- Yamaha Snowmobile Service Manual Mountain Max 500 Escritorio
- Yamaha Snowmobile Service Manual Mountain Max 500 Efi
- Yamaha Snowmobile Service Manual Mountain Max 500 Tablet
1984-1987 YAMAHA VMAX-450 SNOWMOBILE MODELS COVERED: 1984-1987 V-max vmx540 vmx540h vmx540j vmx540k vmx540l 1984-1999 YAMAHA PHAZER SNOWMOBILE MODELS COVERED: 1984-1999 Phazer 2 Phaser Fazer Faser 480 485 PZ480. 1987-1990 YAMAHA EXCITER 570 SNOWMOBILE MODELS COVERED: 1987-1990 exiter deluxe ex570 ex570l ex570m ex570em ex570n ex570en ex570p ex570hp ex570ep ex570ehp 570, EX, I, M, N, P, RP, EHP. 1988-1989 YAMAHA ENTICER SNOWMOBILE MODELS COVERED: 1988-1989 Enticer long track reverse deluxe et400trn (ET-400-TRN, 400TRN) et340trm (ET-340TRM) et400 (ET-400) et340 (ET-340). 1990-1998 YAMAHA PHAZER - PHAZER II (2) SNOWMOBILE MODELS COVERED: 1990-1998 Phazer 2 Phaser Fazer Faser 480 485 (PZ, P, EP, R, ER, STR, T, ET, STT, W, EW, STW) pz480p pz480ep pz480r pz480er pz480str pz480t pz480et pz480stt pz480w pz480ew pz480stw. 1991-1997 YAMAHA VENTURE 485 SNOWMOBILE MODELS COVERED: 1991-1997 Yamaha Venture 485 XL, GT and TF versions vt480 vt480gt vt480tf. 1994-2006 YAMAHA VMAX VENTURE VENOM SNOWMOBILE MODELS COVERED: 1994-1996: VMAX 500/600, 1997-1999: Mountain Max 600/700, Venture 500/600, VMAX 500/600/700, 2000-2003: Venture 600, VMAX 600, 2004-2006: SX Venom 600, Venture 600 v-max v max DX ER LE ST SX XL XT XTC. 1994-1997 YAMAHA V-MAX-4 750-800 SNOWMOBILE MODELS COVERED: 1994-1997 Yamaha VMAX-4 and Mountain Max four cylinder snowmobiles, 1994 VMAX-4 750, 1994 VMAX-4 750 ST (Long Track), 1995-1997 VMAX-4 800, 1995-1996 VMAX-4 800 ST (Long Track), 1997 Mountain Max 800, v-max vmax vx750 vx750st vx800 vx800st mm800.
1997-2002 YAMAHA 600-700 SNOWMOBILE MODELS COVERED: 1997-2002 Mountain Max 600 (MM600), Mountain Max 700 (MM700), SX600R (SX600), SX700R (SX700), Venture 600 (VT600), Venture 700 (VT700), Vmax 600 ER (VX600ER), Vmax 600 SX (VX600SX), Vmax 700 SX (VX700SX), Vmax 700 SXS (VX700SXS), V-max 700 XT (VX700-XT), V-max 700 XTC (VX700XTC), V-max 700 XTCD (VX700XTD), V-max 700 XTCP (VX-700-XTP). 1999-2001 YAMAHA PHAZER 500-VENTURE 500 SNOWMOBILES COVERED: 1999-2001 Yamaha Phazer 500, Phazer 500 Mountain Lite, Phazer 500 Deluxe and Venture 500 two-stroke snowmobiles, mountain light dlx electric start pz500 pz500dx vt500xl.
2003-2006 YAMAHA RX-1 SNOWMOBILE MODELS COVERED: 2003, 2004, 2005, 2006 RX1, RX10, RX10GTL (RX-10-GTL), RX10ML, RX10RL, RX10RTL, RX10RTRL, RXW10L, TL, GTL, ML, RL, RTL, RTRL, RXW-10-L, RX1, RX10H, RH10SH, RX10MH, RX10MSH, RX10RH, RX10RSH, H, SH, MH, MSH, RH, RSH, S, M, MS, R, RS, RXW10J (RXW-10-J), RXW10SJ (RXW-10-SJ), S, RX10, RX10K, R, RK, RS, RSK, RXW10K, S, SK, RX10MK, M, MK, MS, MSK, RX10RTL (RX-10-RTL), RL, RTRL, GTL, ML, RXW10L, R, RTR, GTL, M. 2006-2008 YAMAHA APEX-ATTAK SNOWMOBILE MODELS COVERED: 2006, 2007 & 2008 ER GT SE mountain ltx mtx rtx rxt attack rx10 rx10s rx10r rx10rs rx10m rx10ms rx10rl rx10gtl rx10ml rx10rtl rx10rtrl rxw10l rx10rw rx10gtw rx10mw rx10msw rx10rtrw rxw10w rxw10gtw rx10gtax rx10lgtx rx10ltx rx10ltgtax rx10mtx rx10mtax rx10rtrx.
2007-2008 YAMAHA PHAZER-VENTURE LITE SNOWMOBILE MODELS COVERED: 2007-2008 Yamaha Phazer and Venture Lite 500cc 4-stroke snowmobiles, venture light PZ50 (PZ-50) PZ50FX PZ50RT PZ50GT PZ50MW PZ50MT mountain lite PZ50VT PZ50MP 2008 YAMAHA NYTRO 1000 SNOWMOBILE MODELS COVERED: 2008 Yamaha FX Nytro FX10 (FX10X, FX-10-X), 2008 FX10RTX (FX10-RTX), 2008 FX10RTRX (FX10-RTRX), 2008 FX10RTRAX (FX10-RTRAX), 2008 FX10MTX (FX-10-MTX), 2008 FX10MTRX (FX10-MTRX) and 2008 FX10MTRAX (FX-10-MTRAX) snowmobile. COMMON YAMAHA SNOWMOBILE SEARCHES: 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. All service technicians or do-it-yourself mechanics should be familiar with this entire chapter. PERIODIC MAINTENANCE TABLE Check condition of spark plugs and adjust gap and clean if necessary. Valves Check valve clearance and adjust clearance when engine is cold.
Engine oil - Check oil level. Engine oil filter cartridge Replace. Fuel Check fuel level. Fuel filter Check condition and replace if necessary. Fuel line Check fuel hose for cracks or damage and replace any fuel hoses if necessary. Engine coolant and check coolant level.
Air bleed the cooling system if necessary and check the throttle lever operation. Carburetor - Adjust the jets whenever operating condition (elevation/temperature) is changed. Engine stop switch - Check operation and 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 and tighten or replace gasket if necessary. Drive guard - Check for cracks, bends or damage and replace if necessary. V-belt - Check for wear and damage and replace if necessary. Drive track and idler wheels - Check deflection, and for wear and damage and adjust/ replace if necessary. Slide runners - Check for wear and damage and replace if necessary. Brake and parking brake Adjust free play and/or replace pads if necessary. Repair brake fluid.
Disc brake installation Check for slight free play. Lubricate shaft with specified grease as required. Drive chain oil Check oil level. Drive chain Check deflection and adjust if necessary. Skis and ski runners - Check for wear and damage abd repair if necessary. Steering system Check operation and adjust toe-out if necessary.
Lights Check operation and replace bulbs if necessary. Check engagement and shift speed. Adjust if necessary. Whenever operating elevation is changed. Primary and secondary clutches Inspect sheaves for wear/damage.
Inspect weights/ rollers and bushings for wear-for primary. Inspect ramp shoes/ bushings for wear-for secondary and replace if necessary. 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 Lubricate with specified grease. Check cable for damage and replace if necessary. Shroud latches - Make sure that the shroud latches and hooked. Fittings and fasteners Check tightness and replace if necessary. Tool kit and recommended equipment - Check for proper placement. WIRING DIAGRAMS.
A.C. Magneto. Rectifier/regulator. Main switch. Load relay. Fuse (MAIN).
Fuse (FUEL INJECTION SYSTEM). Starter relay.
Starter motor. Battery.
Diode. Engine stop switch. Throttle switch. Grip warmer. Thumb warmer. Oil presser switch.
Fuse (ELECTRONIC CONTROL SUSPENSION). Electronic control suspension solenoid. E.C.U.
Covers: 1994 1995 1996 Yamaha VMAX 500/600 Snowmobiles (all models including DX, LE, ST) Pages: 355 Format: PDF file Compatibility: Windows/Mac/Tablet File details: Bookmarked: Yes, Searchable: Yes, Printable: Yes File size: 47mb This PDF service manual contains all the necessary instructions needed for any repair your 1994-1996 Yamaha VMAX 500 600 Snowmobile may require. This is the same manual technicians use to diagnose and repair your snowmobile. Whether its routine maintenance, such as tune-ups and brake service, or more extensive repairs involving engine and track disassembly, this manual provides the most reliable information to perform the job. Sample topics in this manual:. General Information. Specifications. Maintenance.
Adjustments and Tune-Up. Covers. Steering. Ski. Suspension.
Drive. Chains. Brakes.
Axles. Tracks.
Engine Repair. Engine Disassembly/Assembly. Radiator. Thermostat. Water Pump. Fuel System.
Air Intake. Throttle. Electrical System. Switches. Wiring Diagram.
Specifications. Torques. And much more Example manual details (actual manual may vary): How does this work? It’s simple – after purchasing this manual through our secure checkout, a download link will be sent to the email address you specify. You have up to 30 days to retrieve and save the file.
After that it is yours for good. Have any questions or need more details?
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1994 RM250 and RM125, packed with state-of-the-art Suzuki technology, are. The 1994 RM125 engine incorporates a new carburettor, revised port timing. 1994 rm125 service manual. This manual is presented as a means whereby you can maintain your RM125 in top working condition at all times. Your riding skill and the maintenance. View and Download Suzuki RM125 owner's service manual online. RM125 Motorcycle pdf manual download. Also for: 125. Page 94: Inspection.
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Yamaha Snowmobile Manuals This is the BEST, most complete workshop repair and maintenance manual available anywhere on the internet! All of the manual listed below are full factory service manuals with hundreds of pages containing step by step instructions, full wiring diagrams and detailed illustrations on how to repair, rebuild or maintain virtually anything to your sled. It also includes: General Information Engine Engine Related Items Fuel Systems (EFI or Carbureted) Engine Electrical Systems Chassis Electrical Systems Steering and Body Drive Train and Brake Systems Track/Rear Suspension Almost everything you would ever want or need to know about your Yamaha snowmobile. It is fully printable, print 1 page, 1 chapter or print the entire manual and put it in a 3-ring binder. Once you download your manual it is yours forever. Unlike other manuals on the internet my manuals don't need a password to view or print and you can back them up any way you see fit to make sure it's aways there when you need it.Tip, use the links below to avoid scanning through all the manuals. Click on the engine size below for your Snowmobile.
Yamaha Snowmobile Snowmobile Manuals 1988-1991 Yamaha SnoScoot 80 Series Repair and Maintenance Manual Only $8.50 Professional Keyword Searchable Factory OEM Manual - 209 Pages Covers the SV80 & the SV80E Sno Scoot snowmobile model series.
CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLYALL REPLACEMENT PARTS GASKETS, OIL SEALS, AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS LOCTITE SPECIAL TOOLS FOR TUNE UP FOR ENGINE SERVICE FOR POWER TRAIN SERVICE FOR CARBURETION SERVICE FOR ELECTRICAL SERVICE CHAPTER 2. ENGINE SEAT AND FUEL TANK EXHAUST PIPE AND MUFFLER ENGINE ASSEMBLY CAMSHAFTS CYLINDER HEAD VALVES AND VALVE SPRINGS A.C.
MAGNETO AND STARTER CLUTCH OIL PAN AND OIL PUMP CRANKCASE CHAPTER 6. COOLING SYSTEM HEAT EXCHANGER THERMOSTAT WATER PUMP CHAPTER 7.
CARBURETION OR EFI CARBURETORS FUEL LEBEL ADJUSTMENT THROTTLE POSITION SENSOR FUEL PUMP CHAPTER 8. ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION INSPECTING A SWITCH SHOWN IN THE MANUAL IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING A.C. MAGNETO SPARK PLUG IGNITION SPARK GAP IGNITION COIL THROTTLE OVERRIDE SYSTEM (T.O.R.S.) HANDLEBAR SWITCH (RIGHT) CARBURETOR SWITCH MAIN SWITCH MAIN RELAY ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING MAIN SWITCH STARTER MOTOR CHARGING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING BATTERY STATOR COIL LIGHTING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING BULB(S) HEADLIGHT BEAM SWITCH HEADLIGHT RELAY. Related Snowmobile Searches: CARBURETOR TUNING 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 main jet with a larger size. White or gray insulator with small black or grayish brown spots and electrodes having a bluish-burnt appearance Mixture is too lean. The piston is damaged or seized. 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 Mixture is too lean. The spark plug melted. 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. Troubleshooting Trouble Diagnosis Adjustment Hard starting Insufficient fuel Add gasoline. Excessive use of the starter or choke Return the starter lever to its seated position so that the starter valve is fully closed. Fuel passage is clogged or frozen Check and, if necessary, clean the fuel tank air vent, the fuel filter and all of the fuel passages. 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. Poor idling: Poor performance Improper idling speed adjustment Adjust the engine idle speed.
Refer to “Low speed tuning”. At low speeds Damaged pilot screw Replace the pilot screw. Poor acceleration Slow response to res onse throttle. Clogged bypass hole Clean the bypass hole. Engine tends to stall. Clogged or loose pilot jet Remove the pilot jet, clean it with compressed air and then install it. Make sure that the pilot jet is fully tightened.
Air leaking into the carburetor joint. Retighten the clamp screws on the carburetor joints. Defective starter valve seat Clean or replace the starter valve seat. Overflow Adjust the fuel level. Poor performance at mid-range speeds: Momentary slow response to the Clogged or loose pilot jet. Remove the pilot jet, clean it with compressed air, and then install it. Make sure that the pilot jet is fully tightened.
Throttle Poor acceleration normal speeds: Lean mixture Overhaul the carburetors. Poor performance at Clogged air vent Remove the air vent hose and clean it.
Excessive fuel consumption Poor acceleration Clogged or loose main jet. Make sure that the main jet is fully tightened.
Overflow Check and, if necessary, clean the float and float valve. Poor performance at Starter valve is left open Return the starter lever to its seated position High speeds: Power loss Poor acceleration Clogged air vent Remove and clean the air vent. Clogged or loose main air jet Remove the main jet, clean it with compressed air, and then install it. 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 performance Repair or replace the fuel pump. Clogged fuel filter Replace the fuel filter.
Clogged intake Remove any obstructions (e.g., ice). Abnormal combustion: Lean mixture Clean and adjust the carburetors. Backfiring Dirty carburetors Clean the carburetors. Dirty or clogged fuel line Clean or replace the fuel line. Overflow: Clogged air vent Clean the air vent. Poor idling Poor performance at low, mid-range, high speeds. Clogged float valve Disassemble and clean the float valve.
Do not scratch the valve seat. Excessive fuel consumption Hard starting Scratched or unevenly worn float valve or valve seat Clean or replace the float valve and valve seat. The valve seat and body must be replaced as a set Power loss Broken float Replace the float. Poor acceleration Incorrect float level Check and, if necessary, replace the following parts: Float tang Float (entire assembly) Arm pin.
This is the Highly Detailed factory service repair manual for the2001 YAMAHA MM600D MOUNTAIN MAX / MM700D MOUNTAIN MAX SNOWMOBILE, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. They are specifically written for the do-it-yourself-er as well as the experienced mechanic.2001 YAMAHA MM600D MOUNTAIN MAX / MM700D MOUNTAIN MAX SNOWMOBILE Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine.
It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable.
Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: General Information Periodic Inspection and Adjustment Chassis Power Train Engine Cooling System Carburetion Electrical Specifications File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have2001 YAMAHA MM600D MOUNTAIN MAX / MM700D MOUNTAIN MAX SNOWMOBILE Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: Thanks for visiting!
2001 Yamaha MM600D MOUNTAIN MAX / MM700D MOUNTAIN MAX Snowmobile Service Repair Manual. 1. MM600D MM700D SERVICE MANUAL LIT-12618-02-12 8EJ-28197-10 (981033). HOW TO USE THIS MANUAL Particularlyimportantinformationisdistinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snowmobile.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the snowmo- bile. NOTE: A NOTE provides key information that can make procedures easier or clearer. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format.
The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that con- tains comprehensive explanations of all inspec- tion, repair, assembly, and disassembly opera- tions. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g.,. Bearings Pitting/Damage → Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct dis- assembly and assembly procedures. NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics.
It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understand- ing of the mechanical concepts and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to this model may render it unfit and/or unsafe to use. Yamaha Motor Company, Ltd. Is continually striv- ing to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will, where applicable,appearinfutureeditionsofthismanual. MM600, MM700 SERVICE MANUAL ©1999 by Yamaha Motor Corporation, U.S.A. 1st Edition, June 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. Is expressly prohibited. Printed in U.S.A.
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustratedsymbols1to9aredesignedasthumb tabs to indicate the chapter’s number and con- tent. 1 General information 2 Periodic inspection and adjustment 3 Chassis 4 Power train 5 Engine 6 Cooling system 7 Carburetion 8 Electrical 9 Specifications Illustrated symbols 0 to F are used to identify the specifications which appear. 0 Filling fluid A Lubricant B Tightening C Wear limit, clearance D Engine speed E Special tool F Ω, V, A Illustrated symbols G to O in the exploded dia- gram indicate grade of lubricant and location of lubrication point. G Apply locking agent (LOCTITE® ) H Apply Yamabond No.5® I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply low-temperature lithium-soap base grease N Apply molybdenum disulfide grease O Use new one 1 3 5 7 9 0 F I L 4 6 8 G K M N CHAS POWR TR ENG COOL – + ELEC GEN INFO SPEC H J B MGE 5LT M CARB INSP ADJ 2 A C D E B O New T R.
LS. 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. 2-12 THROTTLE CABLE FREEPLAY ADJUSTMENT. 2-13 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK. 2-14 STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT. 2-15 EXHAUST SYSTEM INSPECTION.
2-15 POWER TRAIN. 2-16 SHEAVE DISTANCE AND OFFSET ADJUSTMENT. 2-16 DRIVE V-BELT. 2-18 ENGAGEMENT SPEED CHECK.
2-20 PARKING BRAKE PAD INSPECTION. 2-20 PARKING BRAKE ADJUSTMENT. 2-20 BRAKE FLUID LEVEL INSPECTION.
2-21 BRAKE PAD INSPECTION. 2-21 BRAKE HOSE INSPECTION. 2-22 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM). 2-22 DRIVE CHAIN. 2-23 TRACK TENSION ADJUSTMENT. 2-25 SLIDE RUNNER INSPECTION.
Yamaha Snowmobile Service Manual Mountain Max 500 Escritorio
2-27 CHASSIS. 2-28 SKI/SKI RUNNER. 2-28 STEERING SYSTEM. 2-28 LUBRICATION. 2-30 ELECTRICAL.
2-31 HEADLIGHT BEAM ADJUSTMENT. 2-31 TUNING. 2-32 CARBURETOR TUNING. 2-32 CLUTCH. 2-39 GEAR SELECTION. 2-41 HIGH ALTITUDE TUNING.
2-47 FRONT SUSPENSION. 2-48 REAR SUSPENSION. 2-49 CHAPTER 3. CHASSIS STEERING. 3-1 INSPECTION. 3-3 INSTALLATION. 3-4 SKI.
3-6 INSPECTION. 3-7 FRONT SUSPENSION. 3-8 INSPECTION. 3-9 INSTALLATION. 3-10. CHAPTER 4. POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT.
4-1 REMOVAL. 4-3 DISASSEMBLY. 4-3 INSPECTION. 4-4 ASSEMBLY. 4-6 INSTALLATION.
4-8 SECONDARY SHEAVE. 4-9 DISASSEMBLY. 4-11 INSPECTION. 4-11 ASSEMBLY. 4-12 INSTALLATION. 4-14 DRIVE CHAIN HOUSING.
4-15 INSPECTION. 4-16 INSTALLATION. 4-18 JACKSHAFT. 4-19 INSPECTION. 4-20 JACKSHAFT AND DRIVE CHAIN HOUSING INSTALLATION. 4-21 BRAKE.
4-22 BRAKE PAD REPLACEMENT. 4-23 BRAKE CALIPER DISASSEMBLY. 4-27 BRAKE CALIPER INSPECTION AND REPAIR. 4-27 BRAKE CALIPER ASSEMBLY. 4-28 BRAKE CALIPER INSTALLATION. 4-28 INSPECTION.
4-30 BRAKE MASTER CYLINDER ASSEMBLY. 4-30 INSTALLATION. 4-30 SLIDE RAIL SUSPENSION. 4-31 INSPECTION.
Yamaha Snowmobile Service Manual Mountain Max 500 Efi
4-36 ASSEMBLY. 4-37 INSTALLATION. 4-37 FRONT AXLE AND TRACK.
4-38 INSPECTION. 4-39 INSTALLATION. 4-39 CHAPTER 5. ENGINE EXHAUST ASSEMBLY. 5-1 INSTALLATION. 5-2 ENGINE ASSEMBLY. 5-3 INSPECTION.
5-4 INSTALLATION. 5-4 CYLINDER HEAD AND CYLINDER. 5-5 REMOVAL. 5-6 INSPECTION.
5-7 INSTALLATION. 5-12 OIL PUMP, CRANKCASE AND CRANKSHAFT. 5-15 INSPECTION. 5-16 INSTALLATION. 5-18 CDI MAGNETO.
5-21 REMOVAL. 5-22 INSTALLATION. 5-23 RECOIL STARTER. 5-25 REMOVAL. 5-26 INSPECTION. 5-26 INSTALLATION.
5-27 CHAPTER 6. COOLING SYSTEM HEAT EXCHANGER.
6-1 INSPECTION. 6-2 INSTALLATION. 6-2 WATER PUMP. 6-3 REMOVAL.
Yamaha Snowmobile Service Manual Mountain Max 500 Tablet
6-4 INSPECTION. 6-4 INSTALLATION. 6-4.
CHAPTER 7. CARBURETION CARBURETORS. 7-1 INSPECTION. 7-5 ASSEMBLY.
7-6 FUEL LEVEL ADJUSTMENT. 7-8 INSTALLATION.
7-9 FUEL PUMP. 7-10 INSPECTION. 7-11 INSTALLATION. 7-11 CHAPTER 8. ELECTRICAL SWITCH INSPECTION. 8-1 SWITCH INSPECTION.
8-1 INSPECTING A SWITCH SHOWN IN THE MANUAL. 8-1 IGNITION SYSTEM. 8-2 CIRCUIT DIAGRAM. 8-2 TROUBLESHOOTING.
8-3 SPARK PLUG CAP. 8-4 IGNITION COIL. 8-4 CDI MAGNETO. 8-4 SPARK PLUG. 8-5 THROTTLE OVERRIDE SYSTEM (T.O.R.S.).
8-5 HANDLEBAR SWITCH (RIGHT). 8-6 CARBURETOR SWITCH.
8-6 MAIN SWITCH. 8-7 LIGHTING SYSTEM. 8-8 CIRCUIT DIAGRAM. 8-8 TROUBLESHOOTING.
8-9 BULB(S). 8-10 HEADLIGHT BEAM SWITCH. 8-10 CDI MAGNETO.
8-11 SIGNAL SYSTEM. 8-12 CIRCUIT DIAGRAM. 8-12 TROUBLESHOOTING.
8-13 TAIL/BRAKE LIGHT BULB. 8-15 BRAKE LIGHT SWITCH. 8-15 WATER TEMPERATURE SENSOR.
8-16 OIL LEVEL SWITCH. 8-17 FUEL SENDER. 8-17 CONDENSER.
8-18 GRIP WARMER SYSTEM. 8-19 CIRCUIT DIAGRAM. 8-19 TROUBLESHOOTING. 8-20 GRIP AND THUMB WARMER COIL. 8-21 VARIABLE RESISTOR. 8-21 CDI MAGNETO.
8-22 CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS. 9-1 MAINTENANCE SPECIFICATIONS. 9-3 ENGINE. 9-3 POWER TRAIN. 9-6 CHASSIS.
9-9 ELECTRICAL. 9-10 HIGH ALTITUDE SETTINGS. 9-11 TIGHTENING TORQUE.
9-13 GENERAL TORQUE SPECIFICATIONS. 9-17 DEFINITION OF UNITS.
9-17 CABLE ROUTING. 9-19. 1-1 GEN INFOMACHINE 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. SEJ1010 SEJ1020 1. 1-2 GEN INFOIMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1.
Removealldirt,mud,dust,andforeignmaterialbeforeremovaland disassembly. While cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc., from high pres- sure water splashes. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”.
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. 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. Keep all parts away from any source of fire. Be sure to keep to the tightening torque specifications.
Chevrolet astro van repair manual 2000 ford. HAYNES 24010 Chevrolet Astro & GMC Safari Mini Van, '85-'05 Info. Does not include all-wheel drive models. Transmission Repair Manual.
When tightening bolts, nuts, and screws, start with those that have larger diameters,andproceedfromtheinsidetotheoutsideinacrisscross pattern. ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements.
Use oil and grease recommended by Yamaha for assembly and adjust- ments. SEJ1030 SEJ1040 SEJ1050 SEJ1060 SEJ1070 SEJ1080. 1-3 GEN INFOIMPORTANT 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. 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.Locktab(s)shouldbebentalongtheboltornutflat(s)afterthe 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 ispositionedoppositetothethrust3itreceives.Seethesectionalview. 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. SEJ1090 SEJ1100 SEJ1110 SEJ1120.
1-4 GEN INFOSPECIAL TOOLS SPECIAL TOOLS Somespecialtoolsarenecessaryforacompletelyaccuratetune-upand assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. NOTE: Be sure to use the correct part number when ordering the tool, since the part number may differ according to country. FOR TUNE UP. Sheave gauge P/N: YS-42421-1 (15 mm offset) This gauge is used to measure the sheave distance and for offset adjustment. Dial gauge P/N: YU-03097 (for U.S.A./Canada) 7 (for Europe) This gauge is used for run out measurement. Fuel level gauge P/N: YM-01312-A (for U.S.A./Canada) 2 (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) 2 (for Europe) This gauge is used to measure the distance between the center of the primary sheave and the center of the secondary sheave. SEJ1130 SEJ1160 SEJ1150 SEJ1140.
1-5 GEN INFO FOR ENGINE SERVICE. Piston pin puller P/N: YU-01304 (for U.S.A./Canada) 4 (for Europe) This tool is used to remove the piston pin. Rotor holding puller P/N: YU-33270 (for U.S.A./Canada) 2 (for Europe) This tool is used to remove the magneto rotor. Cooling system tester P/N: YU-24460-01 (for U.S.A./Canada) 5 (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) 1 (for Europe) This tool is used to hold the primary sheave. Primary sheave puller (18 mm) P/N: YS-39962 This tool is used for removing the primary sheave. Clutch spider separator P/N: YS-28890-B (for U.S.A./Canada) 1 (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) 0 (for Europe) This tool is used when disassembling and assembling the primary sheave. YXR clutch bushing jig kit P/N: YS-39752 This tool is used for removal and installation of primary clutch weight and roller bushings. SPECIAL TOOLS SEJ1170 SEJ1180 SEJ1190 SEJ1200 SEJ1210 SEJ1220 SEJ1230 SEJ1240.
1-6 GEN INFOSPECIAL 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) 1 (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) 6 (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) 2 (for Europe) This instrument is necessary for checking the electrical components. Electro tester P/N: YU-33260-A (for U.S.A./Canada) 1 (for Europe) This instrument is invaluable for checking the electrical system. SEJ1250 SEJ1260 SEJ1280 SEJ1290 SEJ1300 SEJ1310.
2-1 INSP ADJINTRODUCTION/PERIODIC MAINTENANCE TABLE PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE Item Remarks Spark plugs Engine oil Fuel Fuel filter Fuel line Oil line Engine coolant Carburetors Recoil starter Engine stop switch Throttle override system (T.O.R.S.) Throttle lever Exhaust system Decarbonization Drive guard Drive V-belt Drive track/idler wheels Slide runners Pre- operation check (Daily) Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 3,200 km (2,000 mi) (160 hr) Check condition. Adjust gap and clean. Replace if necessary. Check oil level. Air bleed the oil pump if necessary.
Check fuel level. Check condition. Replace if necessary.
Check fuel hose for cracks or damage. Replace if necessary. Check oil hose for cracks or damage.
Replace if necessary. Check coolant level. Air bleed the cooling system if necessary.
Check throttle lever operation. Adjust the jets. Check operation and rope damage. Replace if necessary. Check operation Repair if necessary.
Check operation. Repair if necessary. Check operation.
Repair if necessary. Check for leakage. Retighten or replace gasket if necessary. More frequently if necessary. Check cracks, bends or damage. Replace if necessary. Check wear and damage.
Replace if necessary. Check deflection, wear and damage. Adjust/replace if necessary. Check wear and damage. Replace if necessary. Whenever operating condition (elevation/temperature) is changed.
2-2 INSP ADJPERIODIC MAINTENANCE TABLE Check operation and fluid leakage. Adjust free play and/or replace pads if necessary. Replace brake fluid. Check oil level. Check deflection.
Adjust if necessary. Check wear and damage. Replace if necessary. Check operation. Adjust toe-out if necessary. Check damage.
Replace if necessary. Check operation. Replace bulbs if necessary. Check engagement and shift speed.
Adjust if necessary. Check wear and damage. Replace if necessary. Lubricate with specified grease.
Lubricate with specified grease. Adjust if necessary. Lubricate with specified grease. Lubricate with specified grease. Lubricate with specified grease.
Lubricate with specified grease. Check cable damage. Replace if necessary. Make sure the shroud latches are hooked. Check tightness. Repair if necessary. Check proper placement.
Whenever operating elevation is changed. Whenever operating elevation is changed. Initial at 80 km (50 mi) and every 800 km (500 mi) thereafter. Brake/ parking brake Drive chain oil Drive chain Skis and ski runners Steering system Strap Lights Primary sheave Secondary sheave Steering column bearing Ski and front suspension Suspension component Parking brake cable end and lever end/throttle cable end Shroud latches Fittings and fasteners Tool kit and recommended equipment NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required.
On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. Replace the brake hoses every four years, or if cracked or damaged.
Item Remarks Pre- operation check (Daily) Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 3,200 km (2,000 mi) (160 hr) 2. 2-3 INSP ADJSPARK PLUGS ENGINE SPARK PLUGS 1. Remove:. Spark plug caps. Spark plugs 2. Inspect:. Electrodes 1 Damage/wear → Replace the spark plug.
Insulator color 2 3. Measure:.
Spark plug gap a Out of specification → Regap. Use a wire thickness gauge. Spark plug gap a: 0.7 0.8 mm (0.028 0.031 in) If necessary, clean the spark plugs with a spark plug cleaner.
Standard spark plug: BR9ES (NGK) Before installing a spark plug, clean the gasket surface and spark plug surface. 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. SEJ2010 SEJ2020 SEJ2030. 2-4 INSP ADJOIL 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.
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. Place a rag under the oil pump assembly to soak up any spilled oil. Disconnect:. Oil hose 5. Drain the oil until no more air bubbles appear in the oil hose.
Connect:. Oil hose 7.
Disconnect:. Oil delivery hose 8. Feed the “YAMALUBE 2-cycle oil” into the oil delivery hose using an oil can for complete air bleeding.
Connect:. Oil delivery hose 10. Remove:. Bleed bolt 1. Gasket (bleed bolt) 11.
Drain the oil until no more air bubbles appear from the bleed hole. Inspect:. Gasket (bleed bolt) Damage/wear → Replace. SEJ2040 SEJ2050.
2-5 INSP ADJOIL PUMP 13. Install:. Gasket (bleed bolt). Bleed bolt 14. Install:.
Carburetors Refer to “CARBURETORS” in CHAPTER 7. Cable adjustment NOTE: Before adjusting the oil pump cable, the throttle cable distance should be adjusted. Adjustment steps:. Slide back the adjuster cover. Loosen the locknut 1. Turntheadjuster2inoroutuntilthespecified distance a is obtained. Distance a: MM600: 23 ± 1 mm (0.906 ± 0.04 in) MM700: 22 ± 1 mm (0.866 ± 0.04 in) Turning in → Distance a is increased.
Turning out → Distance a is decreased. Tighten the locknut and push in the adjuster cover. SEJ2060 SEJ2070. 2-6 INSP ADJ 2 2 FUEL LINE INSPECTION/COOLING SYSTEM FUEL LINE INSPECTION 1. Remove:. Intake silencer Refer to “FUEL PUMP” in CHAPTER 7. Inspect:.
Fuel hose 1. Fuel delivery hoses 2 Cracks/damage → Replace. Install:.
Intake silencer Refer to “FUEL PUMP” in CHAPTER 7. COOLING SYSTEM Coolant replacement NOTE: The coolant should be changed at least every season.
Place the machine on a level surface. Remove:. Exhaust pipe. Exhaust joint Refer to “EXHAUST ASSEMBLY” in CHAP- TER 5. Make sure that the carburetor heating lever 1 is turned to “ON” a. SEJ2080 SEJ2090 SEJ2100.
2-7 INSP ADJ 1 1 4. Remove:. Coolant filler cap 1 WARNING Do not remove the coolant filler cap 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.Thisallowsanyresidualpressuretoescape. Whenthehissingsoundhasstopped,pressdown on the cap while turning it counterclockwise to remove it.
Place an open container under the coolant drain bolt 1. Remove:. Coolant drain bolt. Gasket (coolant drain bolt) 7. Drain the coolant. NOTE: Lift up the tail of the machine to drain the coolant. Remove:.
Right side cover 1 9. Disconnect:. Coolant hose 3 1 10. Drain the coolant. NOTE: Lift up the tail of the machine to drain the coolant completely. COOLING SYSTEM SEJ2110 SEJ2120 SEJ2130 SEJ2140.
2-8 INSP ADJ 1 WARNING Coolant is poisonous. It is harmful or fatal if swallowed. If coolant is swallowed, induce vomiting im- mediately and get immediate medical atten- tion. 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. Connect:.
Coolant hose 3 12. Install:.
Right side cover 1 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. Install:. Coolant reservoir cap 17. Connect:.
Coolant reservoir hose 18. Inspect:. Gasket (coolant drain bolt) Damage → Replace. Install:.
Gasket. Coolant drain bolt 1 Coolant drain bolt 1: 13 Nm (1.3 m. kg, 9.4 ft. lb) COOLING SYSTEM T R.
SEJ2150 SEJ2160 SEJ2145 SEJ2163. 2-9 INSP ADJCOOLING SYSTEM 20. Install:. Exhaust joint.
Exhaust pipe Refer to “EXHAUST ASSEMBLY” in CHAP- TER 5. Bolt (exhaust joint) 1: 27 Nm (2.7 m. kg, 19 ft. lb) 21.Fill:. Cooling system Recommended coolant: High quality ethylene glycol antifreeze containing corrosion inhibitors Coolant: water mixed ratio: 3: 2 (60%: 40%) Total amount: 4.2 L (3.65 lmp qt, 4.41 US qt) Reservoir tank capacity: 0.17 L (0.15 lmp qt, 0.18 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. Bleed the air from the cooling system.
Inspect:. Cooling system Decrease of pressure (leaks) → Repair as required. SEJ2167. 2-10 INSP ADJ 1 1 Inspection steps:.
Attach the cooling system tester 1 to the coolant filler 2. Cooling system tester: 5, YU-24460-01. Apply 100 120 kPa (1.0 1.2 kg/cm2, 14 17 psi). Measure the pressure with the gauge.
Air bleeding 1. Remove:. Bleed bolt cap 1 2. Bleed air from the cooling system.
Air bleeding steps:. Lift up the tail of the machine. Remove the bleed bolt 1 on the heat ex- changer.
While slowly adding coolant to the coolant reservoir, drain the coolant until no more air bubbles appear. Tighten the bleed bolt. Bleed bolt: 4 Nm (0.4 m. kg, 2.9 ft. lb). 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. 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 thermostat opens and the coolant circulates (approximately 3 5 min- utes). The rear heat exchanger will be warm to the touch.
COOLING SYSTEM T R. SEJ2170 SEJ2180 SEJ2190 SEJ2200. 2-11 INSP ADJCOOLING SYSTEM WARNING To avoid severe injury or death:.
Makesurethemachineissecurelysupported with a suitable stand. Do not exceed 3,000 r/min.
Drive line dam- age 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. 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. Install:.
Bleed bolt cap SEJ2210. 2-12 INSP ADJ 1 CARBURETOR SYNCHRONIZATION 1. Remove:.
Carburetors Refer to “CARBURETORS” in CHAPTER 7. 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 a: 1.2 mm (0.047 in).
Adjust the throttle valve height a on carbure- tor #1 2 and #3 3 with the adjusting screw 4. Move the throttle lever 2 3 times. Make sure that all of the carburetor throttle valves are at the same height. Install:.
Carburetors Refer to “CARBURETORS” in CHAPTER 7. 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.
CARBURETOR SYNCHRONIZATION/ ENGINE IDLE SPEED ADJUSTMENT SEJ2220 SEJ2230 SEJ2240. 2-13 INSP ADJ 2 1 THROTTLECABLEFREEPLAYADJUSTMENT NOTE:. Before adjusting the throttle cable freeplay, the engine idle speed should be adjusted. Adjust the throttle cable freeplay while the cable is in the cable guide. Measure:. Throttle cable freeplay a Out of specification → Adjust.
Throttle cable freeplay a: 1.0 2.0 mm (0.04 0.08 in) 2. Adjust:.
Throttle cable freeplay Adjustment steps:. Loosen the locknut 1. Turn the adjusting nut 2 in or out until the specified freeplay is obtained. Turning in → Freeplay is increased.
Turning out → Freeplay is decreased. Tighten the locknut. NOTE: After adjusting the freeplay, turn the handlebar to rightandleft,andmakesurethattheengineidling does not run faster. THROTTLE CABLE FREEPLAY ADJUSTMENT SEJ2250 SEJ2260. 2-14 INSP ADJ 1 2 3 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. Start the engine. Hold the pivot point of the throttle lever away fromthethrottleswitchbyputtingyourthumb (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. TheT.O.R.S.willoperateandtheengineshould 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.
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK SEJ2270. 2-15 INSP ADJ STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT/ EXHAUST SYSTEM INSPECTION STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT 1.
Measure:. Starter cable freeplay a Out of specification → Adjust. Starter cable freeplay a: 0.5 1.5 mm (0.02 0.06 in) 2.
Adjust:. Starter cable freeplay Adjustment steps:. Loosen the locknut 1.
Turn the adjusting nut 2 in or out until the specified freeplay is obtained. Turning in → Freeplay is increased.
Turning out → Freeplay is decreased. Tighten the locknut. EXHAUST SYSTEM INSPECTION 1. Open the shroud. Remove:. Springs Refer to “EXHAUST ASSEMBLY” in CHAP- TER 5. Inspect:.
Exhaust joint 1. Exhaust pipe 2. Exhaust silencer 3 Cracks/damage → Replace.
Exhaust gasket 4. Exhaust gasket 5. Exhaust gasket 6 Exhaust gas leaks → Replace. Check:. Tightening torque 7 Bolt (exhaust pipe) 7: 27 Nm (2.7 m. kg, 19 ft. lb) 5.
Install:. Springs Refer to “EXHAUST ASSEMBLY” in CHAP- TER 5. SEJ2280 SEJ2290. 2-16 INSP ADJSHEAVE DISTANCE AND OFFSET ADJUSTMENT POWER TRAIN SHEAVE DISTANCE AND OFFSET ADJUSTMENT 1. Open the shroud.
Remove:. Drive V-belt guard. Drive V-belt 3.
Measure:. Sheave distance a Use the sheave gauge. Out of specification → Adjust. Sheave distance a: 267 270 mm (10.52 10.62 in) Distance gauge: YS-91047-3 4. Measure:. Sheave offset a Use the sheave gauge.
Out of specification → Adjust. Sheave offset a: 13.5 16.5 mm (0.53 0.64 in) Sheave gauge: YS-42421-1 (15 mm offset) 5. Adjust:. Sheave distance Adjustment steps:.
Loosen the engine mounting bolts. Adjust the position of the engine so that the sheave distance is within the specification. Tighten the engine mounting bolts. Mounting bolt (front) 1: 90 Nm (9.0 m. kg, 65 ft.
lb) Mounting bolt (rear) 2: 57 Nm (5.7 m. kg, 41 ft.
lb) T R. SEJ2300 SEJ2310 SEJ2320 SEJ2330.
2-17 INSP ADJ 1 2 3 a 6. Measure:. Secondary sheave freeplay (clearance) a Use a feeler gauge. Out of specification → Adjust.
Secondary sheave freeplay (clearance) a: 1.0 2.0 mm (0.04 0.08 in) 7. Adjust:. Secondary sheave freeplay (clearance) Adjustment steps:. Apply the brake to lock the secondary sheave. Remove the bolt 1 and washer 2. Adjust the secondary sheave freeplay (clear- ance) by adding or removing a shim(s) 3.
Shim size: Part number Thickness 90201-222F0 0.5 mm (0.02 in) 90201-225A4 1.0 mm (0.04 in) SHEAVE DISTANCE AND OFFSET ADJUSTMENT SEJ2340 SEJ2350. 2-18 INSP ADJDRIVE V-BELT 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 (–0.020 in) below the edge a. If the V-belt is not positioned correctly, the clutch engagement speed will be changed. The ma- chine 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 neces- sary. To ensure proper clutch performance, the V- beltpositionshouldbeadjustedbyaddingaspacer on each adjusting bolt when the V-belt position reaches 1.5 mm (0.06 in) below the edge. 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.DonotforcetheV-beltbetweenthesheaves; the sliding and fixed sheaves must touch each other. Standard V-belt height a: –0.5 1.5 mm (–0.020 0.06 in) SEJ2370 SEJ2360. Thank you very much for your reading.
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