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Manual Coverage
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Systems Covered
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Engine Systems:
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Engine disassembly, assembly, inspection, lubrication, cooling, ignition, fuel delivery (carburetion), exhaust
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Drivetrain Systems:
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Clutch operation, drive clutch, driven clutch, chain case, final drive, track system
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Chassis Systems:
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Frame inspection, suspension components (front and rear), skis, steering system, brakes
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Electrical Systems:
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Wiring diagrams, ignition system, lighting, starter, charging system, battery, instruments
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Procedures Included
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Maintenance Procedures:
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Scheduled maintenance, fluid checks and changes, lubrication points, filter replacement, spark plug service
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Repair Procedures:
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Engine rebuild, transmission repair, clutch adjustments, suspension component replacement, brake caliper service, electrical component troubleshooting
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Diagnostic Procedures:
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Troubleshooting guides for common issues, diagnostic flowcharts, electrical system testing
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Assembly Disassembly:
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Step-by-step instructions for disassembling and reassembling all major components and systems.
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Inspection Adjustments:
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Detailed procedures for inspecting components for wear or damage and making necessary adjustments (e.g., chain tension, carburetor synchronization).
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Technical Depth
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Diagnostic Level:
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Advanced diagnostics, including electrical system troubleshooting and engine performance analysis
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Rebuild Level:
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Complete engine and component rebuild procedures
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Wiring Diagrams Coverage:
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Detailed, full-color wiring diagrams for all electrical systems, crucial for troubleshooting electrical faults.
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Specifications Tables:
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Comprehensive tables for torque specifications, clearances, fluid capacities, and electrical component resistance values.
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Engine Specifications
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Primary Engine
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Engine Type:
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2-stroke, liquid-cooled, reed valve, parallel twin cylinder (typical for this era and Yamaha models)
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Engine Details
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Displacement Mm600:
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Approximately 593cc (based on model designation, specific bore/stroke not provided)
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Displacement Mm700:
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Approximately 698cc (based on model designation, specific bore/stroke not provided)
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Bore Stroke Estimation:
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Specific bore and stroke dimensions are critical for engine rebuilds and are contained within the manual.
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Performance
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Horsepower Estimation Mm600:
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Estimated 90-100 HP (typical for 600cc class 2-stroke snowmobiles of the late 90s/early 2000s)
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Horsepower Estimation Mm700:
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Estimated 100-115 HP (typical for 700cc class 2-stroke snowmobiles of the late 90s/early 2000s)
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Torque Estimation:
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Torque figures for critical engine components are provided for proper assembly.
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Fuel System
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Fuel Delivery:
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Carbureted (likely Mikuni or Keihin constant velocity carburetors, specific sizes not provided in product info)
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Carburetor Details:
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The manual will detail specific carburetor models, jetting, needle settings, and float bowl adjustments.
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Lubrication
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Oil System:
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Oil injection system (likely oil-injected 2-stroke)
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Maintenance
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Service Intervals
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Spark Plug Replacement:
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Typically recommended every 1,000-2,000 miles or annually, specific plug types and gap settings are detailed in the manual.
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Drive Belt Inspection:
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Regular inspection for wear, cracks, and proper tension. Replacement intervals vary based on usage, but typically every 2,000-4,000 miles or when wear is evident.
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Engine Oil Change Frequency:
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While 2-stroke, engine internal lubrication relies on oil injection, with checks on oil pump operation.
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Suspension Greasing:
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Lubrication points for suspension arms, spindles, and bushings are specified.
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Chain Case Oil Change:
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Recommended every 2,000 miles or annually, critical for drivetrain longevity.
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Fluid Specifications
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Coolant Type:
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Proprietary Yamaha coolant or equivalent ethylene glycol-based antifreeze mixture (specific ratio and type detailed in manual).
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Chain Case Oil:
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Yamaha Gear Oil 10W-40 or equivalent (specific viscosity and capacity detailed in manual).
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2-Stroke Oil:
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Yamalube 2R or approved NMMA TC-W3 certified 2-stroke oil (critical for proper lubrication and engine longevity).
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Known Issues
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Drive Clutch Wear:
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Common for high-mileage sleds; requires inspection and potential recalibration or replacement of rollers, buttons, and springs.
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Carburetor Cleaning:
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Periodic cleaning and adjustment of carburetors is often necessary for optimal fuel-air mixture and performance, especially after storage.
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Track Tension:
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Maintaining correct track tension is crucial for proper function and longevity of the track and suspension components.
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Exhaust System Maintenance:
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De-carbonization of exhaust ports and muffler is often required for optimal performance.
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