SUPPLEMENTARY SERVICE MANUAL
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the VX500SXBC, VX700ERC.
OE031 1 2 3 4 5 6 7 8 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspection and adjustment 3 Chassis 4 Power train 5 Engine overhaul 6 Cooling system 7 Carburetion 8 Electrical 9 Specifications 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Illustrated symbols 11 to 17 are used to identify the specifications which appear.
CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . 1 MACHINE IDENTIFICATION . . . . . . . . . 1 FRAME SERIAL NUMBER . . . . . . . 1 ENGINE SERIAL NUMBER . . . . . . . 1 IMPORTANT INFORMATION . . . . . . . . 1 LOCTITE . . . . . . . . . . . . . . . . . . . . . . 1 POWER TRAIN . . . . . . . . . . . . . . . . . . . . . 2 DRIVE V-BELT . . . . . . . . . . . . . . . . . . 2 BRAKE PAD INSPECTION . . . . . . . . 4 SLIDE RUNNER INSPECTION . . . . 4 TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . .
MACHINE IDENTIFICATION/IMPORTANT INFORMATION GEN INFO 1E001 GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number 1 is located on the right-hand side of the crankcase. 500 NOTE: Designs and specifications are subject to change without notice.
DRIVE V-BELT INSP ADJ POWER TRAIN DRIVE V-BELT When installing the new V-belt, make sure that it is positioned within the specified distances 1 from the edge of the secondary sheave. If not, the clutch engagement speed will be changed. The machine may move unexpectedly when the engine is started. Adjust the V-belt position by removing or adding a spacer 2 on each adjusting bolt. For this adjustment, consult a Yamaha dealer or another qualified mechanic.
DRIVE V-BELT INSP ADJ 2. Adjust the position of the V-belt by removing or adding a spacer 1 on each adjusting bolt 2 . V-belt height adjustment To move V-belt up: Add spacer To move V-belt down: Reduce spacer 3. Tighten: S Adjusting bolt Adjusting bolt: 10 Nm (1.0 mSkg, 7.2 ftSlb) 4. Inspect: S Drive V-belt Cracks/damage/wear ! Replace. Oil or grease on the V-belt ! Check the primary and secondary sheaves. 5.
BRAKE PAD INSPECTION/SLID RUNNER INSPECTION INSP ADJ BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Inspect: S Brake pad Wear indicator 1 nearly contacts the brake disc ! Replace the brake pads as a set. Wear limit a : 4.7 mm (0.185 in) SLIDE RUNNER INSPECTION 1. Inspect: S Slide runner 1 Cracks/damage/wear ! Replace. 2. Measure: S Slide runner thickness 2 Out of specification ! Replace. Slide runner wear limit: 10 mm (0.
CLUTCH INSP ADJ TUNING W White S Silver L CLUTCH High altitude P R Red O Orange Pink Y Yellow Blue G Green Specifications Model: VX500SXB A Elevation X 3,500 ft B Idle speed Approx. 1,600 r / min C Clutch engagement Approx. 4,000 r / min D Shift speed Approx. 7,800 r / min E Main jet #151.
CLUTCH INSP ADJ W white S Silver L P R Red O Orange Pink Y Yellow Blue G Green Specifications Model: VX700ER A Elevation X 3,500 ft 3,000 X 5,000 ft 4,500 X 7,000 ft 6,500 X 10,000 ft B Idle speed Approx. 1,600 r / min z z z C Clutch engagement D Shift speed Approx. 4,000 r / min z z z Approx. 8,300 r / min z z z E Main jet #1: #145 #2, 3: #143.
CLUTCH INSP ADJ 2E331 The clutch may require tuning depending upon the area of operation and desired handling characteristics. The clutch can be tuned by changing engagement and shifting speed. Clutch engagement speed is defined as the engine speed where the machine first begins to move from a complete stop. Shifting speed is when the machine has been started at full-throttle from a dead stop and has travelled 200 X 300 m (650 X 1,000 ft).
INSP ADJ GEAR SELECTION GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions. If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions exist, decrease the ratio. Gear ratio chart The following drive and driven gears and chains are available as options.
GEAR SELECTION INSP ADJ 3 Secondary spring A Parts No. B Spring rate C No. of NSmm/ rad coils (kgmm/ rad) D Color E Wire gauge (mm) F Free length (mm) G Standard 90508-500B1 6003 (613) 5.2 BROWN 5.0 75 90508-536A9 7147 (729) 5.5 RED 5.3 75 VX500 90508-556A2 8314 (848) 5.5 GREEN 5.5 75 VX700 90508-556A7 9460 (965) 4.8 SILVER 5.
INSP ADJ GEAR SELECTION 6 Primary spring B A Parts No. Spring rate N / mm (kg / mm) C Preload (kg) D Color E F Wire gauge (mm) Outside diameter (mm) G No. of coils H Free length (mm) 90501-481J1 9.8 (1.0) 196.1 (20) S-B-S 4.8 60 5.16 85.4 90501-487G8 14.7 (1.5) 147 (15) G 4.8 60 4.19 75.4 90501-507G2 14.7 (1.5) 196.1 (20) G-B-G 5.0 60 4.61 78.7 90501-524G5 14.7 (1.5) 245 (25) G-Y-G 5.2 60 5.08 82.1 90501-507G7 17.1 (1.75) 147 (15) R-G-R 5.0 60 4.24 74.
INSP ADJ FRONT SUSPENSION FRONT SUSPENSION Spring preload (700) 1. Adjust: S Turn the adjusting ring 1 to the proper position. Spring adjuster position 1 2 3 Preload Softer z Standard 1 4 5 ! Harder CAUTION: Be sure that the left and right spring preload is the same. Spring preload (500) 1. Adjust: S Turn the spring seat 1 in or out. Spring seat distance Preload a Length Standard Shorter z ! Longer Harder z ! Softer Max. Min. 213 mm 223 mm 233 mm (8.39 in) (8.78 in) (9.
INSP ADJ REAR SUSPENSION REAR SUSPENSION Stopper band 1. Adjust: S Stopper band tension CAUTION: Be sure that the left and right length is the same. NOTE: This adjustment affects the handling characteristics of the machine. Adjustment steps: S Loosen the locknut 1 . S Turn the adjusting nut 2 in or out to adjust the stopper band tension. Adjuster Thread length Longer z ! Shorter maximum minimum STD 500 15 mm (0.59 in) 700 10 mm (0.39 in) Effects More weight on skis.
REAR SUSPENSION INSP ADJ Spring preload (500) 1. Adjust: S Turn the spring seat 1 in or out. A B Spring seat distance Standard Shorter z ! Longer Preload Harder z ! Softer A Length a (front) Max. Min. 172 mm 182 mm 192 mm (6.77 in) (7.17 in) (7.56 in) B Length b (rear) Max. Min. 302 mm 312 mm 322 mm (11.89 in) (12.28 in) (12.68 in) This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly.
SKI CHAS CHASSIS SKI (500) A : 10 Nm (1.0 mSkg, 7.2 ftSlb) B : 21 Nm (2.1 mSkg, 15 ftSlb) C : 48 Nm (4.8 mSkg, 35 ftSlb) : ESSO beacon 325 grease or Aeroshell grease #7A Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Ski removal Cotter pin Ski column lower bracket Ski stopper Collar Washers Ski Ski runner Washers Ski handle Remarks Remove the parts in the order below. 1 1 1 1 6 1 1 6 1 For installation, reverse the removal procedure.
SKI/FRONT SUSPENSION CHAS INSPECTION 1. Inspect: S Ski 1 S Ski runner 2 S Ski column lower bracket 3 S Ski handle 4 S Ski stopper 5 Wear/cracks/damage ! Replace. S Mounting bolt 6 S Collar 7 Wear/damage ! Replace. FRONT SUSPENSION This shock absorber contains highly compressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information.
FRONT SUSPENSION CHAS INSTALLATION 1. Install: S Control rod 1 S Nut 2 S Joint 3 a Set length D Left hand C Model VX500 F Set length a (mm) H Upper I Lower VX700 H Upper I Lower B Set angle (_) 460.2 ± 0.5 mm (18.11 ± 0.0197 in) 94 ± 1 458.7 ± 0.5 mm (18.059 ± 0.0197 in) 94 ± 1 475.5 ± 0.5 mm (18.012 ± 0.0197 in) 93 ± 1 472.6 ± 0.5 mm (18.606 ± 0.0197 in) 93 ± 1 E Right hand C Model VX500 F Set length a (mm) H Upper I Lower VX700 H Upper I Lower B Set angle (_) 460.2 ± 0.5 mm (18.
SECONDARY SHEAVE POWR TR ASSEMBLY 1. Install: S Secondary sheave spring 1 S Bolts 2 (along with the shims) Bolt: 10 Nm (1.0 mSkg, 7.2 ftSlb) 2. Install: S Stopper S Sliding sheave Screw (stopper): 6.5 Nm (0.65 mSkg, 4.6 ftSlb) 3. Install: S Secondary sheave spring 1 S 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.
DRIVE CHAIN HOUSING POWR TR DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL (500) A : 10 Nm (1.0 mSkg, 7.2 ftSlb) B : 24 Nm (2.4 mSkg, 17 ftSlb) C : 48 Nm (4.8 mSkg, 35 ftSlb) D : 60 Nm (6.0 mSkg, 43 ftSlb) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “BRAKE”.
DRIVE CHAIN HOUSING POWR TR INSTALLATION During installation, pay attention to the following point: A Make sure that the bearing seals face towards the drive chain, as shown. B Properly install the rubber seal onto the drive chain housing, making sure that these are no gaps. C Be sure to install the spacers in their original positions of the brake disc and jackshaft will stick. D 0.1 X 0.5 mm (0.004 X 0.
DRIVE CHAIN HOUSING POWR TR DRIVE CHAIN HOUSING AND JACKSHAFT INSTALLATION 1. Install: S Drive chain housing S Jackshaft Installation steps: D Install the drive chain housing 1 . D Tighten the bolts 2 . Bolt (drive chain housing): 48 Nm (4.8 mSkg, 35 ftSlb) D Temporarily tighten the nuts 3 . D Tighten the nuts 3 . Nut (jackshaft): 60 Nm (6.0 mSkg, 43 ftSlb) D Retighten the nuts 3 . Nut (bearing holder): 23 Nm (2.3 mSkg, 17 ftSlb) D Tighten the set screws 5 . Set screw (bearing): 8.5 Nm (0.85 mSkg, 6.
DRIVE CHAIN HOUSING POWR TR WITH REVERSE MODEL (700) Order Job name/Part name 10 Nm (1.0 mSkg, 7.2 ftSlb) B : 24 Nm (2.4 mSkg, 17 ftSlb) C : 48 Nm (4.8 mSkg, 35 ftSlb) D : 60 Nm (6.0 mSkg, 43 ftSlb) Q’ty Drive chain housing removal Battery Battery bracket Brake caliper Parking brake Tension adjuster 1 2 3 4 5 6 7 8 9 A : Remarks Remove the parts in the order below. Refer to “BRAKE”. Loosen. Refer to “SLIDE RAIL SUSPENSION”.
DRIVE CHAIN HOUSING Order 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Job name/Part name Q’ty Reverse drive gear 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 POWR TR Remarks 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
DRIVE CHAIN HOUSING/JACKSHAFT POWR TR INSTALLATION During installation, pay attention to the following point: A Properly install the rubber seal onto the drive chain housing, making sure that these are no gaps. B Make sure that the bearing seals face towards the drive chain, as shown. C Be sure to install the spacers in their original positions of the brake disc and jackshaft will stick. D 0.1 X 0.5 mm (0.004 X 0.
BRAKE POWR TR BRAKE A : 1.5 Nm (0.15 mSkg, 1.1 ftSlb) B : 6 Nm (0.6 mSkg, 4.3 ftSlb) A Order B Job name/Part name Q’ty Brake caliper disassembly 1 2 3 4 5 6 7 8 9 Remarks Disassembly the parts in the order below. Cap bolt Retaining pin Pad spring Brake pads Shim 1 Shim 2 Bleed screws Oil seals Pistons 1 1 1 2 2 2 2 4 2 For assembly, reverse the disassembly procedure.
BRAKE POWR TR CAUTION: Disc brake components rarely require disassembly. DO NOT: D Disassemble components unless absolutely necessary. D Use solvents on internal brake components. D Use contaminated brake fluid for cleaning. Use only clean brake fluid. D Allow brake fluid to come in contact with the eyes, otherwise eye injury may occur. D Allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur.
BRAKE POWR TR 2. Install: S Brake pads S Pad spring Installation steps: S Connect a suitable hose 1 tightly to the caliper bleed screw 2 . Put the other end of this hose into an open container. S Loosen the caliper bleed screw and push the pistons into the caliper with the finger. S Tighten the caliper bleed screw 2 . Bleed screw: 6 Nm (0.6 mSkg, 4.3 ftSlb) S Install the brake pads and pad spring. NOTE: The tangs a of the pad spring must point in the direction of the disc rotation. 3.
SLIDE RAIL SUSPENSION POWR TR SLIDE RAIL SUSPENSION A : Order 1 2 3 4 71 Nm (7.1 mSkg, 51 ftSlb) Job name/Part name Q’ty Slide rail suspension removal Tension adjuster Blind caps Bolts Washer Slide rail suspension Remarks Remove the parts in the order below. Loosen. 2 6 2 1 For installation, reverse the removal procedure.
SLIDE RAIL SUSPENSION Order Job name/Part name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 A : 4 Nm (0.4 mSkg, 2.9 ftSlb) B : 15 Nm (1.5 mSkg, 11 ftSlb) C : 30 Nm (3.0 mSkg, 22 ftSlb) D : 49 Nm (4.9 mSkg, 35 ftSlb) E : 71 Nm (7.1 mSkg, 50 ftSlb) F : 24 Nm (2.4 mSkg, 17 ftSlb) Q’ty Slide rail suspension disassembly POWR TR Remarks Disassemble the parts in the order below.
SLIDE RAIL SUSPENSION A : 24 Nm (2.4 mSkg, 17 ftSlb) B : 49 Nm (4.9 mSkg, 35 ftSlb) C : 71 Nm (7.
SLIDE RAIL SUSPENSION A : 49 Nm (4.9 mSkg, 35 ftSlb) B : 71 Nm (7.
SLIDE RAIL SUSPENSION A : 24 Nm (2.4 mSkg, 17 ftSlb) B : 71 Nm (7.1 mSkg, 50 ftSlb) C : 75 Nm (7.
FRONT AXLE AND TRACK A FRONT AXLE AND TRACK 27 mm (1.06 in) 132.6 mm (5.22 in) 164.1 mm (6.46 in) B 102 mm (4.0157 in) 43.1 mm (1.70 in) 60 mm (2.36 in) 39 mm (1.535 in) 201.4 mm (7.93 in) NOTE: D When pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel. D Locate each sprocket wheel and guide wheel on the axle where shown in the illustration. 102 mm (4.0157 in) 39 mm (1.535 in) 60 mm (2.36 in) 132.6 mm (5.22 in) 164.1 mm (6.
ENG ENGINE ASSEMBLY ENGINE ENGINE ASSEMBLY 500 A : 90 Nm (9.0 mSkg, 65 ftSlb) B : 60 Nm (6.0 mSkg, 43 ftSlb) A B 8 Order Job name/Part name Q’ty Engine removal Exhaust pipe Carburetor Recoil starter Water pump Remove the parts in the order below. Refer to “CARBURETOR”. Refer to “RECOIL STARTER”. Refer to “WATER PUMP AND THERMOSTATIC VALVE”. Refer to “PRIMARY SHEAVE AND DRIVE V-BELT”.
ENGINE ASSEMBLY ENG 700 A : 23 Nm (2.3 mSkg, 17 ftSlb) B : 60 Nm (6.0 mSkg, 43 ftSlb) C : 90 Nm (9.0 mSkg, 65 ftSlb) D : 23 Nm (2.3 mSkg, 17 ftSlb) Order Job name/Part name Q’ty Engine removal Exhaust pipe Carburetor Recoil starter CDI Magneto rotor Frame cross member Primary sheave Remove the parts in the order below. Refer to “CARBURETOR”. Refer to “RECOIL STARTER”. Refer to “CDI MAGNETO”. Refer to “PRIMARY SHEAVE AND DRIVE V-BELT”. Drain. Refer to “COOLANT REPLACEMENT”.
ENG CYLINDER HEAD AND CYLINDER CYLINDER HEAD AND CYLINDER INSPECTION 1. Measure: S Piston-to-cylinder clearance Measurement steps: 1st step: S Measure the cylinder bore “C” with a cylinder bore 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 Standard Cylinder bore “C” 500: 68.00 X 68.02 mm (2.677 X 2.678 in) 700: 70.50 X 70.52 mm (2.775 X 2.776 in) Wear limit 68.1 mm (2.681 in) 70.6 mm (2.
CYLINDER HEAD AND CYLINDER ENG 2nd step: S Measure the piston skirt diameter “P” with a micrometer from distance a . a 500: 25 mm (0.98 in) 700: 15 mm (0.59 in) from the piston bottom edge. P Piston size P Standard 500: 67.930 X 67.935 mm (2.6745 X 2.6746 in) 700: 70.425 X 70.430 mm (2.7727 X 2.7728 in) S If out of specification, replace piston and piston rings as a set.
HEAT EXCHANGER COOL COOLING SYSTEM HEAT EXCHANGER 1. Measure: S Filler cap opening pressure Cap opens at pressure below the specified pressure ! Replace. Cap opening pressure: 95 X 125 kPa (0.95 X 1.25 kg/cm2, 13.58 X 17.87 psi) Measurement steps: D Attach the cooling system tester 1 (90890-01325, YU-24460-01) to the coolant filler cap 2 . D Apply the specified pressure for 10 seconds, and make sure there is no pressure drop.
CARBURETORS CARB CARBURETION CARBURETORS 500 3 4 1 5 2 7 2 6 * Intake silencer D First, remove the throttle cable from the cable guide on the steering column. D Adjust the throttle cable free play while the cable is in the cable guide. D After adjusting the throttle cable free play, properly install the upper and lower intake silencer plates and seal. Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Carburetors removal Air chamber Clamp screws Throttle cable Carburetor switch (T.O.R.S.
CARBURETORS CARB 700 * Intake silencer D First, remove the throttle cable from the cable guide on the steering column. D Adjust the throttle cable free play while the cable is in the cable guide. D After adjusting the throttle cable free play, properly install the upper and lower intake silencer plates and seal. Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Carburetors removal Spark plug caps Clamp screws Carburetor switch (T.O.R.S.
CARBURETORS Order Job name/Part name Q’ty Carburetor separation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CARB Remarks Separation the parts in the order below. Coolant hoses Starter cable holder Collar Spring Screw Starter rod Spring Starter levers Breather hoses Top covers Gaskets Throttle shaft connecting screws Connecting plate (upper) Connecting plate (lower) 4 1 1 1 3 1 1 3 3 3 3 3 1 1 Loosen For assembly, reverse the separation procedure.
CARBURETORS CARB ASSEMBLY 1. Measure: S Float height a Out of specification ! Adjust. Float height: 500 22.3 ± 2.0 mm (0.878 ± 0.080 in) 700 13.3 ± 2.0 mm (0.524 ± 0.080 in) Measurement and adjustment steps: S Hold the carburetor in an upside down position. S Measure the distance between the carburetor body and top of the floats. NOTE: The float arm should be resting on the valve, but not compressing the needle valve spring.
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model VX500SXB VX700ER Model code number: 8CT 8DY Dimensions: Overall length Overall width Overall height 2,760 mm (108.7 in) 1,170 mm (46.1 in) 1,085 mm (42.7 in) z 1,200 mm (47.2 in) 1,300 mm (51.2 in) Weight: 222 kg (488 lb) 236 kg (520 lb) Minimum turning radius: Clockwise Counterclockwise 3.8 m (12.5 ft) 3.8 m (12.5 ft) 4.0 m (13.1 ft) 4.0 m (13.
SPEC GENERAL SPECIFICATIONS Model VX500SXB VX700ER TM36 2 MIKUNI TM33 z BR9ES NGK 0.7 X 0.8 mm (0.028 X 0.031 in) z z z V-Belt 3.8 X 1.0 : 1 Automatic centrifugal engagement Chain 1.77 (39/22) No z z z Chassis: Frame type Caster Ski stance (center to center) Monocoque 22.5_ 1,040 mm (40.9 in) z z 1,070 mm (42.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model Cylinder head: Volume (with spark plug) 500 VX500SXB VX700ER 23.3 X 23.9 cm3 <0.03 mm (0.0012 in)> * Lines indicate straight edge measurement. 22.9 X 23.5 cm3 z z Aluminum alloy with dispersion coating 68.00 X 68.02 mm (2.677 X 2.678 in) <0.05 mm (0.0019 in)> <0.01 mm (0.0004 in)> z 67.930 X 67.935 mm (2.6745 X 2.6746 in) 25 mm (0.98 in) 0.095 X 0.100 mm (0.0037 X 0.0039 in) <0.11 mm (0.0043 in)> 20.004 X 20.
MAINTENANCE SPECIFICATIONS Model Crankshaft: Crank width “A” Crank width “B” Crankshaft deflection “C” : C1 500: C2, C3 500: C4 700: C2 X C5 700: C6 Measuring points: 1 Measuring points: 2 Connecting rod big end side clearance “D” Connecting rod small end free play “F” SPEC VX500SXB VX700ER 61.95 X 62.00 mm (2.439 X 2.440 in) 179.85 X 180.15 mm (7.080 X 7.093 in) Below 0.03 mm (0.0012 in) Below 0.04 mm (0.0016 in) Below 0.05 mm (0.0020 in) – – 80 mm (3.15 in) 99 mm (3.90 in) 0.25 X 0.75 mm (0.01 X 0.
MAINTENANCE SPECIFICATIONS Model Carburetor: Type/Quantity Manufacturer I.D. mark Main jet (M.J) VX500SXB VX700ER TM36/2 pcs. MIKUNI 8CJ10 #151.3 SPEC Main air jet (M.A.J) Pilot jet (P.J) Jet needle (J.N) Needle jet (N.J) ø2.5 #45 8CFY14-56-2 Q-6 Pilot air jet (P.A.J) Pilot outlet (P.O) Bypass (B.P.I) Pilot screw (P.S) Throttle valve (Th.V) Valve seat size (V.S) Starter jet (G.S) Float height (F.H) 2.5 ø0.9 1.0 1-3/4 3.0 ø1.5 ø0.9 22.3 ± 2.0 mm (0.878 ± 0.080 in) 41 mm (1.
MAINTENANCE SPECIFICATIONS Model Thermostat: Opening temperature Valve lift VX500SXB VX700ER 50 X 55_C (122_F X 132_F) 8 mm/70_C (159_F) z –47– z SPEC
MAINTENANCE SPECIFICATIONS SPEC POWER TRAIN Model Transmission: Type Range of ratio Engagement r/min Shift r/min Sheave center distance “A” Sheave offset “B” V-Belt: Part number Outside circumference Width “A” Wear limit “B” Primary sheave spring: Part number Color code Diameter Wire diameter Preload Spring rate Number of coils Free length Primary sheave weight arm: Part number (with bushing) Weight VX500SXB VX700ER V-belt automatic 3.8 X 1.0 : 1 4,000 ± 200 r/min 7,800 ± 250 r/min 267 X 270 mm (10.
MAINTENANCE SPECIFICATIONS Model Rivet: Outer Part number Material Size Quantity Hole quantity Inner Part number Material Size Quantity Hole quantity Secondary sheave spring: Part number Color code Outside diameter Wire diameter Hole position Sheave side-spring side (twist angle) Spring rate Number of coils Free length Torque cam angle Drive chain: Type Number of links SPEC VX500SXB VX700ER 90261-06034 Steel 13.9 mm (0.55 in) 3 pcs 3 pcs 90261-06015 z 10.3 mm (0.40 in) z z 90261-06028 Aluminum 10.
MAINTENANCE SPECIFICATIONS Model SPEC VX500SXB VX700ER 8AB-47110-10 381 mm (15.0 in) 3,072 mm (120.9 in) 64 mm (2.52 in) 48 16 mm (0.63 in) 8CH-47110-00 z z z z z 25 X 30 mm (0.98 X 1.18 in) z 178 mm (7 in) 203 mm (8 in) 228 mm (9 in) 279 mm (11 in) 47 N/mm (4.8 kg/mm, 274 lb/in) 27.44 X 47.04 N/mm (2.8 X 4.8 kg/mm, 160 X 273 lb/in) 19.6 N/mm (2 kg/mm, 112 lb/in) 29.4 X 44.1 N/mm (3.0 X 4.5 kg/mm, 174 X 251 lb/in) Spring wire diameter Front Rear 9.0 mm (0.35 in) 10.8 mm (0.425 in) 7.8 mm (0.
MAINTENANCE SPECIFICATIONS Model SPEC VX500SXB VX700ER 3,320N ± 460N/0.3m/s 1,110N ± 225N/0.3m/s 720 N ± 150N/0.3m/s 1,020 N ± 210N/0.3m/s 1,950N ± 264N/0.3m/s 1,380N ± 235N/0.3m/s 2,206 N ± 657N/0.3m/s 726 N ± 216N/0.3m/s Slide runner: Thickness Wear limit 17.8 mm (0.70 in) 10 mm (0.39 in) z z Track sprocket wheel: Material Number of teeth Polyethylene 9T z z Rear guide wheel: Material Aluminum with rubber 178 mm (7 in) High-molecular-weight polyethylene with rubber z 10.2 mm (0.40 in) 4.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Model VX500SXB VX700ER Frame: Frame material Seat height Luggage box location Aluminum 685 mm (26.8 in) Rear side of seat z 730 mm (28.7 in) z Steering: Lock-to-lock angle (left) (right) Ski alignment Toe-out size Caster angle 29.6_ (R ski) 34.8_ (L ski) 34.8_ (R ski) 29.6_ (L ski) Toe-out 0 X 15 mm (0 X 0.59 in) 22.5_ 29.4_ (R ski) 34.7_ (L ski) 34.7_ (R ski) 29.
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Model VX500SXB VX700ER Voltage: 12 V z Ignition system: Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advanced type 16_ at 1.600 r/min 18_ at 4.500 r/min Electrical type 18_ at 1.500 r/min 24_ at 4.500 r/min z Ignition coil: Model/Manufacturer Minimum spark gap Primary coil resistance 8AB-00/YAMAHA 3 mm (0.118 in) or more 0.2 Ω ± 20% at 20_C (68_F) 4.9 kΩ ± 20% at 20_C (68_F) 8DG-00/YAMAHA z 0.06 Ω ± 20% at 20_C (68_F) 3.
MAINTENANCE SPECIFICATIONS Model Rectifier/regulator: Model/manufacturer No load regulated voltage VX500SXB 8CR-00/MATSUSHITA AC 13.8 X 14.8 V DC 14.0 X 15.0 V SPEC VX700ER z z z Battery: (for electric model) Specific gravity Type – – 1.280 GM18Z-3A Electric starter system: (for electric model) Type – Bendix DB4XF/DENSO 0.6 kW 0.014 X 0.018 Ω at 20_C (68_F) 12 mm (0.47 in) 8.5 mm (0.33 in) 6.5 X 9.5 N (650 X 950 g, 22.9 X 33.5 oz) 28 mm (1.10 in) 27 mm (1.06 in) 0.4 X 0.8 mm (0.016 X 0.
MAINTENANCE SPECIFICATIONS SPEC High altitude settings VX500SXB Tempera- – 40_C ture (– 40_F) Altitude 0 X 100 m (0 X 330 ft) – 29_C (– 20_F) – 18_C (0_F) – 7_C (20_F) 4_C (40_F) 15_C (60_F) MJ#155 JN-2.0 MJ#153.8 JN-2.0 MJ#152.5 JN-2.0 MJ#151.3 JN-2.0 MJ#150 JN-2.0 100 X 500 m (330 X 1,600 ft) MJ#153.8 JN-2.0 MJ#152.5 JN-2.0 MJ#151.3 JN-2.0 MJ#150 JN-2.0 MJ#148.8 JN-2.0 500 X 1,000 m (1,600 X 3,300 ft) MJ#151.3 JN-2.0 MU#150 JN-1.5 MJ#148.8 JN-1.5 MJ#147.5 JN-1.5 MJ#146.3 JN-1.
SPEC MAINTENANCE SPECIFICATIONS High altitude settings VX700ER Tempera- – 40_C ture (– 40_F) Altitude – 29_C (– 20_F) – 18_C (0_F) – 7_C (20_F) 4_C (40_F) 15_C (60_F) 0 X 100 m (330 ft) MJ#1 MJ#2#3 PJ JN PS #148.8 #147.5 #45.0 3.0 1-1 / 2 MJ#1 MJ#2#3 PJ JN PS #147.5 #146.3 #45.0 3.0 1-1 / 2 MJ#1 MJ#2#3 PJ JN PS #146.3 #145.0 #45.0 3.0 1-1 / 2 MJ#1 MJ#2#3 PJ JN PS 1 #145.0 #143.8 #45.0 3.0 1-3 / 8 MJ#1 MJ#2#3 PJ JN PS #143.8 #142.5 #45.0 2.
MAINTENANCE SPECIFICATIONS SPEC Tightening torque: Tightening torque Parts to be tightened Crankcase (first) Crankcase (final) Engine bracket (front) and frame 500 Engine bracket (front) and frame 700 Engine bracket damper (front) Engine bracket and engine Engine bracket upper and lower (rear) Engine bracket damper and frame (rear) Water pump housing Cylinder head Nut 500 (first) Nut 500 (final) Nut 700 (first) Nut 700 (final) Cylinder body Nut 500 Nut 700 Spark plug Thermostatic valve cover Water pump d
MAINTENANCE SPECIFICATIONS Tightening torque Parts to be tightened Sliding frame and slide runner Slide rail suspension mounting bolt Rear pivot arm and bracket Shock absorber and rear pivot arm Rear pivot arm and rod Rear suspension bracket and rod Control rod and sliding frame Front pivot arm and sliding frame Shock absorber and front pivot arm Shock absorber and bracket Shock absorber and rear pivot arm Bracket shaft and sliding frame Collar (front axle) Speedometer gear Handlebar holder Steering column
MAINTENANCE SPECIFICATIONS –59– SPEC
CABLE ROUTING CABLE ROUTING <500> –60– SPEC
CABLE ROUTING CABLE ROUTING 1 Oil pump cable 2 Throttle cable 3 Fasten the wire harness. Do not fasten the throttle cable and oil pump cable. 4 Fasten the throttle cable and oil pump cable with a plastic clamp. Route the cable along the side of the handle holder. 5 Thumb warmer coupler 6 Engine stop switch coupler 7 Grip warmer lead 8 Brake light switch coupler 9 Head light switch coupler 10 Fasten oil breather hose and wire harness with a plastic clamp.
CABLE ROUTING –62– SPEC
CABLE ROUTING 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 To the conduction Voltage regulator Rectifire regulator Fasten the wire harness with a plastic clamp. Rectifire regulator (ECC model) Brake hose holder Fasten the wire harness with a plastic clamp. To reverse gear Fasten the wire harness, fuel breather hose and oil breather hose with a plastic clamp.
CABLE ROUTING 30_ –64– SPEC
CABLE ROUTING 1 Wire lead (electrical starter model) 2 Carburetor switch coupler 3 Fasten the throttle cable and oil pump cable with a plastic clamp. 4 Air temperature sensor coupler (ECC model) 5 Coolant hose 6 Starter relay lead 7 Starter relay sub lead (electrical starter model) 8 Fasten the wire harness, battery negative lead and coolant hose with a plastic clamp. (electrical starter model) 9 Route the battery lead along the behind coolant hose.
CABLE ROUTING 30_ –66– SPEC
CABLE ROUTING 32 Solenoid coupler (ECC model) 33 Ignition coil 34 Carburetor heating lever 35 Coolant hose 36 Speedometer cable 37 Fasten the throttle cable, water temperature sensor lead, carburetor switch lead and solenoid lead with a plastic clamp. 38 Water temperature sensor coupler 39 Under 50 mm (1.97 in) 40 Fasten the speedometer cable and wire harness with a plastic clamp.
CABLE ROUTING –68– SPEC
CABLE ROUTING 1 Make sure that the oil tank cap and oil breather hose do not touch each other. 2 Route the fuel breather hose along the upper of the main harness. 3 Route the oil breather hose along the upper of the main harness. 4 Install the tail / brake light lead behind the instrument panel. 5 Holder 6 Clip 7 To tail / brake light 8 50 mm (1.
CABLE ROUTING CABLE ROUTING <700> –70– SPEC
CABLE ROUTING CABLE ROUTING 1 Oil pump cable 2 Throttle cable 3 Do not fasten the throttle cable and oil pump wire with a plastic clamp. 4 Thumb warmer coupler 5 Engine stop switch coupler 6 Holder 7 Grip warmer coupler 8 Brake light switch coupler 9 Head light switch coupler 10 Fasten the oil breather hose with a plastic clamp. 11 Parking brake cable 12 Oil breather hose 13 Fasten the oil breather hose with a plastic clamp.
CABLE ROUTING –72– SPEC
CABLE ROUTING 37 DC back buzzer (reverse model) 38 Voltage regulator 39 Rectifier regulator 40 DC back buzzer coupler 41 Fasten the wire harness with a plastic clamp. 42 Brake hose holder 43 Fasten the wire harness with a plastic clamp. 44 To reverse gear 45 Fasten the wire harness, fuel breather hose and oil breather hose with a plastic clamp.
CABLE ROUTING –74– SPEC
CABLE ROUTING 1 Fasten the carburetor switch, water temperature sensor lead, coolant hose, wire lead and battery negative lead with a plastic clamp. 2 Clamp 3 Fasten the ignition coil and starter cable with a plastic clamp. 4 Fasten the wire lead, battery negative lead and coolant hose with a plastic clamp. 5 Cap (without electlic starter model) 6 Fasten the coolant hose with a plastic clamp. 7 Route the battery lead along the behind coolant hose.
CABLE ROUTING –76– SPEC
CABLE ROUTING 1 Wire harness 2 50 mm (1.97 in) 3 Make sure that the oil tank cap and oil breather hose do not touch each other. 4 Route the fuel breather hose along the upper of the main harness. 5 Route the oil breather hose along the upper of the main harness. 6 Install the tail / brake light lead behind the instrument panel. 7 Holder 8 Clip 9 To tail / brake light 10 50 mm (1.
WIRING DIAGRAM VX500SXB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 COLOR CODE B ........ G ....... L ........ O ....... P ........ R ........ W ....... Y ........ Br . . . . . . . Ch . . . . . . B/R . . . . . B/W . . . . . B/Y . . . . . G/R . . . . . G/Y . . . . . L/R . . . . . R/B . . . . . R/W . . . . . W/G . . . . W/R . . . . . Y/B . . . . . Y/R . . . . . Y/W . . . . .
WIRING DIAGRAM VX700ER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 COLOR CODE B ............ G ........... L ............ O ........... P ............ R ............ W ........... Y ............ Br . . . . . . . . . . . Ch . . . . . . . . . . B/R . . . . . . . . . B/W . . . . . . . . . B/Y . . . . . . . . . G/B . . . . . . . . . G/R . . . . . . . . . G/Y . . . . . . . . . L/R . . . . . . . . . R/B . . . . . . . . . R/W . . . . . . . . . W/G . . . . . . . . W/R . . . . . . . . . Y/B . . . . . . . . .
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