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Title: SXV70MH Service Manual
Author: YMC, Ltd.

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SUPPLEMENTARY SERVICE MANUAL

SXV70MH

LIT-12618-02-27

8EN-28197-10
981071

FOREWARD
This Supplementary Service Manual has been prepared to introduce new service and new data for the
SXV70MH.
For complete information, on service procedures, it is
necessary to use this Supplementary Service Manual
together with following manuals:
VX700F, VX700DXF, SX700F,
MM700F, VT700F
SERVICE MANUAL:
8CH-28197-10 (981050) E. June 2000
(LIT-12618-02-17)
SXV70G, SXV70ERG
SUPPLEMENTARY SERVICE MANUAL:
8EK-28197-10 (981061) E. June 2001
(LIT-12618-02-22)
Use the service information for the MM700F in the
Service Manual and the service information for the
SXV70G in the Supplementary Service Manual to
service the SXV70MH.

HOW TO USE THIS MANUAL
Particularly important information is distinguished in
this manual by the following notations:

The Safety Alert Symbol means ATTENTION!
BE ALERT! YOUR SAFETY IS INVOLVED!

WARNING
Failure to follow WARNING instructions could result
in severe injury or death to the snowmobile operator,
a bystander, or a person inspecting or repairing the
snowmobile.

CAUTION:
A CAUTION indicates special precautions that must
be taken to avoid damage to the snowmobile.

NOTE:
A NOTE provides key information that can make
procedures easier or clearer.

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 understanding of the mechanical concepts
and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to
this model may render it unfit and/or unsafe to use.
Yamaha Motor Company, Ltd. is continually striving
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 manual.
SXV70MH
SUPPLEMENTARY SERVICE MANUAL
2002 by Yamaha Motor
Corporation, U.S.A.
1st Edition, April 2002
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-12618-02-27

MANUAL FORMAT
All of the procedures in this manual are organized in
a sequential, step-by-step format. The information
has been compiled to provide the mechanic with an
easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course of
action required to correct the problem will follow the
symbol, e.g.,
• Bearings
Pitting/damage → Replace.

EXPLODED DIAGRAM
Each chapter provides exploded diagrams before
each disassembly section to facilitate correct disassembly and assembly procedures.

1

ILLUSTRATED SYMBOLS

2

(Refer to the illustration)

INSP
ADJ

GEN
INFO
3

Illustrated symbols 1 to 9 are designed as thumb
tabs to indicate the chapter’s number and content.

4

1
2
3
4
5
6
7
8
9

POWR
TR

CHAS
5

6

COOL

ENG
7

General information
Periodic inspection and adjustments
Chassis
Power train
Engine
Cooling system
Carburetion
Electrical
Specifications

8

CARB

ELEC



+

9

SPEC
0

A

Illustrated symbols 0 to F are used to identify the
specifications which appear.

B

T.

R.

C

D

E

F

G

H

I

J

L

K

G

E
M
B

O

New

M
N

LS

Filling fluid
Lubricant
Tightening
Wear limit, clearance
Engine speed
Special tool
Ω, V, A

Illustrated symbols G to O in the exploded diagram
indicate grade of lubricant and location of lubrication
point.

5

LT

0
A
B
C
D
E
F

M

G
H
I
J
K
L
M
N
O

Apply locking agent (LOCTITE®)
Apply Yamabond No.5®
Apply engine oil
Apply gear oil
Apply molybdenum disulfide oil
Apply wheel bearing grease
Apply low-temperature lithium-soap base grease
Apply molybdenum disulfide grease
Use new one

GENERAL INFORMATION

ENGINE

MACHINE IDENTIFICATION .............................. 1
FRAME SERIAL NUMBER ............................ 1
ENGINE SERIAL NUMBER ........................ 1

CYLINDER HEAD AND CYLINDER ................ 18
INSTALLATION ........................................... 18

SPECIAL TOOLS ................................................ 1
FOR TUNE UP .............................................. 1

COOLING SYSTEM
HEAT EXCHANGER ......................................... 19
INSPECTION ............................................... 20

PERIODIC INSPECTIONS AND
ADJUSTMENTS

CARBURETION

ENGINE .............................................................. 2
COOLING SYSTEM ...................................... 2
HEAT SHIELD CLAMP REPLACEMENT ...... 2
POWER TRAIN ................................................... 3
DRIVE CHAIN ............................................... 3
ELECTRICAL ..................................................... 4
SPEEDOMETER UNIT INSPECTION ........... 4
TUNING ..............................................................
CLUTCH ........................................................
GEAR SELECTION .......................................
FRONT SUSPENSION ..................................
REAR SUSPENSION ....................................

5
5
6
8
9

CARBURETORS .............................................. 21
THROTTLE POSITION SENSOR (T.P.S.)
INSPECTION AND ADJUSTMENT ............. 21

SPECIFICATIONS
GENERAL SPECIFICATIONS .......................... 23
MAINTENANCE SPECIFICATIONS ................
ENGINE .......................................................
POWER TRAIN ...........................................
CHASSIS .....................................................
ELECTRICAL ..............................................
HIGH ALTITUDE SETTINGS ......................
TIGHTENING TORQUE ..............................

25
25
28
31
32
34
35

CHASSIS
CABLE ROUTING ............................................ 39
STEERING ........................................................ 11
INSTALLATION ........................................... 12
SKI .................................................................... 13
FRONT SUSPENSION ..................................... 14
INSTALLATION ........................................... 15

POWER TRAIN
SLIDE RAIL SUSPENSION .............................. 17
INSTALLATION ........................................... 17

MACHINE IDENTIFICATION/SPECIAL TOOLS

GEN
INFO

GENERAL INFORMATION

1

MACHINE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number 1 is located on the right-hand side of the frame (just
PEN0010

below the front of the seat).

ENGINE SERIAL NUMBER
The engine serial number 1 is located on the right-hand side of the
crankcase.

1

NOTE:
PEN0020

Designs and specifications are subject to change without notice.

SPECIAL TOOLS
Some special tools are necessary for a completely accurate tune-up and
assembly. Using the correct special tool will help prevent damage that can
be caused by the use of improper tools or improvised techniques.

NOTE:
Be sure to use the correct part number when ordering the tool, since the part
number may differ according to country.

FOR TUNE UP

• Sheave gauge
P/N: YS-42421-1 (15 mm offset)
This gauge is used to measure the sheave distance and for offset adjustment.
PEN0030

• Digital multimeter
P/N: YU-34899-A (for U.S.A./Canada)
90890-03174 (for Europe)
This tester is used for adjusting the T.P.S. position.
PEN0125

1

COOLING SYSTEM/HEAT SHIELD CLAMP REPLACEMENT

INSP
ADJ

PERIODIC INSPECTIONS
AND ADJUSTMENTS

1

ENGINE
COOLING SYSTEM

2

Air bleeding
1. Remove:
• Bleed bolt cap 1
• Bleed bolt 2

PEN0240

2. Bleed air from the cooling system.

T.

R.

Bleed bolt
4 Nm (0.4 m · kg, 2.9 ft · lb)

HEAT SHIELD CLAMP REPLACEMENT
Clamps on the exhaust pipe heat shields may become
loose and cause a ratting noise, which is due to the
deformation of the heat shields.
These clamps are not adjustable and must be replaced
when they become loose.
When replacing the clamps use and adjustable clamp
from the list below.

1
PEN0250

1 Clamps

a

Part number

90450-99047
PEN0260

2

Size a
Maximum

Minimum

180 mm
(7.1 in)

160 mm
(6.3 in)

DRIVE CHAIN

INSP
ADJ

POWER TRAIN
DRIVE CHAIN

5

Drive chain slack adjustment
1. Adjust:
• Drive chain slack

1

Adjustment steps:
• Loosen the locknut 1.
• Turn the secondary shaft 2 clockwise a to
bring the slack of the drive chain 3 near the
tensioner roller 4.
• Turn the adjusting bolt 5 in until it is finger tight.
• Turn the adjusting bolt 1/4 turn out.
• Tighten the locknut.

PEN0320

2

3

a
1

R.

4

T.

5
PEN0330

3

Locknut:
24 Nm (2.4 m · kg, 17 ft · lb)

SPEEDOMETER UNIT INSPECTION

INSP
ADJ

ELECTRICAL
SPEEDOMETER UNIT INSPECTION
1. Inspect:
• Speedometer unit

Inspection steps:
• Remove the speedometer coupler 1 and headlight coupler 2.
• Connect the speedometer unit test coupler 3 to
the speedometer coupler and headlight coupler.
• Connect the speedometer unit test coupler leads
as follows.
Speedometer unit test coupler lead (red) 4 →
Battery (+) terminal
Speedometer unit test coupler lead (black) 5 →
Battery (–) terminal

PEN0500

Speedometer unit test coupler:
YS-45686

• Check that the light and LCD in the speedometer
light up.

• If the light does not light up. → Check the bulbs.
Refer to “BULB (S)”.

• If the LCD is not indicated. → Replace the speed-

PEN0510

ometer unit.

PEN0520

4

CLUTCH

INSP
ADJ

TUNING

G

Green

CLUTCH

R

Red

High altitude

W White
Y

Yellow

Specifications
Å Elevation
ı Engine idle speed
Ç Engagement r/min
Î Shift r/min
‰ Main jet
Ï Pilot jet
Ì Pilot screw
Ó Secondary reduction
ratio (number of links)
È Primary sheave spring
Ô Color
 Free length
Ò Preload
˜ Spring rate
ˆ Wire diameter
Ø Outside diameter
∏ Weight (ID)
ΠWeight rivet
 Weight bushing
Í Roller outer dia.
Ê Roller bushing
Ë Pri. clutch shim
◊ Secondary sheave spring
„ Color
Ù Free length
Á Preload rate
Û Wire diameter
å Outside diameter
∫ Sec. torque cam angle
Ç Sec. clutch shim

~ 800 m
600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m
(~ 2,500 ft)
(2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft)
APPROX 1,800 r/min




APPROX 3,900 r/min




APPROX 8,400 r/min




∂ Refer to “HIGH ALTITUDE SETTINGS” in “MAINTENANCE SPECIFICATIONS”.

23/40 (70 L)



22/40 (70 L)

21/40 (70 L)



90501-603L3




G-W-G




89.8 mm (3.54 in)




441 N (45 kg, 99 lb)




27.5 N/mm




(2.75 kg/mm, 154 lb/in)
6.0 mm (0.236 in)




59.5 mm (2.34 in)




8DN-17605-10




(8DN10)
Steel 17.2 mm (OUT) Steel 13.9 mm (OUT) Steel 13.3 mm (OUT) Steel 10.3 mm (OUT) None (OUT)
Steel 17.2 mm (IN) Steel 13.9 mm (IN)

Steel 13.3 mm (IN)

Duralon




15.6 mm (0.61 in)




Duralon




None




90508-556A2
G
75 mm (2.95 in)
70° (1-6)
848 kg·mm/rad
5.5 mm (0.217 in)
69.5 mm (2.736 in)
45°
1.0 mm (0.04 in)













































5

GEAR SELECTION

INSP
ADJ

GEAR SELECTION
1 Chain and sprocket part number
Å Part name

ı Teeth & links

Ç Part no.

18 teeth
19 teeth
20 teeth
21 teeth
22 teeth
23 teeth
37 teeth
38 teeth
39 teeth
40 teeth
68 links
70 links

8DW-17682-80
8DW-17682-90
8DW-17682-00
8DW-17682-10
8DW-17682-20
8DW-17682-30
8DW-47587-70
8DW-47587-80
8DW-47587-90
8DW-47587-00
94890-09068
94890-09070

‰ Drive sprocket

Ï Driven sprocket

Ì Chain

Î Standard

U.S.A./Canada
Europe

U.S.A./Canada/Europe
U.S.A./Canada/Europe

2 Gear ratio
Å Drive sprocket
18 teeth 19 teeth 20 teeth 21 teeth 22 teeth 23 teeth
ı Driven sprocket
1.76
68 links
1.90
1.81
68 links 68 links
2.05
1.95
1.86
68 links 68 links 68 links
2.11
2.00
1.91
2.22
68
links
68
links
70
links
68 links

37 teeth
38 teeth
39 teeth
40 teeth

1.68
68 links
1.73
68 links
1.77
70 links
1.82
70 links

1.61
68 links
1.65
70 links
1.70
70 links
1.74
70 links

3 Secondary sheave spring
ı Spring rate
(torsion)
N·mm/rad
(kg·mm/rad)

N/mm (kg/mm) (lb/in)

90508-500B1

6003 (613)

6.2 (0.63), 35.28

Brown

5.0 (0.196)

90508-536A9

7147 (729)

7.3 (0.74), 41.44

Red

90508-556A2

8314 (848)

8.5 (0.87), 48.72

90508-556A7

9460 (965)

10.21 (1.04), 58.24

Å Part no.

Ç Spring rate

‰ Wire

(compression) Î Color

Ï No. of

gauge

Ì Free

Ó Outside

length

diameter

mm (in)

mm (in)

5.19

75 (2.95)

69.5 (2.736)

5.3 (0.208)

5.53

75 (2.95)

69.5 (2.736)

Green

5.5 (0.217)

5.53

75 (2.95)

69.5 (2.736)

Silver

5.5 (0.217)

4.86

75 (2.95)

69.5 (2.736)

coils

mm (in)

È Standard

U.S.A./
Canada/
Europe

4 Secondary spring twist angle
90508-500B1 (brown) / 90508-536A9 (red) / 90508-556A2 (green) / 90508-556A7 (silver)
Å Seat

ı Sheave
1
2
3

0
10°
20°
30°

3
40°
50°
60°

6

6
70°
80°
90°

9
100°
110°
120°

GEAR SELECTION

INSP
ADJ

5 Rollers
I.D. 9 mm (0.4 in)
Å ROLLER with
BUSHING
PART NUMBER
8CR-17624-00

ı OUTSIDE
DIAMETER

Ç BUSHING
TYPE (P/N)

14.5 mm
(0.57 in)

Duralon

Î IDENTIFICATION
MARK (Width)

‰ Standard

90380-09245
8CR-17624-10

15.0 mm
(0.59 in)

Duralon

90380-09245
8CR-17624-20

15.6 mm
(0.61 in)

Duralon
U.S.A/
Canada/
Europe
90380-09245

8CR-17624-30

16.0 mm
(0.63 in)

Duralon

90380-09245

7

Ï EFFECTS

FRONT SUSPENSION

INSP
ADJ

FRONT SUSPENSION
Spring preload
1. Adjust:
• Spring preload

WARNING
This shock absorber contains highly pressurized
nitrogen gas.
Do not tamper with or attempt to open the shock
absorber assembly.
Do not subject the shock absorber assembly to
flames or high heat, which could cause it to
explode.

PEN0440

CAUTION:
Be sure that the left and right spring preloads are
the same.
Adjustment steps:
• Turn the spring 1 in or out.
Standard

Spring seat
distance

Shorter ←

→ Longer

Preload

Harder ←

→ Softer

Length a

220 mm
(8.66 in)

Min.

8

Max.
230 mm
(9.06 in)

240 mm
(9.45 in)

REAR SUSPENSION

INSP
ADJ

REAR SUSPENSION
Stopper band
1. Adjust:
• Stopper band tension

CAUTION:
Make sure the left and right sides of the rear
suspension stopper band are adjusted evenly.

NOTE:
This adjustment affects the handling characteristics
of the machine.

PEN0450

Adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting nut 2 in or out to adjust the
stopper band tension.

1
a
2

Adjuster
thread
length a

Standard:
10 ± 0.5 mm (0.39 ± 0.02 in)
Longer
Shorter

Effects

More weight
on skis;
Less weight
transfer

Less weight
on skis;
More weight
transfer

• Tighten the locknut.

T.

R.

9

Locknut:
16 Nm (1.6 m · kg, 11 ft · lb)

INSP
ADJ

REAR SUSPENSION
Spring preload
1. Adjust:
• Spring preload

A

1
1

Adjustment steps:
• Turn the adjusting ring 1 to the proper position.
2

3

4

5

Spring adjuster
position

PEN0460

Preload
B

1

2

3

Softer ←

4

5

→ Harder

Å Front Standard 3

PEN0470

10

Spring adjuster
position

1

Preload

Softer ←

ı Rear Standard

4

2

3

4

5

6

7

→ Harder

STEERING

CHAS

CHASSIS
STEERING
Å: 23 Nm (2.3 m · kg, 17 ft · lb)
ı: 25 Nm (2.5 m · kg, 18 ft · lb)
Ç: 35 Nm (3.5 m · kg, 25 ft · lb)
Î: 42 Nm (4.2 m · kg, 30 ft · lb)
‰: 67 Nm (6.7 m · kg, 48 ft · lb)

: 1 ESSO beacon 325 grease
or Aeroshell grease #7A

Order

Job name/Part name

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Steering column and tie rod removal
Engine assembly
Handlebar
Cotter pin
Clip
Relay rod
Lock washer
Bearing holder
Bearing
Collar
Steering column
Cotter pin
Tie rod
Washer
Washer
Bushing 1
Bushing 2
Collar
Relay arm

PEN0540

Q’ty

Remarks
Remove the parts in the order listed below.
Refer to “ENGINE ASSEMBLY”.

1
1
1
2
3
4
4
1
4
2
2
2
1
1
1
1
For installation, reverse the removal procedure.
11

STEERING

CHAS

INSTALLATION
1. Install:
• Bushing 1 1
• Bushing 2 2

a

3

1
2

NOTE:
Mount the bushing with clearance a to the end of the
relay arm 3.

a
PEN0550

a Approx. 1 mm (0.04 in)

2. Install:
• Tie rod 1
• Locknut 2
• Joints 3

a
b

3

2

1

2

Å Tie rod
part number

3

8CS-23831-00
PEN0560

length a

Ç Tie rod
length b

474.5 mm
(18.6811 in)

411.5 mm
(16.2008 in)

ı Set

3. Install:
• Handlebar 1

CAUTION:
Be sure to install the handlebar holder (upper) 2
by pushing the projection on the handlebar a
into the slot b of the handlebar holder (lower) 3,
then tightening the bolts.
PEN0570

T.

R.

Bolt (handlebar holder):
15 Nm (1.5 m · kg, 11 ft · lb)

CAUTION:
The handlebar has “8EN-10” stamped on one end
for identification. The handlebar has “8EN-10”
stamped on one end. Since these handlebars are
specifically designed for the SXV70MH (8EN1,
8EN2), do not use them on any future models.

8EN-10

PEN0580

12

SKI

CHAS

SKI
Å: 11 Nm (1.1 m · kg, 8.0 ft · lb)
ı: 17 Nm (1.7 m · kg, 12 ft · lb)
Ç: 21 Nm (2.1 m · kg, 15 ft · lb)
Î: 48 Nm (4.8 m · kg, 35 ft · lb)
: 1 ESSO beacon 325
grease or Aeroshell
grease #7A

PEN0590

Order
1
2
3
4
5
6
7
8
9
10

Job name/Part name
Ski removal
Cotter pin
Ski stopper
Collar
Washer
Ski column lower bracket
Ski runner
Collar
Ski
Washer
Ski handle

Q’ty

Remarks
Remove the parts in the order listed below.

1
1
1
6
1
1
4
1
4
1
For installation, reverse the removal procedure.

13

FRONT SUSPENSION

CHAS

FRONT SUSPENSION
Å: 35 Nm (3.5 m · kg, 25 ft · lb)
ı: 42 Nm (4.2 m · kg, 30 ft · lb)
Ç: 48 Nm (4.8 m · kg, 35 ft · lb)
Î: 50 Nm (5.0 m · kg, 36 ft · lb)
‰: 56 Nm (5.6 m · kg, 40 ft · lb)
Ï: 78 Nm (7.8 m · kg, 56 ft · lb)

: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
PEN0600

Order

1
2
3
4
5
6
7
8
9
10
11
12

Job name/Part name
Front suspension removal
Ski
Tie rod
Shock absorber
Cap
Clip
Steering arm
Ski column
Bushing
Washer
Control rod
Collar
Bushing
Front arm

Q’ty

Remarks
Remove the parts in the order listed below.
Refer to “SKI”.

1
1
1
1
1
1
2
1
2
2
4
1
For installation, reverse the removal procedure.

14

FRONT SUSPENSION

CHAS

INSTALLATION
1. Install:
• Control rod 1
• Locknut 2
• Joint 3
a Set length

Å Left hand
Ç Set

ı Set length a

PEN0610

angle

Ï Upper

423.7 ± 0.5 mm
(16.6811 ± 0.0197 in)

93 ± 1°

Ì Lower

422.2 ± 0.5 mm
(16.6220 ± 0.0197 in)

87 ± 1°

Î color
b

Green

‰ Right hand
ı Set length a

Î color

angle

b

Ï Upper

423.7 ± 0.5 mm
(16.6811 ± 0.0197 in)

87 ± 1°

Ì Lower

422.2 ± 0.5 mm
(16.6220 ± 0.0197 in)

93 ± 1°

T.

R.

15

Ç Set

White

Locknut (upper control rod):
12 mm = 56 Nm (5.6 m · kg, 40 ft · lb)
Locknut (lower control rod):
14 mm = 73 Nm (7.3 m · kg, 53 ft · lb)
LOCTITE®

FRONT SUSPENSION

CHAS

Front arm part number

d

a

b
c

N

PEN0620

ı Caster a

Å Part number
8EN-2382E-00 (L/H)
8EN-2382F-00 (R/H)

Ç Control rod bracket
angle b

24.6°

Î Shock absorber bracket ‰ ID mark
d
angle c





N

Control rod part number

b

a
PEN0630

Ç Part Number
Å Upper
ı Lower

8EN-2384E-00
8EN-2384F-00

Î Length a
388.0 ± 1 mm (15.2755 ± 0.0394 in)
380.0 ± 1 mm (14.9606 ± 0.0394 in)

16

‰ Angle b
4.5 ± 0.5°
8.6 ± 0.5°

SLIDE RAIL SUSPENSION

POWR
TR

POWER TRAIN
SLIDE RAIL SUSPENSION
INSTALLATION
Control rod parts number

a
b
PEN0780

ı Parts number

Ç Length a

Î Length b

Å Control rod 1

8ED-4745A-00

262.5 mm (10.3346 in)

146.0 mm (5.7480 in)

‰ Control rod 1 parts
number

Ï Control rod 2 parts
number

8ED-4745A-00

8CR-4745B-00

Ì Washer plate parts number
Ó Washer plate thickness
È Upper
90202-16229
2.5 mm (0.0984 in)

17

Ô Lower
90202-16231
7.5 mm (0.2953 in)

CYLINDER HEAD AND CYLINDER

ENG

ENGINE
CYLINDER HEAD AND CYLINDER
INSTALLATION
1. Install:
• Gaskets (cylinder head)

NOTE:
The letter “A” is on one side and the letter “B” is on the
opposite side. These letters are not intended as
reference for installation. The head gasket can be
installed with either letter facing up.

PEN0870

18

HEAT EXCHANGER

COOL

COOLING SYSTEM
HEAT EXCHANGER
1

13
8

2
3
5

4

11
6

9

7

14

12

16
15
10

PEN0880

Order

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Job name/Part name
Heat exchanger removal
Coolant
Coolant filler cap
Coolant reservoir tank
Thermostat housing
Coolant hose 1
Coolant hose 2
Joint pipe
Coolant hose 3
Coolant hose 4
Heat exchanger (right)
Coolant hose 5
Coolant hose 6
Heat exchanger (left)
Heat exchanger (rear)
Coolant hose 7
Coolant hose 8
Heat exchanger (front)

Q’ty

Remarks
Remove the parts in the order listed below.
Drain. Refer to “COOLING SYSTEM”.

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
19

HEAT EXCHANGER

COOL

INSPECTION
1. Inspect:
• Coolant hoses 1
• Heat exchangers 2
• Joint pipe 3
• Coolant reservoir tank 4
• Carburetor heating hoses 5
Cracks/damage → Replace.

2
1

4

1

1

1

3 2
5 1
2
1
2

1

PEN0885

20

CARBURETORS

CARB

CARBURETION
CARBURETORS
THROTTLE POSITION SENSOR (T.P.S.)
INSPECTION AND ADJUSTMENT
NOTE:
Before adjusting the T.P.S., properly adjust the idle
speed.

1. Inspect:
• T.P.S.
Inspection steps:
• Disconnect T.P.S. coupler.
• Connect the digital multimeter (Ω × 1k) to the
T.P.S. coupler.

1 3

2

Digital multimeter
90890-03174, YU-34899-A

PEN0890

Tester (–) lead → Gray/Black terminal 1
Tester (+) lead → Red/Yellow terminal 2

• Check the T.P.S. resistance.
T.P.S. resistance “R1”:
4 ~ 6 kΩ at 20°C (68°F)
(Gray/Black - Red/Yellow)
Out of specification → Replace the T.P.S.
• Connect the digital multimeter (Ω × 1k) to the
T.P.S. coupler.
Tester (–) lead → Gray/Black terminal 1
Tester (+) lead → Green/Yellow terminal 3

• While slowly pushing the throttle lever, check the
T.P.S. resistance.
T.P.S. resistance “R2”:
0 ~ 5 kΩ at 20°C (68°F)
(Gray/Black - Green/Yellow)
Out of specification → Replace the T.P.S.

21

CARBURETORS

CARB

2. Adjust:
• T.P.S. position
Adjustment steps:
• Disconnect the T.P.S. coupler.
• Connect the test coupler to the T.P.S.
(If not available go to the next step)
• Connect three dry cells (1.5 V × 3 pcs.) in series to
the test coupler or to the terminals as indicated
below.
Dry cells (–) → 1
Dry cells (+) → 2

3

• Connect the digital multimeter to the test coupler or
to the terminals 1 and 2.

2
1

Digital multimeter (–) lead → 1
Digital multimeter (+) lead → 2
PEN0900

• Measure the voltage A.
NOTE:
When measuring the voltage A be sure that the test
coupler is connected to the T.P.S.

• Calculate voltage B with the following formula.
4

Voltage B = Voltage A × (0.136)
PEN1000

• Loosen the T.P.S. bolts 4.
• Connect the digital multimeter to the test coupler or
terminals 1 and 3.
Digital multimeter (–) lead → 1
Digital multimeter (+) lead → 3

• Adjust the T.P.S. position to obtain the specified
voltage B.

• Tighten the T.P.S. bolts 4.
• Disconnect the test coupler (if applicable) and
connect the T.P.S. coupler from the wire harness.

22

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
SXV70MH

Model
Model code number

8EN1 (for U.S.A./Canada)
8EN2 (for Europe)

Dimensions:
Overall length
Overall width
Overall height

3,090 mm (121.7 in)
1,110 mm (43.7 in)
1,300 mm (51.2 in)

Dry weight

234 kg (515 lb)

Minimum turning radius:
Clockwise
Counterclockwise

4.3 m (14.1 ft)
4.3 m (14.1 ft)

Engine:
Engine type
Induction system
Cylinder arrangement
Displacement
Bore × Stroke
Compression ratio
Maximum horse power r/min
Maximum torque r/min
Starting system

Liquid cooled 2-stroke, 7-port
Crankcase reed valve
Forward inclined parallel 3-cylinder
696 cm3 (42.5 cu.in)
69 × 62 mm (2.72 × 2.44 in)
#1: 5.8 : 1
#2, #3: 6.6 : 1
8,500 r/min
8,000 r/min
Recoil hand starter

Lubrication system

Separate lubrication (YAMAHA AUTOLUBE)

Engine oil:
Type
Tank capacity

YAMALUBE 2-cycle oil
3.0 L (2.6 Imp qt, 3.2 US qt)

Drive chain housing oil:
Type
Capacity

Gear oil API “GL-3” SAE #75 or #80
0.25 L (8.8 Imp oz, 8.5 US oz)

Coolant:
Total amount
Reservoir tank capacity

5.1 L (4.48 Imp qt, 5.40 US qt)
0.28 L (0.25 Imp qt, 0.30 US qt)

Fuel:
Type

Tank capacity

R+M
; 88 or higher)
2
Research Octane; 93 or higher (for Europe)
44.3 L (9.7 Imp gal, 11.7 US gal)
Regular unleaded gasoline (Pump Octane

Carburetor:
Type/Quantity
Manufacturer

TM33/3
MIKUNI

Spark plug:
Type
Manufacturer
Gap

BR9ES
NGK
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

23

GENERAL SPECIFICATIONS
Model

SXV70MH

Transmission:
Primary reduction system
Primary reduction ratio
Clutch type
Secondary reduction system
Secondary reduction ratio
Reverse system

V-Belt
3.8 ~ 1.0 : 1
Automatic centrifugal engagement
Chain
1.90 (40/21) U.S.A./Canada/Europe
No

Chassis:
Frame type
Caster
Ski stance (center to center)

Monocoque
24.6°
980 mm (38.6 in)

Suspension:
Front suspension type
Rear suspension type

Leading arm
Slide rail suspension

Track:
Track type
Track width
Length on ground
Track deflection mm/10 kg (22 lb)

Internal drive type
381 mm (15.0 in)
917 mm (36.1 in)
25 ~ 30 mm (0.98 ~ 1.18 in)

Brake:
Brake type
Operation method

Caliper type disc brake
Handle lever, left hand operated

Electrical:
Ignition system/Manufacturer
Generator system

DC-CDI/MITSUBISHI
Flywheel magneto

Bulb wattage × Quantity:
Headlight
Tail/Brake light
Meter light
High beam indicator light
Information indicator light

12 V, 60 W/55 W × 2
12 V, 5 W/21 W × 2
14 V, 50 mA × 6
14 V, 80 mA × 1
14 V, 80 mA × 1

24

SPEC

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Model

SXV70MH

Cylinder head:
Volume (with spark plug)
<Warp limit>

Cylinder:
Material
Bore size

Aluminum alloy with dispersion coating
69.000 ~ 69.014 mm
(2.7105 ~ 2.7171 in)
<69.100 mm (2.7205 in)>
<0.05 mm (0.002 in)>
<0.01 mm (0.0004 in)>

<Wear limit>
<Taper limit>
<Out-of-round limit>
Piston:
Piston size (D)
Measuring point a
Piston to-cylinder clearance
<Limit>
Piston offset
Piston offset direction
Piston pin bore inside diameter
Piston pin:
Piston pin outside diameter
Piston pin length
Piston ring:
Sectional sketch
Top Ring

Side clearance
Coating

68.927 ~ 68.930 mm
(2.7137 ~ 2.7138 in)
10 mm (0.39 in)
0.070 ~ 0.075 mm
(0.0028 ~ 0.0030 in)
<0.25 mm (0.010 in)>
0.75 mm (0.0295 in)
EX side
20.004 ~ 20.015 mm (0.7876 ~ 0.7880 in)
19.995 ~ 20.000 mm (0.7872 ~ 0.7874 in)
55.7 ~ 56.0 mm (2.193 ~ 2.205 in)

Keystone
B = 1.20 mm (0.047 in)
T = 2.75 mm (0.108 in)

2nd Ring

End gap (installed)

#1: 24.55 ~ 24.85 cm3 (1.50 ~ 1.52 cu. in)
#2, #3: 21.35 ~ 21.65 cm3 (1.30 ~ 1.32 cu. in)
<0.03 mm (0.0012 in)>
∗Lines indicate straight edge measurement.

Top Ring
2nd Ring
Top Ring
2nd Ring
Top Ring
2nd Ring

Keystone
B = 1.20 mm (0.047 in)
T = 2.75 mm (0.108 in)
0.35 ~ 0.55 mm (0.014 ~ 0.022 in)
0.35 ~ 0.55 mm (0.014 ~ 0.022 in)
0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in)
0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in)
Chrome plated/Parkerrizing
Chrome plated/Parkerrizing

25

MAINTENANCE SPECIFICATIONS
Model
Crankshaft:
Crank width “A”
Crank width “B”
Maximum runout “C” : C1
C2 ~ C5
C6
Measuring points: 1
2
Connecting rod big end side clearance
“D”
Connecting rod big end radial clearance “E”
Connecting rod small end free play “F”

SXV70MH
56.95 ~ 57.00 mm (2.242 ~ 2.244 in)
292.75 ~ 293.30 mm (11.526 ~ 11.547 in)
0.03 mm (0.0012 in)
0.04 mm (0.0016 in)
0.03 mm (0.0012 in)
89.5 mm (3.52 in)
84.5 mm (3.33 in)
0.25 ~ 0.75 mm (0.01 ~ 0.03 in)
0.026 ~ 0.040 mm (0.0010 ~ 0.0016 in)
0.8 ~ 1.0 mm (0.03 ~ 0.04 in)

Big end bearing:
Type

Needle bearing

Small end bearing:
Type

Needle bearing

Crank pin:
Crank pin outside diameter

26.991 ~ 27.000 mm (1.0626 ~ 1.0630 in)

Connecting rod:
Small end diameter
Big end diameter

24.995 ~ 25.005 mm (0.9841 ~ 0.9844 in)
34.020 ~ 34.033 mm (1.3394 ~ 1.3399 in)

Reed valve:
Material
Thickness
<Bending limit>
Stopper height

Resin
0.35 ~ 0.49 mm (0.014 ~ 0.019 in)
<1.5 mm (0.059 in)>
10.3 ~ 10.7 mm (0.41 ~ 0.42 in)

26

SPEC

MAINTENANCE SPECIFICATIONS
Model

SXV70MH

Carburetor:
Type/Quantity
Manufacturer
I.D. mark
Main jet
(M.J)
Pilot jet
(P.J)
Jet needle
(J.N)
Needle jet
(N.J)
Pilot air jet
(P.A.J)
Pilot outlet
(P.O)
Bypass
(B.P.1)
Pilot screw
(P.S)
Throttle valve
(Th.V)
Valve seat size
(V.S)
Starter jet
(G.S)
Float height
(F.H)
Fuel level (from the bore center)
Engine idle speed
Throttle cable free play

TM33/3
MIKUNI
8EK100
#156.3
#45
6HEY2-59-3
P-8
1.0
ø0.9
ø0.8
1-7/8 turns out
C.A 1.5
ø1.3
ø1.5
11.3 ~ 15.3 mm (0.44 ~ 0.60 in)
36 ~ 38 mm (1.42 ~ 1.50 in)
1,800 ± 100 r/min
1.0 ~ 2.0 mm (0.04 ~ 0.08 in)

Fuel pump:
Type
Manufacturer

Diaphragm
TAIYO GIKEN

Oil pump:
Pump cable adjusting distance

20.5 ± 1 mm (0.807 ± 0.039 in)

Cooling system:
Filler cap opening pressure
Water pump type
Coolant type
Coolant mixing ratio (coolant:water)
Coolant total amount

SPEC

95 ~ 125 kPa (0.95 ~ 1.25 kg/cm2, 14 ~ 18 psi)
Impeller type
High quality silicate-free ethylene glycol antifreeze containing
corrosion inhibitors
3:2 (60%:40%)
5.1 L (4.48 Imp qt, 5.40 US qt)

27

MAINTENANCE SPECIFICATIONS
POWER TRAIN
Model

SXV70MH

Transmission:
Type
Range of ratio
Engagement speed r/min
Shift r/min
Sheave distance “A”
Sheave offset “B”

V-belt automatic
3.8 ~ 1.0 :1
3,900 ± 200 r/min (3,700 ~ 4,100 r/min)
8,400 ± 250 r/min (8,150 ~ 8,650 r/min)
268 ~ 271 mm (10.55 ~ 10.67 in)
12.5 ~ 15.5 mm (0.49 ~ 0.61 in)

V-Belt:
Part number/Manufacturer
Circumference
Width “A”
Wear limit “B”

8DN-17641-00/MITSUBOSHI
1,129 ~ 1,137 mm (44.4 ~ 44.7 in)
34.5 mm (1.36 in)
32.5 mm (1.28 in)

Primary sheave spring:
Part number
Color code
Diameter
Wire diameter
Preload
Spring rate
Number of coils
Free length

90501-603L3
Green-White-Green
60 mm (2.362 in)
6.0 mm (0.236 in)
441 N (45 kg, 99 lb)
27.5 N/mm (2.75 kg/mm, 154 lb/in)
5.08
89.8 mm (3.54 in)

Primary sheave weight arm:
Part number (with bushing)
Weight

8DN-17605-10
39.76 g (1.403 oz)

Rivet:
Outer
Part number
Material
Size
Quantity
Hole quantity
Inner
Part number
Material
Size
Quantity
Hole quantity

90261-06033 (for Europe)
Steel
17.2 mm (0.68 in) (for Europe)
3 (for Europe)
3
90261-06019 (for U.S.A./Canada)
90261-06033 (for Europe)
Steel
13.3 mm (0.52 in) (for U.S.A./Canada)
17.2 mm (0.68 in) (for Europe)
3
3

28

SPEC

MAINTENANCE SPECIFICATIONS
SXV70MH

Model
Secondary sheave spring:
Part number
Color code
Outside diameter
Wire diameter
Hole position
Sheave side-spring side (twist angle)

Spring rate
Number of coils
Free length
Torque cam angle

SPEC

90508-556A2
Green
69.5 mm (2.736 in)
5.5 mm (0.217 in)
1-6 (70°)

8.5 N/mm (0.87 kg/mm, 48.72 lb/in)
5.53
75 mm (2.95 in)
45°

Drive chain:
Type
Number of links

Borg Warner Automotive. 23RH303-70A SM
70 L

Track:
Part number
Width
Length
Pitch
Number of links
Thickness “A”

8EN-47110-00
381 mm (15.0 in)
3,648 mm (144 in)
64 mm (2.52 in)
57
5.8 mm (0.23 in)

Height “B”

50.8 mm (2.00 in)

Track deflection mm/10 kg (22 lb)

25 ~ 30 mm (0.98 ~ 1.18 in)

Slide rail suspension (Rear suspension):
Center travel
Rear travel
Suspension spring rate
Front
Rear
Spring wire diameter
Front
Rear

205 mm (8.1 in)
270 mm (10.6 in)
32.4 N/mm (3.3 kg/mm, 185 lb/in)
22.6 ~ 42.2 N/mm (2.3 ~ 4.3 kg/mm, 129 ~ 241 lb/in)
8.5 mm (0.33 in)
10.5 mm (0.413 in)

29

MAINTENANCE SPECIFICATIONS
Model
Suspension setting position:
Hook setting length ∗

Full rate adjusting position ∗∗

Shock absorber: Damping force
Front
Extension
Compression
Rear
Extension
Compression

SPEC

SXV70MH
10 ± 0.5 mm (0.39 ± 0.02 in)

B

700 N/0.3 m/s (71 kg/0.3 m/s, 157 lb/0.3 m/s)
920 N/0.3 m/s (94 kg/0.3 m/s, 206 lb/0.3 m/s)
1,480 N/0.3 m/s (151 kg/0.3 m/s, 332 lb/0.3 m/s)
960 N/0.3 m/s (98 kg/0.3 m/s, 215 lb/0.3 m/s)

Slide runner:
Thickness
Wear limit

12.8 mm (0.50 in)
10 mm (0.39 in)

Track sprocket wheel:
Material
Number of teeth

Polyethylene
8T

Rear guide wheel:
Material
Outside diameter

High molecular weight polyethylene with rubber
178 mm (7.01 in)

Brake:
Pad thickness
Pad wear limit
Pad to disk clearance
Disc outside diameter
Disc minimum thickness

10.2 mm (0.40 in)
4.7 mm (0.19 in)
0.025 ~ 0.115 mm (0.001 ~ 0.005 in)
220 mm (8.66 in)
10 mm (0.39 in)

30

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS
Model
Frame:
Frame material
Seat height
Luggage box location
Steering:
Lock-to-lock angle

SXV70MH
Aluminum
730 mm (28.7 in)
Rear side of seat

(left)
(right)

Ski alignment
Toe-out size
Caster angle

26.7° (R ski) 32.0° (L ski)
32.0° (R ski) 26.7° (L ski)
Toe-out
0 ~ 15 mm (0 ~ 0.59 in)
24.6°

Ski:
Ski material
Length
Width

Plastic
1,020 mm (40.2 in)
132.0 mm (5.20 in)

Ski suspension (Front suspension):
Type
Travel
Spring type
Spring rate
Wire diameter
Spring preload length(Standard)
(Maximum)
(Minimum)

Proaction system
170 mm (6.7 in)
Coil spring
22.5 ~ 28.4 N/mm (2.3 ~ 2.9 kg/mm, 128.5 ~ 162.2 lb/in)
8.5 mm (0.335 in)
230 mm (9.06 in)
240 mm (9.45 in)
220 mm (8.66 in)

Shock absorber: damping force
Extension
Compression

530 N/0.3 m/s (54 kg/0.3 m/s, 119 lb/0.3 m/s)
260 N/0.3 m/s (27 kg/0.3 m/s, 58 lb/0.3 m/s)

31

MAINTENANCE SPECIFICATIONS
ELECTRICAL
Model

SXV70MH

Voltage

12 V

Ignition system:
Ignition timing (B.T.D.C.)
Advanced type

5° at 1,800 r/min
Digital type

Ignition coil:
Model/Manufacturer
Minimum spark gap
Primary coil resistance
Secondary coil resistance

F6T535/MITSUBISHI
6 mm (0.236 in) or more
0.36 ~ 0.48 Ω at 20°C (68°F)
5.4 ~ 7.4 kΩ at 20°C (68°F)

Spark plug cap:
Type
Model/Manufacturer
Resistance

Resin type
T156/TOKAI DENSO
5 kΩ at 20°C (68°F)

Charging system:
Type
Nominal output

AC magneto
14 V/21 A at 5,000 r/min

DC-CDI:
Magneto model/Manufacturer
Standard
Pickup coil resistance
(color code)
Stator coil resistance
(color code)
CDI unit model/Manufacturer

F4T36971/MITSUBISHI
14 V 20 A, 280 W at 5,000 r/min
189 ~ 231 Ω at 20°C (68°F)
(White/Red – White/Green)
0.36 ~ 0.44 Ω at 20°C (68°F)
(White – White)
F8T37574/MITSUBISHI

Rectifier/regulator:
Type
Model/Manufacturer
No load regulated voltage
Capacity (DC)
Withstand voltage

Short circuit type
SH650D-11/SHINDENGEN
14.1 ~ 14.9 V
25 A
200 V

DC

Oil level switch:
Model/Manufacturer
Fuel sender:
Model/Manufacturer
Sender resistance

8CR/ASTI

Full
Empty

8CW/NIPPON SEIKI
4 ~ 10 Ω at 20°C (68°F)
90 ~ 100 Ω at 20°C (68°F)

Starting circuit cut-off relay:
Model/Manufacturer
Coil resistance

8DM/MATSUSHITA
76 ~ 93 Ω at 20°C (68°F)

Headlight relay:
Model/Manufacturer
Coil resistance

5DM/OMRON
95 ~ 116 Ω at 20°C (68°F)

Grip warmer:
Heater resistance

(left)
(right)

1.53 ~ 1.87 Ω at 20°C (68°F)
1.53 ~ 1.87 Ω at 20°C (68°F)

32

SPEC

MAINTENANCE SPECIFICATIONS
SXV70MH

Model
Water temperature sensor:
Model/Manufacturer
Resistance

Indicator light:
Speed sensor:
Model/Manufacturer

8CC/MITSUBISHI
5.2 ~ 6.4 kΩ at 0°C (34°F)
0.300 ~ 0.364 kΩ at 80°C (176°F)
0.170 ~ 0.208 kΩ at 100°C (212°F)
(ON)
(OFF)

90 ~ 110°C (194 ~ 230°F)
85 ~ 105°C (185 ~ 221°F)
8EK/YAMAHA

33

SPEC

SPEC

MAINTENANCE SPECIFICATIONS
HIGH ALTITUDE SETTINGS
Tempera- –40°C
ture (–40°F)
Altitude
0 ~ 100 m
(0 ~ 300 ft)

–29°C
(–20°F)

–18°C
(0°F)

–7°C
(20°F)

4°C
(40°F)

16°C
(60°F)

MJ
PJ
PS
JN

#160
#45
1-7/8
3.5

MJ
PJ
PS
JN

#158.8
#45
1-7/8
3.5

MJ
PJ
PS
JN

#157.5
#45
1-7/8
3.5

MJ
PJ
PS
JN

#156.3
#45
1-7/8
3.5

MJ
PJ
PS
JN

#155
#45
1-7/8
3.0

MJ
PJ
PS
JN

#153.8
#45
1-7/8
2.5

MJ

#158.8
#45
1-7/8
3.5

MJ
PJ
PS
JN

#157.5
#45
1-7/8
3.5

MJ
PJ
PS
JN

#156.3
#45
1-7/8
3.0

MJ
PJ
PS
JN

#155
#45
1-7/8
3.0

MJ
PJ
PS
JN

#153.8
#45
1-7/8
2.5

MJ
PJ
PS
JN

#152.5
#45
1-7/8
2.5

#156.3
#45
2-3/8
3.5

MJ
PJ
PS
JN

#155
#45
2-1/8
3.5

MJ
PJ
PS
JN

#153.8
#45
2-1/8
3.0

MJ
PJ
PS
JN

#152.5
#45
2-1/8
3.0

MJ
PJ
PS
JN

#151.3
#45
2-1/8
2.5

MJ
PJ
PS
JN

#150
#45
1-7/8
2.5

#153.8
#47.5
2-5/8
3.0

MJ
PJ
PS
JN

#152.5
#47.5
2-3/8
3.0

MJ
PJ
PS
JN

#151.3
#47.5
2-3/8
3.0

MJ
PJ
PS
JN

#150
#47.5
2-3/8
3.0

MJ
PJ
PS
JN

#148.8
#47.5
2-3/8
2.5

MJ
PJ
PS
JN

#147.5
#47.5
2-1/8
2.5

#151.3
#50
2-7/8
2.5

MJ
PJ
PS
JN

#150
#50
2-5/8
2.5

MJ
PJ
PS
JN

#148.8
#50
2-5/8
2.5

MJ
PJ
PS
JN

#147.5
#50
2-5/8
2.5

MJ
PJ
PS
JN

#146.3
#50
2-5/8
2.5

MJ
PJ
PS
JN

#145
#50
2-3/8
2.5

#148.8
#52.5
3-1/8
2.5

MJ
PJ
PS
JN

#147.5
#52.5
2-7/8
2.5

MJ
PJ
PS
JN

#146.3
#52.5
2-7/8
2.5

MJ
PJ
PS
JN

#143.8
#52.5
2-7/8
2.5

MJ
PJ
PS
JN

#141.3
#52.5
2-7/8
2.5

MJ
PJ
PS
JN

#140
#52.5
2-5/8
2.5

#146.3
#55
3-3/8
2.0

MJ
PJ
PS
JN

#145
#55
3-1/8
2.0

MJ
PJ
PS
JN

#143.8
#55
3-1/8
2.0

MJ
PJ
PS
JN

#141.3
#55
3-1/8
2.0

MJ
PJ
PS
JN

#140
#55
3-1/8
2.0

MJ
PJ
PS
JN

#138.8
#55
2-7/8
2.0

100 ~ 500 m
PJ
(300 ~ 1,700 ft) PS
JN
MJ

500 ~ 1,000 m PJ
(1,700 ~ 3,300 ft) PS
JN
MJ

1,000 ~ 1,500 m PJ
(3,300 ~ 5,000 ft) PS
JN
MJ

1,500 ~ 2,000 m PJ
(5,000 ~ 6,700 ft) PS
JN
MJ

2,000 ~ 2,500 m PJ
(6,700 ~ 8,300 ft) PS
JN
MJ

2,500 ~ 3,000 m PJ
(8,300 ~ 10,000 ft) PS
JN

[Production spec] MJ#1: #156.3 PJ: #45 JN: 6HEY2-59-3 PAJ: 1.0 PS: 1-7/8
#: Main jet number JN: Jet needle clip position PS: Pilot screw turns out PJ: Pilot jet number

NOTE:

• Jet needle (JN) position.
Refer to the following information for the Jet needle shims installation.
JN:2

JN:1.5

JN:1

• Oxygenated fuels
Use one size larger Main Jet than specified.

34

JN:0.5

MAINTENANCE SPECIFICATIONS

SPEC

TIGHTENING TORQUE
ENGINE
Tightening torque

Parts to be tightened
Crankcase (M8 × 80) (1st)
(2nd)
Crankcase (M8 × 35)
Engine bracket (front) and frame
Engine bracket damper (front/rear)
Engine bracket (front) and engine
Engine bracket right (rear) and engine
Engine bracket left (rear) and engine
Engine bracket (rear) and frame
Exhaust joint
Water pump cover
Cylinder head
Nut (1st)
(2nd)
Cylinder
Nut (1st)
Spark plug
Water temperature sensor
Ignition coil and bracket
Thermostatic cover
Oil pump
Oil pump cable adjuster locknut
Fuel pump
Starter pulley
Drive plate
Recoil starter case
Clamp and intake manifold
Bracket and intake manifold
Reed valve assembly
Servo motor assembly and frame
Y.P.V.S. valve assembly
Y.P.V.S. locknut
Y.P.V.S. pulley
Y.P.V.S. valve housing
Throttle position sensor
Carburetor
Pilot jet
Valve seat
Main jet
Pilot air jet
Starter plunger assembly
Clamp (coolant hose 2)
Impeller
Carburetor heating lever assembly
Coolant drain bolt
Bleed bolt front (cooling system)
Bleed bolt rear (cooling system)
Magneto rotor

35

Remarks

Nm

m · kg

ft · lb

13
27
15
50
40
33
33
33
50
14.5
13

1.3
2.7
1.5
5.0
4.0
3.3
3.3
3.3
5.0
1.5
1.3

9.4
19
11
36
29
24
24
24
36
10
9.4

Tighten the bolts in two
stages.

13
28

1.3
2.8

9.4
20

Tighten the nuts in two
stages.

33
20
23
10
10
8
7
10
23
18
12
14
14
1
6.5
11
7
7
8
3.5

3.3
2.0
2.3
1.0
1.0
0.8
0.7
1.0
2.3
1.8
1.2
1.4
1.4
1.0
0.65
1.1
0.7
0.7
0.8
0.35

24
14
17
7.2
7.2
5.8
5.1
7.2
17
13
8.7
10
10
0.7
4.7
8.0
5.1
5.1
5.8
2.5

0.7
1
1.8
0.7
2.5
7
10
10
13
3.5
4
110

0.07
0.1
0.18
0.07
0.25
0.7
1.0
1.0
1.3
0.35
0.4
11

0.51
0.7
1.3
0.51
1.8
5.1
7.2
7.2
9.4
2.5
2.9
80

Apply LOCTITE®

Apply LOCTITE®

MAINTENANCE SPECIFICATIONS

SPEC

POWER TRAIN
Tightening torque

Parts to be tightened

Nm

m · kg

ft · lb

Primary sheave

(1st)
(2nd)
Spider and fixed sheave

120
60
200

12.0
6.0
20.0

85
43
145

Primary sheave cap and sliding sheave
Roller and weight nut (primary sheave)
Starter motor driven gear
Secondary sheave
Stopper (secondary sheave)
Spring seat (secondary sheave)
Bolt (secondary sheave clearance)
Drive sprocket
Locknut chain tensioner
Chain housing and frame
Driven sprocket
Drain bolt (drive chain housing)
Chain housing cover
Chain housing and brake caliper
Bleed screw (brake caliper)
Brake hose
Brake hose joint
Brake master cylinder side
Brake hose side
Bearing set screw (jackshaft)
Bearing holder (jackshaft)
Stopper band
Hook and front pivot arm
Wheel bracket and sliding frame
Front suspension bracket bolt (rear)
Front suspension bracket bolt (front)
Shaft and sliding frame
Front pivot arm and front pivot arm bracket
Front pivot arm bracket and sliding frame
Suspension wheel
Rear axle
Slide rail suspension mounting bolt
(M10)
Rear pivot arm and bracket
Shock absorber and rear pivot arm
Rear pivot arm and pull rod
Rear suspension bracket and pull rod
Shock absorber and rear suspension bracket
Control rod and sliding frame
Shock absorber and front pivot arm
Shock absorber and front suspension bracket
Rear pivot arm bracket

14
6
19
64
6.5
23
10
60
24
48
48
16
24
48
6
30

1.4
0.6
1.9
6.4
0.65
2.3
1.0
6.0
2.4
4.8
4.8
1.6
2.4
4.8
0.6
3.0

10
4.3
1.3
46
4.6
17
7.2
43
17
35
35
11
17
35
4.3
22

14
30
8.5
23
4
16
24
30
72
72
72
72
72
75
72
24
49
49
49
49
72
49
49
72

1.4
3.0
0.85
2.3
0.4
1.6
2.4
3.0
7.2
7.2
7.2
7.2
7.2
7.5
7.2
2.4
4.9
4.9
4.9
4.9
7.2
4.9
4.9
7.2

10
22
6.1
17
2.9
11
17
22
52
52
52
52
52
54
52
17
35
35
35
35
52
35
35
52

36

Remarks
Tighten the bolts in two
stages. See NOTE.
Left-hand thread.
Apply LOCTITE®

Apply LOCTITE®

Apply LOCTITE®

Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®

Apply LOCTITE®

Apply LOCTITE®
Apply LOCTITE®

Apply LOCTITE®

MAINTENANCE SPECIFICATIONS
Tightening torque

Parts to be tightened
Wheel bracket shaft and sliding frame
Set bolt (front axle)
Speedometer gear assembly
Gear unit (speed sensor)

Nm

m · kg

ft · lb

72
9
20
40

7.2
0.9
2.0
4.0

52
6.5
14
29

NOTE:
Tightening steps:
1. Tighten the bolt to a torque of 120 Nm (12 m · kg, 85 ft · lb).
2. Loosen the bolt completely.
3. Retighten the bolt to a torque of 60 Nm (6.0 m · kg, 43 ft · lb).

37

SPEC
Remarks

Apply LOCTITE®

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS
Tightening torque

Parts to be tightened
Handlebar holder
Steering column
Upper
Lower
Steering column and relay rod
Relay rod and relay arm
Relay arm and tie rod
Tie rod and steering arm
Relay arm
Locknut (relay rod/tie rod)
Ski
Ski runner
Ski column lower bracket
Ski and ski handle
Shock absorber (upper)
Shock absorber (lower)
Steering arm and ski column
Lower control rod and frame
Upper control rod and frame
Upper control rod locknut
Lower control rod locknut
Front arm pivot bolt
Frame cross member (M10 × 17)
Front bumper (M8 × 35)
Master cylinder assembly
Brake switch nut
Brake lever bolt
Brake hose nut
Brake hose bolt
Parking brake lever bolt
Parking brake cable bolt
Side cover
Seat and frame (nut)
Shroud

38

Nm

m · kg

ft · lb

15

1.5

11

23
23
35
35
35
42
67
25
48
17
11
17
48
48
35
50
50
56
73
78
48
17
10
3
3
14
30
23
10
3
9
3

2.3
2.3
3.5
3.5
3.5
4.2
6.7
2.5
4.8
1.7
1.1
1.7
4.8
4.8
3.5
5.0
5.0
5.6
7.3
7.8
4.8
1.7
1.0
0.3
0.3
1.4
3.0
2.3
1.0
0.3
0.9
0.3

17
17
25
25
25
30
48
18
35
12
8.0
12
35
35
25
36
36
40
53
56
35
12
7.2
2.2
2.2
10
22
17
7.2
2.2
6.5
2.2

Remarks

Apply LOCTITE®

CABLE ROUTING

SPEC

PEN1170

39

CABLE ROUTING
CABLE ROUTING
1 Thermo sensor
2 Ignition coil coupler
3 T.O.R.S. coupler
4 CDI magneto coupler cover
5 Clamp the CDI magneto coupler,
harness and T.P.S. lead.
6 Pass the starter (choke) throttle
and oil pump cables through the
holder of the intake silencer.
7 T.P.S. coupler
8 Route the main switch coupler
under the fuel tank breather hose
and oil tank breather hose and
then it should be hidden by the
instrument panel.
9 Route the main switch harness
behind the instrument panel
attaching screw.
0 Pass the parking brake cable
under the oil tank breather hose.
A Main switch
First, the main switch lead shall
be looped, and then route it
accordingly.
B Starter (choke) lever
C Brake hose
D Throttle cable
E Oil pump cable
F Thumb warmer resistor
G Grip warmer resistor
H Oil level gauge
I Variable resistor coupler
J Speed sensor
K Coolant hose
L Carburetor heating lever
M The spark plug caps and hightension leads are positioned as
indicated in the illustration.
Å 30°
N Fold back the clamp and secure
it.
O Drive V-belt guard bracket
P Clamp the headlight harness.

40

SPEC

CABLE ROUTING

SPEC

PEN1170

41

CABLE ROUTING
Q Rectifier/regulator
R Bracket
S Condensor
T Rivet
U Y.P.V.S. check coupler, sub lead
coupler

42

SPEC

CABLE ROUTING

SPEC

PEN1180

43

CABLE ROUTING
1 Clamp the fuel hose using the
frame directly attached clamp.
2 Clamp the oil hose using the
frame directly attached clamp.
3 Clamp so that the oil tank cap
and oil tank breather hose do not
interfere with each other. Band
them beside the instrument panel
attaching bolt.
4 Lay the fuel tank breather hose
along the steering gate.
5 Lay the oil tank breather hose
along the steering gate.
6 Do not let the tail light lead
interfere with the frame edge.
7 Hide the tail light lead coupler in
the instrument panel and route on
the front side of frame clamp.
8 Make sure to pass the tail light
lead between the fuel tank and
panel without being caught and
secure the lead in the groove of
fuel tank bottom surface using
the adhesive tape (at 3
positions).
9 To tail light unit
0 50 mm (1.97 in)
A Adhesive tape
B Pass the fuel tank breather hose
through the holder.
C Variable resistor coupler
D Attach the clip with its pawl
directed downward.
E Insert the fuel tank breather hose
to the end.
F Compression spring
G Ground lead
H Attach the hexagon bolt to the
Y.P.V.S. bracket.
I Fuel sender coupler
J Oil level gauge coupler
K Frame directly attached clamp
L Fuel hose
M Pulser hose
N Oil delivery hose 1
O Headlight relay (dimmer) (black)
P Load control relay (white)
Q Situate the C.D.I. unit coupler in
the footrest.
R CDI unit

44

SPEC

CABLE ROUTING

SPEC

PEN1190

45


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