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Yamaha VT VX MM SXV 500 600 700 Snowmobile 1994-2006 Factory Service Repair Workshop Manual

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This manual covers Yamaha VT VX MM SXV snowmobiles, including model variants such as the VT500, VX500, MM500, SXV500, VT600, VX600, MM600, SXV600, VT700, VX700, MM700, and SXV700, produced between 1994 and 2006. These models represent Yamaha's commitment to performance and reliability in the snowmobile market, featuring robust 2-stroke, liquid-cooled engines and advanced suspension systems for their time. Yamaha's reputation for engineering excellence ensures these snowmobiles offer dependable power and handling for various snow conditions, making them a popular choice for both recreational riders and utility use. This comprehensive Factory Service Repair Workshop Manual provides detailed information for all repair and servicing procedures. It covers engine overhaul, fuel and ignition systems, drivetrain, suspension, steering, brakes, and the complete electrical system. Included are systematic troubleshooting guides, maintenance schedules, rebuild instructions, and technical specifications with precise torque values and clearances. Numerous illustrations, diagrams, and photographs accompany step-by-step instructions, making it an essential resource for owners, mechanics, and technicians to maintain the performance and longevity of their Yamaha snowmobile. 🏷️ Basic Information Identification Make: Yamaha Model: VT VX MM SXV Model Variants: VT500, VX500, MM500, SXV500, VT600, VX600, MM600, SXV600, VT700, VX700, MM700, SXV700 Model Years Covered: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Vehicle Type: Snowmobile 👋 Introduction Market Position Segment: Performance and utility snowmobiles Target Audience: Snowmobile owners, mechanics, service centers Competitive Analysis Competitors: Ski-Doo, Arctic Cat, Polaris (for the period) Key Features Manual Selling Points: Comprehensive coverage, factory-level accuracy, detailed illustrations, step-by-step instructions, essential for maintaining performance and longevity Vehicle Appeal: Yamaha's reputation for reliability and performance in the snowmobile market during this era 📋 Manual Details Coverage Areas Primary Coverage: All repair and servicing procedures for Yamaha VT VX MM SXV 500, 600, and 700 series snowmobiles Secondary Coverage: Troubleshooting, diagnostics, maintenance schedules, specifications Page Count Estimated Page Count: Over 800 pages (estimated based on comprehensive nature for multiple models/engines) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, overhaul, specifications, and troubleshooting for 500cc, 600cc, and 700cc engines (including carburetion, ignition, cooling, lubrication) Fuel System: Carburetor identification, adjustment, rebuilding, fuel pump, fuel lines, fuel tank inspection and maintenance Ignition System: CDI unit, ignition coils, spark plugs, wiring, troubleshooting ignition faults Drive Train: Clutch (primary and secondary), drive belt inspection and replacement, chaincase service, lubrication, gears, shafts Suspension: Front and rear suspension systems, shock absorbers, springs, linkages, bushings, lubrication, adjustment, and repair Steering: Handlebar assembly, steering post, tie rods, skis, ski carbides, alignment, and adjustment Brakes: Brake caliper, master cylinder, brake lines, brake fluid, brake pad replacement, bleeding procedure, and adjustment Electrical System: Wiring diagrams for all models, starter motor, lighting, battery, charging system, switches, sensors, diagnostic connectors, troubleshooting electrical faults Cooling System: Coolant types, radiator, hoses, thermostat, water pump inspection and service Body And Chassis: Body panel removal and installation, seat, track, tunnel inspection and maintenance, chassis alignment Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid), filter replacements, lubrication points, track tension adjustment Troubleshooting: Systematic diagnosis of common problems, diagnostic charts, fault codes (if applicable) Repair: Step-by-step repair procedures for all major components and systems, including complete engine rebuilds, transmission overhauls, and suspension repairs Rebuilds: Comprehensive instructions for rebuilding engines, carburetors, clutches, and other key components Installation: Instructions for installation of replacement parts and accessories Technical Depth Depth: Factory-level diagnostic and repair procedures, suitable for professional technicians and experienced DIY enthusiasts Detail Level: Highly detailed, with specific torque values, clearances, and adjustment procedures Visuals: Numerous illustrations, diagrams, and photographs to guide users through procedures Wiring Diagrams: Complete and detailed electrical wiring diagrams for all covered models 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval Print Quality Resolution: High-resolution (suitable for printing key pages) Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Types: 2-stroke, reed-valve, liquid-cooled gasoline engines Displacements: Approximately 497cc, 593cc, and 698cc (specific values may vary by exact model variant) Performance Horsepower Range: Estimated 80-120+ HP (depending on engine size and tune) Torque Characteristics: Designed for strong low-end and mid-range power delivery for snowmobile operation Fuel System Carburetion: Twin Mikuni VM or similar carburetors (specific models and sizes detailed in manual) Fuel Type: Unleaded gasoline (87 octane recommended, check specific requirements) Cooling System Cooling Type: Liquid-cooled Lubrication System Oil Injection: Automatic oil injection system (Yamalube specified) 🔧 Transmission Standard Type: CVT (Continuously Variable Transmission) with Yamaha's Constant-Torque (CT) Drive System Optional Gears: N/A (CVT is standard) Features Clutch System: Yamaha Drive clutch (primary) and torque sensing drive clutch (secondary) Drive Chain: Chaincase drive system with lubrication Fluid Specifications Chaincase Oil: Yamaha Chaincase Oil (specific viscosity detailed in manual) 📐 Dimensions...
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Yamaha VT VX MM SXV 500 600 700 Snowmobile 1994-2006 Factory Service Repair Workshop ManualYamaha VT VX MM SXV 500 600 700 Snowmobile 1994-2006 Factory Service Repair Workshop ManualYamaha VT VX MM SXV 500 600 700 Snowmobile 1994-2006 Factory Service Repair Workshop Manual
This manual covers Yamaha VT VX MM SXV snowmobiles, including model variants such as the VT500, VX500, MM500, SXV500, VT600, VX600, MM600, SXV600, VT700, VX700, MM700, and SXV700, produced between 1994 and 2006. These models represent Yamaha's commitment to performance and reliability in the snowmobile market, featuring robust 2-stroke, liquid-cooled engines and advanced suspension systems for their time. Yamaha's reputation for engineering excellence ensures these snowmobiles offer dependable power and handling for various snow conditions, making them a popular choice for both recreational riders and utility use. This comprehensive Factory Service Repair Workshop Manual provides detailed information for all repair and servicing procedures. It covers engine overhaul, fuel and ignition systems, drivetrain, suspension, steering, brakes, and the complete electrical system. Included are systematic troubleshooting guides, maintenance schedules, rebuild instructions, and technical specifications with precise torque values and clearances. Numerous illustrations, diagrams, and photographs accompany step-by-step instructions, making it an essential resource for owners, mechanics, and technicians to maintain the performance and longevity of their Yamaha snowmobile.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
VT VX MM SXV
Model Variants:
VT500, VX500, MM500, SXV500, VT600, VX600, MM600, SXV600, VT700, VX700, MM700, SXV700
Model Years Covered:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Vehicle Type:
Snowmobile
👋 Introduction
Market Position
Segment:
Performance and utility snowmobiles
Target Audience:
Snowmobile owners, mechanics, service centers
Competitive Analysis
Competitors:
Ski-Doo, Arctic Cat, Polaris (for the period)
Key Features
Manual Selling Points:
Comprehensive coverage, factory-level accuracy, detailed illustrations, step-by-step instructions, essential for maintaining performance and longevity
Vehicle Appeal:
Yamaha's reputation for reliability and performance in the snowmobile market during this era
📋 Manual Details
Coverage Areas
Primary Coverage:
All repair and servicing procedures for Yamaha VT VX MM SXV 500, 600, and 700 series snowmobiles
Secondary Coverage:
Troubleshooting, diagnostics, maintenance schedules, specifications
Page Count
Estimated Page Count:
Over 800 pages (estimated based on comprehensive nature for multiple models/engines)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, tuning, overhaul, specifications, and troubleshooting for 500cc, 600cc, and 700cc engines (including carburetion, ignition, cooling, lubrication)
Fuel System:
Carburetor identification, adjustment, rebuilding, fuel pump, fuel lines, fuel tank inspection and maintenance
Ignition System:
CDI unit, ignition coils, spark plugs, wiring, troubleshooting ignition faults
Drive Train:
Clutch (primary and secondary), drive belt inspection and replacement, chaincase service, lubrication, gears, shafts
Suspension:
Front and rear suspension systems, shock absorbers, springs, linkages, bushings, lubrication, adjustment, and repair
Steering:
Handlebar assembly, steering post, tie rods, skis, ski carbides, alignment, and adjustment
Brakes:
Brake caliper, master cylinder, brake lines, brake fluid, brake pad replacement, bleeding procedure, and adjustment
Electrical System:
Wiring diagrams for all models, starter motor, lighting, battery, charging system, switches, sensors, diagnostic connectors, troubleshooting electrical faults
Cooling System:
Coolant types, radiator, hoses, thermostat, water pump inspection and service
Body And Chassis:
Body panel removal and installation, seat, track, tunnel inspection and maintenance, chassis alignment
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid), filter replacements, lubrication points, track tension adjustment
Troubleshooting:
Systematic diagnosis of common problems, diagnostic charts, fault codes (if applicable)
Repair:
Step-by-step repair procedures for all major components and systems, including complete engine rebuilds, transmission overhauls, and suspension repairs
Rebuilds:
Comprehensive instructions for rebuilding engines, carburetors, clutches, and other key components
Installation:
Instructions for installation of replacement parts and accessories
Technical Depth
Depth:
Factory-level diagnostic and repair procedures, suitable for professional technicians and experienced DIY enthusiasts
Detail Level:
Highly detailed, with specific torque values, clearances, and adjustment procedures
Visuals:
Numerous illustrations, diagrams, and photographs to guide users through procedures
Wiring Diagrams:
Complete and detailed electrical wiring diagrams for all covered models
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval
Print Quality
Resolution:
High-resolution (suitable for printing key pages)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Types:
2-stroke, reed-valve, liquid-cooled gasoline engines
Displacements:
Approximately 497cc, 593cc, and 698cc (specific values may vary by exact model variant)
Performance
Horsepower Range:
Estimated 80-120+ HP (depending on engine size and tune)
Torque Characteristics:
Designed for strong low-end and mid-range power delivery for snowmobile operation
Fuel System
Carburetion:
Twin Mikuni VM or similar carburetors (specific models and sizes detailed in manual)
Fuel Type:
Unleaded gasoline (87 octane recommended, check specific requirements)
Cooling System
Cooling Type:
Liquid-cooled
Lubrication System
Oil Injection:
Automatic oil injection system (Yamalube specified)
🔧 Transmission
Standard
Type:
CVT (Continuously Variable Transmission) with Yamaha's Constant-Torque (CT) Drive System
Optional
Gears:
N/A (CVT is standard)
Features
Clutch System:
Yamaha Drive clutch (primary) and torque sensing drive clutch (secondary)
Drive Chain:
Chaincase drive system with lubrication
Fluid Specifications
Chaincase Oil:
Yamaha Chaincase Oil (specific viscosity detailed in manual)
📐 Dimensions
Exterior
Length Width Height:
Varies by model, specific dimensions provided in manual
Weights
Dry Weight:
Varies significantly by model and engine size, typically 450-550 lbs (check manual for specific model)
Track Dimensions:
Standard track sizes (e.g., 121-inch, 136-inch length) and width (e.g., 15-inch) covered
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Snowmobiles do not typically undergo standardized crash testing like cars)
Active Features
Braking System:
Hydraulic disc brake system
Throttle Safety:
Thumb throttle with safety lockout
Passive Features
Kill Switch:
Emergency engine kill switch (lanyard type typically)
Lighting:
Headlights, taillights, brake lights
💡 Technology Features
Infotainment
Features:
Basic instrumentation (speedometer, tachometer, fuel gauge, engine temp/warning lights)
Driver Assistance
Features:
N/A (No electronic driver assistance systems typical for this era of snowmobile)
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change:
Every 50-100 operating hours or annually (refer to manual for specific)
Spark Plugs:
Inspect every 50 hours, replace as needed (specific part numbers in manual)
Drive Belt:
Inspect every 25 hours, replace based on wear and condition (recommended replacement interval often around 200-300 hours or sooner)
Clutch Service:
Inspect secondary clutch roller and buttons every 100 hours, clean and service primary clutch annually
Fluid Specifications
Engine Oil:
Yamalube 2-stroke oil (specific grade and mixture ratio in manual)
Coolant:
Yamaha All-Season Coolant or equivalent (50/50 mix with distilled water)
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for exact specification)
Known Issues
Common Problems:
Carburetor gumming (especially if stored with fuel), drive belt wear, clutch wear, potential for overheating if cooling system is not maintained, CDI unit failure in some cases
Preventative Maintenance:
Proper storage procedures (fuel stabilizer, fogging oil), regular cleaning of cooling system intake, timely belt replacement, and keeping carburetors clean are crucial.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation, a long-standing leader in powersports and engines
Model Evolution
Platform:
These models represent Yamaha's offerings in the late 1990s and early 2000s, often featuring the 'ProAction' rear suspension and reliable 2-stroke engines.
Key Advancements:
Improvements in suspension design, engine efficiency, and chassis dynamics across these model years
Production
Manufacturing Period:
1994-2006
Key Markets:
North America, Scandinavia, Russia, and other snow-prone regions
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Yamaha snowmobiles from this era were generally well-regarded for their engine reliability and suspension performance, often receiving positive reviews in Powersports magazines.
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