Yamaha 4UF8MD40 Owner'S Manual Download

Page: 36 / 54

PC011A

7. Using a flat-blade tool, slowly and

carefully push the piston into the cal-

iper.

8. Position the outer brake pad into the

caliper; then install the hair-pin clip

into the caliper assembly.

9. Repeat steps 5-8 for the inner pad; then

secure the pad with the hairpin clip.

10. Remove the reservoir cover and

remove the remaining fluid; then fill

the reservoir with fresh fluid and

install the cover.

11. Pump the brake lever to ensure cor-

rect positioning of the brake pads

and proper brake lever travel; then

release.



NOTE: If brake lever travel is not

within specification, bleed the
brake system.

12. Remove the reservoir cover and fill

the reservoir (if necessary) to the

proper level with fresh brake fluid;

then install the cover.

13. Secure the brake shield, the driven

clutch; then install and secure the

left-side access panel.



NOTE: When new brake pads are

installed, a “burnishing” process is
required (see Burnishing Brake
Pads sub-section).

Burnishing Brake Pads

After changing brake pads, the new brake

pads must be burnished to achieve full

braking effectiveness. Braking distance

will be extended until brake pads are

properly burnished.
To properly burnish the brakes, use fol-

lowing procedure:

1. Choose an area sufficiently large to

safely accelerate to 50-65 km/h (30-

40 mph) and to brake to a stop.



NOTE: This procedure can also

be accomplished using a shielded
jack stand.

2. Accelerate to 50-65 km/h (30-40

mph); then compress brake lever to

decelerate to a stop.



NOTE: Lightly apply the brake

lever to come to an easy stop; do
not overapply brakes or “lock up”
the track.

3. Repeat procedure 10-15 times allow-

ing some cooling between stops.



NOTE: Do not repeat too soon or

too aggressively as to get the
brake disc “red hot.”



NOTE: This procedure stabilizes

the pad material and extends the
life of the pads.

Chain Tension

1. Remove both access panels; then

remove the hood.

2. Remove the five torx screws and

washers securing the turbo heat

shield to the turbo. Remove the

shield.

XM484

3. Remove the six torx screws securing

the resonator to the turbo; then

remove the spring securing the reso-

nator. Remove the resonator and

account for a gasket.

WARNING

Do not attempt sudden stops or put
yourself into a situation where a
sudden stop will be required until the
brake pads are properly burnished.

U8KCS1E0.book Page 31 Tuesday, May 16, 2017 5:42 PM

Summary of Contents for 4UF8MD40

Page 1: ...ä käsikirja huolellisesti ennen moottorikelkan käyttöä Läs den här instruktionsboken noga innan snöskotern används Leggere attentamente questo manuale prima di utilizzare questo veicolo Read this manual carefully before operating this vehicle Il convient de lire attentivement ce manuel avant la première utilisation du véhicule SW1AML53J SW1AML62J SW1AXS41J SW1AXS37J SW1AXL41J SW1ABL53J 8KC F8199 S...

Page 2: ...DIC183 PRINTED IN U S A ESU12520 Original instructions Notice originale Istruzioni originali Bruksanvisning i original Alkuperäiset ohjeet Opprinnelige instruksjoner ...

Page 3: ...Read this manual carefully before operating this vehicle OWNER S MANUAL SW1AML53J SW1AML62J SW1AXS41J SW1AXS37J SW1AXL41J SW1ABL53J 8KC F8199 S1 E0 U8KCS1E0 book Page 1 Tuesday May 16 2017 5 42 PM ...

Page 4: ...te of issue of the other Directives of EEC to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC and to the other relevant Directive of EEC If applicable To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted If a...

Page 5: ...e 15 Braking 15 Emergency Stopping 16 Throttle Ignition Monitor Switch 16 Lubrication 18 20 Chain Case 18 Replacing Lubricant 19 Rear Suspension 20 Maintenance 21 43 Periodic Maintenance Checklist 21 Fuel System 22 Checking Engine Oil Level 22 Changing Engine Oil Filter 22 Coolant Level 24 Air Filter 24 Spark Plugs 25 Checking Adjusting Valve Clearance 25 Battery 25 Fuses 28 Brake System 28 Burnis...

Page 6: ... study the entire Owner s Manual Failure to follow this warning could result in personal injury to yourself or others Personal Injury To avoid injury to yourself and others NEVER operate the snowmobile with out first reading and understanding this manual then follow the instructions and heed the warnings given USE COMMON SENSE DON T DRINK and DRIVE STAY IN CONTROL at ALL TIMES TELL YOUR FRIENDS If...

Page 7: ...t an autho rized Yamaha Snowmobile dealer for professional service At the time of publication all information and illustrations were technically correct Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions Because Yamaha constantly refines and improves its products no retroactive obligation is incurred This Owner s Manual should...

Page 8: ...model 0749 256C Gasoline Oil Recommended Gasoline The recommended gasoline to use is 91 octane premium unleaded PON for North America or 95 octane premium unleaded RON for Europe In many areas oxygenates are added to the gaso line Oxygenated gasolines containing up to 10 ethanol are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since etha...

Page 9: ...pre mixed fuel during the break in period There is never a more important period in the life of the engine than the first 500 km 300 miles Since the engine is brand new do not put an excessive load on it for the first 500 km 300 miles The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition ...

Page 10: ...ture the indicator will cease flashing and will remain constantly illuminated NOTE If the indicator is con stantly on the engine will shut off if vehicle speed is reduced to 1 5 km h 0 9 MPH or slower B High Beam Indicator The indicator is on whenever the high beam mode is selected by the headlight switch C Oil Pressure Indicator The indicator relates to engine oil pres sure not the oil level howe...

Page 11: ...ting the 12 hour or 24 hour clock is available press the either Left Button to alternate between the two modes Next press the Lower Right Button to set the clock Press either Left Button to set the hours then press the Lower Right Button to set the min utes Press either Left Button to set the minutes When the proper time has been set press the Lower Right Button to return to the main gauge display...

Page 12: ...ccur Code Trouble 8 Shift Switch Abnormality 12 Crank Sensor 13 Manifold Pressure Sensor PB 14 Manifold Pressure Sensor PB 15 Throttle Position Sensor 19 Wastegate Solenoid 21 Water Temperature Sensor 22 Intake Air Temperature Sensor 23 Atmospheric Pressure Sensor 25 Upstream Pressure Sensor PC 26 Upstream Pressure Sensor PC 30 Oil Pressure Reduction 33 Ignition Abnormality 1 34 Ignition Abnormali...

Page 13: ...harge it however in an emergency it may be necessary to jump start a snowmobile If so use the following procedure to carefully and safely complete this procedure NOTE To access the battery the seat must be removed 1 For the snowmobile to be jump started slide any terminal boots away 2 Inspect the battery for any signs of electrolyte leaks loose terminals or bulging sides Leaking or bulging battery...

Page 14: ...ith the good battery Allow the vehicle to run for several minutes applying some charge to the dead battery 9 Start the snowmobile with the dead battery and allow it to run for several minutes before disconnecting the jumper cables 10 Remove the jumper cables in oppo site order of hook up 4 3 2 1 Be careful not to short cables against bare metal NOTE Have the battery and elec trical system checked ...

Page 15: ...ening the track Avoid spinning the drive track Studs may catch on an object and pull out of the track leaving tears and damage around the already weakened area To minimize possible damage consult your stud man ufacturer for installation and stud pattern recommendations Yamaha does not rec ommend studding a track Paddle Track On Equipped Models These models are equipped with a Power Claw style trac...

Page 16: ...erse to for ward or from forward to reverse apply the throttle slowly and evenly to allow the driven pulley to engage properly Access Panel Hood To remove the access panel and hood use the following procedure 1 Rotate the two quarter turns to the vertical position then pull the top of the side panel out and up and off the skid plate YM 148A 2 Disconnect the hood harness on the left side of the hoo...

Page 17: ...seat Make sure to dis connect the seat heater harness 0748 419 To install the seat route the front tabs on the seat base through the console then install the seat and secure using the torx head screw SNO 895A On S TX DX 146 models route the front tabs on the seat base through the console then press down on the rear of the seat until the rear latches NOTE Prior to lowering and securing the seat con...

Page 18: ...t exercise care when using the seat heater The seat heater may cause burns even at low tempera tures especially if used for long peri ods of time Do not place anything on the seat that insulates against heat such as a blanket or cushion because this may cause the seat heater to overheat Do not puncture the seat with pins needles or other pointed objects because this may damage the heating element ...

Page 19: ...ver Do not allow moisture to con taminate the brake system 4 Test the throttle control lever by completely compressing and releas ing it several times The lever MUST return to the idle position quickly and completely 5 Make sure the battery is fully charged to ensure the engine is turn ing over at a sufficient RPM to start NOTE Even though the engine turns over the engine may not have sufficient R...

Page 20: ...uge to com pletely power down before attempting to start the engine Braking The following items are items that the operator must be familiar with when operating this snowmobile and its hydraulic brake system Important addi tional information on the proper mainte nance of the brake system is found in the Maintenance section 1 Use the brakes wisely Each time the brakes are applied in all hydraulic b...

Page 21: ...wing the snowmobile under a variety of situations Identified in the following chart are the ways a snowmobile may be brought to a stop and the effectiveness under normal conditions Throttle Ignition Monitor Switch The throttle control is equipped with a monitor switch for safety purposes which will stop the engine when a loss of return spring force occurs If ice forms in the throttle system or if ...

Page 22: ...re emergency exists wherein the engine must be started disconnect the throttle monitor switch located in the right side handlebar control NOTE If disconnection of the throttle monitor switch is needed to start the engine take the snowmo bile to an authorized Yamaha Snowmobile dealer for service as soon as possible If not under war ranty this service is at the discre tion and expense of the snowmob...

Page 23: ...ure to add a small amount of white lithium grease to the O rings of the new actuator extension and the shift actuator detent block before installing 4 Install the actuator extension and gently rotate counter clockwise to make sure the shift fork is in the for ward position When the shift fork is in the forward position make sure the notch in the extension is directed downward YM 101 5 Install spri...

Page 24: ... oil tank assembly to the chain case housing starting with the bottom screws first NOTE Do not remove all eleven screws completely until the chain lube has been completely removed This will help keep debris oil out of the screw holes 4 Remove all eleven screws then swing the chain case out of the way Account for a thrust washer on the countershaft YM 128A 5 Inspect all chain case components along ...

Page 25: ...ear posi tion sensor then secure the connec tor to the main harness using a Cable Tie 13 Install the resonator and secure using existing hardware 14 Install the lower console then install the seat hood and both access pan els 15 Start the engine then shift the snow mobile into and out of reverse three times Rear Suspension This procedure should be done every 40 operating hours NOTE Yamaha recommen...

Page 26: ... damage Electrical Wiring Weekly Check for wear damage and tight connections Exhaust System Weekly 7 Check for damage leakage and obstructions Nuts Bolts Fasteners Weekly Check tightness Shock Absorbers Weekly 37 Check for fluid leakage and damage and air pres sure Fox Air Shocks Spark Plugs 4000 km 2500 Mi Seasonal 25 Check center electrode insulator color carbon and gap Valve Clearance 40000 km ...

Page 27: ...er warranty this service is at the discretion and expense of the snowmobile owner 0747 833 Checking Engine Oil Level NOTE The snowmobile must be on a level surface for this procedure 1 Start the engine and let it idle and warm up until the engine reaches operating temperature 2 Shut the engine off Remove the right side access panel then look at the oil level tube on the backside of the oil tank Th...

Page 28: ... to the tunnel and the support then with a drain pan in position remove the drain plug from the oil tank 746 121A NOTE To aid in draining the oil from the tank position a funnel between the tank and the opening of the tunnel running board 11 After the oil has drained completely install the drain plug with a new O ring and tighten to 2 2 kg m 16 ft lb 12 Install the four screws securing the right s...

Page 29: ... in the vapor tank located above the exhaust Once the plug is removed verify the coolant is just below the treads Install the plug YM 210A Air Filter The air filter inside the air filter housing must be clean to provide good engine power and gas mileage If operating the snowmobile in deep powder conditions the air filter should be inspected for snow buildup 1 Remove the left side access panel then...

Page 30: ...ter 40 000 km 25 000 miles valve clearance should be checked and adjusted as necessary NOTE Take the snowmobile to an authorized Yamaha Snowmobile dealer for inspection and service This service is at the discretion and expense of the snowmobile owner Battery These sealed batteries after being in ser vice require regular cleaning and charg ing in order to deliver peak performance and maximum servic...

Page 31: ...ing the following guidelines A When using an automatic battery charger always follow the char ger manufacturer s instructions WARNING Improper handling or connecting of a battery may result in severe injury including acid burns electrical burns or blindness as a result of an explosion Always remove rings and watches Any time service is per formed on a battery the following must be observed keep sp...

Page 32: ...sher and a flat washer Tighten securely 11 Secure the main black negative cable and the small black negative cable to the battery using a cap screw lock washer and a flat washer Tighten securely NOTE Assure the harness wires and cables are routed properly as noted during removing battery proce dure XM167A 12 Install the battery bracket solenoid and tighten the two lock nuts to 1 2 kg m 105 in lb t...

Page 33: ...oad is not determined If the fuse continues to blow take the snowmobile to an autho rized Yamaha Snowmobile dealer for ser vice If not under warranty this service is at the discretion and expense of the snowmobile owner Brake System Yamaha recommends that the brake sys tem brake lever fluid reservoir hose caliper pads and brake disc be checked daily for fluid leakage wear or damage and for proper ...

Page 34: ...ing Brake System If the brake lever feels spongy when applied the brake system may need to be bled To bleed the brake use the follow ing procedure NOTE The brake system may be bled by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an authorized Yamaha Snowmobile dealer for this service This service is at the dis cretion and expense of the sno...

Page 35: ...his service This service is at the dis cretion and expense of the snow mobile owner NOTE When installing new brake pads always install them as a set Never install just one pad or use brake pads which have been used in another snowmobile 1 Remove the brake fluid reservoir cover then remove most of the brake fluid from the reservoir Install the cover NOTE The above procedure will allow room for the ...

Page 36: ...raking distance will be extended until brake pads are properly burnished To properly burnish the brakes use fol lowing procedure 1 Choose an area sufficiently large to safely accelerate to 50 65 km h 30 40 mph and to brake to a stop NOTE This procedure can also be accomplished using a shielded jack stand 2 Accelerate to 50 65 km h 30 40 mph then compress brake lever to decelerate to a stop NOTE Li...

Page 37: ... drive belt The belt should be at least 34 5 mm 1 36 in on a new belt or 32 5 mm 1 28 in on a broken in belt 3 Check the belt for cracking fraying etc If any of the specifications or conditions are unsatisfactory replace the drive belt NOTE Drive belts should be pur chased from an authorized Yamaha Snowmobile dealer as Yamaha drive belts are made to exact specifica tions and of quality material Be...

Page 38: ...1 then push towards the engine 2 so it will sep arate from the fixed sheave 3 Install the drive belt 3 between the sheaves SNO 326 SNO 327 4 Install the left side access panel Track Tension Track tension is directly related to the overall performance of the snowmobile If the track is too loose it may slap against the tunnel causing wear or it may ratchet on the track drive sprockets If extremely l...

Page 39: ...ws 0745 811 0750 086 0748 441 2 If the deflection distance between the bottom of the wear strip and the inside surface of the track clip exceeds specifications tighten the adjusting bolts to take up excessive slack in the track 3 If the distance between the bottom of the wear strip and the inside surface of the track clip is less than specified loosen the adjusting bolts to increase the slack in t...

Page 40: ...rack drive lugs no adjustment is necessary 0745 809 0748 448 5 If the idler wheels are not centered between the inner track drive lugs an adjustment is necessary Adjusting Track Alignment 1 On the side of the track which has the inner track drive lugs closer to the rear idler wheel loosen the idler wheel axle cap screw then rotate the adjust ing bolt clockwise 1 to 1 1 2 turns WARNING Always make ...

Page 41: ...r a bent shaft If any one of these conditions is detected replacement is necessary Take the snow mobile to an authorized Yamaha Snow mobile dealer for this service If not under warranty this service is at the discretion and expense of the snowmobile owner WARNING Always make sure the adjusting bolts are snug against the axle and the idler wheel cap screws are tightened to specifications Failure to...

Page 42: ...ection is desired Tighten the locking collar against the adjuster nut 0748 941 To adjust the damping use the adjust ment lever located above the EVOL chamber on the shock There are three settings that may be chosen 1 2 or 3 0745 159 Adjusting Fox Air Shocks NOTE It is recommended to monitor the air pressure in the air shocks once every month NOTE Adjusting air shocks may be done by the snowmobile ...

Page 43: ...sed climbing capabilities and limited transfer of the rear suspension The third setting should only be used when riding in the back country This set ting is not designed for trail riding Rebound Adjustment The Rebound Adjust feature on certain shocks gives the ability to externally adjust the shock rebound damping Adjustments are made by turning the knob or using a small flat bladed screw driver t...

Page 44: ...d Adjusting Skid Frame Rear Shock Fox QS3 To adjust the damping use the adjust ment lever located above the EVOL chamber on the shock There are three settings that may be chosen 1 2 or 3 SNO 550 Adjusting Rear Spring Pre Load Proper adjustment of rear spring pre load is necessary to get the most desirable ride The chart is designed to help in set ting up rear spring pre load however riding style i...

Page 45: ...ht harness con nector then secure the taillight to the rear rack fascia with the screws Tighten to 0 5 kg m 48 in lb Install the storage box tray and lid Adjusting Headlight Aim The headlight can be adjusted for vertical aim of the HIGH LOW beam The geo metric center of HIGH beam zone is to be used for vertical aiming 1 Position the snowmobile on a level floor so the headlight is approxi mately 8 ...

Page 46: ...ont End Lift elevate the front of the snowmobile 2 Remove the lock nuts securing the wear bar to the ski 0750 102 3 Remove the wear bar from the ski Installing Single 1 Move the wear bar into position on the bottom of the ski 2 Align the wear bar studs with the holes in the ski then install the lock nuts Tighten to 14 3 23 4 N m 124 203 in lb Removing Dual 1 Using Front End Lift elevate the front ...

Page 47: ...ust the damper 5 Apply an all temperature grease to the non threaded portion of the cap screw then slide the cap screw through the ski accounting for the rub ber damper inserts and washers NOTE Install the cap screw so the nut will be located to the inside of the ski 6 Apply Yamabond Red Threadlocker to the threads of the cap screw then tighten the nut to 6 2 kg m 45 ft lb 7 Place the cotter pin i...

Page 48: ...he snowmobile to an authorized Yamaha Snowmobile dealer for this ser vice This service is at the discretion and expense of the snowmobile owner Each time a new set of wear strips are installed they should be tempered Tem per the wear strips by driving the snow mobile for approximately a mile on a hard pack trail then immediately drive into deep snow and allow the wear strips to cool Repeat the pro...

Page 49: ...n If adjust ment is needed proceed to step 4 SNO 720 4 If offset adjustment needs to be made remove the driven clutch and add shims p n 8JP RA448 00 1 mm 0 04 8JP RA449 00 2 mm 0 08 to increase the offset or remove shims to decrease the offset 5 Once the correct offset is reached install driven clutch and tighten cap screw to 60 N m 6 0 kg m 43 ft lb DRIVE BELT POSITION Drive belt length condition...

Page 50: ...cleaned of any drive belt accumulation using compressed air The sheaves can be cleaned using a clean cloth and parts cleaning solvent CAUTION As the belt wears adjustment may be necessary To ensure proper clutch performance the belt posi tion should be adjusted by adding a spacer A on each adjusting bolt whenever the belt position reaches 1 5 mm 0 06 in below the edge of the sheaves Belt Position ...

Page 51: ...the upper steering post bushing and shafts of the shock absorbers 10 Lubricate the rear suspension with low temperature grease 11 Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely Make sure all rivets hold ing the components together are tight Replace all loose rivets 12 Clean and polish the hood console and chassis DO NOT USE SOL VENTS THE PROP...

Page 52: ...connect the battery cables making sure to connect the positive cable first Test the electric start system 9 Inspect the entire brake system all controls headlight taillight brake light ski wear bars and headlight aim adjust or replace as necessary 10 Adjust the track to the proper tension and alignment Noise level and vibration level Noise level 77 311 EEC 96 dB A 4375 r min Uncertainty of measure...

Page 53: ...48 Snowmobile Safety Rules U8KCS1E0 book Page 48 Tuesday May 16 2017 5 42 PM ...

Page 54: ...PRINTED IN U S A U8KCS1E0 book Page 1 Tuesday May 16 2017 5 42 PM ...

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