SNOWMOBILE OWNER’S MANUAL MM600G SX600G VT600G VX600ERG PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 4 - 8.
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E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM A ESU00286 1- MACHINE IDENTIFICATION Identification number records A. FRAME NUMBER: CZ-01E B B. ENGINE NUMBER (PRIMARY ID): CZ-01E C. KEY NUMBER: C CZ-01E Record the frame number, engine number (Primary ID), and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer. 1 The frame number is the seventeen-digit number stamped on the frame of the snowmobile. (See fig. È.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00001 INTRODUCTION 1- Congratulations! Your choice of a Yamaha snowmobile assures you of the highest quality and dependability. Your Yamaha snowmobile is manufactured by a company well-known for excellence in the field of snowmobiles. The most advanced production equipment and technology have made Yamaha one of the best snowmobile manufacturers. We are confident that this snowmobile will meet the greatest expectations of our customers.
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM WARNING @ PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE SNOWMOBILE. @ NOTE: @ ● ● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your snowmobile and this manual. If there is any question concerning this manual, please consult a Yamaha dealer.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00003 CONTENTS YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTY .......................................1-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ...............................................1-4 LOCATION OF THE IMPORTANT LABELS .......................2-1 SAFETY INFORMATION ...................3-1 DESCRIPTION ...................................4-1 CONTROL FUNCTIONS ....................5-1 Main switch......................................
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM Maximizing drive track life .............7-10 Strap ..............................................7-11 Driving ...........................................7-12 Stopping the engine.......................7-13 Transporting ..................................7-14 PERIODIC MAINTENANCE ...............8-1 Periodic maintenance chart .............8-1 Tool kit .............................................8-4 Spark plug inspection ......................
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00004 YAMAHA MOTOR CORPORATION, U.S.A.
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E_8DG.book Page 4 Friday, June 29, 2001 4:20 PM ESU00005 YAMAHA EXTENDED SERVICE (Y.E.S.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00007 LOCATION OF THE IMPORTANT LABELS 2- Please read the following labels carefully before operating this snowmobile. NOTE: @ Maintain or replace safety and instruction labels, as necessary. @ 2 3 SX600 WARNING DO NOT OPERATE ENGINE WITHOUT V-BELT OR DRIVE GUARD. AVERTISSEMENT NE PAS FAIRE FONCTIONNER LE MOTEUR SANS COURROIE EN V OU PROTECTEUR D’EMBRAYAGE. WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion.
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM 1 VX600ER 4 MM600 AVERTISSEMENT WARNING Improper use of STRAP on the handlebar can result in SEVERE INJURY or DEATH. • Use strap only as an operator grip point to shift weight uphill to maintain balance during traverse ( sidehill ) riding. • Keep one hand on handlebar. Do not change speed or direction abruptly. • Only experienced operators should traverse slopes steep enough to require strap use.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00009 SAFETY INFORMATION 3- When you ride your snowmobile, you must know and use the following for your safety. Severe injury or death may result if you ignore any of the following. Before operating 1. Read the Owner’s Manual and all labels before operating this snowmobile. Become familiar with all of the operating controls and their function. Consult a Yamaha dealer about any control or function you do not understand. 2.
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM 7. Do not allow anyone to stand behind the snowmobile when starting, inspecting, or adjusting the snowmobile. A broken track, track fittings, or debris thrown by the track could be dangerous to the operator or bystanders. 8. Handle fuel with care; it is HIGHLY FLAMMABLE. ● Never add fuel when the engine is running or hot. Allow the engine to cool for several minutes after running. ● Use an approved fuel container.
E_8DG.book Page 3 Friday, June 29, 2001 4:20 PM 3. This snowmobile is not designed for use on surfaces other than snow or ice. Use on dirt, sand, grass, rocks, or bare pavement may cause loss of control and may damage the snowmobile. 4. Avoid operating on glare ice, or on snow which has a lot of dirt or sand mixed in. Operation under such conditions will damage or result in rapid wear of ski runners, drive track, slide runners, and drive sprockets. 5.
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E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00013 5- CONTROL FUNCTIONS ESU00256 Main switch The main switch controls the following items. 1 “OFF” The ignition circuit is switched off. The key can be removed only in this position. A 2 “ON” The ignition circuit is switched on. The engine can be started. NOTE: @ The headlight, meter lights, and taillight will come on after the engine starts. @ B For VT600 / VX600ER 3 “START” The starting circuit is switched on. The starter motor starts.
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM ESU00020 Starter lever (choke) Use the starter lever (choke) when starting and warming up a cold engine. 1 2 3 4 Starter lever (choke) When starting a cold engine. Warming up When the engine is warm. NOTE: @ Refer the “Starting the engine” section for proper operation. @ ESU00022 Throttle lever Once the engine is running cleanly, squeezing a the throttle lever 1 will increase the engine speed and cause engagement of the drive system.
E_8DG.book Page 3 Friday, June 29, 2001 4:20 PM WARNING @ ● ● A If the T.O.R.S. is activated, make sure 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 specified spark plug and spark plug cap. Otherwise, the T.O.R.S. will not work properly.
E_8DG.book Page 4 Friday, June 29, 2001 4:20 PM ESU00278 Coolant temperature warning light This snowmobile is equipped with a self-diagnosis device which is able to detect a malfunctioning sensor, disconnected coupler, broken lead, abnormally high coolant temperature, etc. The coolant temperature warning light warns the rider of the above problems by flashing or staying on. If necessary, ask a Yamaha dealer for further details. (See page 5-5 for warning light flash patterns.
E_8DG.book Page 5 Friday, June 29, 2001 4:20 PM No. 0 1 Coolant temperature warning light flash patterns 0.5 s 0.5 s Light bulb check: Light flashes three times, then goes off. 3s Engine overheat warning: Light flashes continuously in this pattern. · · · 0.25 s 0.25 s Light flashes continuously in this pattern. · · · 2 3 0.75 s 0.25 s 4s · · · Light flashes continuously in this pattern. · · · Light flashes continuously in this pattern. 0.75 s 2.5 s 4 0.75 s 0.25 s 3.
E_8DG.book Page 6 Friday, June 29, 2001 4:20 PM ESU00031 Engine stop switch The engine stop switch 1 is used to stop the engine in an emergency. Simply push 2 the stop switch to stop the engine. To start the engine, pull 3 the stop switch and proceed with starting the engine. (See page 7-1 for more details.) During the first few rides, practice using the stop switch so that you can react quickly in an emergency. ESU00241 Brake lever The snowmobile is stopped by braking the entire drive system.
E_8DG.book Page 7 Friday, June 29, 2001 4:20 PM A ESU00035 Parking brake lever When parking the snowmobile or starting the engine, apply the parking brake by moving the brake lever 1 to the left. To release the parking brake, move the parking brake lever 1 to the right. B È To apply the parking brake É To release the parking brake WARNING @ ● ● Always set the parking brake before attempting to start the engine. Never run the snowmobile with the parking brake applied.
E_8DG.book Page 8 Friday, June 29, 2001 4:20 PM ESU00039 Headlight beam switch Push the headlight beam switch to change the headlight beam to high or low. 1 2 3 4 Headlight beam switch Push High beam Low beam ESU00279 Grip warmer control knob The grip warmer control knob controls the electrically heated handlebar grips.
E_8DG.book Page 9 Friday, June 29, 2001 4:20 PM ESU00044 Passenger grip warmer switch For VT600 The passenger grip warmer switch controls the electrically heated passenger grips. 1 Passenger grip warmer switch 2 “OFF” 3 “HI” High 4 “LO” Low ESU00046 Tripmeter reset knob Use the tripmeter reset knob to reset the tripmeter. 1 Tripmeter reset knob 2 Turn counterclockwise ESU00048 Shroud latches To open the shroud, unhook the shroud latches, and then slowly raise the shroud forward until it stops.
E_8DG.book Page 10 Friday, June 29, 2001 4:20 PM ESU00052 Drive guard The drive guard is designed to cover the V-belt clutch and V-belt in case parts break or come loose. WARNING ● ● Make sure that the drive guard is tightened securely before operating the snowmobile. Never run the engine with the V-belt or drive guard removed. @ ESU00053 V-belt holders Keep a spare V-belt for emergency use by placing it into the V-belt holders provided.
E_8DG.book Page 11 Friday, June 29, 2001 4:20 PM ESU00067 Backrest For VT600 The backrest is adjustable. Pull the backrest adjusting lever 1 upward to adjust the backrest position. Turn the backrest adjusting knob 2 right or left to further adjust the backrest. WARNING @ Do not sit on the backrest. @ When riding without a passenger, the backrest can be adjusted for the rider as shown in the illustration.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00072 PRE-OPERATION CHECKS 6- NOTE: @ Pre-operation checks should be made each time the snowmobile is used. @ WARNING @ The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair. @ ESU00075 Fuel Make sure that there is sufficient fuel in the fuel tank.
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM ● ● ● age. Consult a Yamaha dealer. Gasohol containing methanol is not recommended. Make sure that snow or ice does not enter the fuel tank when refueling. Do not use alcohol deicers or water absorbing additives with oxygenated fuel. The fuel tank should be filled with straight gasoline as specified. @ ESU00083 Engine oil Make sure that there is sufficient oil in the oil tank. Oil tank capacity: 3.0 L (2.6 Imp qt, 3.
E_8DG.book Page 3 Friday, June 29, 2001 4:20 PM ESU00087 Throttle lever Check the throttle lever operation before starting the engine. The throttle lever must open smoothly and spring back to its home position when released. ESU00088 Recoil starter Check the recoil starter for proper operation and the recoil starter rope for damage. ESU00090 Throttle override system (T.O.R.S.) Check the T.O.R.S. for proper operation. WARNING @ When checking T.O.R.S.: ● Make sure that the parking brake is applied.
E_8DG.book Page 4 Friday, June 29, 2001 4:20 PM ESU00091 Brake 1. Brake lever Test the brake at a low speed when starting out to make sure that it is working properly. If the brake does not provide proper braking performance, inspect the brake for wear or brake fluid leakage. (See pages 8-16–8-18 for more details.) WARNING @ ● ● A soft, spongy feeling in the brake lever indicates a failure in the brake system. Do not operate the snowmobile if you find any problems in the brake system.
E_8DG.book Page 5 Friday, June 29, 2001 4:20 PM ESU00093 Brake fluid leakage Apply the brake for a few minutes. Check to see if any brake fluid leaks out from the brake hose joints or the master cylinder. WARNING @ If brake fluid leakage is found, ask a Yamaha dealer for immediate repairs. @ CAUTION: @ Brake fluid may deteriorate painted surfaces or plastic parts. Never spill any brake fluid. If any is spilled, clean it up immediately. @ ESU00094 V-belt Open the shroud and remove the drive guard.
E_8DG.book Page 6 Friday, June 29, 2001 4:20 PM ESU00097 Drive track Check the drive track for deflection, wear, or damage. Adjust or replace if necessary. (See pages 8-24–8-26 for more details.) WARNING @ Do not operate the snowmobile if you find damage to the drive track, or if it has been maladjusted. Drive track damage or failure could result in loss of braking ability and snowmobile control, which could cause an accident. @ ESU00243 51-mm (2.
E_8DG.book Page 7 Friday, June 29, 2001 4:20 PM A ESU00244 Skis and ski runners Check the skis and ski runners for wear and damage. Replace if necessary. È For MM600 / SX600 Ski runner wear limit a: 8 mm (0.31 in) Ski wear limit b: 8 mm (0.31 in) A B É For VT600 / VX600ER Ski runner wear limit c: 8 mm (0.31 in) Ski wear limit d: 13 mm (0.
E_8DG.book Page 8 Friday, June 29, 2001 4:20 PM ESU00106 Battery For VT600 / VX600ER Check the fluid level and fill if necessary. Use only distilled water if refilling is necessary. (See page 8-31 for more details.) ESU00107 Air filter Always check that no snow is on the air filter elements. If there is any snow on the air filter elements, take them out and remove the snow. After riding the snowmobile, make sure that there is no snow on the air filter elements.
E_8DG.book Page 9 Friday, June 29, 2001 4:20 PM ESU00110 Fittings and fasteners Check the tightness of the fittings and fasteners. Tighten in proper sequence and torque if necessary. ESU00111 Tool kit and recommended equipment It is good practice to carry the tool kit, spare parts, and other necessary equipment with you while riding the snowmobile so that minor repairs can be done if necessary.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00112 OPERATION 7- ESU00281 Starting the engine WARNING @ ● ● Be sure to check the “SAFETY INFORMATION” section carefully before starting the engine. Make sure that the parking brake is applied. @ NOTE: @ Make sure that the engine stop switch is in the on position. @ 1. Fully open the starter lever (choke).
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM Electric starting model For VT600 / VX600ER 2. Turn the main switch to the “START” position. After the engine starts, put the starter lever (choke) in the half-open position. Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the closed position. 1 “START” CAUTION: @ ● ● Release the switch immediately after the engine starts.
E_8DG.book Page 3 Friday, June 29, 2001 4:20 PM 3. Mesh the rope stopper with the edge of the primary sheave assembly. 1 Rope stopper 2 Primary sheave assembly edge 4. Wind the rope counterclockwise three turns on the primary sheave assembly. 5. Grasp the screwdriver handle and pull briskly. WARNING @ Do not wind the emergency starter rope around your hand. @ 6. After the engine starts, put the starter lever (choke) in the half-open position.
E_8DG.book Page 4 Friday, June 29, 2001 4:20 PM ESU00126 Break-in There is never a more important period in the life of your snowmobile than the break-in period. For the first 10 hours, approximately 200 km (125 mi), do not put an excessive load on the engine. Avoid prolonged full throttle operation. Also avoid lugging the engine, such as laborious operation in wet snow. If any abnormal condition is noticed, such as excessive vibration or noise, consult a Yamaha dealer.
E_8DG.book Page 5 Friday, June 29, 2001 4:20 PM ESU00127 Riding your snowmobile Getting to know your snowmobile A snowmobile is a rider active vehicle, and your riding position and your balance are the two basic factors of maneuvering your snowmobile. Riding your snowmobile requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
E_8DG.book Page 6 Friday, June 29, 2001 4:20 PM To start out and accelerate 1. With the engine idling, release the parking brake. 2. Apply the throttle slowly and smoothly. The V-belt clutch will engage and you will start to accelerate. WARNING @ The operator should always keep both hands on the handlebar. Never put your feet outside the running boards. Avoid high speeds until you have become thoroughly familiar with your snowmobile and all of its controls.
E_8DG.book Page 7 Friday, June 29, 2001 4:20 PM Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your snowmobile. Riding uphill You should practice first on gentle slopes. Try more difficult climbs only after you have developed your skill. As you approach a hill, accelerate before you start the climb, and then reduce the throttle opening to prevent track slippage. It is also important to keep your weight on the uphill side at all times.
E_8DG.book Page 8 Friday, June 29, 2001 4:20 PM Traversing a slope WARNING @ Traversing slopes is not recommended for a novice snowmobiler. @ Traversing a slope requires you to properly position your weight to maintain proper balance. As you travel across the slope, lean your body to position your weight towards the uphill side. A recommended riding position is to kneel with the knee of the downhill leg on the seat and the foot of the uphill leg on the running board.
E_8DG.book Page 9 Friday, June 29, 2001 4:20 PM Operation on surfaces other than snow or ice Operation of your snowmobile on surfaces other than snow or ice should be avoided. Operation under such conditions will damage or result in rapid wear of the ski runners, drive track, slide runners, and drive sprockets. Operation of the snowmobile under the following conditions should be avoided at all costs: 1. Dirt 2. Sand 3. Rocks 4. Grass 5.
E_8DG.book Page 10 Friday, June 29, 2001 4:20 PM ESU00251 Maximizing drive track life Recommendations Track tension During initial break-in, the new drive track will tend to stretch quickly as the track settles. Be sure to correct the track tension and alignment frequently. (See pages 8-24–8-26 for adjustment procedures.) A loose track can slip (ratchet), derail or catch on suspension parts causing severe damage.
E_8DG.book Page 11 Friday, June 29, 2001 4:20 PM ESU00245 Strap For MM600 The strap 1 should be used only by experienced operators to assist them when traverse (side-hill) riding. WARNING @ Improper use of the strap on the handlebar can result in severe injury or death. ● Use the strap only as an operator grip point when needed to shift weight uphill to maintain balance during traverse (side-hill) riding. Only experienced operators should traverse slopes steep enough to require strap use.
E_8DG.book Page 12 Friday, June 29, 2001 4:20 PM ESU00135 Driving WARNING @ Be sure to read the “SAFETY INFORMATION” and “Riding your snowmobile” sections carefully before operating the snowmobile. @ NOTE: @ Make sure that the engine is warmed up enough before riding. @ For MM600 / SX600 1. Release the parking brake by moving the parking brake lever to the right. 2. Press the throttle lever slowly to move the snowmobile. 3. Turn the handlebar in the desired direction. 4.
E_8DG.book Page 13 Friday, June 29, 2001 4:20 PM 2. Release the parking brake by moving the parking brake lever to the right. 3. Press the throttle lever slowly to move the snowmobile. 4. Turn the handlebar in the desired direction. 5. Squeeze the brake lever to stop the snowmobile. 6. Apply the parking brake by moving the parking brake lever to the left. A B ESU00137 Stopping the engine Turn the main switch to the “OFF” position to stop the engine.
E_8DG.book Page 14 Friday, June 29, 2001 4:20 PM ESU00138 Transporting When transporting your snowmobile on a trailer or in a truck, observe the following recommendations to help protect it from damage: ● ● ● Make sure that the fuel level in the fuel tank is lower than the bottom of the carburetors. Otherwise, the vibration and bumps from the road surface could make it possible for fuel to flow through the carburetors into the crankcase.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00139 PERIODIC MAINTENANCE 8- ESU00140 Periodic maintenance chart Regular maintenance is most important for best performance and safe operation. CD-01E Item Spark plugs Preoperation check (Daily) Remarks Check condition. Adjust gap and clean. Replace if necessary. Every Seasonally or 3,200 km (2,000 mi) (160 hr) ● ● Check oil level. Engine oil Initial 1 month or 800 km (500 mi) (40 hr) ∗ Air bleed the oil pump if necessary.
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM Item Preoperation check (Daily) Remarks Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 3,200 km (2,000 mi) (160 hr) Page ∗ Decarbonization More frequently if necessary. Drive guard Check for cracks, bends or damage. ∗ Replace if necessary. ● 5-10, 6-5 V-belt Check for wear and damage. Replace if necessary. ● 6-5, 8-12–8-14 Drive track and idler wheels Check deflection, and for wear and damage. ∗ Adjust/replace if necessary.
E_8DG.book Page 3 Friday, June 29, 2001 4:20 PM Item Preoperation check (Daily) Remarks Check engagement and shift speed. Adjust if necessary. Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 3,200 km (2,000 mi) (160 hr) Page ● Whenever operating elevation is changed. Inspect sheaves for wear/ damage. ∗ Primary and second- Inspect weights/rollers and bushings for wear-for primary. ary clutches Inspect ramp shoes/bushings for wear-for secondary. Replace if necessary.
E_8DG.book Page 4 Friday, June 29, 2001 4:20 PM A ESU00143 Tool kit The owner’s tool kit has the tools which are sufficient for most periodic maintenance and minor repair. A torque wrench is also necessary to properly tighten nuts and bolts. 1Tool kit B È MM600 / SX600 / VX600ER É VT600 CAUTION: @ Before starting the engine, make sure that the tool kit is firmly seated in the holder and is secured with the holding band.
E_8DG.book Page 5 Friday, June 29, 2001 4:20 PM Spark plugs are produced in several different thread lengths. The thread length or reach is the distance from the spark plug gasket seat to the end of the threaded portion. If the reach is too long, overheating and engine damage may result. If the reach is too short, spark plug fouling and poor performance may result. Also, if the reach is too short, carbon will form on the exposed threads resulting in combustion chamber hot spots and thread damage.
E_8DG.book Page 6 Friday, June 29, 2001 4:20 PM ESU00147 Throttle cable adjustment CAUTION: @ Be sure to adjust the engine idle speed first. @ 1. Loosen the locknut. 2. Turn the adjuster in or out until the proper throttle lever free play is achieved. Throttle lever free play a: 1.0–2.0 mm (0.04–0.08 in) 1 Locknut 2 Adjuster 3. Tighten the locknut. ESU00149 Oil pump cable adjustment CAUTION: @ Be sure to adjust the throttle cable first. @ 1. Loosen the locknut. 2.
E_8DG.book Page 7 Friday, June 29, 2001 4:20 PM ESU00150 Carburetor adjustment CAUTION: @ ● ● Be sure to have a Yamaha dealer make this adjustment. Make sure that the carburetor silencer is installed during running to prevent engine damage. @ Under some operating conditions the carburetor setting may have to be changed due to air temperature changes, elevation changes, use of alcohol oxygenated fuels, etc., and should be set by a Yamaha dealer.
E_8DG.book Page 8 Friday, June 29, 2001 4:20 PM Jet needle adjustment Adjust the jet needle by changing its clip position according to the setting chart which is available at a Yamaha dealer. Standard jet needle clip 1 position: 3rd groove from upper end CD-03E Clip position Mixture 2 Upper end Lean 3 Lower end Rich Condition Warm weather High altitude Cold weather Low altitude 1. Remove the top cover of the carburetor and jet needle. 2. Change the clip to the proper position.
E_8DG.book Page 9 Friday, June 29, 2001 4:20 PM Standard main jet: 1 No.1 Carburetor (P.T.O. side) # 136.3 2, 3 No.2 and No.3 Carburetors (center and magneto side) # 133.8 CD-04E Main jet 4 Mixture Small No. Lean Large No. Rich Condition Warm weather High altitude Cold weather Low altitude 1. Loosen the carburetor clamps and remove the carburetor. 2. Pinch the fuel hose to prevent fuel flowing. 3. Remove the drain plug and install the proper main jet. 4. Assemble by reversing the removal steps.
E_8DG.book Page 10 Friday, June 29, 2001 4:20 PM Remember: less air at higher altitude means there is less horsepower available, even with proper carburetion. Expect acceleration and top speed to be reduced at higher altitudes. To overcome operating with less power at high altitudes, your snowmobile may also require different settings for the drive chain gears and V-belt clutch to avoid poor performance and rapid wear.
E_8DG.book Page 11 Friday, June 29, 2001 4:20 PM CAUTION: @ Operating the engine with an improperly bled cooling system can cause overheating and severe engine damage. @ Coolant replenishment 1. Remove the coolant filler cap and pour the coolant to the proper level. 1 Coolant level 2 To coolant reservoir Recommended coolant: High quality ethylene glycol antifreeze containing corrosion inhibitors. Coolant and water mixing ratio: 60:40 Total amount: For MM600 4.0 L (3.52 Imp qt, 4.
E_8DG.book Page 12 Friday, June 29, 2001 4:20 PM ESU00166 V-belt replacement WARNING @ When installing the new V-belt, make sure it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave assembly to 0.5 mm (0.02 in) below the edge a. If not, the V-belt clutch engagement speed will be changed. The snowmobile may move unexpectedly when the engine is started. Adjust the V-belt position by removing or adding a spacer 1 on each adjusting bolt. Have a Yamaha dealer make this adjustment.
E_8DG.book Page 13 Friday, June 29, 2001 4:20 PM 3. Pull 3 the V-belt up over the secondary fixed sheave. 4. Remove the V-belt from the secondary sheave assembly and primary sheave assembly. 5. Put the new V-belt back on the secondary sheave assembly only. Do not force the V-belt between the sheaves; the secondary sliding and fixed sheave must touch each other. Measure the V-belt position. Standard V-belt position a: From 1.5 mm (0.06 in) above the edge of the secondary sheave to 0.5 mm (0.
E_8DG.book Page 14 Friday, June 29, 2001 4:20 PM 8. Install the V-belt over the primary sheave assembly. 9. Rotate the secondary sliding sheave clockwise 6 and push 7 it so that it separates from the secondary fixed sheave. 10. Install the V-belt 8 between the secondary sliding and secondary fixed sheaves. 11. Install the drive guard. WARNING @ Never run the engine with the V-belt or drive guard removed.
E_8DG.book Page 15 Friday, June 29, 2001 4:20 PM ESU00171 Checking the oil level of the drive chain housing WARNING @ The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair. @ 1. Place the snowmobile on a level surface. 2. Remove the dipstick 1 and wipe it off with a clean rag. Then put the dipstick in the hole.
E_8DG.book Page 16 Friday, June 29, 2001 4:20 PM 4. Reinstall the dipstick and fit the loop 4 of the dipstick handle onto the projection 5 of the gear case. Chain tension adjustment 1. Loosen locknut. 2. Turn the adjuster bolt clockwise until it is finger tight. 3. Hold the adjuster bolt in place while tightening the chain adjuster locknut. 1 Locknut 2 Adjuster bolt ESU00174 Checking the brake pads Check the brake pads for wear.
E_8DG.book Page 17 Friday, June 29, 2001 4:20 PM Adjustment As the parking brake pads wear, adjustment may be necessary to ensure proper brake performance. WARNING @ Be sure to have a Yamaha dealer make this adjustment. @ 1. Loosen the locknut 1. 2. Turn the parking brake adjuster 2 in or out to adjust the clearance between the parking brake pad 3 and brake disc 4. Clearance a: 1.2–1.3 mm (0.047–0.051 in) 3.
E_8DG.book Page 18 Friday, June 29, 2001 4:20 PM ESU00181 Brake fluid replacement Brake fluid replacement is necessary when the following components are replaced during the periodic maintenance or if they are damaged or leaking. a. All oil seals of the master cylinder and caliper cylinder b. The brake hose WARNING @ Make sure that the brake fluid and the above parts are replaced by a Yamaha dealer. @ ESU00183 Suspension The suspension can be adjusted to suit rider preference.
E_8DG.book Page 19 Friday, June 29, 2001 4:20 PM For VT600 / VX600ER N-CD-??E Spring adjuster position 5 4 3 2 Hard Preload Standard 2 1 Soft 3 1 CAUTION: @ The left and right ski spring preload must be set to the same pressure. Uneven settings can cause poor handling and loss of stability. @ For SX600 N-CD-??E Spring seat length Standard Long ← → Short Preload Hard ← → Soft a Length Maximum 137 mm (5.39 in) 127 mm (5.00 in) Minimum 117 mm (4.
E_8DG.book Page 20 Friday, June 29, 2001 4:20 PM ESU00193 Rear suspension spring preload adjustment The rear suspension is equipped with two shock absorbers. One is in the front 1 and the other is in the rear 2 of the rear suspension assembly. The spring preload can be adjusted by turning the spring preload adjuster 3 on the front and rear shock absorbers. WARNING @ Be sure to have a Yamaha dealer make this adjustment.
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E_8DG.book Page 22 Friday, June 29, 2001 4:20 PM F For SX600 N-CD-??E Spring seat length Standard Long ← → Short Preload Hard ← → Soft Í a Length (front) Maximum 96.8 mm (3.81 in) Minimum 86.8 mm 76.8 mm (3.42 in) (3.02 in) Î b Length (rear) Maximum 80.3 mm (3.16 in) Minimum 70.3 mm 60.3 mm (2.77 in) (2.37 in) G WARNING @ Be sure to have a Yamaha dealer make this adjustment. This shock absorber contains highly pressurized nitrogen gas.
E_8DG.book Page 23 Friday, June 29, 2001 4:20 PM ESU00197 Rear suspension full rate adjustment The total suspension spring rate and damping characteristics can be adjusted by changing the installed position of the shock absorber. WARNING @ Be sure to have a Yamaha dealer make this adjustment. @ CD-07E Installation position Spring rate and damping Standard C B A Hard Medium Soft B NOTE: @ Be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile. @ 1.
E_8DG.book Page 24 Friday, June 29, 2001 4:20 PM ESU00199 Drive track adjustment WARNING @ A broken track, track fittings or debris thrown by the drive track could be dangerous to an operator or bystanders. Observe the following precautions: ● Do not allow anyone to stand behind the snowmobile when the engine is running. ● When the rear of the snowmobile is raised to allow the drive track to spin, a suitable stand must be used to support the rear of the snowmobile.
E_8DG.book Page 25 Friday, June 29, 2001 4:20 PM Drive track adjustment WARNING @ ● ● ● Be sure to have a Yamaha dealer make this adjustment. Support the snowmobile securely on a suitable stand before working underneath the snowmobile. Operate the engine in a well-ventilated area. @ 1. Lift the rear of the snowmobile onto a suitable stand to raise the drive track off the ground. 2. Loosen the rear axle nut 1. NOTE: @ It is not necessary to remove the cotter pin 2. @ 3.
E_8DG.book Page 26 Friday, June 29, 2001 4:20 PM CAUTION: @ Jc The right and left adjusters should be turned to an equal amount. @ 6. Recheck alignment and deflection. If necessary, repeat steps 3 to 5 until the proper adjustment is achieved. 7. Tighten the rear axle nut. Rear axle tightening torque: 75 Nm (7.5 m·kgf, 54.2 ft·lb) ESU00200 Ski alignment 1. Turn the handlebar so the skis face straight ahead. 2. Check the following for ski alignment: a. Skis are facing forward. b.
E_8DG.book Page 27 Friday, June 29, 2001 4:20 PM ESU00246 Handlebar adjustment For VT600 / VX600ER 1. Remove the handlebar cover 1. 2. Loosen the handlebar bolts. Move the handlebar up or down to adjust the handlebar height to the desired position. 3. Tighten the handlebar bolts and install the handlebar cover. Handlebar bolt tightening torque: 23 Nm (2.3 m·kgf, 17 ft·lb) CAUTION: @ Make sure that the small gap a side of the handlebar holders faces forward b. @ A B For MM600 / SX600 1.
E_8DG.book Page 28 Friday, June 29, 2001 4:20 PM 3. Move the handlebar up or down (± 7°) to adjust the handlebar height to the desired position. A È MM600 É SX600 B CAUTION: @ Make sure that the projection on the handlebar is not installed into the area a shown. @ 4. Tighten the handlebar bolts and install the handlebar cover. Handlebar bolt tightening torque: 23 Nm (2.3 m·kgf, 17 ft·lb) CAUTION: @ Make sure that the small gap b side of the handlebar holders faces forward c.
E_8DG.book Page 29 Friday, June 29, 2001 4:20 PM ESU00247 Lubrication Lubricate the following points. Lubricant: Low-temperature grease 1 Throttle cable ends 2 WARNING @ Apply a dab of grease onto the cable end only. Do not grease the brake or throttle cables themselves because they could become frozen, which could cause loss of control.
E_8DG.book Page 30 Friday, June 29, 2001 4:20 PM ESU00208 Headlight bulb replacement 1. Lift up the shroud. 2. Disconnect the headlight connector. 3. Remove the bulb holder cover. 4. Remove the bulb holder by depressing and turning it counterclockwise. 1 Bulb holder cover 5. Remove the bulb. WARNING @ Keep flammable products or your hands away from the hot bulb until it cools down. @ 6. Install the new bulb.
E_8DG.book Page 31 Friday, June 29, 2001 4:20 PM ESU00213 Battery For VT600 / VX600ER Replenishing the battery fluid 1. Check the fluid level. The level should be between the upper and lower level marks. a “UPPER LEVEL” b “LOWER LEVEL” 2. Add only distilled water if necessary. CAUTION: @ Normal tap water contains minerals which are harmful to a battery; therefore refill only with distilled water. @ WARNING @ Battery electrolyte is poisonous and dangerous.
E_8DG.book Page 32 Friday, June 29, 2001 4:20 PM ESU00282 Fuse replacement For VT600 / VX600ER WARNING @ Be sure to use the specified fuse. A wrong fuse will cause electrical system damage and A FIRE HAZARD. @ CAUTION: @ Make sure that the main switch is turned off to prevent accidental short circuiting. @ 1. Lift up the shroud. 2. Replace the blown fuse with one of proper amperage. NOTE: @ If the fuse immediately blows again, ask a Yamaha dealer to inspect the snowmobile.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00294 ● TROUBLESHOOTING 9- A. Engine turns over but does not start 1. Fuel system No fuel supplied to combustion chamber ● No fuel in tank ... Supply fuel. ● Clogged fuel line ... Clean fuel line. ● Clogged carburetor ... Clean carburetor. Fuel supplied to combustion chamber ● Flooded engine (too much choke) ... Crank engine with throttle open or wipe the spark plugs dry.
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM F. Engine overheats 1. Insufficient coolant ... Add coolant. 2. Air in cooling system ... Bleed air or ask a Yamaha dealer to inspect. 3. Leaking coolant ... Ask a Yamaha dealer to inspect. B. Engine does not turn over with the recoil starter 1. Seized engine ... Seizure is caused by poor lubrication, inadequate fuel, or an air leak—Ask a Yamaha dealer to inspect. 2. “Hydrolock” occurs when fuel has filled the crankcase when the vehicle has been transported.
E_8DG.book Page 3 Friday, June 29, 2001 4:20 PM J. Engine does not upshift or downshift properly or engages harshly 1. Worn or damaged V-belt ... Replace the V-belt or ask a Yamaha dealer to inspect. 2. Incorrect V-belt clutch settings for altitude or conditions ... Ask a Yamaha dealer to inspect. 3. Worn or sticking primary sheave assembly ... Ask a Yamaha dealer to inspect. 4. Worn or sticking secondary sheave assembly ... Ask a Yamaha dealer to inspect. K.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM chamber and crankshaft from corrosion. An alternate method is to remove the carburetor silencer and squirt oil into the carburetor throats while the engine is running. ESU00252 STORAGE 10- Long term storage requires some preventive procedures to guard against deterioration. 1. Cleaning Thoroughly clean the snowmobile, inside and out, to remove the corrosive salts and acids that can accumulate.
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM Returning to service after storage WARNING @ ● ● ● Never smoke around the battery while it is being charged. Sparks may ignite the hydrogen gas created by the battery. Never connect or disconnect the battery to the snowmobile while it is being charged. Sparks may ignite the hydrogen gas created by the battery. Make sure that the battery terminals are tight and that the battery vent tube is properly routed and is securely attached to the battery.
E_8DG.book Page 1 Friday, June 29, 2001 4:20 PM ESU00228 1- SPECIFICATIONS ESU00229 Dimensions CS-01E Overall length Overall width Overall height Dry weight Ski tread MM600 / SX600 / VT600 / VX600ER 2,990 mm (117.7 in): MM600 / VT600 2,760 mm (108.7 in): SX600 2,780 mm (109.4 in): VX600ER 1,115 mm ( 43.9 in): MM600 1,200 mm ( 47.2 in): SX600 / VT600 / VX600ER 1,215 mm ( 47.8 in): MM600 1,230 mm ( 48.4 in): SX600 / VX600ER 1,330 mm ( 52.
E_8DG.book Page 2 Friday, June 29, 2001 4:20 PM ESU00231 Chassis CS-03E MM600 / SX600 / VT600 / VX600ER Drive track and suspension: Track Width Track deflection Length on ground Suspension type Drive sprocket Transmission: Type Sheave distance Sheave offset Engagement speed∗ Shift speed∗ Drive chain Reduction ratio Fuel tank: Tank capacity Oil tank: Tank capacity Molded rubber, fiber glass rod reinforced 381 mm (15.0 in) 20–25 mm (0.79–0.98 in)/ 100 N (10 kg, 22 lb): MM600 25–30 mm (0.98–1.
E_8DG.book Page 3 Friday, June 29, 2001 4:20 PM MM600 / SX600 / VT600 / VX600ER Brake: Type Operation Throttle: Operation Hydraulic disc type (ventilated disc) Handle lever, left hand operated Handle lever, right hand operated ESU00232 Electric CS-04E Ignition system Spark plug Battery Headlight Tail/brake light Meter light Indicator light Type Gap Capacity Maximum charge rate Bulb × Quantity Bulb × Quantity Bulb × Quantity Bulb × Quantity MM600 / SX600 / VT600 / VX600ER DC-CDI BR9ES (NGK) 0.7–0.
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1- 12-1 Y Lg (BLACK) L/W Y Lg G B 1 L G (10A) c L/W L/W Y G G B B Lg L/W L/R R G R L b Br R W/G W/R a Y B A B B G L/ W Lg R/Y g f e (10A) B 2 W W W L W/G W/R W W W G Ê (20A) É W W W R B W W W W/R W/G W W W Br/W HI LO G Y B G B B Y G Lg Y L/W Br/W d a L R Br Y R B F R B R B B B 6 R È G 3 R R R L/W B L/W B 7 R R 5 4 (30A) R/W B B F L È R/W (BLACK) B R R B R B Y L/W W È F START ON OFF 8 Y/B B
12-2 M N O P 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L AC magneto Rectifier/regulator Condenser (MM600 / SX600) Main fuse (VT600 / VX600ER) Starter relay (VT600 / VX600ER) Battery (VT600 / VX600ER) Starter motor (VT600 / VX600ER) Main switch Engine stop switch Throttle switch Grip warmer Thumb warmer Carburetor switch Coolant temperature sensor CDI unit Variable resistor (thumb warmer) Variable resistor (grip warmer) Ignition coil Spark plug Engine ground Frame ground Passenger grip warmer switch (VT60
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SNOWMOBILE OWNER’S MANUAL MM600G SX600G VT600G VX600ERG PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 4 - 8.
