm (0.307 in) (SX600)
7.5 mm (0.295 in) (MM600)
1,170 N/0.3 m/s (119 kg/0.3 m/s, 262 lb/0.3 m/s) (VX600ER)
1,597 N/0.3 m/s (163 kg/0.3 m/s, 359 lb/0.3 m/s) (SX600)
490 N/0.3 m/s (50 kg/0.3 m/s, 110 lb/0.3 m/s) (MM600)
1,274 N/0.3 m/s (130 kg/0.3 m/s, 287 lb/0.3 m/s) (VT600)
720 N/0.3 m/s (73 kg/0.3 m/s, 161 lb/0.3 m/s) (VX600ER)
461 N/0.3 m/s (47 kg/0.3 m/s, 104 lb/0.3 m/s) (SX600)
274 N/0.3 m/s (28 kg/0.3 m/s, 62 lb/0.3 m/s) (MM600)
794 N/0.3 m/s (81 kg/0.3 m/s, 179 lb/0.3 m/s) (VT600)
9-11
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Model
VX600ER/SX600/MM600/VT600
Voltage
12 V
Ignition system:
Ignition timing (B.T.D.C.)
Advanced type
18° at 1,500 r/min
Digital type
Ignition coil:
Model/Manufacturer
Minimum spark gap
Primary coil resistance
Secondary coil resistance
F6T535/MITSUBISHI
6 mm (0.236 in) or more
0.36 ~ 0.48 Ω at 20°C (68°F)
5.4 ~ 7.4 kΩ at 20°C (68°F)
Spark plug cap:
Type
Model/Manufacturer
Resistance
Rubber type
T156/TOKAI DENSO
5 kΩ at 20°C (68°F)
Charging system:
Type
Nominal output
AC magneto
14 V/21 A at 5,000 r/min
DC-CDI:
Magneto model/Manufacturer
Standard
Pickup coil resistance
(color code)
Stator coil resistance
(color code)
CDI unit model/Manufacturer
F4T374/MITSUBISHI
14 V 21 A, 294W at 5,000 r/min
189 ~ 231 Ω at 20°C (68°F)
(White/Red – White/Green)
0.36 ~ 0.44 Ω at 20°C (68°F)
(White – White)
F8T37573/MITSUBISHI
Rectifier/regulator:
Type
Model/Manufacturer
No load regulated voltage
Capacity (DC)
Withstand voltage
Semiconductor-short circuit type
SH650A-12/SHINDENGEN
14.1 ~ 14.9 V
25 A
200 V
Battery (VX600ER/VT600):
Specific gravity
Manufacturer
Type
Ten hour rate amperage
DC
1.280
GS
GM18Z-3A
2.0 A
Electric starter system (VX600ER/VT600):
Bendix type
Type
9-12
MAINTENANCE SPECIFICATIONS
VX600ER/SX600/MM600/VT600
Model
Starter motor (VX600ER/VT600):
Model/Manufacturer
Output
Armature coil resistance
Continuity check
Insulation check
Brush
Overall length
<Wear limit>
Spring pressure
Commutator diameter
<Wear limit>
Mica undercut
DB4XF/DENSO
12 V-0.6 kW
0.014 ~ 0.018 Ω at 20°C (68°F)
More than 100 kΩ at 20°C (68°F)
12 mm (0.47 in)
<8.5 mm (0.33 in)>
6.38 ~ 9.32 N (650 ~ 950 g, 22.9 ~ 33.5 oz)
28 mm (1.10 in)
<27 mm (1.06 in)>
0.6 mm (0.024 in)
Starter relay (VX600ER/VT600):
Model/Manufacturer
Amperage rating
Coil resistance
MS5F-441/JIDECO
180 A
4.2 ~ 4.6 Ω at 20°C (68°F)
Oil level switch:
Model/Manufacturer
8CR/ASTI
Fuel sender:
Model/Manufacturer
Sender resistance
Full
Empty
8CW/NIPPON SEIKI
4 ~ 10 Ω at 20°C (68°F)
90 ~ 100 Ω at 20°C (68°F)
Load control relay:
Model/Manufacturer
Coil resistance
8DM/MATSUSHITA
76 ~ 92 Ω at 20°C (68°F)
Headlight relay:
Model/Manufacturer
Coil resistance
5DM/OMRON
95 ~ 116 Ω at 20°C (68°F)
Grip warmer:
Heater resistance
(left)
(right)
Circuit breaker (VX600ER/VT600):
Type
Amperage for individual circuit
Main fuse
Head fuse
Tail fuse
Ignition fuse
Reserve fuse
Reserve fuse
Reserve fuse
Water temperature sensor:
Model/Manufacturer
Resistance
SPEC
1.53 ~ 1.87 Ω at 20°C (68°F)
1.53 ~ 1.87 Ω at 20°C (68°F)
Fuse
30 A × 1
20 A × 1
10 A × 1
10 A × 1
30 A × 1
20 A × 1
10 A × 1
8CC/MITSUBISHI
5.2 ~ 6.4 kΩ at 0°C (34°F)
0.300 ~ 0.364 kΩ at 80°C (176°F)
0.170 ~ 0.208 kΩ at 100°C (212°F)
9-13
MAINTENANCE SPECIFICATIONS
SPEC
HIGH ALTITUDE SETTINGS
Tempera- –40°C
ture (–40°F)
Altitude
–29°C
(–20°F)
–18°C
(0°F)
–7°C
(20°F)
4°C
(40°F)
16°C
(60°F)
0 ~ 100 m
(0 ~ 300 ft)
MJ #1
MJ #2#3
PJ
JN
PS
#142.5
#140
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#140
#137.5
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#137.5
#135
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#135
#132.5
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#132.5
#130
#42.5
3
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#130
#127.5
#42.5
3
2 1/2
100 ~ 500 m
(300 ~ 1,700 ft)
MJ #1
MJ #2#3
PJ
JN
PS
#141.3
#138.8
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#138.8
#136.3
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#136.3
#133.8
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#133.8
#131.3
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#131.3
#128.8
#42.5
2.5
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#128.8
#126.3
#42.5
2.5
2 1/2
MJ #1
MJ #2#3
500 ~ 1,000 m
PJ
(1,700 ~ 3,300 ft) JN
PS
#140
#137.5
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#137.5
#135
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#135
#132.5
#42.5
2.5
2
MJ #1
MJ #2#3
PJ
JN
PS
#132.5
#130
#42.5
2.5
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#130
#127.5
#42.5
2.5
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#127.5
#125
#42.5
2.5
3
MJ #1
MJ #2#3
1,000 ~ 1,500 m
PJ
(3,300 ~ 5,000 ft) JN
PS
#138.8
#136.3
#42.5
3
2
MJ #1
MJ #2#3
PJ
JN
PS
#136.3
#133.8
#42.5
2.5
2
MJ #1
MJ #2#3
PJ
JN
PS
#133.8
#131.3
#42.5
2.5
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#131.3
#128.8
#42.5
2.5
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#128.8
#126.3
#42.5
2
3
MJ #1
MJ #2#3
PJ
JN
PS
#126.3
#123.8
#45
2
3
MJ #1
MJ #2#3
1,500 ~ 2,000 m
PJ
(5,000 ~ 6,700 ft) JN
PS
#136.3
#133.8
#42.5
2.5
2
MJ #1
MJ #2#3
PJ
JN
PS
#133.8
#131.3
#42.5
2.5
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#131.3
#128.8
#42.5
2
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#128.8
#126.3
#42.5
2
3
MJ #1
MJ #2#3
PJ
JN
PS
#126.3
#123.8
#45
2
3
MJ #1
MJ #2#3
PJ
JN
PS
#123.8
#121.3
#45
1.5
3 1/4
MJ #1
MJ #2#3
2,000 ~ 2,500 m
PJ
(6,700 ~ 8,300 ft) JN
PS
#133.8
#131.3
#42.5
2
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#131.3
#128.8
#42.5
2
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#128.8
#126.3
#42.5
2
3
MJ #1
MJ #2#3
PJ
JN
PS
#126.3
#123.8
#45
1.5
3
MJ #1
MJ #2#3
PJ
JN
PS
#123.8
#121.3
#45
1.5
3 1/4
MJ #1
MJ #2#3
PJ
JN
PS
#121.3
#118.8
#45
1.5
3 1/4
MJ #1
MJ #2#3
2,500 ~ 3,000 m
PJ
(8,300 ~ 10,000 ft) JN
PS
#131.3
#128.8
#42.5
1.5
2 1/2
MJ #1
MJ #2#3
PJ
JN
PS
#128.8
#126.3
#42.5
1.5
3
MJ #1
MJ #2#3
PJ
JN
PS
#126.3
#123.8
#45
1.5
3
MJ #1
MJ #2#3
PJ
JN
PS
#123.8
#121.3
#45
1.5
3 1/4
MJ #1
MJ #2#3
PJ
JN
PS
#121.3
#118.8
#45
1
3 1/4
MJ #1
MJ #2#3
PJ
JN
PS
#118.8
#116.3
#45
1
3 1/4
[Production spec] MJ#1: #136.3 MJ#2, 3: #133.8 PJ: #42.5 JN: 6DHN50-3 PAJ: 1.0 PS: 2
#: Main jet number JN: Jet needle clip position PS: Pilot screw turns out PJ: Pilot jet number
NOTE:
• Jet needle (JN) position.
Refer to the following information for the Jet needle shims installation.
JN:3
JN:2.5
JN:1
JN:0.5
Clip
0.4 mm shim
• Oxygenated fuels
Use one size larger Main Jet than specified.
9-14
MAINTENANCE SPECIFICATIONS
SPEC
TIGHTENING TORQUE
ENGINE
Tightening torque
Parts to be tightened
Crankcase (M8 × 80) (1st)
(2nd)
Crankcase (M8 × 35)
Engine bracket (front) and frame
Engine bracket damper (front/rear)
Engine bracket (front) and engine
Engine bracket right (rear) and engine
Engine bracket left (rear) and engine
Engine bracket (rear) and frame
Exhaust joint
(1st)
(2nd)
Water pump cover
Cylinder head
Nut (1st)
(2nd)
Cylinder
Nut
Spark plug
Water temperature sensor
Ignition coil and bracket
Thermostatic cover
Oil pump
Oil pump cable adjuster locknut
Fuel pump
Starter pulley
Drive plate
Recoil starter case
Clamp and intake manifold
Bracket and intake manifold
Reed valve assembly
Carburetor
Pilot jet
Screw (valve seat)
Main jet
Pilot air jet
Starter plunger assembly
Clamp (coolant hose 2)
Impeller
Carburetor heating lever assembly
Coolant drain bolt
Bleed bolt front (cooling system)
Bleed bolt rear (cooling system)
Magneto rotor
Starter motor
Starter motor assembly
Remarks
Nm
m · kg
ft · lb
13
27
15
90
40
33
33
33
57
18
27
13
1.3
2.7
1.5
9.0
4.0
3.3
3.3
3.3
5.7
1.8
2.7
1.3
9.4
19
11
65
29
24
24
24
41
13
19
9.4
Tighten the bolts in two
stages.
11
23
1.1
2.3
8.0
17
Tighten the nuts in two
stages.
28
20
23
10
10
8
15
10
23
18
12
14
14
1
2.8
2.0
2.3
1.0
1.0
0.8
1.5
1.0
2.3
1.8
1.2
1.4
1.4
0.1
20
14
17
7.2
7.2
5.8
11
7.2
17
13
8.7
10
10
0.7
0.7
1
1.8
0.7
2.5
7
10
5
13
7
13
4
110
23
7
0.07
0.1
0.18
0.07
0.25
0.7
1.0
0.5
1.3
0.7
1.3
0.4
11
2.3
0.7
0.51
0.7
1.3
0.51
1.8
5.1
7.2
3.6
9.4
5.1
9.4
2.9
80
17
5.1
9-15
Tighten the bolts in two
stages.
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
(VX600ER/SX600/VT600)
(MM600)
(VX600ER/VT600)
(VX600ER/VT600)
MAINTENANCE SPECIFICATIONS
SPEC
POWER TRAIN
Tightening torque
Parts to be tightened
Nm
m · kg
ft · lb
Primary sheave
(1st)
(2nd)
Spider and fixed sheave
120
60
200
12.0
6.0
20.0
85
43
145
Primary sheave cap and sliding sheave
Roller and weight nut (primary sheave)
Set screw (weight)
Starter motor driven gear
Secondary sheave
Secondary sheave plate 1, 2
Stopper (secondary sheave)
Spring seat (secondary sheave)
Bolt (secondary sheave clearance)
Drive sprocket
Locknut chain tensioner
Chain housing and frame
Driven sprocket
Drain bolt (drive chain housing)
Chain housing cover
Shift lever assembly
Lever and drive chain housing cover
Shaft (reverse drive gear)
Chain housing and brake caliper
Bleed screw (brake caliper)
Brake hose
Brake hose joint
Brake master cylinder side
Brake hose side
Bearing set screw (jackshaft)
Bearing holder (jackshaft)
Stopper band
Hook and front pivot arm
Wheel bracket and sliding frame
Bracket bolt (rear)
Bracket bolt (front)
Front suspension bracket bolt (rear)
Front suspension bracket bolt (front)
Shaft and sliding frame
Front pivot arm and front pivot arm bracket
Front pivot arm bracket and sliding frame
Suspension wheel
Rear axle
Slide rail suspension mounting bolt
(M10)
(M8)
14
6
4
20
64
4
6.5
23
10
60
24
48
48
16
24
10
13
10
48
6
30
1.4
0.6
0.4
2.0
6.4
0.4
0.65
2.3
1.0
6.0
2.4
4.8
4.8
1.6
2.4
1.0
1.3
1.0
4.8
0.6
3.0
10
4.3
2.9
14
46
2.9
4.6
17
7.2
43
17
35
35
11
17
7.2
9.4
7.2
35
4.3
22
14
30
8.5
23
4
16
24
30
72
30
72
72
72
72
72
75
72
24
1.4
3.0
0.85
2.3
0.4
1.6
2.4
3.0
7.2
3.0
7.2
7.2
7.2
7.2
7.2
7.5
7.2
2.4
10
22
6.1
17
2.9
11
17
22
52
22
52
52
52
52
52
54
52
17
9-16
Remarks
Tighten the bolts in two
stages. See NOTE.
Left-hand thread.
Apply LOCTITE®
Apply LOCTITE®
(VX600ER/VT600)Apply LOCTITE®
(SX600)
Apply LOCTITE®
(VX600ER/VT600)
(VX600ER/VT600)Apply LOCTITE®
(VX600ER/VT600)Apply LOCTITE®
Apply LOCTITE®
(VX600ER/SX600)Apply LOCTITE®
(VX600ER/SX600)Apply LOCTITE®
(MM600/VT600)
(MM600/VT600)Apply LOCTITE®
(MM600/VT600)Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
(VT600)
MAINTENANCE SPECIFICATIONS
Tightening torque
Parts to be tightened
Rear pivot arm and bracket
Shock absorber and rear pivot arm
Rear pivot arm and pull rod
Rear suspension bracket and pull rod
Shock absorber and rear suspension bracket
Control rod and sliding frame
Shock absorber and front pivot arm
Shock absorber and front suspension bracket
Rear pivot arm bracket
Rear bracket and suspension wheel
Wheel bracket shaft and sliding frame
Set screw (front axle)
Speedometer gear assembly
Nm
m · kg
24
49
49
49
49
72
49
49
72
72
72
8.5
20
2.4
4.9
4.9
4.9
4.9
7.2
4.9
4.9
7.2
7.2
7.2
0.85
2.0
NOTE:
Tightening steps:
1. Tighten the bolt to a torque of 120 Nm (12 m · kg, 85 ft · lb).
2. Loosen the bolt completely.
3. Retighten the bolt to a torque of 60 Nm (6.0 m · kg, 43 ft · lb).
9-17
ft · lb
17
35
35
35
35
52
35
35
52
52
52
6.1
14
SPEC
Remarks
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
(VT600) Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Tightening torque
Parts to be tightened
Handlebar holder
Steering column
Upper
Lower
Steering column and relay rod
Relay rod and relay arm
Relay arm and tie rod
Tie rod and steering arm
Relay arm
Locknut (relay rod/tie rod)
Ski
Ski runner
Ski column lower bracket
Ski and ski handle (M8 × 55)
Ski and ski handle (M8 × 100)
Ski and ski handle
Shock absorber (upper)
Shock absorber (lower)
Steering arm and ski column
Lower control rod and frame
Upper control rod and frame
Control rod and front arm
Locknut (control rod) (M12)
Locknut (control rod) (M14)
Front arm pivot bolt
Stabilizer bar and connecting rod
Connecting rod and front arm
Frame cross member (M10 × 20)
Master cylinder assembly
Brake lever adjuster locknut
Side cover
Seat and frame (nut)
Shroud
9-18
Nm
m · kg
ft · lb
23
2.3
17
23
23
35
35
35
43
80
25
48
21
11
11
17
11
48
48
56
50
50
56
56
73
78
23
23
48
10
6
3
9
3
2.3
2.3
3.5
3.5
3.5
4.3
8.0
2.5
4.8
2.1
1.1
1.1
1.7
1.1
4.8
4.8
5.6
5.0
5.0
5.6
5.6
7.3
7.8
2.3
2.3
4.8
1.0
0.6
0.3
0.9
0.3
17
17
25
25
25
31
58
18
35
15
8.0
8.0
12
8.0
35
35
40
36
36
40
40
53
56
17
17
35
7.2
4.3
2.2
6.5
2.2
Remarks
Apply LOCTITE®
Apply LOCTITE®
(VX600ER/VT600)
(VX600ER/VT600)
(SX600/MM600)
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
(MM600)
GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITS
SPEC
GENERAL TORQUE
SPECIFICATIONS
General torque
specifications
A
(nut)
This chart specifies torque for standard fasteners
with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To
avoid warpage, tighten multi-fastener assemblies in
a crisscross fashion, in progressive stages, until full
torque is reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Components should be at room temperature.
B
(bolt)
Nm
m · kg
ft · lb
10 mm
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
A: Distance across flats
B: Outside thread diameter
DEFINITION OF UNITS
Unit
Read
Definition
-3
Measurement
mm
cm
Millimeter
Centimeter
10 meter
10-2 meter
kg
Kilogram
103 gram
N
Newton
1 kg × m/sec
Force
Nm
m · kg
Newton meter
Meter kilogram
N×m
m × kg
Torque
Torque
Pa
N/mm
Pascal
Newtons per millimeter
N/m2
N/mm
Pressure
Spring rate
L
cm3
Liter
Cubic centimeter
—
Volume or capacity
r/min
Rotations per minute
—
Engine speed
Length
Length
Weight
2
9-19
GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITS
9-20
SPEC
CABLE ROUTING
SPEC
SEA9010
9-21
CABLE ROUTING
CABLE ROUTING
1 Water temperature sensor
coupler
2 Fasten the carburetor switch
leads and water temperature
sensor leads and ignition coil
leads to the coolant hose with a
plastic band. For the VX600ER/
VT600, include the starter motor
and battery negative leads.
3 Ignition coil coupler
4 Connectors of the carburetor
switch
5 Fasten the starter motor and
battery negative leads and starter
relay leads to the coolant hose
with a plastic band. (VX600ER/
VT600)
6 Fasten the coolant reservoir hose
and coolant hose with a plastic
clamp.
7 Ensure this is not kink.
8 Fasten the starter motor and
battery negative leads to the
coolant hose with a plastic band
above the brake caliper.
(VX600ER/VT600)
9 Route the starter motor and
battery negative leads behind the
coolant hose. (VX600ER/VT600)
0 To the starter relay (VX600ER/
VT600)
A Brake hose
B To the battery negative terminal
(VX600ER/VT600)
C To the gear position switch
(VX600ER/VT600)
9-22
SPEC
CABLE ROUTING
SPEC
SEA9010
9-23
CABLE ROUTING
D Connectors of the gear position
switch (VX600ER/VT600)
E Route the main switch wire
harness under the oil tank
breather hose and fuel tank
breather hose.
F Install the main switch coupler
behind the instrument panel.
G Make sure that the main switch
wire harness is on the inside of
the instrument panel screw (away
from the engine).
H Route the parking brake cable
under the oil tank breather hose.
I Make sure that the brake hose
passes over the oil pump and
throttle cables and through the
right side of the hose guide.
(VX600ER/VT600)
J Oil pump cable (VX600ER/
VT600)
K Throttle cable (VX600ER/VT600)
L Oil level switch
M Variable resistor couplers
N Fuse box (VX600ER/VT600)
O Route the oil pump and throttle
cables in the groove of the intake
silencer and route the throttle
cable above the oil pump cable.
(VX600ER/VT600)
P Carburetor heating lever
Q Coolant hose
R Speedometer cable
S Under 50 mm (1.97 in)
T Fasten the speedometer cable
and wire harness with a plastic
clamp. Install the clamp as close
to the drive V-belt guard bracket,
as possible (rearward).
9-24
SPEC
CABLE ROUTING
SPEC
SEA9020
9-25
CABLE ROUTING
1 Brake hose
2 Oil pump cable
3 Throttle cable
4 Wire harness
5 Starter cable
9-26
SPEC
CABLE ROUTING
SPEC
SEA9030
9-27
CABLE ROUTING
1 Wire harness
2 Ensure this is not kink.
3 50 mm (1.97 in)
4 Make sure that the oil tank cap
and oil tank breather hose do not
touch each other.
5 Route the fuel tank breather hose
over the main switch wire
harness.
6 Route the oil tank breather hose
over the main switch wire
harness.
7 Install the tail/brake light lead
behind the instrument panel.
8 When fastening the tail/brake
light lead with the attached
clamp, bend the clamp inward to
fasten it.
9 Fasten the oil tank breather hose,
fuel tank breather hose and wire
harness at the inside of the
instrument panel screw with a
plastic band.
; Route the tail/brake light lead
between the fuel tank and the
snowmobile body. Make sure that
the fuel tank does not crush the
tail/brake light lead. Then, fasten
the three pieces of adhesive tape
below the fuel tank as shown.
A Adhesive tapes
B To the tail/brake light
C Pass the wire harness and fuel
tank breather hose through the
cable holder.
D Fuel sender coupler
E Install the metal clip facing
downward.
F Insert the fuel tank breather hose
until it can not be inserted further.
G Oil level switch coupler
H Fuel delivery hoses
I Vacuum hose
J Oil delivery hose
9-28
SPEC
CABLE ROUTING
SPEC
SEA9030
9-29
CABLE ROUTING
K Fuel tank breather hose
L Ground lead
M Install the clamp so that it does
not come into contact with the
ground lead terminal.
N Route the fuel tank breather hose
behind the condenser. (SX600/
MM600)
O Condenser (SX600/MM600)
P Fasten the CDI unit leads with a
plastic band. For the SX600/
MM600, include the condenser
leads.
Q CDI unit
R Pass the CDI unit lead behind the
footrest.
S Condenser coupler (SX600/
MM600)
T Load control relay (with the white
coupler)
U Headlight relay (with the black
coupler)
V Rectifier/regulator
9-30
SPEC
CABLE ROUTING
SPEC
SEA9040
9-31
CABLE ROUTING
1 Speedometer coupler
2 Tachometer coupler
3 Plastic band
4 Clamp
5 Headlight leads
6 Speedometer cable
7 Fasten the wire harness and
speedometer cable at the white
tape mark, with a plastic band.
8 Route the wire harness and
speedometer cable under the
shroud’s stopper wire.
9-32
SPEC
CABLE ROUTING
SPEC
SEA9050
9-33
CABLE ROUTING
1 Oil pump cable
2 Throttle cable
3 Do not fasten the throttle cable
and oil pump cable.
4 Pass only the throttle, and oil
pump cables through the inside
of the cable holder.
5 Thumb warmer coupler
6 Engine stop switch coupler
7 Connectors of the grip warmer
8 Brake light switch coupler
9 Headlight beam switch coupler
0 Fasten the brake light switch
lead, headlight beam switch lead
and grip warmer leads with a
plastic band.
A Parking brake cable
B Oil tank breather hose
C Fasten the oil tank breather hose
with a plastic band.
D Fasten the wire harness, and the
oil tank breather hose behind the
steering column, with a plastic
band. Do not fasten the parking
brake cable and brake hose.
E Fasten the wire harness and fuel
tank breather hose with a plastic
band, and make sure that the
band’s end faces downward.
F Fuse box (VX600ER/VT600)
G Condenser coupler (SX600/
MM600)
H Ground lead
I Fuel sender coupler
J Oil level switch coupler
K Fuel tank breather hose
L Fasten the fuel tank breather
hose, rectifier/regulator leads,
CDI unit harness and ground lead
with a plastic band.
M Fuel hose
N Fasten the fuel hose clip so that it
faces outward.
9-34
SPEC
CABLE ROUTING
SPEC
SEA9050
9-35
CABLE ROUTING
O To the carburetor
P Vacuum hose
Q Oil delivery hose
R To the oil pump
S When fastening the wire harness
with the attaches clamp, bend the
clamp inward to fasten.
T Do not fasten.
U Fasten the wire harness at the
white tape mark, with a clamp.
V Oil hose
W Coolant reservoir hose
X To filler cap body
Y Passenger grip warmer relay
coupler (VX600ER/SX600/
MM600)
Z Passenger grip warmer relay
(VT600)
[ DC back buzzer (VX600ER/
VT600)
\ DC back buzzer coupler
(VX600ER/VT600)
] DC back buzzer coupler (SX600/
MM600)
` Connectors of the gear position
switch (SX600/MM600)
a Pass the brake hose through the
hose guide.
b Fasten the wire harness with a
plastic band. For the SX600/
MM600, include the connectors
of the gear position switch.
c Connectors of the gear position
switch (VX600ER/VT600)
d To the gear position switch
e Ensure this is not kink.
f Fasten the wire harness, fuel
tank breather hose and oil tank
breather hose with a plastic band.
g Install the starter lever to the
position as illustrated.
9-36
SPEC
CABLE ROUTING
SPEC
SEA9060
9-37
CABLE ROUTING
1 Make sure a plastic band is
routed through the projection
located on the silencer, when
fastening it around the wire
harness and the starter cable.
(VX600ER/VT600)
2 Starter cable
3 Make sure the plastic bands are
routed through the projection
located on the silencer, when
fastening them around the wire
harness.
4 Connectors of the carburetor
switch
5 Water temperature sensor
coupler
6 Starter relay lead (VX600ER/
VT600)
7 Ignition coil coupler
8 To filler cap body.
9 Make sure a plastic band is
fastened around the wire harness
to prevent the coolant reservoir
hose from kinking.
0 AC magneto couplers
A Starter relay coupler (SX600/
MM600)
B To the coolant reservoir tank
C Coolant reservoir hose
D Wire harness
E Gear position switch (VX600ER/
VT600)
F Route the parking brake cable
outside the gear position switch
leads.
a 0 ~ 5 mm (0 ~ 0.20 in)
9-38
SPEC
Y
Lg
(BLACK)
L/W
Y
Lg G B
Ç
ı
W
W
W
R
B
W
W W
1
L
G
(10A)
c
L/W
L/W
Y
G
G
B
B
Lg L/W
L/R
G
R
R
L
b
Br
R
W/G
W/R
a
Y
B
A
B
B
G
L/ W Lg
R/Y
g f e
(10A)
B
2
W W W
L
W/G W/R
W W W
G
(20A)
W/R W/G
W
W W
Br/W
HI
LO
G
Y
B
G
B
Y
G
B
Lg
Y
L/W
Br/W
a
L
d
R Br
Y
R
B
F
R
B
R
B
B
B
6
R
Å
G
3
R
R
R
L
B
L/W
B
7
R
R
R
5
4
(30A)
R/W
B
B
F
L
Å
R/W
(BLACK)
B
R
R
B
R
B
Y
L
W
Å
F
START
ON
OFF
8
Y/B B Y/B Y/B
R
B
3
WIRING DIAGRAM
VX600ER/SX600/MM600/VT600
B
Y R/B
L G/R
X
Y
Z
B
R/B Y
G/R L
R/B
G/R
B
R/B
B
G/B
A
G/R
A
A
V
R/B
B
A
B
G/B
B R/W
Br
B/W R/Y
B
L
G/B Y/B
R/W B
Br
R B/W
Br B
L G/B
B/W
\
B
[
]
`
R/W
R/Y
R/W
Br
B
R/B
G/R
U
G/B
Br
Gy
B
R/B
B
(GREEN)
(GREEN)
A
A
Ch
B/Y
Lg
B
B
B
G/Y
B
C
B
B
D
B
B
L/R G/Y
D D
L/R G/Y
L/R G/Y
C C
L/R G/Y
L
G/Y
B
G/Y
L
S
B
Lg
RUN
IDLE
G/Y
L/R
Ch
B
G
W/G
B/Y W/R
L/R
G/Y
B
(BLACK)
L/R B
(BLACK)
B/Y
Y/B
L/W
L/R Y/W W/B
C
L/R G/Y
T
ON
OFF
L/R
B
W
Ch
B/W B/Y
B/W Y Br/W
Lg G/R
B/Y B/W
(WHITE)
Br
B Y/R
G/B
B
B
B
B
Y/R
OPEN
OFF
0
W
G
B
G/B
OFF
RUN
9
B/W
O
Gy
B
D
L/R
L/R
Y/R
Lg
W/G
W/R
Br
B/W
B/Y
B
L/R
P
Br/W Y/B
E
G/R
Br
P
R
P
B
P
Q
L/R
G
Y
Y
O/B
Y/W
L/R
L/R
P
Y/W
W/B
L/W
O
Gy
W
L/R
O/B
Y/R
O/B
Y/L
L
Y/W
B/R
LO
HI
Y/L
G/R
(BLACK)
G/R
B
L
(BLACK)
O
B
R
R
G/R
O/B
O/B
D
O/B
G/R
N
C
O/B
Y/L
M
J
O/B
Y/L
Y/W
W/B
B
L
(BLACK) (BLACK)
G/R
R
L/W
W/B
B
(BLACK) (BLACK)
OFF
Y/W
B/R
F
W/B
B
Y/L
B
G/R
(BLACK) (BLACK)
Y
G
G/R
O/B
Y/L
L/R
W/B
L/W
O E O
Gy E Gy
W E W
K
B
A
H
H
H
L/R O/B
G/Y B
SUB-WIRE
HARNESS 1
O/B L/R
B G/Y
HEADLIGHT
SUB-WIRE
HARNESS
Y G
L Y/B
HEADLIGHT
SUB-WIRE
HARNESS
(BLACK)
B G/B
R/B G/R
B/W
B/W
B/W
TAIL/BRAKE
SUB-WIRE
LIGHT SUB-WIRE
HARNESS 1
HARNESS
O/B L/R
B G/Y
D
WIRE HARNESS
L/R O/B
G/Y B
C
WIRE HARNESS
G Y
Y/B L/W
B
WIRE HARNESS
(BLACK)
G/B B
G/R R/B
B
E
B
B
W
B
Gy
B
O
ı
Å
I
I
I
O
W
Gy
B
B
R R/W
Gy
B
O
W
(BLACK)
R/Y
L/W L/R
SUB-WIRE
HARNESS 3
(BLACK)
B
R/W R
SUB-WIRE
HARNESS 2
(BLACK)
WIRE HARNESS WIRE HARNESS
(BLACK)
R
L L
G
WIRE HARNESS
(BLACK)
F
WIRE HARNESS
(BLACK)
E
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
_
a
b
c
d
e
f
g
∗1
∗2
∗3
AC magneto
Rectifier/regulator
Condenser∗1
Main fuse∗2
Starter relay∗2
Battary∗2
Starter motor∗2
Main switch
Engine stop switch
Throttle switch
Grip warmer
Thumb warmer
Carburetor switch
Water temperature sensor
CDI unit
Variable resistor
(thumb warmer)
Variable resistor (grip warmer)
Ignition coil
Spark plug
Engine ground
Frame ground
Passenger grip warmer switch∗3
Resistor∗3
Passenger grip warmer (left)∗3
Passenger grip warmer (right)∗3
Passenger grip warmer relay∗3
DC back buzzer∗2
Gear position switch∗2
Brake light switch
Tail/brake light
Fuel sender
Oil level switch
Speedometer
Oil level indicator light
Water temperature indicator light
High beam indicator light
Speedometer light
Tachometer light
Tachometer
Fuel meter
Headlight
Headlight beam switch
Headlight relay
(with the black coupler)
Load control relay
(with the white coupler)
“IGNITION” fuse∗2
“TAIL” fuse∗2
“HEAD” fuse∗2
SX600/MM600
VX600ER/VT600
VT600
Å SX600/MM600
ı SX600/MM600
Ç VX600ER/VT600
COLOR CODE
B .....................
Br ...................
Ch ..................
G ....................
Gy ..................
L .....................
Lg ...................
O ....................
P .....................
R ....................
W ....................
Y .....................
B/R .................
B/W ................
B/Y .................
Br/W ...............
G/B .................
G/R .................
G/Y .................
L/R .................
L/W .................
O/B .................
R/B .................
R/W ................
R/Y .................
W/B ................
W/G ................
W/R ................
Y/B .................
Y/L ..................
Y/R .................
Y/W ................
Black
Brown
Chocolate
Green
Gray
Blue
Light green
Orange
Pink
Red
White
Yellow
Black/Red
Black/White
Black/Yellow
Brown/White
Green/Black
Green/Red
Green/Yellow
Blue/Red
Blue/White
Orange/Black
Red/Black
Red/White
Red/Yellow
White/Black
White/Green
White/Red
Yellow/Black
Yellow/Blue
Yellow/Red
Yellow/White
PRINTED ON RECYCLED PAPER
Printed in USA (E) CR