YAMAHA | xowsosn: OWNER’S MANUAL VX500XTB/VX600XTB VX500XTCB/VX600XTCB VX500XTRB/VX600XTRB VX500XTCDB/VX600XTCDBESS03100 MACHINE IDENTIFICATION Identification numbers record A. FRAME NUMBER: oo B. ENGINE NUMBER (PRIMARY 1.D.): oo C. KEY NUMBER: [ Record your frame number, engine number (Primary 1.D.) and key number in the spaces provided, to assist you in ordering spare parts from your Yamaha dealer. @The frame number is the nine-digit number stamped on the frame of the machine. (See Fig. {Al) @®The model code number is the first three digits of the frame number. @The engine number is stamped in the location as shown. (See Fig. [B]) @ Key number (See Fig. [C)) Also, record and keep these 1.D. num- bers in a separate place in case your machine is stolen.VX500XTB/VX600XTB VX500XTCB/VX600XTCB VX500XTRB/VX600XTRB VX500XTCDB/VX600XTCDB OWNER’S MANUAL ©1997 by Yamaha Motor Corporation, U.S.A. 1st Edition, March 1997 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan P/N LIT-12628-01-90 8800000 INTRODUCTION Congratulations! Your choice of a Yamaha snowmobile assures you of the highest quality and dependability. Your Yamaha snowmobile is manufac- tured by a company well-known for ex- cellence in the field of snowmobiles. The most advanced production equip- ment and technology have made Yamaha one of the best machine manu- facturers, We are confident that this snowmobile will meet the greatest ex- pectations of our customers. This manual is designed to acquaint you with the operation of this snowmobile and minor maintenance required for satis- factory service. Should major repairs ever be required, you are advised to consult a nearby Yamaha dealer who has the tech- niques, tools and parts to ensure your satisfaction. We hope that the informa- tion within this booklet will help you enjoy many hours of pleasure with your Yamaha snowmobile.1s (| —1assostenstasinasstasssinsadsontssntesstassaisnaii Yamaha continually seeks advance- menis in product design and quality. Therefore, while this manual con- tains the most current product infor- mation available at the time of print- ing, there may be minor discrepan- cies between your machine and this manual. If there is any question con- cerning this manual, please consult your Yamaha dealer. This manual should be considered a permanent part of this machine and should remain with this machine when resold. WAG IN Ce PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BE- FORE OPERATING THE MACHINE. Particularly important information is dis- tinguished in this manual by the follow- ing notations. AN The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! 4 WARNING Failure to follow WARNING instructions. could result in severe injury or death to the machine operator, a bystander, ora person inspecting or repairing the ma- chine. _ CAUTION: | A CAUTION indicates special precau- tions that must be taken to avoid dam- age to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer.Ss01300 CONTENTS SNOWMOBILE LIMITED WARRANTY YAMAHA EXTENDED SERVICE (VES) LOCATION OF THE IMPORTANT LABELS 21 SAFETY INFORMATION ..............3-1 DESCRIPTION....... CONTROL FUNCTIONS MAIN SWITCH .... STARTER LEVER (CHOKE) THROTTLE LEVER ....... THROTTLE OVERRIDE SYSTEM (T.O.R.S.) ....-+ OIL LEVEL WARNING LIGHT . WATER TEMPERATURE WARNING LIGHT ENGINE STOP SWITCH BRAKE LEVER PARKING BRAKE LEVER V-BELT GUARD. V-BELT HOLDER SHROUD LATCH HEADLIGHT BEAM SWITCH GRIP WARMER CONTROL 5-9 SPARK PLUG HOLDER 5-9 DRIVE SELECT LEVER (SHIFT LEVER) (VX500XTR/XTCD, VX600XTR/XTCD) LUGGAGE BOX... PRE-OPERATION CHECKS FUEL ENGINE Ol COOLANT. THROTTLE LEVER MANUAL STARTER THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHEC! BRAKE .. BRAKE FLUID LEAKAGE V-BELT... DRIVE V-BELT GUARD. DRIVE TRACK .. SLIDE RUNNERS SKI/SKI COVER/SKI RUNNER ...6-8 STEERING SYSTEM AIR FILTER LIGHTS ...... FITTINGS/FASTENERS BATTERY (Electric starting model) ... SERVICE TOOLS AND SPARE OPERATION .... STARTING THE ENGINE .. EMERGENCY ENGINE STARTING BREAK-INRIDING YOUR SNOWMOBILE... GETTING TO KNOW YOUR SNOWMOBILE ...... oe LEARNING TO RIDE YOUR SNOWMOBILE TO START OUT AND ACCELERATE BRAKING . TURNING RIDING UPHILL . RIDING DOWNHIL CROSSING A SLOPE (SIDE HILL) ICE OR ICY SURFACE. HARD-PACKED SNOW OPERATION ON SURFACES OTHER THAN SNOW OR ICE... 7-12 DRIVING STOPPING THE ENGINE TRANSPORTING » a PERIODIC MAINTENANCE .........8-1 MAINTENANCE CHART TOOL KIT... SPARK PLUG INSPECTION ENGINE IDLE SPEED ADJUSTMENT ....... THROTTLE CABLE ADJUSTMENT OIL PUMP CABLE ADJUSTMENT CARBURETOR ADJUSTMENT . HIGH ALTITUDE ADJUSTMENTS... 8-14 COOLING SYSTEM ........2.:0 8-16 DRIVE V-BELT REPLACEMENT DRIVE CHAIN HOUSING 8-21 8-23 CHECKING THE BRAKE FLUID LEVEE w+ 8-23. BRAKE FLUID REPLACEMENT .. PARKING BRAKE SUSPENSION SKI SPRING PRELOAD. REAR SUSPENSION SPRING PRELOAD ..... FULL RATE ADJUSTER TRACK ADJUSTMENT SKI ALIGNMENT ..... HANDLEBAR ADJUSTMENT ... LUBRICATION HEADLIGHT .. ESS65800..... BATTERY (Electric starting model) FUSE REPLACEMENT (Electric starting model) ............ TROUBLESHOOTING .... STORAGE .... RETURN TO SERVICE AFTER STORAGE....... +. 10-2 SPECIFICATIONS DIMENSIONS .. ENGINE CHASSIS ELECTRIC WIRING DIAGRAMESs79000 YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTY Yamata Motor Corporation, U.S.A. hereby warrants that new Yamaha snowmobiles purchased from an autho- rized Yamaha snowmobile dealer in the continental United States will be free from defects in material and ‘workmanship for the period of time stated herein, subject to certain stated limitations. WARRANTY PERIOD: 1. All Yamaha snowmobiles shall be warranted for a. term of one (1) year from the date of purchase, plus a special early-season extension (if applicable). 2. AllYamaha snowmobile clutch components are war- ranted against abnormal wear for one (1) year from the date of purchase, plus a special early-season exiension (if applicable) DURING THE PERIOD OF WARRANTY any au- thorized Yamaha snowmobile dealer will, ree of charge, repairor replace, at Yamaha's option, any part adjudged detectve by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the snowmobile’s warranty period. All parts replaced under warranty be- come :he property of Yamaha Motor Corporation, U.S.A, GENERAL EXCLUSIONS from this warranty shall include any failures to the machine caused by: 1. Competition, racing, or non-Yamaha authorized rental use. Operation on surfaces other than snow or ice. installation of parts or accessories that are not quall- tatively equivalent to genuine Yamaha parts. Abnormal strain, neglect, or abuse. Lack of proper maintenance. Accident or collision damage. Modification to original parts. en Noose ‘SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance including oil, spark plugs, clutch drive belts, and side runners. THE CUSTOMER'S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the snowmobile as specifiedin the appropriate Owner's Manual. 2. Give notice to an authorized 1 Yamaha snowmobile dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer's place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory. WARRANTY TRANSFER: To transfer any remain- ing warranty from the original purchaser to any subse- quent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized ‘Yamaha snowmobile dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days atter ownership transter. An inspection and registration fee will be charged for this service. YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IM- PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR- POSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WAR- RANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY. SOME STATES DONOT ALLOWLIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDEN- TAL OR CONSEQUENTIAL DAMAGES IN- CLUDING LOSS OF USE, SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITA- TION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LE- GAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.SPECIAL EARLY-SEASON WARRANTY EX- TENSION A special warranty extension is available for all new Yamaha snowmobiles purchased between June 1 and December 1 All new Yamaha snowmobiles purchased between June 1 and December 1 will have the warranty extended to November 30 of the following year. YAMAHA MOTOR CORPORATION, U.S.A. Post Office Box 6555 Cypress, California 90630 WARRANTY QUESTIONS AND ANSWERS Q. What costs are my responsibility during the warranty period? The customer's responsibilty includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, as well as oil, spark plugs, clutch drive belts, and slide runners. A What are some examples of “abnormaf” strain, ne~ glect, or abuse? These terms are general and overlap each other in areas. Specific examples include: Running the ma- chine out of cil, hitting an object submerged under snow, operation on surfaces other than snow or ice, ‘operating the machine with a broken or damaged part which causes another part to fail, and so on. If you have any specific questions on operation or maintenence, please contact your dealer for advice. May { perform any or all of the recommended main- tenance shown in the Owner's Manual instead of having the dealer do them? Yes, ifyou are a qualified snowmobile mechanic and follow the procedures specified in the Owner's and Service Manual. We do recommend, however, that items requiring special tools or equipmentbe done by a Yamaha snowmobile dealer. Under what conditions is the clutch not covered by warranty? Clutches as well as clutch components wear with use. Normal wearisnot covered under warranty such service is the customer's responsibility. Abnormal wear is, however, covered for one (1) year from the date of purchase. Your Yamaha snowmobile dealer possesses criteria as to what constitutes abnormal wear. Will the warranty be void or cancelled if | do not operate or maintain my new Yamaha exactly as specified in the Owner's Manual? No. The warranty on a new Yamaha cannot be “voided" or “cancelled.” Howover, if a particular fail- Ure is caused by operation ar maintenance otherthan ‘as shownin the Owner's Manual, that failure may not be covered under warranty. What responsibility does my dealer have under this warranty? Each Yamaha snowmobile dealor is expected to: 1. Completely set up every new machine before sale. Explain the operation, maintenance, and warranty requirements to your satistaction at the time of sale, ‘and upon your request at any later date. 3. Inaddition, each Yamaha snowmobile dealer is held responsible forhis setup, service and warranty repair work. Whom should | contact if | have further questions about this warranty? Your Yamaha snowmobile dealer has the informa- tion and experience necessary toanswer almost any questions about this warranty. Ifthe dealeris not able to do s0, he is expected to contact Yamaha Motor Corporation, U.S.A., for clarification or assistance. CUSTOMER SERVICE yourmachine requires warranty service, you musttake it to any authorized Yamaha snowmobile dealer within the continental United States. Be sure to bring your warranty identification card or other valid proof of the original date of purchase. Ita question or problem arises regarding warranty, first contact the owner of the dealer- ship. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satistied and require additional assistance, please write: YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPART- MENT P.O. Box 6555 Cypress, California 90630When contacting Yamaha Motor Cor- poration, U.S.A. be sure to include the model, serial number, names, dates, and receipts. CHANGE OF ADDRESS The federal government requires each manufacturer ofa motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility ofa safety-related detect and recall, This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase. It you should move after you have purchased your new snowmobile, please advise us of your new address by sending. postcard isting your snowmobile model name, engine serial number, dealer number (or dealer’s name) asitis shown on your warranty registration identification, your name and new mailing address. Mail to: YAMAHA MOTOR CORPORATION, U.S.A. WARRANTY DEPARTMENT P.O. Box 6555 Cypress, California 90630 This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law. 43ESS79500 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Ex- tended Service (Y.E.S.). * YES. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get un- interrupted factory-backed coverage for extra peace of mind. Y.E.S. is flexible. You choose the plan that's right for you: 12 months, 24 months, or 36 months beyond your warranty period. Y.E.S. is designed and administered by the same Yamaha people who handle your warranty —anditshowsin the comprehen- sive coverage benefits. There are no mile- age limitations. Coverage isn't limited to “moving parts" or the “drive train” like many other plans. And Y.E.S. covers manu- facturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted fac- tory-backed protection can be. You don't have to pay anything for covered repairs. There’s no deductible to pay, and repairs aren’t “pro-rated.” Youdon’thave any “out- of pocket” expenses for covered repairs. Inaddition, Travel and Recreation Interrup- tion Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reim- bursement per occurrence for any reason- able expenses you incur because your Yamaha needs covered service: replace- ment vehicle rental, emergency towing , phone calls, even food and lodging when you are away from home, This superb cov- erage goes into effect when you purchase Y.E.S,, o it applies to any warranty repairs as well as covered repairs during your en- tire Y.E.S. plan period. Y.E.S. coverage is honored at any author- ized Yamaha dealer nationwide. Y.E.S. coverage is transferrable to a new ‘owner if you sell or trade-in, That can make your Yamaha much more valuable! This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your author- ized Yamaha dealer to get all the facts. He can show you how easy itis to protect your invest- ment with Yamaha Extended Service. We urge you to act now. You'll get the excel- lent benefits of TRIP coverage right away, and you'll rest easy knowing you'll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha, See your dealer today! A special note: If visiting your dealer isn't convenient, contact Yamaha with your Primary ID number (your engine number). We'll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.Box 6555, Cypress, CA 90630 (714) 761-7631 7 YAMAHA EXTENDED SERVICE 148801500 LOCATION OF THE IMPORTANT LABELS Please read the following labels care- fully before operating this machine. NOTE Soe Maintain or replace safety and instruc- tion labels, as necessary. AVERTISSEMENT > “rw Doren TO ee oF ESCO SNE Ou wine @ VX500XTC/XTCD VX600XTC/XTCD A WARNING ‘This unit contains high pressure nitrogen gas. Mishandling can cause exalosion. Read owner's manual for instructions. # Do not incinerate, puncture or open. ‘Cette unité content de azote & haute ‘Une mauvaise manipulation peut entralner explosion. fit la manuel d'utilsateur pour {es instructions. (e pas broler ni pertorerni ouvri. DONOT, as ‘WITHOUT V-BELTORDRIVEGUARD. | A A AVERTISSEMENT | TNE PAS FAIRE FONCTIONNER LE | MOTEUR SANS COURAOIE EN V | QU PROTECTEUR D’ EMBRAYAGE._851-006 34 ess30202 SAFETY INFORMATION 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 ma- chine. Become familiar with all of the operating controls and their func- tion. Consulta Yamaha dealer about any control or function you do not understand. 2. This machine was not manufactured for use on public streets, roads, or highways. Such use is prohibited by law, and you could collide with an- other vehicle. 3. This machine is designed to carry the OPERATOR ONLY. Passengers are prohibited. Carrying a passenger can cause loss of con- trol. 4.Do not operate the machine after drinking alcohol or taking drugs. Your ability to operate the machine is reduced by the influence of alco- hol or drugs.32 5. For safety and proper care of the machine, always perform the Pre- Operation Checks on page 6-1 ~ 6-11 before starting the engine. Check the throttle, steering and brake operation every time before starting the engine. Be sure the throttle lever moves freely and it re- turns to the idle position when it is released. @ . Apply the parking brake before start- ing the engine. Never drive the ma- chine with the parking brake applied. This may overheat the brake disc and reduce braking ability. ~N . Do not allow anyone to stand behind the machine when starting, inspect- ing or adjusting the machine. A bro- ken track, track fittings or debris thrown by the track could be danger- ous to the operator or bystanders. 8. Handle fuel with care; it is highly flammable. Neveradd fuel when the engine is running or hot. Allow the engine to cool for sev- eral minutes after running. e Use an approved fuel container. Fill the fuel tank outdoors with extreme care. Never remove the fuel cap indoors. Never fill the fuel tank indoors. Never refuel while smoking or in the vicinity of an open flame.Make sure the fuel tank cap is closed securely after refueling. Wipe up any spilled fuel immedi- ately. 9. Ifyou swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline into your eye(s), see your doctor immediately. If any gasoline spills on your skin or clothing, imme- diately wash your skin with soap and water, and change your clothes. 10.Wear protective clothing. Wear an approved helmet, and a face shield or goggles. Also, weara good quality snowmobile suit, boots, and a pair of snowmobile gloves or mittens that will permit use of your thumbs and fingers for operation of the controls. Operation 1.Do not run the engine indoors, ex- cept when starting the engine to transport the machine in or out of the building. Open the outside doors; exhaust fumes are dangerous. 3334 2.Be careful where you ride. There may be obstacles hidden beneath the snow. Stay on established trails to minimize your exposure to haz- ards. Ride slowly and cautiously when you ride off of established trails. Hitting a rock or stump, or run- ning into wires could cause an acci- dent and injury. 3. This machine 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 ma- chine. 4. Avoid operating on glare ice, or on snow which has a lot of dirt or sand mixed in. Operation under such con- ditions will damage or result in rapid wear of ski runners, drive track, slide runners and drive sprockets. a Always have other snowmobilers with you when going on a ride. You may need help if you run out of fuel, have an accident, or damage your snowmobile. 6. Many surfaces such as ice and hard- packed snow require much longer stopping distances. Be alert, plan ahead and begin decelerating early. The best braking method on most surfaces is to release the throttle and apply the brake gently — not sud- denly.35 Maintenance and Storage 1. Do not leave the machine on its left side for an extended period of time. Fuel may leak out from the fuel breather hose. Ny . Modifications made to the machine not approved by Yamaha, or the re- moval of original equipment may ren- der your machine unsafe for use and may cause severe personal injury. Modifications may also make your machine illegal to use. 3. Never store the machine with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters, open flame, spark, clothes dryers, and the like. Allow the engine to cool before storing in any enclosure. = Always refer to “STORAGE” for im- portant details if the machine is to be stored for an extended period. 5, Maintain or replace safety and in- struction labels, as necessary.ESGos100 DESCRIPTION @ Windshield @ Steering handlebar @ Seat @ Steering ski © Drive track © Slide rail suspension @ FrameHeadlight @ Shroud @ Luggage box @ Taillight @® Flap @ Headlight beam switch @ Brake lever @ Parking brake lever Engine stop switch @ Throttle lever ® Drive select lever (VXSOOXTR/XTCD, VX600XTR/XTCD) @ Starter handle @ Shroud latch @ Grip warmer control knob @ Starter lever @ Main switch @ “HIGH BEAM” indicator light @ Odometer @ Speedometer @ Fuel gauge @ Tachometer @ “OIL LEVEL” warning indicator light @ “WATER TEMP” warning indicator light 6 Trip odometer @ Trip odometer reset knob ®®D ®@ == r7) = DE Oo51 SG05000 CONTROL FUNCTIONS 9808802 MAIN SWITCH The main switch controls the following items. @OFF: The ignition circuit is switched off. The key can be removed only in this position. @ON: The ignition circuit is switched on. The engine can be started. @® WARMER: The grip and thumb warmer circuit is switched on. Also, the ignition circuit is switched on and the engine can be started. NOTE: —___________ The handlebar grips and throttle lever will heat electrically after the engine starts. @STAAT: (Electric starting model) The starting circuit is switched on. The starter motor starts. NOTE: —__________ The lights will come on after the engine starts. CAUTION: Release the switch immediately after the engine starts. | Manual starting model [B] Electric starting model816-001 ess22200 STARTER LEVER (CHOKE) Use this lever when starting and warm- ing up a cold engine. @ Starter lever (choke) @ When starting a cold engine. © Warming up @ When the engine is warm. NOTE: ———___ Refer to “Starting the engine” for proper operation. ss21600 THROTTLE LEVER Once the engine is running cleanly, squeezing © the throttle lever @ will increase the engine speed and cause engagement of the drive system. Regu- late the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will re- turn to an idle when the thumb is re- leased ©. A WARNING Check the throttle, brake, and steer- ing for proper operation before start- ing engine. 52816-010 816-011 53 Ess09400 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should malfunction during operation, T.O.R.S. will operate when the throttle lever is released. The T.O.R.S. is designed to interrupt the ignition and keep the engine revolu- tion between 2800 and 3000 r/min if the carburetor fails to return to idle when the lever is released. © IfT.0.R.S. begins to operate, make sure that the cause of the malfunc- tion has been corrected and that the engine can be operated with- out a problem before restarting the engine. Be sure to use the standard resis- tance-type spark plug and spark plug cap. Otherwise T.O.R.S. will not work properly. MODE IA) jgie {Bi iC or Run Trouble switch | Starting Throttle witch OFF ON OFF [Carburetor babe ON OFF OFF T.O.R.S. will Engine BUN | RUN | oorate (Al Idie or Starting [B) Run [c] Troublear6-012 B4 @ Carburetor switch @ Throttle switch © Throttle cable @ Throttle valve @°On” Orr” 8821900 OIL LEVEL WARNING LIGHT If the oil level falls below the lower level, this light comes on. If the light comes on, add engine oil to the oil tank at the first opportunity. ess2260 WATER TEMPERATURE WARNING LIGHT For VX500XT/XTC/XTR/XTCD: If the water temperature becomes too hotfornormal operation, this light comes on. If the light comes on, stop the engine and allow it to cool off. Then, check the coolant level in the reservoir tank. (See page 6-3) For VX600XT/XTC/XTR/XTCD: These machines are equipped with self- diagnosis device which is able to detect a malfunctioning sensor, disconnected coupler, broken lead, abnormally high water temperature, etc.55 The water temperature warning light warns the rider of the above problems by flashing or staying on. (Ask your Yamaha dealer for further details, ifnec- essary.) After the engine starts, this light flashes 3 times to check the bulb, then goes off if there are no problems. If it does not flash, ask your Yamaha dealer to inspect the electrical circuit. _ CAUTION: If the water temperature warning light flashes continually or stays on dur- ing operation, there may be some problem with the electronic circuit, lead couplers or engine cooling sys- tem. Stop the engine and allow it to cool off. Then check that the wireharness couplers are connected properly in the engine compartment and that the coolant level of the reservoir tank is within the specified range. (See page 6-3) After restarting the engine, ifthe water temperature warning light still flashes continually or stays on, ask an au- thorized Yamaha dealer to inspect the electronic circuit at the first op- portunity.ss20800 ENGINE STOP SWITCH The engine stop switch @ is used to stall the engine in an emergency. Simply push @ the engine stop switch, and the engine will stop. To start the engine, pull @ the engine stop switch and see page 7-1 ~ 7-2 for more details. During the first few rides, you should practice using the switch while driving so that you can react quickly in an emergency. Ess28100 BRAKE LEVER The machine is stopped by braking the entire drive system. Squeeze the brake lever towards the handlebar to stop the machine. @ Brake lever @ Brake lever end @ Handlebar end NOTE, When the brake is operated, the brake light will illuminate. SCAUTION: Be sure the brake lever end does not project out over the handlebar end. This will help prevent brake lever damage when the machine is placed on its side for service.57 ESS27100 PARKING BRAKE LEVER When parking the machine or starting the engine, apply the parking brake by moving the parking brake lever @ to the left. To release the parking brake, move the parking brake lever © to the right. >) To apply the parking brake To release the praking brake 4 WARNING ¢ Always set the parking brake before attempting to start the en- gine. ¢ Never run the machine with the parking brake applied. This may overheat the brake disc and reduce braking ability. @ Ess28700 V-BELT GUARD The V-belt guard is designed to cover the clutch and V-belt in case parts break or come loose. Ge © Be sure the V-belt guard is tight- ened securely before operating the machine. © Never run the engine without the V-belt or with the V-belt guard re- moved.58 8808100 V-BELT HOLDER Keep a spare V-belt for emergency use by putting it into the holder provided. CAUTION: | Be sure the V-belt is installed se- curely in the holder. Ess29100 SHROUD LATCH To open the shroud, unhook the latch, then slowly raise the shroud forward until it stops. When closing the shroud, slowly lower it to its home position, then hook the shroud latches. @Latch @ Shroud CAUTION: | Be sure all cables and wires are in place when closing the shroud. 4 WARNING © Do not drive the machine with the shroud open or unlatched or with the shroud removed. © Keep your body and clothing away from rotating parts when servic- ing with the shroud open. Do not touch the hot muffler and engine during or immediately af- ter operation.831-012 59 8828300 HEADLIGHT BEAM SWITCH Push the switch to change the head light beam alternately to high or low. @ Headlight beam switch @Push @ High beam @Low beam ESS09000 GRIP WARMER CONTROL KNOB This knob controls the electrically heated handlebar grips and throttle lever when the main switch is in the “WARMER” position. @ Grip warmer control knob Knob Position Warmer Temperature @ Tum clockwise Higher @ Turn counterclockwise | Lower 8829000 TRIP ODOMETER RESET KNOB Use the knob to reset the trip odometer. @ Reset knob @ Push essz640t SPARK PLUG HOLDER Keep spare spark plugs for emergency use by placing them into the holder provided.8828701 DRIVE SELECT LEVER (SHIFT LEVER) (VX500XTR/XTCD, VX600XTR/XTCD) The drive select lever is used to shift your machine into forward or reverse. After coming to a coamplete stop, move the lever to the desired direction. @ Drive select lever (shift lever) @ Push down @ Move to forward @ Move to reverse Taner Machine movement FWD Forward REV Reverse | CAUTION: - Do not shift from “Forward” to “Re- verse” or “Reverse” to “Forward” while the machine is moving. Other- wise the drive system could be dam- aged. £$824200 LUGGAGE BOX Open the box to store the service tools, spare parts, or other small items. 5-10801-015 8830000 PRE-OPERATION CHECKS NOTE: —___ Pre-operation checks should be made each time the machine is used. The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muf- fler while they are still hot with any part of your body or clothing during inspection or repair. 8830303 FUEL Make sure that there is sufficient fuel in the tank. [A] VXS00XT/XTR, VX600XT/XTR B] VX500XTC/XTCD, VX600XTC/XTCD Recommended fuel: Unleaded gasoline Pump Octane R+M ; 88 2 Fuel tank capacity: Total: 45.0 L (9.9 Imp gal, 11.9 US gal) 4 WARNING ¢ Fuel is highly flammable and poi- sonous. Check “SAFETY INFOR- MATION” (See page 3-2) carefully before refueling. 64* Do not fill the fuel tank above the bottom of the filler tube ©. The fuel could overflow if the machine is tilted or if the ambiant tempera- ture rises, causing the fuel to warm up and expand. © Make sure that the fuel tank cap is closed securely after refueling. Leaking fuel can catch fire. @ Fuel level _ CAUTION: © Oxygenated fuels (“gasohol”) containing max. 5% of ethanol can be used, although richer jetting may be required to prevent engine damage. Consult a Yamaha dealer. Gasohol containing methanol is not recommended. © Be sure that snow and/or ice does not enter into the fuel tank when refueling. © Do not use alcohol deicers or wa- ter absorbing additives with oxy- genated fuel. © The tank should be filled with straight gasoline as specified. ES$33100 ENGINE OIL Make sure there is sufficient oil in the oil tank. Oil tank capacity: 2.4L (2.1 Imp at, 2.5 US qt) Recommended oil: YAMALUBE 2-cycle oil63 ESS35800 COOLANT (See page 8-16 for more details) Make sure that the coolant level is be- tween “FULL” © and “LOW” ® when the — engine is cold. If the coolant level is at or below “LOW”, add soft water until “FULL”. Reservoir tank capacity: “LOW?” to “FULL” 0.13 L (0.11 Imp qt, 0.14 US qt) 4 WARNING Do not remove the radiator cap when the engine is hot. | CAUTION: - ¢ Hard water or salt water is harmful to the engine parts. You may use boiled water or dis- tilled water, if you can’t get soft water. ¢ Tap water can be used temporarily in an emergency. 8831500 THROTTLE LEVER Check the throttle lever operation be- fore starting the engine. It must open smoothly and spring back to idle when released.64 8831200 MANUAL STARTER Check for proper operation. Check the rope for damage. essoes01 THROTTLE OVERRIDE SYSTEM (T.0.R.S.) CHECK 4 WARNING When checking T.O.R.S.: © Be sure the parking brake Is ap- plied. ¢ Be sure the throttle lever moves smoothly. © Donotrun the engine up to clutch engagement rpm. Otherwise, the machine could start moving for- ward unexpectedly, which could cause an accident. . Start the engine. NOTE; —_______ Refer to STARTING THE ENGINE. 2.Hold the pivot point of the throttle lever away from the throttle switch 0. 3. Press @ the throttle lever gradually. The T.O.R.S. will operate and the engine should run between 2800 and 3000 r/min.65 If the engine does not run between 2800 and 3000 r/min, stop the engine by turning the main switch to the “OFF” position and consulta Yamaha dealer. 5837000 BRAKE (See page 8-23 for more details) . Brake lever Test the brake at slow speed when starting out to make sure itis working properly. If the brake does not pro- vide proper braking performance, in- spect the brake for wear or brake fluid leakage. A WARNING A soft, spongy feeling in the brake lever indicates a failure in the brake system. Do not operate the machine if you find any problems in the brake sys- tem. Consult a Yamaha dealer for immediate repairs. You could lose braking ability, which could lead to an accident. _ CAUTION: Make sure that the brake lever end does not project out over the handle- bar end. This is to prevent brake lever damage when the machine is placed on its side.66 2. Brake fluid Check the brake fluid level. Add fluid if necessary. @ Lower level Recommended brake fluid: DOT4 (See page 8-23) ESS37100 BRAKE FLUID LEAKAGE Apply the brake fora few minutes. Check to see if any brake fluid leaks out from the pipe joints or the master cylinder. If brake fluid leakage is found, con- sult a Yamaha dealer for immediate repairs. CAUTION: © Brake fluid may deteriorate painted surfaces or plastic parts. Never spill any fluid. If any is spilled, clean it up immediately.e7 Ess31800 V-BELT Open the shroud and remove the V-belt guard. Check V-belt wear and damage. Re- place if necessary. A WARNING ¢ Be sure the V-belt guard is tight- ened securely before operating the machine. Never run the engine without the V-belt or with the V-belt guard re- moved. Essaz700 DRIVE V-BELT GUARD Check the drive belt guard mounts for damage. Make sure that the drive belt guard is firmly in place. Ess34000 DRIVE TRACK (See page 8-31 ~ 8-34 for more de- tails) Check the drive track for deflection, wear and damage. Adjust/replace if necessary. 4 WARNING Do not operate the machine if you find damage to the drive track, or misadjustment. Drive track damage and/or failure could result in loss of braking ability and machine control, which could cause an accident.68 ss32200 SLIDE RUNNERS Check wear and damage. If the slide runners reach the wear limit, they should be replaced. @ Slide runners @ Wear limit Wear limit height: 10 mm (0.4 in) CAUTION, Ride on fresh snow frequently. Operating on ice or hard packed snow will rapidly wear the slide runner. S835401 SKV/SKI COVER/SKI RUNNER Check wear and damage. Replace if necessary. Ski runner wear limit @: 8 mm (0.31 in) 5834800 STEERING SYSTEM 1.Check the following for excessive free play: 1) Push the handlebar up and down and back and forth. 2) Turn the handlebar slightly to the right and left. 2. If excessive free play is noticed, consult a Yamaha dealer.69 ESs36702 AIR FILTER Always check that no snow is on the air filter elements. If there is any snow, take out the elements and remove the snow from them. After use, make sure that there is no snow on the elements. NOE The air filter elements can be removed when the ambient temperature is 5 °C (41.5 °F) or higher. Before removing the air filter elements, consult a Yamaha dealer.8836500 LIGHTS Check the lights. Replace any burned out bulbs. CAUTION: Avoid using the scraper or hot water for cleaning to protect the plastics lens ©. ESLs4800 FITTINGS/FASTENERS Check the tightness of the fittings/fas- teners. Tighten in proper sequence and torque if necessary. 8836000 BATTERY (Electric starting model) (See page 8-38 ~ 8-39 for more de- UPPER. LEVEL ——- tails) nia rower teva td Check the fluid level and fill if neces- sary. Use only distilled water if refilling is necessary.ett 8836600 SERVICE TOOLS ANDSPARE PARTS, Itis a good practice to carry service tools and spare parts with your machine so that minor repairs can be done by your- self. The following should be carried in the luggage box. Tool kit Flashlight Roll of plastic tape Steel wire Tow rope Emergency starter rope In addition to these, it is advisable to have the following spare parts: © Drive belt © Light bulbs e Spark plugs When you start out for a long distance trip, extra fuel and oil should be carried.TA ee” OPERATION essao201 STARTING THE ENGINE AG © Besuretocheck “SAFETY INFOR- MATION” carefully before starting the engine. ¢ Be sure the parking brake is ap- plied. NOTE: — Be sure the engine stop switch is in the “ON” position. 1. Fully open the starter lever. (choke) @ Starter lever (choke) @ Fully open (cold engine starting) @ Half-open (warm engine up) @ Close (warm engine starting) NOTE: —______ The starter lever (choke) is not required when the engineis warm. Putthe starter lever in the “Close” position. Manual Starting Model (VX500XT/ XTC, VX600XT/XTC) 2. Turn the main switch to the “ON” or “WARMER’ position. ON’ @ “WARMER”72 3. Pull slowly on the recoil starter until it is engaged, then pull it briskly. After the engine starts, put the starter lever (choke) in the “Half-open” position. Warm up the engine until it does not sun roughly or begin to stall when the starter lever is returned to the “Close” position. Electric Starting Model (VX500XTR/ XTCD, VX600XTR/XTCD) 2. Turn the main switch to the “START” position. Afterthe engine starts, put the starter lever (choke) in the “Half-open” posi- tion. Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the “Close” position. @ “START” CAUTION: - e Release the switch immediately after the engine starts. © If the engine fails to start, release the switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery. Do notcrank the engine more than 10 seconds on any one attempt.Essa1601 EMERGENCY ENGINE STARTING 1. Proceed with the “STARTING THE ENGINE?’ item 1 and 2. Manual Starting Model (VX500XT/ XTC, VX600XT/XTC) NOTE: ee The emergency starter rope is supplied in the tool kit box at the factory. If the recoil starter system should fail, take the emergency starter rope out of the tool kit box and proceed as follows. 2. Tighten the emergency starter rope on the screwdriver handle. @ Screwdriver handle 3. Mesh the rope stopper with the pri- mary sheave edge. @ Rope stopper @ Primary sheave edge 7374 4.Wind the rope 3-counterclockwise turns on the primary sheave. 5.Grasp the screwdriver handle and pull briskly. 4 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” posi- tion. Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the “Close” position. 7. Install the drive guard and shroud. WGN) Avoid contact with the moving pri- mary sheave. Electric Starting Model (VX500XTR/ XTCD, VX600XTR/XTCD) 2. Follow the “STARTING THE EN- GINE” procedures for the “Manual Starting Model”.TS ES841501 BREAK-IN There is never a more important period in the life of your machine than the Break-In period. For the first 10 hours, approximately 200 km (125 miles), do not putan 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. NOTE: —___ To ensure proper engine break-in, use a 50:1 fuel/oil mixture when filling the fuel tank of a new machine for the first time. For EX: 0.2 Lofoil per 10 L of gas (or 2.6 ounces of oil per one gallon of gas) equals a 50:1 mixing ratio. See page 6-1 ~ 6-2 for the recom- mended fuel and oil. ESS41301 RIDING YOUR SNOWMOBILE GETTING TO KNOW YOUR SNOW- MOBILE A snowmobile is a rider active vehicle, and your riding position and your bal- ance are the two basic factors of ma- neuvering 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.78 Riding your new snowmobile can be a very enjoyable activity, providing you with hours of pleasure. Butit is essential to familiarize yourself with the operation of the snowmobile to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read this Owner's Manual completely and understand the operation of the con- trols. Pay particular attention to the safety information on page 3-1 ~ 3-5. Please read all warning and caution labels on your snowmobile. Also read the Snowmobiler’s Safety Handbook originally supplied with your machine. LEARNING TO RIDE YOUR SNOW- MOBILE Before you ride, always perform the Preoperation checks listed on page 8-1 ~ 8-4, The short time spent checking the condition of the machine will be re- warded with added safety and a more reliable snowmobile. Always wear the proper clothing for both warmth and to help protect you from injury if an acci- dent occurs. Become familiar with this snowmobile at slow speeds, even if you are an experienced operator. Do notattemptto operate at maximum performance until you are totally familiar with the ma- chine’s handling and performance char- acteristics.77 Set the parking brake and follow the instructions on page 7-1 ~ 7-2 to start the engine. Once it has warmed up, you are ready to begin riding your snowmo- bile. TO START OUT AND ACCELERATE 1. With the engine idling, release the parking brake. 2.Apply the throttle slowly and smoothly, The centrifugal clutch will engage and you will start to accel- erate. A WARNING The operator should always keep both hands on the handlebars. Never put your feet outside the running boards. Avoid high speeds until you have become thoroughly familiar with your snowmobile and all of its con- trols. BRAKING When slowing down or stopping, re- lease the throttle and apply the brake gently-not suddenly. Many surfaces such as ice and hard packed snow require much longer stopping distances. Be alert, plan ahead and begin decelerating early. Improper use of the brake can cause the drive track to lose traction, re- ducing control and increasing the possibility of an accident.78 TURNING For most snow surfaces, “body english” is the key to turning. As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the running board to the in- side of the turn and lean your upper body into the turn. This procedure should be practiced at slow speed many times in a large flat area with no obstacles. Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. Lean more as the turn gets sharper or is made at higher speeds. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the snowmobile to tip. If your snowmobile begins to tip while turning, lean more into the turn to regain balance. If necessary, gradually let off on the throttle and/or steer to the out- side of the turn. Remember: Avoid higher speeds until you are thor- oughly 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 slip- page. It is also important to keep your weight on the uphill side at all times. On climbs straight up the hill this can be accomplished by leaning forward and, on steeper inclines, standing on the running boards and leaning forward over the handlebars. (Also see “CROSSING A SLOPE.”) Slow down as you reach the crest of the hill, and be prepared to react to obst- acles, sharp drops, or other people or vehicles which may be on the other side. Ifyou are unable to continue up a hill, do not spin the track. Stop the engine and set the parking brake. Then pull the rear of the snowmobile around to point the machine back down the hill. Do not get on the downhill side of the machine. When the snowmobile is pointed down- hill, restart the engine, release the park- ing brake, and descend the hill. Side hills and steep slopes are not recommended for a beginner or nov- ice snowmobiler.7-10 RIDING DOWNHILL When riding downhill, keep speed to a minimum. It is important to apply just enough throttle to keep the clutch en- gaged while descending the hill. This will allow you to use engine compres- sion to help slow the machine, and to keep the snowmobile from rolling freely down the hill. Also apply the brake fre- quently, with light pressure. Use extra caution when applying the brake during a descent. Excessive braking will cause the track to lock and will cause a loss of control. CROSSING A SLOPE (SIDE HILL) Side hills are not recommended fora beginner or novice snowmobiler. Crossing the face of a slope (side hill) requires you to properly position your weight to maintain proper balance. As you travel across the slope, lean your body to position yourweighttowards the uphill side. A recommended riding posi- tion is to kneel with the knee of the downhill leg on the seat and the foot of the uphill leg on the running board. This position will make it easier for you to shift your body weight as needed.TH Snow and ice are slippery, so be pre- pared for the possibility that your snow- mobile could begin to slip sideways on the slope. If this happens, steer in the direction of the slide if there are no obstacles in your path. As you regain proper balance, gradually steeragainin the direction you wish to travel. If your snowmobile starts to tip, steer down the hill to regain balance. 4 WARNING If you are unable to maintain correct balance, and your snowmobile is going to tip over, dismount your snowmobile immediately on the up- hill side. ICE OR ICY SURFACE Operating on ice or icy surfaces can be very dangerous. Traction for turning, stopping or starting is much less than that on snow. A WARNING When you have to operate on ice or icy surfaces, drive slowly and cau- tiously. Avoid rapid acceleration, turning or braking. Steering is mini- mal and uncontrolled spins are an ever-present danger.TA2 HARD-PACKED SNOW it can be more difficult to negotiate on hard-packed snow as both skis and track do not have as much traction. Avoid rapid acceleration, turning or braking. OPERATION ON SURFACES OTHER THAN SNOW OR ICE Operation of your snowmobile on sur- faces other than ice or snow should be avoided. Operation under such condi- tions will damage or result in rapid wear of the ski runners, drive track, slide runners and drive sprockets. Operation of the machine under the following con- ditions should be avoided at all costs: 1. Dirt 2. Sand 3. Rocks 4. Grass 5. Bare pavement Other conditions that should be avoided for the sake of drive track and slide runner life are: 1. Glare ice surfaces 2. Snow mixed with a lot of dirt and sand All the above conditions have one thing in common in regard to drive track and slide runners; little or no lubricating abil- ity. Drive track and all slide rail systems require lubrication (snow or water) be- tween the plastic runners and the metal track inserts. In the absence of lubrica- tion, the plastic runners will rapidly wear andin severe cases, literally melt away,7-13 and the drive track will be subjected to damage and/or failure. Also, traction aids such as studs, cleats etc., may cause further track damage and/or failure. Drive track damage and/or failure could result in loss of braking ability and machine control, which could cause an accident. Always check the drive track for damage or misadjustment before operating the machine. © Do not operate the machine if you find damage to the drive track. _ CAUTION: | Ride on fresh snow frequently. Oper- ating on ice or hard packed snow will rapidly wear the slide runner.714 3842010 DRIVING ‘inn Be sure to read “SAFETY INFORMA- TION” and “RIDING YOUR SNOW- MOBILE” carefully before operating the machine. NC Besure the engine is warmed up enough before riding. VX500XT/XTC, VX60OXT/XTC; 1. Release the parking brake by mov- ing the parking brake lever to the right. 2. Press the throttle leverslowly tomove the machine. 3. Turn the handlebar in the desired direction. 4. Squeeze the brake lever to stop the machine. 5. Apply the parking brake — move the parking brake lever to the left. VX500XTR/XTCD, VX600XTR/XTCD; 1. Select the desirable shifting position by moving the shift lever. @ Push down @ “FWD” Forward @ “REV” ReverseONG © Be sure the throttle lever is fully released and the machine is at a full stop before shifting. © Be sure to move the shift lever to forward or reverse until it stops completely while the engine is idling. © Be sure the area behind is clear before reversing. Watch behind. © Reduce speed and avoid sharp turning when reversing. NOTE: —____ The back buzzer beeps while the shift lever is in reverse. 2. Release the parking brake by mov- ing the parking brake lever to the right. 3. Press the throttle lever slowly tomove the machine. 4. Turn the handlebar in the desired direction. 5. Squeeze the brake lever to stop the machine. 6. Apply the parking brake — move the parking brake lever to the left.essae200 STOPPING THE ENGINE 1. Turn the main switch to the “OFF” position to stop the engine. @*OFF" >| Manual starting model Electric starting model A WARNING e Push down the engine stop switch to stop the engine in an emer- gency. © Be sure the key is removed from the switch whenever the operator leaves the machine, to prevent accidental starting. o) 7A68845400 TRANSPORTING When transporting your machine on a trailer orin a truck, observe the following recommendations to help protect your machine from damage: © Make sure that the fuel level in the fuel tank is lower than the carbure- tors. Otherwise, the vibration and bumps from the road surface could make it possible for fuel to flow through the carburetor into the crank- case. This can result in “hydrostatic lock,” a condition where the engine cannot rotate because of fuel accu- mulated in the engine. Severe en- gine damage can result from hydro- static lock. When possible, the fuel tank should be empty during trans- portation, especially if the trip will be 30 minutes or longer. ¢ If transporting the machine in an open trailer or truck, put a tight fitting cover on the machine. A cover spe- cifically designed for your snowmo- bile is best. This will help keep foreign objects out of the cooling vents in the shroud, and also help protect the machine against damage from de- bris on the road. © |f transporting the machine in an open trailer or truck in areas where road salt is used, coat metal suspen- sion surfaces lightly with oil or other protectant. This will help protect against corrosion. Be sure to clean the machine when you get to your destination to remove any corrosive salts.Esc50000 Essso102 PERIODIC MAINTENANCE MAINTENANCE CHART Regular maintenance is most important for best performance and safe operation. [ Initial |_ Every ] Pre-_ | 1 Month [Seasonally ttem Remarks loperation} or or heck "| 800 km | 3,200 km | P99° (Daily) | (500 Mi) | (2,000 Mii (40 hr) | “(160 br) Check condition. Adjust the Spark Plug: gap and clean, @ |e5-87 Replace if necessary. Check oil level. e 62 Engine Oil: + Air bleed the oil pump if 7 necessary. | Fuet: Check fue! level. e 61-62 ei cae ‘Check condition, _ Replace if necessary. Check fuel hose for cracks * Fuel Line: or damage. e Replace if necessary. Check oil hose for cracks or Oil Line: damage. e Replace if necessary. elt 6-3, i Check coolant level. ° eee Engire Coolant + Air bleed the cooling ace eae ane system if necessary. Check throttle lever is 5-2, 6-3, operation. a8 Carburetor wn seaeaaihen see renever operating condi + Adjust the jets. (clevation/temperature) is changed. Check wear and damage. . Replace if necessary. » Water Pump Belt 2 ny. Adjust water pump belt if a e168 necessary. & ; Itis recommended that these items be serviced by a Yamaha dealer. etInitial. |_Every Pre-_ | 1 Month Seasonally loperation| or or P. al a eheck | 00 km | 3.200km | P49? (Dally) | (600 Mi | (2,000 Mi) (40 hr) | (460 hr) Check operation and rope Manual Starter: damage. e 6-4 + Replace if necessary Check operation fitch: = Engine Stop Switen: | Oe eae ary ° 56 Throttle Override Check operation. e 5-3 ~ 5-4, System: + Repair if necessary 6-4 ~ 6-5 Throttle Lever: Check operation. e 52,63 # Repair if necessary. Check for leakage. Exhaust System: | Retighten or replace gasket e if necessary. %Decarbonization: _ | More frequently if necessary. e Check cracks, bends or Drive V-belt Guard: | damage. ° 5-8, 6-7 » Replace if necessary. i Check wear and damage. 6-7, een Replace if necessary. . 8-18 ~ 821 Check deflection, wear and Drive Track/idier —_| damage. e 6-7, Wheels: + Adjustreplace if neces- 8-31 ~ 8-34 sary i e 5 cant Check wear and damage. 6-8 % Replace if necessary. e Check operation and fluid 56~57, pei e 65-66, ge. Brake/ 8-24 ~ 8-25 Parking Brake Adjust free play and/or ie replace pads if necessary ‘ Replace brake fluid ‘See NOTE. (Page 8-4) 8-24 Check oil level. e 8-21 ~ 8-28 Drive Chain Oil ‘& Replace. e & : Itis recommended that these items be serviced by a Yamaha dealer. 82Initial |_Every | Pre- | 1 Month [Seasonally ttem Remarks Joperation] __ or or Page heck | 800 km | 3,200km| "99 (Daily) | (500 Mi) | (2,000 Mi) (40 hr) | (160 hr) ; Check deflection. Initial at 0 km (50 Mi) and every ae + Adjust if necessary. 800 km (500 Mi) thereatter, [21 ~:28 ‘Ski/Ski Cover! Check wear and damage. e 68 ‘Ski Runner Replace if necessary. e Check operation. e 68 Steering System : + Adjust toe-out if necessary e ; Check operation Ughts: Replace bulbs if necessary. | © Check fluid level. o Battery ++ Check specific gravity and breather pipe operation. 7 Charge/Correct if neces- sary Check engagement and shift . + Primary Sheave speed. Adjust it necessary. Whenever operating elevation is changed. ‘Check wear and damage. Replace if necessary. id Lubricate with specified e grease. Lubricate with specified e Secondary Sheave | grease. Adjust if necessary. Whenever operating elevation is changed. Steering Column —_| Lubricate with specified : ae Bearing: grease. + Ski and Front Lubricate with specified 7 a Suspension: grease. * Suspension Lubricate with specified e Component: grease. % : Itis recommended that these items be serviced by a Yamaha dealer. 83_—_—- Initial | _Every Pre- | 1 Month [Seasonally loperation| or or P: oa fae ‘check | 800 km | 3,200km| 199° (Dally) | (500 Mi) | (2,000 Mi) (40 hr) | “(460 hr) »* Parking Brake Lubricate with specified e 8-36 Cable Endand —_| grease. Lever End Throttle [ Check cable damage a Cable End Replace if necessary. | Make sure the shroud Shroud Latches: | latches are hooked. ° 58-59 | Check tightness. Fittings/Fasteners: : ingsiFasteners: | Repair if necessary. - 6-10 panfce ToolsiSpare | Check proper placement. e ett % : Itis recommended that these items be serviced by a Yamaha dealer. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required. 2. Onthe inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3. Replace the brake hoses every four years, or if cracked or damaged. 84essstt01 TOOL KIT The owner's toolkit has the tools which are sufficient for most periodic main- tenance and minor repair. A torque wrench is also necessary to properly tighten nuts and bolts. @Tool kit 85 A] Manual starting model (VX500XT/ XTC, VX600XT/XTC) Electric starting model (VX500XTR/ XTCD, VX600XTR/XTCD) _ CAUTION: Before starting the engine, make sure that the tool kit box is firmly seated in the holder and is secured with the holding band. i] | (° 1 || -{ sesesesnnisasaeseisedeieonisGaesaneniananiananHanat If you do not have a torque wrench available during a service operation which requires one, take your machine toa Yamaha dealer or another qualified mechanic to check the torque settings and adjust them if necessary. s$52000 SPARK PLUG INSPECTION The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. Check the coloration on the white porcelain insula-86 tor around the center electrode. The ideal coloration at this pointis amedium toa light tan color for a machine that is being ridden normally. If a spark plug shows a distinctly different color, there could be something wrong with the en- gine. For example, a very white center electrode porcelain color could indicate an intake track air leak or carburetion problem forthat cylinder. Do not attempt to diagnose such problems yourself. Instead, take the machine to your Yamaha dealer. You should periodi- cally remove and inspect the spark plug because heat and deposits will cause a spark plug to slowly break down and erode. Consult your dealer before changing to a different type of spark plug. Standard spark plug: BR9ES (NGK) VX500XT/XTC/XTR/XTCD BR9ECS (NGK) VX600XT/XTC/XTR/XTCD Spark plugs are produced in several different thread lengths. The thread length (reach) is the distance from the spark plug gasket seat to the end of the threaded portion. If the reachis too long, overheating and engine damage may result. If the reach is too short, spark plug fouling and poor performance may8 result. Also, iftoo short, carbon will form on the exposed threads resulting in combustion chamber hot spots and thread damage. Always use a spark plug with the proper reach. Spark plug reach @: 19.0 mm (0.75 in) Before installing any spark plug, meas- ure the electrode gap with a wire thick- ness gauge and adjust to specification. Spark plug gap @: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) When installing the plug, always clean the gasket surface. Wipe off any grime from the threads and torque the spark plug properly. Spark plug torque: 20 Nm (2.0 m-kg, 14 ft-lb) Esss2400 ENGINE IDLE SPEED ADJUSTMENT _ CAUTION: | © Be sure this adjustment is serv- iced by a Yamaha dealer or an- other qualified mechanic. © Be sure the throttle lever moves smoothly. © Be sure the carburetor is syn- chronized first.1. Start the engine. NOTE; —_____ Refer to STARTING THE ENGINE. 2. Turn the throttle stop screw © in or out to adjust the engine idle speed. Standard Engine Idle Speed: VX500XT/XTC/XTR/XTCD 1600 + 100 r/min VX600XT/XTC/XTR/XTCD 1550 + 100 r/min ES$54500 THROTTLE CABLE ADJUSTMENT “CAUTION: Be sure the engine idle speed is ad- justed first. 1. Loosen the adjuster locknut. 2.Turn the adjuster in or out until the proper throttle lever free play is achieved. Throttle Lever Free Play @: 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) @Locknut @ Adjuster 3. Tighten the locknut. 8889 ES853100 OIL PUMP CABLE ADJUSTMENT CAUTION, e Be sure this adjustment is ser- viced by a Yamaha dealer or an- other qualified mechanic. ¢ Be sure the throttle cable is ad- justed first. . Stop the engine. 2. Loosen the adjuster locknut on the oil pump cable. @ Locknut @ Adjuster 3. With the throttle lever in the full-throttle position, turn the adjuster in or out to align the mark on the control lever © with the mark on the pump boss @. 4. Tighten the locknut.8-10 8951207 CARBURETOR ADJUSTMENT _ GAUTION: © Be sure this adjustment is serv- iced by a Yamaha dealer or an- other qualified mechanic. © Be sure the carburetor silencer is installed during running to pre- vent engine damage. Under some operating conditions the carburator setting may have to be changed due to air temperature changes, elevation changes, use of al- cohol oxygenated fuels, etc. and should be done by an authorized Yamaha Dealer. _ CAUTION: The drive chain gears and V-belt clutch should be adjusted when op- erating over 900 m (3000 ft) high alti- tude. Consult a Yamaha dealer.Pilot Screw Adjustment Turn the pilot screw in or out to adjust low speed tuning. Standard Pilot Screw Position: VXS500XT/XTC/XTR/XTCD 13/4 VX600XT/XTC/XTR/XTCD 11/2 turns out from the seated position Pilot Screw (| Mixture | Condit Warmer Weather Higher Altitude Colder Weather ion Turn in Leaner Turn out RicherJet Needle Adjustment Adjust jet needle clip position according to the setting chart which is available at an authorized Yamaha dealer. Standard Jet Needle Clip @ Position: 2nd groove from upper end Clip Position| Mixture | Condition Warmer Weather Higher Altitude Colder Weather Lower Altitude @ Upper Leaner © Lower 1.Remove the mixing chamber top, and jet needle. 2. Change the clip to the proper posi- tion. Be sure that the plastic washer is in place below the clip. A WARNING © Be sure the throttle outer cable is firmly seated in the holder and the throttle operates smoothly after assembling the carburetor. © When reinstalling the carburetor silencer, be sure the fuel hose is properly seated in the holder lo- cated on top of the carburetor si- lencer. 3.Assemble by reversing removal steps. 812Main Jet Replacement Replace the main jet according to the setting chart which is available at an authorized Yamaha dealer. AG e@ Never remove the drain plug orthe float chamber while the engine is hot. Fuel will flow out from the float chamber which could ignite and cause injury. ¢ Place a rag under the carburetor before removing the drain plug or float chamber to catch any spilled fuel. Handle fuel with care: it is highly flammable. Standard Main J #151.3 Main Jet © Mixture | Condition Warmer Weatht Smaller No.| Leaner | weal er Higher Altitude Lower L Colder Weather Larger No. | Richer Altitude 813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 removal steps. A WARNING © Be sure the throttle outer cable is firmly seated in the holder and throttle operates smoothly after assembling the carburetor. When reinstalling the carburetor silencer, be sure the fuel hose is properly seated in the holder lo- cated on top of the carburetor si- lencer. Esss8401 HIGH ALTITUDE ADJUSTMENTS, Operating at high altitude reduces the performance of a gasoline engine, about 3% for every 305 m (1000 ft.) of elevation. This is because there is less air as altitude increases. Less air means less oxygen available for com- bustion. 8-14Your snowmobile can be adjusted to overcome most of the problems found in high altitude riding. Carburetor ad- justments are the most important. Less air at high altitude makes the fuel/ air ratio too rich, which can cause poor performance. Common problems are hard starting, bogging, and plug fouling. Follow the Main Jet Setting chart which is available at an authorized Yamaha dealer carefully. Proper carburetion ad- justments will correct the fuel/air ratio. Remember: less air at higher altitude means there is less horsepower avail- able, even with proper carburetion. Ex- pect 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 clutch and driv- eline settings to avoid poor perform- ance and rapid wear. If you plan to operate your snowmobile at an altitude different from the area where you bought your machine, be sure to consult your Yamaha dealer. He can tell you if there arc any changes necessary for the altitude where you plan to ride.ES$62000 COOLING SYSTEM Water Pump Belt Deflection Check 1. Lift up the shroud. 2. Measure the water pump belt deflec- tion by applying 120 N {12 kgf (26 Ibs.)} of force through the hole. @ Deflection @® 120 N {12 kgf (26 Ibs.)} Standard Belt Deflection: 8.0 mm (0.31 in)/ 120 N {12 kgf (26 Ibs.)} 8-16 If the deflection exceeds the specifica- tion, consult a Yamaha dealer. Air Bleeding A WARNING ¢ Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick rag or towel over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any resid- ual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.© The cooling system must be bled ofairifthereservoirtank becomes empty, if air can be seen in the cooling system, or if there is a cooling system leak. Consult a Yamaha dealer. _ CAUTION: Operating the engine with an improp- erly bled cooling system can cause overheating and severe engine dam- age. 1. Remove the coolant filler cap and pour the coolant to the proper level. Recommended coolant: High quality ethylene glycol antifreeze containing corrosion inhibitor. Coolant and water mixed ratio: 60%/40% Total amount: 3.3 L (2.90 Imp qt, 3.49 US qt) Reservoir tank capacity: 0.17 L (0.15 Imp qt, 0.18 US qt) From LOW to FULL level: 0.13 L (0.11 Imp at, 0.14 US at) @ Coolant level @To reservoir tank 8172. Start the engine and add coolant until the coolant level does not go down. Stop the engine. 3. Fill the reservoir tank with coolant to “FULL” ®. 4. Install the radiator and reservoir tank caps. Check for any coolant leakage. NOTE: —_____ If you find any leaks, consult your Yamaha dealer. esse6s02 DRIVE V-BELT REPLACEMENT When installing the new belt, be sure the V-belt is positioned 0 ~ 2mm (0 ~ 0.08 in) below the secondary sheave edge ©. If not, the clutch engagement speed will be changed. The machine may move unexpectedly when the engine is started. Adjust the V-belt position by remov- ing or adding a spacer @ on each adjusting bolt. For this adjustment, consult a Yamaha dealer or another qualified mechanic. 8-18