Yamaha FX Nytro FX10X Page 84 Assembly Manual Download

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ASSEMBLY MANUAL

FX10X

FX10RTX

FX10RTRX

FX10RTRAX

FX10MTX

FX10MTRX

FX10MTRAX

LIT-12618-02-69

8GL-28107-10

PRINTED ON RECYCLED PAPER

PRINTED IN U.S.A.

2007.06 CR

(E)

YAMAHA MOTOR CO., LTD.

Summary of Contents for FX Nytro FX10X

Page 1: ...ASSEMBLY MANUAL FX10X FX10RTX FX10RTRX FX10RTRAX FX10MTX FX10MTRX FX10MTRAX LIT 12688 02 69 8GL 28107 10 PRINTED ON RECYCLED PAPER PRINTED IN U S A 2007 06 CR E YAMAHA MOTOR CO LTD ...

Page 2: ...t a hard object or subject it to heavy shocks during transportation or in the service shop PREPARATION To assemble the snowmobile correctly supplies and working space are required Supplies Oils greases shop rags Workshop The workshop where the snowmobile is assembled should be clean and large The floor should be level Self protection Protect your eyes with suitable safety spectacles or safety gogg...

Page 3: ...ng symbols are used 1 Filling fluid 2 Lubricant 3 Special tool 4 Tightening torque 5 Wear limit clearance 6 ESSO beacon 325 grease or Aeroshell grease 7A 7 Apply locking agent LOCTITE Size or material of parts 8 d D Diameter of part l Length of part e g 5 0 2 5 mm 0 20 in T R LT d D d d D d 1 2 3 5 7 8 4 6 ...

Page 4: ...e to damage inspect thor oughly If damage is noted make note on freight bill Shipper assumes no further liability to the transporta tion company Your claim should be filed against carrier for damage of any nature b WARNING Only stack this unit with same crate size Assure units are stacked securely All four corners fit securely onto bottom unit Maximum handling transport movement stack 3 units DO N...

Page 5: ...3 8 DRIVE CHAIN HOUSING OIL LEVEL CHECK 3 10 DRIVE CHAIN TENSION ADJUSTMENT 3 11 THROTTLE CABLE ADJUSTMENT 3 11 BATTERY INSTALLATION 3 12 TRACK TENSION ADJUSTMENT 3 14 HEADLIGHT BEAM ADJUSTMENT 3 16 PARKING BRAKE ADJUSTMENT 3 17 SKI ADJUSTMENT 3 18 FRONT SUSPENSION SPRING PRELOAD 3 19 REBOUND DAMPING FORCE ADJUSTMENT FX10 3 20 COMPRESSION DAMPING FORCE ADJUSTMENT FX10 3 21 REAR SUSPENSION STOPPER ...

Page 6: ...on box 1 Windshield For FX10 FX10MT FX10MTR FX10MTRA 2 Windshield For FX10RT FX10RTR FX10RTRA 3 Front cover 4 Front bumper 5 Flap 6 Flap stopper For FX10 FX10RT FX10RTR FX10RTRA 7 Handlebar cover For FX10 FX10RT FX10RTR FX10RTRA FX10MTRA 8 Wind deflector stay For FX10 FX10RT FX10RTR FX10RTRA 9 Wind deflector For FX10 FX10RT FX10RTR FX10RTRA 1 2 3 4 5 6 7 8 9 ...

Page 7: ...10MTRA 7 Flange bolt M8 L 35 mm 1 38 in For FX10RT FX10RTR FX10RTRA 8 Flange bolt M8 L 185 mm 7 28 in For FX10MT FX10MTR FX10MTRA 9 Steering joint For FX10MT FX10MTR FX10MTRA 0 Collar L 76 2 mm 3 00 in For FX10 FX10RT FX10RTR FX10RTRA L 101 6 mm 4 00 in For FX10MT FX10MTR FX10MTRA A Owner s tool bag B Pouch C Owner s manual D Safety handbook For USA Canada E Tag 1 For USA F Battery fluid electroly...

Page 8: ...g Socket wrench 14 h Spark plug box wrench 16 i Special wrench j Combination wrench 19 30 For FX10MT FX10MTR FX10MTRA k Owner s tool bag a G b c d e f g h i j k C Carton box 1 Front shock absorbers 2pcs For FX10 2 Front shock absorbers 2pcs For FX10MT FX10MTR FX10MTRA 3 Front shock absorbers 2pcs and shock absorber pump For FX10RT FX10RTR FX10RTRA 1 2 3 ...

Page 9: ...1 4 D Vinyl bag 1 Key 1 E Carton box 1 Ski assemblies For FX10 FX10RT FX10RTR FX10RTRA 2 Ski assemblies For FX10MT FX10MTR FX10MTRA 1 2 F Shroud For FX10 FX10RT FX10RTR FX10RTRA 1 Shroud 1 ...

Page 10: ...emove the crate cover 1 3 Remove the bolts 2 and then remove the top of the crate 3 4 Remove the bolts 4 and then remove the sides of the crate 5 Remove the carton box 6 Remove the bolts 5 and then remove the brackets 6 ÈFX10RT FX10RTR FX10RTRA ÉFX10MT FX10MTR FX10MTRA 6 5 È 6 5 5 É ...

Page 11: ... NOTE The bolts collars and nuts installed are not used for installa tion 7 9 8 8 Remove the PPband 0 0 9 Remove the clips A and pins B and then remove the brackets C Left and right side NOTE The clips pins and brackets are not used for installation A C B B A A B C A ...

Page 12: ...t bumper 1 in the carton box A 6 Flange bolt 4 in the vinyl bag 1 M8 L 20 mm 0 79 in 7 Screw 3 in the vinyl bag 3 M6 L 15 mm 0 59 in 8 Quick fastener 2 in the vinyl bag 3 9 Quick fastener washer 2 in the vinyl bag 3 0 Reflector 2 in the vinyl bag 4 A Nut 2 in the vinyl bag 4 d 5 2 9 9 4 0 0 A A 6 5 6 6 6 7 7 7 1 3 8 8 7 Nm 0 7 m kg 5 1 ft lb 23 Nm 2 3 m kg 17 ft lb 7 Nm 0 7 m kg 5 1 ft lb 23 Nm 2 ...

Page 13: ...e front cover 1 onto the front bumper 2 and then install the bumper to the snowmobile using the flange bolts 3 Then install the front cover using the screws 4 2 Install the reflectors 5 using the nuts 6 6 1 5 3 5 2 3 3 4 4 4 3 ...

Page 14: ... 20 in 2 Windshield 1 in the carton box A For FX10 FX10MT FX10MTR FX10MTRA 3 Windshield 1 in the carton box A For FX10RT FX10RTR FX10RTRA 4 Screw 6 in the vinyl bag 3 M5 L 18 mm 0 71 in 3 2 4 4 1 4 4 4 4 1 1 1 1 1 0 4 Nm 0 04 m kg 0 29 ft lb 0 4 Nm 0 04 m kg 0 29 ft lb 0 4 Nm 0 04 m kg 0 29 ft lb ...

Page 15: ... in the carton box c For FX10RT FX10RTR FX10RTRA 4 Flange bolt 2 in the vinyl bag 2 M10 L 47 mm 1 85 in 5 Self locking nut 2 in the vinyl bag 2 d 10 6 Collar 2 in the vinyl bag 2 D 15 L 36 mm 1 42 in For FX10 FX10MT FX10MTR FX10MTRA 7 Flange bolt 2 in the vinyl bag 2 M10 L 54 mm 2 13 in 8 Self locking nut 2 in the vinyl bag 2 d 10 4 5 1 7 8 Valve face Valve face 2 3 6 45 Nm 4 5 m kg 33 ft lb 45 Nm...

Page 16: ...FX10MT FX10MTR FX10MTRA 2 Washer 4 in the vinyl bag 2 d 16 mm 0 63 in D 25 mm 0 98 in 3 Collar 2 in the vinyl bag 2 L 13 8 mm 0 54 in For FX10 FX10RT FX10RTR FX10RTRA L 30 7 mm 1 21 in For FX10MT FX10MTR FX10MTRA 4 Collar 2 in the vinyl bag 2 L 18 0 mm 0 71 in For FX10 FX10RT FX10RTR FX10RTRA L 26 5 mm 1 04 in For FX10MT FX10MTR FX10MTRA 4 2 2 1 5 3 A 0 9 6 8 7 LS È ...

Page 17: ...X10RTRA 7 Ski stopper 2 in the carton box B For FX10MT FX10MTR FX10MTRA 8 Ski assembly 2 in the carton box E For FX10MT FX10MTR FX10MTRA 9 Flange bolt 2 in the vinyl bag 2 M10 L 130 mm 5 12 in For FX10 FX10RT FX10RTR FX10RTRA M10 L 153 mm 6 02 in For FX10MT FX10MTR FX10MTRA 0 Self locking nut 2 in the vinyl bag 2 M10 A Cotter pin 2 in the vinyl bag 2 4 2 2 1 5 3 A 0 9 6 8 7 LS È ...

Page 18: ...lector stay 1 in the carton box A 6 Bolt 2 in the vinyl bag 3 M5 L 20 mm 0 79 in 7 Left wind deflector 1 in the carton box A 8 Bolt 2 in the vinyl bag 3 M6 L 15 mm 0 59 in 9 Right wind deflector stay 1 in the carton box A 0 Bolt 2 in the vinyl bag 3 M5 L 20 mm 0 79 in A Right wind deflector 1 in the carton box A B Bolt 2 in the vinyl bag 3 M6 L 15 mm 0 59 in C Handlebar cover 1 in the carton box A...

Page 19: ...tion Remark 1 Steering joint 1 in the carton box B 2 Handlebar assembly 1 on the snowmobile 3 Steering joint holder 2 in the carton box B 4 Flange bolt 4 in the carton box B M8 L 185 mm 7 28 in 5 Handlebar cover 1 in the carton box A For FX10MTRA 23 Nm 2 3 m kg 17 ft lb 2 1 3 5 3 4 4 ...

Page 20: ... bolt on the rear side NOTE The handlebar holders 2 should be installed with the punch mark a facing forward Align the punch mark b on the handlebar with the upper surface of the steering joint 2 1 a b 1 2 a Wind deflector For FX10 FX10RT FX10RTR FX10RTRA 1 Install the wind deflector stay holder 1 with the taller end facing forward 1 FWD 2 Align the punch mark a on the handlebar with the top of th...

Page 21: ...y Location Remark 1 Flap stopper 1 in the carton box A 2 Rivet 6 in the vinyl bag 1 3 Flap 1 in the carton box A 4 Rivet 4 in the vinyl bag 1 5 Rear bumper 1 in the carton box B 6 Flange bolt 4 in the carton box B M8 L 20 mm 0 79 in 5 3 6 6 4 1 2 2 26 Nm 2 6 m kg 19 ft lb ...

Page 22: ...0MTRA Parts List No Parts name Qty Location Remark 1 Flap 1 in the carton box A 2 Rivet 4 in the vinyl bag 1 3 Rear bumper 1 in the carton box B 4 Flange bolt 4 in the carton box B M8 L 20 mm 0 79 in 3 4 4 2 1 26 Nm 2 6 m kg 19 ft lb ...

Page 23: ...e shroud left side cover and right side cover in order to per form the adjustments and predelivery service For installation reverse the removal procedure Loosen the fastener 1 and the shroud 2 1 1 2 Loosen the fastener 3 and the right side cover 4 3 4 3 Loosen the fastener 5 and the left side cover 6 6 5 5 SHEAVE OFFSET ADJUSTMENT 1 Remove Shroud Left side cover Refer to SHROUD AND COVERS Drive gu...

Page 24: ...fset Adjustment steps Apply the brake to lock the secondary sheave Remove the secondary sheave bolt 1 washer 2 shim s left and secondary sheave 3 1 2 3 Install the appropriate shim s right 4 from the following table so that the sheave offset is within specification Install the secondary sheave secondary sheave bolt and washer Recheck the sheave offset If out of specifica tion repeat the above step...

Page 25: ...e free play clear ance 1 0 2 0 mm 0 04 0 08 in 5 Adjust Secondary sheave free play clearance Adjustment steps Apply the brake to lock the secondary sheave Remove the secondary sheave bolt 1 and washer 2 Install the appropriate shim s left 3 from the following table so that the secondary sheave free play is within specification Shim size Part number Thickness 90201 252F1 0 5 mm 0 02 in 90201 25527 ...

Page 26: ...ght a Make sure that the secondary clutch is all the way together before measuring the V belt height a 7 Adjust the position of the V belt by removing or adding a spacer 4 on each adjusting bolt 5 8 Tighten the adjusting bolt 5 9 Install the V belt guard WARNING Never run the engine without the V belt or with the V belt guard removed Standard V belt height 0 5 1 5 mm 0 02 0 06 in V belt position A...

Page 27: ...Europe 40 40 20 29 0 18 20 7 40 4 60 F 16 C YAMALUBE 4 S 0W 30 or SAE 0W 30 È 40 29 18 7 4 16 C SAE 0W 30 É ENGINE OIL LEVEL The engine oil level should be checked before each use CAUTION Do not run the engine with too much or not enough oil in the oil tank Oil could flow into the air filter case and the engine could be damaged Checking the engine oil level 1 Place the snowmobile on a level surfac...

Page 28: ...ION When adding the engine oil be careful not to fill above the H level mark on the oil level gauge Make sure that no foreign material enters the engine oil tank 7 Insert the oil level gauge into the oil filler hole and then tighten it securely 8 Connect the oil level switch coupler 9 Install the right side cover Refer to SHROUD AND COVERS Recommended engine oil type For USA Canada YAMALUBE 4 S 0W...

Page 29: ...During this period prolonged full throttle operation or any condition that might result in engine over heating must be avoided Operating your snowmobile for the first time Start the engine and let it idle for 15 minutes 0 160 km 0 100 mi Avoid prolonged operation above 6 000 r min 160 500 km 100 300 mi Avoid prolonged operation above 8 000 r min 500 km 300 mi and beyond The snowmobile can now be o...

Page 30: ... in the cooling system or if there is a cooling system leak CAUTION Operating the engine with an improperly bled cooling system can cause overheating and severe engine damage Checking steps 1 Place the snowmobile on a level surface 2 Check Coolant level The coolant level should be between the FULL mark a and LOW mark b Below the minimum level mark Add the recommended coolant to the proper level 3 ...

Page 31: ...e heat exchanger will be warm to the touch FX10MT FX10MTR FX10MTRA È FX10MT FX10MTR FX10MTRA WARNING To avoid severe injury or death Make sure the snowmobile is securely sup ported with a suitable stand Do not exceed the clutch engagement speed Drive line damage and excessive V belt wear could occur or the snowmobile could unex pectedly move forward if the clutch engages Operate the engine only in...

Page 32: ...ipstick and check that the oil level is within the range shown at the bottom of the dipstick If the oil does not reach the bottom of the dipstick add sufficient oil of the recom mended type to raise it to the correct level È FX10RT FX10MT É FX10 FX10RTR FX10RTRA FX10MTR FX10MTRA CAUTION Be sure no foreign material enters the drive chain housing 5 Install the dipstick 1 6 Install the right side cov...

Page 33: ...ble guide 1 Measure Throttle cable free play a Out of specification Adjust 2 Adjust Throttle cable free play Throttle cable free play 3 0 4 0 mm 0 12 0 16 in a Throttle body side adjustment steps Remove the shroud and then left side cover Loosen the locknut 1 Turn the adjusting nut 2 in direction a or b until the specified free play is obtained 3 Tighten the locknut NOTE If the specified throttle ...

Page 34: ...tains sulfu ric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flames cigarettes etc away Ventilate when charging o...

Page 35: ...ty at 20 C 68 F before installation 5 Install the battery 6 Install the battery bracket 1 7 Connect the battery leads CAUTION First connect the positive battery lead 2 then the negative battery lead 3 Never hammer the battery terminals when connecting the lead terminals to the battery Make sure battery leads are connected prop erly Reversing the leads can seriously dam age the electrical system 8 ...

Page 36: ...yone to hold the rear of the snowmobile off the ground to allow the track to spin Never allow anyone near a rotat ing track Inspect the condition of the track frequently Replace the track if it is damaged to a level where the fabric reinforcement material is vis ible 1 Lift the rear of the snowmobile onto a suitable stand to raise the track off the ground 2 Measure Track deflection a Pull at the t...

Page 37: ...7 Track metal a Gap Ê Forward c Adjust the track deflection until the specified amount is obtained CAUTION The adjusters should be turned an equal amount Recheck alignment and deflection If necessary repeat steps a to c until proper adjustment is achieved Tighten the rear axle nut Track alignment È Shifted to right É Shifted to left 3 Left adjuster nut Turn out Turn in 4 Right adjuster nut Turn in...

Page 38: ...ke start the engine and let it idle 5 Turn the headlight to high beam and check the headlight projection height on the wall The pro jection should be at the parallel mark on the wall H to 1 2 down S from the mark If not adjust the headlight angle D Distance H Height S Set range D 3 0 m 10 ft 7 6 m 25 ft S 26 mm 1 0 in 66 mm 2 6 in 6 Adjust Headlight beam Vertically Adjustment steps Remove the shro...

Page 39: ...nce a is obtained Tighten the locknut 4 Measure Brake pad clearance b c Out of specification Adjust 5 Adjust Brake pad clearance Adjustment steps Loosen the locknut 1 Turn the adjuster 2 in or out to until the speci fied clearance between the brake pads 3 and brake disc 4 is obtained Tighten the locknut Parking brake cable distance 43 5 46 5 mm 1 713 1 831 in Turning in Distance a is increased Tur...

Page 40: ...til the specified toe out is obtained Tighten the locknuts tie rods 1 CAUTION After tightening the inside and outside ball joint locknuts 1 make sure the tie rods 2 can be rotated freely through the ball joint travel If not loosen the locknuts 1 and reposition the ball joint so that the tie rods 2 can be rotated freely Tighten the locknuts to specification Ski toe out 0 15 mm 0 0 59 in Ski stance ...

Page 41: ...e left and right spring preloads are the same Check the front suspension spring preload and adjust if needed Loosen the locknut 1 Adjust the spring preload by turning the spring seat 2 FX10 FX10MT FX10MTR FX10MTRA È FX10 É FX10MT FX10MTR FX10MTRA Spring seat distance Standard Short Long Preload Hard Soft Length a Min 250 mm 9 84 in 260 mm 10 24 in Max 260 mm 10 24 in Spring seat distance Standard ...

Page 42: ...rn the adjusting knob in direction b more than 20 clicks Even if the adjusting knob is continually turned after 20 clicks there will be no change in the rebound damp ing force Be sure to stop the adjusting knob at a posi tion where there is a click The damping forces for the left and right ski shock absorbers must be adjusted to the same settings Uneven settings can cause poor handling and loss of...

Page 43: ...y turned after 12 clicks there will be no change in the compression damping force Be sure to stop the adjusting knob at a posi tion where there is a click The damping forces for the left and right ski shock absorbers must be adjusted to the same settings Uneven settings can cause poor handling and loss of stability Adjusting knob position 12 clicks out 6 clicks out 2 clicks out Minimum Standard Ma...

Page 44: ...nstall the hose connector 2 of the shock absorber pump onto the air valve of the shock absorber and tighten it approximately six turns until the pressure registers on the pump gauge CAUTION Do not overtighten the connector onto the air valve as this will damage the connector seal NOTE If the shock absorber has no air pressure the gauge reading will be zero To increase the air pressure operate the ...

Page 45: ...gf cm 150 psi Install the air valve cap NOTE If the front suspension bottoms too easily or rolls too much during cornering increase the air pres sure by 34 kPa 0 3 kgf cm 5 psi If the suspen sion is too firm and you want a more compliant ride decrease the air pressure by 34 kPa 0 3 kgf cm 5 psi Air pressure range 345 kPa 3 4 kgf cm 50 psi to 1 034 kPa 10 3 kgf cm 150 psi Recommended air pressure 5...

Page 46: ...cs of the snowmobile Adjustment steps Remove the stopper band bolts 1 nuts and washers Adjust the length of the stopper bands 2 by inserting the bolts in different holes È FX10 FX10RT FX10RTR FX10RTRA front side É FX10 FX10RT FX10RTR FX10RTRA rear side Ê FX10MT FX10MTR FX10MTRA Tighten the stopper band nuts Standard setting No 1 holes T R Stopper band nut 4 Nm 0 4 m kg 2 9 ft lb 1 2 No 1 No 2 No 3...

Page 47: ...t the suspension È FX10 FX10RT FX10RTR FX10RTRA front side É FX10 FX10RT FX10RTR FX10RTRA rear side Ê FX10MT FX10MTR FX10MTRA È No 5 hole É No 5 hole Ê No 6 hole shortest No 1 hole longest More weight on skis Heavy steering oversteer More maneuverabil ity Favors hardpack snow ice smooth trails tight turns Less weight on skis Light steering understeer Better acceleration and speed Favors deep snow ...

Page 48: ... Loosen the locknut 1 Adjust the spring preload by turning the spring seat 2 FX10 FX10RT FX10RTR FX10RTRA È FX10 É FX10RT FX10RTR FX10RTRA Spring seat distance Standard Short Long Preload Hard Soft Length a Min 186 mm 7 32 in 196 mm 7 72 in Max 196 mm 7 72 in Spring seat distance Standard Short Long Preload Hard Soft Length a Min 186 mm 7 32 in 196 mm 7 72 in Max 196 mm 7 72 in 2 1 a È a 2 1 É Tur...

Page 49: ...lways adjust both spring preloads left and right to the same setting Uneven adjustment can cause poor handling and loss of stability È FX10 FX10RT FX10RTR FX10RTRA É FX10MT FX10MTR FX10MTRA Spring preload adjuster position S M H Spring preload Soft Medium Hard Standard M 1 È É 1 ...

Page 50: ...ng dial fully turned lightly in direc tion a CAUTION Do not continue to turn the adjusting dial in direction a after it stops The shock absorber can be damaged and damping force adjust ments cannot be made Do not turn the adjusting dial in direction b more than 20 clicks Even if the adjusting dial is continually turned after 20 clicks there will be no change in the damping force Be sure to stop th...

Page 51: ... absorber can be damaged and damping force adjust ments cannot be made Do not turn the adjusting dial in direction b more than 20 clicks Even if the adjusting dial is continually turned after 20 clicks there will be no change in the damping force Be sure to stop the adjusting dial at a position where there is a click Adjusting dial position 20 clicks out 11 clicks out 3 clicks out Minimum Standard...

Page 52: ...absorber can be damaged and damping force adjust ments cannot be made Do not turn the adjusting screw in direction b more than 12 clicks Even if the adjusting screw is continually turned after 12 clicks there will be no change in the damping force Be sure to stop the adjusting screw at a posi tion where there is a click Adjusting screw position 12 clicks out 6 clicks out 2 clicks out Minimum Stand...

Page 53: ...licks there will be no change in the damping force Be sure to stop the adjusting screw at a posi tion where there is a click Adjusting screw position 12 clicks out 6 clicks out 2 clicks out Minimum Standard Maximum Direction b Direction a Compres sion force Soft Hard b a 1 È b a 1 É CONTROL ROD ADJUSTMENT FX10MT FX10MTR FX10MTRA The weight transfer can be adjusted by turning the control rod adjust...

Page 54: ...ight adjusting nut must be set to the same position Uneven settings can cause poor handling and loss of stability WARNING Never adjust the control rod beyond the maxi mum range indicated on the rod with red paint 3 T R Locknut 25 Nm 2 5 m kg 18 ft lb ...

Page 55: ...d level goes down consult a Yamaha dealer CAUTION Brake fluid may deteriorate painted surfaces or plastic parts Never spill any fluid If any is spilled clean it up immediately Recommended brake fluid DOT4 BRAKE FLUID REPLACEMENT Brake fluid replacement is necessary when the fol lowing components are replaced during the peri odic maintenance or if they are damaged or leaking a All rubber seals of t...

Page 56: ...lastic hoses 1 tightly to the cal iper bleed screws 2 d Place the other end of the hoses into a con tainer e Slowly apply the brake lever several times f Pull the lever in Hold the lever in position g Loosen the bleed screws and allow the lever to travel towards its limit h Tighten the bleed screws when the lever limit has been reached then release the lever i Repeat steps e to h until all air bub...

Page 57: ...tainer which comes with the battery Avoid using any electrolyte other than speci fied The specific gravity of the MF battery electro lyte is 1 320 20 C 68 F the specific gravity of the general type battery electrolyte is 1 280 If the electrolyte whose specific grav ity is less than 1 320 the sulfuric acid will decrease and thus low battery performance will result Should any electrolyte whose speci...

Page 58: ...er from the battery until all electrolyte has drained from the con tainer g Leave the container in this position for 20 min utes or longer to allow proper chemical reaction NOTE Make sure air bubbles are rising from all six filler ports If air bubbles are not rising from a filler port tap the top of the container a few times h Be certain that all the electrolyte has been drained from container i F...

Page 59: ...ce explosive gases Keep sparks flame ciga rettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 2 Check Using a digital volt meter the state of a dis charged MF battery can be checked by measur ing open circuit voltage the voltage measured with the positive and negative terminals being disconnected CAUTION Th...

Page 60: ...ce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may ge...

Page 61: ...ge Refer to BATTERY INSPEC TION If the current does not exceed the standard charging current after 5 minutes replace the battery If charging requires more than 5 hours it is advisable to check the charg ing current after a lapse of 5 hours If there is any change in the amper age readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after leaving the ...

Page 62: ...TRA Europe Throttle body Type quantity 41EIDW 2 Throttle valve ø41 Idling engine speed 1 450 1 550 r min Spark plug Type CR9E NGK Gap 0 7 0 8 mm 0 028 0 031 in Clutch Engagement r min 3 100 3 500 r min FX10MTR Europe FX10MTRA Europe 3 300 3 700 r min FX10MT FX10MTR USA Canada FX10MTRA USA Canada 3 550 3 950 r min FX10 FX10RT FX10RTR FX10RTRA Shift r min 8 550 8 950 r min Clutch alignment Offset 13...

Page 63: ...sion 1 Use a grease gun to inject grease into the nip ples 2 Apply grease to the pivoting parts È FX10 FX10RT FX10RTR FX10RTRA É FX10MT FX10MTR FX10MTRA 1 Nipple 2 Nipple both sides Recommended lubricant ESSO Beacon 325 Grease or Aeroshell Grease 7A 1 2 È É ...

Page 64: ...6 1 CABLE ROUTING G K L N M P O I H J R 8 9 9 g 0 A B C D F E 1 2 3 4 5 6 7 Q S T U V W X Y Z _ D a b c d e f j i h k l 6 m ...

Page 65: ... cross member with the plastic band K Fasten the wire harness and fuel tank breather hose to the frame rear cross member L Fasten the hose protector of the fuel tank breather hose to the rear frame cross member with the plastic band making sure to fasten it after the bend in the hose as shown in the illustration M Fuel tank breather hose N The ends of the hose protector should be 20 mm 0 79 in or ...

Page 66: ...6 3 G K L N M P O I H J R 8 9 9 g 0 A B C D F E 1 2 3 4 5 6 7 Q S T U V W X Y Z _ D a b c d e f j i h k l 6 m ...

Page 67: ...ight Face the ends of the hose clamp rearward ISC idling speed control unit _ 20 40 mm 0 79 1 57 in a Speed sensor coupler b Radiator fan motor coupler c Fuel injection system sub wire harness coupler d Intake air pressure sensor 1 cyl inders 1 2 and 3 e Intake air pressure sensor 2 cyl inders 1 f Fasten the wire harness oil pres sure switch sub lead and crank shaft position sensor lead to the fra...

Page 68: ...6 5 I H N O P J K L M Q R S T U V W 9 A 0 B C D E F G 1 2 3 4 5 6 7 8 Y Z X _ a 2 b c d e f d A B B A ...

Page 69: ...fuel tank breather hose to the frame with a plastic locking tie and then cut off the excess end of the tie D Face the ends of the hose clamp rearward E Install the fuel tank breather hose completely onto the hose joint making sure that the end of the hose contacts the frame F Fasten the corrugated tube of the speed sensor lead with the hold ers G Speed sensor H Water pump inlet hose I Fasten the w...

Page 70: ...6 7 I H N O P J K L M Q R S T U V W 9 A 0 B C D E F G 1 2 3 4 5 6 7 8 Y Z X _ a 2 b c d e f d A B B A ...

Page 71: ...plastic band X To the headlight left Y Slide the rubber coupler over the engine stop switch coupler throt tle switch couplers right grip warmer coupler and thumb warmer coupler Z Pass the plastic band through the holes in the rubber cover and then fasten the cover with the band making sure that the band is not fastened over the projections at the top of the cover To the headlight right Speedometer...

Page 72: ...6 9 B C D E F G H I J 9 0 A 2 3 4 5 7 6 1 8 K Q M L N O P R S T U X W V Y Z 1 a _ b c d T f g d 8 h e A A B B A B B A ...

Page 73: ...tch coupler B To the air filter case C Fasten the wire harness to the headlight stay with the plastic band D Oil tank breather hose E Main fuse F Starter relay G Starter motor lead H Fasten the starter motor lead to the oil tank inlet hose with the plastic band making sure not to pinch the hose I Fasten the stator coil lead to the front frame with the plastic band making sure to route it to the in...

Page 74: ...6 11 B C D E F G H I J 9 0 A 2 3 4 5 7 6 1 8 K Q M L N O P R S T U X W V Y Z 1 a _ b c d T f g d 8 h e A A B B A B B A ...

Page 75: ...brake light coupler Y Negative battery lead Z Negative battery lead coupler Fuel sender coupler Battery DC back buzzer coupler FX10 FX10RTR FX10RTRA FX10MTR FX10MTRA _ Fuel tank breather hose a Fasten the brake hose with the holder b Fasten the fuel tank breather hose to the rear cross member with the plastic band c Main switch coupler d Wire harness e To the wire harness f Pass the wire harness t...

Page 76: ...6 13 G H I J K L L M A 0 0 0 B C D E H 9 F 1 1 2 3 4 5 6 9 O P L 2 6 1 M L 1 6 2 N M A A A A 8 7 ...

Page 77: ...dlight stay with the plastic band mak ing sure to route the tube to the rear of the stay and the harness to the rear of the tube 0 To the wire harness A Fasten the headlight unit lead and speedometer unit sub lead to the headlight stay with the plastic band B To the headlight left C To the throttle body D To the headlight right E To the coolant reservoir F To the parking brake G To the brake calip...

Page 78: ...6 15 G H I J K L L M A 0 0 0 B C D E H 9 F 1 1 2 3 4 5 6 9 O P L 2 6 1 M L 1 6 2 N M A A A A 8 7 ...

Page 79: ...t switch lead brake light switch lead and headlight beam switch lead cor rugated tube engine stop switch lead throttle switch leads right grip warmer lead and thumb warmer lead and brake hose with the plastic band FX10MT FX10MTR FX10MTRA O 40 70 mm 1 57 2 76 in P 30 60 mm 1 18 2 36 in ...

Page 80: ...6 17 9 1 2 3 4 5 6 6 7 7 8 ...

Page 81: ... brake light lead 4 After routing the tail brake light lead bend the holder around the lead to fasten it 5 Fasten the tail brake light lead with the holder FX10 FX10RT FX10RTR FX10RTRA 6 Pass the tail brake light lead through the notch in the tail brake light bracket 7 Tail brake light 8 Tail brake light sub wire harness 9 Tail brake light sub wire harness coupler ...

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Page 84: ...ASSEMBLY MANUAL FX10X FX10RTX FX10RTRX FX10RTRAX FX10MTX FX10MTRX FX10MTRAX LIT 12618 02 69 8GL 28107 10 PRINTED ON RECYCLED PAPER PRINTED IN U S A 2007 06 CR E YAMAHA MOTOR CO LTD ...

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