1994–2001 Yamaha VMAX/Venture 500/600, VX700SX & MM600/MM700 Snowmobile Service Manual Set

This Yamaha service manual set combines the early VMAX 500/600 base manual, two supplements, and a later VX/VT/MM service manual for the 1994–2001 listing. Coverage extends to the specified Venture, VX700SX, MM600, and MM700 models; each publication has its own model-specific procedures and specifications.

• Engine repair: Engine removal, crankcase separation, crankshaft inspection, piston and cylinder measurements, reed-valve inspection, and recoil starter service.

• Carburetion: Mikuni carburetor disassembly, synchronization, fuel-level adjustment, throttle position sensor testing, and electronically controlled carburetor diagnosis.

• Cooling and lubrication: Coolant replacement, pressure checks, thermostat inspection, heat exchanger removal, water pump service, and oil pump bleeding.

• Powertrain: Primary and secondary sheave overhaul, drive V-belt positioning, clutch tuning, gear selection, chain housing service, jackshaft repair, and reverse gear procedures.

• Brakes: Mechanical caliper service in the early manual, plus hydraulic caliper and master cylinder inspection, pad replacement, and bleeding in the later manual.

• Chassis: Steering adjustment, front suspension service, slide rail suspension disassembly, track alignment, front axle removal, and suspension setup.

• Electrical troubleshooting: Starting, charging, ignition, lighting, warning circuits, and grip warmer tests, supported by circuit diagrams and model-specific wiring diagrams.

This set is suited to mechanics familiar with two-stroke snowmobile service and equipped for clutch disassembly and electrical testing.

Engine Overhaul and Cooling Systems

The engine chapters document internal inspection as well as removal and installation. Piston-to-cylinder clearance, ring gaps, crankshaft runout, and connecting rod inspection data accompany the assembly information.

The later manual separates the 500/600 twin-cylinder engines from the 700 three-cylinder configuration. Its cooling coverage distinguishes the water pump belt used on the 500/600 engines from the pump drive gears used on the 700.

Coolant Flow drawings show the heat exchanger circuits. The cooling chapters also cover cap testing, thermostat operation, pump bearings, seals, and system bleeding. Oil pump coverage includes cable adjustment and bleeding after oil-system disconnection.

Mikuni Carburetors and E.C.C. Diagnosis

The early sections cover Mikuni TM36/TM38 carburetors; the later manual also documents the TM33 arrangement used on the 700 models. Carburetor service includes float and fuel-level checks, throttle valve synchronization, and fuel pump operation testing.

The Guide for Carburetion charts relate throttle opening to the metering circuits. Main jet selection charts and the High Altitude Tuning flowchart connect fuel-system settings with clutch and gearing adjustments.

The XT/ST supplement adds E.C.C. diagnosis for VX600ST. Separate later sections cover VT600/MM600, including the test lead, fault-location tables, atmospheric pressure and temperature sensors, fuel select switch, and main and slow solenoid valves. These tables help narrow a fault to the relevant sensor or circuit before carburetor components are replaced.

The VT600/MM600 SMART carburetor information describes automatic altitude compensation. Its coverage differs from the manual jet-selection charts provided for other configurations.

The carburetor tuning section warns that operating without the air silencer box can create a lean mixture and cause severe engine damage.

Clutch, Chain Housing, and Reverse Gear Service

Primary sheave procedures include weight and roller inspection, bushing checks, spider removal, and assembly alignment. The special-tool section identifies the clutch spider separator YS-28890-B and separator adapter YS-34480.

The primary sheave spider has a left-hand thread; its removal and assembly cautions address the risk of cracking or damaging the spider and sheaves. Secondary sheave coverage includes ramp-shoe wear, spring indexing, preload, offset, and free-play adjustment.

Gear Ratio Charts support the gearing sections. Separate chain housing procedures address configurations with and without reverse, while optional-kit chapters describe reverse gear and electric starter installation.

Brakes, Suspension, and Electrical Systems

The brake chapters distinguish the early cable-operated caliper from the later hydraulic system. Later coverage extends to caliper pistons and seals, master cylinder inspection, parking brake adjustment, and hydraulic bleeding.

Suspension assembly views accompany slide rail, pivot arm, wheel bearing, stopper band, and shock absorber service. Steering coverage includes rod-end inspection, toe-out adjustment, and later ski spindle camber checks.

Electrical fault charts cover weak spark, starting faults, charging problems, warning lights, and warmer circuits. Wiring diagrams distinguish VT600/MM600, VX700SX/MM700, and the listed VX500/VX600 variants, with connector views and wire color codes.

Clutch work and running-track checks involve stored spring tension and moving drive components; follow the manual’s workshop safety precautions.

Preview of Cooling Checks and Relay Rod Torque

These are a few of the inspection and assembly specifications in the early VX500/VX600 base manual.

The cooling inspection section specifies thermostat opening at 50–55°C and coolant filler cap opening pressure of 80–100 kPa. Both appear alongside the corresponding inspection information.

The chassis torque table lists 25 Nm for the relay rod locknut, with threadlocking compound specified. Other steering fasteners have separate entries.

PDF Bookmarks, Diagram Viewing, and Included Publications

Search, navigation, and diagram detail: PDF text search is not available. Embedded bookmarks organize the manuals, supplements, and major system sections. Small labels in the wiring diagrams require zooming, and several diagram pages require rotation.

The download is one printable, 622-page PDF containing the following publications and additional sheets.

The two additional wiring sheets, including the sheet labeled SX600/SX700, are already included in the total. Index and illustrated-symbol pages are included within the respective publication counts.