Yamaha VX500SXBC Service Manual

SUPPLEMENTARY SERVICE MANUAL

–6–CLUTCHINSPADJABCDEFGHIJKLMNOPQRSTUVWXZYabSee MAINTENANCE SPECIFICATIONS(High altitude settings)dW white S Silver L BlueP Pink R Red O OrangeY Yello

–7–CLUTCHINSPADJ2E331The clutch may require tuning dependingupon the area of operation and desired han-dling characteristics. The clutch can betuned b

–8–GEAR SELECTIONINSPADJNOTE:A B C DEFGDriven gearDrive gearBAGEAR SELECTIONThe reduction ratio of the driven gear to thedrive gear must be set accord

–9–GEAR SELECTIONINSPADJABCDE FGASheaveSeatBA B C3Secondary springParts No.Spring rateNSmm/rad(kgmm/ rad)No. ofcoilsColorWiregauge(mm)Freelength(mm)St

–10–GEAR SELECTIONINSPADJAE HBCDFGI6Primary springParts No.Spring rateN/mm(kg/ mm)Preload(kg)ColorWiregauge(mm)Outsidediameter(mm)No. ofcoilsFreelengt

–11–FRONT SUSPENSIONINSPADJCAUTION:aCAUTION:FRONT SUSPENSIONSpring preload (700)1. Adjust:S Turn the adjusting ring 1 to the properposition.Spring adj

–12–ABREAR SUSPENSIONINSPADJCAUTION:NOTE:ABREAR SUSPENSIONStopper band1. Adjust:S Stopper band tensionBe sure that the left and right length is thesam

–13–ABREAR SUSPENSIONINSPADJAaBbSpring preload (500)1. Adjust:S Turn the spring seat 1 in or out.Spring seatdistanceStandardShorter z! LongerPreload H

–14–SKICHASOrder Job name/Part name Q’ty Remarks123456789Ski removalCotter pinSki column lower bracketSki stopperCollarWashersSkiSki runnerWashersSki

–15–SKI/FRONT SUSPENSIONCHASINSPECTION1. Inspect:S Ski 1S Ski runner 2S Ski column lower bracket 3S Ski handle 4S Ski stopper 5Wear/cracks/damage ! Re

CAUTION:NOTE:FOREWORDThis Supplementary Service Manual hasbeen prepared to introduce new service andnew data for the VX500SXBC, VX700ERC.For complete

–16–FRONT SUSPENSIONCHASCaHIF BDHICaHIF BEHINOTE:INSTALLATION1. Install:S Control rod 1S Nut 2S Joint 3aSet lengthLeft handModelSet length(mm)Setangle

–17–SECONDARY SHEAVEPOWRTRNOTE:NOTE:ASSEMBLY1. Install:S Secondary sheave spring 1S Bolts 2(along with the shims)Bolt:10 Nm (1.0 mSkg, 7.2 ftSlb)2. In

–18–Order Job name/Part name Q’ty Remarks12345678910Drive chain housing removalBrake caliperParking brakeTension adjusterBoltDrive chain housing cover

–19–DRIVE CHAIN HOUSINGPOWRTRINSTALLATIONDuring installation, pay attention to the fol-lowing point:AMake sure that the bearing seals face towardsthe

–20–DRIVE CHAIN HOUSINGPOWRTRDRIVE CHAIN HOUSING AND JACKSHAFTINSTALLATION1. Install:S Drive chain housingS JackshaftInstallation steps:D Install the

–21–Order Job name/Part name Q’ty Remarks123456789Drive chain housing removalBatteryBattery bracketBrake caliperParking brakeTension adjusterJointsShi

–22–OrderJob name/Part name Q’ty Remarks10111213141516171819202122232425262728Reverse drive gearSpringChain tensionerRollerCollarSpringJournalReverse

–23–DRIVE CHAIN HOUSING/JACKSHAFTPOWRTRINSTALLATIONDuring installation, pay attention to the fol-lowing point:AProperly install the rubber seal onto t

–24–Order Job name/Part name Q’ty RemarksBrake caliper disassemblyCap boltRetaining pinPad springBrake padsShim 1Shim 2Bleed screwsOil sealsPistons111

–25–BRAKEPOWRTRCAUTION:NOTE:NOTE:Disc brake components rarely require disas-sembly. DO NOT:D Disassemble components unless abso-lutely necessary.D Use

13579172024818623261921 2224 2514 15 1611 12 13OE031ILLUSTRATED SYMBOLS(Refer to the illustration)Illustrated symbols 1 to 9 are designed asthumb tabs

–26–BRAKEPOWRTRNOTE:2. Install:S Brake padsS Pad springInstallation steps:S Connect a suitable hose 1 tightly to thecaliper bleed screw 2. Put the oth

–27–Order Job name/Part name Q’ty Remarks1234Slide rail suspension removalTension adjusterBlind capsBoltsWasherSlide rail suspension2621Remove the par

–28–Order Job name/Part name Q’ty RemarksSlide rail suspension disassemblyStopper bandsHooksBushingsCollarsFront shock absorberRubber damperFront susp

–29–Order Job name/Part name Q’ty RemarksSuspension wheelsCollarWheel bracketsCirclipsSuspension wheelsBushingsShaftRear suspension bracketSpacersBush

–30–Order Job name/Part name Q’ty RemarksRear shock absorberBushingsCollarPull rodCollarsBushingsCollarsSuspension wheelsControl rodsBushingsScrewBush

–31–Order Job name/Part name Q’ty RemarksRear pivot armBushingsCollarCollarRear pivot arm bracketCollarCirclipsSuspension wheelsWheel bracketRear axle

–32–AB102 mm(4.0157 in)123 mm(4.84 in)102 mm(4.0157 in)43.1 mm(1.70 in)27 mm(1.06 in)201.4 mm(7.93 in)60 mm(2.36 in)123 mm(4.84 in)132.6 mm(5.22 in)16

–33–Order Job name/Part name Q’ty Remarks12345678Engine removalExhaust pipeCarburetorRecoil starterWater pumpPrimary sheaveCoolant hoseOil hosesOil pu

–34–Order Job name/Part name Q’ty Remarks12345678910Engine removalExhaust pipeCarburetorRecoil starterCDI Magneto rotorFrame cross memberPrimary sheav

–35–CCYLINDER HEAD AND CYLINDERENGNOTE:CYLINDER HEAD AND CYLINDERINSPECTION1. Measure:S Piston-to-cylinder clearanceMeasurement steps:1st step:S Measu

CONTENTSGENERAL INFORMATION 1. . . . . . . . . . . . . . MACHINE IDENTIFICATION 1. . . . . . . . . FRAME SERIAL NUMBER 1. . . . . . . ENGINE SERIAL NU

–36–PCYLINDER HEAD AND CYLINDERENG2nd step:S Measure the piston skirt diameter “P”with a micrometer from distance a.a500: 25 mm (0.98 in)700: 15 mm (0

–37–HEAT EXCHANGERCOOL12COOLING SYSTEMHEAT EXCHANGER1. Measure:S Filler cap opening pressureCap opens at pressure below the speci-fied pressure ! Repl

–38–Order Job name/Part name Q’ty Remarks1234567Carburetors removalAir chamberClamp screwsThrottle cableCarburetor switch (T.O.R.S.) leadsStarter cabl

–39–Order Job name/Part name Q’ty Remarks123456789Carburetors removalSpark plug capsClamp screwsCarburetor switch (T.O.R.S.) leadsClampCoolant hosesTh

–40–Order Job name/Part name Q’ty RemarksCarburetor separationCoolant hosesStarter cable holderCollarSpringScrewStarter rodSpringStarter leversBreathe

–41–CARBURETORSCARBNOTE:ASSEMBLY1. Measure:S Float height aOut of specification ! Adjust.Float height:50022.3 ± 2.0 mm(0.878 ± 0.080 in)70013.3 ± 2.0

–42–GENERAL SPECIFICATIONSSPECSPECIFICATIONSGENERAL SPECIFICATIONSModel VX500SXB VX700ERModel code number: 8CT 8DYDimensions:Overall lengthOverall wid

–43–GENERAL SPECIFICATIONSSPECModel VX500SXB VX700ERCarburetor:Type/quantityManufacturerTM36 2MIKUNITM33 3zSpark plug:TypeManufacturerGapBR9ESNGK0

–44–MAINTENANCE SPECIFICATIONSSPECaMAINTENANCE SPECIFICATIONSENGINEModel VX500SXB VX700ERCylinder head:Volume (with spark plug)<Warp limit>50070

–45–MAINTENANCE SPECIFICATIONSSPEC500 700Model VX500SXB VX700ERCrankshaft:Crank width “A”Crank width “B”Crankshaft deflection “C” : C1500: C2, C3500:

–1–500700MACHINE IDENTIFICATION/IMPORTANT INFORMATIONGENINFONOTE:1E001GENERAL INFORMATIONMACHINE IDENTIFICATIONFRAME SERIAL NUMBERThe frame serial num

–46–MAINTENANCE SPECIFICATIONSSPECModel VX500SXB VX700ERCarburetor:Type/QuantityManufacturerI.D. markMain jet (M.J)Main air jet (M.A.J)Pilot jet (P.J)

–47–MAINTENANCE SPECIFICATIONSSPECModel VX500SXB VX700ERThermostat:Opening temperatureValve lift50 X 55_C(122_F X 132_F)8 mm/70_C (159_F)zz

–48–MAINTENANCE SPECIFICATIONSSPECPOWER TRAINModelVX500SXB VX700ERTransmission:TypeRange of ratioEngagement r/minShift r/minSheave center distance “A”

–49–MAINTENANCE SPECIFICATIONSSPECModel VX500SXB VX700ERRivet:OuterPart numberMaterialSizeQuantityHole quantityInnerPart numberMaterialSizeQuantityHol

–50–MAINTENANCE SPECIFICATIONSSPECModel VX500SXB VX700ERTrack:Part numberWidthLengthPitchNumber of linksHeight “B”Deflection at 10 kg (22 lb)8AB-47110

–51–MAINTENANCE SPECIFICATIONSSPECModel VX500SXB VX700ERShock absorber: Damping forceFrontExtensionCompressionRearExtensionCompression3,320N ± 460N/0.

–52–MAINTENANCE SPECIFICATIONSSPECCHASSISModelVX500SXB VX700ERFrame:Frame materialSeat heightLuggage box locationAluminum685 mm (26.8 in)Rear side of

–53–MAINTENANCE SPECIFICATIONSSPECELECTRICALModelVX500SXB VX700ERVoltage: 12 V zIgnition system:Ignition timing (B.T.D.C.)Advanced timing (B.T.D.C.)Ad

–54–MAINTENANCE SPECIFICATIONSSPECModel VX500SXB VX700ERRectifier/regulator:Model/manufacturerNo load regulated voltage ACDC8CR-00/MATSUSHITA13.8 X 14

–55–MAINTENANCE SPECIFICATIONSSPECTempera-tureAltitudeNOTE:JN: 2 (STD) JN: 1.5 JN: 1 JN: 0.5Clip0.4 mm shimHigh altitude settingsVX500SXB–40_C –29_C –

–2–DRIVE V-BELTINSPADJCAUTION:NOTE:POWER TRAINDRIVE V-BELTWhen installing the new V-belt, make surethat it is positioned within the specified dis-tanc

–56–MAINTENANCE SPECIFICATIONSSPECTempera-tureAltitudeNOTE:JN: 2 (STD) JN: 1.5 JN: 1 JN: 0.5Clip0.4 mm shimHigh altitude settingsVX700ER–40_C –29_C –1

–57–MAINTENANCE SPECIFICATIONSSPECTightening torque:Parts to be tightenedTightening torqueRemarksParts to be tightenedNm mSkg ftSlbRemarksCrankcase (f

–58–MAINTENANCE SPECIFICATIONSSPECParts to be tightenedTightening torqueRemarksParts to be tightenedNm mSkg ftSlbRemarksSliding frame and slide runner

–59–MAINTENANCE SPECIFICATIONSSPEC

–60–CABLE ROUTINGSPECCABLE ROUTING<500>

–61–CABLE ROUTINGSPEC1 Oil pump cable2 Throttle cable3 Fasten the wire harness.Do not fasten the throttlecable and oil pump cable.4 Fasten the throttl

–62–CABLE ROUTINGSPEC

–63–CABLE ROUTINGSPEC35 To the conduction36 Voltage regulator37 Rectifire regulator38 Fasten the wire harness witha plastic clamp.39 Rectifire regulat

–64–CABLE ROUTINGSPEC30_

–65–CABLE ROUTINGSPEC1 Wire lead (electrical startermodel)2 Carburetor switch coupler3 Fasten the throttle cable andoil pump cable with a plasticclamp

–3–DRIVE V-BELTINSPADJ2. Adjust the position of the V-belt by re-moving or adding a spacer 1 on eachadjusting bolt 2.V-belt height adjustmentTo move V

–66–30_CABLE ROUTINGSPEC

–67–CABLE ROUTINGSPEC32 Solenoid coupler(ECC model)33 Ignition coil34 Carburetor heating lever35 Coolant hose36 Speedometer cable37 Fasten the throttl

–68–CABLE ROUTINGSPEC

–69–CABLE ROUTINGSPEC1 Make sure that the oil tankcap and oil breather hose donot touch each other.2 Route the fuel breather hosealong the upper of th

–70–CABLE ROUTINGSPECCABLE ROUTING<700>

–71–CABLE ROUTINGSPEC1 Oil pump cable2 Throttle cable3 Do not fasten the throttlecable and oil pump wire witha plastic clamp.4 Thumb warmer coupler5 E

–72–CABLE ROUTINGSPEC

–73–CABLE ROUTINGSPEC37 DC back buzzer (reversemodel)38 Voltage regulator39 Rectifier regulator40 DC back buzzer coupler41 Fasten the wire harness wit

–74–CABLE ROUTINGSPEC

–75–CABLE ROUTINGSPEC1 Fasten the carburetor switch,water temperature sensorlead, coolant hose, wire leadand battery negative leadwith a plastic clamp

–4–BRAKE PAD INSPECTION/SLID RUNNER INSPECTIONINSPADJBRAKE PAD INSPECTION1. Apply the brake lever.2. Inspect:S Brake padWear indicator 1 nearly contac

–76–CABLE ROUTINGSPEC

–77–CABLE ROUTINGSPEC1 Wire harness2 50 mm (1.97 in)3 Make sure that the oil tankcap and oil breather hose donot touch each other.4 Route the fuel bre

1 CDI magneto2 Rectifier / regulator3 Starter relay / fuse4 Battery5 Starter motor6 Main switch7 Engine stop switch8 Throttle switch9 Carburetor switc

1 CDI magneto2 Rectifier / regulator3 Starter relay / fuse4 Battery5 Starter motor6 Main switch7 Engine stop switch8 Throttle switch9 Carburetor switc

PRINTED IN USA(ੑ)PRINTED ON RECYCLED PAPER

–5–CLUTCHINSPADJABCDEFGHIJKLMNOPQRSTUVWXZYabdTUNINGCLUTCHHigh altitudeWWhite S Silver L BlueP Pink R Red O OrangeY Yellow G GreenSpecifications Model