Yamaha VENTURE 600, VMAX User Manual
OWNER’S MANUAL
SNOWMOBILE
LIT-12628-02-25
SX600H
VT600H
VX600ERH
8DG-28199-14
A
ESU00286
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
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.
SX600H
VT600H
VX600ERH
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-12628-02-25
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
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
Maximizing drive track life ...............7-9
Driving ...........................................7-10
......................................7-1
..............6-1
Stopping the engine.......................7-11
Transporting ..................................7-12
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 ................................8-15
Checking the brake pads...............8-16
Checking the parking
brake pads.....................................8-16
Checking the brake fluid level........8-17
Brake fluid replacement.................8-18
Suspension....................................8-18
Drive track adjustment...................8-23
Ski alignment .................................8-25
Handlebar adjustment ...................8-26
Lubrication .....................................8-28
Headlight bulb replacement...........8-29
Headlight beam adjustment...........8-29
Battery ...........................................8-30
Fuse replacement..........................8-31
TROUBLESHOOTING .......................9-1
STORAGE ........................................10-1
SPECIFICATIONS............................11-1
Dimensions....................................11-1
Engine ...........................................11-1
Chassis..........................................11-1
Electric...........................................11-2
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
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.
@
23
1
SX600
SX600
2-1
1 VT600
1 VX600ER
2-2
ESU00009
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. SX600 and VX600ER are 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 gently—not 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
SX600
VT600
VX600ER
ESU00012
4-
DESCRIPTION
Windshield
1
Steering handlebar
2
Seat
3
Passenger grip warmer switch (VT600)
4
Frame
5
Slide rail suspension
6
Drive track
7
Skis
8
4-1
VT600
Headlight
9
Shroud
0
Storage compartment
A
Tail/brake light
B
Snow flap
C
Side mirror (VT600 / VX600ER)
D
Brake lever
E
Headlight beam switch
F
Parking brake lever
G
Engine stop switch
H
Throttle lever
I
Shift lever (VT600 / VX600ER)
J
Starter handle
K
Shroud latch
L
Main switch
M
Starter lever
N
Thumb warmer control knob
O
Grip warmer control knob
P
Tr i p m e t e r
Q
Odometer
R
Speedometer
S
Tachometer
T
Fuel meter
U
Coolant temperature warning light
V
Oil level warning light
W
High beam indicator light
X
Tripmeter reset knob
Y
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 VT600 / VX600ER
“START”
3
The starting circuit is switched on.
The starter motor starts.
CAUTION
@
:
Release the switch immediately after the engine
starts.
@
SX600
È
VT600 / VX600ER
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.
ESU00033
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.
@
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 VT600 / VX600ER
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” Forward
“REV” 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 VT600
The passenger grip warmer switch controls the electrically heated passenger grips.
Passenger grip warmer switch
1
“OFF”
2
“HI” High
3
“LO” Low
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 VT600
The backrest is adjustable.
Pull the backrest adjusting lever 1 upward to adjust the
backrest position.
Turn the backrest adjusting knob 2 right or left to further
adjust the backrest.
WARNING
@
Do not sit on the backrest.
@
When riding without a passenger, the backrest can be
adjusted for the rider as shown in the illustration.
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.
SX600 / VX600ER
È
VT600
É
5-11
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