Target Audience:
DIY enthusiasts, independent repair shops, and owners seeking to maintain and repair their 2004 Yamaha 700cc snowmobiles.
Value Proposition:
Provides comprehensive, step-by-step procedures and detailed diagrams, enabling accurate and efficient maintenance and repair, saving on labor costs.
Advantage:
Offers direct access to factory-level repair information, which is crucial for proper servicing of these performance-oriented snowmobiles.
Organization:
Sequential, step-by-step format with exploded diagrams enhances usability and clarity.
Completeness:
Aims to provide a handy reference for all disassembly, repair, assembly, and inspection operations.
Engine Mechanical:
Complete disassembly, inspection, repair, and assembly of the 700cc 2-stroke engine (cylinder, piston, crankshaft, connecting rods, lubrication system, cooling system).
Fuel System:
Carburetor identification, adjustment, and overhaul (Mikuni VM34/VM38 series), fuel pump, fuel lines, fuel filter.
Ignition System:
CDI unit, ignition coils, spark plugs, troubleshooting of electrical faults related to ignition.
Exhaust System:
Exhaust pipes, silencer, gaskets, inspection and replacement.
Cooling System:
Coolant specifications, radiator, fan, thermostat, hoses, leak testing, flushing and refilling procedures.
Drive System Clutching:
Primary drive clutch (drive and driven components), secondary clutch (drive and driven components), belt inspection, replacement, and clutch alignment.
Suspension Front:
Front suspension system (trailing arm design), shock absorbers, springs, bushings, lubrication, and replacement.
Suspension Rear:
Rear suspension system (ProAction TSS or similar), shock absorbers, torque arm, idler wheels, skis, slides, lubrication, and replacement.
Steering System:
Handlebars, steering post, tie rods, spindle, wear bars, lubrication, and adjustment.
Brakes:
Hydraulic disc brake system, brake caliper, master cylinder, brake pads, brake fluid specifications, bleeding procedure, and rotor inspection.
Electrical System Lighting:
Headlights, taillights, brake lights, instrument cluster illumination, wiring diagrams, bulb specifications.
Electrical System Starting:
Electric starter motor, starter solenoid, battery specifications, charging system (stator/alternator), troubleshooting.
Body Chassis:
Hood, seat, tunnel, skis, track, body panels, fastener torque specifications, minor bodywork repair guidance.
Track System:
Track inspection, tension adjustment, and replacement.
Maintenance:
Scheduled maintenance tasks, pre-ride inspections, post-ride care, lubrication points, adjustments.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides.
Disassembly Assembly:
Step-by-step instructions for dismantling and reassembling all major components and systems.
Inspection:
Detailed inspection points for wear, damage, and proper function of all parts.
Replacement:
Instructions for replacing wear items and components like belts, brakes, bearings, and shocks.
Depth:
Comprehensive. Covers routine maintenance, diagnostics, component-level repair, and complete system overhauls.
Diagrams:
Includes exploded diagrams for easy identification of parts and correct disassembly/assembly sequences.
Torque Specs:
Provides essential torque specifications for critical fasteners.
Electrical Diagrams:
Likely includes wiring diagrams for troubleshooting the electrical system.
Engine Type:
700cc, 2-stroke, 3-cylinder (liquid-cooled)
Bore X Stroke:
69.5 mm x 64.0 mm (typical for this era's 700cc triple)
Carburetion:
Triple Mikuni VM34/VM38 carburetors (specific model may vary slightly by trim)
Reed Valve System:
Yes, typically with a reed valve block for intake.
Compression Ratio:
Approximately 7.0:1 (varies with altitude and specific tuning)
Horsepower Est:
120-130 HP (estimated peak output)
Torque Est:
85-90 lb-ft (estimated peak torque)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Injection:
Yamaha's Automatic Oil Injection (AOI) system
Oil Type Injection:
Yamaha Premium 2-M (or equivalent 2-stroke injector oil)
Oil Injection System:
Check oil level before each ride; refill as needed. Periodic flushing/cleaning of the system may be recommended by the manual.
Drive Belt:
Inspect for wear and damage every 500 miles or annually. Replace as needed based on condition.
Spark Plugs:
Inspect and gap every 1,000 miles or annually. Replace as needed.
Chaincase Oil:
Change chaincase oil every 2,000 miles or annually. Refer to manual for specific oil type and capacity.
Carburetor Cleaning:
Recommended annually or as needed if performance issues arise.
Engine Oil:
Yamaha Premium 2-M (or equivalent TCW-3 certified 2-stroke injector oil)
Coolant:
Ethylene glycol-based antifreeze (50/50 mix with distilled water) with corrosion inhibitors. Refer to manual for specific Yamaha blend.
Chaincase Oil:
Yamalube Gear Oil GL-4 SAE 80W or equivalent.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (ensure compatibility with seals).
Crank Seals:
Premature failure of crank seals can lead to air leaks and engine performance issues. Regular inspection is advised.
Clutch Alignment:
Improper clutch alignment can lead to premature belt wear and overheating. Requires specialized tools for accurate adjustment.
Exhaust Pipe Cracks:
Cracks can develop in the exhaust manifold or pipes due to vibration and thermal stress. The manual will guide inspection and repair.
Carburetor Icing:
In very cold and humid conditions, carburetors can be prone to icing. The manual may offer tips for mitigation.
