Yamaha VT600G Manuel de service

VX600ERGSX600GMM600GVT600GSERVICE MANUALLIT-12618-02-20 8EA-28197-10981059

1-2GENINFOIMPORTANT INFORMATIONIMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DISASSEMBLY1.Remove all dirt, mud, dust, and foreign material before r

POWRTR4-2PRIMARY SHEAVE AND DRIVE V-BELT4 Nm (0.4 m · kg, 2.9 ft · lb)Å:14 Nm (1.4 m · kg, 10 ft · lb)Ç:6 Nm (0.6 m · kg, 4.3 ft · lb)ı:20 Nm (2.0 m ·

POWRTR4-3PRIMARY SHEAVE AND DRIVE V-BELTREMOVAL1. Remove:• Primary sheave assembly 1NOTE:Use the primary sheave holder 2 and primary sheavepuller 3.Pr

POWRTR4-4SEA4040SEA4050SEA4060SEA4070DISASSEMBLY1. Remove:• Fixed sheave 1• Stopper 2• Sliding sheave 3• Bushing 4• Spider 5Removal steps:• Immerse th

POWRTR4-5PRIMARY SHEAVE AND DRIVE V-BELTINSPECTION1. Inspect:• Spider 1• Sliding sheave 2• Fixed sheave 3• Primary sheave cap 4Cracks/damage → Replace

POWRTR4-6PRIMARY SHEAVE AND DRIVE V-BELT5. Inspect:• Weight 1• Roller 2• Bushing 3• Slider 4• Rivet 5• CollarWear/scratches/damage → Replace.• Slider

POWRTR4-7baLTLTPRIMARY SHEAVE AND DRIVE V-BELTNOTE:When replacing the weight and roller bushings, usethe YXR clutch bushing jig kit.YXR clutch bushing

POWRTR4-8PRIMARY SHEAVE AND DRIVE V-BELT3. Install:• Fixed sheave stoppers 1NOTE:Stopper tapered portion should face fixed sheave.4. Tighten:• SpiderT

POWRTR4-9TR..135246PRIMARY SHEAVE AND DRIVE V-BELT5. Install:• Weight• Nuts 1Nut (weight):6 Nm (0.6 m · kg, 4.3 ft · lb)NOTE:To maintain the primary s

POWRTR4-10PRIMARY SHEAVE AND DRIVE V-BELTINSTALLATION1. Install:• Primary sheave assemblyCAUTION:Be sure to remove any oil or grease from thetapered p

POWRTR4-11SECONDARY SHEAVESECONDARY SHEAVEQ’ty11–11RemarksRemove the parts in the order listed below.Refer to “SHEAVE DISTANCE AND OFFSETADJUSTMENT” i

1-3GENINFOIMPORTANT INFORMATIONGASKETS, OIL SEALS, AND O-RINGS1.All gaskets, seals, and O-rings should be replaced when an engine isoverhauled. All ga

POWRTR4-12SECONDARY SHEAVEQ’ty1111111RemarksRemove the parts in the order listed below.(SX600)(SX600)For assembly, reverse the disassembly proce-dure.

POWRTR4-13SECONDARY SHEAVEDISASSEMBLYWARNING• Use extreme CAUTION when disassemblingthe secondary sheave since serious injury canoccur due to the sudd

POWRTR4-14SECONDARY SHEAVE5. Measure:• Ramp shoe thickness aOut of specification → Replace the ramp shoe.Wear limit:1.0 mm (0.04 in)ASSEMBLY1. Install

POWRTR4-15aTR..Installation steps:• Hold the spring seat 1 and turn the fixed sheave2 counterclockwise to the specified angle a.NOTE:The holes in the

POWRTR4-16Adjustment steps:• Disassemble the secondary sheave.• Remove the bolts and original shims 1.• Install new shims of the proper thickness andr

POWRTR4-17Job name/Part nameDrive chain housing removalCoolant hose bracketFrame cross member bolt (M10 × 65)Brake caliperParking brakeChain tension a

POWRTR4-18DRIVE CHAIN HOUSINGINSPECTION1. Inspect:• Drive chain housing 1• Drive chain housing cover 2Cracks/damage → Replace.• Oil seals (drive chain

POWRTR4-191234567890ABCDEabDRIVE CHAIN HOUSINGSEA4440SEA44503. Measure:• 14 link section a of the drive chainUsing a spring scale, pull on the drive c

POWRTR4-20DRIVE CHAIN HOUSINGINSTALLATION1. During installation, pay attention to the following.Å Make sure that the bearing seals face towards thedri

POWRTR4-21Job name/Part nameDrive chain housing removalBatteryBattery bracketCoolant hose bracketFrame cross member bolt (M10 × 65)Brake caliperParkin

1-4GENINFOSPECIAL TOOLSSPECIAL TOOLSSome special tools are necessary for a completely accurate tune-up andassembly. Using the correct special tool wil

POWRTR4-22RemarksFor installation, reverse the removal procedure.DRIVE CHAIN HOUSINGQ’ty111111111111111111Order111213141516171819202122232425262728Job

POWRTR4-23INSPECTION1. Inspect:• Drive chain housing 1• Drive chain housing cover 2Cracks/damage → Replace.• Shift fork 3Pitting/wear/damage → Replace

POWRTR4-24DRIVE CHAIN HOUSINGINSTALLATION1. During installation, pay attention to the following.Å Properly install the rubber seal onto the drive chai

POWRTR4-254. Install:• Shift rod 15. Adjust:• Shift rod length aAdjustment steps:• Move the shift lever to the “FWD.” position.• Loosen the locknuts 2

POWRTR4-26JACKSHAFTJACKSHAFTQ’ty11111121RemarksRemove the parts in the order listed below.Refer to “SECONDARY SHEAVE”.Refer to “FUEL PUMP” in CHAPTER

POWRTR4-27JACKSHAFTINSPECTION1. Inspect:• Jackshaft 1Scratches (excessive)/damage → Replace.• Splines 2Wear/damage → Replace the jackshaft.• Bearing c

POWRTR4-28JACKSHAFTJACKSHAFT AND DRIVE CHAIN HOUSINGINSTALLATION1. Install:• Drive chain housing• JackshaftInstallation steps:• Install the drive chai

POWRTR4-29BRAKEQ’ty111222RemarksRemove the parts in the order listed below.For installation, reverse the removal procedure.Order123456Job name/Part na

POWRTR4-30BRAKECAUTION:Disc brake components rarely require disassem-bly. DO NOT:• Do not disassemble components unless abso-lutely necessary.• Do not

POWRTR4-31BRAKE2. Install:• Brake pads• Pad springInstallation steps:• Connect a suitable hose 1 tightly to the caliperbleed screw 2. Put the other en

1-5GENINFOFOR ENGINE SERVICE• Piston pin pullerP/N: YU-01304 (for U.S.A./Canada)90890-01304 (for Europe)This tool is used to remove the piston pin.• R

POWRTR4-32BRAKE30 Nm (3.0 m · kg, 22 ft · lb)Å:48 Nm (4.8 m · kg, 35 ft · lb)ı:Q’ty112111222RemarksRemove the parts in the order listed below.Drain.Fo

POWRTR4-33BRAKEQ’ty111222242RemarksRemove the parts in the order listed below.For assembly, reverse the disassembly proce-dure.Order123456789Job name/

POWRTR4-34BRAKEBRAKE CALIPER DISASSEMBLYNOTE:Before disassembling a caliper, drain brake fluid frombrake hose, master cylinder, brake caliper and brak

POWRTR4-35BRAKE1. Inspect:• Caliper piston 1Scratches/rust/wear → Replace the caliperassembly.• Caliper cylinder 2Wear/scratches → Replace the caliper

POWRTR4-36BRAKE14 Nm (1.4 m · kg, 10 ft · lb)Å :30 Nm (3.0 m · kg, 22 ft · lb)ı :SEA46901111Remove the parts in the order listed below.For assembly, r

POWRTR4-3730˚a30˚30˚BRAKEINSPECTION1. Inspect:• Master cylinder 1Wear/scratches → Replace the master cylin-der assembly.• Master cylinder body 2Cracks

POWRTR4-38SLIDE RAIL SUSPENSIONSLIDE RAIL SUSPENSIONVX600ER/SX600Q’ty2212RemarksRemove the parts in the order listed below.Loosen.Loosen.For installat

POWRTR4-39SLIDE RAIL SUSPENSIONVT600Q’ty221RemarksRemove the parts in the order listed below.Loosen.Loosen.For installation, reverse the removal proce

POWRTR4-40Q’ty224212221212142221RemarksRemove the parts in the order listed below.(VT600)(VX600ER/SX600)(VX600ER/SX600)Order1234567890ABCDEFGH4 Nm (0.

POWRTR4-41SLIDE RAIL SUSPENSIONQ’ty222222211221Remarks(VX600ER/VT600)OrderIJKLMNOPQRSTJob name/Part nameSuspension wheelCollarWheel bracketCirclipSusp

1-6GENINFOSPECIAL TOOLS• YXR clutch bushing jig kitP/N: YS-39752This tool is used for removal and installation of primary clutch weight androller bush

POWRTR4-42SLIDE RAIL SUSPENSIONQ’ty121244222222Remarks(VX600ER/VT600)(VX600ER/VT600)(VT600)(VT600)OrderUVWXYZ[\]^abJob name/Part nameRear shock absorb

POWRTR4-43Q’ty12111122113 (4)221 (2)12RemarksFor assembly, reverse the disassembly proce-dure.OrdercdefghijklmnopqrJob name/Part nameRear pivot armBus

POWRTR4-44SLIDE RAIL SUSPENSIONMM600Q’ty212RemarksRemove the parts in the order listed below.Loosen.Loosen.For installation, reverse the removal proce

POWRTR4-45Q’ty22211421121421222RemarksRemove the parts in the order listed below.Order1234567890ABCDEFG4 Nm (0.4 m · kg, 2.9 ft · lb)Å:16 Nm (1.6 m ·

POWRTR4-46SLIDE RAIL SUSPENSIONQ’ty2222222211221RemarksOrderHIJKLMNOPQRSTJob name/Part nameSuspension wheelCollarWheel bracketFront pivot arm bracketC

POWRTR4-47SLIDE RAIL SUSPENSIONQ’ty12124422221RemarksOrderUVWXYZ[\]^aJob name/Part nameRear shock absorberBushingCollarPull rodCollarBushingSuspension

POWRTR4-48Q’ty1211112211422212RemarksFor assembly, reverse the disassembly proce-dure.OrderbcdefghijklmnopqJob name/Part nameRear pivot armBushingColl

POWRTR4-49SLIDE RAIL SUSPENSIONINSPECTION1. Inspect:• Suspension wheel• Guide wheelCracks/damage → Replace.• Wheel bearingWheel turns roughly → Replac

POWRTR4-50ab132213SLIDE RAIL SUSPENSIONASSEMBLY1. Install:• Shaft 1 (MM600)NOTE:Ensure the rubber collars 2 are not pinched betweenthe shaft and slidi

POWRTR4-51baSEA4890Control rod parts numberı Parts number Ç Length aÎ Length bÅ Control rod 1 8CR-4745A-01 310.5 mm (12.2244 in) 200.0 mm (7.8740 in)Å

2-1INSPADJSpark plugsEngine oilFuelFuel filterFuel lineOil lineEngine coolantCarburetorsRecoil starterEngine stop switchThrottle override system(T.O.R

POWRTR4-52FRONT AXLE AND TRACKRemarksRemove the parts in the order listed below.Refer to “DRIVE CHAIN HOUSING”.Refer to “SLIDE RAIL SUSPENSION”.Refer

POWRTR4-53104 mm(4.09 in)132.6 mm(5.22 in)164.1 mm(6.46 in)123 mm(4.84 in)104 mm(4.09 in)41 mm(1.61 in)41 mm(1.61 in)43.1 mm(1.70 in)60 mm(2.36 in)111

POWRTR4-54aaaa2. Place the track in the chassis.NOTE:• For track with a direction of rotation mark a:Install the track with the mark pointing in the d

5-1ENGEXHAUST ASSEMBLYENGINEEXHAUST ASSEMBLYOrder1234567891011RemarksRemove the parts in the order listed below.Open.For installation, reverse the rem

5-2ENG532412141532 6aEXHAUST ASSEMBLYINSTALLATION1. Install:• Gasket 3• Exhaust jointNOTE:• Install the gasket 3 with its projection a facing theprima

5-3ENGENGINE ASSEMBLYENGINE ASSEMBLYOrder123456789101112131415RemarksRemove the parts in the order listed below.Refer to “EXHAUST ASSEMBLY”.Refer to “

5-4ENG1ENGINE ASSEMBLYINSPECTION1. Inspect:• Rear bracket (right) 1Cracks/damage → Replace.INSTALLATIONNOTE:After installing all parts, refer to “CABL

5-5ENG3. Bleed:• Oil systemRefer to “OIL PUMP” in CHAPTER 2.• Cooling systemRefer to “COOLING SYSTEM” in CHAPTER 2.4. Adjust:• Oil pump cable distance

5-6ENGCYLINDER HEAD AND CYLINDERCYLINDER HEAD AND CYLINDERQ’ty3111312111Order12345678910Job name/Part nameCylinder head and cylinder removalSpark plug

5-7ENGCYLINDER HEAD AND CYLINDERQ’ty31133113336636333Order1112131415161718192021222324252627Job name/Part nameSpark plugWater temperature sensorCylind

2-2INSPADJPERIODIC MAINTENANCE TABLECheck oil level.Replace.Check deflection.Adjust if necessary.Check for wear and damage.Replace if necessary.Check

5-8ENGCYLINDER HEAD AND CYLINDERREMOVAL1. Remove:• Piston pin clip• Piston pin• Piston• Small end bearingNOTE:• Before removing the piston pin clip, c

5-9ENGCYLINDER HEAD AND CYLINDERINSPECTION1. Eliminate:• Carbon deposits(from the combustion chamber)Use the rounded scraper 1.CAUTION:Do not use a sh

5-10ENGCYLINDER HEAD AND CYLINDERSEA5170SEA5180SEA51907. Eliminate:• Score marks and lacquer deposits(from the piston wall)Use 600 ~ 800 grit wet sand

5-11ENG2nd step:• Measure the piston skirt diameter (P) with amicrometer.a 10 mm (0.39 in) from the bottom edge of the pistonPiston size (standard) (P

5-12ENGCYLINDER HEAD AND CYLINDER10. Install:• Piston ring(into the cylinder)Push in the ring with the piston crown.NOTE:Insert the ring into the cyli

5-13ENGCYLINDER HEAD AND CYLINDER14. Inspect:• Reed valves 1Bends/cracks/damage → Replace.15. Measure:• Valve stopper height aOut of specification → R

5-14ENGCYLINDER HEAD AND CYLINDERINSTALLATION1. Install:• Reed valves• Reed valve stoppersNOTE:• Place the reed valve 1 with its concave surfacefacing

5-15ENGabCYLINDER HEAD AND CYLINDER4. Check:• Piston ring positionCAUTION:• Make sure that the ring ends are properly fittedaround the ring locating p

5-16ENG1 2 3Gy OBWB/W B B/W B B/W BO BGyBBWBTR..TR..9. Tighten:• Nuts (cylinder head)Tightening steps:• Temporarily tighten the cylinder head nuts 1 ~

5-17ENGOIL PUMP, CRANKCASE AND CRANKSHAFTOIL PUMP, CRANKCASE AND CRANKSHAFTQ’ty111221211111111Order123456789101112131415Job name/Part nameOil pump, cr

2-3INSPADJSPARK PLUGSENGINESPARK PLUGS1. Remove:• Spark plug caps• Spark plugs2. Inspect:• Electrodes 1Damage/wear → Replace the spark plug.• Insulato

5-18ENGOIL PUMP, CRANKCASE AND CRANKSHAFTINSPECTION1. Measure:• RunoutUse the V-blocks and a dial gauge.Out of specification → Replace or repair thecr

5-19ENGOIL PUMP, CRANKCASE AND CRANKSHAFT3. Inspect:• Crankshaft bearing 1Pitting/damage → Replace.• Stopper ring 2Bends/damage → Replace.• Crankshaft

5-20ENGOIL PUMP, CRANKCASE AND CRANKSHAFTINSTALLATION1. Install:• Stopper ring 1[onto the crankshaft bearing 2 (primary sheaveside) as shown]3 Knock p

5-21ENG624513DEB9A07246FC5138OIL PUMP, CRANKCASE AND CRANKSHAFT3. Fill:• Gear room 1Recommended oil:YAMALUBE 2-cycleGear room capacity:25 cm3 (0.81 Im

5-22ENGaOIL PUMP, CRANKCASE AND CRANKSHAFT6. Install:• Oil hose 1NOTE:Install so that the mark a on the check valve facesthe crankcase.SEA5550

5-23ENGAC MAGNETOAC MAGNETOQ’ty1211111111RemarksRemove the parts in the order listed below.Refer to “RECOIL STARTER”.Disconnect.For installation, reve

5-24ENGAC MAGNETOREMOVAL1. Remove:• Bolts 1• Starter pulley 2• Nut 3NOTE:Attach the primary sheave holder to hold the primarysheave.Primary sheave hol

5-25ENG12AC MAGNETOINSTALLATIONNOTE:After installing all parts, refer to “CABLE ROUTING”in CHAPTER 9, to check the cable, lead and hoseroutings.1. Ins

5-26ENGAC MAGNETO4. Tighten:• Bolts 1• Nut 2Bolt (starter pulley):23 Nm (2.3 m · kg, 17 ft · lb)Nut (magneto rotor):110 Nm (11 m · kg, 80 ft · lb)NOTE

5-27ENGRECOIL STARTERRECOIL STARTERQ’ty11111111111RemarksRemove the parts in the order listed below.Refer to “EXHAUST ASSEMBLY”.For installation, reve

2-4INSPADJ111OIL PUMPOIL PUMPAir bleedingCAUTION:The oil pump and oil delivery line must be bled inthe following cases:• Any portion of the oil system

5-28ENGRECOIL STARTERREMOVAL1. Remove:• Starter handle 1NOTE:To remove the starter handle, untie the knot 2 in thestarter rope and then re-tie a knot

5-29ENGRECOIL STARTERINSTALLATION1. Wind:• Starter rope (2-1/2 times counterclockwise)(in the sheave drum)2. Install:• Starter spring 1• Sheave drum a

6-1COOLHEAT EXCHANGERCOOLING SYSTEMHEAT EXCHANGERVX600ER/SX600/VT600Q’ty11111111111111111111RemarksRemove the parts in the order listed below.Drain. R

6-2COOLHEAT EXCHANGERMM600Q’ty11111111111111111111RemarksRemove the parts in the order listed below.Drain. Refer to “COOLING SYSTEM” in CHAP-TER 2.For

6-3COOLHEAT EXCHANGERINSPECTION1. Inspect:• Coolant hoses 1• Heat exchangers 2• Filler cap body 3• Carburetor heating lever assembly 4• Carburetor hea

6-4COOL2. Measure:• Filler cap opening pressureCap opens with a pressure below the specifiedpressure → Replace.Cap opening pressure:95 ~ 125 kPa(0.95

6-5COOLWATER PUMPWATER PUMPQ’ty11111111111RemarksRemove the parts in the order listed below.Refer to “EXHAUST ASSEMBLY” in CHAPTER 5.Drain. Refer to “

6-6COOLWATER PUMPREMOVAL1. Remove:• Impeller 1NOTE:Attach the primary sheave holder to hold the primarysheave.Primary sheave holder:90890-01701, YS-01

7-1CARBCARBURETORSQ’ty121112333RemarksRemove the parts in the order listed below.Refer to “FUEL PUMP”.Before removing the carburetors, make sure thatt

7-2CARBCARBURETORSQ’ty211131136333111RemarksRemove the parts in the order listed below.Loosen.For assembly, reverse the separation proce-dure.Order123

2-5INSPADJOIL PUMP14. Install:• Gasket (bleed bolt)• Bleed bolt15. Install:• Rear bracket (right)M8 mounting bolt (rear):33 Nm (3.3 m · kg, 24 ft · lb

7-3CARBCARBURETORSQ’ty111111111111RemarksRemove the parts in the order listed below.Turn clockwise.Order1234567890ABJob name/Part nameCarburetor disas

7-4CARBQ’ty1111111111111RemarksFor assembly, reverse the disassembly proce-dure.OrderCDEFGHIJKLMNOJob name/Part nameGasketMain jetMain jet ringMain no

7-5CARBCARBURETORSINSPECTION1. Inspect:• Carburetor body• Fuel passageContamination → Clean.NOTE:• Use a petroleum based solvent for cleaning.• Blow o

7-6CARBCARBURETORS5. Inspect:• Throttle valve 1Wear/damage → Replace.6. Check:• Throttle valve movementSticks → Replace carburetor body assembly.ASSEM

7-7CARBCARBURETORSMeasurement and adjustment steps:• Hold the carburetor upside down.• Measure the distance between the carburetorbody and top of the

7-8CARBCARBURETORSFUEL LEVEL ADJUSTMENT1. Measure:• Fuel level aOut of specification → Adjust.Fuel level (from the bore center):36 ~ 38 mm (1.42 ~ 1.5

7-9CARB12aCARBURETORSINSTALLATIONNOTE:After installing all parts, refer to “CABLE ROUTING”in CHAPTER 9, to check the cable, lead and hoseroutings.1. F

7-10CARBFUEL PUMPVX600ER/VT600FUEL PUMPQ’ty1133111113111RemarksRemove the parts in the order listed below.Loosen.NOTE:• First, remove the throttle and

7-11CARBSX600/MM600FUEL PUMPQ’ty11331113111RemarksRemove the parts in the order listed below.Loosen.Disconnect.Disconnect.Disconnect.Disconnect.For in

7-12CARBFUEL PUMPINSPECTION1. Inspect:• Fuel hose 1• Fuel delivery hoses 2• Vacuum hose 3• Oil delivery hose 4Clogs/damage → Replace.2. Check:• Fuel p

HOW TO USE THIS MANUALParticularly important information is distinguished inthis manual by the following notations:The Safety Alert Symbol means ATTEN

2-6INSPADJ122FUEL LINE INSPECTION/COOLING SYSTEMFUEL LINE INSPECTION1. Remove:• Intake silencerRefer to “FUEL PUMP” in CHAPTER 7.2. Inspect:• Fuel hos

8-1–+ELECONOFFRBr/LL/YL/BRBr/LL/YL/BSWITCH INSPECTIONELECTRICALSWITCH INSPECTIONSWITCH INSPECTIONUse a pocket tester to check the terminals for conti-

8-2–+ELECEWIRE HARNESSSUB-WIREHARNESS 2BWOGyBWOGy(BLACK) (BLACK)BWIRE HARNESSHEADLIGHTSUB-WIREHARNESSY/BLYGY/BL/WYGAWIRE HARNESSHEADLIGHTSUB-WIREHARNE

8-3–+ELECIGNITION SYSTEMIGNITION SYSTEMCIRCUIT DIAGRAM1 AC magneto2 Rectifier/regulator3 Condenser∗14 Main fuse∗26 Battery∗28 Main switch9 Engine stop

8-4–+ELECTROUBLESHOOTINGNO SPARK OR WEAK SPARK.For VX600ER/VT600:Check the main fuse and“IGNITION” fuse.Refer to “FUSE INSPECTION”in CHAPTER 2.OK FAUL

8-5–+ELECFor SX600/MM600:Check the lighting, signal and meter system.Refer to “LIGHTING SYSTEM” and“SIGNAL SYSTEM”.OK FAULTY Repair the lighting syste

8-6–+ELEC– +Ω×1WWWbIGNITION SYSTEMCONDENSER (SX600/MM600)1. Disconnect:• Condenser 12. Connect:• Condenser(to the LCR meter)3. Measure:• Condenser cap

8-7–+ELECIGNITION SYSTEMSPARK PLUG1. Remove:• Spark plugs2. Measure:• Spark plug gapStandard spark plug:BR9ES (NGK)Spark plug gap:0.7 ~ 0.8 mm (0.028

8-8–+ELECB/YB/WB+–Ω× 1ACIGNITION SYSTEMBCTHROTTLE OVERRIDE SYSTEM (T.O.R.S.)If the carburetor or throttle cable should malfunctionduring operation, T

8-9–+ELECB/YB+–Ω× 1B/YB/WB+–Ω× 1SEA8160SEA81704. Check:• Throttle switch continuityFaulty → Replace the handlebar switch (right).Throttle switchpositi

8-10–+ELEC432 1RLBrBr/WIGNITION SYSTEMSEA8210SEA8200LOAD CONTROL RELAY1. Inspect:• Load control relay (with the white coupler) 1Inspection steps:• Dis

2-7INSPADJ114. Remove:• Coolant filler cap 1WARNINGDo not remove the coolant filler cap 1 when theengine is hot. Pressurized scalding hot fluid andste

8-11–+ELEC1W/GW/RW/RW/GW/GW/RWWWWWWWWWWWWBR2WBRWWRR3BRRRRBBRBRB345BRBRBRRBBFL/WGL/WR/YLRGÅÅR/WRB(BLACK)6R/WR/WFÅFR7BOFFONSTART8R/YR/WBrB/WBBrB/WR/WR/Y

8-12–+ELECELECTRICAL STARTING SYSTEMTROUBLESHOOTING (VX600ER/VT600)STARTER MOTOR DOES NOT OPERATE.WARNINGBefore starter motor operation, push the engi

8-13–+ELECCheck the main fuse and “IGNITION” fuse.Refer to “FUSE INSPECTION” in CHAPTER 2.OKCorrect the connection.FAULTYReplace the main fuse and/or

8-14–+ELECÅ:7 Nm (0.7 m · kg, 5.1 ft · lb)Q’ty1111122111111111RemarksRemove the parts in the order listed below.Refer to “ENGINE REMOVAL” in CHAPTER 5

8-15–+ELECInspection1. Inspect:• Commutator (outer surface)Dirty → Clean with #600 grit sandpaper 1.Hold the armature in a vise 2 and copper oralumini

8-16–+ELEC4. Measure:• Armature coil resistance(insulation/continuity)Defect(s) → Replace the starter motor.Inspecting steps:• Connect the pocket test

8-17–+ELECAssemblyReverse the “Disassembly” procedure.Note the following points.1. Before installing the front bracket and rear bracket,apply bearing

8-18–+ELEC1W/GW/RW/RW/GW/GW/RWWWWWWWWWWWWBR2WBRWWRR3BRRRRBBRBRB345BRBRBRRBBFL/WGL/WR/YLRGÅÅR/WRB(BLACK)6R/WR/WFÅFR7BOFFONSTART8R/YR/WBrB/WBBrB/WR/WR/Y

8-19–+ELECTROUBLESHOOTING (VX600ER/VT600)BATTERY IS NOT CHARGED.1. Connect:• Pocket tester(to the battery terminals)2. Measure:• Battery voltage• Flui

8-20–+ELEC– +Ω×1WWWBATTERYInspection1. Inspect:• Battery fluid levelRefer to “BATTERY INSPECTION” in CHAP-TER 2.2. Check:• Specific gravityLess than 1

2-8INSPADJ11119. Disconnect:• Coolant hoses 1Å VX600ER/SX600/VT600ı MM60010. Drain the coolant.NOTE:Lift up the front of the machine to drain the cool

8-21–+ELECCHARGING SYSTEM

8-22–+ELECEWIRE HARNESSSUB-WIREHARNESS 2BWOGyBWOGy(BLACK) (BLACK)BWIRE HARNESSHEADLIGHTSUB-WIREHARNESSY/BLYGY/BL/WYGAWIRE HARNESSHEADLIGHTSUB-WIREHARN

8-23–+ELECLIGHTING SYSTEMLIGHTING SYSTEMCIRCUIT DIAGRAM1 AC magneto2 Rectifier/regulator3 Condenser∗14 Main fuse∗26 Battery∗28 Main switchE CDI unitK

8-24–+ELECLIGHTING SYSTEMTROUBLESHOOTINGHEADLIGHT AND/OR METER LIGHT DO NOT COME ON.Check the bulb(s).OK NO CONTINUITY Replace the bulb(s).For VX600ER

8-25–+ELECLIGHTING SYSTEMTAIL LIGHT DOES NOT COME ON.Check the bulb(s).OK NO CONTINUITY Replace the bulb(s).For VX600ER/VT600:Check the main fuse,“IGN

8-26–+ELECBULB(S)1. Remove:• Headlight bulb a• Tail/brake light bulb b• Meter light bulb c2. Connect:• Pocket tester(to the bulb terminals)WARNINGKeep

8-27–+ELEC6543L/WYLg BG12L/WYLg BGLIGHTING SYSTEMHEADLIGHT RELAY1. Inspect:• Headlight relay (with the black coupler) 1Inspection steps:• Disconnect t

8-28–+ELECEWIRE HARNESSSUB-WIREHARNESS 2BWOGyBWOGy(BLACK) (BLACK)BWIRE HARNESSHEADLIGHTSUB-WIREHARNESSY/BLYGY/BL/WYGAWIRE HARNESSHEADLIGHTSUB-WIREHARN

8-29–+ELECSIGNAL SYSTEMSIGNAL SYSTEMCIRCUIT DIAGRAM1 AC Magneto2 Rectifier/regulator3 Condenser∗14 Main fuse∗26 Battery∗28 Main switchD Water temperat

8-30–+ELECSIGNAL SYSTEMTROUBLESHOOTINGBRAKE LIGHT DOES NOT COME ON.Check the tail/brake light bulb.Refer to “LIGHTING SYSTEM”.OK NO CONTINUITY Replace

2-9INSPADJCOOLING SYSTEMTR..SEA2130TR..18. Inspect:• Gasket (coolant drain bolt)Damage → Replace.19. Install:• Gasket• Coolant drain bolt 1Coolant dra

8-31–+ELECWATER TEMPERATURE AND/OR OIL LEVEL INDICATOR LIGHTS DO NOT COME ON.SIGNAL SYSTEMCheck the water temperature and/or oillevel indicator light

8-32–+ELECSIGNAL SYSTEMFUEL METER DOES NOT OPERATE.For VX600ER/VT600:Check the main fuse,“IGNITION” fuse and “HEAD” fuse.Refer to “FUSE INSPECTION” in

8-33–+ELECSIGNAL SYSTEMBACK BUZZER DOES NOT SOUND. (VX600ER/VT600)Check the main fuse,“IGNITION” fuse and “TAIL” fuse.Refer to “FUSE INSPECTION” in CH

8-34–+ELECG/YLBRAKE LIGHT SWITCH1. Disconnect:• Brake light switch coupler 12. Connect:• Pocket tester(to the brake light switch coupler)3. Check:• Br

8-35–+ELECSIGNAL SYSTEMWATER TEMPERATURE SENSOR1. Disconnect the water temperature sensor cou-pler 1 and remove the water temperature sen-sor.CAUTION:

8-36–+ELECGBab+–Ω× 1SIGNAL SYSTEMSEA8520SEA8530SEA8540SEA8550OIL LEVEL SWITCH1. Remove:• Intake silencerRefer to “FUEL PUMP” in CHAPTER 7.• Oil level

8-37–+ELECSIGNAL SYSTEM

8-38–+ELECEWIRE HARNESSSUB-WIREHARNESS 2BWOGyBWOGy(BLACK) (BLACK)BWIRE HARNESSHEADLIGHTSUB-WIREHARNESSY/BLYGY/BL/WYGAWIRE HARNESSHEADLIGHTSUB-WIREHARN

8-39–+ELECGRIP WARMER SYSTEMGRIP WARMER SYSTEMCIRCUIT DIAGRAM1 AC magneto2 Rectifier/regulator3 Condenser∗14 Main fuse∗26 Battery∗28 Main switchA Grip

8-40–+ELECGRIP WARMER SYSTEMTROUBLESHOOTINGGRIP WARMER AND THUMB WARMER DO NOT OPERATE.For VX600ER/VT600:Check the main fuse and “IGNITION” fuse.Refer

2-10INSPADJ121122. Bleed the air from the cooling system.23. Inspect:• Cooling systemDecrease of pressure (leaks) → Repair asrequired.Inspection steps

8-41–+ELECGRIP WARMER SYSTEMPASSENGER GRIP WARMER DOES NOT OPERATE. (VT600)Check the main fuse,“IGNITION” fuse and “TAIL” fuse.Refer to “FUSE INSPECTI

8-42–+ELECY/WB/R+–Ω× 1–+Ω× 1BW(L) (R) 21GRIP WARMER SYSTEMSEA8580SEA8590SEA8600GRIP AND THUMB WARMER COIL1. Disconnect:• Grip warmer leads 1• Thumb wa

8-43–+ELEC+–Ω× 1LBY/WB/R+–Ω× 1SEA8610SEA8620VARIABLE RESISTOR (GRIP WARMER)1. Disconnect:• Variable resistor coupler 12. Connect:• Pocket tester(to th

8-44–+ELECBB+–Ω× 1Y/LY/RO/B+–Ω× 1Y/LY/RO/B+–Ω× 1PASSENGER GRIP WARMER SWITCH(VT600)1. Disconnect:• Passenger grip warmer switch coupler 12. Connect:•

8-45–+ELEC432 1L/RO/BL/RYSEA8710SEA8700PASSENGER GRIP WARMER RELAY (VT600)1. Inspect:• Passenger grip warmer relay 1Inspection steps:• Disconnect the

8-46–+ELEC0.75 sRepeats2.5 sFAULT LOCATION TABLEFAULT LOCATION TABLENOTE:When more than one problem is detected, the water temperature indicator light

8-47–+ELEC0.75 s0.25 s6.5 sRepeats0.75 s0.25 s5.5 sRepeats0.75 s0.25 s4.5 sRepeats0.75 s0.25 sRepeats3.5 sFAULT LOCATION TABLENo. Patterns Condition R

SPEC9-1VX600ER/SX600/MM600/VT6008DG4 (VX600ER)8EA4 (SX600)8EJ3 (MM600)8EB4 (VT600)2,780 mm (109.4 in) (VX600ER)2,760 mm (108.7 in) (SX600)2,990 mm (11

9-2SPECGENERAL SPECIFICATIONSModelFuel:TypeTank capacityCarburetor:Type/QuantityManufacturerSpark plug:TypeManufacturerGapTransmission:Primary reducti

SPEC9-3ModelBulb wattage × Quantity:HeadlightTail/Brake lightTachometer lightSpeedometer lightHigh beam indicator lightWater temperature indicator lig

2-11INSPADJ1COOLING SYSTEMAir bleeding steps:• Lift up the tail of the machine.• Remove the bleed bolt 1 on the heat exchanger.• While slowly adding c

9-4SPECMAINTENANCE SPECIFICATIONSENGINEMAINTENANCE SPECIFICATIONSVX600ER/SX600/MM600/VT60018.7 ~ 19.3 cm3(1.14 ~ 1.18 cu.in)<0.03 mm (0.0012 in)>

SPEC9-5MAINTENANCE SPECIFICATIONSCrankshaft:Crank width “A”Crank width “B”Maximum runout “C” : C1C2 ~ C5C6Measuring points: 12Connecting rod big end s

9-6SPECMAINTENANCE SPECIFICATIONSCarburetor:Type/QuantityManufacturerI.D. markMain jet (M.J)Pilot jet (P.J)Jet needle (J.N)Needle jet (N.J)Pilot air j

SPEC9-7MAINTENANCE SPECIFICATIONSPOWER TRAINTransmission:TypeRange of ratioEngagement speed r/minShift r/minSheave distance “A”Sheave offset “B”V-Belt

9-8SPECVX600ER/SX600/MM600/VT6008DG-17605-0034.30 g (1.211 oz)90261-06028 (VX600ER/MM600)90261-06015 (SX600)90261-06034 (VT600)Aluminum (VX600ER/MM600

SPEC9-9VX600ER/SX600/MM600/VT600REXNORD S37TNB1368 L8DY-47110-00 (VX600ER)8EA-47110-10 (SX600)8ED-47110-01 (MM600)8DM-47110-00 (VT600 for U.S.A./Canad

9-10SPECMAINTENANCE SPECIFICATIONSModelSuspension setting position:Hook setting length ∗Full rate adjusting position ∗∗Shock absorber: Damping forceFr

SPEC9-11MAINTENANCE SPECIFICATIONSCHASSISModelFrame:Frame materialSeat heightLuggage box locationSteering:Lock-to-lock angle (left)(right)(left)(right

9-12SPECMAINTENANCE SPECIFICATIONSELECTRICALModelVoltageIgnition system:Ignition timing (B.T.D.C.)Advanced typeIgnition coil:Model/ManufacturerMinimum

SPEC9-13ModelStarter motor (VX600ER/VT600):Model/ManufacturerOutputArmature coil resistanceContinuity checkInsulation checkBrushOverall length<Wear

2-12INSPADJ3• Remove the coolant filler cap and bleed thecooling system again, as described above.No air bubbles → OK.• Add coolant to the specified l

9-14SPECClip0.4 mm shimNOTE:• Jet needle (JN) position.Refer to the following information for the Jet needle shims installation.JN:3 JN:2.5 JN:1 JN:0.

SPEC9-15MAINTENANCE SPECIFICATIONSTightening torqueNm m · kg ft · lbParts to be tightened Remarks13271590403333335718271311232820231010815102318121414

9-16SPECTightening torqueNm m · kg ft · lbParts to be tightened Remarks120602001464206446.523106024484816241013104863014308.52341624307230727272727275

SPEC9-17Apply LOCTITE®Apply LOCTITE®Apply LOCTITE®Apply LOCTITE®(VT600) Apply LOCTITE®Apply LOCTITE®Apply LOCTITE®24494949497249497272728.5202.44.94.9

9-18SPECApply LOCTITE®Apply LOCTITE®(VX600ER/VT600)(VX600ER/VT600)(SX600/MM600)Apply LOCTITE®Apply LOCTITE®Apply LOCTITE®Apply LOCTITE®Apply LOCTITE®A

SPEC9-19GENERAL TORQUESPECIFICATIONSThis chart specifies torque for standard fastenerswith standard I.S.O. pitch threads. Torque specifica-tions for s

9-20SPECGENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITS

SPEC9-21CABLE ROUTINGSEA9010

9-22SPECCABLE ROUTING1 Water temperature sensorcoupler2 Fasten the carburetor switchleads and water temperaturesensor leads and ignition coilleads to

SPEC9-23CABLE ROUTINGSEA9010

2-13INSPADJENGINE IDLE SPEED ADJUSTMENT1. Adjust:• Engine idle speedAdjustment steps:• Start the engine and let it warm up.• Turn the throttle stop sc

9-24SPECD Connectors of the gear positionswitch (VX600ER/VT600)E Route the main switch wireharness under the oil tankbreather hose and fuel tankbreath

SPEC9-25CABLE ROUTINGSEA9020

9-26SPECCABLE ROUTING1 Brake hose2 Oil pump cable3 Throttle cable4 Wire harness5 Starter cable

SPEC9-27CABLE ROUTINGSEA9030

9-28SPECCABLE ROUTING1 Wire harness2 Ensure this is not kink.3 50 mm (1.97 in)4 Make sure that the oil tank capand oil tank breather hose do nottouch

SPEC9-29CABLE ROUTINGSEA9030

9-30SPECCABLE ROUTINGK Fuel tank breather hoseL Ground leadM Install the clamp so that it doesnot come into contact with theground lead terminal.N Rou

SPEC9-31CABLE ROUTINGSEA9040

9-32SPECCABLE ROUTING1 Speedometer coupler2 Tachometer coupler3 Plastic band4 Clamp5 Headlight leads6 Speedometer cable7 Fasten the wire harness andsp

SPEC9-33CABLE ROUTINGSEA9050

2-14INSPADJ1232. Adjust:• Throttle cable free playAdjustment steps:• Loosen the locknut 1.• Turn the adjusting nut 2 in or out until thespecified free

9-34SPECCABLE ROUTING1 Oil pump cable2 Throttle cable3 Do not fasten the throttle cableand oil pump cable.4 Pass only the throttle, and oilpump cable

SPEC9-35CABLE ROUTINGSEA9050

9-36SPECCABLE ROUTINGO To the carburetorP Vacuum hoseQ Oil delivery hoseR To the oil pumpS When fastening the wire harnesswith the attaches clamp, ben

SPEC9-37CABLE ROUTINGSEA9060

9-38SPECCABLE ROUTING1 Make sure a plastic band isrouted through the projectionlocated on the silencer, whenfastening it around the wireharness and th

WIRING DIAGRAMVX600ER/SX600/MM600/VT600EWIRE HARNESSSUB-WIREHARNESS 2BWOGyBWOGy(BLACK) (BLACK)BWIRE HARNESSHEADLIGHTSUB-WIREHARNESSY/BLYGY/BL/WYGAWIRE

COLOR CODEB ... BlackBr ... BrownCh ... ChocolateG ... GreenGy ... Gr

Printed in USA (E) CRPRINTED ON RECYCLED PAPER

2-15INSPADJSTARTER (CHOKE) CABLE FREE PLAY ADJUSTMENT/EXHAUST SYSTEM INSPECTIONSTARTER (CHOKE) CABLE FREE PLAYADJUSTMENT1. Measure:• Starter cable fre

ILLUSTRATED SYMBOLS(Refer to the illustration)Illustrated symbols 1 to 9 are designed as thumbtabs to indicate the chapter’s number and content.1 Gene

2-16INSPADJSHEAVE DISTANCE AND OFFSET ADJUSTMENTPOWER TRAINSHEAVE DISTANCE AND OFFSETADJUSTMENT1. Open the shroud.2. Remove:• Drive V-belt guard• Driv

2-17INSPADJTR..2a1235. Adjust:• Sheave distanceAdjustment steps:• Loosen the mounting bolts (front) 1 and mount-ing bolts (rear) 2.• Adjust the posit

2-18INSPADJDRIVE V-BELTDRIVE V-BELTWARNINGWhen installing the new V-belt, make sure that itis positioned from 1.5 mm (0.06 in) above theedge of the se

2-19INSPADJDRIVE V-BELT2.Adjust the position of the V-belt by removing oradding a spacer 1 on each adjusting bolt 2.V-belt positionMore than 1.5 mm(0.

2-20INSPADJENGAGEMENT SPEED CHECK1. Place the machine on a level surface of hard-packed snow.2. Check:• Clutch engagement speedChecking steps:• Start

2-21INSPADJPARKING BRAKE ADJUSTMENT1. Measure:• Clearance aOut of specification → Adjust.Clearance:1.2 ~ 1.3 mm (0.047 ~ 0.051 in)2. Adjust:• Clearanc

2-22INSPADJBRAKE FLUID LEVEL INSPECTION/BRAKE PAD INSPECTIONBRAKE FLUID LEVEL INSPECTION1. Place the machine on a level surface.2. Check:• Fluid level

2-23INSPADJBRAKE HOSE INSPECTION1. Inspect:• Brake hoseCracks/damage/wear → Replace.2. Check:• Fluid leakageApply the brake lever several times.Fluid

2-24INSPADJ1d. Tighten the bleed screws when the brake leverlimit has been reached, then release the lever.• Repeat steps (a) to (d) until all of the

2-25INSPADJCAUTION:There is a magnet attached to the end of thedipstick. It is used to remove any metal particlesthat may accumulate in the drive chai

–+GENERAL INFORMATIONPERIODIC INSPECTION ANDADJUSTMENTCHASSISPOWER TRAINENGINECOOLING SYSTEMCARBURETIONELECTRICALSPECIFICATIONSINDEXGEN INFOCHASENGPOW

2-26INSPADJ112Oil replacementOil replacement steps:• Place the oil pan under the drain hole.• Remove the oil drain bolt 1 and drain the oil.CAUTION:Be

2-27INSPADJ3. Install:• Battery bracket (VX600ER/VT600)• Battery (VX600ER/VT600)CAUTION:• Connect the positive lead to the battery termi-nal first.• M

2-28INSPADJ45TRACK TENSION ADJUSTMENT3. Adjust:• Track deflectionAdjustment steps:• Place the machine onto a suitable stand to raisethe track off of t

2-29INSPADJSLIDE RUNNER INSPECTIONSLIDE RUNNER INSPECTION1. Inspect:• Slide runner 1Cracks/damage/wear → Replace.2. Measure:• Slide runner thickness a

2-30INSPADJMAXIMIZING DRIVE TRACK LIFERecommendationsTrack tensionDuring initial break-in, the new drive track will tend tostretch quickly as the trac

2-31INSPADJaCHASSISSKI/SKI RUNNER1. Inspect:• Ski• Ski runnerDamage/wear → Replace.2. Measure:• Ski runner wear limit a• Plastic ski wear limit bOut o

2-32INSPADJSTEERING SYSTEMFree play check1. Check:• Steering system free playMove the handlebar up and down and backand forth.Turn the handlebar sligh

2-33INSPADJSTEERING SYSTEM/LUBRICATIONATR..B3. Adjust:• Ski toe-outAdjustment steps:• Loosen the locknuts (tie rod) 1.• Turn the tie rods 2 in or out

2-34INSPADJLUBRICATIONBCFront and rear suspension1. Use a grease gun to inject grease into thenipples 1.Lubricate the ball joints 2, 3.Recommended lub

2-35INSPADJHEADLIGHT BEAM ADJUSTMENTELECTRICALHEADLIGHT BEAM ADJUSTMENT1. Place the machine on a level surface.2. Place the machine in front of a wall

CHAPTER 1.GENERAL INFORMATIONMACHINE IDENTIFICATION... 1-1FRAME SERIAL NUMBER... 1-1ENGINE SERIAL NUMBE

2-36INSPADJBATTERY INSPECTION (VX600ER/VT600)BATTERY INSPECTION (VX600ER/VT600)WARNINGBattery fluid is poisonous and dangerous, causessevere burns, et

2-37INSPADJBATTERY INSPECTION (VX600ER/VT600)Replace the battery if:• Battery voltage will not rise to a specific value orbubbles fail to rise even af

2-38INSPADJBATTERY CHARGING (VX600ER/VT600)BATTERY CHARGING (VX600ER/VT600)The battery must be charged properly before usingfor the first time. This i

2-39INSPADJ2. Install:• BatteryCAUTION:• Connect the positive lead to the battery termi-nal first.• Make sure the battery leads are connectedproperly.

2-40INSPADJ2. Replace:• Blown fuseReplacing steps:• Set the main switch to “OFF”.• Install a new fuse of the correct amperage.• Set the main switch to

2-41INSPADJCARBURETOR TUNINGTUNINGCARBURETOR TUNINGThe carburetors are set at the factory to run attemperatures of 0°C ~ –20°C (32°F ~ –4°F) atsea lev

2-42INSPADJCARBURETOR TUNINGMid-range and high speed tuningAdjustments are normally not required, but may some-times be necessary, depending on temper

2-43INSPADJCARBURETOR TUNINGGuide for carburetionSEA2720

2-44INSPADJCARBURETOR TUNINGA Standard main jetB Main jet whose diameter is 10% smaller thanstandardC Main jet whose diameter is 10% larger thanstanda

2-45INSPADJCARBURETOR TUNINGLow-speed tuningThe carburetors are built so that low speed tuning canbe done by adjusting the pilot mixture screw 2 andth

SKI ... 3-8VX600ER/VT600 ... 3-8SX600/MM600 ...

2-46INSPADJRemedyReplace the main jet with the next smaller size.Replace the main jet with the next larger size.Replace the piston and spark plug.Tune

2-47INSPADJTroublePoor performance atmid-range speeds:• Momentary slow re-sponse to the throttle• Poor accelerationPoor performance atnormal speeds:•

2-48INSPADJCLUTCHSpecifications Model: VX600ERCLUTCHHigh altitudeÅ Elevation~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m(~ 3,500 ft) (3,000

2-49INSPADJCLUTCHSpecifications Model: SX600Å Elevation~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m(~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~

2-50INSPADJCLUTCHSpecifications Model: MM600Å Elevation~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m(~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~

2-51INSPADJCLUTCHSpecifications Model: VT600Å Elevation~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m(~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~

2-52INSPADJCLUTCHÅ Elevation~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m(~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000

2-53INSPADJCLUTCH/GEAR SELECTIONThe clutch may require tuning depending upon wherethe machine will be operated and the desired han-dling characteristi

2-54INSPADJÓ Outsidediametermm (in)69.5 (2.736)69.5 (2.736)69.5 (2.736)69.5 (2.736)Ì Freelengthmm (in)75 (2.95)75 (2.95)75 (2.95)75 (2.95)Ï No. ofcoil

2-55INSPADJ5 Torque cam (secondary sheave spring seat)Ç Part no.8BV-17604-718BV-17604-518BV-17604-318BV-17604-118BV-17604-91GEAR SELECTIONÏ StandardÎ

CHAPTER 6.COOLING SYSTEMHEAT EXCHANGER ... 6-1VX600ER/SX600/VT600 ... 6-1MM600...

2-56INSPADJ19.6 (2.00)19.6 (2.00)19.6 (2.00)24.5 (2.50)27.0 (2.75)24.5 (2.50)27.0 (2.75)22.1 (2.25)24.5 (2.50)19.6 (2.00)22.1 (2.25)22.1 (2.25)22.1 (2

2-57INSPADJGEAR SELECTION7 Clutch weights8CH-17605-10 35.32 gÅ Standard8CR-17605-10 38.09 g8DG-17605-00 34.30 g8DJ-17605-00 37.77 g8DN-17605-20 42.09

2-58INSPADJDuralon90380-092459 mm (0.4 in)90387-0514UDuralon90380-092459 mm (0.4 in)90387-0514UDuralon90380-092459 mm (0.4 in)90387-0514UDuralon90380-

2-59INSPADJHIGH ALTITUDE TUNINGAdjust the size of the main jetRe-testTry high altitude settingsDecide if the problem is with thepilot jet and adjust a

2-60INSPADJFRONT SUSPENSIONSpring adjusterpositionPreloadStandard12 34 5FRONT SUSPENSIONSpring preload (VX600ER/MM600/VT600)1. Adjust:• Spring preload

2-61INSPADJ12aREAR SUSPENSIONREAR SUSPENSIONStopper band1. Adjust:• Stopper band tensionCAUTION:Make sure the left and right sides of the rearsuspensi

2-62INSPADJSpring preload (VX600ER/MM600/VT600)1. Adjust:• Spring preloadAdjustment steps:• Turn the adjusting ring 1 to the proper position.12 34 5So

2-63INSPADJREAR SUSPENSIONRear suspension-full rate1. Adjust:• Full rate adjusterAdjustment steps:InstallationpositionABCSpring rateand dampingSoft Me

2-64INSPADJababTR..Rear suspension position (MM600)1. Adjust:• Rear suspension positionNOTE:Select the rear suspension position according to thesnow c

2-65INSPADJREAR SUSPENSION

PASSENGER GRIP WARMER (VT600) .. 8-43PASSENGER GRIP WARMERSWITCH (VT600) ... 8-44RESISTOR (VT600) ...

3-1CHASSTEERINGCHASSISSTEERINGVX600ER/SX600/VT60010 Nm (1.0 m · kg, 7.2 ft · lb)Å:RemarksRemove the parts in the order listed below.Disconnect.Disconn

3-2CHASSTEERINGMM60010 Nm (1.0 m · kg, 7.2 ft · lb)Å:RemarksRemove the parts in the order listed below.Disconnect.Disconnect.Disconnect.Disconnect.Dis

3-3CHASSTEERINGÅ:25 Nm (2.5 m · kg, 18 ft · lb)ı:Ç:Î:‰:RemarksRemove the parts in the order listed below.Refer to “ENGINE ASSEMBLY” in CHAPTER 5.For i

3-4CHASSTEERINGINSPECTION1. Inspect:• Handlebar 1 (VX600ER/SX600/VT600)• Handlebar 2 (MM600)• Steering column 3Bends/cracks/damage → Replace.WARNINGDo

3-5CHAS12aaab32123STEERINGINSTALLATION1. Install:• Bushings 1NOTE:Mount the bushing with clearance a to the end of therelay arm 2.a Approx. 1 mm (0.04

3-6CHASLTLTSTEERINGTR..5. Adjust:• SkisAdjustment steps:• Temporarily install the handlebar.• Hold the handlebar straight and check that theskis are a

3-7CHAS8CH-108ED-10TR..6. Install:• HandlebarCAUTION:• For SX600/MM600:Be sure the projection on the handlebar is notinstalled into the area a shown.•

3-8CHASSKISKIVX600ER/VT600Q’ty11161122141RemarksRemove the parts in the order listed below.Color : BlackColor : GoldFor installation, reverse the remo

3-9CHASSKISX600/MM600Q’ty111611161RemarksRemove the parts in the order listed below.For installation, reverse the removal procedure.Order123456789Job

3-10CHASFWDa125374168999SKIINSPECTION1. Inspect:• Ski 1• Ski runner 2• Ski stopper 3• Ski column lower bracket 4• Ski handle 5Wear/cracks/damage → Rep

1-1GENINFOMACHINE IDENTIFICATIONGENERAL INFORMATIONMACHINE IDENTIFICATIONFRAME SERIAL NUMBERThe frame serial number 1 is located on the right-hand sid

3-11CHASFRONT SUSPENSIONFRONT SUSPENSION23 Nm (2.3 m · kg, 17 ft · lb)Å:Q’ty1111121224121RemarksRemove the parts in the order listed below.Refer to “S

3-12CHASFRONT SUSPENSIONINSPECTION1. Inspect:• Shock absorber 1Oil (gas) leaks/bends/damage → Replace.2. Inspect:• Ski column 1• Steering arm 2Cracks/

3-13CHAS4. Inspect:• Connecting rod 1• Stabilizer 2Cracks/bends/damage → Replace.• Collar 3Wear/scratches/damage → Replace.5. Inspect:• Front arm 1Cra

3-14CHASFRONT SUSPENSIONINSTALLATION1. Install:• Control rod 1• Nut 2• Joint 3SEA3300Å Left handı Set length a93 ± 1°93 ± 1°475.5 ± 0.5 mm(18.7204 ± 0

3-15CHASccTR..2. Install:• Steering arm 1NOTE:• Align the punch mark a on the ski column with thepunch mark b on the steering arm.• Install sections c

3-16CHASFRONT SUSPENSIONSki spindle camber:–0.5° to +0.5°Angle finder:YS-42422Å USE AN ANGLE FINDER TO CHECK THAT THEUNIT IS LEVEL.SEA3340SEA3350SEA33

3-17CHASFRONT SUSPENSIONÅ Ski toe out:0 ~ 15 mm (0 ~ 0.59 in)a – b = Toe outSEA3380SEA33704 Install the radius rod onto the trailing arm and tighten t

3-18CHASabcRabcdVX600ER/VT600SX600MM600Å Part numberFRONT SUSPENSIONFront arm part numberı CasteraÇControl rodbracket anglebÎShock absorberbracket ang

3-19CHASabFRONT SUSPENSIONControl rod part numberVX600ER/SX600/VT600MM600Ç Part NumberÅ Upperı LowerÅ Upperı LowerÎ Length a‰Angleb8CR-2384E-208CR-238

POWRTR4-1PRIMARY SHEAVE AND DRIVE V-BELTPOWER TRAINPRIMARY SHEAVE AND DRIVE V-BELTQ’ty111RemarksRemove the parts in the order listed below.For install