1998-2002 Yamaha Venture VX500/VX600 Snowmobiles OEM Service & Repair Manual

@ @ ICHASI~II-~-R R""-ICIlI-a I ® ENG" OE031 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to @) are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Periodic inspection and adjustment @ Chassis @ Power train ® Engine overhaul ® Cooling system (j) Carburetion ® Electrical ® Specifications @> Optional kit Illustrated symbols ® to ® are used to identify the specifications which appear. ® Filling fluid @ Lubricant @ Tightening @ Wear limit, clearance @ Engine speed @ Special tool @n,V,A @ -C s *, Illustrated symbols @ to @ in the exploded dia- gram indicate grade of lubricant and location of lubrication point. @ Apply locking agent (LOCTITE~) @) 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 @ Apply Yamabond No.5® , A @ @ @ --.ott -eM*, cEJJII

INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE OVERHAUL COOLING SYSTEM CARBURETION ELECTRICAL SPECIFICATIONS OPTIONAL KIT ~ GEN INFO ~ CHAS crD ----- POWR ~ TR \) ENG CARB u-- SPEC •

__________ I=I~I 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 DIS- ASSEMBLY 1-2 ALL REPLACEMENT PARTS 1-3 GASKETS, OIL SEALS, AND a-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 1-6 FOR ELECTRICAL SERVICE '-7 [II

MACHINE IDENTIFICATION II~~~ I~I 1EOO1 GENERAL INFORMATION MACHINE IDENTIFICATION 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). ENGINE SERIAL NUMBER The engine serial number CD is located on the right-hand 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: VX500U .11 ••••• 8AB-0001 01-- VX500EU 8BP-000101-- VX500STU 8BN-000101-- VX500DXU 8BB-000101-- VX600U 8CA-0001 01-- VX600EU 8CF-000101-- VX600STU 8CC-000101-- VX600DXU 8CB-000101-- NOTE: _ Designs and specifications are subject to change without notice. 1-1

IMPORTANT INFORMATION I ~~~ I~I 1E011 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 ensure that all parts are rein- stalled correctly. 5. Keep away from fire. 6. Be sure to keep to tightening torque specifications. 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

IMPORTANT INFORMATION II~~~ I~I ALL REPLACEMENT PARTS 1.We recommend use of Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and a-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and a-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. .. 300-000 300-002 300-003 1-3 LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates CD and cotter pins must be replaced when they are removed. Lock tabts) should be bent along the bolt or nut tlatts) after the bolt or nut has been properly tightened. BEARINGS AND OIL SEALS 1.lnstall the bearing(s) CD and oil sealts) ® with their manufacturer's marks or numbers facing outwards. (In other words, the stamped letters must be on the side exposed to view.) When installing ollseatts). apply a light coating of lightweight lithium base grease to the seal lipts). Oil the bearings liberally when installing. '._1, _ Do not use compressed air to spin the bearings dry. This causes damage to the surface of the bearings.

IMPORTANT INFORMATION/SPECIAL TOOLS II~~~ I~I CIRCLIPS 1.All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing acirclip CD, make sure that the sharp edged corner ® is positioned opposite to the thrust @ it receives. See the sectional view. 300-001 @ Shaft 1E021 SPECIAL TOOLS Some special tools are necessary for 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 differs according to the area as shown below. The first part number is for Europe, and the second part is for the U.S.A. and Canada. e.g. 90890 - *****, YU- ***** FORTUNE UP • Sheave Gauge PIN YS-91047-3 CD, YS-39506-5 ® This gauge is used to measure sheave distance and for offset adjustment. 1E041 • Dial Gauge PIN 90890-03097, YU-03097 This gauge is used for run out measurement. 1-4

1-5 SPECIAL TOOLS II~~~ I~I 1E051 • Fuel Level Gauge PIN 90890-01312, YM-01312-A This gauge is used to measure the fuel level in the float chamber. 1E061 • Vacuum Gauge PIN -, YS-33275 This gauge is used for carburetor synchroniza- tion. 1E071 FOR ENGINE SERVICE • Piston Pin Puller PIN 90890-01304, YU-01304 This tool is used to remove the piston pin. 1E081 • Rotor Puller PIN 90890-01362, YU-33270 This tool is used to remove the magneto rotor. 1E091 • Cooling System Tester PIN 90890-01325, YS-22 460-0 1 This tester is used for checking cooling system.

SPECIAL TOOLS II~~~ I~I 1E101 FOR POWER TRAIN SERVICE • Primary Sheave Holder PIN 90890-01701, YS-01880 This tool is used to hold the primary sheave. 1E111 • Primary Sheave Puller (18 mm) PIN YS-01881-1 CD, YS-38517 ® 2 This tool is used for removing the primary sheave. o 1-6 1E121 • Clutch Spider Separator PIN 90890-01711, YS-28890-B This tools are used when disassembling and as- sembling the primary sheave. 1E131 • Clutch Separator Adapter PIN 90890-01740, YS-34480 This tool is used when disassembling and assem- bling the primary sheave. 1E171 • Clutch busing jig kit PIN YS-39752 Thistool is used when removing and installingthe primary sheave busing.

SPECIAL TOOLS __________ I=I~I 1E141 • Track Clip Installer PIN 90890-01721, YS-91045-A This tool is used for installing the track clip. 1E151 FOR ELECTRICAL SERVICE • Pocket Tester PIN 90890-03112, YU-03112 This instrument is necessary for checking the electrical components. 1E161 • Electro Tester PIN 90890-03021, YU-33260-A This instrument is invaluable for checking the electrical system. 1-7

1998-2002 Yamaha Venture VX500/VX600 Snowmobiles OEM Service & Repair Manual

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