Yamaha VX600ERG, Service Manual

Page 1: ...VX600ERG SX600G MM600G VT600G SERVICE MANUAL LIT 12618 02 20 8EA 28197 10 981059 ...

Page 2: ...mage Replace EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct disas sembly and assembly procedures NOTICE This manual was written by the Yamaha Motor Com pany 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 as sumed that persons using thi...

Page 3: ...ng 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 diagram 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 ...

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

Page 5: ...14 STARTER CHOKE CABLE FREE PLAY ADJUSTMENT 2 15 EXHAUST SYSTEM INSPECTION 2 15 POWER TRAIN 2 16 SHEAVE DISTANCE AND OFFSET ADJUSTMENT 2 16 DRIVE V BELT 2 18 ENGAGEMENT SPEED CHECK 2 20 PARKING BRAKE PAD INSPECTION 2 20 PARKING BRAKE ADJUSTMENT 2 21 BRAKE LEVER ADJUSTMENT VX600ER SX600 VT600 2 21 BRAKE FLUID LEVEL INSPECTION 2 22 BRAKE PAD INSPECTION 2 22 BRAKE HOSE INSPECTION 2 23 AIR BLEEDING HY...

Page 6: ...NSTALLATION 4 28 BRAKE 4 29 BRAKE PAD REPLACEMENT 4 30 BRAKE CALIPER DISASSEMBLY 4 34 BRAKE CALIPER INSPECTION AND REPAIR 4 34 BRAKE CALIPER ASSEMBLY 4 35 BRAKE CALIPER INSTALLATION 4 35 INSPECTION 4 37 BRAKE MASTER CYLINDER ASSEMBLY 4 37 INSTALLATION 4 37 SLIDE RAIL SUSPENSION 4 38 VX600ER SX600 4 38 VT600 4 39 MM600 4 44 INSPECTION 4 49 ASSEMBLY 4 50 INSTALLATION 4 50 FRONT AXLE AND TRACK 4 52 I...

Page 7: ...S 8 8 HANDLEBAR SWITCH RIGHT 8 8 CARBURETOR SWITCH 8 9 MAIN SWITCH 8 9 LOAD CONTROL RELAY 8 10 EMERGENCY ENGINE STARTING SX600 MM600 8 10 ELECTRICAL STARTING SYSTEM VX600ER VT600 8 11 CIRCUIT DIAGRAM 8 11 TROUBLESHOOTING 8 12 MAIN SWITCH 8 13 STARTER MOTOR 8 14 CHARGING SYSTEM VX600ER VT600 8 18 CIRCUIT DIAGRAM 8 18 TROUBLESHOOTING 8 19 BATTERY 8 20 STATOR COIL 8 20 LIGHTING SYSTEM 8 22 CIRCUIT DI...

Page 8: ...ER RELAY VT600 8 45 FAULT LOCATION TABLE 8 46 CHAPTER 9 SPECIFICATIONS GENERAL SPECIFICATIONS 9 1 MAINTENANCE SPECIFICATIONS 9 4 ENGINE 9 4 POWER TRAIN 9 7 CHASSIS 9 11 ELECTRICAL 9 12 HIGH ALTITUDE SETTINGS 9 14 TIGHTENING TORQUE 9 15 GENERAL TORQUE SPECIFICATIONS 9 19 DEFINITION OF UNITS 9 19 CABLE ROUTING 9 21 ...

Page 9: ...RIAL NUMBER Theframeserialnumber1islocatedontheright handsideoftheframe 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 SEA1010 SEA1020 ...

Page 10: ...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 a...

Page 11: ...rks or numbers facing outwards In other words the stamped letters must be on the side exposed to view When installing oil seals apply a light coating of lightweightlithiumbasegreasetotheseallips Oilthebearingsliberallywhen installing CAUTION Do not use compressed air to spin the bearings dry This causes damage to the surface of the bearings CIRCLIPS All circlips should be inspected carefully befor...

Page 12: ... 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 910...

Page 13: ...cking the cooling system FOR POWER TRAIN SERVICE Primary sheave holder P N YS 01880 for U S A Canada 90890 01701 for Europe This tool is used to hold the primary sheave Primary sheave puller 18 mm P N YS 01881 1 1 YS 01859 1 2 This tool is used for removing the primary sheave Clutch spider separator P N YS 28890 C This tool is used when disassembling and assembling the primary sheave Clutch separa...

Page 14: ... is used for installing the track clip Angle finder P N YS 42422 This tool is used for checking and adjusting the ski spindle camber FOR CARBURETION SERVICE Mity vac P N YS 42423 for U S A Canada 90890 06756 for Europe This tool is used to check the fuel pump FOR ELECTRICAL SERVICE Pocket tester P N YU 03112 for U S A Canada 90890 03112 for Europe This instrument is necessary for checking the elec...

Page 15: ...tly if necessary Check for cracks bends or damage Replace if necessary Check for wear and damage Replace if necessary Check deflection and for wear and damage Adjust replace if necessary Check for wear and damage Replace if necessary Check operation and fluid leakage Adjust free play and or replace pads if necessary Replace brake fluid INTRODUCTION PERIODIC MAINTENANCE TABLE PERIODIC INSPECTION AN...

Page 16: ...y Make sure that the shroud latches are hooked Check tightness Repair if necessary Check for proper placement Whenever operating elevation is changed Initial at 500 km 300 mi and every 800 km 500 mi thereafter Drive chain oil Drive chain Skis and ski runners Steering system Strap MM600 Lights Battery VT600 VX600ER NOTE Brake fluid replacement 1 When disassembling the master cylinder or caliper cyl...

Page 17: ... Regap Use a wire thickness gauge Spark plug gap 0 7 0 8 mm 0 028 0 031 in If necessary clean the spark plugs with a spark plug cleaner Standard spark plug BR9ES NGK Before installing a spark plug clean the gasket sur face and spark plug surface 4 Install Spark plugs Spark plug 20 Nm 2 0 m kg 14 ft lb NOTE Finger tighten a the spark plug before torquing b it to specification T R SEA2010 SEA2020 SE...

Page 18: ...emove 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...

Page 19: ...n 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 23 1 mm 0 906 0 039 in Turning in Distance a is increased Turning out Distance a is decreased Tighten the locknut and push in the ad...

Page 20: ... 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 SEA2090 SEA2100 SEA2110 ...

Page 21: ...ant filler cap Slowly turn the cap counterclockwise until it stop This allows any residual pressure to es cape Whenthehissingsoundhasstopped 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 1 Gasket coolant drain bolt 7 Drain the coolant NOTE Lift up the tail of the machine to drain the coolan...

Page 22: ...n 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 MM600 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 In...

Page 23: ...ooling 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 wat...

Page 24: ...h 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 VX600ER SX600 VT600 Rear bumper cover 1 VT600 Bleed bolt cap 1 MM600 Å VT600 ı MM600 2 Bleed air from the cooling system COOLING SYSTEM SEA2220 SEA2210 SEA2220 A B ...

Page 25: ...the coolant until no more air bubbles ap pear Tighten the bleed bolt 2 Bleed bolt 7 Nm 0 7 m kg 5 1 ft lb Install the coolant filler cap Applyandlocktheparkingbrake Starttheengine 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 secu...

Page 26: ...e 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 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 carburet...

Page 27: ... 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 ...

Page 28: ...run the engine up to the clutch engage mentspeed Otherwise themachinecouldstart 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 ...

Page 29: ...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 CHAP TER 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 Bolt ...

Page 30: ...tance 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 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 Sheave gauge YS 42421 1 15 mm offset YS 42421 2 20 mm offset SEA2350 SEA2360 ...

Page 31: ...5 7 m kg 41 ft lb 6 Measure Secondary sheave free play clearance a Use a thickness gauge Out of specification Adjust Secondary sheave free play clearance 1 0 2 0 mm 0 04 0 08 in 7 Adjust Secondary sheave free play clearance Adjustment steps Apply the brake to lock the secondary sheave Remove the bolt 1 and washer 2 Adjust the secondary sheave free play clear ance by adding or removing a shim s 3 S...

Page 32: ...ng 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 be...

Page 33: ...7 2 ft lb 4 Inspect Drive V belt Cracks damage wear Replace Oil or grease on the V belt Check the pri mary and secondary sheaves 5 Inspect Primary sheave Secondary sheave Oil or grease on the primary and secondary sheaves Usearagsoakedinlacquerthinner or solvent to remove the oil or grease Check the primary and secondary sheaves 6 Measure V belt circumference a Out of specification Replace V belt ...

Page 34: ...ward 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 EN...

Page 35: ...ntil the specified clearance between the brake pad 6 and disc 4 is obtained Tighten the locknuts 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 Whilelightlypushingthebrakeleverindirectiona turn the adjusting bolt2 by fingers to set the brake lever to the desired position Tighten the locknut se...

Page 36: ...ays clean up spilled fluid immedi ately WARNING Use only the designated brake fluid Other fluids may deteriorate the rubber seals caus ing leakage and poor brake performance Refill with the same type of fluid Mixing fluids may result in a harmful chemical reaction lead ing to poor brake performance When refilling be careful that water does not enter the brake master cylinder reservoir Wa ter will ...

Page 37: ...rly 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 Slow...

Page 38: ...em 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 ...

Page 39: ...inserting the dipstick into the drive chain housing 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 Recommended oil Gear oil API GL 3 SAE 75 or 80 CAUTION Makesurethatnoforeignmaterialentersthegear case Reinsert the dips...

Page 40: ...Gear oil API GL 3 SAE 75 or 80 Oil capacity 0 25 L 8 8 Imp oz 8 5 US oz Å VX600ER SX600 VT600 ı MM600 Chain slack adjustment 1 Remove Battery VX600ER VT600 Battery bracket VX600ER VT600 WARNING Whenremovingthebattery disconnectthenega tive lead first 2 Adjust Drive chain slack Adjustment steps Loosen the locknut 1 Turn the adjusting bolt 2 in until it is finger tight Tighten the locknut 1 Locknut ...

Page 41: ...chine 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 s...

Page 42: ...e runner 9 Track 0 Track metal A Gap B Forward Å VX600ER SX600 VT600 ı MM600 c Adjust the track deflection until the specified amount is obtained CAUTION The adjusters should be turned an equal amount Recheck the alignment and deflection If neces sary repeat steps a to c until the specified amount is obtained Tighten the rear axle nut Nut rear axle 75 Nm 7 5 m kg 54 ft lb Track alignment 4 Left ad...

Page 43: ...DJ SLIDE RUNNER INSPECTION 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 ...

Page 44: ... avoid sus tained 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 ...

Page 45: ...m 0 31 in Plastic ski wear limit VX600ER VT600 13 mm 0 51 in SX600 MM600 8 mm 0 31 in CAUTION To avoid scratching wearing and damaging the plastic skis be careful when loading and unload ing 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 SEA2595 SEA2600 SEA2605 SEA2610 SKI SKI RUNNER A A B B ...

Page 46: ...talled securely in position If free play still exists check the steering bearing front sus pension links and ski mounting area for wear Replace if necessary 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 ...

Page 47: ...ed freely through the ball joint travel If not loosenthelocknut1andre positiontheballjoint so that the tie rod 2 can be rotated freely Tighten the locknuts to specification Å Left side ı Right side Ç Inside 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 W...

Page 48: ... the ball joints 2 3 Recommended lubricant Esso Beacon 325 Grease or Aeroshell Grease 7A Å Front ı Rear VX600ER SX600 VT600 Ç Rear MM600 SEA2650 SEA2660 SEA2665 SEA2645 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 SEA2655 A A ...

Page 49: ...ight 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 7 Adjust Headli...

Page 50: ... 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 Whenremovingthebattery disconnectthenega tive lead first 2 Inspect Fluid level should be between UPPER LEVEL a and LOWER LEVEL b mar...

Page 51: ...he rest Warpage or buckling of plates or insulators is evident 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 5 Install Battery CAUTION Connect the positive lead to the battery termi nal first Make sure ...

Page 52: ...el 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 hou...

Page 53: ... 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 indic...

Page 54: ... fuse 2 HEAD fuse 3 TAIL fuse 4 IGNITION fuse 5 Reserve fuse 6 Reserve fuse Amperage 30 A 20 A 10 A 10 A 20 A 10 A 30 A Q ty 1 1 1 1 1 1 1 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 light ing ignition grip warmer signal and meter sys tems to malfunction ...

Page 55: ...ptimum fuel oil mixture depending on the throttle opening Therefore after the carbure tors 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 spe...

Page 56: ...heck 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 NOTE Bycheckingtheconditionofthesparkplugs itiseasy to get some idea of the condition of the engine This maydiagnosepotentialproblemsbeforeenginedam age occurs High altitude tuning Us...

Page 57: ...2 43 INSP ADJ CARBURETORTUNING Guide for carburetion SEA2720 ...

Page 58: ... silencer is removed from the carbure tors 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 se curedtothecarburetorsduringcarburetortuning and adjustment Also it must always be in place when the engine is operated Regularly clean the silencer and keep it free from obstruc...

Page 59: ...rns Pilot mixture screw 2 2 turns out Pilot mixture screw effects Turn in STD setting Turn out Leaner Richer Mixture Mixture 2 Set the engine idle speed by turning the throttle stopscrewin toincreaseenginespeed orout to decrease engine speed Engine idle speed 1 600 100 r min 3 If low speed performance is still poor at higher elevations under extreme conditions the stan dard pilot jets may need to ...

Page 60: ...hooting Trouble Hard starting Poor idling Poor performance at low speeds Poor acceleration Slow response to throttle Engine tends to stall Diagnosis Insufficient fuel Excessive use of the starter or choke Fuel passage is clogged or frozen Overflow Improper idling speed adjustment Damaged pilot screw Clogged bypass hole Clogged or loose pilot jet Air leaking into the carbu retor joint Defective sta...

Page 61: ...jet clean it with compressed air and then install it Make sure that the pilot jet is fully tightened Overhaul the carburetors Remove the air vent hose and clean it Remove the main jet clean it with compressed air and then install it Make sure that the main jet is fully tightened Check and if necessary clean the float and float valve Return the starter lever to its seated position so that the start...

Page 62: ...olor Y G Y G G G Free length 89 4 mm 3 52 in 87 9 mm 3 46 in Ò Preload 392 N 40 kg 88 lb Spring rate 24 5 N mm 2 50 kg mm 27 0 N mm 2 75 kg mm 140 lb in 154 lb in ˆ Wire diameter 5 8 mm 0 228 in 6 0 mm 0 236 in Ø Outside diameter 60 mm 2 362 in Weight ID 8DG 17605 00 8DG00 Œ Weight rivet Aluminum 10 3 OUT None OUT None OUT Aluminum 10 3 OUT Steel 13 9 IN Steel 13 9 IN Steel 10 3 IN None IN  Weigh...

Page 63: ...5 in Ò Preload 392 N 40 kg 88 lb 343 N 35 kg 77 lb Spring rate 24 5 N mm 2 50 kg mm 29 4 N mm 3 00 kg mm 140 lb in 168 lb in ˆ Wire diameter 5 8 mm 0 228 in 6 0 mm 0 236 in Ø Outside diameter 60 mm 2 362 in Weight ID 8DG 17605 00 8DG00 Œ Weight rivet Steel 10 3 OUT Aluminum 10 3 OUT Aluminum 10 3 OUT Aluminum 10 3 OUT Steel 13 9 IN Steel 13 9 IN Steel 10 3 IN Aluminum 10 3 IN  Weight bushing Dura...

Page 64: ...lor Y W Y Free length 91 4 mm 3 60 in Ò Preload 441 N 45 kg 99 lb Spring rate 24 5 N mm 2 50 kg mm 140 lb in ˆ Wire diameter 6 0 mm 0 236 in Ø Outside diameter 60 mm 2 362 in Weight ID 8DG 17605 00 8DG00 Œ Weight rivet Steel 17 2 OUT Steel 13 3 OUT Steel 13 3 OUT Aluminum 10 3 OUT Steel 17 2 IN Steel 13 9 IN Steel 10 3 IN Steel 10 3 IN  Weight bushing Duralon Í Roller outer dia 15 6 mm 0 61 in Ê ...

Page 65: ...68 L for Europe for Europe 90501 602L9 È Primary sheave spring 90501 582L2 90501 602L9 for Europe Ô Color P G P P G P G S G for Europe 86 7 mm 3 41 in Free length 87 4 mm 3 44 in 86 7 mm 3 41 in for Europe 392 N 40 kg 88 lb Ò Preload 343 N 35 kg 77 lb 392 N 40 kg 88 lb for Europe 29 4 N mm 3 00 kg mm 168 lb in Spring rate 27 0 N mm 2 75 kg mm 29 4 N mm 3 00 kg mm 154 lb in 168 lb in for Europe 6 0...

Page 66: ...0508 536A9 Secondary sheave spring 90508 556A2 90508 536A9 for Europe R Color G R for Europe Free length 75 mm 2 95 in 70 1 6 Á Preload rate 729 kg mm rad 70 1 6 80 2 6 729 kg mm rad 848 kg mm rad 5 3 mm 0 209 in Ω Wire diameter 5 5 mm 0 217 in 5 3 mm 0 209 in for Europe å Outside diameter 69 5 mm 2 736 in Sec torque cam angle 43 ç Sec clutch shim 1 0 mm 0 04 in G Green P Pink S Silver R Red Speci...

Page 67: ...s wet snow icy snow hills or rough terrain however engine speed may decrease after the shift ing 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 GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions I...

Page 68: ...070 GEAR SELECTION 1 Chain and sprocket part number Å Part name Drive sprocket Ï Driven sprocket Ì Chain ı Teeth links Î Standard VT600 for Europe MM600 SX600 VT600 for U S A Canada VX600ER VX600ER VT600 SX600 MM600 VX600ER SX600 MM600 VT600 2 Gear ratio 39 teeth 40 teeth Å Drive sprocket 19 teeth 20 teeth 21 teeth 22 teeth 23 teeth 2 053 1 950 1 857 1 773 1 696 68 links 68 links 68 links 70 links...

Page 69: ...heave spring seat Ç Part no 8BV 17604 71 8BV 17604 51 8BV 17604 31 8BV 17604 11 8BV 17604 91 GEAR SELECTION Ï Standard Î Cam angle 47 45 43 41 39 ı Effects Identification mark 8BV71 8BV51 8BV31 8BV11 8BV91 SEA2750 VX600ER SX600 MM600 VT600 ...

Page 70: ...9 5 08 5 00 6 Primary sheave spring Ò Standard GEAR SELECTION 90501 551L3 90501 551L9 90501 552L5 90501 581L5 90501 581L6 90501 582L1 90501 582L2 90501 582L6 90501 582L7 90501 583L0 90501 583L1 90501 583L4 90501 583L5 90501 601L7 90501 601L8 90501 602L3 90501 602L8 90501 602L9 90501 603L2 90501 603L3 90501 624L8 294 30 343 35 392 40 294 30 294 30 343 35 343 35 392 40 392 40 441 45 441 45 343 35 29...

Page 71: ...N 7 Clutch weights 8CH 17605 10 35 32 g Å Standard 8CR 17605 10 38 09 g 8DG 17605 00 34 30 g 8DJ 17605 00 37 77 g 8DN 17605 20 42 09 g VX600ER SX600 MM600 VT600 SEA2760 SEA2765 SEA2770 SEA2775 SEA2780 8EK 17605 00 39 00 g SEA2785 ...

Page 72: ... mm 0 4 in 90387 0514U GEAR SELECTION 8 Rollers Å ROLLER with BUSHING PART NUMBER ı OUTSIDE DIAMETER Ç BUSHING TYPE P N COLLAR OUTSIDE DIAMETER P N Î IDENTIFICATION MARK Width Standard Ï EFFECTS 8CR 17624 00 8CR 17624 10 8CR 17624 20 8CR 17624 30 14 5 mm 0 57 in 15 0 mm 0 59 in 15 6 mm 0 61 in 16 0 mm 0 63 in SX600 VT600 VX600ER MM600 SEA2790 SEA2795 SEA2800 SEA2805 ...

Page 73: ...ance Adjust the primary clutch as re quired Adjust the secondary clutch as required High altitude tuning OK OK Check to see if the gearing is too high or low OK Not OK Not OK Not OK OK Not OK Not OK OK Check STD settings Carburetors Spark plugs HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions carefully tune the snowmobile as outlined below Test the main jet performan...

Page 74: ...ent steps Turn the spring seat 1 in or out 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 Softer Harder VX600ER VT600 1 MM600 3 SEA2810 Min Max 2...

Page 75: ...achine Adjustment steps Loosen the locknut 1 Turn the adjusting nut 2 in or out to adjust the stopper band tension Adjuster VX600ER thread 15 0 5 mm 0 59 0 02 in length a 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 Less weight on skis on skis Less weight More weight transfer transfer Tighten the locknut Locknut 16 Nm 1 6 m kg 1...

Page 76: ...ntains 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 Spring preload SX600 1 Adjust Spring preload Adjustment steps Turn the spring seat 1 in or out Standard Shorter Longer Preload Harder Softer Spring seat distance Å Front length a ı Rear length b Mi...

Page 77: ...e 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 the nut 1 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 rateadjuster Thebolthasteethonit Sowhenthe bolt is turned it rides up and d...

Page 78: ...nsion position MM600 1 Adjust Rear suspension position NOTE Select the rear suspension position according to the snow conditions a standard b deep new snow Bolt slide rail suspension 72 Nm 7 2 m kg 52 ft lb LOCTITE REAR SUSPENSION SEA2865 ...

Page 79: ...2 65 INSP ADJ REAR SUSPENSION ...

Page 80: ...se the removal procedure 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 upp...

Page 81: ...procedure 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...

Page 82: ... Part name 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 80 Nm 8 0 m kg 58 ft lb 23 Nm 2 3 m kg 17 ft lb 35 Nm 3 5 m kg 25 ft lb 43 Nm 4 3 m kg 31 ft lb Q ty 1 1 1 2 3 4 4 1 4 2 2 2 2 1 1 SEA3030 1 ESSO beacon 325 grease or Aeroshell grease 7...

Page 83: ...g column 1 Collars 2 Wear damage Replace Steering column 3 bearing contact sur faces Scratches wear damage Replace 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 4 Check Rod end movement Rod end free play exists Replace the rod end Rod end turns roughly Replace the rod end 5 Inspect Relay arm Cracks d...

Page 84: ...tie rod faces out The threads on both rod ends must be the same length CAUTION Always use new cotter pins 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 T R SEA3100 SEA3110 SEA3090 Å Tie rod part number 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 88...

Page 85: ... direction until the handlebars at right angles with respect to the direction of movement Tighten the locknuts relay rod 1 Locknut relay rod 25 Nm 2 5 m kg 18 ft lb LOCTITE Turning the relay rod in direction b Turningthehandlebar in direction d Turning the relay rod in direction a Turningthehandlebar in direction c T R 4 Install Relay rod 1 NOTE Make sure that the end of the relay rod with the ind...

Page 86: ...ders 2 Bolt handlebar holder 23 Nm 2 3 m kg 17 ft lb CAUTION First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side For SX600 MM600 The handlebar for the SX600 8EA4 has 8CH 10 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 ...

Page 87: ...se the removal procedure 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 11 Nm 1 1 m kg 8 0 ft lb Å 21 Nm 2 1 m kg 15 ft lb Ç 48 Nm 4 8 m kg 35 ft lb Î 1 ESSO beacon 325 grease or Aeroshell grease 7A SEA3190 17 Nm 1 7 m kg 12 ft lb ı ...

Page 88: ...n reverse the removal procedure 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 11 Nm 1 1 m kg 8 0 ft lb Å 21 Nm 2 1 m kg 15 ft lb ı 48 Nm 4 8 m kg 35 ft lb ç 1 ESSO beacon 325 grease or Aeroshell grease 7A SEA3200 ...

Page 89: ... Ski handle 5 Wear cracks damage Replace Mounting bolt 6 Collar 7 Bolts 8 Collars 9 Wear damage Replace Å VX600ER VT600 ı SX600 MM600 SEA3210 INSTALLATION VX600ER VT600 1 Install Ski column lower bracket 1 NOTE Besuretoinstalltheskicolumnlowerbracketwiththe arrow mark a pointing forward the tip of the ski SEA3220 SEA3230 A B ...

Page 90: ... 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 1 ESSO beacon 325 grease or Aeroshell grease 7A 48 Nm 4 8 m kg 35 ft lb Ç 50 Nm 5 0 m kg 36 ft lb Î 56 Nm 5 6 m kg 40 ft lb 78 Nm 7 8 m kg 56 ft lb Ï 43 Nm 4 3 m kg 31 ft lb ı SEA3240 For SX600 å Fo...

Page 91: ...ckabsorbercontainshighlycompressed nitrogengas Beforehandlingtheshockabsorber read and make sure that you understand the following information The manufacturer cannot be held responsible for property damage or per sonal injury that may result from improper han dling 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 ma...

Page 92: ...3 13 CHAS 4 Inspect Connecting rod 1 Stabilizer 2 Cracks bends damage Replace Collar 3 Wear scratches damage Replace 5 Inspect Front arm 1 Cracks bends damage Replace SEA3280 SEA3290 FRONT SUSPENSION ...

Page 93: ... 1 429 7 0 5 mm 16 9173 0 0197 in 428 7 0 5 mm 16 8779 0 0197 in Upper MM600 Ï Lower MM600 Ç Set angle b Ì color c White 93 1 93 1 429 7 0 5 mm 16 9173 0 0197 in 428 7 0 5 mm 16 8779 0 0197 in Upper MM600 Ï Lower MM600 Green Ï Lower VX600ER SX600 VT600 87 1 87 1 475 5 0 5 mm 18 7204 0 0197 in 472 6 0 5 mm 18 6062 0 0197 in Upper VX600ER SX600 VT600 Ï Lower VX600ER SX600 VT600 Yellow Locknut contro...

Page 94: ... 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 Nut steering arm 56 Nm 5 6 m kg 40 ft lb Å VX600ER VT600 ı SX600 MM600 FRONT SUSPENSION SEA3310 SEA3320 SEA3330 A B ...

Page 95: ...gle 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 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 3 To adjust the camber loosen the lower radius rod ball joint locknut and remove the bolt securing the radius rod to the tra...

Page 96: ...he other side 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 s...

Page 97: ...5 25 5 M R S 3 3 3 10 10 7 8DM 2382E 10 L H 8DM 2382F 10 R H 8CR 2382E 20 L H 8CR 2382F 20 R H 8CS 2382E 20 L H 8CS 2382F 20 R H Stabilizer part number VX600ER SX600 MM600 VT600 Å Part number ı Size length a bar diameter b Ç ID color c 8CR 2386E 00 8CS 2386E 00 8CW 2386E 00 Purple White Light green 896 16 mm 35 2755 0 6299 in 832 16 mm 32 7558 0 6299 in 896 18 mm 35 2755 0 7087 in SEA3390 SEA3400 ...

Page 98: ...600 Ç Part Number Å Upper ı Lower Å Upper ı Lower Î Length a Angle b 8CR 2384E 20 8CR 2384F 20 8CS 2384E 20 8CS 2384F 20 439 5 1 mm 17 3031 0 0394 in 431 6 1 mm 16 9921 0 0394 in 393 7 1 mm 15 5000 0 0394 in 387 7 1 mm 15 2637 0 0394 in 10 8 0 5 10 8 0 5 8 8 0 5 8 8 0 5 SEA3410 ...

Page 99: ...E V BELT Q ty 1 1 1 Remarks Remove the parts in the order listed below For installation reverse the removal procedure Order 1 2 3 Job name Part name Primary sheave removal V belt Blind cap Primary sheave assembly Å 1st 120 Nm 12 0 m kg 85 ft lb 2nd 60 Nm 6 0 m kg 43 ft lb SEA4010 ...

Page 100: ...ks Remove the parts in the order listed below VX600ER VT600 For assembly reverse the disassembly proce dure 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 200 Nm 20 0 m kg 145 ft lb 4 ...

Page 101: ...Y SHEAVE AND DRIVE V BELT REMOVAL 1 Remove Primary sheave assembly 1 NOTE Usetheprimarysheaveholder2andprimarysheave puller 3 Primary sheave holder 90890 01701 YS 01880 Primary sheave puller YS 01881 1 YS 01859 1 SEA4030 ...

Page 102: ...it 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 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 mak...

Page 103: ...ee 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 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 bushi...

Page 104: ...n 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 Pressorpeentherivetheadsothatthediameter a of the rivet head measures 8 2 mm 0 32 in or larger 6 Measure Bushing inside diameter Out of specification Replace as a set Bushing inside diameter Å Roller New 9 077 mm 0 357 in Wear limit 9 3 mm 0 366 in ı Weight New 8 07...

Page 105: ...1 Install Sliding sheave onto the spider NOTE Be sure the sliding sheave match mark X is aligned with the spider match mark X 2 Install Fixed sheave onto the spider NOTE Clean the threads Apply LOCTITE 648 to the fixed sheave as shown 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 SEA4150 SEA4160 C...

Page 106: ...ns on the clutch separator adapter 2 into the fixed sheave holes Tighten the spider to specification using the bar wrench 3 Spider 200 Nm 20 m kg 145 ft lb CAUTION The spider has a left handed thread WARNING Do not operate the primary sheave until the 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 s...

Page 107: ...kwise direction as illustrated 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 Bolt primary sheave cap 14 Nm 1 4 m kg 10 ft lb 7 Tighten Bolts VX600ER VT600 Tightening steps Temporarity tighten the bolts 1 6 in the order shown Bolt starter motor driven gear 20 Nm 2 0 m kg 14 ft lb NOTE Clean the threads Apply L...

Page 108: ...primary sheave 3 using the primary sheave holder 2 and tighten the bolt primary sheave to specification Primary sheave holder 90890 01701 YS 01880 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 specifica tion Bolt primary sheave 60 Nm 6 0 m kg 43 ft lb 4 Adjust V belt position Refer to DRIVE V BELT in C...

Page 109: ...rts in the order listed below Refer to SHEAVE DISTANCE AND OFFSET ADJUSTMENT in CHAPTER 2 For installation reverse the removal procedure Order 1 2 3 4 5 Job name Part name Secondary sheave removal V belt Washer Shim Collar Secondary sheave assembly 64 Nm 6 4 m kg 46 ft lb Å SEA4260 ...

Page 110: ...ure 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 1 ESSO beacon 325 grease or Aeroshell grease 7A 6 5 Nm 0 65 m kg 4 6 ft lb ı 10 Nm 1 0 m kg 7 2 ft lb Ç 4 Nm 0 4 m kg 2 9 ft lb Å SEA4270 23 Nm 2 3 m kg 17 ft lb Î ...

Page 111: ...uc tions thoroughly 1 Remove Nuts spring seat INSPECTION 1 Inspect Sliding sheave 1 Fixed sheave 2 Spring seat 3 Cracks damage Replace Stopper 4 Wear damage Replace 2 Inspect Bushing spring seat 1 Sliding sheave V belt contact surface 2 Scratches wear damage Replace Sliding bushing 3 Unsymmetrical wear damage Replace 3 Inspect Secondary sheave spring 1 Cracks damage Replace 4 Measure Secondary she...

Page 112: ...2 Install Fixed sheave 1 Bolts 2 along with the shims Bolt 10 Nm 1 0 m kg 7 2 ft lb 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 Standard spring position 2 6 VX600ER SX600 MM600 VT600 for Europe 1 6 VT600 for U S A Canada T R T R SEA4320...

Page 113: ... 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 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 5 Calculate Shim thickness NOTE For example if the clearance is 36 mm 1 42 in install a ...

Page 114: ...ecommends keeping the original shims Shims Part number Thickness 90201 061H1 0 5 mm 0 02 in 90201 06037 1 0 mm 0 04 in SEA4380 INSTALLATION 1 Lubricate Splines fixed sheave Recommended grease ESSO beacon 325 grease or Aeroshell grease 7A 2 Tighten 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...

Page 115: ...ollar Drive chain housing 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 Order 1 2 3 4 5 6 7 8 9 10 DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL SEA4390 16 Nm 1 6 m kg 11 ft lb Å 24 Nm 2...

Page 116: ...er as a set Replacement steps Remove the circlip 5 drive chain housing Remove the bearing s 3 using a general bear ing puller Install the new bearing s 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 CAUTION Always use new circlips ...

Page 117: ...e chain Maximum 14 link drive chain section length 133 35 mm 5 25 in Limit 137 35 mm 5 41 in NOTE Measure the length between drive chain pin 1 and E as shown Perform this measurement at two or three different places Ifreplacementisnecessary alwaysreplacethechain and the sprockets as a set 4 Inspect Drive chain 1 Stiffness Clean and lubricate or replace Drive chain plates 2 Damage wear Replace the ...

Page 118: ...ng 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 t...

Page 119: ...everse drive gear DRIVE CHAIN HOUSING Q ty 2 1 1 1 1 1 2 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 Disconnect the gear position switch leads Drain the oil Order 1 2 3 4 5 6 7 8 9 10 WITH REVERSE MODEL SEA4470 16 Nm 1 6 m kg 11 ft lb Ç 24 Nm 2 4 m kg 17 ft lb Î 48 Nm 4 8 m kg 35...

Page 120: ...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 16 Nm 1 6 m kg 11 ft lb Ç 24 Nm 2 4 m kg 17 ft lb Î 48 Nm 4 8 m kg 35 ft lb 60 Nm 6 0 m kg 43 ft lb Ï SEA4470 10 Nm 1 0 m kg 7 2 ft lb Å 13 Nm 1 3 m kg 9 4 ft lb ı ...

Page 121: ... 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 Replacethebearingandthe inner race holder as a set For the bearing replacement and drive chain inspec tion refe...

Page 122: ... 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 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 ...

Page 123: ...cknuts 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 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 SEA4520 DRIVE CHAIN HOUSING ...

Page 124: ...to FUEL PUMP in CHAPTER 7 Refer to DRIVE CHAIN HOUSING For installation reverse the removal procedure 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 8 5 Nm 0 85 m kg 6 1 ft lb Å 23 Nm 2 3 m kg 17 ft lb ı SEA4530 ...

Page 125: ...ontact surface 3 Scratches wear damage Replace the jackshaft 2 Inspect Bearing holder 1 Cracks damage Replace Bearing 2 Pitting damage Replace 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 SEA4540 SEA4550 SEA4560 ...

Page 126: ... the nuts 3 Tighten the nuts 4 Nut jackshaft 60 Nm 6 0 m kg 43 ft lb Retighten the nuts 3 Nut bearing holder 23 Nm 2 3 m kg 17 ft lb Tighten the set screws 5 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 Bolt drive chain housing cover...

Page 127: ...parts in the order listed below For installation reverse the removal procedure 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 6 Nm 0 6 m kg 4 3 ft lb Å 48 Nm 4 8 m kg 35 ft lb ı BRAKE SEA4580 ...

Page 128: ...occur Do not disconnect any hydraulic connection otherwise the entire system must be disas sembled 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 ot...

Page 129: ...aliper bleed screw and push the pistons into the caliper with your finger Tighten the caliper bleed screw 2 Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pads and pad spring 3 Inspect Brake fluid level Referto BRAKEFLUIDLEVELINSPECTION in CHAPTER 2 4 Check Brake lever operation A soft or spongy feeling Bleed brake sys tem Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 2 T R SEA461...

Page 130: ...ks Remove the parts in the order listed below Drain For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 Job name Part name Brake caliper and parking brake re moval Brake fluid Brake hose Brake caliper assembly Cotter pin Parking brake cable Pin Pin Collar Spring Brake shoe SEA4620 ...

Page 131: ...move the parts in the order listed below For assembly reverse the disassembly proce dure 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 SEA4630 ...

Page 132: ...e piston seals and reinstall the piston Repeat the previous steps to force out the right piston from the caliper body WARNING Never try to pry out the pistons Do not loosen the retaining pin 3 BRAKE CALIPER INSPECTION AND REPAIR Recommended brake component replacement schedule WARNING All internal brake components should be cleaned only with new brake fluid Do not use solvents as they will cause s...

Page 133: ...hen ever 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 when ever a caliper is disassembled BRAKE CALIPER INSTALLATION 1 Install Brake hose 1 CAUTION When installing the brake hose 1 onto t...

Page 134: ...cylinder kit Master cylinder body Q ty 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed below Drain For installation reverse the removal procedure 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 å For VX600ER SX600 VT600 1 ESSO beacon 32...

Page 135: ...TER 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 when ever a caliper is disassembled INSTALLATION 1 Connect Brake hose NOTE Install the brake hose with the mark a facing up wards as shown in the diagram Brake hose join...

Page 136: ... Remove the parts in the order listed below Loosen Loosen For installation reverse the removal procedure 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 72 Nm 7 2 m kg 52 ft lb Å SEA4730 ...

Page 137: ...order listed below Loosen Loosen For installation reverse the removal procedure 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 24 Nm 2 4 m kg 17 ft lb Å ı 72 Nm 7 2 m kg 52 ft lb SEA4740 ...

Page 138: ...m kg 35 ft lb 72 Nm 7 2 m kg 52 ft lb Ï 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 SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Î 30 Nm 3 0 m kg 22 ft lb SEA4750 1 ESSO beaco...

Page 139: ... 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 24 Nm 2 4 m kg 17 ft lb Å 49 Nm 4 9 m kg 35 ft lb ı 72 Nm 7 2 m kg 52 ft lb Ç å For SX600 SEA4760 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 140: ...00 VT600 VT600 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 49 Nm 4 9 m kg 35 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı SEA4770 1 ESSO beacon 325 grease or Aeroshell grease 7A å For SX600 ...

Page 141: ... 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 SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı 75 Nm 7 5 m kg 54 ft lb Ç For SX600 å SEA4780 1 ESSO beacon 325 grease or Aeroshell grease 7A For VX600ER VT600 For SX600 VT600 ç ...

Page 142: ...e parts in the order listed below Loosen Loosen For installation reverse the removal procedure Order 1 2 3 Job name Part name Slide rail suspension removal Rear axle nut Tension adjuster Suspension rear plate Slide rail suspension Collar 72 Nm 7 2 m kg 52 ft lb Å SEA4790 ...

Page 143: ... 35 ft lb 72 Nm 7 2 m kg 52 ft lb Ï 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 SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Î 30 Nm 3 0 m kg 22 ft lb SEA4800 1 ESSO beacon 325 grease or Aerosh...

Page 144: ...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 24 Nm 2 4 m kg 17 ft lb Å 49 Nm 4 9 m kg 35 ft lb ı 72 Nm 7 2 m kg 52 ft lb Ç SEA4810 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 145: ...Remarks 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 49 Nm 4 9 m kg 35 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı SEA4820 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 146: ...e 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 SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı 75 Nm 7 5 m kg 54 ft lb Ç SEA4830 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 147: ...topper 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 Å VX600ER SX600 VT600 ı MM600 SEA4840 SEA4850 SEA4860 B A ...

Page 148: ...52 ft lb LOCTITE 2 Install Stopper band 1 NOTE For VX600ER SX600 VT600 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 Nut stopper band 4 Nm 0 4 m kg 2 9 ft lb INSTALLATION 1 Adjust Slide rail suspension position MM600 Referto REARSUSPENSION inCHAPTER2 SEA4870 SEA4880 T R T R ...

Page 149: ...m 5 7480 in Ì Washer plate parts number Ó Washer plate thickness È Upper Ô Lower VX600ER 8CR 4745A 01 90202 16232 90202 16232 SX600 10 0 mm 0 3937 in 10 0 mm 0 3937 in MM600 8ED 4745A 00 8CR 4745B 00 90202 16229 90202 16231 2 5 mm 0 0984 in 7 5 mm 0 2953 in VT600 8CR 4745A 01 90202 16230 90202 16229 5 0 mm 0 1969 in 2 5 mm 0 0984 in Ï Control rod 2 parts number Control rod 1 parts number SLIDE RAI...

Page 150: ...Y SHEAVE For installation reverse the removal procedure 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 FRONT AXLE AND TRACK 8 5 Nm 0 85 m kg 6 1 ft lb Å 20 Nm 2 0 m kg 14 ft lb ı Q ty 1 1 2 1 1 1 SEA4900 ...

Page 151: ...ocket wheels Guide wheels NOTE When pressing the sprocket wheels onto the front axle align the lugs on each sprocket wheel Position each sprocket wheel on the axle as shown in the illustration Å VX600ER VT600 ı SX600 Ç MM600 SEA4910 SEA4920 102 mm 4 02 in 132 6 mm 5 22 in 164 1 mm 6 46 in 123 mm 4 84 in 102 mm 4 02 in 27 mm 1 06 in 39 mm 1 54 in 39 mm 1 54 in 43 1 mm 1 70 in 60 mm 2 36 in 111 9 mm...

Page 152: ...NOTE For track with a direction of rotation mark a Install the track with the mark pointing in the direc tion of track rotation Å VX600ER VT600 for U S A Canada ı SX600 Ç MM600 Î VT600 for Europe SEA4960 SEA4970 FRONT AXLE AND TRACK A B SEA4980 C SEA4990 D ...

Page 153: ...pen For installation reverse the removal procedure Q ty 2 2 1 1 1 1 1 1 2 1 1 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 1st 18 Nm 1 8 m kg 13 ft lb Å SEA5010 2nd 27 Nm 2 7 m kg 19 ft lb ...

Page 154: ...l the gasket 3 with its projection a facing the primary sheave side Tighten the bolts 1 6 in a crisscross pattern 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 NOTE Install the springs as shown T R SEA5020 SEA5030 5 ...

Page 155: ...ER VT600 VX600ER VT600 For installation reverse the removal procedure Q ty 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 Job name Part name Engine removal Exhaust assembly Carburetors Recoil starter AC magneto rotor Primary sheave Coolant 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 ...

Page 156: ...e routings 1 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 heatinghose3 2togethersothatthewhitetapeon the starter motor lead 3 is positioned behind the front bracket 2 Install Starter motor lead 1 VX600ER VT600 NOTE Route the starter motor lead as shown in the illustra tion SEA5050 SEA5060 SEA5...

Page 157: ... 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 ENGINE ASSEMBLY SEA5080 ...

Page 158: ... 6 7 8 9 10 Job name Part name 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 Remarks Remove the parts in the order listed below Å 10 Nm 1 0 m kg 7 2 ft lb SEA5090 ı 14 Nm 1 4 m kg 10 ft lb ...

Page 159: ...sor Cylinder head Gasket Cylinder Gasket Clamp Intake manifold Spacer Reed valve seat Reed valve stopper Reed valve Gasket Piston ring Piston pin Piston Bearing Remarks For installation reverse the removal procedure 14 Nm 1 4 m kg 10 ft lb Å 20 Nm 2 0 m kg 14 ft lb Ç 1st 11 Nm 1 1 m kg 8 0 ft lb 2nd 23 Nm 2 3 m kg 17 ft lb ı 23 Nm 2 3 m kg 17 ft lb Î SEA5100 28 Nm 2 8 m kg 20 ft lb ...

Page 160: ... 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 ...

Page 161: ...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 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 5 Eliminate Carbon deposits from the piston crown and ring grooves 6 Inspect Piston crown Burrs ...

Page 162: ...erbore C withacylinderbore gauge 1 NOTE Measure the cylinder bore C parallel to and at right angles to the crankshaft Then find the average of the measurements 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 re place piston and piston rings as a set Standard Wear limit Cylinder bore C Taper T Out of ...

Page 163: ... 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 befo...

Page 164: ...auge 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 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 13 Measure Piston pin to piston clearance Out of specification Replace the piston Piston pin to piston ...

Page 165: ...ce 15 Measure Valve stopper height a Out of specification Replace the valve stop per Valve stopper height 10 3 10 7 mm 0 41 0 42 in 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 SEA5260 SEA5270 SEA5280 ...

Page 166: ...en each screw gradually to avoid warping 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 front of the engine Before installing the piston pin clip cover the crankcase with a clean rag so that you do not accidentallydropthepinclipandothermaterialinto the crankcase Position each piston very carefully in its original p...

Page 167: ...5 Install Gasket cylinder NOTE Install the gasket cylinder with its projection a facing the AC magneto side CAUTION Always use new gasket 6 Install Cylinder NOTE Install the cylinder with one hand while compressing the piston rings with the other hand 7 Tighten Nuts cylinder Nut cylinder 28 Nm 2 8 m kg 20 ft lb 8 Install Gaskets cylinder head NOTE Install with the mark a facing upwards and the pro...

Page 168: ...lack 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 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 short...

Page 169: ... bracket Damper Clamp Front upper bracket Clamp Water pump cover Gasket Oil hose 2 Lower crankcase Crankshaft assembly Oil seal Upper crankcase 8 Nm 0 8 m kg 5 8 ft lb Å 13 Nm 1 3 m kg 9 4 ft lb ı 15 Nm 1 5 m kg 11 ft lb Ç 40 Nm 4 0 m kg 29 ft lb Remarks Remove the parts in the order listed below VX600ER VT600 VX600ER VT600 For installation reverse the removal procedure 2nd 27 Nm 2 7 m kg 19 ft lb...

Page 170: ...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 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 defect...

Page 171: ... immediately after examin ing 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 5 Inspect Impeller driven gear teeth 1 Wear damage Replace the impeller shaft Impeller shaft 2 Bearing 3 Pitting damage Replace 6 Inspect Oil pump Cracks damage Replace Oil hoses Clogs damage Repl...

Page 172: ... 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 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 CAUTION The oil seal lip must fit into the crankcase groove SEA5470 SEA5480 SEA5500 SEA5490 ...

Page 173: ...bolts be sure to check that the crankshaft turns smoothly 4 Tighten Crankcase bolts 1 F M8 80 NOTE Tighten the bolts in order starting with the lowest number and torque the bolts in two stages 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 NOTE Tighten the bolts in order starting with the lowest number Bolt crankcase 15 Nm 1 5 m kg 11 ft...

Page 174: ...5 22 ENG a OIL PUMP CRANKCASE AND CRANKSHAFT 6 Install Oil hose 1 NOTE Install so that the mark a on the check valve faces the crankcase SEA5550 ...

Page 175: ...or installation reverse the removal procedure 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 23 Nm 2 3 m kg 17 ft lb Å 48 Nm 4 8 m kg 35 ft lb ı 110 Nm 11 m kg 80 ft lb Ç SEA5560 ...

Page 176: ...sheave holder 90890 01701 YS 01880 2 Remove Magneto rotor 1 NOTE Remove the magneto rotor using the rotor 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 SEA5570 SEA5580 ...

Page 177: ...e to remove any oil or grease from the tapered portion of the crankshaft using a cloth dampened with thinner NOTE 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 ...

Page 178: ...ghten Bolts 1 Nut 2 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 T R SEA5610 ...

Page 179: ...For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 11 12 Nm 1 2 m kg 8 7 ft lb Å 18 Nm 1 8 m kg 13 ft lb ı 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 SEA5620 ...

Page 180: ...o that it is not pulled into the recoil starter case 4 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 SEA5630 SEA5640 SEA5650 ...

Page 181: ...eter 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 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 NOTE Pass the rope through the case hole and make a knot 1 in...

Page 182: ... 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 le...

Page 183: ...5 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 rea...

Page 184: ...XCHANGER INSPECTION 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 SEA6040 A B ...

Page 185: ...e 95 125 kPa 0 95 1 25 kg cm2 14 18 psi 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 SEA6050 HEAT EXCHANGER ...

Page 186: ...allation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 11 Job name Part name Water pump and thermostatic valve removal Exhaust joint Coolant Thermostatic cover Plain washer Gasket Plastic band Clamp Engine bracket Carburetor heating hose 3 Coolant hose 6 Water pump cover Gasket Impeller 10 Nm 1 0 m kg 7 2 ft lb Å 13 Nm 1 3 m kg 9 4 ft lb ı 33 Nm 3 3 m kg 24 ft lb Ç 90 Nm 9 0 m kg 65 ft ...

Page 187: ... 1 Install Impeller 1 NOTE Attach the primary sheave holder to hold the primary sheave Primary sheave holder 90890 01701 YS 01880 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 heatinghose3 2togethersothatthewhitetapeon the starter motor lead 3 is positio...

Page 188: ...eating lever is turned to OFF Unfasten Loosen Disconnect For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 Job name Part name Carburetors removal Intake silencer Carburetor heating lever Carburetor switch T O R S lead Throttle cable Starter cable Clamp Carburetor heating hose Clamp screw Fuel delivery hose Carburetor CARBURETION CARBURETORS SEA7010 7 ...

Page 189: ...oce dure 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 SEA7020 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 190: ...sembly 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 0 7 Nm 0 07 m kg 0 51 ft lb Å 1 Nm 0 1 m kg 0 7 ft lb ı 1 8 Nm 0 18 m kg 1 3 ft lb Ç 2 5 Nm 0 25 m kg 1 8 ft lb Î SEA7030 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 191: ... 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 CARBURETORS 0 7 Nm 0 07 m kg 0 51 ft lb Å 1 Nm 0 1 m kg 0 7 ft lb ı 1 8 Nm 0 18 m kg 1 3 ft lb Ç 2 5 Nm 0 25 m kg 1 8 ft lb Î SEA7030 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 192: ...pressed air 2 Inspect Rubber seals 1 Bearing 2 Wear damage Replace 3 Inspect Float 1 Damage Replace 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 SEA7040 SEA7050 SEA7060 SEA7070 ...

Page 193: ...clean gaso line Always use new gaskets and O rings 1 Tighten Inner parts 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 T R SEA7080 SEA7090 ...

Page 194: ...eat 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 de grees CARBURETOR SYNCHRONIZATI...

Page 195: ...01312 A NOTE 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 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...

Page 196: ...Carburetor heating hose 2 1 NOTE Fasten the carburetor heating hose 2 with a clamp 2 at the white mark a 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 SEA7150 ...

Page 197: ...up the throttle and oil pump cables Disconnect Disconnect Disconnect Disconnect For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name Part name Fuel pump removal Carburetor heating lever assembly Air filter element Screw Plastic band Wire harness Throttle cable Oil pump cable Intake silencer Fuel hose Fuel delivery hose Vacuum hose Oil delivery hose Fuel pump ...

Page 198: ...nect For installation reverse the removal procedure 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 5 Nm 0 5 m kg 3 6 ft lb Å 10 Nm 1 0 m kg 7 2 ft lb ı SEA7170 ...

Page 199: ...2 Mity vac 90890 06756 YS 42423 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...

Page 200: ... switch turn it on and off a few times INSPECTING A SWITCH SHOWN IN THE MANUAL 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 The exa...

Page 201: ...R B B Y B W Br O Gy W G W R W G W B L W Y W B W C B Y B G R B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C O B O B O B D LO HI OFF L M G R Y L O B Y R O B Y L G R Y L Y L G R R Y L G R B B BL...

Page 202: ...round K Frame ground S Brake light switch T Tail brake light U Fuel sender V Oil level switch W Speedometer X Oil level indicator light Y Water temperature indicator light Z High beam indicator light Speedometer light Tachometer light Tachometer _ Fuel meter a Headlight b Headlight beam switch c Headlight relay with the black coupler d Load control relay with the white coupler e IGNITION fuse 2 1 ...

Page 203: ...CATION 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 ...

Page 204: ...hting 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 IGNITION SYSTEM ...

Page 205: ...e Condenser capacity 6 800 µF at 20 C 68 F SEA8040 SEA8050 SEA8060 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 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 ...

Page 206: ...Spark plug cap resistance Out of specification Replace Spark plug cap resistance 5 kΩ at 20 C 68 F 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 Primary coil resistance 0 36 0 48 Ω at 20 C 68 F Secondary coil resistance 5 4 7 ...

Page 207: ...t 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 Throttle switch OFF OFF T O R S operating ON OFF Running Idling or starting OFF ON Running Carburetor switch Status Switch Engine Trouble Running B 1 Carburetor switch 2 Throttle switch 3 Throttle cable 4 Throttle stop screw a ON b OFF SEA8110 ...

Page 208: ...Carburetor switch lead 1 2 Connect Pocket tester 3 Check Carburetor switch continuity Faulty Replace Carburetor switch position Continuity Throttle lever is operated No Throttle lever is not operated Yes SEA8180 SEA8190 IGNITION SYSTEM MAIN SWITCH 1 Disconnect Main switch coupler 1 2 Connect Pocket tester 3 Check Main switch continuity Faulty Replace Switch position Continuity OFF Yes ON No Switch...

Page 209: ... battery terminal Brown 1 Negative battery terminal Brown White 2 Positive tester probe Red 3 Negative tester probe Blue 4 If load control relay does not have continuity between the red and blue terminals replace it 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 ...

Page 210: ... W B Y Ch Ch RUN IDLE B Y L R Br W Y R B B Y B W Br W R W G C B Y B G R B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK BLACK L R B R L Br Br W D B L R Y R B A A B Lg B Lg B W B B B Br B B L d ı Ç Br R L e f g Br W L W 30A 10A 10A 20A Lg L G L R E ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM VX600ER VT600 ELECTRICAL STARTING SYSTEM SCH8230 4 Main fuse 2 5 Starter rela...

Page 211: ...ly to produce sparks so be sure that no flammable gas or fluid is in the vicinity 3 Disconnect Starter relay coupler 4 Connect Starter relay coupler terminals 1 Jumper lead 2 Check Starter motor operation OK 1 Jumper lead 5 Check Starter motor operation NO Replace the starter relay OK Repair or replace the starter motor Charge and or replace the battery Refer to BATTERY CHARGING in CHAPTER 2 NO Ch...

Page 212: ...use and or IGNITION fuse ELECTRICAL STARTING SYSTEM Check the main switch FAULTY Replace the main switch MAIN SWITCH 1 Disconnect Main switch coupler 1 2 Connect Pocket tester 3 Check Main switch continuity Faulty Replace Switch position Continuity OFF Yes ON No Switch Color code position Br R R W B B W OFF ON START Continuity SEA8190 OK ...

Page 213: ...embly reverse the disassembly proce dure 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 ELECTRICAL STARTING SYSTEM SEA8260 STARTER MOTOR VX600ER VT600 ...

Page 214: ...ter 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 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 ELECTRICAL STARTING S...

Page 215: ...il 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 ELECTRICAL STARTING SYSTEM SEA8300 5 Measure Brush length a Out of specification Replace the starter motor Brush length wear limit 8 5 mm 0 33 in 6 Measure Brush spring pressure Fatigue out of specification Replace as a set Brush spring p...

Page 216: ...ings of the front bracket and rear bracket 2 Make sure the front bracket and rear bracket cover are fitted with O rings 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 ELECTRICAL STARTING SYSTEM SEA8320 SEA8330 ...

Page 217: ...Ch B Y B W B RUN OFF OFF OPEN 0 9 B W B Y Ch Ch RUN IDLE B Y L R Br W Y R B B Y B W Br W R W G C B Y B G R B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK BLACK L R B R L Br Br W D B L R Y R B A A B Lg B Lg B W B B B Br B B L d ı Ç Br R L e f g Br W L W 30A 10A 10A 20A Lg L G L R E 1 AC magneto 2 Rectifiler regulator 4 Main Fuse 2 6 Battery 2 2 VX600ER VT600 CHARGIN...

Page 218: ... the startor coil assembly FAULTY Replace the rectifier regulator OK 3 Start the engine and accelerate to 5 000 r min 4 Measure Charging voltage Charging voltage 14 V 5 000 r min Correct connector OK WARNING Be sure the V belt is removed CAUTION Never disconnect battery cables while generator isoperating otherwise therectifier regulatorwill be damaged OUT OF SPECIFICATIONS Check the battery Refer ...

Page 219: ...e tips Recharge the battery periodically Store the battery in a cool dry place Recharge the battery before reinstalling Specific gravity 1 280 at 20 C 68 F 2 0 Amp for 10 hours new battery 10 hours or until specific gravity reaches 1 280 Distilled water to maximum level line Check once per month or more often as required Battery Electrolyte Initial charg ing rate Recharging rate Refill fluid Refil...

Page 220: ...8 21 ELEC CHARGING SYSTEM ...

Page 221: ...R B B Y B W Br O Gy W G W R W G W B L W Y W B W C B Y B G R B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C O B O B O B D LO HI OFF L M G R Y L O B Y R O B Y L G R Y L Y L G R R Y L G R B B BL...

Page 222: ...switch E CDI unit K Frame ground T Tail brake light Z High beam indicator light Speedometer light Tachometer light a Headlight b Headlight beam switch c Headlight relay with the black coupler d Load control relay with the white coupler e IGNITION fuse 2 f TAIL fuse 2 g HEAD fuse 2 1 SX600 MM600 2 VX600ER VT600 ı SX600 MM600 Ç VX600ER VT600 ...

Page 223: ... 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 headlig...

Page 224: ...IFICATION 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...

Page 225: ...ulb while it is on it will be hot Do not touch the bulb until it cools down 3 Check Bulb s 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 Switch position Continuity HI Yes LO No Lg L W LIGHTING SYSTEM SEA8380 SEA8390 SEA8400 ...

Page 226: ...lue White 1 Negative tester probe Green 2 If headlight relay does not have continuity be tween the blue white and green terminals re place it Connect the pocket tester Ω 1 and battery 12V to the headlight relay terminals as shown Positive battery terminal Light green 3 Negative battery terminal Black 4 Positive tester probe Blue White 5 Negative tester probe Yellow 6 If headlight relay does not ha...

Page 227: ...Y R B B Y B W Br O Gy W G W R W G W B L W Y W B W C B Y B G R B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C O B O B O B D LO HI OFF L M G R Y L O B Y R O B Y L G R Y L Y L G R R Y L G R B B ...

Page 228: ...r E CDI unit K Frame ground Q DC back buzzer 2 R Gear position switch 2 S Brake light switch T Tail brake light U Fuel sender V Oil level switch X Oil level indicator light Y Water temperature indicator light Fuel meter d Load control relay with the white coupler e IGNITION fuse 2 f TAIL fuse 2 g HEAD fuse 2 1 SX600 MM600 2 VX600ER VT600 ı SX600 MM600 Ç VX600ER VT600 ...

Page 229: ... 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 li...

Page 230: ... 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 ...

Page 231: ...or 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 fuel sender OK FAULTY Replace the fuel sender Check the load control relay Refer to...

Page 232: ...RY 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...

Page 233: ...on Continuity Brake lever operates Yes Brake lever does not operate No SIGNAL SYSTEM SEA8450 GEAR POSITION SWITCH VX600ER VT600 1 Check Gear position switch 1 continuity Faulty Replace Shift lever position Continuity FORWARD No REVERSE Yes DC BACK BUZZER VX600ER VT600 1 Disconnect DC back buzzer coupler 1 2 Connect Battery 3 Check DC back buzzer Does not sound Replace SEA8470 SEA8480 SEA8490 SEA84...

Page 234: ...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 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...

Page 235: ... Replace Continuity No continuity FUEL SENDER 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 Fuel sender resistance full 4 10 Ω at 20 C 68 F Fuel sender resistance empty 90 100 Ω at 20 C 68 F Switch positio...

Page 236: ...8 37 ELEC SIGNAL SYSTEM ...

Page 237: ... B Y B W Br O Gy W G W R W G W B L W Y W B W C B Y B G R B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C O B O B O B D LO HI OFF L M G R Y L O B Y R O B Y L G R Y L Y L G R R Y L G R B B BLACK...

Page 238: ...rmer E CDI unit F Variableresistor thumbwarmer G Variable resistor grip warmer K Frame ground L Passenger grip warmer switch 3 M Resistor 3 N Passenger grip warmer left 3 O Passenger grip warmer right 3 P Passenger grip warmer relay 3 d Load control relay with the white coupler e IGNITION fuse 2 f TAIL fuse 2 1 SX600 MM600 2 VX600ER VT600 3 VT600 ı SX600 MM600 Ç VX600ER VT600 ...

Page 239: ...k 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 ...

Page 240: ...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 Check the resistor CORRECT INCORRECT Replace the resistor Check the passeng...

Page 241: ...rip warmer 1 continuity Thumb warmer 2 continuity No continuity Replace both grips together or separately and or the handlebar switch VARIABLE RESISTOR THUMB WARMER 1 Disconnect Variable resistor coupler 1 2 Connect Pocket tester to the variable resistor coupler 3 Check Variable resistor resistance When pulley is turned once Out of specification Replace the variable resistor Variable resistor resi...

Page 242: ...ulley is turned once Out of specification Replace the variable resistor Variable resistor resistance Yellow White Black Red 400 600 Ω at 20 C 68 F GRIP WARMER SYSTEM PASSENGER GRIP WARMER VT600 1 Disconnect Passenger grip warmer coupler 1 2 Connect Pocket tester to the passenger grip warmer coupler 3 Check Passenger grip warmer continuity Nocontinuity Replacebothpassengergrips together or separate...

Page 243: ...warmer switch coupler 3 Check Passenger grip warmer switch continuity Faulty Replace Y L O B LO OFF HI Continuity Y R RESISTOR VT600 1 Disconnect Resistor coupler 1 2 Connect Pocket tester to the resistor coupler 3 Measure Resistor resistance Out of specification Replace Resistor resistance Black Black 1 4 1 7 Ω at 20 C 68 F GRIP WARMER SYSTEM SEA8650 SEA8660 SEA8670 SEA8680 SEA8690 ...

Page 244: ...m the coupler Connect the pocket tester Ω 1 and battery 12 V to the passenger grip warmer relay termi nals 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 If load control relay does not have continuity between the blue red and orange black termi nals replace it GRIP WARMER SYSTEM ...

Page 245: ...orrected No Patterns Condition Reference Refer to SIGNAL SYSTEM Refer to WATER TEMPERATURE SENSOR Refer to VARI ABLE RESISTOR GRIP WARMER Water temperature indicator light is good If the water tempera ture indicator light does not come on replace it Overheat Shorting of the water temperature sensor is detected Discontinuity of the variable resistor grip warmer is detected 0 1 2 3 ON Warning light ...

Page 246: ... GRIP WARMER SYSTEM Refer to VARI ABLE RESIS TOR THUMB WARMER Refer to GRIP WARMER SYSTEM Refer to GRIP WARMER SYSTEM Shorting of grip warmer is detected Discontinuity of the variable resistor thumb warmer is detected Shorting of thumb warmer is detected Abnormal electric source voltage 4 5 6 7 SEA8760 SEA8770 SEA8780 SEA8790 ON Warning light is on OFF Warning light is off s Second ...

Page 247: ... recoil hand starter VX600ER VT600 Separate lubrication YAMAHA AUTOLUBE YAMALUBE 2 cycle oil 3 0 L 2 6 Imp qt 3 2 US qt Gear oil API GL 3 SAE 75 or 80 0 25 L 8 8 Imp oz 8 5 US oz 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 SPECIFICATIONS GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model code number...

Page 248: ...ER SX600 MM600 VT600 Regular unleaded gasoline Pump Octane R M 88 or higher 2 Research Octane 93 or higher for Europe 44 3 L 9 7 Imp gal 11 7 US gal TM31 3 MIKUNI BR9ES NGK 0 7 0 8 mm 0 028 0 031 in 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 Mono...

Page 249: ...achometer light Speedometer light High beam indicator light Water temperature indicator light Oil level indicator light 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 GENERAL SPECIFICATIONS ...

Page 250: ... B 1 20 mm 0 047 in T 2 55 mm 0 100 in 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 Model Cylinder head Volume with spark plug Warp limit Cylinder Material Bore size Wear limit Taper limit Out of round limit Piston Piston size D...

Page 251: ...diameter Big end diameter Read valve Material Thickness Bending limit Stopper height 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 Needle bearing Needle bearing 26 991 27 000 mm 1 0626 1 0630 ...

Page 252: ...e Water pump type Coolant type Coolant mixing ratio coolant water Coolant total amount Reservoir tank capacity 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 Diaphragm TAIYO GIKEN 23 1 mm 0 906 0 039 in 95 125 kPa 0 95 1 25 kg cm2 14 18 psi Impell...

Page 253: ...600ER 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...

Page 254: ...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 Model Primary sheave weight arm Part number with bushi...

Page 255: ... 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 ...

Page 256: ...57 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 16...

Page 257: ...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 ...

Page 258: ...urer No load regulated voltage DC Capacity DC Withstand voltage Battery VX600ER VT600 Specific gravity Manufacturer Type Ten hour rate amperage Electric starter system VX600ER VT600 Type VX600ER SX600 MM600 VT600 12 V 18 at 1 500 r min Digital type 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 Rubber type T156 TOKAI DENSO 5 kΩ at 20 C 68 F AC magneto 14 V...

Page 259: ...e for individual circuit Main fuse Head fuse Tail fuse Ignition fuse Reserve fuse Reserve fuse Reserve fuse Water temperature sensor Model Manufacturer Resistance 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 MS5F 441 JIDECO 180 A 4 2 4 6 Ω at 20 C 68 F 8CR...

Page 260: ... 5 JN 3 PS 2 MJ 1 136 3 MJ 2 3 133 8 PJ 42 5 JN 3 PS 2 MJ 1 135 MJ 2 3 132 5 PJ 42 5 JN 2 5 PS 2 MJ 1 133 8 MJ 2 3 131 3 PJ 42 5 JN 2 5 PS 2 1 2 MJ 1 131 3 MJ 2 3 128 8 PJ 42 5 JN 2 PS 2 1 2 MJ 1 128 8 MJ 2 3 126 3 PJ 42 5 JN 2 PS 3 MJ 1 126 3 MJ 2 3 123 8 PJ 45 JN 1 5 PS 3 MJ 1 142 5 MJ 2 3 140 PJ 42 5 JN 3 PS 2 MJ 1 141 3 MJ 2 3 138 8 PJ 42 5 JN 3 PS 2 MJ 1 140 MJ 2 3 137 5 PJ 42 5 JN 3 PS 2 MJ ...

Page 261: ...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 va...

Page 262: ...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 re...

Page 263: ...ivot 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 NOTE Tightening steps 1 Tighten ...

Page 264: ...m kg ft lb Parts to be tightened Remarks 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 colu...

Page 265: ...e General torque specifications Nm m kg ft lb A nut B bolt 4 3 11 22 40 61 94 6 15 30 55 85 130 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 0 6 1 5 3 0 5 5 8 5 13 0 A Distance across flats B Outside thread diameter DEFINITION OF UNITS Unit Read Definition Measurement mm cm kg N Nm m kg Pa N mm L cm3 r min Millimeter Centimeter Kilogram Newton Newton meter Meter kilogram P...

Page 266: ...9 20 SPEC GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS ...

Page 267: ...SPEC 9 21 CABLE ROUTING SEA9010 ...

Page 268: ...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 hos...

Page 269: ...SPEC 9 23 CABLE ROUTING SEA9010 ...

Page 270: ...e 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 ...

Page 271: ...SPEC 9 25 CABLE ROUTING SEA9020 ...

Page 272: ...9 26 SPEC CABLE ROUTING 1 Brake hose 2 Oil pump cable 3 Throttle cable 4 Wire harness 5 Starter cable ...

Page 273: ...SPEC 9 27 CABLE ROUTING SEA9030 ...

Page 274: ...l 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 t...

Page 275: ...SPEC 9 29 CABLE ROUTING SEA9030 ...

Page 276: ...l 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 ...

Page 277: ...SPEC 9 31 CABLE ROUTING SEA9040 ...

Page 278: ...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 ...

Page 279: ...SPEC 9 33 CABLE ROUTING SEA9050 ...

Page 280: ...nk 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 SX...

Page 281: ...SPEC 9 35 CABLE ROUTING SEA9050 ...

Page 282: ...armer 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...

Page 283: ...SPEC 9 37 CABLE ROUTING SEA9060 ...

Page 284: ...rness 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 harne...

Page 285: ... OFF OPEN 0 9 B W B Y Ch Ch RUN IDLE B Y L R Y R B B Y B W Br O Gy W G W R W G W B L W Y W B W C B Y B G R B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C O B O B O B D LO HI OFF L M G R Y L O...

Page 286: ...tch D Water temperature sensor E CDI unit F Variable resistor thumb warmer G Variable resistor grip warmer H Ignition coil I Spark plug J Engine ground K Frame ground L Passenger grip warmer switch 3 M Resistor 3 N Passenger grip warmer left 3 O Passenger grip warmer right 3 P Passenger grip warmer relay 3 Q DC back buzzer 2 R Gear position switch 2 S Brake light switch T Tail brake light U Fuel s...

Page 287: ...Printed in USA E CR PRINTED ON RECYCLED PAPER ...