Yamaha SRX700SD & SRX700D - Factory Maintenance, Troubleshooting & Repair Manual (2000)

Yamaha SRX700 / SRX700SD Service Manual - 1998-2002 Edition

This professional-grade technical manual provides authoritative engineering data and diagnostic protocols for the 696 cm³ liquid-cooled, three-cylinder SRX powerplants. Precision maintenance of the separate lubrication system is paramount; technicians must perform a mandatory air bleeding of the oil pump and delivery lines whenever the system is disconnected to ensure immediate oil flow and prevent terminal engine failure. This document serves as the primary factory reference for the Yamaha Power Valve System (Y.P.V.S.) and chassis synchronization for the SRX series.

Technical Applicability & Serial Ranges

SRX700D / SRX700 Series (Standard Configuration)

• Machine ID Prefix: 8DN.
• Production Era: 1998–2002.
• Chassis Type: Monocoque Aluminum.

SRX700SD / SRX700S Series (High-Performance Edition)

• Machine ID Prefix: 8DW.
• Production Era: 1998–2002.
• Chassis Type: Performance-tuned with adjustable front suspension (S-model specific tools required).

Operational Parameters & Asset Integrity

• Calibration Reliability: Exact engine idle settings of 1,800 ± 100 r/min ensure consistent performance and proper engagement of the centrifugal clutch system.
• System Longevity: Detailed decarbonization schedules for the Y.P.V.S. valves prevent sticking and maintain optimal exhaust timing.
• Environmental Adaptability: Factory-mapped high-altitude jetting and clutching charts allow for precise tuning across diverse elevations and temperature gradients.

Document Metadata

• Print Number: LIT-12618-02-09 (8DN-28197-10).
• Volume: Approximately 350-400 pages.
• Language: US English Technical Edition.

Technical Depth & Factory Benchmarks

Driveline efficiency is governed by strict sheave alignment. The sheave center distance must be maintained between 267 mm and 270 mm (10.52–10.62 in), while sheave offset is calibrated to 13.5–16.5 mm (0.53–0.64 in). Clutch engagement is factory-set at 4,000 ± 200 r/min, with a target shift speed of 8,500 ± 250 r/min for peak power delivery.

Visual Navigation Aids

The manual utilizes high-resolution exploded diagrams and sequential disassembly logic for all major subsystems. Technical symbols indicate specific lubrication requirements, such as the application of ESSO Beacon 325 or Aeroshell Grease #7A to critical pivot points. Electrical diagnostics are supported by comprehensive circuit diagrams and fault location tables for the detonation control and grip warmer systems.

Table of Contents

• General Information: Machine ID, Important Safety Information, Special Tools.
• Periodic Inspection: Maintenance Schedules, Engine/Chassis Adjustments.
• Chassis: Steering, Ski/Suspension, Slide Rail Mechanics.
• Power Train: Sheave Adjustment, V-Belt, Drive Chain Housing, Brakes.
• Engine: Cylinder Head, Crankcase, Recoil Starter, Y.P.V.S..
• Cooling System: Heat Exchanger, Water Pump, Thermostat.
• Carburetion: MIKUNI TM33/3 Settings, Fuel Pump, TPS Calibration.
• Electrical: Ignition, Lighting, T.O.R.S., Monitoring Systems.
• Specifications: Technical Standards, Torque Charts, Wiring Diagrams.

Operational Limits & Specifications

• Spark Plug Gap (NGK BR9ECS): 0.7–0.8 mm (0.028–0.031 in).
• Cylinder Bore size: 69.000–69.014 mm (2.7165–2.7171 in).
• Piston-to-Cylinder Clearance: 0.065–0.070 mm (0.0026–0.0028 in).
• Torque (Cylinder Head Nut): 28 Nm (2.8 m·kg, 20 ft·lb).
• Fluid Capacity (Oil Tank): 3.3 L (3.5 US qt) YAMALUBE 2-cycle oil.
• Fluid Capacity (Chaincase): 0.25 L (8.5 US oz) SAE #75 or #80 Gear Oil.