Yamaha MOUNTAIN MAX 700 User Manual

OWNER’S MANUAL
SNOWMOBILE
LIT-12628-02-26
MM700H
VT700H
8DM-28199-10
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
2
The
engine number
is stamped in the location as
shown. (See fig. É.)
3
Key number
(See fig. Ê.)
Also, record and keep the ID numbers in a separate place in case the snowmobile is stolen.
ESU00001
2-

INTRODUCTION

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. This manual is designed to acquaint you with the opera­tion of this snowmobile and minor maintenance required for satisfactory service. Should major repairs ever be required, you are advised to ask a Yamaha dealer to inspect and repair the snow­mobile whenever it is necessary; they have the tech­niques, tools, and parts to ensure your satisfaction. We hope that the information within this manual will help you enjoy many hours of pleasure with your Yamaha snow­mobile.
MM700H
VT700H
OWNER’S MANUAL
© 2002 by Yamaha Motor Corporation, U.S.A.
1st Edition, March 2002
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-12628-02-26
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.
This manual should be considered a permanent part of this snowmobile and should remain with the snow­mobile when resold.
@
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
WARNING
@
Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snow­mobile.
CAUTION
@
:
A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile.
NOTE:
@
A NOTE provides key information to make procedures easier or clearer.
ESU00003

CONTENTS

YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTY
YAMAHA EXTENDED SERVICE (Y.E.S.)
LOCATION OF THE IMPORTANT LABELS
SAFETY INFORMATION
DESCRIPTION
CONTROL FUNCTIONS
Main switch......................................5-1
Starter lever (choke) ........................5-2
Throttle lever....................................5-2
Throttle override system
(T.O.R.S.) ........................................5-2
Oil level warning light.......................5-3
Coolant temperature warning light...5-4
Engine stop switch...........................5-6
Brake lever ......................................5-6
Parking brake lever..........................5-7
Shift lever.........................................5-7
Headlight beam switch ....................5-8
Grip warmer control knob ................5-8
Thumb warmer control knob............5-8
Passenger grip warmer switch ........5-9
Tripmeter reset knob .......................5-9
Shroud latches.................................5-9
Drive guard ....................................5-10
V-belt holders ................................5-10
Spark plug holders.........................5-10
Carburetor heating lever................5-10
Backrest.........................................5-11
Storage compartment ....................5-11
.......................................1-1
...............................................1-4
.......................2-1
...................3-1
...................................4-1
....................5-1
PRE-OPERATION CHECKS
Fuel .................................................6-1
Engine oil.........................................6-2
Coolant ............................................6-2
Throttle lever ...................................6-3
Recoil starter ...................................6-3
Throttle override system
(T.O.R.S.) ........................................6-3
Brake ...............................................6-4
Brake fluid leakage..........................6-5
V-belt ...............................................6-5
Drive guard......................................6-5
Drive track .......................................6-6
51-mm (2.0-in) high-profile pattern
drive track........................................6-6
Slide runners ...................................6-6
Skis and ski runners ........................6-7
Steering system...............................6-7
Lights...............................................6-7
Battery .............................................6-8
Air filter ............................................6-8
Fittings and fasteners ......................6-9
Tool kit and recommended
equipment........................................6-9
OPERATION
Starting the engine ..........................7-1
Emergency engine starting..............7-2
Break-in ...........................................7-4
Riding your snowmobile ..................7-5
Getting to know your snowmobile ...7-5 Learning to ride your snowmobile ...7-5
To start out and accelerate..............7-5
Braking ............................................7-5
Turning ............................................7-6
Riding uphill.....................................7-6
Riding downhill ................................7-7
Traversing a slope...........................7-7
Ice or icy surface .............................7-7
Hard-packed snow ..........................7-8
Operation on surfaces other than
snow or ice ......................................7-8
......................................7-1
..............6-1
Maximizing drive track life ...............7-9
Strap ..............................................7-10
Driving ...........................................7-11
Stopping the engine.......................7-12
Transporting ..................................7-13
PERIODIC MAINTENANCE ...............8-1
Periodic maintenance chart .............8-1
Tool kit .............................................8-4
Spark plug inspection ......................8-4
Engine idle speed adjustment .........8-5
Throttle cable adjustment ................8-6
Oil pump cable adjustment ..............8-6
Carburetor adjustment.....................8-7
High altitude adjustments ................8-9
Cooling system ..............................8-10
V-belt replacement ........................8-12
Checking the oil level of the drive
chain housing ................................8-14
Checking the brake pads...............8-16
Checking the parking brake
pads...............................................8-16
Checking the brake fluid level........8-17
Brake fluid replacement.................8-17
Suspension....................................8-18
Drive track adjustment...................8-21
Ski alignment .................................8-23
Handlebar adjustment ...................8-24
Lubrication .....................................8-26
Headlight bulb replacement...........8-27
Headlight beam adjustment...........8-27
Battery ...........................................8-28
Fuse replacement..........................8-29
TROUBLESHOOTING .......................9-1
STORAGE ........................................10-1
SPECIFICATIONS............................11-1
Dimensions....................................11-1
Engine ...........................................11-1
Chassis..........................................11-2
Electric...........................................11-3
WIRING DIAGRAM ..........................12-1
ESU00004
CW-01E
1-
YAMAHA MOTOR CORPORATION, U.S.A.
SNOWMOBILE LIMITED WARRANTY
1-1
CW-02E
1-2
CW-03E
1-3
ESU00005
CW-10E

YAMAHA EXTENDED SERVICE (Y.E.S.)

1-4
1
MM700
ESU00007
2-
LOCATION OF THE
IMPORTANT LABELS
Please read the following labels carefully before operat­ing this snowmobile.
NOTE:
@
Maintain or replace safety and instruction labels, as nec­essary.
@
2
1
VT700
2-1
3 MM700
4 MM700
5 MM700
2-2
ESU00325
3-

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 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. This snowmobile was not manufactured for use on public streets, roads, or highways. Such use is pro­hibited by law, and you could collide with another vehicle.
3. MM700 is designed to carry the OPERATOR ONLY. Passengers are prohibited. Carrying a passenger can cause loss of control.
4. Do not operate the snowmobile after drinking alcohol or taking drugs. Your ability to operate the snowmo­bile is reduced by the influence of alcohol or drugs.
5. For safety and proper care of the snowmobile, always perform the pre-operation checks on pages 6-1–6-9 before starting the engine. Check the throttle, brake, and steering for proper operation every time before starting the engine. Make sure that the throttle lever moves freely and it returns to the home position when it is released.
6. Apply the parking brake before starting the engine. Never drive the snowmobile with the parking brake applied. This may overheat the brake disc and reduce braking ability.
3-1
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.
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 that the fuel tank cap is closed securely
after refueling. Wipe up any spilled fuel immedi­ately.
9. If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately 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, wear a good qual­ity snowmobile suit, boots, and a pair of 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, except when starting the engine to transport the snowmobile in or out of the building. Open the outside doors; exhaust fumes are dangerous.
2. Be careful where you ride. There may be obstacles hidden beneath the snow. Stay on established trails to minimize your exposure to hazards. Ride slowly and cautiously when you ride off of established trails. Hitting a rock or stump, or running into wires could cause an accident and injury.
3-2
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. Always ride with other snowmobilers 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 gentlynot suddenly.
Maintenance and storage
1. Do not leave the snowmobile on its left side for an extended period of time. Fuel may leak out from the fuel breather hose.
2. Modifications made to the snowmobile not approved by Yamaha, or the removal of original equipment may render your snowmobile unsafe for use that may cause severe personal injury. Modifications may also make the snowmobile illegal to use.
3. Never store the snowmobile with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters, an open flame, sparks, clothes dryers, and the like. Allow the engine to cool off before storing the snowmobile in an enclosed space.
4. Always refer to the “STORAGE section if the snow- mobile is to be stored for an extended period.
5. Maintain or replace safety and instruction labels, as necessary.
3-3
MM700
VT700
ESU00012
4-

DESCRIPTION

Windshield
1
Steering handlebar
2
Seat
3
Passenger grip warmer switch (VT700)
4
Frame
5
Slide rail suspension
6
Drive track
7
Skis
8
4-1
VT700
Headlight
9
Shroud
0
Storage compartment
A
Tail/brake light
B
Snow flap
C
Side mirror (VT700)
D
Brake lever
E
Headlight beam switch
F
Parking brake lever
G
Strap (MM700)
H
Engine stop switch
I
Throttle lever
J
Shift lever (VT700)
K
Starter handle
L
Shroud latch
M
Main switch
N
Starter lever
O
Thumb warmer control knob
P
Grip warmer control knob
Q
Tr i p m e t e r
R
Odometer
S
Speedometer
T
Tachometer
U
Fuel meter
V
Coolant temperature warning light
W
Oil level warning light
X
High beam indicator light
Y
Tripmeter reset knob
Z
4-2
ESU00013
5-

CONTROL FUNCTIONS

ESU00256
Main switch
The main switch controls the following items.
OFF
1
The ignition circuit is switched off. The key can be removed only in this position.
ON
A
2
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 VT700
START”
3
The starting circuit is switched on. The starter motor starts.
CAUTION
@
:
Release the switch immediately after the engine starts.
@
MM700
È
VT700
É
5-1
ESU00020
Starter lever (choke)
Use the starter lever (choke) when starting and warming up a cold engine.
Starter lever (choke)
1
When starting a cold engine.
2
Warming up
3
When the engine is warm.
4
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. Regulate the speed of the snowmobile by varying the throttle position. Because the throttle is spring-loaded, the snowmobile will deceler­ate, and the engine will return to idle when it is released b.
WARNING
@
Check the throttle, brake, and steering for proper operation before starting the engine.
@
ESU00023
Throttle override system (T.O.R.S.)
If the carburetor or throttle cable should malfunction dur­ing operation, the 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 revolution speed between 2,800 and 3,000 r/min if the carburetor fails to return to idle when the lever is released.
5-2
WARNING
@
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
A
plug cap. Otherwise, the T.O.R.S. will not work properly.
@
CA-01E
Mode
Switch
A
starting
Idle
or
B C
Run Trouble
Throttle switch Off On Off
B
C
Carburetor switch On Off Off
Engine Run Run
Idle or starting
È
Run
É
Tr o u b l e
Ê
Carburetor switch
1
Throttle switch
2
Throttle cable
3
Throttle valve
4
On
a
Off
b
T.O.R.S. will operate
ESU00026
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.
5-3
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.) After the engine starts, this light flashes three times to check the bulb, and then goes off if there are no prob­lems. (See page 5-5 for warning light flash pattern num­ber 0.) If it does not flash, have a Yamaha dealer inspect the electrical circuit.
WARNING
@
If the coolant temperature warning light flashes continually or stays on during operation, there may be some problem with the electrical circuit, lead couplers, or engine cooling system. (See page 5-5 for warning light flash pattern numbers 1–7.)
Stop the engine and allow it to cool off. Then, check that the wire harness couplers are con­nected properly in the engine compartment and that the coolant level of the coolant reservoir is within the specified range. (See page 6-2.)
If the coolant temperature warning light remains on after the engine has been started or if it flashes, note the flash pattern, and then have a Yamaha dealer inspect the snowmobile as soon as possible.
@
5-4
No. Coolant temperature warning light flash patterns
Light bulb check: Light flashes three times, then goes off.
Engine overheat warning: Light flashes continuously in this pattern.
0.25 s
0.25 s
0.5 s
0.5 s 3 s
· · ·
0
1
· · ·
2
3
4
5
6
7
0.75 s
0.25 s
0.75 s
2.5 s
0.75 s
0.25 s
0.75 s
0.25 s
0.75 s
0.25 s
0.75 s
0.25 s
4 s
· · ·
· · ·
3.5 s
· · ·
4.5 s
· · ·
5.5 s
6.5 s
Light flashes continuously in this pattern.
Light flashes continuously in this pattern.
Light flashes continuously in this pattern.
Light flashes continuously in this pattern.
Light flashes continuously in this pattern.
Light flashes continuously in this
· · ·
pattern.
: Warning light is on : Warning light is off s: Second
5-5
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. Squeeze the brake lever towards the handlebar grip to stop the snowmobile.
Brake lever
1
Brake lever end
2
Handlebar end
3
NOTE:
@
When the brake lever is operated, the brake light will illu­minate.
@
CAUTION
@
:
Make sure that the brake lever end does not project out over the handlebar end. This will help prevent brake lever damage when the snowmobile is placed on its side for service.
@
For VT700
The brake lever is equipped with a position adjuster. To adjust the brake lever position:
1. Loosen the locknut 1.
2. While lightly pushing the brake lever in direction a, finger tighten the adjusting bolt 2 to set the brake lever to the desired position.
3. Tighten the locknut securely after adjusting the brake lever.
5-6
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.
To apply the parking brake
B
È
To release the parking brake
É
WARNING
@
Always set the parking brake before attempting to start the engine.
Never run the snowmobile with the parking brake applied. This may overheat the brake disc and reduce braking ability.
@
ESU00321
Shift lever
For VT700
The shift lever is used to put the snowmobile into forward or reverse. After coming to a complete stop, push the shift lever down and move it to the desired direction.
Shift lever
1
Push down
2
Move to “FWD”
3
Move to “REV”
4
CA-02E
Snowmobile movement
FWD ForwardREV Reverse
CAUTION
@
:
Do not shift from “FWD” to “REV” or “REV” to FWD while the snowmobile is moving. Otherwise, the drive system could be damaged.
@
5-7
ESU00039
Headlight beam switch
Push the headlight beam switch to change the headlight beam to high or low.
Headlight beam switch
1
Push
2
High beam
3
Low beam
4
ESU00279
Grip warmer control knob
The grip warmer control knob controls the electrically heated handlebar grips.
Grip warmer control knob
1
OFF
2
ON
3
CA-03E
Knob position Grip warmer temperature
Turn clockwise
a
Turn counterclockwise
ESU00280
b
Higher
Lower
Thumb warmer control knob
The thumb warmer control knob controls the electrically heated throttle lever.
Thumb warmer control knob
1
OFF
2
ON
3
CA-06E
Knob position
Turn clockwise
a
Turn counterclockwise
5-8
Thumb warmer temperature
Higher
Lower
b
ESU00044
Passenger grip warmer switch
For VT700
The passenger grip warmer switch controls the electri­cally heated passenger grips.
Passenger grip warmer switch
1
OFF
2
HIHigh
3
LOLow
4
ESU00046
Tripmeter reset knob
Use the tripmeter reset knob to reset the tripmeter.
Tripmeter reset knob
1
Turn counterclockwise
2
ESU00048
Shroud latches
To open the shroud, unhook the shroud latches, and then slowly raise the shroud forward until it stops. When clos­ing the shroud, slowly lower it to its home position, and then hook the shroud latches.
Shroud latch
1
Shroud
2
CAUTION
@
:
Make sure that all cables and wires are in place when closing the shroud.
@
WARNING
@
Do not drive the snowmobile with the shroud open, unlatched, or removed.
Keep your body and clothing away from rotating parts when servicing with the shroud open.
Do not touch the hot muffler and engine during or immediately after operation.
@
5-9
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.
CAUTION
@
:
Make sure that the V-belt is installed securely in the holders.
@
ESU00056
Spark plug holders
Keep spare spark plugs for emergency use by placing them into the spark plug holders provided.
ESU00057
Carburetor heating lever
The carburetor heating lever controls the flow of coolant through each carburetor body. Make sure that the lever is in the “ON” position to heat the carburetors while the ambient temperature is below 0 °C (32 °F).
Carburetor heating lever
1
ON
2
OFF
3
CAUTION
@
When operating the snowmobile above 0 °C (32 °F), move the carburetor heating lever to the “OFF” posi­tion, since the carburetors do not need to be heated.
@
:
5-10
ESU00067
Backrest
For VT700
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.
To adjust the passenger grip position, remove the pas­senger grip adjusting knobs 3 on both sides of the seat, and change the position of the passenger grip to any one of the three positions shown.
A B
WARNING
@
Make sure that the passenger grip adjusting knobs are tightened securely after adjusting the passenger grip position.
@
ESU00242
Storage compartment
Open the storage compartment to store the service tools, spare parts, or other small items.
MM700
È
VT700
É
5-11
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