1983-1984 Yamaha VMAX VMX540 Snowmobile Service Manual

Description

This 1983-1984 Yamaha VMAX VMX540 Snowmobile Service Manual is a reproduction of the 1983-1984 Yamaha VMAX VMX540 Snowmobile Service Manual.  It provides detailed service information, step-by-step repair instruction and maintenance specifications for 1983 VMAX VMX540G and 1984 Yamaha VMAX VMX540H Snowmobiles. This Service Manual has been written to acquaint the mechanic with the disassembly, reassembly, maintenance, and troubleshooting procedures required to provide optimum performance and longevity of the snowmobile. The information herein should be closely studied to avoid unnecessary repairs and to provide the owner with a sound, safe, dependable machine.

1983-1984 Yamaha VMAX VMX540 Snowmobile Service Manual Table of Contents

CHAPTER 1. GENERAL
EXTERNAL VIEW.
MACHINE IDENTIFICATION
A. Frame serial number
B. Engine serial number.
TERMS.
STORAGE
PRE-SEASON PREPARATION
MAINTENANCE.
A. Periodic maintenance.
B. Lubrication intervals
C. Sealing the carburetor.
HIGH ALTITUDE TUNING . . .
SPECIAL TOOLS.

CHAPTER 2. ENGINE
ENGINE REMOVAL & INSTALLING
A. Engine removal.
B. Mounting the engine
RECOIL STARTER
A. Removal
B. Overhauling
FLYWHEEL MAGNETO
A. Overhauling
B. Inspection.
WATER PUMP GEAR CASE
A. Gear oil.
B. Overhauling
OIL PUMP
A. Oil feed system
B. Oil pump cable adjustment
C. Air bleeding.
D. Overhauling
WATER PUMP
A. Overhauling
TOP END AND BOTTOM END
A. Overhauling
B. Cylinder head
C. Cylinder.
D. Piston & piston ring.
E. Crankshaft.
F. Crankcase

CHAPTER 3. COOLING SYSTEM
BLEEDING THE COOLING SYSTEM
A. Coolant level
B. Coolant type.
C. Air bleeding.
DRAINING THE COOLING SYSTEM
A. Draining coolant.
B. Cooling system compression check
COOLING SYSTEM COMPONENT . .
A. Overhauling
B. Radiator.
C. Heat exchanger.
D. Water pump.
E. Thermostat.

CHAPTER 4. CARBURETION
CARBURATOR OVERHAULING
A. Nomenclature.
B. Disassembly
C. Inspection.
D. Reassembly & Adjustment .
CARBURETOR TUNING.
A. Carburetor tuning data.
B. Cable adjustment.
C. Low speed tuning.
D. Mid-range speed tuning.
E. High speed tuning
FUELPUMP
FUEL COCK

CHAPTER 5. POWERTRAIN
V-BELT CLUTCH
A. Clutch setting
B. Clutch overhauling
C. Clutch alignment
SECONDARY SHAFT & FRONT AXLE.
A. Nomenclature
B. Secondary shaft.
C. Front axle
DRIVE CHAIN
A. Gearing.
B. Overhauling.
C. Chain adjustment
D. Chain oil level.
DISC BRAKE.
A. Overhauling.
B. Adjustment
SLIDE RAIL SUSPENSION
A. Suspension setting
B. Overhauling.
DRIVE TRACK
A. Overhauling.
B. Adjustment

CHAPTER 6. CHASSIS
TELESCOPIC STRUT SUSPENSION
A. Telescopic strut suspension setting
B. Overhauling
STEERING
A. Overhauling
B. Ski adjustment.
C. Handlebar adjustment.
D. Checking the movement of handlebars
OIL TANK
FUEL TANK.

CHAPTER 7. ELECTRICAL
IGNITION SYSTEM
A. Circuit diagram.
B. Troubleshooting.
C. Ignition timing.
D. Spark gap test
E. Ignition coil.
F. Sparkplug.
G. Pulser and charging coils test
H. C.D.I. unit.
LIGHTING SYSTEM
A. Circuit diagram.
B. Retractable headlight beam adjustment.
C. Lighting coil resistance check
D. Voltage regulator.
E. Oil caution switch

CHAPTER 8. APPENDIX
SPECIFICATIONS
A. General
B. Engine.
C. Dirve and track suspension.
D. Chassis
E. Electrical.
F. Tightening torque
GENERAL TORQUE SPECIFICATIONS.
CONVERSION TABLES.
EXPLODED DIAGRAM
WIRING DIAGRAM
WIRE AND PIPE ROUTING DIAGRAM.