Yamaha VK540EF Service Repair Manual – PDF DOWNLOAD

Description

Yamaha VK540EF Service Repair Manual

DESCRIPTION:

Yamaha VK540EF Service Repair Manual

FOREWORD:

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s edumtion into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha generators have a basic under-, standing of the mechanical precepts and pro-V cedures inherent to generator repair technology. Vifithout such knowledge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Company Ltd. is continually striving to further improve all models manufac‘ tured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

MANUAL FORMAT:

The procedures in this manual are organized in a sequential, step-by-step format. The infor- mation has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explana— tions of all cflsassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course.

•  Bearings
• Pitting/damage —> Replace.

TABLE OF CONTENTS:

Yamaha VK540EF Service Repair Manual

CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION 1-1
FRAME SERIAL NUMBER 1-1
ENGINE SERIAL NUMBER1-1
IMPORTANT INFORMATION 1-2
PREPARATION FOR REMOVAL AND
DISASSEMBLY 1-2
ALL REPLACEMENT PARTS 1-3
GASKETS, OIL SEALS, AND
O-RINGS 1-3
LOCK WASHERS/PLATES AND
COTTER PINS 1-3
BEARINGS AND OIL SEALS 1-3
CIRCLIPS 1-4
LOCTITE)1-4
SPECIAL TOOLS 1-5
FOR TUNE UP 1-5
FOR ENGINE SERVICE 1-5
FOR POWER TRAIN SERVICE 1-6
FOR CARBURETION SERVICE 1-7
FOR ELECTRICAL SERVICE 1-7
CHAPTER 2
PERIODIC INSPECTIONS AND
ADJUSTMENTS
INTRODUCTION 2-1
PERIODIC MAINTENANCE TABLE 2-1
ENGINE2-3
SPARK PLUGS 2-3
OIL PUMP2-4
OIL FILTER INSPECTION 2-6
ENGINE OIL LINE INSPECTION 2-6
FUEL LINE INSPECTION 2-7
FUEL FILTER INSPECTION2-7
COOLING FAN BELT TENSION
ADJUSTMENT 2-9
ENGINE IDLE SPEED
ADJUSTMENT 2-10
THROTTLE CABLE FREEPLAY
ADJUSTMENT 2-10
THROTTLE OVERRIDE SYSTEM
(TORS) CHECK 2-11
STARTER (CHOKE) CABLE
FREEPLAY ADJUSTMENT 2-12
EXHAUST SYSTEM
INSPECTION 2-12
POWER TRAIN 2-13
DRIVE V-BELT 2-13
SHEAVE DISTANCE AND OFFSET
ADJUSTMENT 2-16
ENGAGEMENT SPEED CHECK 2-18
ADJUSTING THE BRAKE2-18
BRAKE PAD INSPECTION 2-19
DRIVE CHAIN2-19
TRACK TENSION ADJUSTMENT 2-21
SLIDE RUNNER INSPECTION2-22
CHASSIS 2-23
SKI/SKI RUNNER 2-23
STEERING SYSTEM 2-23
LUBRICATION 2-25
ELECTRICAL 2-27
HEADLIGHT BEAM
ADJUSTMENT 2-27
BATTERY INSPECTION 2-28
FUSE INSPECTION2-30
TUNING 2-31
CARBURETOR TUNING 2-31
CLUTCH2-38
GEAR SELECTION2-39
HIGH ALTITUDE TUNING 2-43
REAR SUSPENSION 2-44
CHAPTER 3
CHASSIS
STEERING 3-1
INSPECTION 3-3
INSTALLATION 3-4
SKI3-6
INSPECTION 3-7
FRONT SUSPENSION 3-8
HANDLING NOTES 3-9
INSPECTION 3-9
INSTALLATION 3-10
CHAPTER 4
POWER TRAIN
PRIMARY SHEAVE AND DRIVE
V-BELT 4-1
REMOVAL4-3
DISASSEMBLY 4-4
INSPECTION 4-5
ASSEMBLY 4-7
INSTALLATION 4-9
SECONDARY SHEAVE4-10
DISASSEMBLY 4-12
INSPECTION 4-13
ASSEMBLY 4-14
INSTALLATION 4-15
DRIVE CHAIN HOUSING 4-16
INSPECTION 4-18
INSTALLATION 4-22
SECONDARY SHAFT (JACKSHAFT) 4-23
INSPECTION 4-25
INSTALLATION 4-25
BRAKE 4-26
BRAKE PAD REPLACEMENT 4-27
BRAKE CALIPER INSPECTION 4-30
INSTALLATION 4-31
SLIDE RAIL SUSPENSION 4-33
INSPECTION 4-37
INSTALLATION 4-37
FRONT AXLE AND TRACK 4-38
INSPECTION 4-40
INSTALLATION 4-40
CHAPTER 5
ENGINE
EXHAUST ASSEMBLY 5-1
INSPECTION 5-2
ENGINE ASSEMBLY 5-3
INSPECTION 5-4
INSTALLATION 5-4
CYLINDER HEAD AND CYLINDER 5-5
REMOVAL5-6
INSPECTION 5-6
INSTALLATION5-11
OIL PUMP, CRANKCASE AND
CRANKSHAFT 5-14
INSPECTION 5-15
OIL PUMP STROKE
ADJUSTMENT 5-16
INSTALLATION 5-18
OIL PUMP 5-19
CDI MAGNETO 5-20
REMOVAL 5-21
INSTALLATION 5-22
ENGINE COOLING FAN 5-23
REMOVAL 5-24
INSPECTION 5-25
INSTALLATION 5-26
RECOIL STARTER 5-27
REMOVAL 5-28
INSPECTION 5-28
INSTALLATION 5-29
CHAPTER 6
CARBURETION
CARBURETOR 6-1
INSPECTION 6-3
ASSEMBLY 6-4
INSTALLATION 6-5
FUEL PUMP 6-6
INSPECTION 6-7
INSTALLATION 6-7
CHAPTER 7
ELECTRICAL
SWITCH INSPECTION 7-1
SWITCH INSPECTION 7-1
INSPECTING A SWITCH SHOWN IN
THE MANUAL 7-1
IGNITION SYSTEM7-2
CIRCUIT DIAGRAM 7-2
TROUBLESHOOTING7-3
SPARK PLUG CAP 7-4
IGNITION COIL 7-4
SOURCE COIL/PULSER COIL 7-4
SPARK PLUG 7-5
THROTTLE OVERRIDE SYSTEM
(TORS) 7-5
HANDLEBAR SWITCH (RIGHT) 7-6
CARBURETOR SWITCH 7-6
MAIN SWITCH 7-7
LIGHTING SYSTEM7-8
CIRCUIT DIAGRAM 7-8
TROUBLESHOOTING7-9
BULB(S)7-10
HEADLIGHT BEAM SWITCH 7-10
LIGHTING COIL 7-10
SIGNAL SYSTEM 7-11
CIRCUIT DIAGRAM 7-11
TROUBLESHOOTING 7-12
TROUBLESHOOTING 7-13
TAIL/BRAKE LIGHT BULB 7-14
BRAKE LIGHT SWITCH 7-14
GEAR POSITION SWITCH 7-14
BACK BUZZER 7-14
GRIP WARMER SYSTEM 7-15
CIRCUIT DIAGRAM7-15
TROUBLESHOOTING 7-16
GRIP AND THUMB WARMER
COIL 7-17
GRIP WARMER SWITCH7-17
ELECTRICAL STARTING SYSTEM 7-18
CIRCUIT DIAGRAM7-18
TROUBLESHOOTING 7-19
MAIN SWITCH 7-20
RECTIFIER 7-20
STARTER MOTOR 7-21
CHARGING SYSTEM 7-24
CIRCUIT DIAGRAM7-24
TROUBLESHOOTING 7-25
BATTERY 7-26
CHARGING COIL 7-26
CHAPTER 8
SPECIFICATIONS
GENERAL SPECIFICATIONS 8-1
MAINTENANCE SPECIFICATIONS 8-3
ENGINE 8-3
POWER TRAIN 8-6
CHASSIS 8-9
ELECTRICAL8-10
HIGH ALTITUDE SETTINGS 8-12
TIGHTENING TORQUE 8-13
GENERAL TORQUE
SPECIFICATIONS 8-15
DEFINITION OF UNITS8-15
CABLE ROUTING 8-16

YAMAHA VK540EF SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.