2002 Yamaha Mountain Max 700 Snowmobile Service Repair Manual

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GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE COOLING SYSTEM CARBURETION ELECTRICAL SPECIFICATIONS INDEX GEN INFO CHAS ENG POWR TR CARB ELEC SPEC COOL 1 INSP ADJ 2 3 4 5 6 7 8 9 – + CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ............................ 1-1 FRAME SERIAL NUMBER......................... 1-1 ENGINE SERIAL NUMBER ....................... 1-1 IMPORTANT INFORMATION .......................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY .......................................... 1-2 ALL REPLACEMENT PARTS .................... 1-2 GASKETS, OIL SEALS, AND O-RINGS .... 1-3 LOCK WASHERS/PLATES AND COTTER PINS ........................................................... 1-3 BEARINGS AND OIL SEALS ..................... 1-3 CIRCLIPS ................................................... 1-3 LOCTITE® ................................................... 1-3 SPECIAL TOOLS ............................................. 1-4 FOR TUNE UP ........................................... 1-4 FOR ENGINE SERVICE ............................ 1-5 FOR POWER TRAIN SERVICE ................. 1-5 FOR CARBURETION SERVICE ................ 1-6 FOR ELECTRICAL SERVICE .................... 1-6 CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ............................................... 2-1 PERIODIC MAINTENANCE TABLE ................ 2-1 ENGINE ............................................................ 2-3 SPARK PLUGS .......................................... 2-3 OIL PUMP .................................................. 2-4 FUEL LINE INSPECTION .......................... 2-6 COOLING SYSTEM ................................... 2-6 CARBURETOR SYNCHRONIZATION ..... 2-12 ENGINE IDLE SPEED ADJUSTMENT .... 2-13 THROTTLE CABLE FREE PLAY ADJUSTMENT ......................................... 2-13 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK .................................... 2-14 STARTER (CHOKE) CABLE FREE PLAY ADJUSTMENT ......................................... 2-15 EXHAUST SYSTEM INSPECTION .......... 2-15 POWER TRAIN ............................................... 2-16 SHEAVE DISTANCE AND OFFSET ADJUSTMENT ......................................... 2-16 DRIVE V-BELT ......................................... 2-18 ENGAGEMENT SPEED CHECK ............. 2-20 PARKING BRAKE PAD INSPECTION ..... 2-20 PARKING BRAKE ADJUSTMENT ........... 2-20 BRAKE LEVER ADJUSTMENT (VX700DX/SX700/VT700) ........................ 2-21 BRAKE FLUID LEVEL INSPECTION ....... 2-21 BRAKE PAD INSPECTION ...................... 2-22 BRAKE HOSE INSPECTION ................... 2-22 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ............. 2-22 DRIVE CHAIN .......................................... 2-23 TRACK TENSION ADJUSTMENT ........... 2-26 SLIDE RUNNER INSPECTION ................ 2-28 MAXIMIZING DRIVE TRACK LIFE .......... 2-29 CHASSIS ........................................................ 2-30 SKI/SKI RUNNER ..................................... 2-30 STEERING SYSTEM ............................... 2-31 LUBRICATION ......................................... 2-32 ELECTRICAL ................................................. 2-34 HEADLIGHT BEAM ADJUSTMENT ......... 2-34 BATTERY INSPECTION (VX700DX/VT700) .................................... 2-35 BATTERY CHARGING (VX700DX/VT700) .................................... 2-37 FUSE INSPECTION (VX700DX/VT700) .. 2-38 TUNING .......................................................... 2-40 CARBURETOR TUNING .......................... 2-40 CLUTCH ................................................... 2-47 GEAR SELECTION .................................. 2-52 HIGH ALTITUDE TUNING ....................... 2-58 FRONT SUSPENSION ............................. 2-59 REAR SUSPENSION ............................... 2-60 CHAPTER 3. CHASSIS STEERING ........................................................ 3-1 VX700/VX700DX/SX700/VT700 ................. 3-1 MM700 ........................................................ 3-2 INSPECTION .............................................. 3-4 INSTALLATION .......................................... 3-5 SKI .................................................................... 3-8 VX700/VX700DX/VT700 ............................ 3-8 SX700/MM700 ............................................ 3-9 INSPECTION ............................................ 3-10 INSTALLATION (VX700/VX700DX/VT700) ........................ 3-10 FRONT SUSPENSION ................................... 3-11 HANDLING NOTES (SX700) ................... 3-12 INSPECTION ............................................ 3-12 INSTALLATION ........................................ 3-14 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 ................................. 4-11 DISASSEMBLY ........................................ 4-13 INSPECTION ............................................ 4-13 ASSEMBLY .............................................. 4-14 INSTALLATION ........................................ 4-16 DRIVE CHAIN HOUSING ............................... 4-17 WITHOUT REVERSE MODEL ................. 4-17 INSPECTION ............................................ 4-18 INSTALLATION ........................................ 4-20 WITH REVERSE MODEL ........................ 4-21 INSPECTION ............................................ 4-23 INSTALLATION ........................................ 4-24 JACKSHAFT .................................................. 4-26 INSPECTION ............................................ 4-27 JACKSHAFT AND DRIVE CHAIN HOUSING INSTALLATION ...................... 4-28 BRAKE ........................................................... 4-29 BRAKE PAD REPLACEMENT ................. 4-30 BRAKE CALIPER DISASSEMBLY ........... 4-34 BRAKE CALIPER INSPECTION AND REPAIR .................................................... 4-34 BRAKE CALIPER ASSEMBLY ................. 4-35 BRAKE CALIPER INSTALLATION .......... 4-35 INSPECTION ............................................ 4-37 BRAKE MASTER CYLINDER ASSEMBLY .............................................. 4-37 INSTALLATION ........................................ 4-37 SLIDE RAIL SUSPENSION ............................ 4-38 VX700/VX700DX/SX700 .......................... 4-38 VT700 ....................................................... 4-39 MM700 ...................................................... 4-44 INSPECTION ............................................ 4-49 ASSEMBLY .............................................. 4-50 INSTALLATION ........................................ 4-50 FRONT AXLE AND TRACK ........................... 4-52 INSPECTION ............................................ 4-53 INSTALLATION ........................................ 4-53 CHAPTER 5. ENGINE EXHAUST ASSEMBLY .................................... 5-1 INSTALLATION .......................................... 5-2 ENGINE ASSEMBLY ....................................... 5-3 INSPECTION .............................................. 5-4 INSTALLATION .......................................... 5-4 CYLINDER HEAD AND CYLINDER ................ 5-6 REMOVAL .................................................. 5-8 INSPECTION .............................................. 5-9 INSTALLATION ........................................ 5-14 OIL PUMP, CRANKCASE AND CRANKSHAFT ............................................... 5-17 INSPECTION ............................................ 5-18 INSTALLATION ........................................ 5-20 AC MAGNETO ................................................ 5-23 REMOVAL ................................................ 5-24 INSTALLATION ........................................ 5-25 RECOIL STARTER ......................................... 5-27 REMOVAL ................................................ 5-28 INSPECTION ............................................ 5-28 INSTALLATION ........................................ 5-29 CHAPTER 6. COOLING SYSTEM HEAT EXCHANGER ........................................ 6-1 VX700/VX700DX/SX700/VT700 ................. 6-1 MM700 ........................................................ 6-2 INSPECTION .............................................. 6-3 INSTALLATION .......................................... 6-4 WATER PUMP .................................................. 6-5 REMOVAL .................................................. 6-6 INSPECTION .............................................. 6-6 INSTALLATION .......................................... 6-6 CHAPTER 7. CARBURETION CARBURETORS .............................................. 7-1 INSPECTION .............................................. 7-5 ASSEMBLY ................................................ 7-6 FUEL LEVEL ADJUSTMENT ..................... 7-8 INSTALLATION .......................................... 7-9 FUEL PUMP ................................................... 7-10 VX700/VX700DX/VT700 .......................... 7-10 SX700/MM700 .......................................... 7-11 INSPECTION ............................................ 7-12 INSTALLATION ........................................ 7-12 CHAPTER 8. ELECTRICAL SWITCH INSPECTION ..................................... 8-1 SWITCH INSPECTION .............................. 8-1 INSPECTING A SWITCH SHOWN IN THE MANUAL ..................................................... 8-1 IGNITION SYSTEM .......................................... 8-2 CIRCUIT DIAGRAM ................................... 8-2 TROUBLESHOOTING ............................... 8-4 CONDENSER (VX700/SX700/MM700) ...... 8-6 AC MAGNETO ........................................... 8-6 SPARK PLUG............................................. 8-7 SPARK PLUG CAP .................................... 8-7 IGNITION COIL .......................................... 8-7 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) ................................................... 8-8 HANDLEBAR SWITCH (RIGHT) ................ 8-8 CARBURETOR SWITCH ........................... 8-9 MAIN SWITCH ........................................... 8-9 LOAD CONTROL RELAY ........................ 8-10 EMERGENCY ENGINE STARTING (VX700/SX700/MM700) ............................ 8-10 ELECTRICAL STARTING SYSTEM (VX700DX/VT700) .......................................... 8-11 CIRCUIT DIAGRAM ................................. 8-11 TROUBLESHOOTING ............................. 8-12 MAIN SWITCH ......................................... 8-13 STARTER MOTOR .................................. 8-14 CHARGING SYSTEM (VX700DX/VT700) ...... 8-17 CIRCUIT DIAGRAM ................................. 8-17 TROUBLESHOOTING ............................. 8-18 BATTERY ................................................. 8-19 STATOR COIL .......................................... 8-19 LIGHTING SYSTEM ....................................... 8-20 CIRCUIT DIAGRAM ................................. 8-20 TROUBLESHOOTING ............................. 8-22 BULB(S) ................................................... 8-24 HEADLIGHT BEAM SWITCH ................... 8-24 HEADLIGHT RELAY ................................ 8-25 SIGNAL SYSTEM ........................................... 8-26 CIRCUIT DIAGRAM ................................. 8-26 TROUBLESHOOTING ............................. 8-28 BRAKE LIGHT SWITCH ........................... 8-32 GEAR POSITION SWITCH (VX700DX/VT700) .................................... 8-32 DC BACK BUZZER (VX700DX/VT700) ... 8-32 WATER TEMPERATURE SENSOR ........ 8-33 OIL LEVEL SWITCH ................................ 8-34 FUEL SENDER ........................................ 8-34 GRIP WARMER SYSTEM .............................. 8-36 CIRCUIT DIAGRAM ................................. 8-36 TROUBLESHOOTING ............................. 8-38 GRIP AND THUMB WARMER COIL ........ 8-40 VARIABLE RESISTOR (THUMB WARMER) ................................. 8-40 VARIABLE RESISTOR (GRIP WARMER) ..................................... 8-41 PASSENGER GRIP WARMER (VT700) .. 8-41 PASSENGER GRIP WARMER SWITCH (VT700) .................................... 8-42 RESISTOR (VT700) ................................. 8-42 PASSENGER GRIP WARMER RELAY (VT700) ..................................................... 8-43 FAULT LOCATION TABLE ............................ 8-44 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 ........................... 9-17 GENERAL TORQUE SPECIFICATIONS ....... 9-21 DEFINITION OF UNITS .................................. 9-21 CABLE ROUTING .......................................... 9-23 1-1 GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is located on the right-hand side of the frame (just 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: Designs and specifications are subject to change without notice. SCH1010 SCH1020 1-2 GEN INFO IMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. While cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc., from high pressure water splashes. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling the machine, keep mated parts together. This includes gears, cylinders, pistons, and other parts that have been “mated” through normal wear. Mated parts must be reused or replaced as an assembly. 4. During disassembly of the machine, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help ensure that all parts are reinstalled correctly. 5. Keep all parts away from any source of fire. 6. Be sure to keep to the tightening torque specifications. When tightening bolts, nuts, and screws, start with those that have larger diameters, and proceed from the inside to the outside in a crisscross pattern. ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments. SCH1030 SCH1040 SCH1050 SCH1060 SCH1070 SCH1080 1-3 GEN INFO IMPORTANT INFORMATION GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS All lock washers/plates 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. BEARINGS AND OIL SEALS 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. CIRCLIPS All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing a circlip 1, make sure that the sharp edged corner 2 is positioned opposite to the thrust 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. SCH1090 SCH1100 SCH1110 SCH1120 1-4 GEN INFO SPECIAL TOOLS SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. NOTE: Be sure to use the correct part number when ordering the tool, since the part number may differ according to country. FOR TUNE UP • Sheave gauge P/N: YS-42421-1 (15 mm offset) 1 YS-42421-2 (20 mm offset) 2 This gauge is used to measure the sheave distance and for offset adjust- ment. • Dial gauge P/N: YU-03097 (for U.S.A./Canada) 90890-03097 (for Europe) This gauge is used for run out measurement. • Fuel level gauge P/N: YM-01312-A (for U.S.A./Canada) 90890-01312 (for Europe) This gauge is used to measure the fuel level in the float chamber. • Distance gauge P/N: YS-91047-3 (for U.S.A./Canada) 90890-01702 (for Europe) This gauge is used to measure the distance between the center of the primary sheave and the center of the secondary sheave. SCH1130 SCH1160 SCH1150 SCH1140 1-5 GEN INFO FOR ENGINE SERVICE • Piston pin puller P/N: YU-01304 (for U.S.A./Canada) 90890-01304 (for Europe) This tool is used to remove the piston pin. • Rotor holding puller P/N: YU-33270 (for U.S.A./Canada) 90890-01362 (for Europe) This tool is used to remove the magneto rotor. • Cooling system tester P/N: YU-24460-01 (for U.S.A./Canada) 90890-01325 (for Europe) This tester is used for checking the cooling system. FOR POWER TRAIN SERVICE • Primary sheave holder P/N: YS-01880 (for U.S.A./Canada) 90890-01701 (for Europe) This tool is used to hold the primary sheave. • Primary sheave puller (18 mm) P/N: YS-01881-11, YS-01882-12 This tool is used for removing the primary sheave. • Clutch spider separator P/N: YS-28890-B (for U.S.A./Canada) 90890-01711 (for Europe) This tool is used when disassembling and assembling the primary sheave. • Clutch separator adapter P/N: YS-34480 (for U.S.A./Canada) 90890-01740 (for Europe) This tool is used when disassembling and assembling the primary sheave. • YXR clutch bushing jig kit P/N: YS-39752 This tool is used for removal and installation of primary clutch weight and roller bushings. SPECIAL TOOLS SCH1170 SCH1180 SCH1190 SCH1200 SCH1210 SCH1220 SCH1230 SCH1240 1-6 GEN INFO SPECIAL TOOLS • Clutch bushing press P/N: YS-42424 This tool is used for removing and installing the post bushings (primary sheave cap bush, sliding sheave bush and torque cam bush). • Track clip installer P/N: YS-91045-A (for U.S.A./Canada) 90890-01721 (for Europe) This tool is used for installing the track clip. • Angle finder P/N: YS-42422 This tool is used for checking and adjusting the ski spindle camber. FOR CARBURETION SERVICE • Mity vac P/N: YB-35956 (for U.S.A./Canada) 90890-06756 (for Europe) This tool is used to check the fuel pump. FOR ELECTRICAL SERVICE • Pocket tester P/N: YU-03112 (for U.S.A./Canada) 90890-03112 (for Europe) This instrument is necessary for checking the electrical components. • Electro tester P/N: YU-33260-A (for U.S.A./Canada) 90890-03021 (for Europe) This instrument is invaluable for checking the electrical system. SCH1250 SCH1260 SCH1270 SCH1280 SCH1290 SCH1300 2-1 INSP ADJ INTRODUCTION/PERIODIC MAINTENANCE TABLE PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE TABLE Item Remarks Spark plugs Engine oil Fuel Fuel filter Fuel line Oil line Engine coolant Carburetors Recoil starter Engine stop switch Throttle override system (T.O.R.S.) Throttle lever Exhaust system Decarbonization Drive guard V-belt Drive track and idler wheels Slide runners Pre- operation check (Daily) Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 3,200 km (2,000 mi) (160 hr) Check condition. Adjust gap and clean. Replace if necessary. Check oil level. Air bleed the oil pump if necessary. Check fuel level. Check condition. Replace if necessary. Check fuel hose for cracks or damage. Replace if necessary. Check oil hose for cracks or damage. Replace if necessary. Check coolant level. Air bleed the cooling system if necessary. Check throttle lever operation. Adjust the jets. Check operation and rope damage. Replace if necessary. Check operation Repair if necessary. Check operation. Repair if necessary. Check operation. Repair if necessary. Check for leakage. Retighten or replace gasket if necessary. More frequently if necessary. Check for cracks, bends or damage. Replace if necessary. Check for wear and damage. Replace if necessary. Check deflection, and for wear and damage. Adjust/replace if necessary. Check for wear and damage. Replace if necessary. Whenever operating condition (elevation/temperature) is changed. 2-2 INSP ADJ PERIODIC MAINTENANCE TABLE Check operation and fluid leakage. Adjust free play and/or replace pads if necessary. Replace brake fluid. Check oil level. Replace. Check deflection. Adjust if necessary. Check for wear and damage. Replace if necessary. Check operation. Adjust toe-out if necessary. Check for damage. Replace if necessary. Check operation. Replace bulbs if necessary. Check fluid level. Add only distilled water if necessary. Check specific gravity and breather hose operation. Charge/correct if necessary. Whenever operating elevation is changed. Initial at 500 km (300 mi) and every 800 km (500 mi) thereafter. See NOTE. Brake and parking brake Drive chain oil Drive chain Skis and ski runners Steering system Strap (MM700) Lights Battery (VX700DX/VT700) NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required. 2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3. Replace the brake hoses every four years, or if cracked or damaged. Item Remarks Pre- operation check (Daily) Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 3,200 km (2,000 mi) (160 hr) Lubricate with specified grease. Lubricate with specified grease. Lubricate with specified grease. Lubricate with specified grease. Check cable damage. Replace if necessary. Make sure that the shroud latches are hooked. Check tightness. Repair if necessary. Check proper placement. Primary and secondary clutches Check engagement and shift speed. Adjust if necessary. Inspect sheaves for wear/damege. Inspect weights/rollers and bushings for wear- for primary. Inspect ramp shoes/bushings for wear-for sec- ondary. Replace if necessary. Lubricate with specified grease. Steering column bearing Ski and front suspension Suspension component Parking brake cable end and lever end/throttle cable end Shroud latches Fittings and fasteners Tool kit and recommended equipment 2-3 INSP ADJ SPARK PLUGS ENGINE SPARK PLUGS 1. Remove: • Spark plug caps • Spark plugs 2. Inspect: • Electrodes 1 Damage/wear → Replace the spark plug. • Insulator color 2 3. Measure: • Spark plug gap a Out of specification → Regap. Use a wire thickness gauge. Spark plug gap a: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) If necessary, clean the spark plugs with a spark plug cleaner. Standard spark plug: BR9ES (NGK) Before installing a spark plug, clean the gasket sur- face and spark plug surface. 4. Install: • Spark plugs Spark plug: 20 Nm (2.0 m · kg, 14 ft · lb) NOTE: Finger-tighten a the spark plug before torquing b it to specification. T R..SCH2010 SCH2020 SCH2030 2-4 INSP ADJ 1 1 1 OIL PUMP OIL PUMP Air bleeding CAUTION: The oil pump and oil delivery line must be bled in the following cases: • Any portion of the oil system has been disconnected. • The machine has been turned on its side. • The oil tank has been run empty. • As part of the pre-delivery service. 1. Fill: • Oil tank 1 Recommended oil: YAMALUBE 2-cycle oil Oil tank capacity: 3.0 L (2.6 Imp qt, 3.2 US qt) 2. Remove: • Carburetors Refer to “CARBURETORS” in CHAPTER 7. 3. Remove: • Rear bracket (right) 1 4. Place a 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 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. SCH2050 SCH2060 SCH2040 2-5 INSP ADJ OIL PUMP 14. Install: • Gasket (bleed bolt) • Bleed bolt 15. Install: • Rear bracket (right) M8 mounting bolt (rear): 33 Nm (3.3 m · kg, 24 ft · lb) M10 mounting bolt (rear): 57 Nm (5.7 m · kg, 41 ft · lb) 16. Install: • Carburetors Refer to “CARBURETORS” in CHAPTER 7. Cable adjustment NOTE: 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 a: 22 ± 1 mm (0.866 ± 0.039 in) Turning in → Distance a is increased. Turning out → Distance a is decreased. • Tighten the locknut and push in the adjuster cover. SCH2070 SCH2080 T R.. 2-6 INSP ADJ 2 2 1 FUEL LINE INSPECTION/COOLING SYSTEM FUEL LINE INSPECTION 1. Remove: • Intake silencer Refer to “FUEL PUMP” in CHAPTER 7. 2. Inspect: • Fuel hose 1 • Fuel delivery hoses 2 Cracks/damage → Replace. 3. Install: • Intake silencer Refer to “FUEL PUMP” in CHAPTER 7. COOLING SYSTEM Coolant replacement NOTE: The coolant should be changed at least every sea- son. 1. Place the machine on a level surface. 2. Remove: • Exhaust pipe • Exhaust joint Refer to “EXHAUST ASSEMBLY” in CHAP- TER 5. 3. Make sure that the carburetor heating lever 1 is turned to “ON” a. SCH2090 SCH2100 SCH2110 2-7 INSP ADJ 1 1 4. Remove: • Coolant filler cap 1 WARNING Do not remove the coolant filler cap 1 when the engine is hot. Pressurized scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, place a thick rag or a towel over the coolant filler cap. Slowly turn the cap counterclockwise until it stop. This allows any residual pressure to es- cape. When the hissing sound has stopped, press down on the cap while turning it counterclock- wise to remove it. 5. Place an open container under the coolant drain bolt 1. 6. Remove: • Coolant drain bolt • Gasket (coolant drain bolt) 7. Drain the coolant. NOTE: Lift up the tail of the machine to drain the coolant. 8. Remove: • Right side cover 1 (MM700) COOLING SYSTEM SCH2120 SCH2130 SCH2140 2-8 INSP ADJ 1 1 1 1 9. Disconnect: • Coolant hoses 1 Å VX700/VX700DX/SX700/VT700 ı MM700 10. Drain the coolant. NOTE: Lift up the front of the machine to drain the coolant completely. WARNING Coolant is poisonous. It is harmful or fatal if swallowed. • If coolant is swallowed, induce vomiting imme- diately 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. 11. Connect: • Coolant hoses 12. Install: • Right side cover 1 (MM700) Bolt (side cover): 3 Nm (0.3 m · kg, 2.2 ft · lb) 13. Disconnect: • Coolant reservoir hose 1 14. Remove: • Coolant reservoir cap 1 15. Drain the coolant from the coolant reservoir. 16. Install: • Coolant reservoir cap 17. Connect: • Coolant reservoir hose COOLING SYSTEM T R..SCH2140 SCH2160 SCH2150 A B SCH2180 SCH2190 2-9 INSP ADJ COOLING SYSTEM T R..SCH2130 T R..18. Inspect: • Gasket (coolant drain bolt) Damage → Replace. 19. Install: • Gasket • Coolant drain bolt 1 Coolant drain bolt 1: 13 Nm (1.3 m · kg, 9.4 ft · lb) 20. Install: • Exhaust joint • Exhaust pipe Refer to “EXHAUST ASSEMBLY” in CHAP- TER 5. Bolt (exhaust joint) 1: 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: VX700/VX700DX/SX700: 3.8 L (3.34 lmp qt, 4.02 US qt) MM700: 3.9 L (3.43 lmp qt, 4.12 US qt) VT700: 4.0 L (3.52 lmp qt, 4.23 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 parts. If soft water is not available, use boiled or distilled water. • Do not use water containing impurities or oil. SCH2210 2-10 INSP ADJ 1 1 1 2 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 • Apply 100 kPa (1.0 kg/cm2, 14 psi). • Measure the pressure with the gauge. Air bleeding 1. Remove: • Seat (VX700/VX700DX/SX700/VT700) • Rear bumper cover 1 (VT700) • Bleed bolt cap 1 (MM700) Å VT700 ı MM700 2 .Bleed air from the cooling system. COOLING SYSTEM SCH2220 SCH2225 SCH2230 A B 2-11 INSP ADJ 1 COOLING SYSTEM Air bleeding steps: • Lift up the tail of the machine. • Remove the bleed bolt 1 on the heat exchanger. • While slowly adding coolant to the coolant filler, drain the coolant until no more air bubbles ap- pear. • Tighten the bleed bolt 1. Bleed bolt 1: VX700/VX700DX/SX700/VT700: 13 Nm (1.3 m · kg, 9.4 ft · lb) MM700: 4 Nm (0.4 m · kg, 2.9 ft · lb) Å VX700/VX700DX/SX700/VT700 ı MM700 • 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 ap- pear. • Tighten the bleed bolt 2. Bleed bolt 2: 7 Nm (0.7 m · kg, 5.1 ft · lb) • 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 sup- ported 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 for- ward if the clutch engages. • Operate the engine only in a well-ventilated area. T R..SCH2260 SCH2240 SCH2250 A B T R.. 2-12 INSP ADJ 3 • Remove the coolant filler cap and bleed the cooling system again, as described above. No air bubbles → OK. • Add coolant to the specified level. • Pour coolant into the coolant reservoir 3 until the coolant level reaches the “FULL” level mark. 3. Install: • Bleed bolt cap (MM700) • Seat (VX700/VX700DX/SX700/VT700) 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 ob- tained. Throttle valve height a: 1.2 mm (0.047 in) • Adjust the throttle valve height a on carburetor #1 2 and #3 3 with the adjusting screws 4. • 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. COOLING SYSTEM/ CARBURETOR SYNCHRONIZATION SCH2280 SCH2290 SCH2270 2-13 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. 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 a: 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) SCH2310 SCH2300 ENGINE IDLE SPEED ADJUSTMENT/ THROTTLE CABLE FREE PLAY ADJUSTMENT 2-14 INSP ADJ 1 2 3 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. 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 engage- ment 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 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 elec- trical system. SCH2330 SCH2320 THROTTLE CABLE FREE PLAY ADJUSTMENT/ THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK Thank you very much for your reading. Please Click Here Then Get More Information.

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