Yamaha VK540EG Service Manual

SERVICE MANUAL

1-1MACHINE IDENTIFICATIONGENINFONOTE:ESS00011GENERAL INFORMATIONESS00012MACHINE IDENTIFICATIONESS00013FRAME SERIAL NUMBERThe frame serial number 1 is

4-25SECONDARY SHAFT (JACKSHAFT)POWRTRESS00136INSPECTION1. Inspect: Secondary shaft (jackshaft) 1Scratches (excessive)/damage  Replace. Splines 2Wea

4-26Order Job name/Part name Q’ty Remarks123Brake pad removalBrake caliper assemblyBrake discBrake pads112Remove the parts in the order listed below.F

4-27BRAKEPOWRTRNOTE:CAUTION:ESS00139BRAKE PAD REPLACEMENT1. Remove: Brake caliper Do not depress the brake lever when the cali-per or disc is off th

4-28BRAKEPOWRTRNOTE: Screw in the adjusting screw 1, and when itcontacts lightly with the end of the back upplate, then back out the adjusting screw

4-29Order Job name/Part name Q’ty RemarksBrake caliper disassemblyBack up plateEnd coverAdjusting ratchetStationary coverLeverAdjusting screw111111Rem

4-30BRAKEPOWRTRCAUTION:BRAKE CALIPER INSPECTION1. Inspect: One way lock 2 1 Stationary cover 2 Lever 3 Spiral gear 4 (lever)Cracks/wear/damage  R

4-31BRAKEPOWRTRINSTALLATION1. Assemble: Caliper bodyAssemblage steps: Lubricate the spiral gears 1 on the caliperbody and lever 2 with silicone grea

4-32BRAKEPOWRTRNOTE: Screw in the adjusting screw 1, and when itcontacts lightly with the end of the back upplate, then back out the adjusting screw

4-33Order Job name/Part name Q’ty Remarks12Slide rail suspension removalTension adjusterBlind capSlide rail suspension21Remove the parts in the order

4-34SLIDE RAIL SUSPENSIONPOWRTRSlide rail suspension disassemblyStopper bandHookBushingCollerFront shock abosrberBracketFront suspension brakcetSnspen

1-21IMPORTANT INFORMATIONGENINFOESS00015IMPORTANT INFORMATIONESS00016PREPARATION FOR REMOVAL AND DIS-ASSEMBLY1. Remove all dirt, mud, dust, and foreig

4-35SLIDE RAIL SUSPENSIONPOWRTROrder Job name/Part name Q’ty RemarksSpacerSuspension wheelSuspension wheelCirclipBushingPull rodRear shock abosrberRea

4-36SLIDE RAIL SUSPENSIONPOWRTROrder Job name/Part name Q’ty RemarksPivot armBase boltPivot shaftCollerCotter pinRear axleGuide wheelCollerTension adj

4-37SLIDE RAIL SUSPENSIONPOWRTRNOTE:ESS00148INSPECTION1. Inspect: Suspension wheel Guide wheelCracks/damage  Replace. Wheel bearingWheel turns rou

4-38Order Job name/Part name Q’ty Remarks12345Front axle and track removalDrive chain housingSlide rail suspensionSecondary sheaveSpeedometer gear ass

4-39Order Job name/Part name Q’ty RemarksFront axle disassemblyFront axle housingBearingSprocket wheel213Remove the parts in the order listed below.Fo

4-40FRONT AXLE AND TRACKPOWRTRNOTE:NOTE:ESS00150INSPECTION1. Inspect: Track 1 Slide metal 2Wear/cracks/damage  Replace.2. Inspect: Sprocket wheel

5-1Order Job name/Part name Q’ty Remarks12345Exhaust assembly removalSpring 1Spring 2Spring 3Exhaust assemblyExhaust pipe joint21111Remove the parts i

5-25EXHAUST ASSEMBLYENGESS00154INSPECTION1. Inspect: Exhaust joint 1 Exhaust pipe 2 Exhaust silencer 3Cracks/damage  Replace. Exhaust gaskets 4Ex

5-3Order Job name/Part name Q’ty Remarks12345Engine removalExhaust assemblyCarburetorRecoil starterEngine cooling fanPrimary sheaveCDI magneto leadVac

5-4ENGINE ASSEMBLYENGNOTE:NOTE:ESS00157INSPECTION1. Inspect: Engine bracket (front) 1 Engine bracket (rear) 2Cracks/damage  Replace.ESS00158INSTALL

1-3IMPORTANT INFORMATIONGENINFOCAUTION:ESS00017ALL REPLACEMENT PARTSWe recommend using genuine Yamaha partsfor all replacements. Use oil and grease re

5-5Order Job name/Part name Q’ty Remarks12345678910Cylinder head and cylinder removalSpark plugCylinder headCylinder head gasketCylinderCylinder gaske

5-6CYLINDER HEAD AND CYLINDERENGNOTE:CAUTION:CAUTION:ESS00160REMOVAL1. Remove: Piston pin clips Piston pins Pistons Small end bearings Before rem

5-7CYLINDER HEAD AND CYLINDERENGCAUTION:NOTE:NOTE:3. Eliminate: Carbon deposits(from the cylinders)Use the rounded scraper 1.Do not use a sharp instr

5-8CYLINDER HEAD AND CYLINDERENGStandard Wear limitCylinder bore(C)73.00  73.02mm(2.874  2.875in)73.10 mm(2.878 in)Taper (T) –0.05 mm(0.002 in)Out o

5-9CYLINDER HEAD AND CYLINDERENGNOTE:NOTE:8. Measure: Side clearance (piston rings)Use the feeler gauge 1.Out of specification  Replace the pistonan

5-10abCYLINDER HEAD AND CYLINDERENG11. Measure: Outside diameter (piston pin) aOut of specification  Replace the pistonpin.Outside diameter (piston

5-11CYLINDER HEAD AND CYLINDERENGNOTE:NOTE:NOTE:ESS00162INSTALLATION1. Install: Reed valves Reed valve stoppers Place the reed valve 1 with its con

5-12CYLINDER HEAD AND CYLINDERENGCAUTION:CAUTION:NOTE:NOTE: Always use new piston pin clips. Do not allow the clip gap to align with thepiston pin s

5-13CYLINDER HEAD AND CYLINDERENG9. Install: Gasket (cylinder head) Cylinder heads10. Tighten: Nuts (cylinder head)Tightening steps: Temporarily t

5-14Order Job name/Part name Q’ty Remarks12345678Oil pump, crankcase and crankshaftremovalOil pumpOil pump drive gearLower crank caseCrankshaftStopper

1-4IMPORTANT INFORMATIONGENINFOESS00021CIRCLIPSAll circlips should be inspected carefully beforereassembly. Always replace piston pin clips af-ter one

5-15bOIL PUMP, CRANKCASE AND CRANKSHAFTENGCAUTION:ESS00168INSPECTION1. Measure: RunoutUse the V-blocks and a dial gauge.Out of specification  Replac

5-16OIL PUMP, CRANKCASE AND CRANKSHAFTENG4. Inspect: Lower crankcase 1 Upper crankcase 2 Front left brackets 3 Front right brackets 4 Rear bracke

5-17OIL PUMP, CRANKCASE AND CRANKSHAFTENGNOTE:4. Measure: Maximum pump stroke bOut of specification  Adjust.Maximum pump stroke b:1.65  1.87 mm (0.

5-18OIL PUMP, CRANKCASE AND CRANKSHAFTENGNOTE:CAUTION:CAUTION:NOTE:ESS00169INSTALLATION1. Install: Stopper rings 1(onto the lower crankcase bearing a

5-19OIL PUMP, CRANKCASE AND CRANKSHAFTENGOIL PUMP1. Install Dowel pins Oil pump 1

5-20Order Job name/Part name Q’ty Remarks123456CDI magneto removalRotorStator assemblyCharge coilLighting coil 1Lighting coil 2Pulser coil111111Remove

5-21CDI MAGNETOENGNOTE:NOTE:ESS00171REMOVAL1. Remove: Nut 1 (CDI magneto)Attach the universal rotor holder 2 to hold theCDI magneto.Universal rotor h

5-22CDI MAGNETOENGNOTE:NOTE:NOTE:CAUTION:NOTE:ESS00172INSTALLATIONAfter installing all parts, refer to “CABLE ROUT-ING” in CHAPTER 8, to check the cab

5-23Order Job name/Part name Q’ty Remarks1234567Engine cooling fan removalCooling fan coverFan belt driven pulleyShimFan beltFan belt drive pulleyCool

5-24ENGINE COOLING FANENGNOTE:ESS00174REMOVAL1. Remove: Cylinder air shroud 1 Seal rubber stay 2 (air duct) Cooling fan cover 32. Remove: Recoil s

1-5SPECIAL TOOLSGENINFONOTE:ESS00023SPECIAL TOOLSSome special tools are necessary for a com-pletely accurate tune-up and assembly. Usingthe correct sp

5-25ENGINE COOLING FANENGNOTE:CAUTION:ESS00175INSPECTION1. Inspect: Upper air shroud 1Cracks/damage  Replace.2. Inspect: Cooling fan grill 1 Cooli

5-26ENGINE COOLING FANENGNOTE:ESS00176INSTALLATION1. Install: Seal rubber 1 Cooling fan housing 2 Engine mounting bracket 3 Starter motor 42. Inst

5-27Order Job name/Part name Q’ty Remarks123456789Recoil starter removalExhaust assemblyRecoil starter assemblyNutSpecial washerDrive plateSpring seat

5-28RECOIL STARTERENGNOTE:ESS00178REMOVAL1. Remove: Starter handle 1 Ground lead 2To remove the starter handle, untie the knot 3in the starter rope

5-29RECOIL STARTERENGNOTE:NOTE:Low-temperature greaseNOTE:ESS00180INSTALLATION1. Hook the starter spring around the post in thestarter case. Carefully

5-30RECOIL STARTERENGNOTE:7. Install: Spring (drive plate) Spring seat Drive plate Special washer Washer Spring washer NutBe sure the cutout po

6-1Order Job name/Part name Q’ty Remarks123456Carburetor removalT.O.R.S. leadStarter cableThrottle cableOil pump cableFuel hoseClamp111112Remove the p

6-26Order Job name/Part name Q’ty RemarksCarburetor disassemblyThrottle switchStarter plungerFloat chamber coverFloatValve seat assemblyPilot jetMain

6-3CARBURETORCARBNOTE:NOTE:ESS00201INSPECTION1. Inspect: Carburetor body Fuel passageContamination  Clean. Use a petroleum based solvent for clean

6-4CARBURETORCARBNOTE:NOTE:6. Check: Throttle valve movementStick  Replace carburetor body.ESS00202ASSEMBLY Before reassembling, wash all parts in

1-6SPECIAL TOOLSGENINFO Rotor holding pullerP/N: YU-33270 (for U.S.A./Canada)90890-01362 (for Europe)This tool is used to remove the magneto rotor.

6-5CARBURETORCARBNOTE: If the float height is not within specification, in-spect the valve seat and needle valve. If either is worn, replace them bo

6-6Order Job name/Part name Q’ty Remarks1234Fuel pump removalFuel hoseFuel delivery hoseVacuum hoseFuel pump assembly1111Remove the parts in the order

6-7FUEL PUMPCARBNOTE:ESS00207INSPECTION1. Inspect: Fuel hose 1 Fuel delivery hoses 2 Vacuum hose 3Clogs/damage  Replace.2. Check: Fuel pump opera

7-17SWITCH INSPECTIONELECNOTE:ELECTRICALSWITCH INSPECTIONSWITCH INSPECTIONUse a pocket tester to check the terminals forcontinuity. If the continuity

7-224202223Main switchSpark plugIgnition coilCDI unitCDI magnetoEngine stop switchThrottle switchCarburetor switch10161719IGNITION SYSTEMELECIGNITION

7-3IGNITION SYSTEMELECCheck the spark plug gap.OUT OF SPECIFICATION Repair or replace the spark plug.Check the spark plug cap resistance.OUT OF SPECIF

7-4IGNITION SYSTEMELECSPARK PLUG CAP1. Remove:D Spark plug cap2. Connect:D Pocket tester(to the spark plug cap)3. Measure:D Spark plug cap resistanceO

7-5IGNITION SYSTEMELECWARNINGA B CStatusSwitchSPARK PLUG1. Remove: Spark plugs2. Measure: Spark plug gapStandard spark plug:BR9ES (NGK)Spark plug ga

7-6IGNITION SYSTEMELECHANDLEBAR SWITCH (RIGHT)Engine stop switch and throttle switch1. Disconnect: Handlebar switch (right) coupler2. Connect: Pocke

7-7IGNITION SYSTEMELECMAIN SWITCH1. Disconnect: Main switch coupler2. Connect: Pocket tester3. Check: Main switch continuityFaulty  Repalce.Switch

1-7SPECIAL TOOLSGENINFO Clutch separator adapterP/N: YS-34480 (for U.S.A./Canada)90890-01740 (for Europe)This tool is used when disassembling and as-

7-821Speedometer lightTachometer lightHeadlightTail/brake lightCDI magnetoVoltage regulator2351520Dimmer switch25LIGHTING SYSTEMELECLIGHTING SYSTEMCIR

7-9Check the bulb(s).NO CONTINUITY Replace the bulb(s).Check the headlight beam switch and lighting coil.FAULTY Replace the headlight beam switch and/

7-10LIGHTING SYSTEMELECabcWARNING1123abBULB(S)1. Remove:D Headlight bulb aD Tail/brake light bulb bD Meter light bulb c2. Connect:D Pocket tester(to t

7-1115Back buzzerGear position switchMain switchFuseBatteryTail/brake light1610111420CDI magneto21Voltage regulator26Brake light switchSIGNAL SYSTEMEL

7-12Check the tail/brake light bulb.NO CONTINUITY Replace the bulb.Check the brake light switch.FAULTY Replace the brake light switch.Check the main s

7-13Check the gear positon switch.FAULTY Replace the gear position switch.Check the lighting coil.OUT OF SPECIFICATION Replace the lighting coil.Check

7-14SIGNAL SYSTEMELEC1123TAIL/BRAKE LIGHT BULB1. Remove: Tail/brake light bulbTerminalContinuity – Yes – YesBRAKE LIGHT SWITCH1. Check: Brake light

7-15Thumb warmerGrip warmerGrip warmer switchCDI magneto78920GRIP WARMER SYSTEMELECGRIP WARMER SYSTEMCIRCUIT DIAGRAM

7-16Check the resistor.NO CONTINUITY Replace the resistor.Check the grip and thumb warmer.NO CONTINUITY Replace the grip warmer and/orthumb warmer.Che

7-17GRIP WARMER SYSTEMELECGRIP AND THUMB WARMER COIL1. Disconnect: Grip warmer leads 1 Thumb warmer coupler 22. Connect: Pocket tester(to the grip

1-8SPECIAL TOOLSGENINFO Electro testerP/N: YU-33260-A (for U.S.A./Canada)90890-03021 (for Europe)This instrument is invaluable for checking theelectr

7-18Starter relayBatteryStarter motor131418Fuse11Main switch10ELECTRICAL STARTING SYSTEMELECELECTRICAL STARTING SYSTEMCIRCUIT DIAGRAM

7-19STARTER MOTOR DOES NOT OPERATE.WARNINGBefore starter motor operation, push the “ENGINE STOP” switch to “OFF”.1. Connect: Starter relay terminals(

7-20Check the main switch, fuse and rectifier.Replace the main switch, fuse and/or rectifi-er.FAULTYCorrect connection.OKELECTRICAL STARTING SYSTEMELE

7-21Order Job name/Part name Q’ty RemarksStarter motor disassemblyRear coverBrush plateStarter yokeClipPinion gearFront cover111111Remove the parts in

7-22ELECTRICAL STARTING SYSTEMELECCAUTION:STARTER MOTORInspection1. Inspect: Commutator (outer surface)Dirty  Clean with #600 grit sandpaper 1.Hold

7-23ELECTRICAL STARTING SYSTEMELECNOTE:5. Measure: Brush length aOut of specification  Replace.Brush length limit a:8.5 mm (0.33 in)6. Measure: Bru

7-24FuseRectifire regulatorBatteryCDI magnetoVoltage regulator1112142021CHARGING SYSTEMELECCHARGING SYSTEMCIRCUIT DIAGRAM

7-251. Connect: Pocket tester(to battery terminals)2. Measure: Battery voltage Fluid gravity Check the battery. Replace and/or charge battery.OUT

7-26CHARGING SYSTEMELECBATTERYInspection1. Inspect:D Battery fluid levelBelow lower level  Refill.1Upper level2Lower level2. Check:D Specific gravity

8-18GENERAL SPECIFICATIONSSPEC9E001SPECIFICATIONSGENERAL SPECIFICATIONSModel VK540EModel code number: 8ACDimensions:Overall lengthOverall widthOverall

2-1INTRODUCTION/PERIODIC MAINTENANCE TABLEINSPADJESS00029PERIODIC INSPECTIONS AND ADJUSTMENTSESS00030INTRODUCTIONThis chapter includes all information

8-2GENERAL SPECIFICATIONSSPECModel VK540ETransmission:Primary reduction systemPrimary reduction ratioClutch typeSecondary reduction systemSecondary re

8-3MAINTENANCE SPECIFICATIONSSPECa9E011MAINTENANCE SPECIFICATIONSENGINEModelVK540ECylinder head:Volume (With spark plug)<Warp limit>30.2  30.8

8-4MAINTENANCE SPECIFICATIONSSPECModel VK540ECrankshaft:Crank width “A”Crank width “B”Crankshaft deflection “C”: C1C2, C3C4Measuring points: 12Connect

8-5MAINTENANCE SPECIFICATIONSSPECModel VK540EFuel pump:TypeManufacturerDIAPHRAMMIKUNIOil pump:Color codePlunger diameterWorm gear ratioMinimum strokeM

8-6MAINTENANCE SPECIFICATIONSSPECPOWER TRAINModelVK540ETransmission:TypeRange of ratioEngagement r/minShift r/minSheave center distance “A”Sheave offs

8-7MAINTENANCE SPECIFICATIONSSPECModel VK540ESecondary sheave spring:Part numberColor codeOutside diameterWire diameterTwist angleHole positionSheave

8-8MAINTENANCE SPECIFICATIONSSPECModel VK540EShock absorber:Damping force (Extension)FrontRearDamping force (Compression)FrontRear510 N/0.3 m/s(52 kg/

8-9MAINTENANCE SPECIFICATIONSSPECCHASSISModel8-9 VK540EFrame:Frame materialSeat heightLaggage box locationSteel713 mm (28.1 in)Under seatSteering:Lock

8-10MAINTENANCE SPECIFICATIONSSPECELECTRICALModelVK540EVoltage: 12 VIgnition system:Ignition timing (B.T.D.C.)17 (1.55 mm) at 7,000 r/minCDI:Magneto

8-11MAINTENANCE SPECIFICATIONSSPECModel VK540EFlywheel magneto:Model/manufacturerLighting voltage (minimum)Lighting coil resistance:(Color code)Chargi

2-2INTRODUCTION/PERIODIC MAINTENANCE TABLEINSPADJ2InitialEveryItem RemarksPre-operationcheck(Daily)1 monthor800 km(500 mi)(40 hr)Seasonallyor3,200 km(

8-12MAINTENANCE SPECIFICATIONSSPECHIGH ALTITUDE SETTINGSVK540E0  100 m(300 ft)100 600 m(2000 ft)600 1200 m(4000 ft)1200 1800 m(6000 ft)1800 2400

8-13MAINTENANCE SPECIFICATIONSSPECTIGHTENING TORQUEPart to be tightenedTightening torqueRemarksPart to be tightenedNm mSkg ftSlbRemarksCrankcase (Firs

8-14MAINTENANCE SPECIFICATIONSSPECNOTE:Part to be tightenedTightening torqueRemarksPart to be tightenedNm mSkg ftSlbRemarksSteering bearing holder (bo

8-15GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITSSPECGENERAL TORQUESPECIFICATIONSThis chart specifies torque for standard fasten-ers with standard

8-16CABLE ROUTINGSPEC

8-17CABLE ROUTINGSPEC1 Fasten the wire harness andspeedometer cable with a steelclamp.2 Ground lead3 Fasten the wire lead and wirenegative lead with a

8-18CABLE ROUTINGSPEC

8-19CABLE ROUTINGSPEC36 Battery37 Fuse box38 Secondary shaft (jackshaft)39 Battery positive lead40 Starter switch41 Carburetor42 Delivery hose43 Faste

8-20CABLE ROUTINGSPEC

8-21CABLE ROUTINGSPEC1 Engine stop switch couplerRoute the engine stop switchlead backward the handlebar.2 Thumb warmer coupler3 Clamp4 Route the thro

2-3SPARK PLUGSINSPADJNOTE:ESS00032ENGINEESS00033SPARK PLUGS1. Remove:S Spark plug capsS Spark plugs2. Inspect:S Electrodes 1Damage/wear  Replace the

8-22CABLE ROUTINGSPEC

8-23CABLE ROUTINGSPEC25 Fasten the wire wariness, fueltank breather hose and oil tankbreather hose with a plasticband.26 Oil tank27 Gear position swit

8-24CABLE ROUTINGSPEC

8-25CABLE ROUTINGSPEC1 Speedometer2 Back buzzer3 Headlight4 Tachometer (option)5 Set the clamp at the illustrated.6 Clamp the tachometer lead for amod

8-26CABLE ROUTINGSPEC

8-27CABLE ROUTINGSPEC1 Clamp on the frame2 Clamp in the cargo space3 Do not be loosen.4 Grommet5 GrommetRoute the tail/stop light lead intothe pipe.6

8-28CABLE ROUTINGSPEC

8-29CABLE ROUTINGSPEC1 Oil hose2 Joint3 Oil level hose4 Clip5 Hose protector6 Oil strainer7 Oil tank breather hose8 Oil tank9 Clamp on the oil tankAft

1 Back buzzer2 Speedometer light3 Tachometer light4 Tachometer5 Headlight6 Gear position switch7 Thumb warmer8 Grip warmer9 Grip warmer switch10 Main

WIRING DIAGRAMVK540E

2-4OIL PUMPINSPADJCAUTION:ESS00034OIL PUMPESS00035Air bleedingThe oil pump and oil delivery line must bebled in the following cases:S Any portion of t

2000. 05  1. E. ITPPRINTED IN U.S.A.PRINTED ON RECYCLED PAPER

2-5OIL PUMPINSPADJNOTE:10. Remove:S Bleed bolt 1S Gasket (bleed bolt)11. Drain the oil until no more air bubbles ap-pear from the bleed hole.12. Inspe

2-6OIL FILTER INSPECTION/ENGINE OIL LINE INSPECTIONINSPADJNOTE:OIL FILTER INSPECTION1. Remove:S Oil tank 12. Remove:S Oil filter 1Plug the oil hoses s

2-7FUEL LINE INSPECTION/FUEL FILTER INSPECTIONINSPADJESS00037FUEL LINE INSPECTION1. Inspect:S Fuel hose 1S Fuel delivery hoses 2S Vacuum hose 3Cracks/

2-8FUEL FILTER INSPECTIONINSPADJ5. Remove:S Seat 16. Remove:S Fuel lever indicator hose 1S Oil level indicator hose 2S Center cover 37. Remove:S Sprin

2-9COOLING FAN BELT TENSION ADJUSTMENTINSPADJNOTE:COOLING FAN BELT TENSION ADJUST-MENT1. Adjust:S Fan belt deflection aPushed at belt center by hand.O

2-10ENGINE IDLE SPEED ADJUSTMENT/THROTTLE CABLE FREEPLAY ADJUSTMENTINSPADJNOTE:NOTE:NOTE:ESS00044ENGINE IDLE SPEED ADJUSTMENT1. Adjust:S Engine idle s

2-11THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECKINSPADJWARNINGWARNINGESS00048THROTTLE OVERRIDE SYSTEM (T.O.R.S.)CHECKWhen checking T.O.R.S.:S Be sure the

2-12STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT/EXHAUST SYSTEM INSPECTIONINSPADJESS00050STARTER (CHOKE) CABLE FREEPLAY AD-JUSTMENT1. Pull back the start

WARNINGCAUTION:NOTE:ESS00002NOTICEThis manual was written by the Yamaha MotorCompany primarily for use by Yamaha dealersand their qualified mechanics.

2-13DRIVE V-BELTINSPADJWARNINGCAUTION:ESS00054POWER TRAINESS00055DRIVE V-BELT1. Remove:S Drive V-belt guard 1S Be sure there are shims (2 pcs) 1 betwe

2-14DRIVE V-BELTINSPADJ1ABCV-belt width Numberof spacers35 mm (1.38 in) or more 2 spacers34 mm (1.34 in) 1 spacer33 mm (1.30 in) No spacer32 mm (1.26

2-15DRIVE V-BELTINSPADJ5. Inspect:S Primary sheaveS Secondary sheaveOil or grease adhered to the primary andsecondary sheaves  Remove the oil orgreas

2-16SHEAVE DISTANCE AND OFFSET ADJUSTMENTINSPADJESS00055SHEAVE DISTANCE AND OFFSET ADJUST-MENT1. Measure:S Sheave distance aUse the sheave gauge.Out o

2-17SHEAVE DISTANCE AND OFFSET ADJUSTMENTINSPADJNOTE:Shim sizePart Number Thickness90201-252F1 0.5 mm (0.02 in)90201-25527 1.0 mm (0.04 in)90201-25526

2-18ENGAGEMENT SPEED CHECK/ADJUSTING THE BRAKEINSPADJNOTE:ESS00057ENGAGEMENT SPEED CHECK1. Place the machine on a level surface of hard-packed snow.2.

2-19BRAKE PAD INSPECTION/DRIVE CHAININSPADJWARNINGESS00062BRAKE PAD INSPECTION1. Apply the brake lever.2. Inspect:S Brake pad thickness aOut of specif

2-20DRIVE CHAININSPADJCAUTION:ESS00067Oil replacementOil replacement steps:S Place the oil pan under the drain hole 1.S Remove the oil drain bolt 2 an

2-21TRACK TENSION ADJUSTMENTINSPADJWARNINGCAUTION:NOTE:ESS00069TRACK TENSION ADJUSTMENTA broken track or track fittings, and debristhrown by the track

2-22TRACK TENSION ADJUSTMENT/SLIDE RUNNER INSPECTIONINSPADJ6 74545CAUTION:a. Start the engine and rotate the track once ortwice. Stop the engine.b. Ch

ESS00006ILLUSTRATED SYMBOLS(Refer to the illustration)Illustrated symbols 1 to 8 are designed asthumb tabs to indicate the chapter’s numberand conten

2-23SKI/SKI RUNNER/STEERING SYSTEMINSPADJESS00071CHASSISESS00072SKI/SKI RUNNER1. Check:S SkiS Ski runnerWear/Damage  Replace.Ski runner wear limit 1:

2-24STEERING SYSTEMINSPADJABCAUTION:ESS00075Toe-out adjustment1. Place the machine on a level surface.2. Check:S Ski toe-outPoint the skis forward.Out

2-25LUBRICATIONINSPADJWARNINGESS00076LUBRICATIONESS00077Brake lever, throttle lever and throttle cableend1. Lubricate the brake lever pivot, throttle

2-26ABALUBRICATIONINSPADJESS00078Front and rear suspension1. Use a grease gun to inject grease into thenipples 1 and ball joints 2.Recommended lubrica

2-27HEADLIGHT BEAM ADJUSTMENTINSPADJDSESS00079ELECTRICALESS00080HEADLIGHT BEAM ADJUSTMENT1. Place the machine on a level surface.2. Measure the distan

2-28BATTERY INSPECTIONINSPADJWARNINGCAUTION:ESS00081BATTERY INSPECTIONBattery electrolyte is dangerous; it containssulfuric acid and therefore is pois

2-29BATTERY INSPECTIONINSPADJCAUTION:CAUTION:3. Check:S Specific gravityLess than 1.280  Recharge battery.Charging current:1.4 amps/10 hrsSpecific gr

2-30FUSE INSPECTIONINSPADJNOTE:NOTE:WARNINGFUSE INSPECTION1. Remove:S Fuse 1S Spare fuse 22. Inspect:S FuseInspection:S Connect a pocket tester to the

2-31CARBURETOR TUNINGINSPADJCAUTION:CAUTION:ABCDEFGESS00083TUNINGESS00084CARBURETOR TUNINGThe carburetors are set at the factory to run attemperatures

2-32CARBURETOR TUNINGINSPADJCAUTION:NOTE:NOTE:ESS00066Mid-range and high speed tuningAdjustments are normally not required, but maysometimes be necess

187654INSPADJGENERAL INFORMATIONPERIODIC INSPECTIONS AND ADJUSTMENTSPOWER TRAINENGINECARBURETIONELECTRICALSPECIFICATIONSGENINFO23POWRTRENGCARBELECSPEC

2-33CARBURETOR TUNINGINSPADJCAUTION:ESS00088Guide for carburetion2E3011. Fuel flow chart:A guide to the fuel flow rate according to thethrottle openin

2-34CARBURETOR TUNINGINSPADJCAUTION:NOTE:ESS00089Low speed tuningThe carburetors are built so that low speed tun-ing can be done by adjusting the pilo

2-35CARBURETOR TUNINGINSPADJESS00090Main jet selection chartMain jet selection chartSpark plug color Diagnosis RemedyLight tan or gray Carburetors are

2-36CARBURETOR TUNINGINSPADJESS00091TroubleshootingTroubleDiagnosis AdjustmentHard startingInsufficient fuel Add gasoline.Excessive use ofthe starter

2-37CARBURETOR TUNINGINSPADJTrouble Diagnosis AdjustmentPoor performanceat high speeds:Starter valve is leftopenReturn the starter lever to its seated

2-38CLUTCHINSPADJABCDEFGHIJKLMNOPYXWVUTSRQESS00092CLUTCHESS00093High altitudeSpecifications Model: VK540ESSilver Y YellowL Blue W White ELEVATION 1,0

2-39CLUTCH/GEAR SELECTIONINSPADJThe clutch may require tuning depending uponwhere the machine will be operated and the de-sired handling characteristi

2-40GEAR SELECTIONINSPADJABC DEFGABABCDEFG HIABSeatSheaveIdentification markAB C DE1Chain and sprocket pat number Part name Teeth & links Part no

2-41Spring identification color codeSpring rate colorPreload colorACBGEAR SELECTIONINSPADJDE FGH IJKLAVK540EJBC DE FIAGH6Primary springParts No.Spring

2-42GEAR SELECTIONINSPADJAC DEBF9RollersI.D. 8 mm (0.3 in) ROLLER withBUSHING PARTNUMBER OUTSIDEDIAMETER BUSHINGTYPE (P/N) IDENTIFICATIONMARK (Width)

CHAPTER 1.GENERAL INFORMATIONMACHINE IDENTIFICATION 1-1. . . . . . . . . . . FRAME SERIAL NUMBER 1-1. . . . . . . . . . ENGINE SERIAL NUMBER 1-1. . .

2-43Test the main jet(performance & plug color)Test the low-speed settingTry high-altitude settingsDecide if the problem is with thepilot jet and

2-44REAR SUSPENSIONINSPADJABCAUTION:NOTE:aABESS00100REAR SUSPENSIONESS00101Stopper band1. Adjust:S Stopper band tensionMake sure the left and right si

2-45REAR SUSPENSIONINSPADJABCAUTION:Extension spring preload1. Adjust:S Extension spring preloadAdjusterTurn in Turn outPreload Harder SofterSnow Cond

2-46REAR SUSPENSIONINSPADJCAUTION:NOTE:CAUTION:CAUTION:ESS00103Rear suspension-full rate1. Adjust:S Full rate adjusterAdjustment steps:S Loosen the nu

2-47REAR SUSPENSIONINSPADJNOTE:This model has a “Easy adjust” system for theFull rate adjuster. The bolt has teeth on it. Sowhen the bolt is turned, i

3-13Order Job name/Part name Q’ty Remarks12345Handlebar removalSteering pad (rear)Steering pad (front)Handlebar holder (upper)HandlebarHandlebar holde

3-2STEERINGCHASOrder Job name/Part name Q’ty Remarks1234567Steering column and tie rod removalHandlebarCotter pinRelay rodTie rodLock washerBearing ho

3-3STEERINGCHASWARNINGWARNINGESS00106INSPECTION1. Inspect: Handlebar 1 Steering column 2Bends/cracks/damage  Replace.Do not attempt to straighten a

3-4STEERINGCHASNOTE:CAUTION:CAUTION:NOTE:ESS00107INSTALLATION1. Install: Tie-rod 1 Relay rod 2 Install the rod end 3 with the left-hand threadonto

3-5STEERINGCHASabcdCAUTION:CAUTION:4. Adjust: SkisAdjustment steps: Temporarily install the handlebar. Hold the handlebar straight and check thatth

FRONT SUSPENSION 3-8. . . . . . . . . . . . . . . . HANDLING NOTES 3-9. . . . . . . . . . . . . . . . INSPECTION 3-9. . . . . . . . . . . . . . . . .

3-6Order Job name/Part name Q’ty Remarks12345Ski removalCotter pinSki stopperCollarSkiSki runner11111Remove the parts in the order listed below.For in

3-7SKICHASESS00109INSPECTION1. Inspect: Ski 1 Ski runner 2 Ski stopper 3Wear/cracks/damage  Replace. Mounting bolt 4 Collar 5Wear/damage  Repla

3-8Order Job name/Part name Q’ty Remarks1234567891011Front suspension removalSKICotter pinFront arm (lower)Front arm (upper)Flange nutSet screwSuspens

3-9FRONT SUSPENSIONCHASWARNINGESS00112HANDLING NOTESThis shock absorber contains highly com-pressed nitrogen gas. Befor handling theshock absorber rea

3-10FRONT SUSPENSIONCHASCAUTION:NOTE:4. Inspect: SpringWear/cracks/damage  Replace.5. Measure: Spring free length aOut of specification  Replace.S

3-11FRONT SUSPENSIONCHASNOTE:NOTE:CAUTION:3. Tighten:Suspension bracket nut:43 Nm (4.3 mkg, 31 ftlb)Set screw:2 Nm (0.2 mkg, 1.4 ftlb)LOCTITEInst

4-1Order Job name/Part name Q’ty Remarks123Primary sheave removalV-beltBlind capPrimary sheave assembly111Remove the parts in the order listed below.F

4-24PRIMARY SHEAVE AND DRIVE V-BELTPOWRTROrder Job name/Part name Q’ty RemarksPrimary sheave disassemblyPrimary sheave capPrimary sheave springCollarR

4-3PRIMARY SHEAVE AND DRIVE V-BELTPOWRTRNOTE:ESS00119REMOVAL1. Remove: Drive V-belt guard Drive V-belt Grommet 12. Remove: Primary sheave assembly

4-4PRIMARY SHEAVE AND DRIVE V-BELTPOWRTRNOTE:CAUTION:ESS00120DISASSEMBLY1. Remove:D Fixed sheave 1D Stopper 2D Sliding sheave 3D Bushing 4D Spider 5Re

CHAPTER 7.ELECTRICALSWITCH INSPECTION 7-1. . . . . . . . . . . . . . . . SWITCH INSPECTION 7-1. . . . . . . . . . . . . INSPECTING A SWITCH SHOWN INTH

4-5PRIMARY SHEAVE AND DRIVE V-BELTPOWRTRA BNOTE:ESS00121INSPECTION1. Inspect: Spider 1 Sliding sheave 2 Fixed sheave 3 Primary sheave cap 4Cracks/

4-6A BPRIMARY SHEAVE AND DRIVE V-BELTPOWRTRNOTE:6. Inspect: Weight 1 Roller 2 Bushing 3 Slider 4 Rivet 5 CollarWear/scratches/damage  Replace.S

4-7PRIMARY SHEAVE AND DRIVE V-BELTPOWRTRNOTE:NOTE:CAUTION:NOTE:NOTE:ESS00122ASSEMBLY1. Install: Sliding sheave (onto the spider)Be sure the sliding s

4-8PRIMARY SHEAVE AND DRIVE V-BELTPOWRTRCAUTION:WARNINGNOTE:NOTE: Tighten the spider to specification using theclutch spider separator (bar wrench) 3

4-9PRIMARY SHEAVE AND DRIVE V-BELTPOWRTRCAUTION:ESS00123INSTALLATION1. Install: Primary sheave assemblyBe sure to remove any oil or grease from theta

4-10Order Job name/Part name Q’ty Remarks12345Secondary sheave removalV-beltSecondary shaft (jackshaft)WasherShimSecondary sheave assembly111–1Remove

4-11SECONDARY SHEAVEPOWRTROrder Job name/Part name Q’ty RemarksSecondary sheave disassemblyCirclipWasherSpring seatSecondary springSliding sheaveShimF

4-12SECONDARY SHEAVEPOWRTRWARNINGESS00125DISASSEMBLY Use extreme CAUTION when disassem-bling the secondary sheave since seriousinjury can occur due t

4-13SECONDARY SHEAVEPOWRTRESS00126INSPECTION1. Inspect: Sliding sheave 1 Fixed sheave 2 Spring seat 3 Shims 4Cracks/damage  Replace.2. Inspect:

4-14SECONDARY SHEAVEPOWRTRNOTE:NOTE:ESS00127ASSEMBLY1. Install:D Secondary sheave spring 1D Spring seat 2Hook the end of the secondary sheave springin

4-15SECONDARY SHEAVEPOWRTRESS00128INSTALLATION1. Lubricate: Splines (fixed sheave)Recommended grease:Esso beacon 325 grease orAeroshell grease #7A2.

4-16Order Job name/Part name Q’ty Remarks123Drive chain housing removalBrake caliperDrain boltBoltDrive chain housing assembly141Remove the parts in t

4-17DRIVE CHAIN HOUSINGPOWRTROrder Job name/Part name Q’ty RemarksDrive chain housing disassemblyShift link leverChain tensioner adjusterChain housing

4-18DRIVE CHAIN HOUSINGPOWRTRNOTE:CAUTION:CAUTION:ESS00133INSPECTION1. Inspect: Drive chain housing 1 Drive chain housing cover 2Cracks/damage  Rep

4-19DRIVE CHAIN HOUSINGPOWRTR3. Inspect: Shift forks 1On the gear and shift cam contact surfaces.Wear/chafing/bends/damage  Replace.4. Check: Shift

4-20DRIVE CHAIN HOUSINGPOWRTR11. Inspect: Axle bearings Shift cam bearingPitting/damage  Replace.12. Inspect: Shift linkage levers 1 Spacer 2 To

4-21DRIVE CHAIN HOUSINGPOWRTRNOTE:14. Measure: 14 link section a of the drive chainUsing a spring scale, pull on the drive chainwith 36 kg (80 lbs) o

4-22DRIVE CHAIN HOUSINGPOWRTRESS00134INSTALLATION1. During installation, pay attention to the fol-lowing.AMake sure that the bearing seals face toward

4-23Order Job name/Part name Q’ty Remarks123Secondary shaft (jackshaft) removalV-beltSecondary shaft (jackshaft)Secondary sheave111With secondary shea

4-24SECONDARY SHAFT (JACKSHAFT)POWRTROrder Job name/Part name Q’ty RemarksSecondary shaft (jackshaft)disassemblySecondary sheaveCirclipBearing housing