94 Vmax4 SM

,
332pgsSnow •YAMAHA
VX750/800,
MM BOO
YAMAHA
SUPPLEMENTARY
SERVICE MANUAL
LIT-12618-01-60
VXSOOV/VXSOOSTV
SUPPLEMENTARY SERVICE MANUAL
©1994 by Yamaha Motor Corporation, U.S.A.
1st Edition, June 1994
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-12618-01-60
FOREWORD
This Supplementary Service Manual has been
prepared to introduce new service and new data
for the VXBOOVNXBOOSTV. For complete infor-
mation on service procedures, it is necessary to
use this Supplementary Service Manual together
with following manual:
VX750U/VX750STU/SERVICE MANUAL:
SAX-28197-10
HOW TO USE THIS MANUAL
Particularly important information is distin-

guished in this manual by the following nota-
tions:
~
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
A WARNING
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting or
repairing the machine.
A CAUTION indicates special precautions that

must be taken to avoid damage to the machine.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
OE031
Q) ®
ILLUSTRATED SYMBOLS
1~~~1--1 p~g!l-1 (Refer to the illustration)
Illustrated symbols Q) to @) are designed as

@ @
thumb tabs to indicate the chapter's number and
lcHAsl..,9 I IPC:Rlo-el content.

Q) General information
® Periodic inspection and adjustment
@Chassis
@ ® @ Power train
IENGI ®• I lcooLI ~I @ Engine overhaul

@ Cooling system
<V Carburetion
@ Electrical
<V @
® Specifications
lcARBI Ii' I IELeclDI @) Optional kit
® @)
lsPecl u--1 l0 PTIOI Illustrated symbols® to@ are used to identify

® @
roJ B
the specifications which appear.
® Filling fluid
@lubricant
@ Tightening
@ ® ® Wear limit, clearance
~ ~
@ Engine speed
@ Special tool
@n.v.A
@ @
@
[0]
@)
~ @> Illustrated symbols@) to @ in the exploded dia-
~
gram indicate grade of lubricant and location of
®
1
®
1
• @
~
l
lubrication point.
@) Apply locking agent (LOCTITE®!
@> Apply Yamabond No.5®
® Apply engine oil
® Apply gear oil
m m Gl
@ Apply molybdenum disulfide oil
® Apply wheel bearing grease
@Apply low-temperature lithium-soap base grease
......
@ @ ® ® Apply molybdenum disulfide grease
~ ~
CONTENTS
GENERAL INFORMATION ........................................................................................... 1
MACHINE IDENTIFICATION .................................................................................. 1
FRAME SERIAL NUMBER ............................................................................... 1
ENGINE SERIAL NUMBER .............................................................................. 1
PERIODIC INSPECTIONS AND

ADJUSTMENTS ............................................................................................................ 2
INTRODUCTION ..................................................................................................... 2
PERIODIC MAINTENANCE TABLE ........................................................................ 2
POWER TRAIN ........................................................................................................ 4
DRIVE V-BELT .................................................................................................. 4
CLUTCH TUNING ............................................................................................. 6
GEARING SELECTION ..................................................................................... 8
POWER TRAIN ............................................................................................................ 10

SECONDARY SHEAVE ......................................................................................... 10
JOB INSTRUCTION CHART .......................................................................... 11
DISASSEMBLY ............................................................................................... 12
INSPECTION ................................................................................................... 12
ASSEMBLY ..................................................................................................... 13
INSTALLATION .............................................................................................. 14
JACKSHAFT .......................................................................................................... 16
ENGINE OVERHAUL ................................................................................................... 18

CRANKCASE AND CRANKSHAFT ...................................................................... 18
SPECIACATIONS ........................................................................................................ 21
GENERAL SPECIFICATIONS ............................................................................... 21
MAINTENANCE SPECIFICATIONS ..................................................................... 23
ENGINE ........................................................................................................... 23
POWER TRAIN ............................................................................................... 26
CHASSIS ......................................................................................................... 29
ELECTRICAL ...................................................................................................30
MACHINE IDENTIACATION I~~~ 1~ I
GENERAL
INFORMATION
MACHINE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number <D is located on the
right-hand side of the frame (just below the front
of the seat).
ENGINE SERIAL NUMBER

The engine serial number <D is located on the
front side of the crankcase.
NOTE:-----------------------
The first three digits of these numbers are for
model identification; the remaining digits are the
unit production number.
Starting serial number:

VXBOOU: BBU-000101 ..
VXBOOSTU: BBT-000101 ..
NOTE:------------------------
Designs and specifications are subject to change
without notice.
-1-
INTRODUCTION/PERIODIC MAINTENANCE TABLE I1:i~s I41it I
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all of the information necessary to perform recommended inspections and
adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine
operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced.
This information applies to machines already in service as well as new machines that are being prepared
for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE

First Every
Pre- Month Season
operation or or
No. Item Remarks check first 800 km 3,200 km
(daily) (500 Mi) (2,000 Mi)
(40 hr) (160 hr)
Check condition, adjust the gap and
1 Spark plug clean.
Replace if necessary.
•
2 Engine oil
Check oil level. •
*Air bleed the oil pump if necessary. •
3 Fuel Check fuel level.
•
4 * Fuel filter
Check condition.
Replace if necessary. •
Check fuel hose for cracks or
5 *Fuel line damage.
Replace if necessary.
•
6 *Oil line
Check oil hose for cracks or damage.
7 Carburetor
Check throttle lever operation.
•
Whenever operating conditions
*Adjust the jets.
(elevation/temperature) are changed.
8 *Fan belt
Check wear and damage.
Adjust fan belt if necessary. •
9 Manual starter
Check operation and rope damage.
*Replace if necessary. •
10 Engine stop switch
Check operation
*Repair if necessary. •
11 Throttle override
system
Check operation.
12 Throttle lever
Check operation.
Check for leakage.
13 *Exhaust system Retighten or replace gasket if
necessary.
•
14 * Decarbonization More frequently if necessary. •
15 Drive V-belt guard
Check for cracks, bending or damage.
16 Drive V-belt
*:It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
**: Perform after 1 Month or 50 Km (31 Mi) (2 hr) and every 1 Month or 400 Km (250 Mi).
-2-
PERIODIC MAINTENANCE TABLE I':gj Iflit I
First Every
Pre- Month Season
operation or or
No. Item Remarks check first 800 km 3,200 km
(Daily) (500 Mil (2,000 Mi)
(40 hr) (160 hr)
Check for deflection, wear and
17
Drive track/
Idler wheels damage.
*Adjust/Replace if necessary.
**
• •
18 Slide runner
Check for wear and damage. •
19
Brake/
Check operation. •
Parking brake *Adjust free play and/or replace
pads if necessary. •
20 *Drive chain oil
Check oil level. •
Replace.
Check for deflection.
•
Initial 50 km (30 Mi) and every 400 km
21 *Drive chain
Adjust if necessary. (250 Mil there after .
22 Ski/Ski runner
Check for wear and damage. •
*Replace if necessary.
•
23 Steering system
Check operation. •
*Adjust toe-out if necessary. •
24 Lights Check operation.
Replace bulbs if necessary. •
25 Battery
Check fluid level.
*Check specific gravity and breather
•
pipe operation.
Charge/Correct if necessary.
•
Check engagement and shift speed.
Adjust if necessary.
•
Whenever operating elevation is changed.
26 *Primary sheave Check for wear and damage.
Lubricate with specified grease. •
27 *Secondary sheave
Lubricate with specified grease.
Adjust if necessary.
•
Whenever operating elevation is changed.
28 *Steering column
bearing
•
29 *Ski and front suspen-
sion
•
30 * Suspention compo-
nent
•
31
*Brake cable end and
lever end/
Lubricate with specified grease. •
Throttle cable end
Check for cable damage.
32 Shroud latches Make sure the shroud latches are
hooked. •
33 Fittings/Fasteners Check tightness.
34 Service tools/
Spare parts
Check proper placement.
•
*:It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
**: Perform after 1 Month or 50 Km (31 Mi) and every month or 400 Km (250 Mi).
-3-
________________________Po_w_E_R_T_RA_•N_p:gsltit.I
POWER TRAIN
DRIVE V-BELT
A WARNING
V-belt position should be 5.0 - 7 .0 mm (0.2 - 0.3
in) above the secondary sheave edge.
If not, the clutch engagement speed will be
changed. The machine may move unexpectedly
when the engine is started.
1.Measure:
@ • V-belt width @
Out of specification -+ Replace.
I-~
~ V-belt wear 1;mk'
33 mm (1.30 in)
2.Measure:
• V-belt position @
Out of specification -+Adjust.
NOTE:------------------------
Putthe V-belt back on the secondary sheave only.
Do not force the V-belt between the sheaves; the
sliding and fixed sheave must touch each other.
Standard V-belt position:

5.0 - 7.0 mm (0.2 - 0.3 in)
Above the sheave edge
3.Adjust:
• V-belt position
Removing or adding the spacer <Don each
adjusting bolt®·
V-belt position Adjustment

805-091
=
® 7.0 mm (0.3 in) Remove spacer
or more
Above the edge
Not necessary
5.0-7.0mm
(it is correct)
(0.2 - 0.3 in)
=
@ 5.0 mm (0.2 in) Add spacer
or less
4.Tighten:
• Adjusting bolt
Adjusting bolt:
10 Nm (1.0 m •kg, 7.2 ft• lb)
_______________________P_o_w_ER_TRA
__ l_Nl':gsl-.tl
5.Measure:
• Drive V-belt length @
Out of specification ~ Replace.
Drive V-belt length:

1,336 .. 1,344 mm (52.6 .. 52.9 in)
-5-
________________________Po_w_E_R_TR_A_1N_l 1:g!l4itl
CLUTCH TUNING
High Altitude Tuning
COLOR CODE
G Green R Red W White
P Pink S Silver Y Yellow
Clutch Setting Data (VXSOOI

0-900m 750-1,700 m 1,500- 2,500 m 2,100 m -
~Item 3,000 ft/900 m 2,500 ft - 5,500 ft 5,000 ft - 8,000 ft 7,000 ft -
(STD) (MA) (MA) (HA)
!ID Idle speed: 1,500 ± 100 rpm +-- +-- +--
~ Clutch engagement: 3,400 ± 300 rpm +-- +-- +--
[QI Shift speed: 8,350 ± 300 rpm +-- +-- +--
111 Gearing: 24137 +-- 22137 22/39
[fl Primary spring:
[§] Color Y-P-Y +-- +-- Y-S-Y
IHILength 77.4mm +-- +-- 79.4mm
OJ Pre-load rate 30.0 kg-2.5 kg/mm +-- +-- 35.0 kg-2.5 kg/mm
Q] Wire dia. Jll5.8mm +-- +-- +--
!Kl Outside dia. ¢60mm +-- +-- +--
III Weight: 8BU-OO +-- +-- +--
IMl Weight rivet:(OUT) Steel 13.9mm Steel 10.3mm None Aluminum 10.3mm
ON) Steel 17.2mm Steel 13.9mm +-- None
ml Weight bush: Dural on +-- +-- +--
!QI Roller outter dia.: ¢15.0mm +-- +-- !ll14.5mm
~ Roller bush: Dura Ion +-- +-- +--
191 Pri. clutch shim: None +-- +-- +--
[ijJ Secondary spring:
[§] Color s +-- +-- +--
IHI Length 75mm +-- +-- +--
OJ Pre-load rate 50° (2-3) 60° (3-3) 50° (2-3) 70° (1-6)
965 kgmm/rad +-- +-- 729 kgmm/rad
Q] Wire dia. Jll5.5mm +-- +-- !ll5.3mm
!Kl Outer dia. ¢69.5mm +-- +-- +--
[ID Sec. torque cam: 41° +-- 390 +--
[I] Sec. clutch shim: None +-- +-- +--
-6-
________________________P_o_w_ER_T_R_A__
IN 1 1:~!1~1
Clutch Setting Data (VXSOOST)
0-900m 750 - 1,700 m 1,500 - 2,500 m 2,100 m -
~Item 3,000 ft/900 m 2,500 ft - 5,500 ft 5,000 ft - 8,000 ft 7,000ft -
[ID Idle speed: 1,500 ± 100 rpm ~ ~ ~
19 Clutch engagement: 3,300 ± 300 rpm ~ ~ ~
[QI Shift speed: 8,250 ± 300 rpm ~ ~ ~
!ID Gearing: 23137 ~ 21/37 21/39

[El Primary spring:
!ID Color W-P-W ~ ~ G-P-G
IEl Length 78.7mm ~ ~ 76.3mm
OJ Pre-load rate 30.0 kg-2.25 kg/mm ~ ~ 30.0 kg-2.75 kg/mm
GD Wiredia. fl)5.5mm ~ ~ fl)5.8mm
00 Outside dia. 11160mm ~ ~ ~
[bl Weight: 8BU-OO ~ ~ ~
[Ml Weight rivet:(OUTl Steel 13.9mm Steel 13.3mm None Steel 10.3mm
UN) Steel 17.2mm ~ ~ None
[ID Weight bush: Dura Ion ~ ~ ~
[QI Roller outter dia.: 11115.Smm ~ ~ 11115.0mm

[El Roller bush: Dural on ~ ~ ~
IQ] Pri. clutch shim: None ~ ~ ~
[BJ Secondary spring:

!ID Color s ~ ~ ~
IEl Length 75mm ~ ~ ~
OJ Pre-load rate 50" (2-3) 60° (3-3) 50° (2-3) 70° (1-6)
965 kgmm/rad ~ ~ ~
GD Wire dia. fl)5.5mm ~ ~ ~
00 Outer dia. 11169.5mm ~ ~ ~
[§] Sec. torque cam: 41° ~ 390 ~
!Il Sec. clutch shim: None ~ ~ ~
-7-
________________________Po_w_e_R_TR_A_1N_1•:g~l41it_I
GEARING SELECTION
COLOR CODE
G Green R Red y Yellow
L Blue s Silver Go Gold
p Pink w White
CD Sprocket and chain parts number

~Parts name [§] Teeth&Links 1£1 Parts No.
. 20T BBU-17682-00
21T BBU-17682-10
[Q) Drive sprocket 22T BBU-17682-20
23T*2 BBU-17682-30
24T*1 BBU-17682-40
33T BBU-47587-30
35T BBU-47587-50
I]] Driven sprocket
37T(STD) BBU-47587-70
39T SBU-47587-90
66 94890-07066
III Chain (links) 68 94890-07068
70(STD) 94890-07070
®Gear ratio
~ r
33T
20T
1.650
21T
x
22T
x
23T
1.435
24T
1.375
66L 68L 68L
1.750 1.667 1.591 1.458
35T
68L 68L 68L
x 70L
1.850 1.682 1.609 1.542
37T
68L
x 70L 70L*2 70L*1
1.950 1.857 1.773
39T
70L 70L 70L
x x
@Secondary spring
Q] Spring rate IMI Wire gauge !ID Free length
!IJ Parts No. 00 No. of coils 11:1 Color
(mm) (mm)
(kg mm/rad)
90508-556 A 7 (STD) 965 4.86 s 5.5 75
90508-536 A 9 729 5.53 R 5.3 75
*1: VX800(STD)
*2: VXSOOST(STD)
-8-
________________________
Po_w_E_R_TRA
__ IN_p:gslt.tl
~Torque cam (secondary spring seat)
[ID Parts No. 19 Cam angle

8BV-17684-10 (STD) 41°
8BV-17684-90 39•
[QI Secondary spring twist angle

rFlSheave fEJ Seat 0 3 6 9
1 10· 40° 10· 100·
2 20· 50°(STD) 80· 110·
3 30° so· go· 120·
[QJ Primary spring

[IJ Spring [kl Wire !Ml Outside [Q] Free
Q] Preload [ID No. of
IBJ Parts No. rate
(kg)
1K1 Color gauge diameter length
coils
(kg/mm) (mm) (mm) (mm)
90501-481 J 1 1.0 20.0 S-L-S 4.8 60.0 5.16 85.4
90501-487 G 8 1.5 15.0 Go 4.8 60.0 4.19 75.4
90501-507 G 2 1.5 20.0 Go-L-Go 5.0 60.0 4.61 78.7
90501-524 G 5 1.5 25.0 Go-Y-Go 5.2 60.0 5.08 82.1
90501-501 G 7 1.5 25.0 Go-Y-Go 5.0 59.0 4.65 81.7
90501-521 J 6 1.5 30.0 Go-P-Go 5.2 60.0 5.09 85.4
90501-507 G 7 1.75 15.0 R-Go-R 5.0 60.0 4.24 74.0
90501-527 G 1 1.75 20.0 R-L-R 5.2 60.0 4.65 76.8
90501-524 G 4 1.75 25.0 R-Y-R 5.2 60.0 4.64 79.7
90501-526 G 4 2.0 15.0 L-Go-L 5.2 60.0 4.32 72.9
90501-556 G 6 2.0 20.0 L 5.5 60.0 4.95 75.4
90501-553 G 0 2.0 25.0 L-Y-L 5.5 60.0 5.10 78.0
90501-557 G 6 2.25 15.0 W-Go-W 5.5 60.0 4.62 72.1
90501-556 G 5 2.25 20.0 W-L-W 5.5 60.0 4.62 74.3
90501-553 G 6 2.25 25.0 W-Y-W 5.5 60.0 4.61 76.5
90501-550 J 8 2.25 30.0 W-P-W 5.5 60.0 4.62 78.7
90501-557 G 5 2.5 15.0 Y-Go-Y 5.5 60.0 4.36 71.4
90501-556 G 7 2.5 20.0 Y-L-Y 5.5 60.0 4.36 73.4
90501-584 G 2 2.5 24.0 y 5.8 60.0 4.95 75.0
90501-555 G 8 2.46 24.0 y 5.5 60.0 4.43 75.2
90501-581 J 7 2.5 25.0 y 5.8 60.0 4.96 75.4
90501-582 J 1 2.5 30.0 Y-P-Y 5.8 60.0 4.96 77.4
90501-586 J 0 2.5 35.0 Y-S-Y ~.8 60.0 4.91 79.4
90501-607 G 4 2.75 15.0 G-Go-G 6.0 60.0 5.12 70.9
90501-607 G 0 2.75 20.0 G-L-G 6.0 60.0 5.12 72.7
90501-584 G 1 2.75 24.0 G-Y-G 5.8 60.0 4.70 74.1
90501-605 G 7 2.75 25.0 G-Y-G 6.0 60.0 5.00 74.1
90501-585 J 3 2.75 30.0 G-P-G 5.8 60.0 4.64 76.3
90501-607 G 3 3.0 15.0 P-Go-P 6.0 60.0 4.86 70.4
90501-606 G 9 3.0 20.0 P-L-P 6.0 60.0 4.86 72.1
90501-604 G 0 3.0 24.0 P-Y-P 6.0 60.0 4.80 73.3
90501-602 J 0 3.0 30.0 p 6.0 60.0 4.74 75.4
-9-
SECONDARY SHEAVE I
PoTwRRio !O'I
I - SI
----------------------------------------------
POWER TRAIN
SECONDARY SHEAVE
10 Nm (1.0 m •kg, 7.2 ft• lb)
-10-
JOB INSTRUCTION CHART
Order Job name/Part name Q'ty Remarks
Remove of secondary sheave Remove the parts in the order.
1 Bolt 1 NOTE:
2 Washer 1 Apply the brake to lock the secondary sheave.
3 Shim NOTE:
Adjust the secondary sheave free play by
shim(s).
4 Collar 1
5 Secondary sheave 1
6 Shim NOTE:
Adjust the sheave offset by shim(s).
Reverse the removal procedure for installa-

ti on.
Disassembly of secondary sheave

<D Nut 3 NOTE:
Use the following special tool to disassemble
or assemble.
Sheave compressor
(90890-01712, YS-28891)
® Spring seat 1
@ Secondary sheave spring 1 NOTE:
Hook the end of the secondary sheave spring
onto the spring hole in the fixed sheave and
spring seat.
© Fixed sheave 1
@ Sliding sheave 1
® Screw 3
(j) Stopper 1
@ Bolt 3
® Shim 3 NOTE:
Adjust the V-belt position by shim(s).
Reverse the disassembly procedure for as-

sembly.
-11-
SECONDARY SHEAVE
--------------------------------------------------------
I
POTWRRia ~1 - U
DISASSEMBLY
A WARNING
• Use extreme CAUTION when disassembling
the secondary sheave as serious injury can
occur from the sudden release of spring tension.
Use the Sheave Compressor (90890-01712, YS-
28891) to contain the spring tension before
removing the nut (spring seat).
• Do not attempt the procedure unless you have
the proper tools and understand the
instructions thoroughly.
1.Remove:
• Nuts (spring seat)
INSPECTION
1. Inspect:
• Sliding sheave <D
• Fixed sheave ®
• Spring seat @
Cracks/Damage ~ Replace.
•Stopper@
Wear/Damage ~ Replace.
2. Inspect:
• Bushing (spring seat) <D
• Sliding sheave (V-belt contact surface) ®
Scratches/Wear/Damage ~ Replace.
• Sliding bushing @
Unsymmetrical wear/Damage ~ Replace.
3.lnspect:
• Secondary sheave spring <D
4.Measure:
• Torsion spring free length@
Less than specification ~ Replace.
@ .I I-~
~ Free length Rmit :
mm 75 in)(2.95
-12-
SECONDARY SHEAVE IPOTWRRio '0\1
- ~
----------------------------------------------------------
5.Measure:
• Ramp shoe thickness@
I~ Wear limit:
1.0 mm 10.04 ;nJ
ASSEMBLY
Reverse the "DISASSEMBLY" procedure.
Note the following points.
1. Install:
• Secondary sheave spring <D
NOTE:------------------------
Hookthe end of the secondary sheave spring onto
the spring hole in the fixed sheave and spring
seat.
Standard spring position:

2-3 (VX800/ST)
Installation steps:
• Attach the sheave compressor.
• Turn the sliding sheave the specified de-
grees@, in the counterclockwise direction.
• Holding the sliding sheave and fixed sheave
in this position.
Standard twist angle @:

50° (VXSOO/ST)
=
@ (Sheave side hole number + Spring seat
side hole number) x 10
• Turn in the screw for the sheave compressor

so thatthe spring seat engages with the fixed
sheave.
• Install the nut (spring seat).
~
Nut (spring seat):
23 Nm (2.3 m • kg, 17 ft • lb)
-13-
SECONDARY SHEAVE IPOTWRRia_ !ii11
~1
------------------------------------------------------~
INSTALLATION
Reverse the "REMOVAL" procedure.
1. Lubricate:
• Splines (fixed sheave)
Recommended grease:
.._,. ESSO beacon 325 grease or
Aero shell grease #7 A
2. Tighten:
~ Secondary sheave bolt:

~ 60 Nm (6.0 m •kg, 43ft •lb)
3.Adjust:
• V-belt position
• Sheave distance
• Sheave offset
• Free play (clearance)
-14-
-15-
JACKSHAF'f.
45 Nm (4.5 m • kg, 32 ft • lb)
/
60 Nm (6.0 m • kg, 43 ft• lb)
-16-
_____________J_Ac_K_s_HA_FT_jP~WRjo ~
Removal of jackshaft Remove the parts in the order.
Side cowling (left) 1
1 V-belt 1 Refer to the "SECONDARY SHEAVE" section.
2 Secondary sheave 1
3 Bolt (bearing holder) 4
4 Bolt (compression rod) 1
5 Jackshaft 1
6 Circlip 2
7 Bearing holder 1
8 Circlip 1
9 Bearing 1
Reverse the removal procedure for installs-
tion.
-17-
CRANKCASE AND CRANKSHAFT IENG I ~ I
CRANKCASE AND CRAN ENGINE OVERHAUL -
KS HAFT
*1
1st step 13 Nm (1 3 m • k
2nd step 26 Nm 6 12 g, 9.4 ft• lb)
· m • kg, 19 ft• lb)
*2
I13 Nm (1.3 m •kg, 9.4ft• lb)I
,-----------
! \___;_:,_:.:::...:.:..:..:..!!:!:.~~
I
I
I
I
I
I 1
I
I
I
I
I
I
I
I
I
I
I
L __ _
-18-
_________c_RA_N_K_c_As_e_A_N_o_c_RA_N_K_s_H_A_FT_I ENG
I ti I
Order Job name/Part name O'ty Remarks
Removal of crankcase and crankshaft
1 Bolt 5 MS x 1.25, I.= 50 mm (1.97 in)*1
13 MS x 1.25, I.= 85 mm (3.35 in)*1
4 M8 x 1.25, I.= 95 mm (3.74 in)*1
2 M6 x 1.0, I.= 35 mm (1.38 in)*2
NOTE:
Tighten all the bolts in order to numerical
sequence (in two steps*).
*=[ *1 : should be two steps. J

*2: to the final tightening torque
2 Crankcase (lower) 1
3 Dowel pin s
4 Crankcase (upper) 1
5 Stopper ring 2
6 Oil seal 2
7 Circlip 1
Reverse the removal procedure for installa-
ti on.
Disassembly of drive shaft

CD Bolt 1
® Washer 1
@ Driven gear assembly 1
© Bearing 1
@ Circlip 1
® Oil seal 1
Reverse the disassembly procedure for as-
sembly.
-19-
CRANKCASE AND CRANKSHAFT I I~ I
ENG
1. Install:
• Crankshaft (left and right)
111111111111111111111111!111111 _ _ _ __
Align the hole@ on the drive gear (left) with the
hole @ on the drive gear (right).
2. Install:
• Drive shaft
Align the hole @ on the drive gear and punch

mark@ on the driven gear.
-20-
GENERAL SPECIFICATIONS lsPEcl ,,-.1
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model VX800 VX800ST
Model code number: 8BU1 8BT1
Frame starting number: 8BU-000101- 8BT-000101-
Engine starting number: 8BU-000101- 8BT-000101-
Dimensions:
Overall length 2,815 mm (110.8 in) 3,020 mm (118.9 in)
Overall width 1,155 mm (45.5 in) 1,125 mm (44.3 in)
Overall height 1,050 mm (41.3 in) 1,070 mm (42.1 in)
Weight:
Dry weight (without fuel and oil) 254 kg (560 lb) 262 kg (578 lb)
Engine:
Engine type Liquid cooled 2-stroke, 7-port
Induction system Piston reed valve
Cylinder arrangement Parallel 4-cylinder
Displacement 791 cm3 (48.3 cu. in)
Bore x Stroke 65.0 x 59.6 mm (2.56 x 2.35 in)
Compression ratio 6.5:1
Starting system Recoil starter
Lubrication system: Separate lubrication (YAMAHA AUTOLUBEl
Engine oil:
Recommended oil YAMALUBE2
Tank capacity 2.7 L (2.4 Imp qt, 2.9 US qt)
Drive chain housing oil:
Recommended oil Gear oil API uGL-3" SAE #75 or #80
Capacity 350 cm 3 (12.3 Imp oz, 11.8 US oz)
Fuel:
Recommended fuel Unleaded regular gasoline
Rating P.O.N. *1 Minimum.SS
Tank capacity 38.0 L (8.4 Imp gal, 10 US gal)
Carburetor:
Type/Quantity TM/33x 4
Manufacturer MIKUNI
Spark plug:
Type BR9ES
Manufacturer NGK
Gap 0.7 - 0.8 mm (0.028 - 0.031 in)
Transmission:
Primary reduction system V-Belt ~
Primary reduction ratio 3.9:1 - 0.95:1 ~
Clutch type Automatic centrifugal

~
engagement
Secondary reduction system Chain ~
Secondary reduction ratio 1.54 (37/24) 1.61 (37/23)

Chassis:
Frame type Monocock ~
Caster 22.5° ~
Ski stance 1,007 mm (39.6 in) 977 mm (38.5 in)

*1: Pump Octane Number; (research octane+ motor octane)/2
-21-
GENERAL SPECIFICATIONS ISPECI o-1
Model VX800 VX800ST
Suspension:
Front suspension type Telescopic strut suspension
Rear suspension type Slide rail suspension
Track:
Track type Internal drive type +-
Track width 381 mm (15.0 in) +-
Length on ground 765 mm (30. 1 in) 961 mm (37 .8 in)
Track deflection 20 - 25 mm (0.79 - 0.98 in) 25 - 30 mm (0.98-1.18 in)
/10 kg (22 lb) /10 kg (22 lb)
Brake:
Brake type Caliper type disc brake
Operation method Handle lever, left hand operated
Electrical:
Ignition system/Manufacturer C.D.l./MITSUBISHI
Generator system Flywheel magneto
Bulb wattage x Quantity:
Headlight 60W/55Wx 1
Tail/Brake light 23W/8Wx 1
Tachometer light 3.4Wx 1
Speedometer light 3.4Wx2
-22-
MAINTENANCE sPEc1F1cAT10Ns lsPEcl a-- I
MAINTENANCE SPECIFICATIONS
ENGINE
Model VX800/ST
Cylinder head:
Volume (with spark plug) 20 cm 3 (0.70 Imp oz, 0.67 US gt)
<Warp limit> <0.03mm (0.0012 in)>
l~*
* Lines indicate straight edge measurement.
Cylinder:
Material Aluminum alloy with dispersion coating
Bore size 65.00 - 65.02 mm (2.5590 - 2.5598 in)
<Taper limit> <0.05 mm (0.0019 in)>
<Out-of-round limit> <0.01 mm (0.0004 in)>
Piston:
Piston size (D)
Measuring point®
z®4®
D
64.935 - 64.940 mm (2.5565 - 2.5567 in)
20 mm (0.79 in)
Piston to-Cylinder clearance 0.065 - 0.070 mm (0.0026 - 0.0028 in)

<Limit> <0.1mm (0.004 in)>
Piston ring:
Sectional sketch Top ring c:J]s Keystone
8=1.2 mm (0.047 in)
I· T
.1
T=2.55 mm (0.1 in)
2nd ring
c:J]s Keystone
8=1.2 mm (0.047 in)
T= 2.55 mm (0.1 in)
I· T
.1
End gap (installed) : Top ring 0.35 - 0.55 mm (0.014 - 0.022 in)
2nd ring 0.35 - 0.55 mm (0.014 - 0.022 in)
Side clearance Top ring 0.02 - 0.06 mm (0.0008 - 0.0024 in)
2nd ring 0.02 - 0.06 mm (0.0008 - 0.0024 in)
Coating Top ring Chromium plating
2nd ring Chromium plating
-23-
MAINTENANCE SPECIFICATIONS ISPECI er-- I
Model VX800/ST
Crankshaft:
Crank width u A" 55.95 - 56.00 mm (2.203 - 2.205 in)
Connecting rod small end free play "F" 0.8 - 1.0 mm (0.031 - 0.039 in)
Connecting rod big end side clearance "D" 0.25 - 0.75 mm (0.010 - 0.030 in)
Crankshaft deflection uc": C1,C4 Below 0.03 mm (0.0012 in)
c2,c3 Below 0.04 mm (0.0016 in)
Measuring points: 1 25 mm (0.98 in)
2 65 mm (3.27 in)
Crank width "B" 168 mm (6.614 in)
D
-·~-A_-J_ --•I --1~--8~

Big end bearing:
Type Needle bearing
Small end bearing:
Type Needle bearing
Carburetor:
Type/Quantity TM33/4pcs.
Manufacturer MIKUNI
l.D. mark 8BU-OO
Main jet (M.J.) #143.8
Pilot jet (P.J.) #47.5
Pilot air jet (P.A.J) 11)1.0
Pilot outlet (P.O.) 11)1.0
Pilot screw (P.S.) 1-1/2 turns out
Throttle valve (TH. V.) #1.0
Valve seat size (V.S.) 11)1.3
Starter jet (G.S.) 11)1.1
Float height (f.H.) 13.3 mm (0.524 in)
Engine idle speed 1,400 - 1,600 r/min
Reed valve:
Valve stopper height 8.1 - 8.5 mm (0.32 - 0.33 in)
Fuel pump:
Type DIAPHRAGM
Manufacturer TAIYOU GIKEN
Oil pump:
Pump cable adjustment 28- 30 mm (1.10 - 1.18 in)
-24-
MAINTENANCE SPECIFICATIONS lsPEcl a-- I
Model vxsoo VXSOOST
Cooling system:
Filler cap opening pressure 80 - 100 kPa
+-
(0.8 -1.0 kg/cm2, 11 - 14 psi)
Thermostat opening temperature 50 - 55°C (122 - 131°F) +-
Thermostat valve lift 8 mm (0.3 in) at 70°C
(158.5F) +-
Water pump type Impeller type +-
Coolant type Long life coolant +-
Coolant mixing ratio (coolant : water) 6:4 +-
Coolant capacity 4.20 L 4.5 L
(3.70 Imp qt. 4.44 US qt) (3.96 Imp qt. 4.76 US qt)
Reservoir tank capacity 0.20 L
+-
(0.18 Imp qt. 0.21 US qt)
High altitude settings
~ E
0-200m
-30°C
(-22°F)
I
-20°C
(-4oF)
I
-10°c
(14°F)
I
#146.3 (STOI-
0°C
(32°F)
I
10°c
(50°FI
I
20°c
(68°F)
I
(600 ft) #148.8- #143.8
200-600 m - #143.8
(2,000 ft) -#146.3 (STDI- - #141.3
600 - 1,200 m - #141.3

(4,000 ft) #143.8 #138.8
1,200 - 1,800 m #138.8

#141.3 #136.3 JN:2
(6,000 ft) PJ#55 PS2-1/4
#136.3 JN:2
1,800 - 2,400 m -PJ#55PS2-1/4- #133.8JN:2
(8,000 ft) #138.8 PJ#55 PS2-1/4
- #133.8JN:2 _
2,400 m - #136.3 JN:2 PJ#55 PS2-1/4 #131.3 JN:2
(8,000 ft -I -PJ#55 PS2-1/4- PJ#55 PS2-1/4
-25-
MAINTENANCE sPEc1F1cAnoNs lsPecl a- I
POWER TRAIN
Model VX800 VX800ST
Transmission:
Type V-belt Automatic
Range of ratio 3.9:1 - 0.95:1
Engagement RPM 3,400 ± 300 r/min
Shift RPM 8,350 ± 300 r/min
Sheave center distance "A" 363.5 - 366.5 mm (14.3 - 14.4 in)
Sheave offset "B" 14.5 - 17.5 mm (0.57 - 0.69 in)
---
_c=. le 1= Fr
--
--
~
I I t
,-- -.......
L 'a :zr:
-
__,J
A
,
!:!~ ~
.
F'
V-Belt:
Outside circumference 1,340 ± 4 mm (52.8 ± 0.16 in)
Width "A" (new belt) 34.5 mm (1.36 in)
Wear limit "B" 33 mm (1.30 in)
~- : ~1
'0 I
I
I
'-
I
_,
I
I
Primary sheave spring:

Color Yellow-Pink-Yellow White-Pink-White
Outside diameter 60 mm (2.36 in) f-
Wire diameter 5.8 mm (0.23 in) 5.5 mm (0.22 in)
Pre-load/Set length 30.0 kg (66.2 lb) f-
Spring rate 25.0 N/mm (2.5 kg/mm) 22.5 N/mm (2.25 kg/mml
Free length 77 .4 mm (3.05 in) 78.7 mm (3.10 in)
Primary sheave weight:
Part number 8BU-17605-00
Quantity 3 pcs.
Secondary sheave spring:
Color code Silver
Outside diameter 69.5 mm (2.74 in}
Wire diameter 5.5 mm (0.22 in)
Twist angle *1 50°
Free length 75 mm (2.95 in}
*1: Twist angle; (sheave hole+ spring seat hole) x 10
-26-
MAINTENANCE SPECIFICATIONS lsPECI cr--1
Model VX800 VX800ST
Hole position
Sheave side* 2
Spring seat side** 3
Spring rate 9,650 N/mm (965 kg/mm, 5,376 lb/in)

Torque cam angle 41°
Drive chain:
Type Silent (chain) 2.3 RH 304 (BWA)
Number of links 70
Track:
Width 381 mm (15.0 in) +-
Length 3,072 mm (121 in) 3,456 mm (136.1 in)
Pitch 64 mm (2.52 in)
Number of links 48 54
Deflection at 10 kg (22 lb) 20-25mm 25-30 mm
(0.79 - 0.98 in) (0.98 - 1.18 in)
Suspension setting position:
Stopper band hole position
Front* No.2
Rear** No.1
* **
-27-
MAINTENANCE SPECIFICATIONS lsPEcl a-- I
Model VX800 VXSOOST
Shock absorber:
Damping force (extension)
Front 126 kg/0.3 m/s 114 kg/0.3 m/s
Rear 208 kg/0.3 m/S 195 kg/0.3 m/s
Damping force (compression)
Front 37 kg/0.3 m/s 53 kg/0.3 m/s
Rear 61 kg/0.3 m/s 65 kg/0.3 m/s
Slide runner:
Thickness 15 mm (0.6 in)
Wear limit 10 mm (0.4 in)
Track sprocket wheel:
Material Polyethylene
Number of teeth 9T
Rear guide wheel:
Material Aluminum with rubber
Outside diameter 178 mm (7 in)
Brake:
Pad thickness
~ 8.2 mm (0.32 in)
Pad wear limit
_./
- L 4.7 mm (0.19 in)
Pad to disc clearance ~~ l 0.15 - 0.30 mm (0.006 - 0.012 in)
Disc outside diameter
Disc thickness
Distance "L"
\0J I 220 mm (8.66 in)
6.0 mm (0.24 in)
67.5 - 71.5 mm (2.66 - 2.81 in)
-28-
MAINTENANCE SPECIFICATIONS lsPEcl a--1
CHASSIS
Model VX800 VX800ST
Frame:
Frame material Aluminum and steel
Seat height 560 mm (22.0 in)
Luggage box location Rear side of seat
Steering:
Steering angle (left) 48° ~
(right) 480 ~
Ski alignment Toe-out ~
Toe-out size 0 - 15 mm (0 - 0.6 in) ~
Distance "A" 2,007 mm (79.0 in) 2,196 mm (86.6 in)
Distance "8" 1,007 mm (39.6 in) 997 mm (38.5 in)
-1·-s--l
Distance "C" 660 mm (26.0 in)
Ski:
Ski material Aluminum
Runner material
Runner1 Carbide
Runner2 Polyethylene
Length 1,021 mm (40.2 in)
Width 146 mm (5.75 in)
Ski ground length 375.6 mm (14.8 in)
Ski suspension:
Type T.S.S. ~
Travel 170 mm (6.69 in) ~
Spring type Coil spring ~
Spring rate 16 N/mm 18 N/mm

(1.6 kg/mm, 89.7 lb/in) (1.8 kg/mm, 100.8 lb/in)
Shock absorber:
Damping force (extension) 69 kg, 0.3 m/s 61 kg, 0.3 m/s
(compression) 41 kg, 0.3 m/s 24 kg, 0.3 m/s
Damping force adjuster 5 clicks out ~
-29-
MAINTENANCE SPECIFICATIONS lsPecl er-- I
ELECTRICAL
Model vxsoo I VXSOOST
Voltage: 12V
Ignition system:
Ignition timing (B.T.D.C.) 16°/1,500 r/min
C.D.I.:
Magneto model/Manufacturer F4T308/MITSUBISHI
Pulser coil resistance 505 ±10% at 20° C (68°F)
(color code) (White/Green - White/Red)
(White/Blue - White/Red)
Change coil resistance (for ignition) 2.55'1 ±10% at 20°c (68°F)
(color code) (Brown - Black/Red)
C.D.I. unit manufacturer MITSUBISHI
Ignition coil:
Model/Manufacturer 89A-OO/YAMAHA, SBR-00/YAMAHA
Minimum spark gap 3 mm (0.12 in) at 3,000 r/min
Primary coil resistance 0.2 n ± 20% at 20°c (68°F)
Secondary coil resistance 4.9 kn± 20% at 20°c (68°F)
Spark plug cap:
Type Rubber type
Model/Manufacturer BR9ES/NGK
Resistance 5.0 kn± 25% at 20°c (68°F)
Charging system:
Type Flywheel magneto
Flywheel magneto:
Lighting voltage (minimum) 11.0 V at 3,000 r/min
(maximum) 15.5 Vat 8,000 r/min
Lighting coil resistance 0.32 n ± 10% at 20°c (68°F)
(color code) (Yellow - Black)
Coil resistance for grip warmer (driver) 1.7 n ± 20% at 20°c (68°F)
(color code) (Yellow/Brack - Black)
Grip warmer:
Grip warmer resistance 3 n ± 20% at 20°c (68°F)
Thumb warmer resistance 8 - 40 n at 20°c (68°F)
Voltage regulator:
Type Rectifier regulator
Mode/Manufacturer 82M-AO/SHINDENGEN
Fuel gauge unite:
Resistance (full) 4-10'1
(empty) 90 - 100 Q
-30-
MAINTENANCE SPECIFICATIONS ISPECI er-- I
Tightening torque:
Tightening torque
Parts to be tightened Remarks
Nm m • kg ft • lb
ENGINE
Crankcase (MS x 1.25) 26 2.6 19 Tighten the bolts in
two steps.
(M6 x 1.0) * 13 1.3 9.4
Engine bracket nut 40 4.0 29

Engine bracket bolt 30 3.0 22
Engine stay bolt (rod) 45 4.5 32
Cylinder body nut 28 2.8 20
Crankcase stud bolt 13 1.3 9.4
Cylinder head nut 22 2.2 . 16
Culinder stud bolt 13 1.3 9.4
Spark plug 20 2.0 14
PTO shaft holder bolt 28 2.8 20
PTO shaft driven gear assembly 48 4.8 35
Water pump impeller 14 1.4 10
Water pump ass'y 10 1.0 7.2
Oil pump ass'y 4 0.4 2.9
Intake manifold 10 1.0 7.2
Exhaust manifold 25 2.5 18
Starter pulley 45 4.5 32
Recoil starter 7 0.7 5.1
Thermostatic cover 7 0.7 5.1
Thermo switch 28 2.8 20
Magnet rotor 85 8.5 61
Starter ass'y 7 0.7 5.1
Water jacket joint 10 1.0 7.2
CARBURETOR
Head cover screw 2 0.2 1.4
Rever shaft screw 4 0.4 2.9
Main jet 0.8 0.08 0.58
Pilot jet 0.7 0.07 0.51
Cynchronization nut 4 0.4 2.9
Planjer 3 0.3 2.2
Float chamber plug 9 0.9 6.5
-31-
MAINTENANCE SPECIFICATIONS lsPEcl o--1
Tightening torque:
Tightening torque
Nm m •kg ft• lb
Handlebar holder 15 1.5 11
Steering column
Upper 22 2.2 16
lower 27 2.7 20
Steering column and relay rod 43 4.3 31
Relay rod and suspension bracket 25 2.5 18
Locknut (relay rod) 25 2.5 18 Apply LOCTITE®
lever holder 4 0.4 2.9
Ski runner 21 2.1 15
Ski 43 4.3 31
Pinch nut (suspension bracket) 21 2.1 15
Set screw (suspension bracket) 2 0.2 1.4 Apply LOCTITE®
Absorber holder 10 1.0 7.2
Mounting nut (shock absorber) 5 0.5 3.6
Locknut (shock absorbser) 16 1.6 11
Front arm (upper) and front arm (lower) 43 4.3 31
Hood 3 0.3 2.2
Seat and frame (nut) 9 0.9 6.5
(screw) 3 0.3 2.2
Front cowling 3 0.3 2.2
-32-
MAINTENANCE SPECIFICATIONS lsPEcl o-1
Tightening torque:
Tightening torque
Nm m·· kg ft• lb
Primary sheave (first) 120 12.0 85 Tighten the bolts in

(final) 60 6.0 43 two steps.
Spider and sliding sheave 200 20.0 145 Left-hand thread.
Apply LOCTITE®
Primary sheave cap and sliding sheave 14 1.4 10
Roller and weight (primary sheave)
Bolt 6 0.6 4.3
Screw 3 0.3 2.2
Secondary sheave 60 6.0 43
Compression rod bracket bolt 40 4.0 29
Engine stay bolt 45 4.5 33
Driven sprocket 48 4.8 35
Chain housing and frame 24 2.4 17 Apply LOCTITE®
Chain housing cover 10 1.0 7.2
Chain housing and brake caliper 48 4.8 35
Bearing holder (jackshaft) 43 4.3 31
Suspension wheel 75 7.5 54 Apply LOCTITE®
Guide wheel 74 7.4 54
Sliding frame and slide runner 3 0.3 2.2
Slide rail suspension mounting bolt 68 6.8 49
Rear pivot arm and bracket 68 6.8 49
Shock absorber and rear pivot arm 42 4.2 30 Apply LOCTITE®
Rear suspension bracket and rod 42 4.2 30
Front pivot arm and sliding frame 56 5.6 41
Shock absorber and front pirot arm 23 2.3 17
Shock absorber and relay arm 28 2.8 20
Bracket shaft and sliding frame 20 2.0 14
Coller (guide wheel) 6 0.6 4.3
Front axle nut 90 9.0 65
Speedometer gear 23 2.3 17
-33-
VXSOOV /800STV WIRING DIAGRAM
(j) ~~~~~~~~~~~
'@ @ @ @ (j) ® ® ®\
9® <D Headlight
~IREOI ® Meter ass'y

@ Speedometer light
~8 VIR
@ High beam warning light
@ Water temp warning light
@ Oil level warning light
<D TORS warning light
@ Tachometer
~ I @ Tachometer light
@Fuel meter
® Fuel sender
@ Oil level gauge
I @ Thermo switch
I
- I ® Variable resistor
@ Voltage regulator
·-
Btw--+-+----+-+-+--~
_._
,, Y/R--+-+----+-.._,
Y/B--+_,__ _ ..._.~
® Grip warmer
@ Thumb warmer
@ Resistor
B l Bt BB/RR
Ir @ Tail/stop light
® Ignition coil A
®~ B - - c : > < > - - - - - Ch -~
@ Spark plug (#1, #2)
~BfV~B/Y 1111 @ Ignition coil B
~IBLUEI @ C.D.I. unit
® Pulsercoil
13 C.0.1. magneto
~
@ Condenser
cf] 0
@
13 Rectifier/regulator
~ Voltage regulator
© Stop light switch
® Headlight beam switcl'i
<il Accel switch
@ Engine stop switch
COLOR CODE ® Carburetor switch
B ........... Black B/R ........ Black/Red ® Main switch
L ............ Blue B/W ....... Black/White
G ........... Green G/B ........ Green/Black
Y ........... Yellow GN ........ GreenNellow
R ........... Red G/R ........ Green/Red
0 ........... Orange Y/B ........ Yellow/Black
P ............ Pink Y/R ........ Yellow/Red
Ch ......... Chocolate Y/W ....... Yellow/White
Gy ......... Gray R/B ........ Red/Black
Br .......... Brown R/W ....... Red/White
Sb ......... Sky blue WIG ...... White/Green
W .......... White W/R ....... White/Red
BN ........ BlackNellow
YAMAHA
SUPPLEMENTARY
SERVICE MANUAL
VX800A/MM800A
SUPPLEMENTARY SERVICE MANUAL
@1996 by Yamaha Motor Corporation, U.S.A.
1st Edition, August 1996
unauthorized use without the written
Printed in U.S.A.
P/N LIT-12628-01-80
OE031
CD ®
ILLUSTRATED SYMBOLS
1~~~1~1 l 1~gj1-1 (Refer to the illustration)
Illustrated symbolsCDto@are designed as thumb

@ ©
el
tabs to indicate the chapter's number and con-
lcHAsl~ I IPC:Rla tent.

CD General information
@Chassis
- IlcooLI ~I
@ ®
@ Power train
!ENGi ®
® Engine overhaul
®Cooling system
<J) Carburetion
@ Electrical
(j) ® ® Specifications
!cARBI i;i IIELEc!DI @ Optional kit
® @)
lsPEcl er-I IOPT I0 I

® @ Illustrated symbols ®to @ are used to identify
@
roJ El ®
® Filling fluid
@Lubricant
@Tightening
@ Wear limit, clearance
~ ~
® Engine speed
@ Special tool
@n,v,A
® @
®
[8]
@
~ @ Illustrated symbols @ to @ in the exploded dia-
[ii] l
a C§W
gram indicate grade of lubricant and location of
lubrication point.
@ Apply locking agent (LOCTITE®)
@ Apply Yamabond No.5®
® @ @ @ Apply engine oil
1 l l @ Apply gear oil
@
m @
~ 9
@ Apply molybdenum disulfide oil
@Apply wheel bearing grease
@ Apply low-temperature lithium-soap base grease
® @ Apply molybdenum disulfide grease
~ ~ ~
CONTENTS
GENERAL INFORMATION ........................................................................................... 1
MACHINE IDENTIFICATION .•......•........................................................................ 1
FRAME SERIAL NUMBER ..............................•....•...........................•.•......••.... 1
ENGINE SERIAL NUMBER ............................................................................. 1 .
PERIODIC INSPECTION AND ADJUSTMENT ............................................................ 2

POWER TRAIN ................................•................................••.•............................•..... 2
PARKING BRAKE PAD INSPECTION ........•...............•...•..............•................. 2
PARKING BRAKE ADJUSTMENT .................................................................. 2
BRAKE FLUID LEVEL INSPECTION ................................................................ 3
BRAKE PAD INSPECTION .............................................................................. 4
BRAKE HOSE INSPECTION ............................................................................ 4
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ............................................ 5
TUNING ................................................................................................................. 6
SUSPENSION ...........................................................•.•.•....•..........•.................. 6
POWER TRAIN ............................................................................................................. 9

BRAKE ...................•..................................................................................••............ 9
BRAKE PAD ..................................................................................................... 9
BRAKE PAD REPLACEMENT ........................................................................ 10
BRAKE CALIPER ASSEMBLY, PARKING BRAKE ASSEMBLY AND
BRAKE DISC ...•........•...•.••.......•.•.........••...................................•.•............•....•. 12
PARKING BRAKE .......................................................................................... 13
BRAKE CALIPER ............................................................................................ 14
CALIPER DISASSEMBLY .............................................................................. 15
BRAKE DISC INSPECTION ........................................................................... 15
CALIPER INSPECTION AND REPAIR ........................................................... 16
CALIPER ASSEMBLY .................................................................................... 16
BRAKE MASTER CYLINDER ......................................................................... 17
MASTER CYLINDER INSPECTION ............................................................... 18
MASTER CYLINDER ASSEMBLY ................................................................. 18
SLIDE RAIL SUSPENSION (VX800) .................................................................... 19
SLIDE RAIL SUSPENSION (MM800) .................................................................. 20
INSPECTION .................................................................................................. 25
ASSEMBLY .................................................................................................... 26
SPECIFICATIONS ....................................................................................................... 28
GENERAL SPECIFICATIONS ............................................................................... 28
MAINTENANCE SPECIFICATIONS ..................................................................... 30
ENGINE .......................................................................................................... 30
POWER TRAIN .............................................................................................. 33
CHASSIS ...................................................................................................•.... 35
ELECTRICAL .................................................................................................. 36
TIGHTENING TORQUE ....................................................................................... 37
CABLE ROUTING ................................................................................................. 40
MACHINE IDENTIFICATION I1~~~ ld!iz; I
GENERAL
INFORMATION
FRAME SERIAL NUMBER
The frame serial number CD is located on the
right-hand side of the frame (just below the front
of the seat).

The engine s.erial number CD is located on the
-1-
- PARKING BRAKE ADJUSTMENT _IANDSJP _ ~ _
_ _ _ _ _ _ _P_A_R_K1_N_G_s_R_A_KE-PA_o_1_N_s_PE_c_T_1o_N_1 I It~I
PERIODIC INSPECTION AND
ADJUSTMENT
POWER TRAIN
PARKING BRAKE PAD INSPECTION
1. Measure:
• Parking brake pad thickness@
Out of specification -7 Replace as a set.
818-040
I~ Wear limit:
1.0 mm (0.04 inl
PARKING BRAKE ADJUSTMENT

1. Measure:
• Clearance @
Out of specification -7 Adjust.
Clearance:
1.1 - 1.25 mm (0.043 - 0.049 in)
2.Adjust:
• Clearance@
*************************************
Adjustment steps:
• Loosen the locknut G).
•Turn the pad adjuster® in or out to adjust the
clearance between the pad @ and disc @.
•Turn the cable adjuster® in or outto adjustthe
clearance between the pad® and disc@.
• Tighten the locknut.
*************************************
-2-
BRAKE FLUID LEVEL INSPECTION I1:g~ 1-1
BRAKE FLUID LEVEL INSPECTION
1. Place the machine on a level surface.
2. Inspect:
• Fluid level
Fluid level is under "LOWER" level line CD
~ Fill to proper level.
NOTE:------------------------
When inspecting the fluid level in the reservoir on
the handlebar, maker sure the master cylindertop
is horizontal.
Brake fluid may corrode painted surfaces or

plastic parts. Always clean up spilled fluid
immediately.
A WARNING
• Use only the designated quality fluid.
Otherwise, the rubber seals may deteriorate
causing leakage and poor brake performance.
• Refill with the same type of fluid. Mixing fluids
may result in a harmful chemical reaction
leading to poor brake performance.
• Be careful that water does no enter the master
cylinder when refilling. Water will significantly
lower the boiling point of the fluid and could
cause vapor lock.
-3-
BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION . IANDSJP I Ito) I
~
------------------------------------------------------
BRAKE PAD INSPECTION
1. Apply the brake lever.
2. lnspect:
• Brake pads
Wear indicator CD nearly contacts the brake
disc ~ Replace brake pads as a set.
I~
v
Wear limit@:
Al 1.0 mm (0.04 in)
BRAKE HOSE INSPECTION
1. lnspect:
• Brake hose
Cracks/wear/damage ~ Replace.
2. Check:
• Fluid leakage
Apply the brake lever several times.
Fluid leakage ~ Replace.
-4-
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1 •:g! 4it I I
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
A WARNING
Bleed the brake system if:
• The system has been disassembled.
• A brake hose has been loosened or removed.
• The brake fluid has been very low.
• The brake operation has been faulty.
A loss of braking performance may occur if the
brake system is not properly bled.
1. Bleed:
• Brake system
*************************************
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. lnstallthe diaphragm. Be careful notto spill any
fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose <D tightly to the
caliper bleed screw ®·
d. Place the other end of the hose into a container.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever to
travel towards its limit.
h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.
i. Repeat steps (e) to (h) until all air bubbles have
disappeared from the fluid.
j. Tighten the bleed screw.
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
NOTE:------------------------
lf bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat the
bleeding procedure when the tiny bubbles in the
system have disappeared.
-5-
AIR BLEEDING (HYDRAuuc BRAKE sYsTEM)/
SUSPENSION
I'NSP
ADJ
I tol I
..................._.._~
......-...--....
k. Add brake fluid to proper level.
Refer to the "BRAKE FLUID LEVEL INSPEC-
TION" section.
A WARNING
Check the operation of the brake after bleeding
the brake system.
*************************************
TUNING
SUSPENSION
Rear suspension stopper band
1. Adjust:
• Stopper band tension
NOTE:------------------------
This adjustment will affect the stability and
maneuverability of the machine.
*************************************
Adjustment steps:
• Loosen the locknut CD.
• Turn the adjuster (?) in or out to adjust the
stopper band tension.
Adjuster Longer~ ~Shorter
Thread Maximum Minimum
Length@ 10mm 0.39in
(STD)
Effects More weight Less weight
on skis. Less on skis. More
weight weight
transter transter
*************************************
-6-
________________________s_u_sP_E_N_s1_0N_1':gSl«fill
Rear suspension spring preload
A
1.Adjust:
@
• Spring preload (VXSOO)
*************************************
Adjustment steps:
•Turn the spring seat <D in or out.
Spring
Longer+- ~Shorter
set length
Preload Softer +- ~ Harder
B Max ·Min
IA! Length@ 221 mm (8.70 in) 201 mm (7.91 in)
(front)
Standard 211 mm (8.31 in)
Max. Min.
[ID Length (6) 381.5 mm (15.02 inl 361.5 mm (14.23 inl
(rear)
Standard 371.5 mm (14.63 in)
*************************************
• Spring preload (MMSOO)
*************************************
Adjustment steps:
•Turn the adjuster® in or out.
Spring Adjuster
Position 1 I I I Is
2 3 4
Preload Softer+- ~Harder
Standard
3
(front)©
Spring Adjuster
1 2 3 4 5 6 7
Position
Preload Softer+- ~Harder
Standard
4
(rear) (d)
*************************************
A 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
open flame or high heat, which could cause it to
explode.
-7-
N 1•:g~l4it.I
_________________________s_u_s_PE_N_s_1o__
Rear suspension full rate
1. Adjust:
• Full rate adjuster
*************************************
Adjustment steps:
• Loosen the nut CD.
--::n::::::. -
-- 820-065
• Move the end of the shock-absorber assembly
to the desired position.
Installation
Position·
c B A
Spring rate
Hard Medium Soft
and Damping
Standar~ B
NOTE:-----------------------
Rotating the track will help to move the shock-
absorber assembly.
• Tighten the nut.

*************************************
-8-
______________BR_A_K_E lp~~o el
POWER TRAIN
BRAKE
BRAKE PAD
2 1~
y A
I
@ : 48 Nm (4.8 m • kg, 35 ft• lb) I
!ID :Is Nm (0.6 m • kg, 4.3 ft • lbl I

Brake pad removal Remove the parts in the given order.
1 Retaining pin plug 1
2 Retaining pin 1
3 Pad spring 1
4 Brake pad 2
5 Bleed screw 2
For installation, reverse the removal proce-
du re.
-9-
______________eR_A_K_E IP~a ~
I~~---------------------
Disc brake components rarely require disassem-
bly. DO NOT:
• Disassemble components unless absolutely
necessary.
• Use solvents on internal brake components.
• Use contaminated brake fluid for cleaning.
Use only clean brake fluid.
• Allow brake fluid to come in contact with the
eyes, otherwise eye injury may occur.
• Allow brake fluid to contact painted surfaces or
plastic parts otherwise damage may occur.
• Disconn~ any hydraulic connection other-
wise the entire system must be disassembled,
drained, cleaned, and then properly filled and
bled after reassembly.
BRAKE PAD REPLACEMENT

NOTE:
It is not necessary to disassemble the brake cali-
per and brake hose to replace the brake pads.
1.Remove:
• Brake pads CD
NOTE:
• Do not depress the brake lever when the caliper
or disc is off the machine otherwise the brake
pads will be forced shut.
• Install new brake pad spring when the brake
pads have to be replaced.
• Replace the pads as a set if either is found to be
=
worn to the wear limit@.
I~ Wear limit@:
1.0 mm (0.04 inl I
-10-
______________sR_A_K_E
2. Install:
IP~Rlo el
• Brake pads m
• Pad spring
*************************************
Installation steps:
• Connect a suitable hose G) tightly to the caliper
bleed screw®· Put the other end of this hose
into an open container.
• Loosen the caliper bleed screw and push the
pistons into the caliper with the finger.
• Tighten the caliper bleed screw®·
~ Bleed screw:
~ 6 Nm (0.6 m • Kg, 4.3 ft • lb)
• Install the brake pads and pad spring.
NOTE:
The tangs@ of the pad spring must point in the
direction of the disc rotation.
*************************************
3. Inspect:
• Brake fluid level
Refer to "BRAKE FLUID LEVEL INSPEC-
TION".
4.Check:
• Brake lever operation
A soft or spongy feeling ~ Bleed brake
system.
Refer to "AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)".
-11-
BRAKE CALIPER ASSEMBL V, PARKING BRAKE ASSEMBLV AND BRAKE DISC
~:I 23 Nm (2.3 m •kg, 17 ft• lb) 8

~ :I48 Nm (4.8 m • kg, 35 ft• lb)
[g: 148 Nm (4.8 m •kg, 35 ft• lb)
[Q] : I48 Nm (4.8 m • kg, 35 ft• lb)

Brake disc removal Remove the parts in the given order.
Brake fluid Drain
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect
4 Brake caliper assembly 1
5 Parking brake cable 1 Disconnect
6 Parking brake assembly 1
7 Straight key 1
8 Brake disc 1
For installation, reverse the removal pro
du re.
-12-
BRAKE
PARKING BRAKE
j)
3

Parking brake disassembly Disassembly the parts in the given order.
CD Collar 2
® Spring 2
@ Brake shoe bracket 1
@ Brake shoe 2 Referto "PARKING BRAKE PAD INSPECTION"
and "PARKING BRAKE ADJUSTMENT".
® Pin 2
® Cotter pin 2
(j) Brake clearance adjuster 1
® Locknut 1
For assembly, reverse the disassembly pro-
cedure.
-13-
BRAKE CALIPER
[6J : Is Nm {0.6 m • kg, 4.3 ft· lb) I
~©
4 -h..~
~~~J A
L-U/
~·
Brake caliper disassembly Disassembly the parts in the given order.
CD Retaining pin plug 1
® Retaining pin 1
@ Pad spring 1
© Brake pad 2
® Caliper piston 2
® Piston seal 4
0 Bleed screw 2
cedure.
-14-
______________sR_A_K_E IP~~~o DI
CALIPER DISASSEMBLY
NOTE:
Before disassembling the caliper, drain the brake
hose, master cylinder, brake caliper and brake
reservoir of their brake fluid.
1. Remove:
• Pistons
• Piston seals CD
*************************************
Removal steps:
• Using a wood piece ®, lock the right side
piston.
• Blow compressed air into the hose joint open-
ing ®to force out the left side piston from the
caliper body.
• Remove the piston seals and reinstall the pis-
ton.
• Repeat previous step to force out the right side
piston from the caliper body.
A WARNING
• Never try to pry out a piston.
• Do not loosen the bolts @.
3
*************************************
BRAKE DISC INSPECTION

1. Measure:
• Brake disc thickness
Out of specification~ Replace.
Minimum thickness:
10 mm (0.39 in)
-15-
______________BR_A_K_E lp~W1o el
CALIPER INSPECTION AND REPAIR
Recommended brake component
replacement schedule:
Brake pads As required
Piston seals, dust seals Every two years
Brake hoses Every two years
Replace only when
Brake fluid brakes are
disassembled.
A WARNING
All internal brake components should be cleaned
in new brake fluid only. Do not use solvents as
they will cause seals to swell and distort.
1. Inspect:
• Caliper pistons CD
Scratches/rust/wear ~ Replace caliper as-
sembly.
• Caliper cylinder ®
Wear/scratches ~ Replace caliper assem-
bly.
• Caliper body @
Cracks/damage ~ Replace.
• Oil delivery passage (caliper body)
Blow out with compressed air.
A WARNING
Replace the piston seals and dust seals whenever
the caliper is disassembled.
CALIPER ASSEMBLY
A WARNING
• All internal parts should be cleaned in new
brake fluid only.
• Internal parts should be lubricated with brake
fluid when installed.
~ Recommended brake fluid:

'LJ DOT4
• Replace the piston seals and dust seals when-

ever a caliper is disassembled.
-16-
--------------BR_A_K_E lp~~Rlcml
BRAKE MASTER CYLINDER

Master cylinder removal Remove the parts in the given order.
Brake fluid Drain
1 Parking brake cable 1 Disconnect
2 Parking brake lever 1
3 Brake switch 1
4 Brake lever 1
5 Dimmer switch 1
6 Brake hose 1 Disconnect
7 Brake lever holder 1
8 Master cylinder 1
For installation, reverse the removal proce-
du re.
Brake master cylinder disassembly Disassembly the parts in the given order.
CD Boot 1
® Circlip 1
@ Master cylinder kit 1
© Master cylinder body 1
cedure.
-17-
___________
BR_AK_E lp~~Rlo el
MASTER CYLINDER INSPECTION
1. Inspect:
• Master cylinder CD
Wear/scratches~ Replace the master cylin-
der assembly.
• Master cylinder body ®
Cracks/damage ~ Replace.
• Oil delivery passage (master cylinder body)
Blow out with compressed air.
2. Inspect:
• Master cylinder kit CD
Scratches/wear/damage~ Replace as a set.
MASTER CYLINDER ASSEMBLY
A WARNING
• All internal parts should be cleaned in new
brake fluid only.
• Internal parts should be lubricated with brake
fluid when installed.
~ Recommended brake fluid:

'V DOT4
• Replace the piston seals and dust seals when-

ever a caliper is disassembled.
-18-
I
SLIDE RAIL SUSPENSION
----------------------------------------------------
POTWRRia ~1
- SI'
SLIDE RAIL SUSPENSION {VX800)
[Al :I 24 Nm (2.4 m •kg, 17 ft• lbH

[§] :l71 Nm (7.1m•kg,51 ft• lbH

Removal of slide rail suspension Remove the parts in the given order.
Track tension Loosen.
Side cowling (left and right) 2
1 Bolt 10
2 Slide rail suspension 1
Reverse the removal procedure for
installation.
-19-
I
POTWRRia ~1
----------------------------------------------------
- iii'
SLIDE RAIL SUSPENSION (MMSOO)
~ :111 Nm (7.1m•kg,51 ft• lb) I

Removal of slide rail suspension Remove the parts in the given order.
Track tension Loosen.
Side cowling (left and right) 2
1 Bolt 6
2 Slide rail suspension 1
Reverse the removal procedure for
installation.
-20-
[8] :l4 Nm (0.4 m • kg, 2.9 ft • lb)
:I
·~
[ID 15 Nm (1.5 m •kg, 11 ft• lb)
[9 : l49 Nm (4.9 m • kg, 35 ft • lb)
[QJ :111 Nm (7.1m•kg,51 ft• lbl
>
·~ [gJ : l30 Nm (3.0 m • kg, 22 ft • lb)

Disassembly of slide rail suspension Disassemble the parts in the given order.
CD Stopper band 2
® Hook 2
@ Bush 4
@ Collar 2
@ Front shock absorber 1
® Front suspension bracket 1
(!) Front pivot arm 1
® Bush 2
® Collar 1
@ Bush 4
® Collar 2
@ Suspension wheel 2
@ Wheel bracket 2
@ Front pivot arm bracket 2
® Shaft (MM800) 1
-21-
SLIDE RAIL SUSPENSION IP~WRlo el
[Al :171 Nm (7.1m·kg,51 ft• lbll
:I
[ID 24 Nm (2.4 m • kg, 17 ft• lbll
[g :149 Nm (4.9 m • kg, 35 ft• lb) I

@ Wheel bracket 2
@) Circlip 2
® Bush 2
@ Collar 1
@ Rear suspension bracket 1
® Spacer 2
@ Bush 2
® Collar 1
-22-
SLIDE RAIL SUSPENSION lp~':RIQ el
IA] :I48 Nm (4.8 m • kg, 35 ft• lb) I
C§:] : 1ss Nm (6.9 m • kg, 50 ft· lbl I

® Rear shock absorber 1
® Bush 2
@ Collar 1
@ Pull rod 2
© Collar 4
@) Bush 4
@ Rear bracket (VX800) 2
@ Collar (VX800) 2
® Circlip (MM800) 2
® Suspension wheel 2
® Control rod 2
® Bush 2
® Collar 2
@ Bush 2
-23-
SLIDE RAIL SUSPENSION IP~Rlo el
~ :124
. Nm (2.4 m • kg, 17 ft • lb>I
rnJ:l71
. Nm (7.1m•kg,51 ft• lb>!·
(g :175 Nm (7 .5 m • kg, 54 ft• lbH·
I I
--1
@ Rear pivot arm 1
-
@ Bush 2
@ Collar 1
@ Collar 1
@ Rear pivot arm bracket 1
@ Collar 1
@ Circlip 2
@ Wheel bracket 1
@ Rear axle 1
® Guide wheel 3
'® Collar 2
® Tension adjuster 2
@ Collar 1
~ Collar 1
@ Sliding frame 2
everse the disassemb
Rssembly. ly procedure for
I I la I
24
SLIDE RAIL SUSPENSION ~1
IPOTWRRio- 1111
----------------------------------------------------------
INSPECTION
1. Inspect:
• Suspension and guide wheels <D
Cracks/damage -+ Replace.
• Wheel bearing ®
Wheel turns roughly -+ Replace.
2. Inspect:
• Stopper band <D
Frayed/damage -+ Replace.
•Pull rod®
Bends/damage -+ Replace.
• Shock absorber @
Oil leaks/damage -+ Replace.
• Bush
Wear/cracks/damage -+ Replace.
• Front pivot arm ©
• Rear pivot arm ®
• Pivot arm bracket @
• Suspension bracket (!)
• Control rod @
• Sliding frame ®
Cracks/damage -+ Replace.
• Slide runner@)
Wear/damage -+ Replace
-25-
SLIDE RAIL SUSPENSION lp~:Rla el
ASSEMBLY
1.Apply:
• Low temperature lithium soap base grease
(to "@" mark points in the illustration)
2. Tighten: (VX800)
Nut (stopper band):

4 Nm (0.4 m • kg, 2.9 ft • lb)
Bolt CD:
71 Nm (7.1m•kg,51 ft• lb)
Nut@:
49 Nm (4.9 m • kg, 35 ft • lb)
Bolt@:
30 Nm (3.0 m • kg, 22 ft • lb)
Nut@:
71 Nm (7.1m•kg,51 ft• lb)
Bolt@:
24 Nm (2.4 m • kg, 17 ft • lb)
Bolt@:
49 Nm (4.9 m • kg, 35 ft • lb)
Nut(?):
24 Nm (2.4 m • kg, 17 ft • lb)
Nut@:
75 Nm (7.5 m •kg, 54 ft• lb)
Nut@:
15 Nm (1.5m•kg,11 ft• lb)
-~111111111 ____________________
Always use a new cotter pin.
-26-
SLIDE RAIL SUSPENSION I POTWRR1~1 ~
----------------------------------------------------
2. Tighten: (MM800)
Nut (stopper band):

4 Nm (0.4 m • kg, 2.9 ft • lb)
Bolt(}):
71 Nm (7.1 m •kg, 51 ft• lb)
Nut®:
49 Nm (4.9 m • kg, 35 ft • lb)
Bolt@:
30 Nm (3.0 m • kg, 22 ft • lb)
Nut@:
71 Nm (7.1m•kg,51 ft• lb)
Bolt@:
49 Nm (4.9 m • kg, 35 ft • lb)
Nut@:
24 Nm (2.4 m •kg, 17 ft• lb)
Nut Cf):
75 Nm (7.5 m •kg, 54 ft• lb)
Nut@:
15 Nm (1.5 m •kg, 11 ft• lb)
-27-
GENERAL SPECIFICATIONS I Ia-- I
SPEC
SPECIFICATIONS
Model VX800 MM800
Model code number: 88U3 8BT3
Dimensions:
Overall length 2,815 mm (110.8 in) 3,020 mm (118.9 in)
Overall width 1,155 mm (45.5 in) 1,125 mm (44.3 in)
Overall height 1,080 mm (42.5 in) 1, 165 mm (45.9 in)
Weight:
Dry weight (without fuel and oil) 259 kg (571 lb) 269 kg (593 lb)
Engine:
Engine type Liquid cooled 2-stroke, 7-port
Induction system Piston reed valve
Cylinder arrangement Parallel 4-cylinder
Displacement 791 cm 3 (48.3,cu. in)
Bore x Stroke 65.0 x 59.6 mm (2.56 x 2.35 in)
Compression ratio 6.5:1
Starting system Recoil starter
Lubrication system: Separate lubrication (YAMAHA AUTOLUBE)
Engine oil:
Recommended oil YAMALUBE 2-cycle oil
Tank capacity 2.8 L (2.5 Imp qt, 3.0 US qt)
Drive chain housing oil:
Recommended oil Gear oil API "GL-3" SAE #75 or #80
Capacity 0.35 L (0.31 Imp qt, 0.37 US qt)
Fuel:
Recommended fuel Unleaded fuel (for USA)
Regular unleaded gasoline (for CON)
Rating P.O.N. *1 Minimum.88
Tank capacity 38.0 L (8.4 Imp gal, 10 US gal)
Carburetor:
Type/quantity TM/33x 4
Manufacturer MIKUNI
Spark plug:
Type BR9ES
Manufacturer NGK
Gap 0.7 - 0.8 mm (0.028 - 0.031 in)
Transmission:
Primary reduction system V-Belt ~
Primary reduction ratio 3.9:1 - 0.95:1 ~
Clutch type Automatic centrifugal

~
engagement
Secondary reduction system Chain ~
Secondary reduction ratio 1.54 (37 /24) 1.61 (37/23)

Chassis:
Frame type Monocock ~
Caster 22.5° ~
Ski stance 1,007 mm (39.6 in) 977 mm (38.S in)

*1: Pump Octane Number; (research octane+ motor octane)/2
-28-
GENERAL SPECIFICATIONS I I er-- I
SPEC
Model VX800 MM800
Suspension:
Front suspension type Telescopic strut suspension
Rear suspension type Slide rail suspension
Track:
Track type Internal drive type ~
Track width 381 mm (15.0 in) ~
Length on ground 754 mm (29.7 in) 950 mm (37 .4 in)

Track deflection 20 - 25 mm (0.79 - 0.98 in) 25 - 30 mm (0.98 - 1.18 in)
/10 kg (22 lb) /10 kg (22 lb)
Brake:
Brake type Caliper type disc brake
Operation method Handle lever, left hand operated
Electrical:
Ignition system/manufacturer C.0.1./MITSUBISHI
Generator system Flywheel magneto
Bulb wattage x quantity:
Tail/brake light 23W/8Wx 1
Tachometer light 1.7W x 1
Speedometer light 1.7W x 1
Indicator light 3.4Wx3
T.O.R.S. light 3Wx 1
-29-
_________________M_A_1_N_TE_N_A_N_c_E_s_P_E_c_1F_1c_A_r1_o_N_s lsPEcl cr--1
ENGINE
Model VX800/MM800
Cylinder head:
Volume (with spark plug) 20.2 - 20.8 cm3 (0.71 - 0.73 Imp oz, 0.68 - 0.70 US oz)
<Warp limit> <0.03 mm (0.0012 in)>
Cylinder:
Material
lIBlt* * Lines indicate straight edge measurement.
Aluminum alloy with dispersion coating

Bore size 65.00 - 65.02 mm (2.5590 - 2.5598 in)
<Taper limit> <0.05 mm (0.0019 in)>
<Out-of-round limit> <0.01 mm (0.0004 in)>
Piston:
~@
Piston size (0) 64.935 - 64.940 mm (2.5565 - 2.5567 in)
Measuring point@ 20 mm (0.79 in)
Piston to-cylinder clearance 0.065 - 0.070 mm (0.0026 - 0.0028 in)

<Limit> <0.1 mm (0.004 in)>
Piston ring:
Sectional sketch Top ring c:Jls
1.. ..1
Keystone
8=1.2 mm (0.047 in)
T=2.55 mm (0.1 in)
T
2nd ring
c:Jls
,.. ...I
Keystone
8=1.2 mm (0.047 in)
T = 2.55 mm (0.1 in)
End gap (installed) : Top ring T 0.35 - 0.55 mm (0.014 - 0.022 in)
2nd ring 0.35 - {).55 mm (0.014 - 0.022 in)
Side clearance Top ring 0.02 - 0.06 mm (0.0008 - 0.0024 in)
2nd ring 0.02 - 0.06 mm (0.0008 - 0.0024 in)
Plating/coating Top ring Chrome plated/parkerizing
2nd ring Chrome plated/parkerizing
-30-
MAINTENANCE SPECIFICATIONS ISPECI a-- I
Model VX800/MM800
Crankshaft:
Crank width "A" 55.95 - 56.00 mm (2.203 - 2.205 in)
Connecting rod small end free play "F" 0.8 - 1.0 mm (0.031 - 0.039 in)
Connecting rod big end side clearance "D" 0.25 - 0.75 mm (0.010 - 0.030 in)
Crankshaft deflection "C": C,,C, Below 0.03 mm (0.0012 in)
C2,C3 Below 0.04 mm (0.0016 in)
Measuring points: 1 25 mm (0.98 in)
2 65 mm (3.27 in)
Crank width "B" 168 mm (6.614 in)
Big end bearing:

Type Needle bearing
Small end bearing:
Type Needle bearing
Carburetor:
Type/quantity TM33/4pcs.
Manufacturer MIKUNI
l.D. mark 8BU-OO
Main jet (M.J.) #143.8
Pilot air jet (P.A.J) !1}1.0
Pilot outlet (P.O.) !1}1.0
Pilot screw (P.S.) 1-1/2 turns out
Throttle valve (TH. V.) #1.0
Valve seat size (V.S.) !1}1.3
Starter jet (G.S.) !1}1.1
Float height (F.H.) 13.3 mm (0.524 in)
Engine idle speed 1,400 - 1,600 r/min (1,500 ± 100 r/min)
Reed valve:
Valve stopper height 8.1 - 8.5 mm (0.32 - 0.33 in)
Fuel pump:
Type DIAPHRAGM
Oil pump:
Pump cable adjustment 28 - 30 mm (1.10 - 1.18 in)
-31-
MAINTENANCE SPECIFICATIONS lsPECI a-- I
Model VX800 MM800
Cooling system:
Filler cap opening pressure 80 - 100 kPa
(0.8 - 1.0 kg/cm 2, 11 - 14 psi)
Thermostat opening temperature 50 - 55"C (122 - 131'F)
Thermostat valve lift 8 mm (0.3 in) at 70'C
(158.5°F)
Water pump type Impeller type
Coolant type Long life coolant
Coolant mixing ratio (coolant : water) 6:4
Coolant capacity 4.7 L 5.1 L
(4.1 Imp qt, 5.0 US qt) (4.5 Imp qt, 5.4 US qt)
Reservoir tank capacity 0.20 L
(0.18 Imp qt, 0.21 US qt)
High altitude settings
-30°C -20°c -10°c 0°C 10°c

(-22°F) (-4°F) (14°F) (32°F) (50°F)
I I I I I
0 - 200 m ......
- - - # 1 4 6 . 3 - - -..~
(600 ft) ---#148.8--... .....:-----#143.8 (STD)------..1
200 - 600 m .....-#143.8 (STD)---11.. ~
(2,000 ft) ---#146.3--... .......:------#141.3-------..1
600 - 1,200 m ......- - - # 1 4 1 . 3 - - -..~
(4,000 ft) -#143.8 (STD)~ .......:11-------#138.8--------'
1,200 - 1,800 m ......- - - # 1 3 8 . 8 - - -..~

---#141.3--... #136.3 JN:2
(6,000 ft) PJ#55 PS2-1/4
#136.3 JN:2
1,800 - 2,400 m . . _ PJ#55 PS2-1/4 __,.. #133.8 JN:2
(8,000 ft) ---#138.8 "' ...:::1------PJ#55 PS2-1/4------1
,..__ #133.8 JN:2 __,..
2,400 m -
#136.3 JN:2 PJ#55 PS2-1/4 - #131.3 JN:2
(8,000 ft -) -PJ#55 PS2-1/4 __,. "'"------PJ#55 PS2-1/4
-32-
MAINTENANCE SPECIFICATIONS !sPECI cr--1
POWER TRAIN
Model vx8oo MM800
Transmission:
Range of ratio 3.9:1 - 0.95:1
Engagement RPM 3,200 - 3,600 r/min
Shift RPM 8, 100 - 8,500 r/min
Sheave center distance "A" 363.5 - 366.5 mm (14.3 - 14.4 in)
Sheave offset "B" 14.5 - 17.5 mm (0.57 - 0.69 in)
le 1r= =r
-
,,.--
"'""'
l I
' --.
t ~
- --
L "11 II':
~ A
,r
~~
- -
V-Belt:
Outside circumference 1,340 mm (52.8 in)
Width "A" (new belt) 33.8 mm (1.33 in)
Wear limit "B" 32 mm (1.26 in)
\D)
Ii· ~ ·ii
I I
I I
I I
I... J
Primary sheave spring:

Part number 90501-582J1 f-
Color Yellow-Pink-Yellow f-
Outside diameter 60 mm (2.36 in) f-
Wire diameter 5.8 mm (0.23 in) f-
Pre-load/set length 30.0 kg (66.2 lb) f-
Spring rate 25.0 N/mm (2.5 kg/mm) 22.5 N/mm (2.25 kg/mm)
Free length 77 .4 mm (3.05 in) f-
Primary sheave weight arm:

Rivet:
Part number 90261-06033
Material Steel
Size 17.2 mm (0.68 in)
Quantity 3 pcs.
Secondary sheave spring:
Part number 90508-556A2 90508-50081
Color code Green Red
Outside diameter 69.5 mm (2.74 in) f-
Twist angle *1 50° 60°
Free length 75 mm (2.95 in)
*1: Twist angle; (sheave hole+ spring seat hole) x 10
-33-
MAINTENANCE SPECIFICATIONS lspecl o-1
Model VX800 MM800
Hole position
Sheave side* 2
Spring seat side** 3
* ** 0
Spring rate •
Torque cam angle
Drive chain:
Type
hQ - 9,650 N/mm (965 kg/mm, 5,376 lb/in)
41°
Silent (chain) 23RH304 (BWA)

Number of links 70
Track:
Width 381 mm (15.0 in) +--
Length 3,072 mm (121 in) +--
Pitch 64 mm (2.52 in) +--
Number of links 48 54
Deflection at 10 kg (22 lb) 20 - 25 mm 25 - 30 mm
(0.79 - 0.98 in) (0.98 - 1.18 in)
Suspension setting position:
Stopper band hole position "L" 10 mm (0.39 in)
L
-~ I
?:2:
Shock absorber:
Damping force (extension)
Front 52 kg/0.3 mis 54 kg/0.3 m/s
Rear 182 kg/0.3 m/s 225 kg/0.3 m/s
Damping force (compression)
Front 163 kg/0.3 m/s +--
Rear 77 kg/0.3 m/s 7 4 kg/0.3 m/s
Slide runner:
Thickness 17.8 mm (0.70 in)
Wear limit 10 mm (0.4 in)
Track sprocket wheel:
Number of teeth 9T
Rear guide wheel:
Outside diameter 178 mm (7 in)
Brake:
Pad thickness 10.2 mm (0.40 in)
Pad wear limit 1.0 mm (0.04 in)
Pad to disc clearance 1.1 - 1.25 mm (0.043 - 0.049 in)
Disc outside diameter 220 mm (8.66 in)
Disc thickness 9.0 mm (0.35 in)
-34-
MAINTENANCE SPECIFICATIONS ISPEC I a-- I
CHASSIS
Model VX800 MM800
Frame:
Frame material Aluminum
Seat height 600 mm (23.6 in)
Luggage box location Rear side of seat
Steering:
Steering angle (right) R ski 35.1°
L ski 29.7°
Steering angle (left) R ski 30.3°
Lski 36°
Ski alignment Toe-out f-
Toe-out size 0 - 15 mm (0 - 0.6 in) f-
Distance "A" 2,007 mm (79.0 in) 2, 196 mm (86.6 in)
Distance "B" 1,007 mm (39.6 in) 977 mm (38.5 in)
Ski:
Ski material Aluminum
Runner material
Runner1 Carbide
Runner2 Polyethylene
Ski ground length 375.6 mm (14.8 in)
Ski suspension:
Type T.S.S. f-
Travel 170 mm (6.69 in) f-
Spring type Coil spring f-
Spring rate 16 N/mm f-
(1.6 kg/mm, 89.7 lb/in) r
Wire diameter 8.2 mm (0.32 in) f-
Shock absorber:
Damping force (extension) 69 kg, 0.3 m/s f-
(compression) 41 kg, 0.3 m/s f-
Damping force adjuster 5 clicks out f-
-35-
_________________M_A_1N_T_E_N_A_N_ce__ sP_E_c_1F_1c_~_r_1o_N__s lsPECI o--1
ELECTRICAL
Model VX800 I MM800
Voltage: 12V
Ignition system:
Ignition timing (B.T.D.C.) 16°/1,500 r/min
C.D.I.:
Magneto model/manufacturer F4T308/MITSUBISHI
Pulser coil resistance 505 ±10 % at 20° C (68°F)
(color code) (White/Green - White/Red)
Change coil resistance (for ignition) 2.55 n ±10 % at 20°c (68°F)
{color code) (Brown - Black/Red)
C.D.I. unit manufacturer MITSUBISHI
Ignition coil:
Model/manufacturer 89A/YAMAHA, 88RNAMAHA
Minimum spark gap 3 mm (0.12 in) at 3,000 r/min
Primary coil resistance 0.2 n ± 20 % at 20°c (68°F)
Secondary coil resistance 4.9 kQ ± 20 % at 20°c {68°F)
Spark plug cap:
Type Rubber type
Model/manufacturer BR9ES/NGK
Resistance 5.0 kQ at 20°c (68°F)
Charging system:
Type Flywheel magneto
Flywheel magneto:
Lighting voltage {minimum) 11.0 V at 3,000 r/min
{maximum) 15.5 Vat 8,000 r/min
Lighting coil resistance 0.32 n ± 10 % at 20°c (68°F)
{color code) {Yellow - Black)
Coil resistance for grip warmer {driver) 1.7 n ± 20 % at 20°c (68°F)
{color code) (Yellow/Brack - Black)
Grip warmer:
Grip warmer resistance 3 n ± 20 % at 20°c (68°F)
Thumb warmer resistance n
8 - 40 at 20°c {68°F)
Voltage regulator:
Type Short circuit type
Mode/manufacturer 82M-AO/SHINDENGEN
Fuel gauge unite:
Resistance {full) 4- 10 Q
(empty) 90 - 100 Q
-36-
TIGHTENING TORQUE lsPecl er-- I
TIGHTENING TORQUE
Tightening torque:
Tightening torque
Nm m • kg ft • lb
ENGINE
Crankcase (M8 x 1.25) 27 2.7 20 Tighten the bolts in
two steps.
(M8 x 1.25) 13 1.3 9.4
(M6 x 1.0) * 13 1.3 9.4
Engine bracket nut 40 4.0 29

Engine bracket bolt 27 2.7 20
Engine stay bolt (rod) 45 4.5 32
Crankcase stud bolt 13 1.3 9.4
Cylinder head nut 22 2.2 16
Cylinder stud bolt 13 1.3 9.4
PTO shaft holder bolt 28 2.8 20
PTO shaft driven gear assembly 48 4.8 35
Water pump ass'y 10 1.0 7.2
Oil pump ass'y 4 0.4 2.9
Exhaust manifold 25 2.5 18
Magnet rotor 85 8.5 61
Starter ass'y 10 1.0 7.2
CARBURETOR
Starter lever shaft screw 4 0.4 2.9
Main jet 0.8 0.08 0.58
Pilot jet 0.7 0.07 0.51
Synchronization nut 4 0.4 2.9
Plunger 3 0.3 2.2
-37-
TIGHTENING TORQUE ISPEC I tr"9' I
Tightening torque:
Tightening torque
Nm m •kg ft. lb
Handlebar holder 15 1.5 11

Steering column
Upper 22 2.2 16
Lower 27 2.7 20
Steering column and relay rod 43 4.3 31
Relay rod and suspension bracket 25 2.5 18
Locknut (relay rod) 25 2.5 18 Apply LOCTITE®
Lever holder 3 0.3 2.2
Master cylinder holder 10 1.0 7.2
Brake hose and brake hose joint 14 1.4 10
Brake hose joint and master cylinder 30 3.0 22
Ski runner 21 2.1 15
Ski 43 4.3 31
Pinch nut (suspension bracket) 21 2.1 15
Set screw (suspension bracket) 2 0.2 1.4 Apply LOCTITE®
Absorber holder 10 1.0 7.2
Mounting nut (shock absorber) 5 0.5 3.6
Locknut (shock absorber) 16 1.6 11
Front arm (upper) and front arm (lower) 43 4.3 31
Hood 3 0.3 2.2
Seat and frame (nut) 9 0.9 6.5
(screw) 3 0.3 2.2
Front cowling 3 0.3 2.2
-38-
TIGHTENING TORQUE ISPECIa-- I
Tightening torque:
Tightening torque
Nm m •kg ft• lb
Primary sheave (first) 120 12.0 85 Tighten the bolts in

(final) 60 6.0 43 two steps.
Spider and sliding sheave 200 20.0 145 Left-hand thread.
Apply LOCTITE®
Primary sheave cap and sliding sheave 14 1.4 10
Roller and weight (primary sheave)
Bolt 6 0.6 4.3
Screw 3 0.3 2.2
Secondary sheave 64 6.4 46
Driven sprocket 48 4.8 35
Chain housing and frame 24 2.4 17 Apply LOCTITE®
Chain housing cover 10 1.0 7.2
Chain housing and brake caliper 48 4.8 35
Brake hose and brake caliper 23 2.3 17
Bearing holder (jackshaft) 43 4.3 31
Suspension wheel 69 6.9 50 Apply LOCTITE®
Rear axle nut 75 7.5 54
Sliding frame and slide runner 3 0.3 2.2
Slide rail suspension mounting bolt 71 7.1 51
Front pivot arm bracket 71 7.1 51
Rear pivot arm and bracket 24 2.4 17
Rear pivot arm and pull rod 49 4.9 35
Rear pivot arm bracket and sliding frame 71 7.1 51
Control rod and sliding frame 71 7.1 51
Shock absorber and rear pivot arm 49 4.9 35 Apply LOCTITE®
Rear suspension bracket and shock absorber 49 4.9 35
Rear suspension bracket and pull rod 49 4.9 35
Front pivot arm and bracket 71 7.1 51
Shock absorber and front pirot arm 49 4.9 35
Front suspension bracket and sliding frame 71 7.1 51
30 3.0 22
Front pivot arm bracket and sliding frame 71 7.1 51
Stopper band hook 15 1.5 11
Front axle nut 90 9.0 65
Speedometer gear 20 2.0 14
-39-
cAeLE Rour1NG lsPEcl a-- I
CABLE ROUTING
CD Grip warmer lead ®Oil hose ~ Clamp the fuel breather hose,
® Oil breather hose @) Starter lever oil breather hose and wire
@ COi unit ® Main switch harness.
© Voltage regulator @ Grip warmer switch [§] to carburetor
@ Fuel breather hose @ Speedometer assembly [£] to crankcase
@ Register assembly @ Headlight lead
(j) Rectifier/regulator ® Speedometer cable
@ Oil delivery hose
-40-
cAeLE Rour1NG lsPEcl a-I
CD Starter cable ~ Fasten the brake hose with the clamp.
® Parking brake cable [ID Fasten the brake hose and right fuel hose with the clamp.
@Brake hose [g Fasten the ignition coil lead, thermo switch lead and carburetor switch
© Throttle cable lead with the clamp.
@ Oil pump cable
@ Ignition coil
·(j) Speedometer cable
-41-
cABLE ROUTING jsPEcj a-I
CD Fuel tank ~ Arrange hoses so that they will not come into contact with the oil
(VClip pump bracket.
@ Fuel sender ffil Pass the delivery hose and oil hoses above the bracket.
@ Voltage regulator 19 Tie the band buckle above the frame pipe so that they will not
® Wire harness interfere with the starter rope.
®Fuel hose
(J) Pulse hose
@Oil tank
® Tail light lead
-42-
NOTICE
This manual was written by the Yamaha Motor
Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to
put an entire mechanic's education into one
manual, so it is assumed that persons using this
book to perform maintenance and repairs on
Yamaha snowmobiles have a basic understand-
ing of the mechanical concepts and procedures
inherent in snowmobile repair technology. With-
out such knowledge, attempted repairs or service
to this model may render it unfit to use and/or
unsafe.
Yamaha Motor Company, Ltd. is continually striv-
ing to improve all models manufactured by
Yamaha. Modifications and significant changes in
specifications or procedures will be forwarded to
all Authorized Yamaha dealers and will, where
applicable, appear in future editions of this man-
ual.
SERVICE DEPT
LEISURE VEHICLES & POWER
PRODUCTS OPERATIONS
YAMAHA MOTOR CO., LTD.
HOW TO USE THIS MANUAL

PARTICULARLY IMPORTANT
INFORMATION
This material is distinguished by the following
notations.
&
The Safety Alert Symbol means ATTENTION!
BE ALERT!
YOUR SAFETY IS INVOLVED!
A WARNING
Failure to follow WARNING instructions could
result in severe injury or death to the snowmobile
operator, a bystander, or a person inspecting or
repairing the snowmobile.
A CAUTION indicates special precautions that
must be taken to avoid damage to the snowmo-
bile.
NOTE:
A NOTE provides key information that can make
procedures easier or clearer.
MANUAL FORMAT
All of the procedures in this manual are organized
in a sequential, step-by-step format. the informa-
tion has been compiled to provide the mechanic
with an easy to read, handy reference that con-
tains comprehensive explanations of all inspec-
tion, repair, assembly, and disassembly opera-
tions,
In this revised format, the condition of a faulty
component will precede an arrow symbol and the .
course of action required to correct the problem
will follow the symbol, e.g.,
• Bearings
Pitting/Damage --+ Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before
each disassembly section for ease in identifying
correct disassembly and assembly procedures.
VX750U/VX750STU
SERVICE MANUAL
©1993 by Yamaha Motor Corporation, U.S.A.
1st Edition, April 1993
ur.authorized use without the written
Printed in U.S.A.
P/N LIT-12628-01-56
CD ® ILLUSTRATED SYMBOLS
l~Elbl~I l~8f l§tl

(Refer to the illustration)
Illustrated symbols CD to ® are designed as

@ thumb tabs to indicate the chapter's number and
©
I
content.
lcHAsl~ l~le11tl CD General information

@Chassis
..
® ® © Power train
@ Cooling system
lcooLIKI IENG I I @Engine

(j) Carburetion
@ Electrical
® Specifications
(j) @
lcARel iJ I IELEcl •I lllustratedsymbols@ to@ areusedtoidentify

® @
lsPEcl rr I ~
@ Filling fluid
@Lubricant
@ Tightening
@ @ @ Wear limit, clearance
1-419\1 ~
@ Engine speed
@ Special tool
@O,V,A
@ @
®
~ ~ @
Illustrated symbols @ to ® in the exploded
~ [ij]
diagram indicate grade of lubricant and location
of lubrication point.
@ Apply locking agent (LOCTITE®)
@ Apply engine oil
@ @ @ Apply gear oil
.!. l
- ® Apply molybdenum disulfide oil
@
a m
® ®
® Apply wheel bearing grease
@ Apply low-temperature lithium-soap base grease
@ Apply molybdenum disulfide grease
@ Apply YAMAHA bond No.5
l l ~
@
Gl A
@ ®
~ ~ 410.5.
INDEX
GENERAL INFORMATION I=i
PERIODIC INSPECTION
AND ADJUSTMENT
~
CHASSIS CHAS I
POWER TRAIN POWRI
TR •
ENGINE OVERHAUL ENG "KI

COOLING SYSTEM COOLI
CARBURETION ~
CARB I
ELECTRICAL -I
ELEC
SPECIFICATIONS
CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ............................. 1-1
FRAME SERIAL NUMBER ......................... 1-1
ENGINE SERIAL NUMBER ........................ 1-1
IMPORTANT INFORMATION ........................... 1-2

PREPARATION FOR REMOVAL
AND DISASSEMBLY ................................ 1-2
ALL REPLACEMENT PARTS ...................... 1-3
GASKETS, OIL SEALS, AND 0-RINGS ..... 1-3
LOCK WASHERS/PLATES AND
COTTER PINS ............................................ 1-3
BEARINGS AND OIL SEALS ...................... 1-3
CIRCLIPS ..................................................... 1-4
SPECIAL TOOLS ................................................ 1-4

FOR TUNE UP ............................................. 1-4
FOR ENGINE SERVICE ............................... 1-5
FOR POWER TRAIN SERVICE .................... 1-5
FOR ELECTRICAL SERVICE ........................ 1-6
MACHINE IDENTIFICATION I~Elb 1~1
GENERAL
INFORMATION
FRAME SERIAL NUMBER
The frame serial number CD is located on the
right-hand side of the frame (just below the
front of the seat).

The engine serial number CD is located on the
NOTE:------------------------
The first three digits of these numbers are for
model identification; the remaining digits are the
unit production number.
Starting Serial Number:

VX750U: 8BW-000101-
VX750STU: SBX-000101-
NOTE: -------------------------
Designs and specifications are subject to change
without notice.
1-1
IMPORTANT INFORMATION I~EFi ~I
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassembly.
While cleaning, take care to protect the
electrical parts, such as relays, switches,
motor, resistors, controllers, etc., from
high pressure water splashes.
2. Use proper tools and cleaning equipment.

Refer to "SPECIAL TOOLS" .
3. When disassembling the machine, keep

mated parts together. This includes gears,
cylinders, pistons, and other parts that have
been "mated" through normal wear. Mated
parts must be reused as an assembly or
replaced.
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 assure that all parts are
reinstalled correctly.
5. Keep away from fire.
6. Be sure to keep to tightening torque specifi-

cations. When tightening bolts, nuts, and
screws, start with larger-diameter pieces, and
proceed from an inner-positioned one to an
outer-positioned one in a criss-cross pattern.
1-2
IMPORTANTINFORMATION l~EFilJal
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine parts
for all replacements. Use oil and/or grease
recommended by Yamaha for assembly and
adjustment.
GASKETS, OIL SEALS, AND 0-RINGS

1. All gaskets, seals, and 0-rings should be re-
placed when an engine is overhauled. All gas-
ket surfaces, oil seal lips, and 0-rings must
be cleaned.
2. Properly oil all mating parts and bearings dur-
ing reassembly. Apply grease to the oil seal
lips.
LOCK WASHERS/PLATES AND COTTER

PINS
1. All lock washers/plates <D and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nutflat(s) after the bolt or nut has been prop-
erly tightened.
300-000
BEARINGS AND OIL SEALS

1. Install the bearing(s) <D and oil seal(s) ®
with their manufacturer's marks or numbers
facing outward. (In other words, the
stamped letters must be on the side exposed
to view.) When installing oil seal(s), apply a
light coating of light-weight lithium base
grease to the seal lip(s). Oil the bearings
300-002 liberally when installing.
Do not use compressed air to spin the bearings

dry. This causes damage to the surface of the
bearings.
300-003
1-3
SPECIAL TOOLS l~E~~I
CIRCLIPS
1. All circlips should be inspected carefully be-
fore reassembly. Always replace piston pin
clips after one use. Replace misshapen
circlips. When installing a circlip CD , make
sure that the sharp edged corner ® is
positioned opposite to the thrust @ it
receives. See the sectional view.
300-001
@ Shaft
SPECIAL TOOLS
The some special tools are necessary for
complete accurate tune-up and assembly. Using
the correct special tool will help prevent damage
thet can be caused by the use of improper tools
or improvised techniques.
NOTE:~----------------------
Be sure to use the correct part number when
ordering the tool, since the part number differs
according to the area as shown below. The first
part number is for Europe, and the last part is for
the U.S.A. and Canada .
. e.g. 90890 - *****,YU-*****
FORTUNE UP
1. Sheave Gauge
P/N YS-39506-2 G), YS-39506-5 ®
This gauge is used to measure sheave distance

and for offset adjustment.
2. Fuel Level Gauge

PIN 90890-01312, YM-01312-A
This gauge is used to measure the fuel level in the

float chamber.
1-4
SPECIAL TOOLS l~EFi!Jztl
FOR ENGINE SERVICE
1. Piston Pin Puller
P/N 90890-01304, YU-01304
This tool is used to remove the piston pin.
2. Rotor Puller
P/N 90890-01362, YU-33270
This tool is used to remove the magneto rotor.
3. Cooling System Tester

P/N 90890-01325, YU-22460-01
This tester is used for checking cooling system.
FOR POWER TRAIN SERVICE

1. Primary Sheave Holder
P/N 90890-01701, YS-01880
This tool is used to hold the primary sheave.
2. Primary Sheave Puller (18 mm)

P/N YS-01881-1 CD, YS-38517 ®
This tool is used for removing the primary

sheave.
1-5
SPECIAL TOOLS l~EFi~I
3. Clutch Spider Separator
PIN 90890-01711, YS-28890-8
This tools are used when disassembling and

assembling the primary sheave.
4. Clutch Separator Adapter

PIN 90890-01740, YS-34480
This tool is used when disassembling and

assembling the primary sheave.
5. Track Clip Installer

PIN 90890-01721, YS-91045-A
This tool is used for installing the track clip.
FOR ELECTRICAL SERVICE

1. Pocket Tester
PIN 90890-03112, YU-03112
This instrument is necessary for checking the

electrical components.
2. Electro Tester
PIN 90890-03021, YU-33260-A
This instrument is invaluabl!'l for checking the

electrical system.
1-6
CHAPTER2.
PERIODIC INSPECTIONS AND
ADJUSTMETS
INTRODUCTION .............................................. 2-1
PERIODIC MAINTENANCE TABLE ................. 2-1

SIDE COWLING ........................................... 2-3
ENGINE .............................................................. 2-3

SPARK PLUG ............................................... 2-3
OIL PUMP .................................................... 2-4
ENGINE OIL LINE INSPECTION ................. 2-6
OIL FILTER INSPECTION ..•......................... 2-6
FUEL LINE INSPECTION ............................. 2-6
FUEL FILTER INSPECTION ......................... 2-7
COOLING SYSTEM ..................................... 2-7
ENGINE GEAR OIL .................................... 2-11
CARBURETOR SYNCHRONIZATION ....... 2-13
ENGINE IDLE SPEED ADJUTMENT ......... 2-13
THROTTLE CABLE ADJUSTMENT .......... 2-14
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK .................................... 2-14
STARTER(CHOCK)CABLE
ADJUSTMENT ........................................ 2-15
EXHAUST SYSTEM .................................. 2-15
POWER TRAIN ................................................ 2-16

DRIVE V-BELT ........................................... 2-16
ENGAGEMENT SPEED CHECK ................ 2-18
BRAKE PAD INSPECTION ........................ 2-18
BRAKE ADJUSTMENT ............................. 2-18
DRIVE CHAIN ............................................ 2-19
TRACK TENSION ADJUSTMENT ............ 2-21
SLIDE RUNNER INSPECTION .................. 2-22
CHASSIS .......................................................... 2-23

SKI/SKI RUNNER ...................................... 2-23
STEERING SYSTEM ................................. 2-23
LUBRICATION ........................................... 2-24
ELECTRICAL ................................................... 2-25

HEADLIGHT AND METER LIGHT
BULB REPLACEMENT ............................ 2-25
HEADLIGHT BEAM ADJUSTMENT ......... 2-27
__________ ,~8f l§ll
TUNING .......................................................... 2-28
CARBURETOR TUNING ..................•...... 2-28
CLUTCH TUNING ................................... 2-37
GEARING SELECTION ........................... 2-39
SUSPENSION ......................................... 2-41
ENGINE ROOM PLATES ........................ 2-43
HIGH ALTITUDE TUNING ...................... 2-44
INTRODUCTION/ I'N s p I~ I
PERIODIC MAINTENANCE TABLE ADJ •
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable machine operation and
a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This
information applies to machines already in service as well as new machines that are being prepared for
sale. All service technicians should be familiar with this entire chapter.
Initial Every
Pre-operation 1 Month Seasonally
Item Remarks or or
check (Daily) BOO km 3,200 km
(500 Mi) (40 hr) (2,000 Mi)
(160 hr)
Spark Plug:
Check condition adjust the gap and clean.
Engine Oil:
Check oil level.
•
* Air bleed the oil pump if necessary.
•
*Oil Filter:
Check condition.
Fuel: Check fuel level.
Check condition.
•
*Fuel Filter:
Check fuel hose for cracks or damage.
*Fuel Line:
Check oil hose for cracks or damage.
*Oil Line: Replace if necessary. •
Engine Coolant
Check coolant level.
•
* Air bleed the cooling system if necessary.
•
Carburetor
Check throttle lever operation.
•
Whenever operating condition
* Adjust the jets.
(elevation/temperature) is changed.
Manual Starter:
Check operation and rope damage.
Check operation
Engine Stop Switch:
* Repair if necessary. •
Throttle Override System:
Check operation.
Throttle Lever:
Check operation.
Check for leakage.
*Exhaust System:
Retighten or replace gasket if necessary. •
*Decarbonization: More frequently if necessary.
Check cracks, bends or damage.
•
Drive V-belt Guard:
* Replace if necessary. •
Drive V-belt: Check wear and damage. Replace if necessary.
Check deflection, wear and damage.
•
Drive Track/Idler Wheels:
* AdjusVreplace if necessary. • •
Slide Runner
•
*Replace if necessary.
*: It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
•
2-1
-------------------------------------------------------------------------
IIANDSJP I~ I ~
Initial Every
Pre-operation 1 Month Seasonally
Item Remarks or or
check (Daily) 800 km 3,200 km
(500 Mi) (40 hr) (2,000 Mi)
(160 hr)
Brake/ Check operation.
•
Parking Brake
* Adjust free play and/or replace pads if necessary. •
Drive Chain Oil
Check oil level.
•
Replace.
•
Engine Gear Oil
Check oil level.
•
* Replace.
Check deflection.
• •
Apply initial 1 (one) Month or 50 km (31 Mi) and
*Drive Chain: Adjust if necessary. every 1 (one) Month or 400 km (250 Mi).
Ski/Ski cover/ Check wear and damage.
•
Ski Runner
* Replace if necessary. •
Steering System
Check operation.
•
* Adjust toe-out if necessary.
Check operation.
•
Lights:
Replace bulbs if necessary. •
Check engagement and shift speed.
Adjust if necessary. Whenever operating elevation is changed.
•
*Primary Sheave Check wear and damage.
•
*Secondary Sheave
Adjust if necessary. Whenever operating elevation is changed.
•
*Steering Column Bearing: Lubricate with specified grease.
•
*Ski and Front Suspension: Lubricate with specified grease.
•
*Suspention Component: Lubricate with specified grease.
•
* Brake Cable End and
Lever End/ Throttle Cable
Check cable damage.
•
End Replace if necessary. •
Shroud Latches: Make sure the shroud latches are hooked.
Check tightness.
•
Fittings/Fasteners: *Repair if necessary. •
Service Tools/Spare Parts: Check proper placement.
•
*: It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
2-2
SIDE COWLING/SPARK PLUG _ 1 ~8r1~1
_ _ ~
A SIDE COWLING
Removal
1.Remove:
• Protector rubber CD (left and right)
• Screws® (right)
• Side cowlings @(left and right)
Pull it forward@ .
[Al Left
rnJ Right
Installation
Reverse the "Removal" steps.
ENGINE
SPARK PLUG
1.Remove:
• Spark plug
2. Inspect:
• Electrode CD
Wear/Damage-+Replace.
• Insulator color ®
377 000 3. Measure:
•Plug gap@
Out of specification-+Regap.
Use wire thickness gauge.
Spark plug gap:

0.7 -0.8 mm (0.028 - 0.031 in)
Clean the plug with a spark plug cleaner if

necessary.
Standard spark plug:

BR9ES (NGK)
Before installing a spark plug, clean the

gasket surface and plug surface.
2-3
4. Tighten:
• Spark plug
Spark plug:
28 Nm (2.8 m • kg, 20 ft • lb)
NOTE: ~-----------------------
Finger-tighten©the spark plug before torquing®
377.004 to specification.
OIL PUMP
Air Bleeding
The oil pump and delivery line must be bled on the

following occasions:
• When any portion of the oil system has been
disconnected.
• When the machine has been turned on its side.
• Whenever the oil tank has been run empty.
• During predelivery.
1.Remove:
• Side cowling (right) (See page 2-3)
• Spring
• Muffler©
2. Loosen:
• Clamp screws (carburetor)
3.Remove:
• Bracket© (ignition coil)
• Intake silencers ®
• Carburetor assembly @
4. Fill:
• Oil tank©
Oil tank capacity:

2.7 L (2.4 Imp qt, 2.9 US qt)
Recommended oil:
Yamalube 2-cycle oil
2-4
5. Disconnect:
• Oil hose CD
6. Keep the oil running out until air bubbles
disappear from the oil hoses CD
7. Connect:
• Oil hose CD
8. Disconnect:
• Oil delivery hoses CD
(from fuel pump side)
9. Feed the "Yamalube 2-cycle oil" into the oil
delivery hoses using a oil can for complete air
bleeding.
10. Connect:
• Oil delivery hoses CD
11. Remove:
• Bleed screw CD
• Gasket (bleed screw)
12. Keep the oil running out until air bubbles
disappear from bleed hole.
13. Inspect:
Wear/Damage ~ Replace.
14. Install:
• Bleed screw
Cable Adjustment
NOTE: ~~~~~~~~~~~~
Before adjusting the oil pump cable, the throttle
cable free play should be adjusted.
1. Adjust:
• Oil pump cable
Adjustment steps:
_
25 • Loosen the locknut CD.
ENGINE OIL LINE INSPECTION/
OIL FILTER INSPECTION/FUEL LINE INSPECTION
11 N s p
ADJ
IQ I
• Turn the adjuster ® in or out until the
specified distance length is obtained.
Oil pump cable distance length @ :

28 - 30 mm (1.10 -1.18 in)
Turning in Free play is increased.
Turning out Free play is decreased.
• Tighten the locknut and push in the adjuster
cover.
ENGINE OIL LINE INSPECTION

1.Remove:
• Intake silencers (See page 2-4)
2. Inspect:
• Oil hose CD
• Oil delivery hoses ®
Crack/Damage -4 Replace.
OIL FILTER INSPECTION

1. Remove:
• Intake silencer (right)
(See page 2-4)
2. Disconnect:
• Oil hose CD
NOTE: ~~~~~~~~~~~~-
Plug the oil hose so that the oil will not run out of
the oil tank and oil pump.
3. Inspect:
• Oil filter ®
Contamination-4Replace.
Recommended replacement interval:

Every season
4. Reverse the removal procedure.
FUEL LINE INSPECTION

1. Remove:
• Intake silnecers (See page 2-4)
2. Inspect:
• Fuel hoses CD
• Fuel delivery hoses ®
Crack/Damage-4Replace.
2-6
FUEL FILTER INSPECTION/ p ~
COOLING SYSTEM _ ADJ _~
I'N s I I_
FUEL FILTER INSPECTION
1.Remove:
•Seat
2. Disconnect:
• Tail/brake light coupler
3.Remove:
• Screws (center cover)
4.Remove:
• Spring bands CD
•Cap@
• Fuel filter @
5. Inspect:
• Fuel filter
Contamination~Replace.
Recommended replacement interval:

Every season
6. Reverse the removal procedure.
COOLING SYSTEM
Coolant level inspection
A WARNING
Do not remove the radiator cap when the engine
is hot.
I 1--------------------~
Hard water or salt water is harmful to the engine
parts; use boiled or distilled water if you can't get
soft water.

2. Inspect:
• Coolant level
Coolant level is below "LOW" level line CD~
Add soft water, until "FULL" level line ®.
2-7
3.Add:
• Softwater
Until the coolant level reaches "FULL" level
line.
Reservoir tank capacity:

Total:
0.20 L (0.18 Imp qt, 0.21 US qt)
From "LOW" to "FULL• level:
0.1 L (0.09 Imp qt, 0.11 US qt)
Coolant replacement
NOTE: ----------------------~
The coolant should be changed at least
seasonally.

2.Remove:
•Seat
3.Remove:
• Exhaust pipe CD (left)
• Exhaust manifold® (left)
4.Remove:
• Radiator cap CD
A WARNING
Do not remove the radiator capCDespecially when
the engine is hot. Scalding hot fluid and steam
may be blown out under pressure, which could
cause serious injury. When the engine has cooled,
place thick rag like a towel over the radiator cap,
slowly rotate the cap counterclockwise to the
detent. This procedure allows any residual
pressure to escape. When the hissing sound has
stopped, press down on the cap while turning
counterclockwise and remove it.
2-8
COOLING SYSTEM I':8f Iit I
6. Place an open container under the drain bolt
CD.
7.Remove:
• Drain bolt CD
Drain the coolant.
NOTE: -~~~~~~~~~-----
Lift up the tail of the machine to drain the coolant.
8. Disconnect:
• Reservoir tank hose CD
Drain the coolant.
NOTE: -~~~~~~~~~~---
Place a container under the reservoir tank to catch
the draining coolant.
A WARNING
Coolant is poisonous. It is harmful or fatal if
swallowed.
• If coolant is swallowed, induce vomiting
immediately. Get immediate medical
attention.
• H coolant splashes in eyes, flush with water.
Call a physician.
• H coolant splashes on skin or clothes, wash
immediately with soap and water.
9. Inspect:
• Gaskets (drain bolt)
Damage --+ Replace.
10. Install:
• Drain bolt (gaskets)
• Exhaust manifolds (gaskets)
Drain bolt:
25 Nm (2.5 m • kg, 18 ft • lb)
....._ ... Bolts (exhaust pipe):
9.5 Nm (0.95 m • kg, 6.9 ft • lb)
2-9
COOLING SYSTEM IIANDSJP I~ I ~
-----------------------------------------------------------
11. Fill:
• Cooling system
Recommended Coolant:
High quality ethylene glycol
anti-freeze containing
corrosion inhibitor
Coolant and water mixed ratio:
60%: 40%
Total amount:
4.2 L (3.7 Imp qt, 4.4 US qt)
Reservoir tank capacity:
0.20 L (0. 18 Imp qt, 0.21 US qt)
• Hard water or salt water is harmful to the

engine parts; use boiled or distilled water if you
can't get soft water.
• Do not use water containing impurities or oil.
12. Bleed air from the cooling system.
Air bleeding
1. Bleed air from the cooling system.
Air bleeding steps:

• Lift up the tail of the machine.
• Connect plastic tubes CD tightly to the bleed
screws ®on the heat exchanger.
• Loosen the bleed screws® of Heat ex-
changer.
• Keep the coolant running out until air bubbles
disappear, while adding coolan.t slowly to the
radiator.
• Tighten the bleed screws.
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft• lb)
• Add coolant to fill the specified level @.

• Loosen the bleed bolt @ on the water pump
housing.
• Keep the coolant running out until air bubbles
disappear.
• Tighten the bleed bolt.
Bleed bolt:
6 Nm (0.6 m •kg, 4.3 ft• lb)
2-10
ENGINE GEAR OIL 1
_ ':8f l~I _~ _
• Install the radiator cap.

Start the engine and keep the engine speed
3,000 rpm for one minute, then stop the en-
gine.
• Remove the radiator cap and bleed air on the
cooling system again, as shown in the steps
above.
No air bubbles - OK.
• Add coolant up to the specified level.
• Pour coolant into the reservoir tank until the
coolant level reaches "FULL" level mark @ .
ENGINE GEAR OIL

Oil level Inspection
2. Place a rag under the checking hole (oil level).
3.Remove:
• Oil filler cap CD
• 0-ring (oil filler cap)
• Checking bolt®
• Gasket (checking bolt)
4. Inspect:
• Oil level (drive gear housing)
Oil flows out - Oil level is correct.
Oil does not flow out - Oil level is low.
Add oil until oil flows out.
CD Checking bolt hole
Recommended oil:
Gear oil API GL-3 SAE #75
or #80 or SAE #10W-30
5. Inspect:
• Gasket (checking colt)
Damage - Replace.
6. Tighten:
Checking bolt:
10 Nm (1.0 m ·kg, 7.2 ft• lb)
2-11
CARBURETOR SYNCHRONIZATION 1i:gr 181
Oil replacement
1. Place a drain pan under the drain hole.
2.Remove:
• Drain bolt ®
• Gasket (drain bolt)
Drain the oil.
3. Inspect:
• Gasket (drain bolt)
Damage -+ Replace.
4. Install:
• Drain bolt ®(with gasket)
Drain bolt:
45 Nm (4.5 m • kg, 33 ft • lb)
5. Fill:
• Drive gear housing
Be sure no foreign material enters the chain

housing case.
Recommended oil:
or #80 or SAE #10W-30
Oil capacity:
250 cm 3 (8.8 Imp oz, 8.5 US oz)
6. Install:
• Oil filler cap (with 0-ring)
2-12
CARBURETOR SYNCHRONIZATION/ 1•NSP I ~ I
ENGINE IDLE SPEED ADJUSTMENT . ADJ _~ _
CARBURETOR SYNCHRONIZATION
1.Remove:
• Carburetor assembly
(see page 7-2)
2.Adjust:
• Carburetor synchronization
Adjustment steps:
• First, adjustthe throttle valve height@atthe
No. 2 carburetor CD by turning the throttle
stop screw ® until the specified height is
obtained.
Throttle valve height:

1.0 - 1.2 mm (0.04 - 0.047 in)
• Second, adjustthe throttle valve height@on

the No. 1@, No. 3©and No. 4@carburetors
with each adjusting screw® .
• Move the throttle lever (J) 2 - 3 times.
• Make sure all the carburetor throttle valves
are on the same height.
If not, repeat above steps until they all match.
ENGINE IDLE SPEED ADJUSTMENT
NOTE: --~~~~~~~~~~--
Be sure the carburetor synchronization (see page
2-13) has been set before making the idle speed
adjustment.
1. Adjust:
• Engine idle speed
Adjustment steps:
• Start the engine and let it warm up.
• Turn the throttle stop screw CD until the idle
speed is in the specified range. Use the in-
ductive tachometer.
2-13
ENGINE IDLE SPEED ADJUSTMENTI
THROTTLE CABLE ADJUSTMENTI
THROTTLE OVERRIDE SYSTEM (T.0.R.S.) CHECK .
I':8f I I ~
.~.
Turning in Idle speed becomes higher.

Turning out Idle speed becomes lower.
Jib Inductive tachometer:

90890-08036, YU-08036
~
Engine idle speed:
1,400 - 1,600 r/min
NOTE:
After adjusting the engine idle speed, the
throttle cable free play should be adjusted.
THROTTLE CABLE ADJUSTMENT
NOTE: -------------------------
Before adjusting the throttle cable free play, the
engine idle speed should be adjusted.
1. Measure:
• Throttle cable free play @
Out of specification --> Adjust.
Throttle cable free play:

1.0 - 2.0 mm (0.04 - 0.08 in)
2.Adjust:
• Throttle cable adjuster CD
THROTTLE OVERRIDE SYSTEM (T.O.R.S.)

CHECK
A WARNING
When checking T.O.R.S.:
• Be sure the parking brake is applied.
• Be sure the throttle lever moves smoothly.
• Do not run the engine up to clutch engagement
rpm. Otherwise, the machine could start
moving forward unexpectedly, which could
2-14------------------
cause an accident.
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK/
STARTER (CHOKE) CABL£ ADJUSTMENT/EXHAUST SYSTEM -
I'NADJs p 181
1. Start the engine.
2. Hold the pivot point of the throttle lever away
from the throttle switch CD .
3. Press ® the throttle lever gradually. The
T.O.R.S. warning light should flash and the
engine should not exceed 2,800to3,000 r.p.m.
If the engine exceeds 2,800 to 3,000 r.p.m.-+
Repair the T.O.R.S. (See page 8-9)
STARTER (CHOKE) CABLE ADJUSTMENT

1. Pull the outer tube of the starter cable CD
upward at the carburetor.
2. Measure:
• Starter cable free play@
Out of specification-+Adjust.
Free play@:
0.5 - 1.5 mm (0.02 - 0.06 in)
3.Adjust:
• Starter cable adjuster CD
EXHAUST SYSTEM
1. Inspect:
• Exhaust pipe gasket (s) CD
Damage-+Replace.
Exhaust gas leakage-+Repair.
Tighten the bolts.
• Joint pipe exhaust gas leakage®
Tension spring@ -+ Replace.
Bolt (exhaust pipe):

25 Nm (2.5 m•kg, 18 ft•lb)
2-15
ORM V-BELT I'r8f IQ I
POWER TRAIN
DRIVE V-BELT
A WARNING
Be sure the V-Belt height @ adjusted to the
standard height with a spacer CD when installing
a NEW belt.
H the height is incorrect, the clutch engagement
speed will be reduced.
The machine may move unexpectedly when the
engine is started.
1.Remove:
• Side cowling (left) (See page 2-3)
• Lock pin CD (drive V-belt guard)
• Drive V-belt guard®
NOTE: ~----------------------
Press the holding pin @ all the way in until it
releases from the hook ©, then rotate it 90' and
pull it out.
2.Remove:
• Drive V-belt CD
Removal steps:
• Rotate the secondary sliding sheave clockwise
®and push@ it so that it separates from the
fixed sheave.
• Pull © the belt up over the secondary fixed
·sheave.
• Remove the belt from the secondary sheave
and primary sheave.
2-16
DRIVE V-BELT I~8f I§l I
3. Inspect:
• Drive V-belt
Crack/Wear/Damage -+ Replace.
Oil or grease adhered to the V-belt-+ Check
the primary and secondary sheaves.
4. Measure:
® • Drive V-belt width
@ Out of specification -+ Replace.
NOTE: --~~~~~~~~~~~-
Be sure to measure the sheave offset, when
adjusted the V-belt.
New belt width @:

34.5 mm (1.36 in)
..,___.,. Belt wear limit width @ :
33 mm (1.30 in)
5. Measure:
• Drive V-belt length@
Drive V-belt length:

1,336 - 1,344 mm (52.6 - 52.9 in)
6. Inspect:
• Primary sheave
• Secondary sheave
Oil or grease adhered to the primary and
secondary sheaves -+ Remove the oil or
grease using a rag soaked in lacquer thinner
or solvent. Check the primary and secon-
dary sheaves.
805-009
7. Install:
• Drive V-belt
2-17
DRIVE V-BELT /ENGAGEMENT SPEED CHECK/ ~8f ~
BRAKE PAD INSPECTION/BRAKE ADJUSTMENT . .~.
I I I
8. Adjust:
• V-belt height @
Adjustment steps:
• Measure from edge of secondary sheave to V-
belt@.
• If out of specification, adjust the sheave gap
by adding or removing a spacer CD.
Adding spacer gap is increased
Removing spacer gap is decreased
V-belt height@:
2 - 3 mm (0.08 - 0.12 in)
2
Spacer size
1pc 0.5 mm (0.02 in)
Bolt®:
10 Nm (1.0 m •kg, 0.4 ft• lb)
ENGAGEMENT SPEED CHECK

1. Place the machine on a level area of hard
packed snow.
2.Check:
• Clutch engagement speed
Checking steps:
• Start the engine, and open the throttle lever
gradually.
• Check the engine speed when the machine
starts moving forward.
Out of specification--+Adjust the primary
sheave.(See page 2-37)
~
Engagement speed:
Approx 3,600 r/min
BRAKE PAD INSPECTION

1. Apply the brake lever.
2. Measure
• Brake pad thickness @
Out of specification -> Replace brake pad as
a set. (See page 4-23)
®
~
tr -.,
I
rAl Wear limit:
5.2 mm 10.20 in>
I
I CD Brake pad
I
I BRAKE ADJUSTMENT
I
I NOTE:------------
I
I Adjust brake every 40 hours of operation, or
I
--' whenever the brake kever becomes loose during
operation.
2-18
1. Measure:
• Distance "L"
Out of specification ---+ Adjust.
''L"
Distance uL"
69.0 - 73.0 mm (2.72 - 2.87 in)
2.Adjust:
• Distance "L"
Adjustment steps:
• Loosen the locknut CD .
•Turn the adjuster® in or out until the specified
distance is obtained.
Turning out Distance uL" is increased.
Turning in Distance uL" is decreased.
• Tighten the locknut CD.
DRIVE CHAIN
Oil Level Inspection
2.Remove:
3. Place a rag under the checking hole CD
(oil level).
4.Remove:
• Checking bolt ®
5. Inspect:
• Oil level (drive chain housing)
Oil flows out ---+ Oil level is correct.
Oil does not flow out ---+ Oil level is low.
Add oil until oil flows out.
Recommended oil:
or #80 or SAE #10W-30
6. Inspect:
Damage ---+ Replace.
7. Install:
• Checking bolt ®
Checking bolt:
6 Nm (0.6 m • kg, 4.3 ft• lb)
2-19
________________________o_R_1v_e_cH_A_1N_l~8f l§AI
Oil Replacement
1. Place a drain pan under the drain hole:
2.Remove:
• 0-ring ®(oil filler cap)
• Drain screw@
• Gasket ©(drain screw)
Drain the oil.
3. Inspect:
• 0-ring ®(oil filler cap)
• Gasket ©(drain screw)
Damage -+ Replace.
4. Install:
• Gasket (drain screw)
• Drain screw
Drain screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
5. Fill:
• Drive chain housing
Be sure no foreign material enters the chain

housing case.
Recommended oil:
or #80 or SAE #10W-30
Oil capacity:
3.5L (3.1 Imp qt, 3.6 US qt)
6. Install:
• Oil filler cap
Chain Slack Adjustment

1.Adjust:
• Drive chain slack
Adjustment steps:
• Loosen the locknut CD and unthread sealing
washer® slightly.
• Turn the adjuster@ in finger tight.
2-20
TRACK TENSION ADJUSTMENT
TRACK TENSION ADJUSTMENT
I~~f I•I
A WARNING
A broken track, track fittings, or debris thrown
by the track could be dangerous to an operator
or bystanders. Observe the following pre-
cautions.
• Do not allow anyone to stand behind the
machine when the engine is running.
• When the rear of the machine 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 track condition frequently. Replace
the track if it is damaged to the depth where
fabric reinforcement material is visible.
• Never install studs (cleats) closer than three
inches from the edge of the track.
1. Place the machine with the right side facing

down.
2. Measure:
• Track deflection CD
CD ...
®
Pull at the track center window by a force
of 10 kg (22 lb) using a spring scale®.
Out of specification--> Adjust.
820-003
Track deflection:
20 ~ 25 mm/10 kg
(0.79 ~ 0.98 in/22 lb)
3. Adjust:
• Track deflection
Adjustment steps:
• Lift the rear of the machine onto a suitable
stand to raise the track off the ground.
• Loosen the rear axle nut CD·
820-004
NOTE: ~~~~~~~~~~~-
It is not necessary to remove the cotter pin®.
a. Start the engine and rotate the track one or

two turns. Stop the engine.
b. Check the track alignment with the slide run-
ner@.
If the alignment is incorrect, turn the left and
right adjusters to adjust.
2-21
TRACK TENSION ADJUSTMENT I~8f I§It I
[Al Shifted ffil Shifted
Track alignment
to right to left
© Left adjuster nut Turn out Turn in
@ Right adjuster nut Turn in Turn out
® Slide runner (j) Track
@ Track metal @ Gap [g Forward
820-oos c. Adjust track deflection to the specified

------------------ amount.
A B More than Less than
Track deflection
Specified Specified
© Left adjuster nut Turn in Turn out
@ Right adjuster nut Turn in Turn out
The adjusters should be turned an equal

820-009 amount.
• Recheck alignment and deflection. If neces-

sary, repeat steps "a" to "c" until proper
adjustment is achieved.
•Tighten the rear axle nut.
Rear axle nut:

75 Nm (7 .5 m•kg, 54 ft-lb)
SLIDE RUNNER INSPECTION

~ ~ 1. Inspect:
• Slide runner CD
~
'--------~
Cracks/Damage/VIJear--+Replace.
2.Measure:
• Slide runner thickness @
820-001 Out of specification --> Replace.
(See page 4-30)
~ Wear limit:
10 mm (0.39 inl
2-22
SKI/SKI RUNNER ~gr ~
STEERING SYSTEM _ .~1. 1 1
CHASSIS
SKI/SKI RUNNER
1. Check:
• Ski CD
• Ski runner ®
•Ski cover@
Wear/Damage -> Replace.
Ski runner wear limit CD :

8 mm (0.31 in)
:111~•-•ll[f; ________
Do not operate the machine withoutthe ski cover
@to prevent the ski wear and damage.
STEERING SYSTEM
Free Play check
1.Check:
• Steering system free play
Push the handlebar up and down and back
and forth.
Turn the handlebar slightly to the right and
left.
Excessive free play->check to be sure the
handlebar, tie rod ends and relay rod ends
are installed securely in position. If free play
still exists, check the steering bearing front
suspension links and ski mounting area for
wear, and replace if necessary.
(See page 3-7)
Toe-Out Adjustment
2. Check:
• Ski toe-out
Direct the skis straightforward.
Out of specification ->Adjust.
Ski toe- out(@-@):

0.0 - 15.0 mm (0.0 - 0.6 in)
..,___ Ski stance (center to center) @ :
977 mm (38.5 in)
2-23
STEERING SYSTEM/LUBRICATION
~~~~~~~~~~~~~~~~~~~~~~~~~~~--
IIANDSJP I~ I ~
3.Adjust:
• Ski toe-out
Adjustment steps:
• Mark both tie-rod ends.
This reference point will be needed during
adjustment.
• Loosen the locknuts CD (tie-rod end) of both
tie-rods.
•The same number of turns should be given to
both tie-rods® right and left until the speci-
fied toe out is obtained, so that the leghts of
the rods will be kept the same.
• Tighten the rod end locknuts of both tie-rods.
locknut (rod end):

25 Nm (2.5 m · kg, 18 ft · lb)
A WARNING
Be sure that both tie-rods are turned the same
amount. H not, the machine will drift right or
left even though the handlebar is positioned
straight. This could lead to mishandling or an
accident.
A LUBRICATION
Front and Rear Suspension
1. lnjectgreasethrough nipplesCDusing a grease
gun.
~ Esso Beacon 325 Grease or

Aeroshell Grease #7 A.
[A] Front
ffil Rear
2-24
LUBRICATION/
HEADLIGHT AND METER LIGHT BULB REPLACEMENT
11 N s p
ADJ
IQ I
Brake Lever, Brake Cable End and
Throttle Lever
1. Lubricate the brake lever pivot, brake cable
end and throttle lever.
j--.1 Esso Beacon 325 G.......
A WARNING
Apply a dab of grease to the cable end only.
Do not grease the brake/throttle cables
themselves because they could become frozen,
which could cause loss of control.
ELECTRICAL
HEADLIGHT AND METER LIGHT BULB
REPLACEMENT
1. Disconnect:
• Speedometer cable CD
.\
• Meter coupler ®
• Condenser @
~!.·.·. " (for fuel meter system)
• Headlight coupler ©
2.Remove:
• Nuts CD (meter assembly)
• Nuts® (meter stay)
Separate the meter and meter stay.
• Meter assembly
• Meter stay
3.Remove:
• Bulb (defective)
Pull out the bulb holder CD from the meter
case and pull out the bulb from bulb holder.
4. Install:
• Bulb (new)
2-25
HEADLIGHT AND METER LIGHT BULB REPLACEMENT I~8f I§111
--.'
ifllll') 5.Remove:
• Bulb cover CD
6. Unhook:
• Bulb holder ®
7.Remove:
• Bulb (defective) @
A WARNING
Keep flammable products (and your hands) away
from the bulb while it is on; it will be hot. Do not
touch the bulb until it cools down.
8. Install:
• Bulb (new) CD
NOTE: ~----------------------~
Make sure the projections @ on the bulb are
meshed with the slots @ on the light case.
Avoid touching the glass part of the bulb. Keep it

free from oil; otherwise, the transparency of the
glass, life of the bulb and illuminous flux will be
adversely affected. If oil gets on the bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
9. Hook:
• Bulb holder CD
10. Install:
• Cover (bulb holder) ®
NOTE: ----------------------~
Install the bulb holder cover so that the "TOP"
mark@ faces upward.
2-26
HEADLIGHT BEAM ADJUSTMENT/
TAIL/BRAKE LIGHT BULB REPLACEMENT
IINSP
ADJ
I~
~
I
HEADLIGHT BEAM ADJUSTMENT
1. Place the machine on a level place.
2. Inspect:
~
• Headlight beam direction (vertically)
The high beam should be directed down-
H .. ward at an angle of 1/2° to the horizontal
line. If not, adjust the direction (vertically).
L 3.0 m (10 ft) 7.6 m (25 ft)

H 26 mm (1.0 in) 66 mm (2.6 in)
3.Adjust:
• Headlight beam (vertically)
Vertical adjustment
Higher
Turn the adjusting screw CD counter
clockwise.
Lower Turn the adjusting screw CD clockwise.
4.Adjust:
• Headlight beam (horizontally)
Horizontal adjustment
Right
Turn adjusting screw ® counter
clockwise.
Left Turn adjusting screw ® clockwise.
2-27
CARBURETOR TUNING IIANDSJP I~ I ~
-----------------------------------------------------------
TUNING
CARBURETOR TUNING
The carburetor is set at the factory to run at
temperatures of 0°C - -20°C (32°F - -4°F) at
sea level. If the machine has to be operated
under conditions other than specified above, the
carburetor must be reset as required. Special
care should be taken in carburetor setting so
that the piston will not be damaged or seized.
In this model, the engine oil is mixed with the

fuel just before the fuel enters the carburetors.
During initial fuel flow to the carburetor it is not
always possible to supply the optimum fuel/oil
mixture depending on the throttle
opening.Therefore, after the carburetors have
been tuned or maintained, or after the float
chamber is removed for cleaning or jet
replacement, be sure to idle the engine for about
three minutes in order to avoid engine trouble.
Before performing the carburetor tuning, make

sure that the following items are set to
specification.
• Engine Idle speed adjustment
• Throttle cable free play adjustment
• Carburetor synchronization
• Starter cable adjustment
• Oil pump cable free play adjustment
Carburetor Tuning Data

1. Standard specifications
Model TM33 x4
Manufacturer MIKUNI
l.D. Mark 8AX-OO
Main jet (M.J.) #135
Jet needle
6GN14-3
(J.N.l
11.3 - 15.3 mm
Float height
(0.44 - o.60 in)
Idle speed 1,400 - 1,600 r/min
2-28
CARBURETOR TUNING
2. High altitude tuning
I':8f I"' I
Use the following guide to select main jets
according to variations in elevation and tem-
perature.
:::::::::
e
0 - 100 m
(300 ft)
-30'C
(-22'F)
I
#140
-
-20'C
(-4'F)
-
I
-10'C
(14°F)
#137.5
I
-
o·c
(32'Fl
I
1o·c
(50'Fl
I
#135
2o·c
(68°Fl
I
100 - 600 m - #135 -

(2,000 ft) #137.5 - #132.5
600-1,200 m c.::: #132.5 -

(4,000 ft) #135 - #131.3
1,200 - 1,800 m - #131.3 -

(6,000 ft) #132.5 - #130, PJ:50
1,800 - 2,400 m #130, PJ:50 -

(8,000 ft) #131.3 :::. - #128.8, PJ:50
2,400 mm - - #128.8, PJ:SO -

(8,000 ft-) -#130, PJ:50--.. - #127.5, PJ:SO
NOTE: ~~~~~~----~~~~~
These jetting specifications are subjectto change.
Consult the latest technical information from
Yamaha to be sure you have the most up-to-date
jetting specifications.
<D Clip
®Jet needle
@ Pilot screw
©Main jet
2-29
CARBURETOR TUNING I~8f IQI
Guide for carburetion
0
[Al Throttle valve opening
[6] Mid-range speed tuning

[QJ High speed tuning
Q)
®
[El Low speed tuning @
©
@
...
...
..c
.....
~Closed 1/8 1/4 1/2 3/4 [Q] Full open

[Al Throttle valve opening
2-30
CARBURETOR TUNING _ 1 ~8f lftl
_ _ ~
A: Standard main jet

B: Main jet whose diameter is 10% smaller than standard
C: Main jet whose diameter is 100.k larger than standard
1/2 3/4 ©Full open

[6J Throttle opning
A: No. 3 position
-GI
...
<II
3:0
B: No. 2 position
C: No. 4 position
I;:
Ci
~
CD
=cCD
-
GI
c: [EJ Clip
CD
[f]Jet needle
-,
IQ]
1/8 1/2 3/4 ©Full open
[6J Throttle opening
If the air intake silencer is removed from the

carburetors, the change in pressure in the intake
will create a LEAN MIXTURE that could likely
result in severe engine damage. The air intake air
silencer has no effect on performance
characteristics and it must be secured to the
carburetor during carb tuning and adjustment
and it must always be in place when the engine is
operated. Examine the air intake silencer
regularly for cleanliness and freedom from
obstruction.
2-31
CARBURETOR TUNING
Low Speed Tuning
I~5f I§l I
The carburetor is built so that low speed tuning
can be done by adjusting the throttle stop screw
CD.
The engine should never be run without the air

intake silencer and air chamber installed; severe
engine damage may result.
1. Start the engine, and allow it to warm up for a

few minutes. The warm-up is complete when
the engine responds normally to the throttle
opening.
A WARNING
Do not move the throttle enough to reach the
following engine speed. The snowmobile could
accidentally start to move forward.
Engine revolutions: 3,300 r/min
2. Settheengine idle speed bytuningthethrottle

stop screws in (to increase engine speed) or
out (to decrease engine speed).
Standard idle speed:

1,400 - 1,600 r/min
3. If the engine low speed performance is still

poor in high elevation under extreme condi-
tions, the standard piliot jets may need to be
replaced to obtain proper pilot air/fuel mix-
ture.
NOTE: ~~~~~~~~~~~~
In this case, set the carburetor on the richer side;
use a larger number pilot jet Ci).
Standard pilot jet: #47.5
4. By repeating steps 1 to 2 above, adjust the

idle speed.
2-32
CARBURETOR TUNING I~8f Iffl I
Middle-Range and High Speed Tuning
No adjustment is normally required, but adjust-
ment is sometimes necessary depending on
temperatures and/or altitude.
Middle-range speed and high speed tuning (from
1/4 to full-throttle) can be done by adjusting the
main jet.
The engine should never be run without the air

intake silencer and air chamber installed; severe
engine damage may result.
1. Start the engine and run it at high speed

to make sure the engine operates smoothly.
2. Stop the engine, and remove the spark plug.
Then, check the spark plug insulator CD color.
3. The main jet should be adjusted on the basis of
the following chart.
Standard main jet: #135
A WARNING
Never remove the main jet cover while the engine
is hot. Fuel will flow out of the float chamber
which could ignite and cause damage to the
snowmobile and possible injury to the mechanic.
Place a rag under the carburetor so fuel does not
spread. Place the main jet cover in a clean place.
Keep it away from fire. After assembling the
carburetor, firmly tighten the intake silencer joint
clamps and intake manifold clamps. Make sure
the throttle cable is in place, and the throttle
operates smoothly.
2-33
CARBURETOR TUNING I~8f I§l I
Main jet selection chart
Spark plug color Check up Remedy
Light tan or gray. Carburetor is tuned properly.
Dry black or fluffy
Mixture is too rich. Replace main jet with a one-step smaller one.
deposits.
White or light gray. Mixture is too lean. Replace main jet with a one-step larger one.
White or gray insulator
with small black or gray Replace the piston and spark plug.
brown spots and with a Due to too lean a mixture,
Tune the carburetor again, starting with low-
bluish-burnt appearance piston is damaged or seized.
speed tuning.
of electrodes.
Melted electrodes and Check the piston for holes or seizure.
possibly blistered Check the cooling system, gasoline octane rating
insulator. Due to too lean a mixture, the and ignition timing. After replacing the spark plug
Metallic deposits on spark plug melts. with colder type, tune the carburetor again starting
insulator. with low-speed tuning.
2-34
Troubleshooting
CARBURETOR TUNING I':8f I§l I
Trouble Check point Remedy Adjustment
Hard starting Insufficient fuel Add gasoline
Excessive use of starter Clean spark plug Return starter level to its
(Excessively opened seated position.
choke)
Fuel passage is clogged Clean Parts other than carburetor.
or frozen • Clogged fuel tank air vent,
clogged fuel filter, or
clogged fuel passage
Carburetor
• Clogged or frozen air vent
clogged valve.
• If water collects in float
chamber, clean.
(Also check for ice)
Overflow Correct
Poor idling Improper idling speed Adjust throttle stop screw so
adjustment the engine idles at specified
(Related symptoms) speed.
• Poor performance • Throttle stop screw Adjust idling speed Tightened too much - Engine
at low speeds speed is higher.
• Poor acceleration Backed out too much -
• Slow response to Engine does not idle.
throttle Clean
Clogged bypass hole
• Engine tends to
stall Clogged or loose pilot Clean and retighten Remove pilot jet, and blow it
jet out with compressed air.
Air leaking into carbure- Retighten clamp
tor joint screws
Defective starter valve Clean or replace
seat
Overflow Correct
Poor performance at Clogged or loose pilot Clean and retighten Remove pilot jet, and blow it
mid-range speeds jet out with compressed air.
(Related symptoms)
• Momentary slow
response to throttle
• Poor acceleration Lean mixtures Overhaul carburetor
Poor performance at Clogged air vent Clean Remove the air vent pipe, and
normal speeds clean.
(Related symptoms) Clogged or loose main Clean and retighten Remove main jet, and blow it
• Excess fuel con- jet out with compressed air.
sumption
Overflow Check float and float
• Poor acceleration
valve and clean
2-35
CARBURETOR TUNING 1
_ ':8f lftl _~ _
Trouble Check point Remedy Adjustment

Poor performance at Starter valve is left Fully close valve Return starter lever to its
high speeds open home position.
(Related symptoms) Clogged air vent Remove and clean
•Power loss
• Poor acceleration Clogged or loose main Clean and retighten Remove main jet, and clean
jet with compressed air, then
install.
Clogged fuel pipe Clean or replace
Dirty fuel tank Clean fuel tank
Air leaking into fuel Check joint and re-
line tighten
Low fuel pump per- Repair pump or re-
formance place
Clogged fuel filter Replace
Clogged intake Check for ice, and
remove
Abnormal combus- Lean mixtures Clean carburetor
ti on and adjust
(Mainly backfire) Dirty carburetor Clean carburetor
Dirty or clogged fuel Clean or replace fuel
pipe pipe
Overflow Clogged air vent Clean
(Related symptoms) Clogged float valve Disassemble and Clean while taking care not to
• Poor idling clean scratch valve seat.
• Poor performance
at low, mid-range, Scratched or unevenly Clean or replace float Replace if seat is damaged.
and high speeds worn float valve or valve and valve seat
• Excessive fuel con- valve seat
sumption Broken float Replace float
• Hard starting If not within the
Incorrect float level
•Power loss range,
specified
• Poor acceleration check the following
parts and replace
any defective part.
• Worn float tang • Replace float Replace float assembly.
•Worn pin • Replace arm pin
• Deformed float arm • Replace float
2-36
_________________________c_L_ur_c_H_r_u_N_•N~Gl':8fl~I
CLUTCH TUNING
Clutch Setting Data (VX750)

0-900m 750 - 1,700 m 1,500 - 2,500 m 2,100 m -
!Al Item 3,000 ft/900 m 2,500 ft - 5,500 ft 5,000 ft - 8,000 ft 7,000ft -
!STD) (MA) IMAl (HA)
[ID Idle speed: Approx. 1,500rpm f- f- f-
[9 Clutch engagement: Approx. 3,300rpm f- f- f-
IQ! Shift speed: Approx. 8,250rpm f- f- f-
[ID Gearing: 22/35 f- 20/35 20/37

[El Primary spring:
[§] Color Y-P-Y f- y P-Y-P
!Bl Length 77.4mm f- 75.4mm 73.3mm
ffi Pre-load rate 30.0 kg-2.5 kg/mm f- 25.0-2.5 25.0-3.0
Q] Wire dia. 1115.8mm f- 1115.8mm 1116.0mm
[fil Outside dia. 11160mm f- f- f-
[]Weight: 89A-10 f- f- f-
10 Weight rivet:(OUT) Lead 14.0mm Steel 10.3mm Steel 10.3mm f-

(IN) Steel 13.3mm Steel 10.3mm None f-
[fil Weight bush: Dura Ion f- f- f-
[Q] Roller outter dia.: 11116.5mm f- f- f-
[El Roller bush: Dural on f- f- f-
[QJ Pri. clutch shim: None f- f- f-
IBl Secondary spring:

[§] Color P-W f- f- f-
!Bl Length 100mm f- f- f-
ffi Pre-load rate 33° IA-3) 53° (C-3) f- f-
782 kgmm/rad f- f- f-
Q] Wire dia. 1115.5mm f- f- f-
[fil Outer dia. 11169.5mm f- f- f-
(§] Sec. torque cam: 39° f- f- 36°

(I] Sec. clutch shim: 1.0mm x 1 pc f- f- f-
Y ............... Yellow
W .............. White
G ............... Green
P ................ Pink
2-37
CLUTCH TUNING
Clutch Setting Data (VX750ST)

0 - 900 m 750 - 1,700 m 1,500 - 2,500 m 2,100m-
[A1 Item 3,000 ft/900 m 2,500 ft - 5,500 ft 5,000 ft - 8,000 ft 7,000 ft -
~ Idle speed: Approx. 1,500rpm +-- +-- +--
~ Clutch engagement: Approx. 3,300rpm +-- +-- +--
[Qi Shift speed: Approx. 8,250rpm +-- +-- +--
!Il Gearing: 22/37 (70L) +-- 21/39 (70L) 20/39 (70L)
[F] Primary spring:
~Color W-P-W +-- W-Y-W G-Y-G
[BJ Length 78.7mm +-- 76.5mm 74.1mm
[i] Pre-I oad rate 30.0 kg-2.25 kg/mm +-- 25.0-2.25 25.0-2.75
QJ Wire dia. 9J5.5mm +-- +-- 9)5.8mm
!Kl Outside dia. 060mm +-- +-- +--
[I] Weight: 89A-10 +-- +-- +--
!Mi Weight rivet:(OUT) Lead 14.0mm Steel 10.3mm Steel 10.3mm +--
(IN) Steel 13.3mm Steel 10.3mm None +--
ffil Weight bush: Duralon +-- +-- +--
[91 Roller outter dia.: 016.5mm +-- +-- +--
[fl Roller bush: Dural on +-- +-- +--
lQ! Pri. clutch shim: None +-- +-- +--
031 Secondary spring:
[GJ Color P-W +-- +-- +--
[8] Length 100mm +-- +-- +--
IJJ Pre-load rate 33° (A-3) 53° (C-3) +-- +--
782 kgmm/rad +-- +-- +--
Q] Wire dia. 9J5.5mm +-- +-- +--
!Kl Outer dia. 069.5mm +-- +-- +--
~ Sec. torque cam: 39° +-- +-- 36°
IIJ Sec. clutch shim: 1.0mm x 1 pc +-- +-- +--
Y ............... Yellow
W .............. White
G ............... Green
P ................ Pink
2-38
GEARING SELECTION I~gf Ifit I
GEARING SELECTION
G) Socondary reduction
~Parts name [§] Teeth&Links 1£] Parts No.

20T 8AX-17682-00
21T 8AX-17682-10
[QJ Drive sprocket 22T(STD) 8AX-17682-20
23T 8AX-17682-30
24T 8AX-17682-40
33T 8AX-47587-30
35T(STD) 8AX-47587-50
WDriven sprocket 8AX-47587-70
37T*
39T 8AX-47587-90
66 94880-08066
[£]Chain (links) 68(STD) 94880-08068
70* 94880-08070
* For VX750ST (STD)
~ r
33T
20T
1.650
21T
x
22T
x
23T
1.435
24T
1.375
66l 68l 68l
1.750 1.667 1.591 1.458
35T
68l 68L 68L(STD)
x 70l
1.850 1.682 1.609 1.542
37T
68l
x 70l* 70l 70l
1.950 1.857 1.773
39T
70L 70l 70L
x x
® Socondary spring
Q] Spring rate [Ml Wire gauge llil Free length
[O Parts No. [Kl No. of coils [b] Color
(kg mm/rad) (mm) (mm)
90508-533 A 1 938 5.0 R 5.5 90.0
90508-551A3 (STD) 782 6.0 P-W 5.5 100.0
90508-553 A 0 670 7.0 y 5.5 110.0
R .................. Red
P .................. Pink
W ................. White
Y .................. Yellow
2-39
~Torque cam (Secondary spring seat)
GEARING SELECTION I':8f I§It I
[ID Parts No. [£] Cam angle
8AX-17684-90 (STD) 39•
8AX-17684-00 38°
8AX-17684-60 36°
8AX-17684-30 33•
S .............. Silver
8AX-17684-R 0 42-37°
L .............. Blue
[Q] Secondary spring twist angle Go ........... Gold
fE] Seat 1 2 3 4 Y .............. Yellow
[fl Sheave
A 93• 3• 33°(STD) 63' P .............. Pink
R .............. Red
B 103' 13' 43' 73'
W ............ White
c 113' 23' 53• 83'
G ............. Green
[§] Primary spring
ITJ Spring [lJ Wire [Ml Outside [QJ Free
QJ Preload [HJ No. of
[8] Parts No. rate [KJ Color gauge diameter length
(kg) coils
(kg/mm) (mm) (mm) (mm)
90501-481 J 1 1.0 20.0 S-L-S 4.8 60.0 5.16 85.4
90501-487 G 8 1.5 15.0 Go 4.8 60.0 4.19 75.4
90501-507 G 2 1.5 20.0 Go-L-Go 5.0 60.0 4.61 78.7
90501-524 G 5 1.5 25.0 Go-Y-Go 5.2 60.0 5.08 82.1
90501-501 G 7 1.5 25.0 Go-Y-Go 5.0 59.0 4.65 81.7
90501-521 J 6 1.5 30.0 Go-P-Go 5.2 60.0 5.09 85.4
90501-507 G 7 1.75 15.0 R-Go-R 5.0 60.0 4.24 74.0
90501-527 G 1 1.75 20.0 R-L-R 5.2 60.0 4.65 76.8
90501-524 G 4 1.75 25.0 R-Y-R 5.2 60.0 4.64 79.7
90501-526 G 4 2.0 15.0 L-Go-L 5.2 60.0 4.32 72.9
90501-556 G 6 2.0 20.0 L 5.5 60.0 4.95 75.4
90501-553 GO 2.0 25.0 L-Y-L 5.5 60.0 5.10 78.0
90501-557 G 6 2.25 15.0 W-Go-W 5.5 60.0 4.62 72.1
90501-556 G 5 2.25 20.0 W-L-W 5.5 60.0 4.62 74.3
90501-553 G 6 2.25 25.0 W-Y-W 5.5 60.0 4.61 76.5
90501-550 J 8 2.25 30.0 W-P-W 5.5 60.0 4.62 78.7
90501-557 G 5 2.5 15.0 Y-Go-Y 5.5 60.0 4.36 71.4
90501-556 G 7 2.5 20.0 Y-L-Y 5.5 60.0 4.36 73.4
90501-584 G 2 2.5 24.0 y 5.8 60.0 4.95 75.0
90501-555 G 8 2.46 24.0 y 5.5 60.0 4.43 75.2
90501-581 J 7 2.5 25.0 y 5.8 60.0 4.96 75.4
90501-582 J 1 2.5 30.0 Y-P-Y 5.8 60.0 4.96 77.4
90501-607 G 4 2.75 15.0 G-Go-G 6.0 60.0 5.12 70.9
90501-607 G 0 2.75 20.0 G-L-G 6.0 60.0 5.12 72.7
90501-584 G 1 2.75 24.0 G-Y-G 5.8 60.0 4.70 74.1
90501-605 G 7 2.75 25.0 G-Y-G 6.0 60.0 5.00 74.1
90501-607 G 3 3.0 15.0 P-Go-P 6.0 60.0 4.86 70.4
90501-606 G 9 3.0 20.0 P-L-P 6.0 60.0 4.86 72.1
90501-604 G 0 3.0 24.0 P-Y-P 6.0 60.0 4.80 73.3
90501-602 J 0 3.0 30.0 p 6.0 60.0 4.74 75.4
2-40
SLIDE RAIL SUSPENSION TUNING I':8f I• I
SUSPENSION
Front suspension
1. Adjust:
• Damping force
Adjustment steps:
• Remove the cover CD .
•Turn the adjuster ® in or out to adjust the
damping force.
19 clicks 10 clicks 5 clicks

out out out 0
Adjuster
Position STD
Turns out...,__ - - . . Turns in
Damping Almost same ~

___.,..
force as 10 clicks out Softer Stiffer
11\&tm\t.
Be sure the left and right damper adjuster is
same position.
• Reinstall the cover.
I~
Nut (ski):
45 Nm (4.5 m • kg , 32.5 ft • lb)
A Rear Suspension
Stopper band setting
1.Adjust:
• Stopper band length
NOTE:-------------------------
This adjustment will affect the stability and
maneuverability of the machine.
Adjustment steps.
• Remove the stopper band CD securing bolt®
and washers.
• Adjust the length of stopper band .
Standard Setting:
Front (A] : No. 3 hole
Rear [§] : No. 1 hole
2-41
SLIDE RAIL SUSPENSION TUNING 1~gr 1 a 1
Front [Al;
Performance Performance
Hole Maneu-
verability of straight of starting
No.
running acceleration
No.1 Less Less Less
I l I
No. 4 Better Better
I
Better
Rear ml;
Hole No. Riding comfort Stability

No. 1 Better Less
I
No.5
I
Less
I
Better
• Tighen the bolt (stopper band).
'~ Nut (stopper band):

4 Nm (0.4 m • kg, 2.9 ft • lbi
Spring Preload
1.Adjust:
• Spring preload
Adjustment steps:
• Turn the spring seat CD in or out.
Spring Seat Standard

B -------- Distance Longer H Shorter
Preload Harder H Softer
@Distance Max. Min.

85.5mm 77.5mm 70.5mm
(front) (3.37 in) (3.05 in) (2.78 in)
@Distance Max. Min.

85mm 77mm 69mm
(Rear)
(3.35 in) (3.03 in) (2.72 in)
[Al Front
ml Rear
A 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
open flame or high heat, which could cause itto
explode.
2-42-----------------
ENGINE ROOM PLATES I':8f Iffil I
2.Adjust:
• Pivot arm setting
~ Performance
Position of starting Maneuverbility
acceleration*1
@(STD) Fair Better
@ Better Less
~
Position Riding comfort
@(STD) Soft
@*2 Hard
* 1: This is due to change of weight transfer on the

track.
*2: When the@ position is selected, the stopper
bands should be at No. 1 position in order to
maintain R/R suspenssion at standard height.
[Al Front
rnJ Rear
ENGINE ROOM PLATES

Open the plates to cool down the engine room.
• Close the plates CD and attach the louver

plates ® when the machine is operated in
deep powder snow.
• Remove the louver plates ® when the
atmospheric temperature is s·c (41.5°F) or
higher.
2-43
HIGH ALTITUDE TUNING I~8f I• I
HIGH ALTITUDE TUNING
To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined
below.
Confirm STD. settings

• Carburetor (Page 2-28)
• Spark plug (Page 2-3)
Adjust main jet size according to the

chart (Page 2-29)
Test main jet size

(Performance & plug color)
Not OK Adjust main jet size
OK
Re-test
t
..~~--~~~~~~~-.-~~--~·1----------___.o~
Tes: low speed setting :.. · - _________~
Not_o_K
I
Not OK OK----------1~ Check to see if gearing is too high or low - - - - .
OK Not OK
Try high altitude settings
Not OK OK
Adjust gearing as required
(Page 2-39)
Decide if problem is pilot jet
and adjust accordingly Not OK OK
Not OK OK Check engagement and shift

speed performance
Not OK OK-----11-t High altitude

tuning OK
Adjust primary clutch as re-

OK
quired (Page 2-37)
Not OK Not OK
Adjust secondary clutch as required

OK
(Page 2-37)
2-44
CHAPTER3.
CHASSIS
STEERING ......................................................... 3-1

REMOVAL ................................................... 3-2
INSPECTION ............................................... 3-4
INSTALLATION ........................................... 3-5
SKI ...................................................................... 3-8

REMOVAL ................................................... 3-9
INSPECTION ............................................... 3-9
INSTALLATION ........................................... 3-9
FRONT SUSPENSION ................................... 3-11

REMOVAL ................................................. 3-12
INSPECTION ............................................. 3-14
INSTALLATION ......................................... 3-15
______________ ..:s:.:TE::E~R::IN:::.,G lcHAsjJ I
CHASSIS
STEERING
CD Handlebar
® Steering column
@Bearing
© Bearing holder
® Lock washer
@Relay rod
(j) Tie-rod
15 Nm (1.5 m •kg, 11 ft• lb)

I21 Nm (2.7 m •kg, 20 ft• lb) I
A USE NEW ONE
43 Nm (4.3 m • kg, 31 ft• lb)
27 Nm (2.7 m •kg, 20 ft• lb)
A USE NEW ONE
25 Nm (2.5 m •kg, 18 ft• lb)
3-1
STEERING lcHAsl..#
REMOVAL
1.Remove:
• Handlebar cover CD
2. Disconnect:
• Handlebar switch coupler (right)
• Brake light switch coupler
• Headlight beam switch coupler
• Grip warmer leads
3.Remove:
• Holder CD (throttle cable)
4. Disconnect:
• Throttle cable@
• Oil pump cable ®
(from throttle lever)
5.Remove:
• Brake cable
Removal steps:
• Loosen the locknut CD .
• Turn in the adjuster fully ® .
• Disconnect the brake cable end ® from the
brake lever.
6.Remove:
•Band
• Handlebar holders CD (upper)
• Handlebar®
3-2
_______________sT_E_E_R_•N_G lcHAS~ I
7.Remove:
•Seat
• Center cover CD
NOTE: ~---------------------
Remove the holding nuts (main switch,
USTARTER" lever, and disconnect the grip
warmer switch coupler when removing the center
cover.
8.Remove:
• Intake silencer (See page 2-11)
• Carburetors (See page 7-3)
• Engine assembly (See page 5-1)
9.Remove:
• Cotter pin CD
• Nut (relay rod)
NOTE: ~~~~~~~~~~~~-
When removing the relay rod from the steering
column, the relay rod end needs to be held fixed
in order to facilitate the lock nut removal.
10. Straighten:
• Lock washer tabs (upper and lower)
11.Remove:
• Nuts CD
•Bolts®
• Lock washers
• Bearing holders @
• Bearings ©(upper)
• Collars
• Steering column @
• Bearings® (lower)
3-3
sTEERING lcHAsjJ I
12. Remove:
• Cotter pins <D
•Bolts®
• Washers @ (suspension arm side)
13. Remove:
• Cotter pin <D
•Bolt
•Relay rod®
•Tie rods@
14. Remove:
• Cotter pin <D
•Nut@
•Washer
•Relay arm@
... ···=
INSPECTION
1. Inspect:
• Handlebar <D
• Steering column ®
Bends/Cracks/Damage --> Replace.
A WARNING
~. IL. Do not attempt to straighten a bent column.
This may dangerously weaken the column.
2. Inspect:
• Bearings <D (steering column)
• Collars®
Wear/Damage --> Replace.
• Steering column @ (bearing contact
surfaces)
Scratches/Wear/Damage --> Replace.
3-4
_______________sT_e_e_R_1N_G lcHASI..# I
3. Inspect:
• Relay rod CD
•Tie-rods®
Bends/Cracks/Damage_,. Replace.
A WARNING
Do not attempt to straighten a bent rod .
........................ This may dangerously weaken the rod.
4.Check:
• Rod end movement
Rod end free play exists _,. Replace.
Rod end turns roughly _,. Replace.
5. Inspect:
• Relay arm
Cracks/Damage _,. Replace.
INSTALLATION
1. Install:
• Relay arm CD
•Tie rod®
•Relay rod@
NOTE:------------------------
• Be sure that the rod-end of the tie rod and relay
rod on the identation@side is connected to the
.. ?; ~ •
GiP
relay arm.
•The threads on both rod-ends must be the
same length.
. : ts!. .
0 •
Always use a new cotter pin .
3-5
STEERING lcHAsjd I
Lock nut (rod-end):
25 Nm (2.5 m • kg, 18 ft • lb)
LOCTITE®
Nut (tie rod/relay rod):
25 Nm (2.5 m •kg, 18 ft• lb)
2.Apply
(to bearing inner surface)
3. Tighten:
Nut (bearing holder):

27 Nm (2.7 m • kg, 20 ft • lb)
Bolt (bearing holder):
27 Nm (2.7 m • kg, 20 ft • lb)
Nut (relay rod):
43 Nm (4.3 m • kg, 31 ft • lb)
Always use a new lock washer and cotter pin.
NOTE:----------------------~
Bend the lock washer tab along the bolts and nuts
flats.
4.Adjust:
•skis
Adjustment steps:
• Temporarily install the handlebar.
0
• Hold the handlebar straight, and check to see
that the skis are at right angles to the handle-
bar.
• Loosen the locknuts (relay rod) CD.
• Direct the skis in parallel to the moving di rec-
ti on.
• With the skis thus, turn the relay rod® either
way to adjust the handlebars at right angles
@
with respect to the direction of movement.
Turning the relay The handlebars move

rod in direction @ in direction ©
Turning the relay The handlebars move
rod in direction @ in direction @
3-6
STEERING lcHAsld I
• Tighten the locknuts (relay rod) CD .
Locknut (relay rod):
25 Nm (2.5 m • kg, 18 ft • lb)
LOCTITE®
5.Tighten:
Handlebar holder bolt:

15 Nm (1.5 m •kg, 11 ft• lb)
NOTE: -------------------------
•The upper handlebar holder should be installed
with the punch mark CD forward.
• Tighten the bolts to specification so that the
"a"< "b" front clearance "a" is smaller than rear
clearance "b".
First tighten the bolts on the front side of the

handlbar holder, and then tighten the bolts
on the rear side.
6.Adjust:
• Brake lever free play (See page 2-9)
3-7
SKl~HASjJ
SKI
CD Collar
® Ski stopper
@Ski
©Ski runner
@Ski cover
Recommended grease:
ESSO Beacon 325 grease or
Aeroshell grease #7 A
A Fit the stopper with its raised

portion positioned in front.
CID- -(i<1Illii:::::lii:1• ©@
®
,)
D USE NEW ONE
21 Nm (2.1 m • kg, 15 ft• lb)
43 Nm (4.3 m • kg, 31 ft• lb)
Be careful not to reverse the mounting SKI DISTANCE:

positions of the left and right ski assembly. C 977 mm (38.8 in)
SKI TOE-OUT
0.0 - 15 mm (0.0 - 0.6 in)
3-8
REMOVAL
1. Elevate the ski by placing a suitable stand
under the chassis.
2.Remove:
• Cotter pin CD
•Ski@
• Dust covers @
• Collar
3.Remove:
• Ski stopper CD
• Ski runner
INSPECTION
1. Inspect:
• Ski CD
• Ski runner ®
• Ski cover @ (See page 2-23)
• Ski stopper ©
Wear/Cracks/Damage --> Replace.
• Mounting bolt @
• Collar®
• Spacer (j)
INSTALLATION
1. Tighten:
Ski runner nut:

21 Nm (2.1 m •kg, 15 ft• lb)
3-9
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _s_K_1 jcHAsjJ I
2. Install:
• Ski stopper
NOTE: -------------------------
• Fitthe stopper with its arrow mark@positioned
in front.
•Be careful not to reverse the mounting
positions of the left and right ski assemblies.
3.Tighten:
Mounting nut:
43 Nm (4.3 m • kg, 31 ft • lb)
NOTE: -------------------------
Lubricate the collar, dust cover and mounting bolt
before installing the ski.
Recommended grease:
Aeroshell grease #7A
3-10
FRONT susPENs10N lcHASl..:f I
FRONT SUSPENSION
CD Absorber holder @ Suspension bracket
® Spring seat (upper) ®Front arm (upper)
@Dumper ® Front arm (lower)
@Spring @ Stabilizer rod
@Spring seat (lower) @ Stabilizer slider
® Shock absorber
(j) Suspension arm
Recommended grease:
Aeroshell. grease #7 A
16 Nm
(1.6 m •kg, 11 ft• lb)
43 Nm (4.3 m • kg, 31 ft• lb)
10 Nm (1.0 m •kg, 7.2 ft• lb)

21 Nm (2.1m•kg,15ft• lb)
21 Nm (2.1 m • kg, 15 ft• lb) 5Nm

(0.5 m • kg, 3.6 ft • lb)
3-11
FRONT SUSPENSION lcHASI..# I
REMOVAL
1.Remove:
• Side cowlings (left and right) (See page 2-1)
• Radiator assembly CD (See page 6-3)
• Reservoir tank ®
(from tie bar@)
NOTE: -------------------------
Do not disconnect the hoses.
2.Remove:
•Tie bar CD
3.Remove:
• Hoods CD
NOTE:------------------------
When removing the hood, the nuts® may fall off.
Be careful not to lose these parts.
4.Remove:
• Ski (See page 3-9)
5.Remove:
• Cotter pin CD
•Tie-rod®
[Al Left
~ Right
6.Remove:
• Cotter pins CD
• Front arm ®(upper)
• Front arm @ (lower)
•Washers©
• Thrust washers@
•Collars®
3-12
FRONT susPENs10N lcHAS~ I
7.Remove:
• Cap CD (suspension)
• Protector®
8.Remove:
• Absorber holder CD
9.Remove:
• Spacer collar CD
• Flange plate ®
• Spring seat @(upper)
• Bump rubber ©
•Spring@
• Spring seat ®(lower)
• Absorber cover Q)
10. Loosen:
• Nuts CD
•Setscrew®
11.Remove:
• Suspension bracket @
12. Remove:
• Shock absorber CD
3-13
FRONT susPENs10N lcHAsl..st I
13. Remove:
• Circlips <D
•Washers®
• Suspension arm @
14. Remove:
• Exhaust pipe (left)
• Protector G) (exhaust pipe)
•Tie laps®
• Circlip@
15.Remove:
• Dowel pin <D
• Pin holders ®
• Stabilizer joint @
• Stabilizer assembly
NOTE: ------------------------
SI ide the stabilizer slidertowerd the machine side
to remove the dowel pin.
INSPECTION
1. Inspect:
• Shock absorber
Oil leaks/Bend/Damage ---+ Replace.
2. Inspect:
• Suspension bracket <D
• Suspension arm ®
• Front arms @
•Bushings©
• Bearings@
Cracks/Wear/Damage ---+ Replace.
3-14
FRONT susPENs10N lcHAsld I
3. Inspect:
• Spring
Wear/Cracks/Damage --+ Replace.
4. Measure:
• Spring free length @
Out of specification --+ Replace.
Spring free length limit:

235.0 mm (9.25 in)
5. Inspect:
• Oil seals CD
•Bushings®
Damage --+ Replace.
6. Inspect:
• Stabilizer joint CD
• Stabilizer ®
• Stabilizer link @
Cracks/Damage --+ Replace.
• Stabilizer slider ©
• 0-ring@
Wear/Cracks/Damage --+ Replace.
Unsmooth movement --+ Apply a low tem-

perature grease into the stabilizer slider.
Recommended grease:
INSTALLATION
Reverse the uREMOVAL" procedure.
1. Lubricate:
• Bushing (suspension support CD)
• Bushing (suspension arm ® )
• Oil seal lips
•Bearings@
• Thrust washers ©
• Collars@
3-15
FRONT susPENs10N lcHAsl..# I
Recommended grease:
2. Install:
• Suspension arm CD
A WARNING
Always use a new circlip.
NOTE: -------------------------
1nsta11 the suspension arm so that the ul" mark
should be on the left side and the "R" mark on the
right side.
3. Install
• Shock absorber CD
NOTE: -------------------------
When attaching the shock absorber, insert it very
carefully from above the bracket, to avoid
damaging the oil seal.
4. Install:
• Suspension bracket ®
Setscrew®:
2 Nm (0.2 m •kg, 1.4 ft• lb)
LOCTITE®
Nut@:
21 Nm (2.1m•kg,15ft •lb)
NOTE: -------------------------
Install the suspension bracket so that the "L" mark
should be on the left side and the "R" mark on the
right side.
5.Tighten:
Bolt (absorber holder CD):

10 Nm (1.0 m •kg, 7.2 ft• lb)
Nut (shock absorber ® ):
5 Nm (0.5 m • kg, 3.6 ft • lb)
Lock nut (shock absorber®):
16 Nm (1.6 m •kg, 11 ft• lb)
3-16
FRONT susPENs10N lcHAS~ I
6. Tighten:
Nut/Bolt (front arm):

43 Nm (4.3 m •kg, 31 ft• lb)
NOTE: -------------------------
• Be sure to install the front arms so that the
"UPPER -L" mark is positioned to the upper-left
and the "LOWER-L" mark is positioned to the
lower-left.
• When installing the stabilizer joint CD to the
front arm, connect ® .
• Lift up the front of the machine first and then
tighten the lock nuts ® . (left and right)
3-17
CHAPTER4.
POWER TRAIN
PRIMARY SHEAVE AND DRIVE V-BELT ......... 4-1

REMOVAL ................................................... 4-2
DISASSEMBLY .........................................., 4-2
INSPECTION ............................................... 4-4
ASSEMBLY ................................................. 4-6
INSTALLATION ........................................... 4-7
SECONDARY SHEAVE ..................................... 4-9

REMOVAL .................................................. 4-10
DISASSEMBLY .......................................... 4-10
INSPECTION .............................................. 4-11
ASSEMBLY ................................................ 4-12
INSTALLATION ......................................... 4-14
SHEAVE DISTANCE AND OFFSET
ADJUSTMENT ........................................ 4-14
DRIVE CHAIN HOUSING AND

JACKSHAFT ................................................. 4-17
REMOVAL ................................................. 4-18
INSPECTION ............................................. 4-19
INSTALLATION ......................................... 4-20
BRAKE ............................................................. 4-22

REMOVAL ................................................. 4-23
DISASSEMBLY ......................................... 4-23
INSPECTION ............................................. 4-24
ASSEMBLY AND INSTALLATION ........... 4-25
SLIDE RAIL SUSPENSION ............................. 4-28

REMOVAL .................................................. 4-30
DISASSEMBLY .......................................... 4-30
INSPECTION .............................................. 4-32
ASSEMBLY ................................................ 4-34
INSTALLATION ......................................... 4-35
FRONT AXLE AND TRACK ............................. 4-36

REMOVAL ................................................. 4-37
INSPECTION ............................................. 4-37
INSTALLATION ......................................... 4-38
PRIMARY SHEAVE AND DRIVE V-BELT l~ICiOI
POWER TRAIN
PRIMARY SHEAVE AND DRIVE V-BELT
<D @V-belt
Spider
®Collar @ Sliding sheave * 1. Tighten the bolt.
@Bushing @Collar
©Roller @Rivet 120 Nm (12 m •kg, 87 ft• lb)
@ Primary sheave spring @Weight 2. Loosen the bolt completely.
® Primary sheave cap @Bushing 3. Retighten the bolt.
<J) Bushing @Bushing 60 Nm (6.0 m • kg, 43 ft• lb)
@ Fixed sheave @Shim
@Stopper
6 Nm (0.6 m • kg, 4.3 ft• lb)
j14 Nm (1.4 m •kg, 10 ft• lb) I
®~
6 Nm (0.6 m • kg, 4.3 ft• lb)
4-1
PRIMARY SHEAVE AND DRIVE V-BELT l~la:ol
REMOVAL
1.Remove:
• Side cowling (left) (See page 2-3)
• Drive V-belt guard (See page 2-16)
• Drive V-belt (See page 2-16)
2.Remove:
• Bolt CD (primary sheave)
NOTE:-------------------------
® to hold the
Use the primary sheave holder
primary sheave @ .
Primary sheave holder:

90890-01701, YS-01880
3.Remove:
• Primary sheave assembly CD
NOTE:-------------------------
® and primary
Use the primary sheave holder
sheave puller @ .

90890-01701, YS-01880
..,.._... Primary sheave puller:
90890-01898, YS-01881-1 & YS38517
DISASSEMBLY
1.Remove:
• Bolts (primary sheave cap)
2.Remove:
• Primary sheave cap CD
• Primary sheave spring ®
4-2
PRIMARY SHEAVE AND DRIVE V-BELT . IPOIVTRR,__...,
_VJ'llll_
3.Loosen:
• Set screws CD
4.Remove:
• NutCD •Weight@
•Bolt@ •Washers@
• Collar@ •Bushing@
• Roller©
•Washers@
• Nut@
• Bolt (j)
•Collar®
5.Remove:
• SpiderCD
NOTE: -------------------------
Special tools and LOCTITE® are necessary for
assembling the spider and fixed sheave. If these
are unavailable, avoid disassembling.
Removal steps:
• Immerse the primary sheave assembly in
appoximately80'-100°C(176° -212°F)water
for several minutes.
• Hold the lower piece of the Clutch Spider
Separator (90890-01711, YS-28890-B)(Don a
rigid table using a suitable mounting bolts.
Then, install the Clutch Separator Adapter
(90890-01740, YS-34480)@ onto the separa-
tor.
• Fit the primary sheave assembly onto the
adapter, and secure the supporting plates@.
NOTE:----------------------
Securely fit the projections of the adapter
into the fixed sheave holes.
• Set the bar wrench onto the spider and turn

the special tool clockwise to loosen the spi-
der.
4-3
PRIMARY SHEAVE AND DRIVE V-BELT l~la:9I
• Spider has a lef,·hand thread.
• To loosen the spider, high torque is required
so be sure that the spider, fixed sheave and
special tool are placed securely. Loosen the
spider carefully to prevent cracks and/or
damage to the sheaves and spider.
• Remove the fixed sheave@, fixed sheave

stopper@, and sliding sheave® from the
spider(l).
INSPECTION
1. Inspect:
• Spider CD (tapered portion)
• Sliding sheave®
• Fixed sheave @
• Primary sheave cap©
Cracks/Damage ->.Replace.
2.Measure:
• Bushing-to-sheave clearance
Out of specification -~ Replace bushing.
Use a feeler gauge CD
Bush clearance (primary sheave

cap) !Al :
.....- - 0.25 mm (0.01 in)
Bush clearance (sliding sheave) [ID :
0.25 mm (0.01 in)
3. Inspect:
• Primary sheave spring CD
Cracks/Damage ___,. Replace.
4.Measure:
• Primary sheave spring free length @
Out of specification --> Replace.
@
Primary sheave spring free length:
77 .4 mm (3.05 in) (VX750l
78.7 mm (3.10 in) IVX750ST)
4-4
PRIMARY SHEAVE AND DRIVE V-BELT IPOWTRR1~1
V...W
----------------------------------------------------------
5. Inspect:
•Weight Ci)
• Roller®
•Bushing@
•Slider©
•Rivet@
• Collar
Wear/Scratches/Damage ~ Replace.
Slider inside clearance@ +@

Min. 0. 1 mm (0.0039 in)
Max. 0.45 mm (0.0177 in)
Rivet replacement steps:

• Remove old rivet with the appropriate drill.
• Insert the rivet CD from the ID mark® side.
• Press or peen the rivet head so that the di-
ameter of rivet head measures to 8.2 mm
(0.32 in) or larger @ .
6.Measure:
• Bushing inside diameter
Out of specification -> Replace.
Bushing inside diameter
Primary sheave cap Sliding sheave
28.0 mm 41.0 mm
New
(1.10 in) (1.61 in)
Wear limit 28.2mm 41.2mm

(1. 11 in) (1.62 in)
7. Measure:
• Bushing inside diameter
Out of specification _. Replace as a set.
Bushing inside diameter
Roller Weight
8.0mm
New f-
(0.31 in)
Wear limit 8.2mm f-

(0.32 in)
A
NOTE: ~-----------------------
When replace the weight and roller bushings, use
the YXR clutch bushing jigkit (YS-59752).
[A] Removing
!ID Installing
4-5
PRIMARY SHEAVE AND DRIVE V-BELT ITIC1:9l
ASSEMBLY
1. Install:
• Sliding sheave
(onto spider)
NOTE: -------------------------
Be sure the sliding sheave match mark (x) is
. aligned with the spider match mark (x).
2. Install:
• Fixed sheave
(onto spider)
NOTE: ----------------------~
Apply LOCTITE® CD to the first 4 threads of the
spider.
LOCTITE® should be applied only to the area

specified. Never apply to the bushings and other
areas.
3. Install:
• Fixed sheave stoppers CD
NOTE: ------------------------
Stoppertapered portion should face fixed sheave.
4.Tighten:
• Spider
Tightening steps:
• Finger-tighten the spider until it stopped
by fixed sheave stopper.
• Hold the fixed sheave with the Clutch Spider
Separator(-, YS-28890-BlCD.
NOTE:-----------------------
Securely fit the projections of the Clutch
Separator Adapter @ into the fixed sheave
holes.
• Tighten the spider to specification using the

bar wrench@.
Spider:
200 Nm (20 m •kg, 145 ft• lb)
4-6
PRIMARY SHEAVE AND DRIVE V-BELT l~lc:col
Spider has a left-hand thread.
A WARNING
• Do not operate the primary sheave until
the LOCTITE® has dried completely. Wait 24
hours before operating primary sheave.
• Since the tightening torque is high, make
sure the spider, fixed sheave, and special tool
are placed securely. Tighten the spider
carefully to prevent cracks and/or damage to
the sheaves and spider.
5. Install:
• Weight and roller
Installing steps:
• Tighten the bolt©.
x Bolt:
6 Nm (0.6 m • kg, 4.3 ft • lb)
• Tighten the set screw® so that clearance@

between bolt and sheave surface is 0 mm
(0 in).
NOTE:
To maintain the balance of primary sheave, the
bolt CD must be installed with their threaded
portions pointing in a counterclockwise
direction, as illustation.
6. Lubricate:
• Primary sheave spring CD
• Primary sheave cap®
NOTE: ----------------------~
• Be sure the sheave cap match mark "X" is
aligned with the spider match mark "X".
• Be sure to use the flange bolts@ to position@
to maintain the balance of primary sheave.
7. Tighten:
Primary sheave cap bolt:

14 Nm (1.4 m •kg, 10 ft• lb)
4-7
PRIMARY SHEAVE AND DRIVE V-BELT _ IPOJVTRR1--a1
_v..JJll_
INSTALLATION
1. Install:
• Primary sheave assembly
Be sure to remove any oil and/or grease from the

SOS-016 tapered portion of the crankshaft and spider
using a cloth dampened with thinner.
2.Apply:
• YAMALUBE 2-cycle oil/equivalent grease
(to threads of primary sheave bolt)
3. Tighten:
• Bolt CD (primary sheave)
Tightening steps:
• Hold the primary sheave@ using the Primary
Sheave Holder(90890-01701,YS-O 1880)@and
tighten the bolt (primary sheave) to specifica-
tion.
Bolt (primary sheave):

(initial tightening)
..,.__... 120 Nm (12 m • kg, 87 ft • lb)
• Loosenthe bolt(primarysheave)completely.
• Retighten the bolt (primary sheave) to speci-
fication.
Bolt (primary sheave):

60 Nm (6.0 m • kg, 43 ft • lb)
4-8
4-9
SECONDARY SHEAVE _ IPOWTRR,__.,
v...w _
_
REMOVAL
1. Remove:
• Side cowling (left) (see page 2-3)
• Drive V-belt guard (see page 2-16)
• Drive V-belt (see page 2-16)
2. Apply the brake to lock the secondary sheave.
3.Remove:
• Bolt CD (secondary sheave)
•Washer®
•Shim (s)@
• Secondary sheave©
DISASSEMBLY
A WARNING
• Use extreme CAUTION when disassembling
the secondary sheave as serious injury can
occur from the sudden release of spring
tension. Use the sheave compressor to contain
the spring tension before removing the
retaining clip.
• Do not attempt the procedure unless you have
the proper tools and understand the
instructions thoroughly.
Sheave compressor:
90890-01712, YS-28891
1.Remove:
• Circlip CD
•Washer®
•Plate@
4-10
2.Remove:
• Spring seat CD
• Secondary sheave spring ®
3.Remove:
• Sliding sheave CD
• Base plate ®
< ••, . (from fixed sheave)
INSPECTION
1. Inspect:
• Sliding sheave CD
• Fixed sheave ®
• Spring seat @
3 Cracks/Damage ~ Replace.
2. Inspect:
• Bushing CD (sliding sheave)
• Sliding sheave @(V-belt contact surface)
Scratches/Wear/Damage~ Replace.
• Sliding bushing @
Unsymmetrical wear/Damage ~ Replace.
4-11
SECONDARY SHEAVE l~la::9I
3. Inspect:
• Secondary sheave spring G)
Cracks/Damage --> Replace.
4. Measure:
• Torsion spring free length @
Less than specification --> Replace.
~ Free length limlt :

[:61 100 mm (3.9 in)
5. Measure:
• Ramp shoe thickness @
Out of specification--> Replace.
Wear limit:
1.0 mm (0.04 in)
ASSEMBLY
Reverse the UDISASSEMBLY" procedure.
1. Install:
• Sliding bushing G)
2.Clean:
• Sliding bushing G) (sliding sheave)
NOTE: ~~~~~~~~~~~~-
Be sure to remove any dust or grease from the
sliding bushing G) of the sliding sheave, using a
cloth dampened with thinner.
3. Install:
• Secondary sheave spring
NOTE: ~~~~~~~~~~~~-
• Hook the end of the secondary sheave spring
onto the spring hole ® in the sliding seat.
• Be sure to install on the short side G) end of
spring to the secondary sheave.

Position u ®"
4-12
SECONDARY SHEAVE _ IPOJVTRR1---1
_.,.__.,_
4. Install:
• Spring seat CD
NOTE: ~~~~~~~~~~~~-
Hook the end of the secondary sheave spring
onto the spring hole in the spring seat.

Position "3"
Installation steps:
• Slide the washer and circlipontothe bolt of the
sheave compressor, and then attach the com-
pressor to the secondary sheave.
• Always use a new circlip.

so that the spring seat splines engage with
the fixed sheave splines.
NOTE: ~~~~~~~~~~~-
Turn inthisscrewto a position where the spring
seat cam CD does not come in contact with
the sliding sheave cam ®·
• Turn the sliding sheave the specified degrees,

in the counterclockwise direction.
• Holding the sliding sheave and fixed sheave in
this position.
Standard twist angle:

33•

so that the spring seat engages with the slid-
ing sheave.
• Install the washer and circlip in proper posi-
tion.
4-13
SECONDARY SHEAVE l~la::ol
INSTALLATION
1. Lubricate:
• Splines (fixed sheave)
Recommended grease:
Esso beacon 325 grease or
Aero shell grease #7 A
2. Tighten:
Secondary sheave bolt:

60 Nm (6.0 m • kg, 43 ft • lb)
3. Adjust:
• Sheave distance
• Sheave offset
• Free play (clearance)
SHEAVE DISTANCE AND OFFSET ADJUST-
MENT
1. Measure:
• Sheave distance@
Use the sheave gauge. (YU-39506-2)
Out of specification -•Adjust.
Sheave distance@ :
363.5 - 366.Smm (14.3 - 14.4 in)
2.Adjust:
• Sheave distance
Adjustment steps:
• Check the engine mounting bracket, dampers
and frame for bends, cracks and corrosion.
Repair or replace as required.
• Loosen the engine mounting nuts CD.
• Adjust the position of the engine with the
adjuster@.
Loosen the lockn uts@and turn the adjuster in
or out until the specified distance is obtained,
the crankshaft and jackshaft being parallel to
each other.
• Tighten the locknuts @.
• Tighten the engine mounting nuts CD.
IAJ Front !ID Rear [QJ Left [QJ Right
I~
Mounting nut:
40 Nm (4.0 m • kg, 29 ft • lb)
Locknut (adjuster):
36 Nm (3.6 m • kg, 26 ft • lb)
4-14
SECONDARY SHEAVE IP<f'irRla::ol
3.Measure:
• Sheave offset @
Use the Sheave Gauge. (YU-39506-3)
Out of specification ~ Adjust.
Sheave offset @ :
14.5- 17.5 mm (0.57 - 0.69 in)
805-010
NOTE: ~~~~~~~~~~~~
Be sure to push the secondary sheave to the
arrow [El and then measure.
4.Adjust:
• Sheave offset
Adjustment steps:
• Apply the brake to lock the secondary
sheave.
• Remove the bolt (secondary sheave) and
secondary sheave ©.
• Adjust the sheave offset by adding or re-
moving shim (s) @.
Adding shim Offset is increased.
Removing shim Offset is decreased.
Shim size
Part Number Thickness
90201-284P9 0.5 mm (0.02 in)
90201-284P8 1.0 mm (0.04 in)
90201-284P7 2.0 mm (0.08 in)
• Install the secondary sheave and bolt (secon-
dary sheave).
I~
Bolt (secondary sheave):
60 Nm (6.0 m •kg, 43 ft• lb)
• Recheck the sheave offset. If out of specifica-

tion, repeat the above steps.
NOTE:
When adjusting the sheave offset, the
secondary sheave free play (clearance) should
be adjusted.
4-15
SECONDARY SHEAVE IP<f¥rRla::ol
5.Measure:
• Secondary sheave free play (clearance)©
Use a feeler gauge.
Out of specification -. Adjust.
Secondary sheave free play

(clearance)·
1.5 mm (0.06 in)
6.Adjust:
• Secondary sheave free play (clearance)
Adjustment steps:
• Apply the brake to lock the secondary
sheave.
• Remove the bolt (secondary sheave) CD and
washer®.
• Adjust the secondary sheave free play (clear-
ance) by adding or removing a shim(s) @ .
Adding shim Free play is decreased.
Removing shim Free play is increased.
Shim size
Part Number Thickness
90201-284P9 0.5 mm (0.02 in)
90201-284P8 1.0 mm (0.04 in)
90201-284P7 2.0 mm (0.08 in)
•Install the washer and bolt (secondary

sheave), and tighten the bolt.
~
Bolt (secondary sheave):
60 Nm (6.0 m·kg, 43 ft·lb)
• Recheck the secondary sheave free play

(clearance). If out of specification, repeat the
above steps.
4-16
DRIVE cHAJN Hous1NG AND JAcKsHAFT ITla •I
DRIVE CHAIN HOUSING AND
JACKS HAFT
CD Jackshaft ®Drive chain tensioner
®Bearing ® Driven sprocket
@ Bearing holder @Drive chain
© Drive sprocket @Torsion spring
@Collar @Pin
@Oil seal
(j) Locknut
@Adjuster
21 Nm (2.1 m • kg, 15 ft• lb)
21 Nm (2.1 m •kg, 15 ft• lb)
43 Nm (4.3 m •kg, 31 ft• lb)
4-17
DRIVE CHAIN HOUSING AND JACKSHAFT IPOTWRR1~1
W....W
~------------------------------------------------------~
tU.i . . . . . REMOVAL
1. Remove
• Side cowlings (See page 2-3)
• Muffler
• Secondary sheave (See page 4-10)
2.Loosen:
• Track tension (See page 4-30)
3.Remove:
• Oil filter cap CD (with 0-ring)
• Drain screw ® (with gasket)
Drain the oil
NOTE: ~~~~~~~~~~~~
Place a container under the drain hole.
4.Remove:
• Brake caliper assembly CD
• Brake disk ®
• Woodruff key @
• Brake pad (inner)
5.Remove:
• Drive chain housing cover CD
•Dowel pins
• Gasket
6.Remove:
• Adjuster CD (chain tensioner)
• Shaft® (chain tensioner)
• Chain tensioner @
• Torsfon spring ©
• Spacer collar@
• Bolt @ (driven sprocket)
• Drive sprocket (j)
• Drive chain @
• Driven sprocket ®
• Spacer collar @ (drive sprocket)
• Spacer collar Qi) (driven sprocket)
• Drive shaft @
• Drive chain housing @
NOTE: ~~~~~~~~~~~~
Remove the drive sprocket, driven sprocket and
drive chain at same time.
4-18
ORNE CHAIN HOUSING AND JACKSHAFT l~l@I
7.Remove:
• Compression rod CD
• Bolts (bearing holder ® )
• Jackshaft assembly @
• Bearing holder/washer
(from jack shaft)
•Bolt
INSPECTION
1. Inspect:
• Drive chain housing CD
• Cover® (drive chain housing)
• Bearing housing @
Cracks/Damage -+ Replace.
• Oil seals ©(drive chain housing)
Wear/Damage -+ Replace.
• Bearings@ (drive chain housing)
Pitting/Damage -+ Replace.
• Bearing ®(bearing housing)
Pitting/Damage-+ Replace bearing and inner
race holder as a set.
Replacement steps:
• Remove the circlip CV (bearing housing).
• Remove the bearing(s)@ ®using a general
bearing puller.
• Install the new bearing(s).
NOTE: ~~~~~~~~~~~~
• Use a socket @ that matches the outside

diameter of the race of the bearing.
Do not strike the inner race ® or balls ® of

the bearing. Contact should be made only with
the outer race Qj) .
• Install the new circlip (bearing housing).
4-19
DRIVE CHAIN HOUSING AND JACKS HAFT . IPCNl/TRR1----1
_"'-W _
2. Inspect
3
r
~~
\~ )@
~
11,"
• Drive gear teeth ©
• Driven gear teeth®
• Chain tensioner @
Pitting/Wear/Damage _,. Replace.
• Drive chain ©
• Torsion spring @
~~~J "~ Wear/Damage _,. Replace.
Stiff_,. Clean or replace.
3. Inspect:
• Jackshaft ©
• Drive shaft ®
• Jackshaft coupler @
Scratches (excessive)/Damage _,. Replace.
• Splines©
Wear/Damage_,. Replace.
• Bearing contact surface@
Scratches/Wear/Damage _,. Replace.
4. Inspect:
• Rubber dampers ©
Wear/Damage _,. Replace.
• Compression rod ®
Cracks/Damage _,. Replace.
INSTALLATION
1.Apply:
(to oil seal lips and splines)
2. Tighten:
Bolt (bearing housing):

21 Nm (2.1 m •kg, 15 ft• lb)
Bolt (drive chain housing):
21 Nm (2.1m·kg,15 ft• lb)
Bolt (drive sprocket):
43 Nm (4.3 m • kg, 31 ft • lb)
Bolt (drive chain housing cover):
8.5 Nm (0.85 m • kg, 6.1 ft • lb)
Bolt (brake caliper body):
65 Nm (6.5 m • kg, 47 ft • lb)
Bolt (compression rod):
40 Nm (4.0 m • kg, 29 ft • lb)
Lock nut (compression rod):
36 Nm (3.6 m • kg, 26 ft • lb)
4-20
DRIVE CHAIN HOUSING AND JACKSHAFT l~Rl@I
3.Adjust:
• Drive chain slack (See page 2-20)
• Sheave distance (See page 4-14)
• Sheave offset (See page 4-15)
4. Fill:
• Drive chain housing (See page 2-20)
4-21
BRAKE l~lcrol
BRAKE
CD Pad ®End cover
® Back up plate @Brake disc
@ Caliper body @ Woodruff key
©Lever
@ Stationary cover *With silicone grease
®One way lock 2
(J) Adjusting screw
@ Adjusting ratchet
I
3
9 Nm (0.9 m • kg,
6.5 ft. lb)
4-22
BRAKE l~l@I
REMOVAL
1. Disconnect:
• Brake cable CD
2.Remove:
•Spring®
• Spring holder @
• Cable holder ©
NOTE: ~~~~~~~~~~~~-
Loosen the locknut @and turn in the adjuster®
fully to release the tension in the brake cable, then
remove the bolt (j) (cable holder).
3.Remove:
4
• Caliper body CD (outer)
• Brake pad ® (outer)
• Brake up plate @
• Brake pad spring ©
4.Remove:
• Brake disk CD
•Woodruff key®
• Brake pad @(inner)
DISASSEMBLV
1.Remove:
• Stationary cover CD
• Stopper pin ®
•End cover@
Do not disassemble the torsion spring © from

the end cover and the guide.
4-23
2.Remove:
• Adjusting ratchet CD
• Adjusting screw ®
INSPECTION
1. Inspect:
• Caliper body CD
Cracks/Damage -+ Replace.
• Spiral gear ®(caliper body)
2. Inspect:
• End cover CD
•Guide®
• One way lock 1 @
• Torsion spring ©
Cracks/Wear/Damage -+ Replace the end
cover unit.
Inspection steps:
• Check the wear of the torsion spring by the
projection mark @ on the guide ® located
between the base marks@ on the end cover
CD. If projection mark ® is not in the range
between the base marks @ , replace the end
cover unit.
4-24
BRAKEl~la:itl
3. Inspect:
• One way lock 2 ©
• Stationary cover ®
•Lever@
• Spiral gear © (lever)
Cracks/Wear/Damage_. Replace.
Replacement steps:
•Remove the one way lock 2 ©using a thin
flat-head screw driver.
• Remove the washer@and stationary cover@
• Replace a damaged part(s) use a new one.
•Reassemble the removed part(s) and reverse
the above steps.
Always use a new one way lock 2.
4. Inspect:
4 • Adjusting ratchet ©
Cracks/Wear/Damage _. Replace.
• Spring ®(brake cable)
Wear/Damage _. Replace.
• Brake pad @thickness
• Brake disk ©
Bend/Cracks/Damage _. Replace.
ASSEMBLY AND INSTALLATION

Reverse the "REMOVAL" and "DISASSEMBLY"
procedures.
1. Assemble:
• Caliper body
Assembly steps:
• Lubricate the spiral gears © on the caliper
body and lever with silicone grease.
• Align the projection mark@on the lever with
the "IN" mark@on the caliper body, screw the
lever@ counterclockwise to the caliper body.
• Install the stopper pin into the holes ®on the
caliper body and stationary cover, then
tighten the bolts (stationary cover).
Bolt (stationary cover):

9 Nm (0.9 m • kg, 6.5 ft • lb)
4-25
BRAKE 1~10::01
• Lubricate the one way locks 1 ©and 2 @with
a lithium grease.
5
• Lubricate the adjusting screw@ and back up

plate ® with a silicone grease.
• Insert the back up plate® into the lever shaft
hole@.
• Screw in the adjusting screw@ , and when it

contacts lightly with the end of the back up
plate, then back out the adjusting screw®
1/2 to 1 turn.
• Fit the end of the adjusting rachet ® into the

adjusting screw @ , and align the cut in the
guide @ with the projection of the stationary
cover @ , then install the guide ® , which is
fitted to the end cover @ twisting the end
cover clockwise approximately 30 degrees
and tighten the screws (end cover) @ .
I'-....
I l\.
Screw (end cover):
2 Nm (0.2 m •kg, 1.4 ft• lb)
2. Lubricate:
• Woodruff key
• Jackshaft
Recommended grease:
~ ESSO Beacon 325 grease or
4-26
BRAKE l~lo •I
3. Tighten:
Bolt (caliper body):

62 Nm (6.2 m • kg, 44 ft • lb)
Bolt (cable holder):
9 Nm (0.9 m • kg, 6.5 ft • lb)
4.Adjust:
• Brake lever distance "L" (See page 2-18)
4-27
SLIDE RAIL SUSPENSION l~la::ol
CD Rear
® axle
Guide wheel (rear)
®
~ ~uide w~eel (center)
@ Bearing l.LlV uspensron wheel
© Circlip (center)
@ Collar @ Suspension wheel
(front)
® Collar (center)
R\ @ Sl"d
\!./ Suspension whe I r.;-. ' e metal .
@ Suspension whe:I ~ Track assembly
(rear)
4-28
SLIDE RAIL SUSPENSION l~lcrel
CD Rear pivot arm @ Sliding frame
@Pivot arm bracket @ Slide runner
@Collar @ Suspension wheel
©Bushing bracket
@Pull rod @ Front suspension
@ Rear suspension @Relay arm
(j) Rear stopper band @Bracket
@Bracket @ Front stopper band
@ Rear suspension @ Front pivot arm
bracket
23 Nm (2.3 m • kg, 17 ft • lb)

4 Nm (0.4 m • kg,
2.9 ft. lb)
48 Nm (4.8 m • kg, 35 ft• lb)

3 Nm (0.3 m •kg, 2.2 ft• lb)
4-29
REMOVAL
1.Remove:
• Cotter pin (rear axle)
2. Loosen:
• Track tension
NOTE: ----------------------~
CD and adjuster nuts (track
Loosen the axle nut
tension)@.
3.Remove:
• Guide wheel (center) CD
4.Remove:
• Suspension mounting bolts
(front CD and rear@)
NOTE: -------------------------
Loosen both right and left bolts (front) CD at the
same time.
5. Lift the rear of the machine with a suitable

stand.
\
6.Remove:
• Slide rail suspension CD
DISASSEMBLY
1. Remove:
• Stopper bands (front CD and rear®)
• Bracket shaft @
4-30
SLIDE RAIL SUSPENSION l~la:ol
2.Remove:
• Suspension wheel bracket CD
• Shock absorber® (front)
• Front pivot arm@
©Collar
@Bushing
®Washer
(j) Flange washer
3.Remove:
• Suspension wheels CD (center)
• Shock absorber® (rear)
• Pull rods@
©Washer
@Collar
®Bushing
4.Remove:
• Rear pivot arm CD
• Suspension wheels ®
• Pivot arm bracket @
©Collar
@washer
4-31
SLIDE RAIL SUSPENSION IPOWTRR1~1
.._.,
------------------------------------------------------~
5.Remove:
• Guide wheels CD (rear)
• Rear suspension bracket ®
• Collars@
•Washers©
6.Remove:
• Slide runner CD
INSPECTION
1. Inspect:
• Suspension wheel
• Guide wheel
Cracks/Damage~ Replace.
• Wheel bearing
Wheel turns roughly ~ Replace.
820-019
Replacement steps:
• Remove the circlipCD.
• Remove the wheel bearing using a general
bearing puller.
• Install the wheel bearing (new) into the
wheel.
4-32
SLIDE RAIL SUSPENSION . IPOIVTRR1---1
_VJilll_
• NOTE:---------------------
Use a socket ® that matches the outside
diameter@ of the race of the bearing.
Do not strike the inner race© or balls of the

bearing@. Contact should be made only with
the outer race.
• Install the circlip.

• Install the wheel to the shaft.
2. Inspect:
• Stopper band ©
Frayed/Damage ~ Replace.
• Pull rod®
4
Bends/Damage ~ Replace.
• Shock absorber@
Oil leaks/Damage ~ Replace.
•Bushings
Wear/Cracks/Damage ~ Replace.
• Front pivot arm©
• Rear pivot arms@
• Pivot arm bracket®
• Suspension wheel bracket (j)
• Front pivot arm @
• Sliding frame®
• Slide runner@
Wear/Damage ~ Replace
(See page 2-22)
4-33
SLIDE RAIL SUSPENSION . IPOWTRR1--a1.~.
ASSEMBLY
1.Apply:
(to "G" mark points in the illustration).
2. Tighten:
Screw (slide runner):

3 Nm (0.3 m • kg, 2.2 ft• lb)
Bolt(j):
48 Nm (4.8 m • kg, 35 ft • lb)
Bolt@:
69 Nm (6.9 m • kg, 50 ft • lb)
Nut@:
23 Nm (2.3 m •kg, 17 ft• lb)
Bolt@:
64 Nm (6.4 m • kg, 46 ft • lb)
Bolt@:
16 Nm (1.6 m •kg, 11 ft• lb)
Bolt@:
10 Nm (1.0 m •kg, 7.2 ft• lb)
Nut(i):
75 Nm (7.5 m •kg, 54 ft• lb)
Nut (stopper band):
4 Nm (0.4 m • kg, 2.9 ft• lb)
NOTE:~-----------------------
• Install the pull rod @ so that the rod is offset
slightly toward the outside.
• When attaching the front pivot arm @ to the
sliding frame@, attach it to the hole @on the
upper side. (for standard setting)
4-34
SLIDE RAIL SUSPENSION _ IP<:M/TRR,_...,
w..w _
_
INSTALLATION
1. Place the slide rail suspension CD into the
track, and fitthe front pivot arm holding bolts.
Then fit the rear pivot arm bracket mounting
bolts.
NOTE: ------------------------
Do not tighten the bolts at this point. Finger -
tighten the bolts.
2. Tighten:
Suspension mounting bolts:

Front(A]:
68 Nm (6.8 m • kg, 49 ft • lb)
Rearffi]:
68 Nm (6.8 m • kg, 49 ft • lb)
Guide wheel bolt (center):
27 Nm (2.7 m •kg, 20 ft• lb)
3.Adjust:
• Spring preload (See page 2-41)
4-35
FRONT AXLE AND TRACK l~la:ol
FRONT AXLE AND TRACK
CDSprocket wheel
@Front axle
@Bearing
© Bearing holder
4-36
FRONT AXLE AND TRACK IPOWTRR1~1
W...W
-----------------------------------------------------------
REMOVAL
1.Remove:
• Side cowlings (See page 2-3)
• Scondaly sheave
• Speedometer cable
• Speedometer gear cover CD
• Speedometer gear assembly ®
• Bearing holder @(outer)
• Cable joint © (speedometer cable)
• Nut @ (front axle)
• Plain washer ®
• Bearing ([)
• Bearing holder @ (inner)
NOTE:------------------------
Apply the parking brake when removing the nut
(front axle).
2.Remove:
• Muffler
• Driven sprocket (See page 4-18)
• Slide rail suspension (See page 4-30)
3.Remove:
• Front axle assembly CD
• Track assembly
INSPECTION
1.lnspect:
•Track CD
• Slide metal ®
Wear/Cracks/Damage ---> Replace.
2. Inspect:
• Sprocket wheels CD
Wear/Break/Damage --• Replace.
• Front axle ®
Bent/Scratched (excessively)/Damage __,.
Replace.
• Splines/Threads (front axle)
• Front axle bearing @
Pitting/Damage --. Replace.
4-37
FRONT AXLE AND TRACK l~l@I
INSTALLATION
200.6mm
1. Install:
(7.90inl
• Sprocket wheels CD
NOTE:~--------------------~
104mm
(4.09in) • When pressing the sprocket wheels onto the
front axle, align the lugs on each sprocket
wheel.
• Locate each sprocket wheel on the axle where
123mm
(4.84in) shown in the illustration.
,....,m
(4.09in)
152.9mm
(6.02 in)
2. Place the track in the chassis.
NOTE:-------------------------
Be sure it is positioned as shown in the illustra-
tion.
[Al TURNING DIRECTION
3. Install:
• Front axle CD
NOTE:~--------------------~
• Install the front axle, push in the splined end
toward the chain housing, and install the
threaded end into the speedometer gear hous-
ing side.
• Be sure the lugs correctly engage the track.
4. Tighten:
Front axle nut:

90 Nm (9.0 m • kg, 65 ft • lb)
Speedometer gear assembly bolt:
23 Nm (2.3 m • kg, 17 ft • lb)
4-38
CHAPTER 5.
ENGINE OVERHAUL
ENGINE REMOVAL .......................................... 5-1

EXHAUST SYSTEM .................................... 5-1
CARBURETOR AND RADIATOR ................. 5-1
OIL HOSE ..................................................... 5-1
CABLE AND LEADS .................................... 5-2
RECOIL STARTER HANDLE ........................ 5-2
ENGINE REMOVAL ..................................... 5-2
DISASSEMBLY ................................................. 5-2

EXHAUST MANIFOLD ................................ 5-2
INTAKE MANIFOLDS AND
REED VALVES ........................................... 5-2
ENGINE BRACKETS .................................... 5-3
RECOIL STARTER ....................................... 5-3
OIL PUMP .................................................... 5-3
WATER JACKET JOINT .............................. 5-3
WATER PUMP ............................................. 5-4
MAGNETO ROTOR ..................................... 5-4
CYLINDER HEAD AND CYLINDER ............. 5-5
PISTON ........................................................ 5-5
CRANKCASE AND CRANKSHAFT ............. 5-6
INSPECTION AND REPAIR ............................... 5-6

CYLINDER HEAD ......................................... 5-6
CYLINDER AND PISTON ............................ 5-7
PISTON RINGS ............................................ 5-9
PISTON PIN AND BEARING ..................... 5-10
CRANKSHAFT ........................................... 5-11
DRIVE SHAFT ............................................ 5-12
REED VALVE AND INTAKE MANIFOLD .. 5-13
CRANKCASE ............................................. 5-14
ENGINE ASSEMBLY AND ADJUSTMENT ... 5-15

CRANKCASE AND CRANKSHAFT ........... 5-15
PISTON ...................................................... 5-19
CYLINDER AND CYLINDER HEAD ........... 5-19
MAGNETO ROTOR ................................... 5-20
WATER PUMP ........................................... 5-21
WATER JACKET JOINT ............................ 5-21
OIL PUMP .................................................. 5-22
RECOIL STARTER ..................................... 5-22
ENGINE BRACKETS .................................. 5-22
INTAKE MANIFOLDS AND
REED VALVES ......................................... 5-23
EXHAUST MANIFOLD .............................. 5-23
REMOUNTING ENGINE ............................ 5-23
RECOIL STARTER ........................................... 5-24
REMOVAL .................................................. 5-25
ASSEMBLY AND INSTALLATION ........... 5-25
ENGINE REMOVAL I I"\I I
ENG
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE: -------------------------
It is not necessary to remove the engine in order
to remove the following components:
• Cylinder head
• Cylinder
• Piston and piston ring
•Water pump
• Recoil starter
•Oil pump
• Primary sheave
EXHAUST SYSTEM
1. Remove:
• Muffler G)
• Exhaust pipes ®
CARBURETOR AND RADIATOR

1.Remove:
• Carburetor assembly (See page 7-3)
• Primary sheave (See page 4-2)
• Secondary sheave (See page 4-10)
• Radiator (See page 6-3)
OIL HOSE
1. Disconnect:
•Oil hose G)
• Oil delivery hoses ®
• Pulser hoses @
NOTE:-----------------------
Plug the oil hoses and oil delivery hoses so that
oil does not run out.
5-1
ENGINE REMOVAL/DISASSEMBLY IENG ' " ' I
CABLE AND LEADS
1. Disconnect:
• Oil pump cable CD
• CDI magneto coupler
• Pickup coil coupler
RECOIL STARTER HANDLE

1.Remove:
• Starter handle CD
NOTE: ----------------------~
To remove the starter handle, loosen the knot®
of the starter rope and then knot@ the rope end
so it will not be pulled into the recoil starter case
©.
ENGINE REMOVAL
1.Remove:
• Nuts CD (engine bracket)
• Engine assembly
DISASSEMBLY
EXHAUST MANIFOLD
1. Remove:
• Exhaust manifolds CD
• Gaskets
INTAKE MANIFOLDS AND REED VALVES

1.Remove:
• Intake manifolds CD
• Reed valves ®
•Gaskets@
5-2
DISASSEMBLY
ENGINE BRACKETS
I I~I
ENG
1.Remove:
• Engine brackets CD
[Al Front
[6] Rear
RECOIL STARTER
1.Remove:
• Recoil starter assembly CD
• Recoil starter pully ®
• Woodruff key
OIL PUMP
1.Remove:
• Oil pump assembly CD
• 0-ring
WATER JACKET JOINT

1. Disconnect:
• Breather hose CD
2.Remove:
• Water jacket joint ®(upper}
• Gaskets
• Water jacket joint @ (lower}
• 0-rings
5-3
DISASSEMBLY I I,. I
ENG
WATER PUMP
1.Remove:
•Water pump assembly CD
•Dowel pins
• Gasket
MAGNETO ROTOR
1.Remove:
• Bearing holder CD
• CDI magneto cover ®
• Dowel pin
• Nut (magneto rotor)
•Washer
2.Remove:
• Nut CD (magneto rotor)
•Washer

90890-01701, YS-01880
3.Remove:
• Magneto rotor CD
NOTE:-----------------------
• Remove the magneto rotor using the rotor
puller®.
Rotor puller ® :
90890-01362, YU-33270
• Fully tighten the tool holding bolts, but make

sure the tool body is parallel with the magneto
rotor. If necessary, one screw may be backed
out slightly to level tool body.
5-4
DISASSEMBLY IENG I"tt I
CYLINDER HEAD AND CYLINDER
1. Remove:
• Cylinder head CD
NOTE:------------------------
• Before removing the cylinder head, loosen the
spark plug 00 .
• The cylinder head holding nuts and bolts
should be loosened 1/2 turn at a time, and then
removed when all are loose.
2. Remove:
• Gaskets CD (cylinder head)
• Cylinders 00
Dowel pins
• Gasket (cylinder)
PISTON
1. Remove:
• Piston pin clip CD
• Piston pin 00
•Piston@
• Small end bearing ©
NOTE: -------------------------
• Before removing the piston pin clip, cover the
crankcase with a clean rag so you will not
accidentally drop the clip into 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 piston pin puller.
• Put identification marks on each piston head
for reference during reinstallation.
Piston pin puller:

90890-01304, VU-01304
Do not use a hammer to drive the piston pin out.
5-5
DISASSEMBLY/INSPECTION AND REPAIR IENG I.._ I
CRANKCASE AND CRANKSHAFT
1. Remove:
• Drain bolt CD
•Gasket®
Drain the oil.
• Crankcase @ (lower)
NOTE: --------------------------
• Remove the bolts starting with the highest
numbered one.
• Loosen each bolt 1/4 turn, and remove them
after all bolts are loosened.
• If the case halves are tightly stuck together, tap
lightly on the tabs indicated on the crankcase
with a soft-head hammer.
• The slits shown in the crankcase can be used to
remove it.
• Be sure not to give damages the mating
surface.
2. Remove:
• Drive shaft assembly CD
•Dowel pin®
• Crankshaft (left @and right © )
•Oil seals®
• Stopper rings ®
INSPECTION AND REPAIR

CYLINDER HEAD
1. Eliminate:
• Carbon deposit
(from combustion chamber)
Use rounded scraper CD.
Do not use a sharp instrument and avoid

damaging or scratching.
2. Inspect:
• Cylinder head water jacket
Crust of minerals/Rust ..... Remove.
5-6
INSPECTION AND REPAIR ENG ...
3. Measure:
• Cylinder head warpage
Out of specification __,. Resurface.
~ Warpage limit:
0.03 mm (0.0012 in)
Measurement and resurfacing steps:

•Attach a straight edgeG) on the cylinder head
and measure the warpage using a thickness
gauge®·
• If the warpage is out of specification, resur-
face the cylinder head.
• Place a 400 - 600 grit wet sandpaper on the
surface plate, and resurface the head using
a figure-eight sanding pattern.
NOTE:-----------------------
Rotate the head several times to avoid re-
moving too much material from one side.
CYLINDER AND PISTON

1. Eliminate:
• Carbon deposits
Use a rounded scraper G) .
NOTE: -------------------------
Do not use a sharp instrument and avoid
damaging or scratching.
2. Inspect:
• Cylinder wall
Wear/Scratches __,. Hone or replace.
• Cylinder water jacket
Crust of minerals/Rust__,. Remove.
3. Eliminate:
• Carbon deposits
(from piston crown and ring grooves)
4. Inspect:
• Piston crown
Burrs/Nicks/Damage__,. Replace.
5-7
INSPECTION AND REPAIR IENG I"1 I
5. Eliminate:
• Score marks and lacquer deposits
(from piston wall)
Use 600 - 800 grit wet sandpaper.
NOTE:------------------------
Sand in a crisscross pattern. Do not sand
excessively.
6. Inspect:
•Piston wall
Wear/Scratches/Damage -+ Replace.
307·002
7. Measure:
• Piston-to-cylinder clearance
Measurement steps:
First step:
• Measure the cylinder bore "C" with a cylin-
der bore gauge <D .
NOTE:
Measure the cylinder bore "C" in parallel to
and at right angles to the crankshaft. Then
find the average of the measurements.
~ Standard Wear limit
Cylinder bore 63.000 - 63.020 mm 63.1 mm

•c" (2.480 - 2.481 in) (2.484 in)
0.05mm
,~----ch-~4-
Taper 0 T" - (0.0019in)
Out of round 0.01 mm
, ... .......
______ .-
,
"R"
- (0.0004 in)
C = MaximumO
T = (Maximum 0 1 or 0 2 ) -
(Maximum 0 5 or 0 6 )
R = (Maximum 01, 0 3 or 0 5 ) -
(Minimum 0 2, 0 4 or 0 6 )
• If out of specification, replace cylinder, and
replace piston and piston rings as a set.
5-8
INSPECTION AND REPAIR ENG ...
2nd step:
• Measure the piston skirt diameter "P" with
a micrometer.
® 20 mm (0.8 in) from the piston bottom
edge.
Piston size P
307-000 63mm
Standard
(2.480 in)
• If out of specification, replace piston and

piston rings as a set.
3rd step:
• Calculate the piston-to-cylinder clearance
with the following formula:
Piston-to-cylinder clearance =
Cylinder bore "C" -
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: 0.1 mm (0.004 in)
PISTON RINGS
1. Measure:
• Side clearance
Out of specification ---> Replace piston and/
or rings.
Use a feeler gauge CD .
NOTE: - - - - - - - - - - - - - - - -
Eliminate the carbon deposits from the piston
ring grooves and rings before measuring the
side clearance.
0.03 - 0.05 mm
Top
(0.001 - 0.002 in)
- - - Side
clearance 0.03 - 0.05 mm
2nd
(0.001 - 0.002 in)
5-9
INSPECTION AND REPAIR IENG I,. I
2. Install:
• Piston ring
(into the cylinder)
Push the ring with piston crown.
NOTE: ~~~~~~~~~~~~~
Insert the ring into the cylinder, and push it
approximately 20 mm (0.8 in) into the cylinder.
Push the ring with the piston crown so that th~
ring will be at a right angle to the cylinder bore.
3. Measure:
•End gap
Out of specification ~ Replace rings as a
® set.
Use a feeler gauge ©.
0.35 - 0.55 mm
Top
(0.014 - 0.020 in)
End gap
'307·02:1 0.35 - 0.55 mm
2nd
(0.014 - 0.020 in)
@20 mm (0.8 in)
PISTON PIN AND BEARING

1. Inspect:
• Piston Pin
Blue discoloration/Grooves ~ Replace
piston pin and inspect lubrication system.
• Small end bearing
Blue discoloration/Bearing turns roughly
~ Replace bearing and inspect lubrication
system.
2. Measure:
@
• Outside diameter @(piston pin)
Outside diameter (l:>iston pin):

16.000 -16.005 mm
(0.6300 - 0.6301 in)
'307-018
5-10
INSPECTION AND REPAIR IENG I~ I
3.Measure:
• Piston pin-to-piston clearance
Out of specification --+ Replace piston.
Piston pin-to-piston clearance =

Bore size (piston pin) @ -
Outside diameter (piston pin) @
Piston pin-to piston clearance =

0.065 .. 0.070 mm
(0.0026 .. 0.0028 in)
CRANKSHAFT
1. Measure:
• Runout
Use V-blocks and a dial gauge
Out of specification--+ Replace or repair.
Dial gauge:
90890-03097 I YU-03097
Runout limit:
C1·C4 : 0.03 mm (0.0012 in)
C2, C3 : 0.04 mm (0.0016 in)
@ 65 mm (2.6 in)
@ 32.5 mm (1.3 in)
2.Measure:
• Small end free play
Use a dial gauge.
Out of specification --+ Replace the defective
, parts.
Small end free play:

0.8 .. 1.0 mm (0.031 .. 0.039 in)
5-11
INSPECTION AND REPAIR I I'- I
ENG
3. Measure:
• Big end side clearance @
Use a feeler gauge.
Out of specification -+ Replace the defective
parts.
Big end side clearance @ :

0.5 mm (0.02 in)
•Crank wide "A", "B"

Out of specification -+ Replace or repair.
Crank wide:
"A": 55.95 - 56.00 mm
(2.202 - 2.204 in)
"B": 167.85 - 168.15 mm
(6.608 - 6.620 in)
4. Inspect:
• Crankshaft bearing CD
Pitting/Damage -+ Replace.
• Stopper ring ®
Bend/Damage -+ Replace.
•Oil seals@
• Drive gear (inner© and outer®)
Lubricate the bearing immediately after

examining them to prevent rust.
DRIVE SHAFT
1. Inspect:
• Drive shaft CD
Bend/Damage-+ Replace.
•Oil seal®
• Bearings@
I Pitting/Damage -+ Replace.
®
5-12
INSPECTION AND REPAIR I I~ I
ENG
• Driven gear ©
Bolt (driven gear):

48 Nm (4.8 m • kg, 35 ft • lb)
REED VALVE AND INTAKE MANIFOLD

1. Disassemble:
• Reed valves
2. Inspect:
• Reed valves
Bent/Cracks/Damage --> Replace.
3. Install:
• Reed valves
• Reed valves stoppers
NOTE:------------------------
• Place the reed valve CD with its concave surface
facing the reed valve seat® .
• Fit the reed valve stopper cut @ with the
corresponding cut© on the reed valve.
u 0
4. Tighten:
• Screws CD (reed valve)
Screws (reed valve):
1 Nm (0.1m•kg,0.7 ft• lb)
LOCTITE®
NOTE:------------------------
Tighten each screw gradually to avoid warping.
5-13
INSPECTION AND REPAIR IENG I'- I
5. Measure:
• Valve stopper height @
Valve stopper height:

8.8 - 9.2 mm (0.35 - 0.36 in)
6.Measure:
• Reed valve bending limit @
Reed valve bending limit:

0.6 mm (0.024 in)
7. Inspect:
• Air chamber
Cracks/Damage -> Replace.
CRANKCASE
1. Thoroughly wash the case halves in mild sol-
vent.
2. Clean all the gasket mating surfaces and case
mating surfaces thoroughly.
3. Inspect:
• Crankcase
Cracks/Damage -> Replace.
5-14
ENGINE ASSEMBLY AND ADJUSTMENT IENG I'ft I
ENGINE ASSEMBLY AND
ADJUSTMENT
CRANKCASE AND CRANKSHAFT
CD Upper crankcase ® Labyrinth seal
®Lower crankcase @Crank pin
@Oil seal @ Stopper ring
©Bearing @ Drive gear (inner)
@crank @Drive gear (outer)
®washer @Driven gear
(J) Connecting rod ® Drive shaft
@ Big end bearing @ Woodruff key
* Yamaha bond No.5
26 Nm (2.6 m • kg, 19 ft• lb)
5-15
ENGINE ASSEMBLY AND ADJUSTMENT I I'\. I
ENG
1. Assembly:
• Crankshaft assembly (left and right)
NOTE:-------------------------
Align the punch mark@ on the drive gear (outer)
with the punch mark@ on the drive gear (inner).
2. Install:
• Crankshaft assembly
• Drive shaft
(to upper crankcase)
NOTE: -------------------------
Set the knock pins CD on the bearing ® and
labyrinth seal into the pin holes on the upper
crankcase by turning the bearings and labyrinth
seal.
• The oil seal lip @ must fit into the crankcase

groove.
• The circlip must fit into the crankcase and
bearing grooves.
3. Install:
• Stopper rings CD
(onto center bearing)
®Knock pin
[A] Lower case
~Uppercase
4. Install:
• Circlips CD
(onto both side bearing)
NOTE: -------------------------
The circlip must fit into the crankcase and oil seal
projection ® .
[A] Lower case

~ Uppercase
5-16
ENGINE ASSEMBLY AND ADJUSTMENT I I~ I
ENG
5.Apply:
• Yamabond No. 5®
(to mating surfaces of both case halves)
6. Install:
• Dowel pins CD
7. Install:
• Lower crankcase CD
(onto upper crankcase ®)
NOTE:-------------------------
Tap lighty on the case with a soft-head hammer.
Before installing and torquing the crankcase

bolts, be sure to check whether the crankshaft
and drive shaft are turning smoothly.
8.Tighten:
• Bolts (crankcase)
NOTE: -------------------------
Tighten the bolts in order starting with the
smallest number and torque the bolts in two
stages.
Bolt (crankcase):
26 Nm (2.6 m • kg, 19 ft• lb)
*marked:
13 Nm (1.3 m •kg, 9.4 ft• lb)
9.Apply:
• 2-stroke engine oil
(to crankpin, bearing and oil delivery hole)
5-17
ENGINE ASSEMBLY AND ADJUSTMENT IENG I~ I
PISTON, CYLINDER AND CYLINDER HEAD
CD Piston ring @ Gasket
® Piston ® Water jacket joint
@ Piston pin @Spark plug
© Piston pin clip @Cylinder head
@ Small end bearing @ Head gasket
®Thermostatic valve cover @Cylinder
CV Thermostatic valve ® Cylinder gasket
7 Nm (0.7 m •kg, 5.1 ft• lb)
28 Nm (2.8 m • kg, 20 ft• lb)
22 Nm (2.2 m •kg, 16 ft• lb)
A USE NEW ONE
28 Nm (2.8 m • kg, 20 ft• lb)
14
A USE NEW ONE

14
5-18
ENGINE ASSEMBLY AND ADJUSTMENT ENG ~".
PISTON
1.Apply:
• 2-stroke engine oil (liberal coating)
(to piston pin, bearing, piston ring grooves
and piston skirt areas)
2. Install:
• Small end bearing
• Piston
• Piston pin
• Piston pin clip
• Piston rings
NOTE: ~-----------------------
• The arrow @ on the piston must point to the
front of the engine.
• Before installing the piston pin clip, cover the
crankcase with a clean rag so you will not
accidentally drop the pin clip and material
into the crankcase.
• Position each piston very carefully in its
original place.
D • Always use a new piston pin clip.

• Do not allow the clip open ends to meet the
piston pin slot.
n 2.Check:
• Piston ring position
• Make sure ring ends are properly fitted around

ring locating pins in piston grooves.
;;-&
-q • Be sure to check the manufacturer's marks or
·.·•1.· •
·l numbers stamped on the rings are on the top
side of the rings.
"
-~--
>.·.·.·.···.·•. CYLINDER AND CYLINDER HEAD

-
' F . •)
$. 1. Install:
• Gasket CD (cylinder)
•Cylinder®
11.,tl•-l1filll,; ________
Always use a new gasket.
NOTE: ~-----------------------
1nsta1 I the cylinder with one hand while
compressing the piston rings with the other hand.
Nut (cylinder ):
28 Nm (2.8 m • kg, 20 ft • lb)
5-19
ENGINE ASSEMBLY AND ADJUSTMENT _ ENG _ 9
2. Install:
I I'--·
• Gaskets G) (cylinder head)
• Cylinder head
Always use a new gasket.
3. Tighten:
• Nuts (cylinder head)
NOTE: -------------------------
Tighten the nuts in order starting with the smallest
number and torque the bolts in two stages.
Nut (cylinder head):

22 Nm (2.2 m •kg, 16 ft• lb)
Spark plug:
28 Nm (2.8 m • kg, 20 ft • lb)
MAGNETO ROTOR
1. Install:
• Woodruff key
2. Install:
• Magneto rotor
•Washer
• Nut (magneto rotor)
Be sure to remove any oil and/or grease from the

tapered portion of the magneto rotor using a
dampened cloth with thinrier.
NOTE: ----------------------~
When installing the magneto rotor, make sure the
woodruff key is properly seated in the keyway of
the crankshaft.
5-20
ENGINE ASSEMBLY AND ADJUSTMENT I I,. I
ENG
3.Tighten:
Nut CD (magneto rotor):

85 Nm (8.5 m • kg, 61 ft • lb)
NOTE: ------------------------
Use the primary sheave holder ® to hold the
magneto rotor @.

90890-01701, VS-01880
4. Install:
•Dowel pin
• COi magneto cover CD
• Bearing holder ®
Bolt (CDI magneto cover):

23 Nm (2.3 m •kg, 17 ft• lb)
Bolt (bearing holder):
26 Nm (2.6 m • kg, 19 ft • lb)
WATER PUMP
1. Install:
• Gasket
•Dowel pins
• Water pump assembly CD
Bolt (water pump housing assembly):
10 Nm (1.0 m •kg, 7.2 ft• lb)
NOTE: -------------------------
Mesh the water pump gear with the drive gear on
the crankshaft.
WATER JACKET JOINT

1. Install:
• 0-rings
• Water jacket joint CD (lower)
• Gaskets
• Water jacket joint ®(upper)
2. Connect:
• Breather hose @
Bolt (water jacket joint):

10 Nm (1.0 m •kg, 7.2ft •lb)
NOTE: -------------------------
Apply the coolanttothe 0-ring, when installing the
water jacket joint (lower).
5-21
ENGINE ASSEMBLY AND ADJUSTMENT
OIL PUMP
I I'tt I
ENG
1. Install:
• 0-ring
Screw (oil pump assembly):
4 Nm (0.4 m • kg, 2.9 ft• lb)
NOTE: ----------------------~
• Apply an engine oil to the 0-ring.
• Make sure the projection @fits into the slot@
on the water pump housing correctly.
RECOIL STARTER
1. Install:
• Woodruff key
• Recoil starter pulley CD
• Recoil starter assembly ®
Bolt (starter polley):

45 Nm (4.5 m • kg, 32 ft • lb)
Bolt (recoil starter assembly):
7 Nm (0.7 m •kg, 5.1 ft• lb)
ENGINE BRACKETS
1. Install:
• Engine brackets CD (front)
Bolts (engine brackets):
30 Nm (3.0 m • kg, 22 ft • lb)
2. Install:
• Engine brackets CD (rear)
Bolts (engine brackets):
30 Nm (3.0 m • kg, 22 ft • lb)
5-22
ENGINE ASSEMBLY AND ADJUSTMENT I ENG , , . ,
INTAKE MANIFOLDS AND REED VALVES
1. Install:
• Gaskets CD
• Reed valves ®
• Intake manifolds @
Bolts (intake manifolds):

10 Nm (1.0 m •kg, 7.2 ft• lb)
EXHAUST MANIFOLD
1. Install:
• Gaskets
• Exhaust manifolds CD
Bolts (exhaust manifolds):
25 Nm (2.5 m • kg, 18 ft • lb)
REMOUNTING ENGINE
Reverse the "ENGINE REMOVAL" procedure.
1. Install:
• Engine assembly
• Nuts CD (engine bracket)
NOTE:------------------------
Before tightening the nuts (engine bracket) the
sheave distance should be adjusted.
Nuts (engine brackets):

40 Nm (4.0 m • kg, 29 ft·· lb)
2. Fill:
• Cooling system (See page 2-12)
· • Drive gear housing (See page 2-11)
3.Air bleed:
• Oil pump (See page 2-4)
4.Adjust:
• Sheave distance (See page 4-14)
• Sheave offset (See page 4-15)
• Throttle cable (See page 2-14)
• Oil pump cable (See page 2-5)
• Starter cable (See page 2-15)
5-23
RECOIL STARTER IENG I~ I
RECOIL STARTER
CDRecoil starter case (J) Drive pawl
®Starter rope @ Drive pawl driver
@ Starter handle ® Drive plate
© Starter spring @ Recoil starter pulley
@ Sheave drum @ Woodruff key
® Return spring
7 Nm (0.7 m • kg, 5.1 ft• lb)
30 Nm (3.0 m • kg, 22 ft• lb)
5-24
RECOIL STARTER
ENG
REMOVAL "·
1.Remove:
• Muffler
• Starter handle CD
• Recoil starter
NOTE: ------------------------
To remove the starter handle, loosen the knot
®in the starter rope and then re-tie a knot @ in
the rope end so that it will not be pulled into the
recoil starter case ©.
ASSEMBLY AND INSTALLATION

1. Hook the starter spring around the post in
the starter case. Carefully wind the spring
counterclockwise, and fit the spring into the
case.
NOTE: ------------------------
After installing the spring thoroughly apply the
low-temperature grease.
2. Pass the starter rope end into the sheave

drum, and knot the rope end. Then fit the knot
into the cutout in the sheave drum.
3.Wind:
• Starter rope (2 turns clockwise)
(to sheave drum)
NOTE: ----------------------~
Make sure the rope CD is more than 400m (15.7 in)
long.
4. Install:
• Sheave drum CD
(into starter case®)
NOTE: -------------------------
Be sure the inner hook on the starter spring
hooks around the post on the sheave drum.
5-25
RECOIL STARTER_
5.Apply:
IENG I""• I _ \IP _
• Grease (lightly)
(to pivot point of the drive pawl)
1-1 Low-temperature grease
6. Install:
• Return spring <D
• Drive pawl ®
NOTE: ------------------------
Hook the return spring end to the drive pawl ® .
Then, hook other end of the return spring to
the hole@ on the sheave drum.
7. Install:
• Drive plate
• Drive pawl driver
•Nut
NOTE:------------------------
Be sure the tip of the drive pawl driver faces to
sheave drum side.
Nut (drive plate):

10 Nm (1.0 m •kg, 7.2 ft• lb)
LOCTITE®
8. Pull about four inches of starter rope from

out of the cutout portion in the sheave drum,
and rotate the sheave drum five times clock-
wise to preload the starter spring.
Then knot the rope end so that it will not be
pulled into the recoil starter case.
5-26
RECOIL STARTER IENG 1-..1
9. Install:
• Recoil starter
• Starter handle
Bolt (recoil starter):

7 Nm (0.7 m •kg, 5.1 ft• lb)
10. Check the starter for smooth operation. If it

does not operate smoothly, repair it.
5-27
CHAPTER 6.
COOLING SYSTEM
COOLANT FLOW .............................................. 6-1
COOLING LINE ................................................. 6-2
COOLING SYSTEM ........................................... 6-3

REMOVAL ................................................... 6-3
INSPECTION ............................................... 6-6
INSTALLATION ........................................... 6-9
cooLANT Flow fooLI ~ I
COOLING SYSTEM
COOLANT FLOW
CD Water pump housing @ Heat exchanger (center)
® Thermostatic valve housing @ Heat exchanger (rear)
@ Hose (inlet) @ Bleeding bolt
© Coolant filler cap [Kl Top view
@ Reservoir tank rnJ Side view
@Radiator
(j) Radiator cap
@ Hose (outlet)
··---r
..
..
---··-
B
"
-~
'
~
s ./
,.---------- ~
~\
\,
(___/ ;
d
6-1
cooLANT Flow lcooLI K I
COOLING LINE
CD
® Heat
Hose exch anger (rear)
@ Heatexch
© Reservo· anger (center)
@Th irtank
ermo switch
® Radiator
(j) Radiator cap
~/ I
~o ! 4
6-2
coouNG svsTEM lcooLI K I
COOLING SYSTEM
REMOVAL
1.Remove:
• Carburetor assembly
(See page 7-3)
• Secondary sheave
(See page 4-10)
2. Drain the coolant. (See page 2-8)

3.Remove:
•Bands CD
4. Disconnect:
• Ground lead ®
• Thermo switch lead @
5.Remove:
• Hose© (inlet)
6.Remove:
• Hose CD (outlet)
7. Disconnect:
• Reservoir tank hose CD
Drain the coolant.
NOTE: ----------------------~
Place a container under the reservoir tank to catch
the draining coolant.
8.Remove:
• Bolts CD (radiator)
• Radiator duct® /radiator @
• Radiator@
(From radiator duct)
6-3
coouNG svsTEM jcooLj KI
9.Remove:
• Thermostatic valve cover CD
• Thermostatic valve @
• Water jacket joint@ (outlet)
• 0-rings
10.Remove:
• Coolant hose CD
NOTE: ------------------------
Place a rag under the coolant hose to catch the
drainning coolant.
• Bolt@ (water pump cover)

• Screws @(water pump cover)
11.Remove:
• Bolts CD (Water jacket joint-inlet)
• Water pump cover @
• Dowel pins @
• Gasket© (water pump cover)
• Impeller@
NOTE:-----------------------
Attach the primary sheave holder to hold the
primary sheave.

90890-01701, YS-01880
12.Remove:
• Water pump assembly CD
•Dowel pins
•Washer@
• Collar@
• Gasket
• Oil pump assembly ©
• Water jacket joint @(inlet)
• 0-rings
6-4
COOLING SYSTEM ~OOLI K I
13. Remove:
• Water pump housing cap CD
•Dowel pins
• Driven gear ® (water pump)
• Baffle plate @
.,,t;;;.i'.
~-vv
,¢_..""';
14. Disconnect:
• Fuel hoses CD
A WARNING
Plug the fuel hoses so fuel dose not run out.
Spilled fuel can be a fire hazard.
• Fuel sender coupler ®
15.Remove:
• Nuts (fuel tank)
• Fuel tank@
NOTE:------------------------
Pull back the fuel tank while lifting up the center
cover©.
16.Remove:
• Slide rail suspension (See page 4-30)
• Track (See page 4-37)
• Rivets CD
• Heat exchangers®
6-5
coouNG svsTEM lcooLI X I
INSPECTION
1. Inspect:
• Radiator core
Obstruction--+ Blowout with compressed air
through rear of the radiator.
Flattened fin --> Repair/replace.
•Hose
2.Measure:
• Radiator cap opening pressure
Cap opens at pressure below the specified
pressure--> Replace.
Cap opening pressure:

80-100 kPa
(0.8 - 1.0 kg/cm2 , 11 - 14 psi)
Measurement steps:
• Attach the cooling system tester CD to the
radiator filler cap ® .
Cooling system tester:

90890-01325, YU-22460-01
• Apply the specified pressure for 10 seconds,

and make sure there is no pressure drop.
3. Inspect:
• Thermostatic valve CD
© Valve does not open at 50.0 - 55.0°C
(122 - 131°F)--.. Replace.
Inspection steps:
• Suspend thermostatic valve CD in a vessel
®·
• Place reliable thermometer in a water @.
• Heat water slowly.
• Observethermometer@,whilestirringwater
continually.
NOTE: ~~~~~~~~~~~~
Thermostatic valve is sealed and its setting is
preset. If its accuracy is in doubt, always replace it.
A faulty unit could cause serious overheating or
overcooli ng.
6-6
coouNG svsTEM lcooLI K I
4. Inspect:
• Thermostatic valve cover CD
• Water jacket joint ®(inlet)
• Water jacket joint @(outlet)
Cracks/Damage --.. Replace.
5. Inspect:
• Water pump housing cover CD
• Impeller®
• Water pump housing @
• Driven gear © (water pump)
• Water pump housing cap ®
Cracks/Damage --.. Replace.
6. Inspect:
• Damper rubber CD
• Thrust collar ®
Wear/Damage--.. Replace.
Replacement steps:
• Pry out the thrust collar® with a thin screw-
driver@ and remove the damper rubber CD.
111111111------------~
Be careful not to scratch the impeller © .
• Apply tap water or coolant to the damper

rubber and install the damper rubber and
thrust collar securely to the impeller.
NOTE:~------------------~
• Be sure the thrust collar® fits squarely.
• The rubber damper and thrust collar should
be replaced as a set.
7. Inspect:
•Oil seal CD
• Mechanical seal ®
Wear/Damage --.. Replace.
•Bearings@
Roughness --.. Replace.
!Al Water pump housing cover

~ Water pump housing cap
6-7
coouNG svSTEM jcooLI K I
Replacement steps:
• Tap off the oil seal CD and bearing(s) ®from
the water pump housing @ and/or water
pump housing cap© .
• Tap off the mechanical seal@from the water
pump housing @.
• Install the new bearing(s) and oil seal.
NOTE:-----------------------
Use a socket ® that matches the outside
diameter of the race (j) of the bearing and oil
3 seal.
Do not strike the inner race or balls of the

bearing.Contact should be made only with the
outer race.
• Install the new mechanical sealCDto the water

pump housing @
• NOTE:----------------------
Apply Yamaha bond No. 4 or Quick gasket® to
the water pump housing before installing seal.
8. Inspect:
• Coolant hoses CD
• Heat exchangers ®
Crack/Damage -+ Replace.
6-8
coot1NG svsTEM lcooLI K I
INSTALLATION
1. Apply a sealant onto matching surfaces of the
pump housing CD and housing cap.
Yamaha bond No. 4:

Quick gasket®:
ACC-11001-03-00
2. Install:
• Baffle plate
• Driven gear (water pump)
• Dowel pins
• Water pump housing cap
Screw (water pump housing cap)

7 Nm (0.7 m •kg, 5.1 ft• lb)
NOTE: ~~~~~~~~~~~~-
Before installing the driven gear, grease the oil
seal lips.
3. Install:
(to water pump housing)
• Water pump assembly®
Screw (Oil pump assembly):

4 Nm (0.4 m • kg, 2.9 ft • lb)
Bolt Screw (water pump housing
assembly):
10 Nm (1.0 m •kg, 7.2 ft• lb)
NOTE: ~~~~~~~~~~~~~
• Before installing the oil pump assembly, grease
the a-ring @.
• Align the slot@on the driven gear shaft with the
projection @on the oil pump shaft.
4. Tighten:
• Impeller CD
'~
· •
•.... ··. ·.·.r.·
. •...· ·.· ..·. .·.······"'····.··.·.·.····;
.·.·. .•.•. Impeller
~- ,_ -_,_/_,
14 Nm (1.4 m •kg, 10 ft• lb)
NOTE: ~~~~~~~~~~~--
Apply LOCTITE® to the first 4 threads of the driven
gear shaft.
6-9
coouNG svsTEM !cooLI K I
5.Tighten:
Bolt (water jacket joints):

10 Nm (1.0 m •kg, 7.2 ft• lb)
Bolt (thermostatic valve cover):
7 Nm (0.7 m •kg, 5.1 ft• lb)
Bolt (radiator duct/radiator): ·
7 Nm (0.7 m • kg, 5.1 ft• lb)
6. Fill:
7. Inspect:
• Cooling system
Inspection steps:
• Attach the radiator cap tester CD to the radia-
tor.
Radiator cap tester:

90890-01325, VU-24460-01
• Apply 90 kPa (0.9 kg/cm 2, 13 psi) pressure.

• Measure pressure with the gauge.
Decrease of pressure (leaks)-> Repair as re-
quired.
6-10
CHAPTER 7.
CARBURETION
CARBURETOR ................................................... 7-1

REMOVAL .................................................... 7-3
DISASSEMBLY ............................................ 7-4
INSPECTION ................................................ 7-7
ASSEMBLY .................................................. 7-8
INSTALLATION ......................................... 7-11
FUEL LEVELADJUSTMENT ..................... 7-11
FUEL PUMP ..................................................... 7-12

OPERATION CHECK .................................. 7-12
cAReuREToR lcARBI 1i1 I
CARBURETION
CARBURETOR
CD Throttle valve ® l\llain jet
®Jet needle @ Pilotjet
@ Pilot air jet (jJ)
Pilot screw
(1) l\llain air jet @Float
@ Starter plunger @ Drain screw
® Valve seat assembly @ Float chamber
(j) l\llain nozzle @ Throttle stop screw
@ l\llain jet ring @Carburetor switch
2 Nm (0.2 m • kg, 1.4 ft• lb)
I 3.5Nm (0.35 m • kg, 2.5 ft• lb) I

v
7-1
_ _ _ _ _ _ _ _ _ _ _ _c_AR_e_u_RE_r_o_R lcARsl iJ I
CDThrottle valve ®Pilot jet
®Jet needle (j) Pilot screw
@ Main nozzle @ Starter plunger
© Needle valve ® Starter jet
@Main jet
II
\I
II
11
I I
II
11
______l11\
I I
I I I I
IL-----------------------~'
~-------------------------~
7-2
cAReuREToR lcARsl ljJ I
REMOVAL:
1.Remove:
• Intake silencers (left and right)
(see page 2-4)
2. Disconnect:
• Carburetor switch (T.O.R.S.) leads <D
3.Remove:
• Air chambers ®(left and right)
4. Disconnect:
• Starter cable <D
• Throttle cable ®
5.Loosen:
• Clamp screws <D (carburetor joint)
6. Disconnect:
• Fuel delivery hoses <D
A WARNING
Plug the fuel delivery hoses so that fuel does not
run out. Spilled fuel can be a fire hazard.
7.Remove:
• Carburetor assembly <D
8. Drain:
•Fuel
(from float chambers@)
@ Drain screw
7-3
cAReuREToR lcARel fjJ I
DISASSEMBLY
Because the pilot screw is adjusted and set at the

factory before being shipped, it should not be
disassembled unless strictly necessary. If the unit
must be disassembled, make a note of the
position in which it is placed, and make sure it is
returned to the same position when assembled.
NOTE:-----------------------
The following parts can be cleaned and inspected
without carburetor separation.
(All inner parts except throttle valve can be
cleaned and inspected without carburetor
separation.)
• Starter plunger
• All jets
• Float
• Needle valve
• Valve seat
• Main nozzle
• Jet needle
1.Remove:
• Starter cable holder <D
• Cap ® (starter shaft)
• Spring @(starter shaft)
2.Loosen:
• Screws <D (starter shaft connector)
3.Remove:
• Starter shaft ®
• Starter shaft connectors @
4.Remove:
•Top covers©
5.Remove:
• Screws <D (inner throttle lever)
7-4
cARsuRETOR lcARBI il I
6.Remove:
• Bands
• Connecting plate CD (upper)
7.Remove:
• Connecting plate CD (lower)
• Carburetors (No. 1 ® , No. 2 @, No. 4 © )
• Return spring@
8.Remove:
• Spring pin CD
• Connecting lever ®
• Return spring@
• Carburetor ©(No. 3)
9.Remove:
•Washer CD
• Spring pin ®
• Connecting lever @
• Throttle lever ©
•Washer@
• Circlip ®
10. Remove:
• Carburetor switch CD (T.O.R.S.)
Turn throttle stop screw ®clockwise.
• Throttle cable holder @
©No. 3 carburetor
7-5
cAReuREToR lcARBI ljJ I
11.Remove:
• Throttle valve assembly CD
•Screws®
• Inner throttle lever assembly@
• Jet needle ©
•Washer@
12. Remove:
• Starter plunger assembly CD
13.Remove:
• Pilot screw CD
•Spring®
•Washer@
• 0-ring ©
• Float chamber @
NOTE: -------------------------
Count and write down the numbers of turns the
pilot screw was turned in.
14.Remove:
• Main jet CD
• Main jet ring ®
• Main nozzele @
• Pilotjet ©
• Pipe @(pilot jet)
15. Remove:
• Float pin CD
•Floats®
• Needle valve @
• Screw ©(valve seat)
• Valve seat assembly @
@O-rings
(i)Fuel strainer
7-6
cARsuRETOR !cARsl il I
16. Remove:
• Pilot air jet CD
• Main air jet®
INSPECTION
1. Inspect:
• Carburetor body
• Fuel passage
Contamination~ Clean.
NOTE: ~~~~~~~~~--~~-
• Use a petroleum based solvent for cleaning.
• Blow out all passagesandjetswithcompressed
air.
2. Inspect:
• Rubber seals CD
• Bearing®
3. Inspect:
• Floats CD
• Main jet®
• Pilot jet@
• Main nozzle ©
• Valve seat assembly @
• Pilot screw assembly ®
• Starter plunger assembly (j)
• Jet needle @
• Pilot air jet @
• Main air jet ®
Bends/Wear/Damage ~ Replace.
Contamination~ Clean.
NOTE: ~~~~~~~~~~-----
I\t-.··
..•..... · ~
• Use a petroleum based solvent for cleaning.
• Blow out all passages and jets with compressed
air.
7-7
cAReuREroR lcARBI fjJ I
3. Inspect:
• Throttle valve CD
4.Check:
• Throttle valve movement
Stick-+ Replace carburetor body assembly.
5. Inspect:
• Connecting plate CD (upper)
• Connecting plate ®(lower)
• Starter shaft @
• Starter connector ©
• Return spring@
• Connecting lever ®
• Throttle lever (j)
• Inner throttle lever assembly@
• Throttle shaft®
Bends/Cracks/Wear/Damage -+ Replace.
ASSEMBLY
Reverse the "DISASSEMBLY" procedure. Note
the following points.
NOTE: ------------------------
• Before reassembling, wash all parts in clean
gasoline.
• Always use a new gasket and 0-ring.
1.Tighten:
• Inner parts
Pilot air jet/Main air jet:

0.7 Nm (0.07 m •kg, 0.51 ft• lb)
Screw (valve seat):
1 Nm (0.1m•kg,0.7 ft• lb)
Pilot jet:
0.7 Nm (0.07 m • kg, 0.51 ft • lb)
Main jet:
0.8 Nm (0.08 m • kg, 0.58 ft • lb)
Startor plunger assembly:
2.5 Nm (0.25 m • kg, 1.8 ft • lb)
7-8
cARsuREToR lcARsl ljl J
2.Measure:
• Float height @
Out of specification -+ Adjust.
@
Float height:
11.3 - 15.3 mm (0.44 - 0.60 in)
Measurement and adjustment steps:

• Hold the carburetor in an upside down posi-
tion.
• Measurethediatance between the carburetor
body and top of the floats.
NOTE:-----------------------
Thefloatarm should be resting on the valve, but
not compressing the needle valve.
• If the float height is not within specification,

inspect the valve seat and needle valve.
• If either is worn, replace them both.
• If both are fine, adjust the float height by
bending the float arm tang CD on the float.
• Recheck the float height.
3. Lubricate:
• Rubber seals
• Bearings
•Washer
• Return spring
Low-temperature lithium soap base

grease
4. Install:
• Return springs CD
• Carburetors (No. 3 ® , No. 2 @)
NOTE: ----------------------~
Hook the spring hooks ©to the projections on the
connecting lever@and carburetor body@, while
twisting the spring clockwise approximately 315
degrees.
7-9 • Carburetors (No. 1, No. 4)

cARsuReToR lcARsl ljl I
5. Install:
• Connecting plate CD (lower)
• Connecting plate ® (upper)
Screw (connecting plates):
3.5 Nm (0.35 m • kg, 2.5 ft • lb)
NOTE: ------------------------
Plate the carburetors on a surface plate with the
intake manifold side down, Install the connecting
plates while pushing the respective carburetors
down with an even force.
6. Tighten:
• Screws CD (inner throttle lever)
Screw (inner throttle lever):
2 Nm (0.2 m •kg, 1.4ft •lb)
7. Install:
• Starter shaft connectors CD
• Starter shaft ®
NOTE: -------------------------
Align the tip @of the screw with the indentation
@on the starter shaft.
8. Install:
• Starter cable holder CD
Screw (starter cable holder):
3.5 Nm (0.35 m • kg, 2.5 ft • lb)
NOTE:------------------------
Make sure the throttle lever and starter lever move
smoothly.
7-10
cARsuReToR lcARsl il I
INSTALLATION
Reverse the uREMOVAL" procedure.
1.Adjust:
• Carburetor synchronization (See Page 2-13)
• Engine idle speed (See page 2-13)
• Throttle cable free play (See page 2-14)
• Starter cable free play (See page 2-15)
FUEL LEVEL ADJUSTMENT

1. Measure:
• Fuel level
Out of specification --+ Adjust.
Fuel level: @
5 - 7 mm (0.20 - 0.28 in)
Measurement and adjustment steps:

• Place the machine on a level place.
• Attach the fuel level gauge CD to the float
chamber nozzle.
~
Fuel level gauge:
90890-01312, YM-01312-A
NOTE:
Use the adapter (outside diameter !116 hose)®
when attaching the fuel level gauge.
• Loosen the drain screw @ and start the

engine.
• Measure the fuel level a with 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 fine, adjust the float height by
bending the float tang© on the floats.
• Recheck the fuel level.
7-11
____________Fu_E_L_Pu_M_P lcARBI iJ I
FUEL PUMP
OPERATION CHECK
1.Remove:
• Intake silencers (left and right)
(See page 2-4)
• Carburetor assembly (See page 7-3)
2. Inspect:
• Fuel hose CD
• Fuel delivery hoses ®
• ~ulser hose@
Clog/Damage _,. Replace.
© Fuel pump (right)

®Fuel pump (left)
3.Check:
• Fuel pump operation
Checking steps:
• Connect a hand-operated vacuum pump CD
(Such as Mighty-Vac®) to the pulser hose®.
• Place a receptacle @ under the fuel delivery
hoses end©.
• Operate the hand-operated vacuum pumpCD
(Such as Mighty-Vac®), when checking the fuel
flow from the fuel delivery hoses © .
• If fuel does not flow out, replace the fuel
pump assembly.
• To replace the fuel pump assembly, perform
the following steps from 4 to 6.
7-12
FUEL PUMP lcARBj i'J I
4. Replace:
• Fuel pump assembly
Nut (fuel pump assembly):

10 Nm (1.0 m •kg, 7.2 ft• lb)
5. Connect:
• Pulser hose CD
• Fuel hose®
• Fuel delivery hose @
(to fuel pump)
© Fuel pump (right)
@ Fuel pump (left)
[Al From oil pump
ml From fuel tank
~ To right side crankcase
IQ] To left side crankcase
~ To No. 1 carburetor
[El To No. 2 carburetor
[ill To No. 3 carburetor
[HJ To No. 4 carburetor
7-13
CHAPTER 8.
ELECTRICAL
CIRCUIT DIAGRAM ........................................... 8-1
ELECTRICAL COMPONENT •.............••.•.....•... 8-3
IGNITION SYSTEM ...••.................•..••...............• 8-5

CIRCUIT DIAGRAM •...............••..•••.............. 8-5
TROUBLESHOOTING ......•.....•..••..............•. 8-7
SPARK PLUG .....•.•.•....•......••....................... 8-7
SPARK PLUG CAP ...............•.•.•••................ 8-7
IGNITION COIL .•..••...........••....•.•••••....•.•••••.•. 8-7
CHARGE COIL AND PULSER COIL ••...•••.... 8-7
HANDLEBAR SWITCH (RIGHT) .••..•......... 8-10
CARBURETOR SWITCH .............•....•........ 8-11
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) ..•.......••.•..•.......•.....•.....•...••....... 8-11
MAIN SWITCH ...••..............•..•••...••.•.••.....•. 8-12
VOLTAGE TEST ..•.•.....•.....••..••••....••..•..•..•. 8-12
CONDENSER ......................•.......••..•.••..•.••. 8-13
BULB •......••.••..•............••........•.........••......... 8-13
LIGHTING COIL (I) ........•.......•.....•............. 8-13
VOLTAGE TEST ..........•.......••...•.••...•......... 8-14
LIGHTING SYSTEM ..........••..•.•••...•..........•..... 8-15

CIRCUIT DIAGRAM ...........••....•...•.•.......••.. 8-15
TROUBLESHOOTING ................•....•......... 8-17
BULB (S) ................•.•...............•................. 8-18
HEADLIGHT BEAM SWITCH ....••..........•... 8-18
SIGNAL SYSTEM ..••.................••.............••..•.. 8-19

CIRCUIT DIAGRAM .............•.•........•...•...•.. 8-19
TROUBLESHOOTING .........•.........•.....•.•... 8-21
BRAKE LIGHT SWITCH .......•........•....•...... 8-24
THERMO SWITCH .........................•.........• 8-24
OIL LEVEL SWITCH .•................••.............. 8-25
LIGHTING COIL .......•.•................•....••........ 8-25
FUEL SENDER ..................................•........ 8-26
FUEL METER .........•...........•..............•........ 8-26
GRIP WARMER SYSTEM ..•..•................•..•••... 8-27

CIRCUIT DIAGRAM ................................... 8-27
TROUBLESHOOTING ...........•................... 8-29
RESISTOR ...•........•.................•.................. 8-30
GRIP AND THUMB WARMER COIL. ....•... 8-30
GRIP WARMER SWITCH .......................... 8-30
GRIP WARMER COIL ....••..•.............•......... 8-31
I 1-..i I
CIRCUIT DIAGRAM ELEC
ELECTRICAL
CIRCUIT DIAGRAM
~--Y/B---
8-1
CD Main switch @
CIRCUIT DIAGRAM ELEC
Brake light switch
I I• I
® "T.0.R.S." indicator light @)Tail/brake light
@Throttle switch ® Headlight beam switch
©Carburetor switch ®Headlight
@ "ENGINE STOP"switch @ "HIGH BEAM" indicator light
@ CDI unit @ Tachometer
(j) Pulser coil ®Thumb warmer
@ Ignition coil ® Grip warmer
@Spark plug @Resistor
@ "OIL LEVEL" warning light ® Grip warmer switch
(j]) Oil level gauge @ CDI magneto
@ "OIL LEVEL" warning light checker @ Condenser (1)
@ "WATER TEMP" warning light ® Rectifier/regulator (I)
@ Thermo switch ® Rectifier/regulator (II)
@"WATER TEMP" warning light checker @ Fuel sender
@ Speedometer light @Fuel meter
@ Tachometer light ® Condenser (II)
COLOR CODE
B Black Gy Grey Y/B Yellow/Black

L Blue w White Y/L Yellow/Blue
G Green B/Y Black/Yellow RIB Red/Black
y Yellow BIR Black/Red ·w/G White/Green
R Red B/W Black/White W/R White/Red
0 Orange G/Y Green/Yellow W/L White/Blue
Br Brown G/B Green/Black Br/R Brown/Red
Sb Sky blue G/R Green/Red
8-2
ELECTRICAL COMPONENT ELEC I Iliijj I
ELECTRICAL COMPONENT
Q) Main switch ® COi unit
® Grip warmer switch (j)
Rectifier/regulator (II)
@ Wireharness @Condenser
@ Oil level gauge ® Rectifier/regulator (I)
@ Ignition coil ®Resister
8-3
I I~ I
ELECTRICAL COMPONENT ELEC
CD Handlebar switch assembly (right)
® Throttle switch
@ CDI magneto
© Pick-up coil
@ Stator coil
® High beam switch
<J) Brake switch
I..
8-4
IGNITION SYSTEM I I~ I
ELEC
IGNITION SYSTEM
CIRCUIT DIAGRAM
CD Main switch @ CDI unit @ Condenser (I)
® uTORS" indicator light (j) Pulser coil ®> Rectifier/regulator (I)
@Throttle switch @ Ignition coil ® Rectifier/regulator (II)
©Carburetor switch ®Spark plug
@ uENGINE STOP" switch @ CDI magneto
@ -=
8-5
IGNITION SYSTEM I I• I
ELEC
TROUBLESHOOTING
IGNITION SYSTEM I I• I
ELEC
NO SPARK OR WEAK SPARK.
OUT OF SPECIFICATION
ICheck the spark plug.
I
t
Repair or replace the spark plug.
ICheck the spark plug cap.
I
l
Replace the spark cap.
ICheck the ignition coil.
I
l
Replace the ignition coils.
ICheck the source coil and pickup coil.
Replace the source coil and/or pickup coil.
FAULTY
Check the ENGINE STOP"switch, throttle . . . . . . . . . .. .
0
switch, carburetor switch and main switch. ..i

n OK
I Check for voltage on the condenser coupler.I:•••••••••••t

..
Replace the handlebar switch( right), car-
buretor switch and/or main switch.
OK
-------
Correct connection and/or replace the
rectifier/regulator(!)
ICheck the condenser (I).
I
l
Replace the condencer.
Correct connection and/or replace theCDI unit.
8-7
IGNITION SYSTEM IELECI liil I
"T.O.R.S." INDICATOR LIGHT DOES NOT COME ON.
NO CONTINUITY
I Check the bulb.
IReplace the bulb.
FAULTY
I Check the lighting coil (I).
IReplace the lighting coil (I).
FAULTY
I Check the throttle switch and carburetor switch. :l•••••••••••i•
OK
-------
Replace the throttle switch and/or carbu-
retor switch.
~'-C-he_c_k_f_o_rv_o_i_ta_g_e_o_n_t_h_e_m_e_t_e_rc_o_u_p_le_r_._ _~l••••••••••i ..
R OK
rectifier/regulator (II).
Correct connection and/or replace theCDI unit.
8-8
IGNITION SYSTEM
SPARK PLUG
I I• I
ELEC
1.Remove:
• Spark plugs
2. Check:
• Spark plug
Standard spark plug:

BR9ES (NGK)
377-000
Spark plug gap:
0.7 - 0.8 mm (0.028 - 0.031 in)
SPARK PLUG CAP
1.Remove:
• Spark plug cap
2. Connect:
• Pocket tester
(to spark plug cap)
3.Measure:
• Spark plug cap resistance
[;:;J ll Spark plug cap resistance:

~ 4.5 - 5.5 kO at 20°C (68°F)
CD
IGNITION COIL
1. Disconnect:
• Ignition coil lead (Orange)
• Spark plug lead
2. Connect:
• Pocket tester
(to ignition coil and spark plug lead)
3.Measure:
• Primary coil resistance CD
• Secondary coil resistance ®
Primary coil resistance:

0.1& - o.24 n at 2o·c (68"F)
Secondary coil resistance:
3.92 - 5.88 kO at 20"C (68°F)
tl-11~1 ___________
When the ignition coil CD has been removed,
always check the stamped printing on the top of
the coil before re-installing it, and make sure it is
installed in the correct position.
88R .... For No. 1 and No. 2 cylinders
88A ..•. For No. 3 and No. 4 cylinders
8-9
IGNITION SYSTEM I I~ I
ELEC
CHARGE COIL AND PULSER COIL
1 . Disconnect:
• CDI magneto coupler
• Pulser coil coupler
2. Connect:
• Pocket tester
(to charge coil leads and pulser coil leads)
3. Measure:
• Charge coil resistance 00
• Pulser coil resistance ~
Charge coil resistance:

(Brown, Black/Red)
2.295 - 2.805 .a at 2o·c (68°F>
Pulser coil resistance:
(White/Red, White/Blue and
White/Red, White/Green)
454.5 - 555.5 .a at 2o·c (68°F)
B
"'\
I
I
I
I
I
I
I
HANDLEBAR SWITCH (RIGHT)

"ENGINE STOP" switch and Throttle Switch
1 . Disconnect:
• Handlebar switch (right) coupler <D
2. Connect:
• Pocket tester
A 3.Check:
• "ENGINE STOP" switch continuity 00
Faulty -+ Replace.
Switch position Good condition

RUN (Pull) x
OFF (Push) 0
O : Continuity x : No continuity
8-10
IGNITION SYSTEM
4.Check:
IELEC Iilliiii I
B
• Throttle switch continuity (m
Faulty • Replace.
Throttle switch
Good condition
position
Throttle lever is
operated. 0
Throttle lever is not

operated. x
O: Continuity x : No continuity
CARBURETOR SWITCH
1. Disconnect:
• Carburetor switch lead CD
2.Connect:
• Pocket tester
3. Check:
• Carburetor switch continuity
Faulty-+ Replace.
Carburetor switch
Good condition
position
Throttle lever is
x
operated.
Throttle lever is not
operated. 0
B B/Y O: Continuity x : No continuity
I I
THROTTLE OVERRIDE SYSTEM (T.0.R.S.)

If the carburetor or throttle cable should malfunc-
tion during operation, the T.O.R.S. warning light
flashes when the throttle lever is released.
The T.O.R.S. is designed to interrupt the ignition
and prevent the engine from exceeding 2,800 to
3,000 rpm. if the carburetor fails to return to idle
when the lever is released.
A WARNING
• H T.O.R.S. warning light flashes, make sure
A
that the cause of the malfunction has been
corrected and that the engine can be operated
without a problem before restarting the
engine.
• Be sure to use the standard spark plug and
spark plug cap which have resistance.
Otherwise T.O.R.S. does not work properly.
8-11
IGNITION SYSTEM
~
I I~ I
ELEC
~
~
B Al1dle
or Run Trouble
SWITCH Starting
Throttle
switch OFF ON OFF
Carburetor
ON OFF OFF
switch
T.O.R.S Warning light
Engine RUN RUN turns on and off
CD Carburetor switch
®Throttle switch
@ Throttle cable
@ Throttle stop screw
@"ON"
@"OFF"
MAIN SWITCH
1. Disconnect:
• Main switch coupler CD
2.Connect:
• Pocket tester
3.Check:
• Main switch continuity
Faulty--> Replace.
Switch Color code

position B BN./ Br R
R
OFF - -
ON/LIGHT ~ ~
Br
0-0 Continuity
VOLTAGE TEST
1. Connect:
,' --.. ,) • Pocket tester
·.... ~-~·/ (to Red CD and Black ® leads on the con-
denser (I) coupler @)
2. Start the engine and run the engine at 3,000
r.p.m.
8-12
IGNITION SYSTEM
3.Measure:
I I• I
ELEC
• Output voltage
Output voltage:
(Red/Black)
14 - 15 Vat 20°C (68°F)
CONDENSER
1. Disconnect:
• Condenser CD
2.Connect:
• Condenser
(to LCR meter as shown)
00 For ignition [ID For fuel
3.Measure:
• Condenser capacity
Out of specification ---+ Replace.
Condenser capacity:
3.760 - 5.640 µFat 20°C (68°F)
BULB
1.Remove:
• T.O.R.S. indicator light bulb CD
(See page 2-25)
2.Connect:
• Pocket tester®
(to bulb terminals)
3.Check:
• Bulb continuity
No continuity ---+ Replace.
LIGHTING COIL (I)
1. Disconnect:
• CDI magneto coupler CD
2.Connect:
• Pocket tester
(to lighting coil (I) leads)
8-13
IGNITION SYSTEM I Iiiliii I
ELEC
3. Measure:
• Lighting coil resistance
Lighting coil resistance:

(Yellow, Black)
0.288 .. 0.352 Q at 20°C (68°F)
VOLTAGE TEST
1. Disconnect:
• Wire harness coupler ©
2. Connect:
• Pocket tester
(to Blue® and Black@leads on the coupler)
3. Start the engine and run the engine at 3,000
r.p.m.
4.Measure:
• Out put voltage
Out put voltage:

(Blue, Black)
12 V or more at 2o·c (68°F)
8-14
LIGHTING SYSTEM I Iliiiiiii I
ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM
@ Speedometer light ® Headlight beam switch @ Tachometer

@Tachometer light ®Headlight @ CDI magneto
@ Tail/brake light @ uHIGH BEAM"indicator light ® Rectifier/regulator
8-15
LIGHTING svsTEM IELEcl •I
19
8-16
LIGHTING SYSTEM I Iliiiiiil I
ELEC
TROUBLESHOOTING
HEADLIGHT, uHIGH BEAM " INDICATOR LIGHT,TAIL LIGHT, SPEEDOMETER LIGHT AND/OR
TACHOMETER LIGHT DO NOT COME ON.
NO CONTINUITY
I
i
Check the bulb (s).
IReplace the bulb(s).
FAULTY
Check the lighting coil (I).
(See page 8-13)
I
l
Replace the lighting coil (I).
FAULTY
I
l
Check the headlight beam switch.
I Replace the headlight beam switch.
Correct connectiont# and/or replace the

8-17
LIGHTING SYSTEM I Iiliil I
ELEC
BULB(S)
1.Remove:
• Headlight bulb (See page 2-25)
• Tail/brake light bulb
• Speedometer light bulb (See page 2-25)
• Tachometer light bulb (See page 2-25)
• "HIGH BEAM" indicatorlightbulb(Seepage
2-25)
2.Check:
• Bulb(s)
No continuity---. Replace.
A WARNING
Keep flammable products or your hands away
from bulb while it is on; it will be hot. Do not touch
bulb until it cools down.
HEADLIGHT BEAM SWITCH

1. Disconnect:
• Headlight beam switch coupler
2.Connect:
• Pocket tester
(to headlight beam switch coupler)
3.Check:
@
• Headlight beam switch continuity
Faulty ---> Replace.
Switch @Good @Good

position condition condition
HI x 0
LO 0 x
0: Continuity x: No continuity
8-18
SIGNAL SYSTEM I Iliiiil I
ELEC
SIGNAL SYSTEM
CIRCUIT DIAGRAM
@ uOIL LEVEL" warning light @ uWATER TEMP" warning light checker @ Fuel sender
@ Oil level gauge @ Brake light switch ®Fuel meter
@ uOIL LEVEL" warning light checker @Tail/brake light @Condenser
@"WATER TEMP" warning light ® COi magneto
® Thermo switch ® Rectifier/Regulator (II)
8-19
SIGNAL SYSTEM I I• I
ELEC
8-20
SIGNAL SYSTEM I 1.-1
ELEC
TROUBLESHOOTING
BRAKE LIGHT DOES NOT COME ON.
NO CONTINUITY
Check the tail/brake light bulb.
(See page 8-18)
IReplace the bulb.

l
FAULTY
i
f Check the brake light switch.
I Replace the brake light switch.
Check the lighting coil (I). (See page 8-13)
f Replace the lighting coil (I).
Correct connection and/or replace the rectifier

regulator (II).
8-21
SIGNAL SYSTEM I 1-..i I
ELEC
uWATER TEMP" AND/OR uOIL LEVEL" WARNING LIGHTS DO NOT COME ON.
NO CONTINUITY
Check the "WATER TEMP" and/or "OIL
LEVEL" warning light bulb(s). (See page 8-18)
lReplace the bulb(s).

l
FAULTY
Check the lighting coil (I). (See page 8-13)
lReplace the lighting coil (I).
FAULTY
l
Check the thermo switch or oil level gauge.
Replace the thermo switch or oil level

gauge.
Correct connection and/or replace the rectifier

regulator (II). NOTE:-------------------------
The warning lights come on for a few seconds
after the engine starts. If the lights do not come on,
check the warning light circuit and bulb(s). If the
lights still do not come on, replace the warning
light checker(s). Recheck to be sure the warning
lights light.
8-22
SIGNALSVSTEM IELECI ~I
FUEL METER DOES NOT OPERATE
FAULTY
I
Check the lighting coil (II).
I
l
Replace the lighting coil (II).
FAULTY
I
Check the main switch. (See page 8-12)
I
l
Replace the main switch.
FAULTY
I
Check the fuel sender.
I
l
Replace the fuel sender.
Check for voltage on the condenser coupler.
(See page 8-12)
l
Check the condencer (II). (See page 8-13)
I
l
Replace the condencer.
DOES NOT MOVE

I Check the fuel meter.
I
l
Replace the fuel meter.
Correct connection for fuel meter system.
8-23
SIGNAL SYSTEM I Iliiiii I
ELEC
BRAKE LIGHT SWITCH
1. Disconnect:
• Brake light switch coupler
2. Connect:
• Pocket tester
(to brake light switch coupler)
3.Check:
• Brake light switch continuity
Faulty..... Replace.
Switch position Good condition

Brake lever is
opetate 0
Brake lever is not
operate
x
0 : Continuity x: No continuity
THERMO SWITCH
1. Disconnect
• Thermo switch lead CD (Green/Red)
2.Remove:
• Thermo switch ®
''----------------------
Handle the thermo switch with special care.
Never subject it to strong or allow it to be
dropped. Should it be dropped, it must be
replaced.
3.Connect:
• Pocket tester
(to thermo switch as shown)
4. Immerse the thermo switch in coolant @and
check the thermo switch for operation.
Coolant
Operation
temperature
Less than The switch is open.
ss·c (209°Fl (ooQ)
102°C (216°F)
The switch is closed.(OQ)
or more
© Temperature gauge
8-24
SIGNAL SYSlEM I I• I
ELEC
Never heatthe coolantto a temperature of 120° C

(248.5°F) or more.
5. If the thermo switch operation is incorrect,

replace it.
6. Install the thermo switch, and connect thermo
switch lead.
Thermo switch:
7.5 Nm (0.75 m •kg, 5.4ft •lb)
Avoid overtightening.
OIL LEVEL SWITCH

1.Remove:
•Oil tank CD
• Oil level gauge ®
2.Connect:
• Pocket tester
(to oil level switch coupler)
3.Check:
• Oil level switch continuity
Fauty --. Replace.
Good
Switch position Bad condition
condition
A Upright position x 0 x 0
Upside down
B
position
0 x x 0
0: Continuity x: No continuity
LIGHTING COIL
1. Disconnect:
• COi magneto coupler
2.Connect:
• Pocket tester
(to lighting coil II leads)
8-25
SIGNAL SYSTEM I I• I
ELEC
3. Measure:
Jo~
• Lighting coil resistance
...
,a'W
B
T
y G_x~_oo]
Out of specification • Replace.
~
Lighting coil resistance:
(White, Black)
-@+I~
.._ l-0 o.297 - 3.63 n at 2o·c (68°F) ·
FUEL SENDER
1. Remove:
• Fuel sender CD
(from fuel tank)
2. Connect:
• Pocket tester
(to fuel sender coupler)
3.Check:
• Fuel sender resistance
Out of specification -.. Replace.
Fuel Sender Resistance (Up @ ):

4 - 10 n at 2o·c (68°F>
Fuel Sender Resistance (Down@):
90 - 100 n at 2o·c (68°F)
FUEL METER
1.Remove:
• Fuel sender
(from fuel tank)
2. Start the engine at idling speed.
3. Check if the fuel meter needle moves towards

"F"@or "E"@, when moving the float "up"
@or "down"@.
Faulty--.. Replace.
M
N
~n
p
Up@ Down@
"F"@ 0 x
"E"@ x 0
0: Good x :Faulty
NOTE:~~~~~~~~~~~--
Before reading the meter, stay put the float for
more than three minutes respectively at "Up" or
"Down".
8-26
GRIP WARMER svsTEM I Iw I
ELEc
GRIP WARMER SYSTEM
CIRCUIT DIAGRAM
®Thumb warmer
@Grip warmer
@Resistor
®Grip warmer switch
@ COi magneto
8-27
GRIP WARMER SYSTEM I Iliiiiil I
ELEC
8-28
GRIP WARMER SYSTEM I I• I
ELEC
TROUBLESHOOTING
GRIP WARMER DOES NOT OPERATE
NO CONTINUITY
I Check the resistor.
I
l
Replace the resistor.
NO CONTINUITY
I Check the grip and thumb warmer.
IReplace the grip warmer.
I Check the grip warmer switch.

INCORRECT
R CORRECT IReplace the grip warmer switch.
Replace the grip warmer coil and/or correct

connection.
8-29
GR1PwARMERsvsTEM IELEcl iiiiiii I
RESISTOR
1.Remove:
• Resistor CD
• Resistor coupler ®
2.Connect:
• Pocket tester
(to resistor leads)
3.Check:
• Resistor continuity
No continuity-+ Replace.
-@+r.w---'
GRIP AND THUMB WARMER COIL

1. Disconnect:
• Grip warmer leads CD
• Thumb warmer leads
2.Connect:
• Pocket tester
(to grip warmer coil leads and/or thumb
warmer coil leads)
3.Check:
• Grip warmer CD continuity
• Thumb warmer® continuity
No continuity-+ Replace.
GRIP WARMER SWITCH

1. Disconnect:
• Grip warmer switch connecters CD
2.Connect:
• Pocket tester
(to grip warmer switch leads)
8-30
GRIP WARMER svsTEM I Iw I
ELEc
3.Check:
• Grip warmer switch continuity
Faulty -+ Replace.
Switch Color code

position Y!R Y/8 Y/L
LO ..., ..., ...,
OFF
HI ...,
-
0-0 Continuity
GRIP WARMER COIL
1. Disconnect:
• COi magneto coupler
2.Connect:
• Pocket tester
(to grip warmer coil leads)
3.Measure:
• Grip warmer coil resistance
Grip warmer coil resistance:

-f y-
_....._ (Yellow/Black - Black)
-J
W Y/9
0.92 - 1.12 Q at 20°C (68°F)
• y
Gd
~
-@+qi
- --0
8-31
lsPEcl rr I
CHAPTER 9.
SPECIFICATIONS
GENERAL SPECIFICATIONS ............................ 9-1
MAINTENANCE SPECIFICATIONS ................. 9-3

ENGINE ........................................................ 9-3
POWER TRAIN ............................................ 9-6
CHASSIS ...................................................... 9-9
ELECTRICAL .............................................. 9-10
CABLE ROUTING ............................................ 9-14
VX750/VX750ST WIRING DIAGRAM

___________G_E_NE_R_A_L_S_P_E_c1_F1_c_AT_1_o_N_S lsPECI rr I
SPECIFICATIONS
Model VX750 VX750ST
Model Code Number: 8BW 8BX
Frame Starting Number: 8BW-000101 8BX-000101-
Engine Starting Number: 8BW-000101 8BX-000101-
Dimensions:
Overall Length 2,815 mm (110.8 in) 3,020 mm (118.9 in)
Overall Width 1, 125 mm (44.3 in) ~
Overall Height 1,070 mm (42.1 in) ~
Weight:
Dry Weight (Without fuel and oil) 256 kg (564 lb) 262 kg (578 lb)
Engine:
Engine Type Liquid cooled 2-stroke, 7-port
Induction System Piston reed valve
Cylinder Arrangement Parallel 2-cylinder
Displacement 743 cm3 (45.3 cu. in)
Bore x Stroke 63 x 59.6 mm (2.56 x 2.35 in)
Compression Ratio 6.5:1
Starting System Recoil Hand Starter
Lubrication System: Separate Lubrication (YAMAHA AUTOLUBE)
Engine Oil:
Type YAMALUBE 2
Tank Capacity 2.7 L (2.4 Imp qt, 2.9 US qt)
Drive Chain Housing Oil:
Type Gear oil API "GL-3" SAE #75 or #85
Capacity 350 cm3 (12.3 Imp oz, 11.8 US oz)
Fuel:
Type Unleaded gasoline R+M/2
Tank Capacity 38.0 L (8.4 Imp gal, 10 US gal)
Carburetor:
Type/Quantity TM/33x4
Manufacturer MIKUNI
Spark Plug:
Type BR9ES
Manufacturer NGK
Gap 0.7 - 0.8 mm (0.028 - 0.031 in)
Transmission:
Primary Reduction System V-Belt
Primary Reduction Ratio 3.9:1 - 0.9:1
Clutch Type Automatic centrifugal engagement
Secondary Reduction System Chain
Secondary Reduction Ratio 1.591 (35/22)
Chassis:
Frame Type Monocock
Caster 22.5°
Ski Stance 977 mm (38.5 in)
9-1
GENERAL SPECIFICATIONS lsPEcl rr--1
Model VX750 VX750ST
Suspension:
Front Suspension Type Telescopic strut suspension
Rear Suspension Type Slide rail suspension
Track:
Track Type Internal drive type +---
Track Width 381 mm (15.0 in) +---
Length on Ground 710 mm (28.0 in) 961 mm (37 .8 in)
Track Deflection 20 - 25 mm (0.79 -
0.98 in)/10 kg (22 lb) +---
Brake:
Brake Type Caliper type disc brake
Operation Method Handle lever, left hand operated
Electrical:
Ignition System/Manufacturer COi/MiTSUBiSHi
Generator System Flywheel magneto
Bulb Wattage x Quantity:
Tail/Brake Light 23W/8W x 1
Tachometer Light 3.4Wx 1
Speedometer Light 3.4Wx2
9-2
MAINTENANCE SPECIFICATIONS lsPEcl a- I
ENGINE
Model VX750 I VX750ST

Cylinder Head:
Volume (with spark plug) 18.3 cm 3
<Warp Limit> <0.03mm (0.0012 in)>
*Lines indicate straight edge measurement.
Cylinder:
Material Aluminum alloy with dispersion coating
Bore Size 63.00 - 63.02 mm (2.48 - 2.481 in)
<Taper Limit> <0.01 mm (0.0004 in)>
<Out-of-Round Limit> <0.05 mm (0.0019 in)>
Piston:
Piston Size (0) 63.0 mm (2.48 in)
~@
Measuring Point @ 18 mm (0.71 in)
Piston to-Cylinder Clearance 0.065 - 0.070 mm (0.0026 - 0.0028 in)

<Limit> <0.1mm (0.004in)>
Oversize 1st 63.25 mm (2.490 in)
2nd 63.50 mm (2.501 in)
Piston Ring:
Sectional Sketch Top Ring Keystone
8=1.2 mm (0.047 in)
T=2.55 mm (0.1 in)
2nd Ring Keystone
8=1.2 mm (0.047 in)
T = 2.55 mm (0.1 in)
End Gap (Installed): Top Ring 0.35 - 0.55 mm (0.014 - 0.022 in)
2nd Ring 0.35 - 0.55 mm (0.014 - 0.022 in)
Side Clearance Top Ring 0.03 - 0.05 mm (0.001 - 0.002 in)
2nd Ring 0.03 - 0.05 mm (0.001 - 0.002 in)
Coating Top Ring Chrome Plated/Ferox Coating
2nd Ring Chrome Plated/Ferox Coating
9-3
MAINTENANCE SPECIFICATIONS lsPEcl u-1
Model VX750 VX750ST
Crankshaft:
Crank Width "A" 55.95 - 56.00 mm (2.203 - 2.205 in)
Connecting Rod Small End Free Play "F" 0.8 - 1.0 mm (0.031 - 0.039 in)
Connecting Rod Big End Side Clearance." D" 0.25 - 0.75 mm (0.010 - 0.030 in)
Crankshaft Deflection "C": C,.C 4 Below 0.03 mm (0.0012 in)
c2.c3 Below 0.04 mm (0.0016 in)
Measuring Points: 1 25 mm (0.98 in)
2 65 mm (3.27 in)
Crank Width "B" 168 mm (6.614 in)
D
Big End Bearing:

Type Needle bearing
Small End Bearing:
Type Needle bearing
Carburetor:
Type/Quantity TM33/4pcs.
Manufacturer MIKUNI
l.D. Mark 8AX-OO
Main Jet (M .•I.) #135
Pilot Jet (P.J.) #47.5
Pilot Air Jet (P ..A..J) 01.2
Pilot Outlet (P.O.) 01.0
Pilot Screw (P.S.) 2 turns out
Throttle Valve (TH. V.l #1.0
Valve Seat Size (V.$.) 01.5
Starter Jet (G.S.) 01.2
Float Height (F.H.) 13.3 mm (0.524 in)
Engine Idle Speed 1,400 - 1,600 r/min
Fuel Pump:
Type DIAPHRAGM
Oil Pump:
Pump Cable Adjustment 28 - 30 mm (1.10 - 1.18 in)
9-4
MAINTENANCE SPECIFICATIONS lsPECI u-1
Cooling System:
Filler Cap Opening Pressure 80 - 100 kPa (0.8 - 1.0 kg/cm 2, 11 - 14 psi)
Thermostat Opening Temperature 50 - 55°C (122 - 131°F)
Thermostat Valve Lift 8 mm (0.3 in) at 1o·c
(158.5Fl
Water Pump Type Impeller Type
Coolant Type Long Life Coolant
Coolant Mixing Ratio (Coolant: Water) 6:4
Coolant Capacity 4.20 L (3.70 Imp qt, 4.44 US qt)
Reservoir Tank Capacity 0.20 L (0.18 Imp qt, 0.21 US qt)
High Altitude Settings
~ E
0 - 100 m
-30°C
(-22°F)
I
-20°c
(-4°F)
I
-10°c
(14°F)
#137.5
I
0°C
(32°F)
I
10°c
(50°F)
I
20°c
(68°F)
I
(300 ft) #140 #135
100-600 m #135
(2,000 ft) #137.5 #132.5
600- t200 m #132.5

(4,000 ft) #135 - #131.3
#131.3 -
1,200 - 1,800 m
(6,000 ft) #132.5- ~ #130, PJ:50
1,800 - 2,400 m - #130, PJ:50

(8,000 ft) #131.3 #128.8, PJ:SO
2,400 m - -#128.8, PJ:5o-

(8,000 ft-) -#130, PJ:5o- #127.5, PJ:SO
-
MAINTENANCE sPEc1F1cAT10Ns jsPEcl a-1
POWER TRAIN
Model VX750 VX750ST
Transmission:
Range of Ratio 3.9:1 - 0.9:1
Engagement RPM Approx 3,300 r/min
Shift RPM Approx 8,256 r/min
Sheave Center Distance "A" 363.5 - 366.5 mm (14.3 - 14.4 in)
Sheave Offset "B" 14.5 - 17.5 mm (0.57 - 0.69 in)
~
~
,--
_c=.
I
'
I
'B
---...
,-- 'ii
I
It'
-
~
L ll 111"
_,J
A
~~
:
V-Belt:
Outside Circumference 1,340 mm (52.8 in)
Width "A" 34.5 mm (1.36 in)
Wear Limit "B" 33 mm (1.30 in)
A
B
I I
I I
I I
I
\\ I
I
I '
!
Primary Sheave Spring:

Color Code Yellow-Pink-Yellow White-Pink-White
Outside Diameter 60 mm (2.36 in) f--
Wire Diameter 5.8 mm (0.23 in) 5.5 mm (0.22 in)
Pre-load/Set Length 30.0 kg (66.2 lb) f--
Spring Rate 24.5 N/mm (2.5 kg/mm) 22.5 N/mm (2.25 kg/mm)
Free Length 77.4 mm (3.05 in) 78.7 mm (3.10 in)
Primary Sheave Weight:
Weight 8BW-17605-00
Quantity 3 pcs.
Secondary Sheave Spring:
Color Code Pink-White
Outside Diameter 60 mm (2.36 in)
Wire Diameter 5.5 mm (0.22 in)
Twist Angle 33•
Free Length 100 mm (3.94 in)
9-6
MAINTENANCE sPEc1FicAT10Ns lsPEcl a-- I
Model VX750 VX750ST
Hole Position
Sheave Side* A
Spring Seat Side** 3
Spring Rate 7,669 N/mm (782 kg/mm, 43,792 lb/in)

Torque Cam Angle 39°
Drive Chain:
Type DID SC-0624 (SILENT CHAIN)
Number of Links 68
Track:
. Width 381 mm (15.0 in) r
Length 3,072 mm (121 in) 3,456 mm (136.1 in)
Pitch 64 mm (2.52 in) r
Number of Links 48 54
Deflection at 10 kg (22 lb) 20- 25 mm
(0.79 - 0.98 in)
Slide Rail Suspension:
Suspension Spring Rate
Front 6.75 kg • mm/deg (0.58 in • lb/deg)
Rear 2.75 kg • mm/deg (0.23 in • lb/deg)
Suspension Setting Position:
Stopper Band Hole Position
Front* No.3
Rear** No.1
* **
9-7
MAINTENANCE SPECIFICATIONS lsPEcl rr--1
Model VX750 VX750ST
Shock Absorber:
Damping Force (Extension)
Front 126 kg/0.3 m/s 114 kg/0.3 m/s
Rear 191 kg/0.3 m/s 159 kg/0.3 m/s
Damping Force (Compression)
Front 37 kg/0.3 m/s 53 kg/0.3 m/s
Rear 44 kg/0.3 m/s 49 kg/0.3 m/s
Slide Runner:
Thickness 15 mm (0.6 in)
Wear Limit 10 mm (0.4 in)
Track Sprocket Wheel:
Number of Teeth 9T
Rear Guide Wheel:
Outside Diameter 178 mm (7 in)
Brake:
Pad Thickness 8.2 mm (0.32 in)
Pad Wear Limit 4.2 mm (0.17 in)
Pad to Disc Clearance 0.15 - 0.30 mm (0.006 - 0.012 in)
Disc Outside Diameter 220 mm (8.66 in)
Disc Thickness 60 mm (0.24 in)
Distance "L" 67.5 - 71.5 mm (2.66 - 2.81 in)
9-8
MAINTENANCE SPECIFICATIONS lsPEcl u--1
CHASSIS
Model VX750 VX750ST
Frame:
Frame Material Aluminum and steel
Seat Height 560 mm (22.0 in)
Luggage Box Location Rear Side of Seat
Steering:
Steering Angle (Left) 48. ~
(Right) 48. ~
Ski Alignment Toe-out ~
Toe-out Size 0 - 15 mm (0 - 0.6 in) ~
Distance "A" 2,007 mm (79.0 in) 2, 196 mm (86.6 in)
Distance "B" 977 mm (38.5 in)
Ski:
Ski Material Aluminum
Runner Material High Polymer Polyethylene
Ski Ground Length 375.6 mm (14.8 in)
Ski Suspension:
Type T.S.S.
Travel 170 mm (6.69 in)
Spring Type Coil Spring
Spring Rate 18 N/mm (1.8 kg/mm, 100.8 lb/in)
Wire Diameter 8.5 mm (0.33 in)
Shock Absorber:
Damping Force (Extension) 61 kg, 0.3 m/s
(Compression) 24 kg, 0.3 m/s
Damping Force adjuster 5turns out
9-9
MAINTENANCE sPEc1F1cA110Ns lsPEcl a- I
ELECTRICAL
Voltage: 12V
Ignition System:
Ignition Timing (B.T.D.C.) 10°/8,000 r/min
COi:
Magneto Model/Manufacturer MITSUBISHI
Pulser Coil Resistance 50.5 ±10% at 20° C (68°F)
(Color Code) (White/Green - White/Red)
Change Coil Resistance (For Ignition) 2.55Q ±10% at 20°C (68°F)
(Color Code) (Brown - Black/Red)
COi Unit Manufacturer 89A-MITSUBISHI
Ignition Coil:
Model/Manufacturer 89A --00/YAMAHA
Minimum Spark Gap 0.7 mm (0.028 in) at 3,000 r/min
Primary Coil Resistance 0.2Q ± 20% at 20°C (68°F)
Secondary Coil Resistance 4.9kQ ± 20% at 20°C (68°Fl
Spark Plug Cap:
Type Rubber Type
Model/Manufacturer BR9ES/NGK
Resistance 5.0 kQ ± 25% at 20°C (68°F)
Charging System:
Type Flywheel Magneto
Flywheel Magneto:
Model/Manufacturer MITSUBISHI
Charging Coil Resistance o.33 n ± 10 % at 2o·c (68°Fl
(Color Code) (White - Black)
Lighting Voltage (Minimum) 11.0 V at 3,000 r/min
(Maximum) 15.5 Vat 8,000 r/min
Lighting Coil Resistance o.33 n ± 10% at 2o·c (68°Fl
(Color Code) (Yellow - Black)
Coil Resistance for Grip Warmer (Driver) 1.02 n ± 10% at 2o·c (68°Fl
(Color Code) (Yellow/Brack- Black)
Heater Coil 1.02 n ± 10% at 2o·c (68°Fl
Grip warmer:
Grip warmer resistance 3 n ± 20% at 2o·c (68°Fl
Thumb warmer resistance 8 - 40 n at 2o·c (68°Fl
Voltage Regulator:
Type Rectifier regulator
Mode/Manufacturer 89A-00/MATSUSHITA
Fuel Gauge unite:
Resistance (Full) 4- 10 n
(Empty) 90-100Q
9-10
MAINTENANCE SPECIFICATIONS lsPEcl a- I
Tightening Torque:
Tightening torque
Nm m • kg ft• lb
ENGINE
Crankcase (Front) 26 2.6 19 Tighten the bolts in
(Rear) * 13 1.3 9.4 two stages.
Engine Bracket nut 40 4.0 29

Engine Bracket bolt 30 3.0 22
Engine stay bolt (Rod) 45 4.5 32
Cylinder stud bolt (Crankcase) 12.5 1.25 9.0
Cylinder head nut 22.0 2.20 16
Culinder stud bolt 12.5 1.25 9.0
PTO shaft holder bolt 26.5 2.65 19.2
Driven gear Ass'y bolt 45 4.5 32
Water pump Ass'y 10 1.0 7.2
Oil pump Ass'y 4 0.4 2.9
Exhaust manifold 25 2.5 7.2
Magnet rotor 85 8.5 6.1
Starter Ass'y 7 0.7 5.1
CARBURETOR
Rever shaft screw 4 0.4 2.9
Main Jet 0.8 0.08 0.58
Pilot Jet 0.7 0.07 0.51
Cynchronization nut 4 0.4 2.9
Planjer 3 0.3 2.2
9-11
MAINTENANCE SPECIRCATIONS lsPEcl r:r-1
Tightening Torque:
Tightening torque
Nm m• kg ft. lb
Handlebar Holder 15 1.5 11
Steering Column
Upper 22 2.2 16
Lower 27 2.7 20
Steering Column and Relay Rod 43 4.3 31
Relay Rod and Suspension Bracket 25 2.5 18
Locknut (Relay rod) 25 2.5 18 Apply LOCTITE®
Lever holder 4 0.4 2.9
Ski Runner 21 2..1 15
Ski 43 4.3 31
Pinch Nut (Suspension bracket) 21 2. 1 15
Set Screw (Suspension bracket) 2 0.2 1.4 Apply LOCTITE®
Absorber Holder 10 1.0 7.2
Mounting Nut (Shock absorber) 5 0.5 3.6
Locknut !Shock absorbser) 16 1.6 11
Front Arm (Upper) and Front Arm (Lower) 43 4.3 31
Hood 3 0.3 2.2
Seat and Frame (Nut) 9 0.9 6.5
(Screw) 3 0.3 2.2
Front Cowling 3 0.3 2.2
9-12
MAINTENANCE SPECIFlCATJONS jsPecl a- l
Ti·ghtening Torque:
Tightening torque
Nm m•kg ft. lb
Primary Sheave (first) 120 . 12.0 85 Tighten the bolts in
:(final) 60 6.0 43 two stages. See NOTE.
Spider and Sliding Sheave 200 20.0 145 Left-hand thread.
Apply LOCTITE®
Primary Sheave Cap and Sliding Sheave 14 1.4 10
Roller and Weight (Primary Sheave)
Bolt 6 0.6 4.3
Screw 3 0.3 2.2
Secondary Sheave 60 6.0 43
Driven Sprocket 48 4.8 35
Chain Housing and Frame 24 2.4 17 Apply LOCTITE®
Chain Housing Cover 10 1.0 7.2
Chain Housing and Brake Caliper 48 4.8 35
Bearing Holder (.Jackshaft) 43 4.3 31
Suspension Wheel 75 7.5 54 Apply LOCTITE®
Guide Wheel 74 7.4 54
Sliding Frame and Slide Runner 3 0.3 2.2
Slide Rail Suspension Mounting Bolt 68 6.8 49
Rear Pivot Arm and Bracket 68 6.8 49
Shock Absorber and Rear Pivot Arm 42 4.2 30 Apply LOCTITE®
Rear Suspension Bracket and Rod 42 4.2 30
Front Pivot Arm and Sliding Frame 56 5.6 41
Shock Absorber and Front Pi.rot Arm 23 2.3 17
Shock Absorber and Relay Arm 28 2.8 20
Bracket Shaft and Sfrding Frame 20 2.0 14
Coller (Guide wheel.) 6 0.6 4.3
Front Axte nut 90 9.0 65
Speedometer Gear 23 2.3 17
9-13
CABLE ROUTING lsPEcl rr-1
CABLE ROUTING
CD Grip warmer leads @Main switch [A] Clamp the fuel breather hose, oil
®Band @Grip warmer switch breather hose and wire harness.
@ Wire harness @Fuel breather hose rnJ to carburetor
©Fuel pump (jJ)
Oil breather hose © to crankcase
@Fuel hose @Condenser (for fuel)
@Clip @Speedometer cable
(f) Starter (chock) lever
9-14
CABLE ROUTING
CD Clip @ Wire harness !Al Pass the starter cable under the
® Starter cable @ Rectifier/regulator brake cable.
@ Brake cable @Clamp rnJ Pass the wire harness through the
©Oil tank groove of the bracket.
@ Throttle cable © Pass the speedometer cable
® Oil pump cable through the hole of the frame.
(J) Ignition coil [Q] Pass the speedometer and wire
@ CDI unit harness above the stabilizer.
@Condenser ~ Clamp the speedometer cable only.
@ Speedometer cable
9-15
cABLE RouTING lsPEcl a- J
CD Tail light lead [A] Arrange the hoses so that they will not come into contact with
® Rectifier/regulator the oil pump bracket.
@Fuel hose Im Pass the delivery hose and oil hoses above the bracket.
© Pulser hose ~Tie the band and buckle above the frame pipe so that they will
@Band not interfere with the starter rope.
@Clip
v;
9·16
VX750/VX750ST WIRING DIAGRAM
®
©
G
@ © @ ® (i) @ ®
~ y
(!)Headlight
® Meter ass'y
@ Speedometer light
©High beam
@Water temp
@Oil level
(i) Tors
@Tachometer
@Tachometer light
@Fuel meter
@Condenser
@ Fuel sender
@ Oil level gauge
@ Thermo switch
@Grip warmer switch
@ Thumb warmer
~--Sb--l--t--H-+-t---+-t---t---,Sb--1---+-H----Sb·----~
~-+-+---+--BIW--+---t--+-+-----il/W'-----+-+-~
®Grip warmer
I"- OFF ON/LIGHT
··--+--..--+--+-+--~ @Resister
• ~>-+--+-t---W--+-if----t~
@ Tall/stop light
..
BIW
R
0
0
n
® Ignition coil A
®Spark plug (#1, #2)
@ Ignition coil B
@CDI unit
.. @Pulser
@ CDI magneto
®Condenser
@ Rectifier/regulator
@ Rectifier/regulator
® Stop light switch
® Headlight beam switch
@ Accel switch
@ Engine stop switch
@ Carb. switch
@ Main switch
@ Checker pilot light
® Checker pilot light
COLOR CODE
B ........... Black Ch ..•...... Chocolate B/R ........ Black/Red Y/L ........ Yellow/Blue
L ............ Blue Br .......... Brown B/W ....... Black/White Y/R ........ Yellow/Red
G ........... Green Sb ......... Sky blue G/Y ........ Green/Yellow R/B ..•..... Red/Black
Y ........... Yellow Gy ......... Gray G/B ........ Green/Black WIG ...... White/Green
R ........... Red W .......... White G/R ........ Green/Red W/R ..•.... White/Red
0 ........... Orange BIY ......•. Black/Yellow Y/B ........ Yellow/Black W/L ....... White/Blue

94 Vmax4 SM

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HOW TO USE THIS MANUAL

Particularly important information is distin-

A CAUTION indicates special precautions that

1~~~1--1 p~g!l-1 (Refer to the illustration)

Illustrated symbols Q) to @) are designed as

lcHAsl..,9 I IPC:Rlo-el content.

IENGI ®• I lcooLI ~I @ Engine overhaul

lcARBI Ii' I IELeclDI @) Optional kit

lsPecl u--1 l0 PTIOI Illustrated symbols® to@ are used to identify

PERIODIC INSPECTIONS AND

POWER TRAIN ............................................................................................................ 10

ENGINE OVERHAUL ................................................................................................... 18

ENGINE SERIAL NUMBER

Starting serial number:

PERIODIC MAINTENANCE TABLE

Standard V-belt position:

V-belt position Adjustment

Drive V-belt length:

Clutch Setting Data (VXSOOI

[ID Idle speed: 1,500 ± 100 rpm ~ ~ ~

19 Clutch engagement: 3,300 ± 300 rpm ~ ~ ~

[QI Shift speed: 8,250 ± 300 rpm ~ ~ ~

!ID Gearing: 23137 ~ 21/37 21/39

[bl Weight: 8BU-OO ~ ~ ~

[QI Roller outter dia.: 11115.Smm ~ ~ 11115.0mm

IQ] Pri. clutch shim: None ~ ~ ~

[BJ Secondary spring:

IEl Length 75mm ~ ~ ~

GD Wire dia. fl)5.5mm ~ ~ ~

00 Outer dia. 11169.5mm ~ ~ ~

[§] Sec. torque cam: 41° ~ 390 ~

!Il Sec. clutch shim: None ~ ~ ~

CD Sprocket and chain parts number

[ID Parts No. 19 Cam angle

[QI Secondary spring twist angle

[QJ Primary spring

10 Nm (1.0 m •kg, 7.2 ft• lb)

Reverse the removal procedure for installa-

Disassembly of secondary sheave

Reverse the disassembly procedure for as-

Standard spring position:

Standard twist angle @:

• Turn in the screw for the sheave compressor

~ Secondary sheave bolt:

45 Nm (4.5 m • kg, 32 ft • lb)

*=[ *1 : should be two steps. J

Disassembly of drive shaft

Align the hole @ on the drive gear and punch

Primary reduction ratio 3.9:1 - 0.95:1 ~

Clutch type Automatic centrifugal

Secondary reduction ratio 1.54 (37/24) 1.61 (37/23)

Ski stance 1,007 mm (39.6 in) 977 mm (38.5 in)

Piston to-Cylinder clearance 0.065 - 0.070 mm (0.0026 - 0.0028 in)

-·~-A_-J_ --•I --1~--8~

(600 ft) #148.8- #143.8

600 - 1,200 m - #141.3

1,200 - 1,800 m #138.8

Primary sheave spring:

=[ 1 : should be two steps. J