1997–1999 Yamaha Mountain Max 500/600/700 Service Repair Manual (P/N 90890-01701 / YS-01880)

This 276-page factory service manual in PDF format covers the MM600 and MM700 Mountain Max models along with the exact VX and VT variants listed in the factory specifications: VX500XT, VX500XTC, VX500XTCE, VX500XTCR, VT500; VX600XT, VX600XTC, VX600XTCE, VX600XTCR, VX600SX, VT600, MM600; VX700SX and MM700. The service data separates the 500/600 two-cylinder engines from the 700 three-cylinder engine and identifies model codes 8CJ, 8CU, 8DC, 8DD, 8CY, 8CR, 8CX, 8DA, 8DB, 8CV, 8CW, 8CS, 8CH, and 8CP. This is service-technician-level material, suited to mechanics and experienced owners who can work from exploded assembly views, electrical test charts, and special-tool procedures.

• Engine and cooling repair: Covers engine removal, cylinder-head and cylinder service, piston and crankshaft inspection, oil-pump and crankcase work, CDI magneto service, recoil starter repair, heat-exchanger removal, and separate water-pump procedures for 500/600 and 700 engines.
• Clutch and drivetrain work: Details primary- and secondary-sheave removal, disassembly, inspection, assembly, and installation; drive-belt service; reverse and non-reverse chain housings; jackshaft inspection; gear selection; and model-specific clutch setup.
• Brake, track, and suspension procedures: Includes hydraulic brake bleeding, pad replacement, caliper and master-cylinder repair, slide-rail suspension service, front-axle and track work, track-tension adjustment, ski inspection, steering installation, and ski-alignment checks.
• Fuel and carburetion systems: Provides carburetor removal and separation, synchronization, fuel-level adjustment, throttle-position sensor testing, fuel-pump checks, jet-selection guidance, and a dedicated electronically controlled carburetor section for VT600 and MM600 models.
• Electrical diagnosis: Supplies system-level troubleshooting for electric starting, charging, ignition, lighting, signal circuits, T.O.R.S., grip and thumb warmers, switches, sensors, and the VT600/MM600 E.C.C. system with its test lead, fault-location table, and component inspections.
• Reference and installation content: Includes model-specific wiring diagrams, 500/600 and 700 cable-routing drawings, torque and clearance tables, wear limits, capacities, electrical test values, plus installation coverage for the optional reverse-gear and starter-motor kits.

Model-Specific Tuning Coverage

The tuning chapter combines carburetor, clutch, gearing, and suspension data. Carburetor charts relate main-jet selection to temperature and elevation, while the clutch tables separate VX500/VT500, VX600, VT600/MM600, and VX700SX/MM700 configurations. Four elevation bands extend to 10,000 feet, with the related gearing, primary spring, weight, secondary spring, torque-cam, and shim selections. A high-altitude troubleshooting flowchart ties jetting, plug condition, low-speed response, gearing, engagement speed, and clutch shift performance together without treating every model as the same machine.

On VT600 and MM600 models, the conventional carburetor-tuning chapter gives way to dedicated E.C.C. diagnosis for the atmospheric-pressure, air-temperature, and water-temperature sensors, fuel-select switch, and solenoid valves. Suspension coverage is similarly model-aware, separating threaded spring-seat and indexed-preload arrangements, VX600SX damping adjustment, rear stopper-band setup, and rear full-rate adjustment. Factory reverse is identified for VX500XTCR, VX600XTCR, VT500, and VT600, with separate chain-housing service information for reverse and non-reverse configurations.

Diagrams, Tools, and Factory Data

Named visual references include the High Altitude Tuning flowchart, ski-spindle camber setup view, primary- and secondary-sheave exploded views, 500/600 and 700 cable-routing drawings, the E.C.C. fault-location table, and full model-family wiring diagrams. The final wiring sheets separately cover VX700SX/MM700, VT600/MM600, the listed VX500/VX600/VT500 group, SX600, and SX700 configurations.

The special-tool register gives European and U.S./Canada part-number pairs and explains each tool's purpose. Examples include the cooling-system tester 90890-01325 / YU-24460-01, primary sheave holder 90890-01701 / YS-01880, clutch spider separator 90890-01711 / YS-28890-B, and pocket tester 90890-03112 / YU-03112. Chapter 9 then consolidates general and maintenance specifications for the engine, power train, chassis, electrical system, and E.C.C., including component torques, fluid data, inspection limits, and test specifications.

The clutch section identifies the primary spider's left-hand thread and warns that poor support during removal can crack the sheaves or spider. It also treats secondary-sheave spring tension as a serious hazard requiring the specified compressor, while the 500/600 cooling section flags the left-hand water-pump impeller thread and bearing-installation practices that can damage the race or balls.