Service manual

WARNING
CAUTION:
NOTE:
ESS00002
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 under-
standing of the mechanical concepts and pro-
cedures 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 for-
warded to all authorized Yamaha dealers and
will, where applicable, appear in future editions
of this manual.
ESS00003
VK540E
SERVICE MANUAL
 2000 by Yamaha Motor
Corporation, U.S.A.
1st Edition, May 2000
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.
LIT-12618-02-13
ESS00004
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!
BE ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the snowmo-
bile operator, a bystander, or a person inspect-
ing or repairing the snowmobile.
A CAUTION indicates special precautions that
must be taken to avoid damage to the snowmo-
bile.
A NOTE provides key information that can
make procedures easier or clearer.
MANUAL FORMAT
All of the procedures in this manual are orga-
nized 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 prob-
lem will follow the symbol, e.g.,
 Bearings
Pitting/damage  Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams be-
fore each disassembly section to facilitate cor-
rect disassembly and assembly procedures.