Yamaha GCH I 237 Owner'S Manual Download Page 1

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DIC183

ESU10022

OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
USO E MANUTENZIONE
INSTRUKTIONSBOK
OMISTAJAN KÄSIKIRJA
EIERHÅNDBOK

Les denne håndboken nøye før du tar kjøretøyet i bruk.

Lue tämä 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.

VK10F

8JE-28199-S2

Summary of Contents for GCH I 237

Page 1: ...u tar kjøretøyet i bruk Lue tämä 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 VK10F 8JE 28199 S2 ...

Page 2: ...IMÉ SUR PAPIER RECYCLÉ STAMPATO SU CARTA RICICLATA TRYCKT PÅ ÅTERVUNNET PAPPER PAINETTU UUSIOPAPERILLE TRYKKET PÅ RESIRKULERT PAPIR 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 VK10F 8JE 28199 S2 E0 U8JES2E0 book Page 1 Friday March 28 2014 11 06 AM ...

Page 4: ...rect application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title and or number and date of issue of standards and or specifications General Manager Engineering Div RV Business Unit Business Development Operations YAMAHA MOTOR CO LTD Signature Date of Issue Akihiro Tsuzuki 10 October 2013 YA...

Page 5: ... uct information available at the time of print ing there may be minor discrepancies between your snowmobile and this manual If there is any question concerning this manual please consult a Yamaha dealer WARNING EWS00671 Please read this manual carefully before operating this snowmobile Do not at tempt to operate this snowmobile until you have attained adequate knowledge of its controls and operat...

Page 6: ...ety messages that follow this symbol to avoid possible injury or death WARNING EWS00022 A WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE ECS00012 A NOTICE indicates special precautions that must be taken to avoid damage to the snowmobile or other property TIP A TIP provides key information to make pro cedures easier or clearer U8JES2E0 ...

Page 7: ...ch bracket 25 Fuel 26 Suspension 27 Pre operation checks 30 Pre operation check list 30 Operation 32 Starting the engine 32 Break in 33 Riding your snowmobile 33 Maximizing drive track life 37 Strap 38 Driving 38 Stopping the engine 39 Transporting 39 Periodic maintenance and adjustment 41 Periodic maintenance chart for the emission control system 42 General maintenance and lubrication chart 43 To...

Page 8: ... a headlight bulb 70 Adjusting the headlight beams 71 Fittings and fasteners 71 Battery 71 Replacing a fuse 72 Troubleshooting 75 Storage 79 Specifications 81 Consumer information 83 Identification number records 83 WARRANTY 83 Index 84 U8JES2E0 book Page 2 Friday March 28 2014 11 06 AM ...

Page 9: ...mportant information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer For EUROPE 8 7 12 13 14 1 2 6 5 3 4 10 11 15 9 U8JES2E0 book Page 1 Friday March 28 2014 11 06 AM ...

Page 10: ...SONT SUSCEPTIBLES DE CHANGER SANS NOTIFICATION PRÉALABLE 350 cm 11 8 oz GL 3 75W or 80W 30 35 mm 1 18 1 38 in 100 N 10 kg 22 lb 350 cm GL 3 75W or 80W 8JD 47578 00 30 35 mm 100 N 10 kg TUNE UP SPECIFICATIONS SPECIFICATIONS DE LA MISE AU POINT TUNE UP SPECIFICATIONS ENGINE 1 SPARK PLUG 2 SPARK PLUG GAP 3 IDLE SPEED SPECIFICATIONS DE LA MISE AU POINT MOTEUR 1 TYPE DE BOUGIE 2 ECARTEMENT DES ÉLECTROD...

Page 11: ...kunnolla akun huollon tai imakammion irrotuksen jälkeen Katso lisätietoja Huolto ohjeesta Allvarlig motorskada kan uppstå vid oljeförlust om vevhusventilatorns slangar inte monterats korrekt Kontrollera att slangar och kiämmor är korrekt monterade efter batteriservice eller avlägsnande av luftlådan Se verkstadshandboken 8GS 2815J S0 8FA S0 8FA 2389C S0 8KB 2156A 00 VK10D 84 7 kW 388 kg 8AC 2817L 0...

Page 12: ...e or open This pictogram shows the sled hitch tow weight limit combined weight of the sled and all cargo in the sled Overloading can cause loss of control Loss of control can result in severe injury or death This pictogram shows the sled hitch tongue weight limit weight on the sled tongue Overloading can cause loss of control Loss of control can result in severe injury or death 1 2 3 Model Name Ma...

Page 13: ...Location of the important labels 5 For RUSSIA 9 8 12 11 13 14 15 16 1 2 7 5 3 4 6 17 10 U8JES2E0 book Page 5 Friday March 28 2014 11 06 AM ...

Page 14: ...S SONT SUSCEPTIBLES DE CHANGER SANS NOTIFICATION PRÉALABLE 350 cm 11 8 oz GL 3 75W or 80W 30 35 mm 1 18 1 38 in 100 N 10 kg 22 lb 350 cm GL 3 75W or 80W 8JD 47578 00 30 35 mm 100 N 10 kg TUNE UP SPECIFICATIONS SPECIFICATIONS DE LA MISE AU POINT TUNE UP SPECIFICATIONS ENGINE 1 SPARK PLUG 2 SPARK PLUG GAP 3 IDLE SPEED SPECIFICATIONS DE LA MISE AU POINT MOTEUR 1 TYPE DE BOUGIE 2 ECARTEMENT DES ÉLECTR...

Page 15: ...7 8GS 77763 S0 5kg 11lbs MAX BELASTNING RASKAINTAAKKA 8FN 24897 10 20kg 44lbs MAX BELASTNING RASKAINTAAKKA 8FM 24897 11 8FN 77761 R1 1176 N 147 N 8HF 2817S 00 8JE 77764 R0 5 6 7 8 9 10 U8JES2E0 book Page 7 Friday March 28 2014 11 06 AM ...

Page 16: ...sätietoja Huolto ohjeesta Allvarlig motorskada kan uppstå vid oljeförlust om vevhusventilatorns slangar inte monterats korrekt Kontrollera att slangar och kiämmor är korrekt monterade efter batteriservice eller avlägsnande av luftlådan Se verkstadshandboken 8GS 2815J S0 8FA S0 8FA 2389C S0 8KB 2156A 00 VK10D 84 7 kW 388 kg 8AC 2817L 00 YAMAHAMOTORCO LTD 2500SHINGAI IWATA JAPAN 2014 8HN 2811S 00 11...

Page 17: ...rake before starting the engine Never drive the snowmobile with the parking brake applied This may over heat the brake disc and reduce braking ability While using your snowmobile This snowmobile was not manufactured for use on public streets roads or highways Such use is prohibited by law and you could collide with another vehicle Be careful where you ride There may be obstacles hidden beneath the...

Page 18: ...ure parts and accessories or offer other modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket companies produce Therefore Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifica tions not specifically recommended by Yamaha even if sold and installed by a Yamaha dealer Maintenance and storage When laying the...

Page 19: ...voir 4 Fuse box 5 Throttle stop screw 6 Main fuse 7 Oil filler cap 8 V belt holder 9 Strap 10 Storage compartment 11 Tool kit 12 Passenger grip warmer switch 13 Rear carrier 14 Tail brake light 15 Tow hitch bracket 16 Slide rail suspension 17 Drive track U8JES2E0 book Page 11 Friday March 28 2014 11 06 AM ...

Page 20: ...ted to change without notice 1 10 2 3 4 5 6 7 8 9 11 12 8 1 Brake lever 2 Parking brake lever 3 Grip warmer adjusting switch 4 Headlight beam switch 5 Engine stop switch 6 Thumb warmer adjusting switch 7 Throttle lever 8 Shroud latch 9 Shift lever 10 Main switch 11 Auxiliary DC jack 12 Starter choke lever U8JES2E0 book Page 12 Friday March 28 2014 11 06 AM ...

Page 21: ...d ESU10302 Starter choke lever Use the starter choke lever when starting and warming up a cold engine TIP Refer to the Starting the engine section on page 32 for proper operation ESU10313 Throttle lever Once the engine is running cleanly squeez ing the throttle lever will increase the engine speed and cause engagement of the drive train Regulate the speed of the snowmobile by varying the throttle ...

Page 22: ...4 will flash in the meter display If this occurs have a Yamaha dealer check the system as soon as possible ESU10357 Multi function meter unit The multi function meter unit is equipped with the following a digital speedometer a tachometer an odometer a tripmeter which shows the distance trav eled since it was last set to zero warning indicators which show engine trouble coolant temperature fuel lev...

Page 23: ...r mode ODO and then push the select reset button for at least 10 seconds while the snowmobile is stopped ESU10412 High beam indicator light The high beam indicator light comes on when the high beams of the headlights are switched on See page 19 for headlight beam switch operation ESU10485 Low coolant temperature indi cator light The low coolant temperature indicator light comes on when the coolant...

Page 24: ... the thumb warmer level Fuel meter The display segments of the fuel meter disap pear towards E Empty as the fuel level de creases When only one segment is left near E the fuel level warning indicator and the warning light come on If the fuel level warning indicator and the warning light come on refuel as soon as pos sible TIP The snowmobile must be stopped on a level surface to obtain an accurate ...

Page 25: ...e maximum level The bottom segment of the grip thumb warmer level indicator flashes once when the grip thumb warmer adjustment reaches the minimum level When the engine is started the grip thumb warmer levels are set to the levels selected when the engine was last stopped ESU10456 Fuel level warning indicator The fuel level warning indicator and the warn ing light come on when the fuel level is lo...

Page 26: ...ry If the oil level warning indicator and the warn ing light still remain on have a Yamaha dealer check the snowmobile ESU10514 Coolant temperature warning indicator If the engine overheats the coolant tempera ture warning indicator and the warning light come on When this occurs stop the engine immediately and allow the engine to cool down and then check the coolant level in the coolant reservoir ...

Page 27: ...starting procedures During the first few rides practice using the stop switch so that you can react quickly in an emergency ESU10662 Headlight beam switch LIGHTS Push the headlight beam switch to change the headlight to high beam HI or to low beam LO ESU12655 Grip thumb warmer adjusting switch The grip warmer adjusting switch and the thumb warmer adjusting switch control the electrically heated ha...

Page 28: ...ack 3 After using the auxiliary DC jack be sure to remove the accessory power plug from the jack and to close the auxiliary DC jack cap NOTICE ECS00123 To avoid circuit overload and a possible fuse blowing do not use accessories re quiring more than the maximum rated capacity for the auxiliary DC jack See page 72 for the specified fuse amper age Do not use an automotive cigarette lighter or other ...

Page 29: ... To release the parking brake move the park ing brake lever to the right ESU12563 Shift lever The shift lever is used to shift your snowmo bile into drive reverse or low After coming to a complete stop pull the shift lever out turn it to the desired position D R or L and then release it TIP Make sure that the shift lever is completely shifted into position NOTICE ECS00073 Do not use the shift leve...

Page 30: ...ase parts break or come loose ESU10762 V belt holders Keep a spare V belt for emergency use by placing it into the V belt holders provided NOTICE ECS00181 Make sure that the V belt is installed se curely in the holders ESU10781 Carburetor coolant shut off le ver The carburetor coolant shut off lever controls the flow of coolant through the carburetor Make sure that the lever is in the ON posi tion...

Page 31: ...r switch controls the electrically heated passenger grips ESU10832 Storage areas This snowmobile is equipped with a storage compartment storage pouches rear storage area and rear carrier Storage compartment The storage compartment is located under the rider seat Use the storage compartment to store the tool kit spare parts and other small items The storage compartment extends under the fuel tank s...

Page 32: ...torage area and the rear carrier are located at the rear of the snowmobile The rear storage area is located under the passenger seat and it can be used only when the seat and backrest are removed WARNING EWS00141 Do not use the rear carrier to lift the snow mobile The snowmobile could fall which could result in severe injury or death To remove the passenger seat and backrest 1 Open the rider seat ...

Page 33: ...at and backrest forward NOTICE Make sure that the wire harness is not pinched when installing the passen ger seat and backrest ECS00232 3 Install the passenger seat bolts and then tighten them to the specified torque ESU10864 Tow hitch bracket NOTICE ECS00242 To prevent premature wear of the V belt avoid traveling under 10 km h 6 mi h when towing for long distances or long pe riods of time This sn...

Page 34: ...s and clothes dry ers 2 Do not overfill the fuel tank Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immediately 4 Be sure the fuel tank cap is closed se curely by turning it clockwise WARNING EWS00681 Gasoline is poisonous and can cause in...

Page 35: ...0152 Read and understand the following infor mation before handling shock absorbers that contain highly pressurized nitrogen gas Do not tamper with or attempt to open the cylinder assemblies Do not subject the shock absorbers to an open flame or other high heat source This may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylinders in any way Cylinder damage w...

Page 36: ... turn the adjusting ring in direction b Rear torsion springs WARNING EWS00751 The left and right spring preloads must be adjusted to the same setting Uneven set tings can cause poor handling and loss of stability To increase the spring preload and thereby harden the suspension turn the adjuster in direction a To decrease the spring preload and thereby soften the suspension turn the adjuster in dir...

Page 37: ...ng preload turn the adjusting nut in direc tion b TIP The spring preload setting is determined by measuring distance A shown in the illustra tion The longer distance A is the higher the spring preload the shorter distance A is the lower the spring preload 1 Spring preload adjuster Spring preload setting Minimum soft S Standard S Maximum hard H 1 b a 1 Spring preload adjusting nut 2 Distance A Spri...

Page 38: ...essary add recommended oil to specified level Check vehicle for oil leakage 50 Coolant Check coolant level Add if necessary 55 V belt Check for wear and damage Replace if necessary 56 Drive guard Make sure the drive guard is installed securely Check the drive guard mounts for damage 22 Brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check brake pads for wear Repl...

Page 39: ...maha dealer replace slide runners 66 Steering Check for excessive free play 65 Strap Check for damage Replace if necessary 38 Lights signals and switch es Check operation Correct if necessary 19 19 70 71 Throttle lever Make sure that operation is smooth and spring back to its original position when released 13 Throttle override system T O R S Check the T O R S for proper operation If system is not...

Page 40: ...rake 2 Be sure the engine stop switch is in the run position The starter motor cannot be operated when the engine stop switch is in the off position 3 Fully open the starter choke lever TIP The starter choke lever is not required when the engine is warm Move the starter choke lever to the closed position 4 Turn the main switch to the start position and release it when the engine starts NOTICE Rele...

Page 41: ...f operation the engine oil must be changed and the oil filter cartridge replaced If any engine trouble should occur dur ing the engine break in period immedi ately have a Yamaha dealer check the snowmobile ESU12626 Riding your snowmobile Getting to know your snowmobile WARNING EWS00212 To avoid severe injury or death Keep both hands on the handlebar dur ing operation Never put your feet outside th...

Page 42: ...ur snowmobile To start out and accelerate 1 With the engine idling release the park ing brake 2 Apply the throttle slowly and smoothly The V belt clutch will engage and you will start to accelerate WARNING Do not allow anyone to stand behind the snowmobile when starting the engine A broken track track fittings or debris thrown by the track could be danger ous to bystanders EWS00691 Braking WARNING...

Page 43: ...n climbs straight up the hill this can be accomplished by leaning forward and on steeper inclines standing on the running boards and leaning forward over the handlebar Also see Traversing a slope Slow down as you reach the crest of the hill and be prepared to react to obstacles sharp drops or other vehicles or people which may be on the other side If you are unable to con tinue up a hill do not sp...

Page 44: ... again in the direction you wish to travel If your snowmobile starts to tip steer down the hill to regain balance WARNING If you are unable to maintain correct balance and your snowmobile is going to tip over dismount your snowmobile immediately on the uphill side to avoid being hit or caught under the snowmobile as it tips over EWS00262 Ice or icy surface WARNING EWS00271 When you have to operate...

Page 45: ...ial break in the new drive track will tend to stretch quickly as the track settles Be sure to correct the track tension and align ment frequently See page 66 for adjustment procedures A loose track can slip ratchet derail or catch on suspension parts causing severe damage Do not overtighten the drive track otherwise it may increase the friction between the track and the slide runners re sulting in...

Page 46: ...e Do not use the strap as a mounting point for cargo or accessories ESU12577 Driving WARNING EWS00301 Be sure to read the SAFETY INFORMA TION section on page 9 and the Riding your snowmobile section on page 33 carefully before operating the snowmo bile WARNING EWS00632 Make sure that the throttle lever is fully released and the snowmobile is at a full stop before shifting Be sure to turn the shift...

Page 47: ... transporting your snowmobile on a trailer or in a truck observe the following rec ommendations to help protect it from dam age Make sure that the fuel level in the fuel tank is lower than the bottom of the carburetors Otherwise the vibration and bumps from the road surface could make it possible for fuel to flow through the carburetors into the cylinders This can result in hydrostatic lock a cond...

Page 48: ...n the shroud and also help protect the snowmobile against damage from debris on the road If transporting the snowmobile in an open trailer or truck in areas where road salt is used coat metal suspension surfaces lightly with oil or another protectant This will help protect against corrosion Be sure to clean the snowmobile when you get to your destination to remove any corrosive salts U8JES2E0 book...

Page 49: ...ing can lead to eye injury burns fire or carbon mon oxide poisoning possibly leading to death See page 9 for more information about carbon monoxide WARNING EWS00791 Brake discs calipers and linings can become very hot during use To avoid possible burns let brake components cool before touching them Maintenance replacement or repair of the emission control devices and systems may be performed by an...

Page 50: ...cessary 46 Valve clearance Check and adjust valve clear ance when engine is cold Every 40000 km 25000 mi 50 Crankcase breath er system Check breather hose for cracks or damage Replace if necessary Fuel filter Check condition Replace if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Idle speed Check and adjust idle speed 47 Carburetors Adjust synchronization Adjust th...

Page 51: ...or wear for primary Inspect ramp shoes bushings for wear for secondary Replace if necessary Lubricate with specified grease Drive chain Check chain slack Adjust if necessary Initial at 500 km 300 mi and every 800 km 500 mi thereafter 59 Drive chain oil Check oil level 59 Change 59 Shift lever Lubricate with specified grease Brake and parking brake Adjust free play and or replace pads if necessary ...

Page 52: ... Steering system Check toe out Adjust if necessary 65 Steering bearings Check bearing assemblies for looseness Lubricate with specified grease Skis and front shock absorbers Lubricate with specified grease 69 Suspension compo nent Lubricate with specified grease 69 Drive track Check the deflection Adjust if necessary Initial at 500 km 300 mi and every 800 km 500 mi thereafter 66 Fittings and faste...

Page 53: ...u while riding the snowmobile so that minor re pairs can be done if necessary The following should be carried at all times Flashlight Roll of plastic tape Steel wire Tow rope V belt Light bulbs When you start out for a long distance trip extra fuel should be carried as well ESU13963 Openingandclosing the shroud and removing and installing the right side cover WARNING EWS00811 Be sure the shroud an...

Page 54: ...ak or carburetion problem for that cylinder Do not attempt to diagnose such problems yourself Instead take the snowmobile to a Yamaha dealer for inspection and possible repairs You should periodically remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode Consult a Yamaha dealer before changing to a different type of spark plug WARNING...

Page 55: ... Start the engine and warm it up TIP Refer to the Starting the engine section on page 32 3 Open the shroud 4 Turn the throttle stop screw in or out to adjust the engine idling speed 5 Close the shroud ESU11825 Adjusting the throttle lever free play NOTICE ECS00411 Be sure to adjust the engine idling speed first 1 Place the snowmobile on a level surface and apply the parking brake 2 Open the shroud...

Page 56: ...gine to the point that the clutch engages Check the T O R S for proper operation 1 Start the engine TIP Refer to the Starting the engine section on page 32 2 Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb above and forefinger be low between the throttle lever pivot and the engine stop switch housing While holding the pivot point as de scribed above s...

Page 57: ...is no snow under the air filter element frame after each ride In addition snow may need to be cleaned during a ride depending on the riding conditions 1 Place the snowmobile on a level surface and apply the parking brake 2 Open the shroud 3 Remove the air filter case cover by un hooking the case fastener and the case cover fasteners 4 Lift up the air filter element frame and check the air filter e...

Page 58: ...your snowmobile may also re quire different settings for the drive chain gears and V belt clutch to avoid poor perfor mance and rapid wear If you plan to operate your snowmobile at an altitude different from the area where you bought it be sure to con sult a Yamaha dealer The dealer can tell you if there are any changes necessary for the al titude where you plan to ride NOTICE The drive chain gear...

Page 59: ...ing the snowmobile allow the engine to idle for at least 10 seconds be fore turning it off 3 Open the shroud 4 Disconnect the oil level gauge coupler NOTICE Disconnect the oil level gauge coupler before removing the oil filler cap otherwise the cable could twist and break ECS00453 5 Remove the oil filler cap wipe the dip stick clean insert it back into the oil filler hole without screwing it in an...

Page 60: ...tighten the oil filler cap 8 Connect the oil level gauge coupler 9 Close the shroud To change the engine oil with or without oil filter cartridge replacement 1 Place the snowmobile on a level surface and apply the parking brake 2 Start the engine warm it up for several minutes and then turn it off 3 Open the shroud 4 Remove the right side cover and the bot tom panel 5 Place an oil pan under the oi...

Page 61: ... crankcase near the engine oil drain bolt Dispose of used oil according to local reg ulations Skip steps 10 12 if the oil filter cartridge is not being replaced 10 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a Yamaha dealer 11 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1 Cylinder head cap 1 Engine oil drain b...

Page 62: ...ral minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and make sure that the en gine oil drain bolt oil tank drain bolt cyl inder head cap and the oil filler cap are installed correctly 19 Turn the engine off and then connect the oil level gauge coupler NOTICE If oil is leaking or the oil level warning indica tor comes on when the engine is run ning immedi...

Page 63: ... coolant until it reaches the FULL mark See the following section Re plenishing the coolant for more details NOTICE If coolant is not available use distilled water or soft tap water in stead Do not use hard water or salt water since it is harmful to the engine If water has been used instead of coolant replace it with coolant as soon as possible otherwise the cool ing system will not be protected a...

Page 64: ...ine with the drive guard removed Make sure that the drive guard is in stalled securely before operating the snowmobile to protect against severe injury or death from a broken V belt or other part should it come off the snow mobile while it is in operation NOTICE ECS00831 Never run the engine with the V belt re moved Clutch components can be dam aged The V belt should be checked before each ride To...

Page 65: ...1 Place the snowmobile on a level surface and apply the parking brake 2 Open the shroud and remove the drive guard 3 Rotate the secondary sliding sheave clockwise and push it so that it separates from the secondary fixed sheave 4 Pull the V belt up over the secondary fixed sheave 5 Remove the V belt from the secondary sheave assembly and primary sheave assembly 6 Temporarily install the new V belt...

Page 66: ...ndard V belt position From 1 5 mm 0 06 in above the edge of the secondary sheave as sembly to 0 5 mm 0 02 in below the edge 2 1 1 V belt position adjusting bolt 2 Spacer V belt position Adjustment More than 1 5 mm 0 06 in above the edge Remove a spacer From 1 5 mm 0 06 in above the edge to 0 5 mm 0 02 in below the edge Not necessary it is correct More than 0 5 mm 0 02 in below the edge Add a space...

Page 67: ...surface and apply the parking brake 2 Remove the rubber cap 3 Check the oil level through the check window located on the drive chain hous ing If the oil is below the minimum level mark remove the dipstick and add suffi cient oil of the recommended type to raise it to the maximum level mark NOTICE Make sure that no foreign material enters the drive chain hous ing ECS00532 1 Secondary sliding sheav...

Page 68: ...ft spongy feeling in the brake lever indicates a failure in the brake system Do not operate the snowmobile if you find any problems in the brake system You could lose braking ability which could lead to an accident Ask a Yamaha dealer to inspect and repair the brake system NOTICE ECS00061 Make sure that the brake lever end does not project out over the handlebar end This will help prevent brake le...

Page 69: ...roud 2 Check the parking brake pads for wear by measuring the thickness of the pads If the parking brake pads reach the wear limit ask a Yamaha dealer to replace them 3 Close the shroud To adjust the parking brake As the parking brake pads wear adjustment may be necessary to ensure proper brake performance 1 Open the shroud 2 Loosen the parking brake pad adjusting bolt locknut and the parking brak...

Page 70: ...ystem reducing brak ing performance Clean the filler cap before removing Use only DOT 4 brake fluid from a sealed container Use only the specified brake fluid other wise the rubber seals may deteriorate causing leakage Refill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reac tion Be careful that water does not enter the brake fluid reserv...

Page 71: ...s are replaced dur ing the periodic maintenance or if they are damaged or leaking All oil seals of the master cylinder and cali per cylinder The brake hose ESU14281 Extrovert drive sprocket Check the extrovert drive sprocket for wear and damage Replace if necessary To measure the drive sprocket wear Measure the drive sprocket tooth width If the tooth width is less than 28 mm 1 10 in re place the d...

Page 72: ...pecification 1 Ski wear limit 2 Ski runner Ski runner wear limit 8 0 mm 0 31 in Ski wear limit 24 0 mm 0 94 in 1 Ski runner wear limit 1 2 1 1 Ski wear limit front 2 Ski runner 3 Ski wear limit center 4 Ski wear limit rear Ski runner wear limit 8 0 mm 0 31 in Ski wear limit front 7 0 mm 0 28 in Ski wear limit center 6 0 mm 0 24 in Ski wear limit rear 12 0 mm 0 47 in 3 2 1 4 2 2 U8JES2E0 book Page ...

Page 73: ...ar slightly to the right and left If excessive free play is felt consult a Yamaha dealer To adjust the handlebar height 1 Remove the handlebar cover 2 Loosen the handlebar bolts 3 Move the handlebar up or down to adjust the handlebar height to the desired posi tion NOTICE Make sure that the pro jection on the handlebar is not installed into the area shown ECS00572 1 Distance A 2 Distance B Ski toe...

Page 74: ...f the snowmo bile off the ground to allow the drive track to spin Never allow anyone near a rotating drive track Inspect the drive track condition fre quently Replace any damaged slide metal Replace the drive track if it is damaged to the depth where fabric rein forcement material is visible or support rods are broken Otherwise track dam age or failure could result in loss of braking ability and s...

Page 75: ... drive track Measuring the drive track deflection 1 Lay the snowmobile on its side 2 Measure the drive track deflection with a spring scale Pull at the center of the drive track with a force of 100 N 10 kgf 22 lbf TIP Measure the gap between the slide runner and the edge of the track window on both sides 3 If the deflection is incorrect adjust the drive track Adjusting the drive track alignment an...

Page 76: ...ICE The right and left ad justing nuts should be turned an equal amount ECS00593 1 Rear axle nut Drive track alignment Shifted to right Shifted to left Left adjusting nut Turn out Turn in Right adjust ing nut Turn in Turn out 1 Left adjusting nut 2 Right adjusting nut 1 Forward 2 Gap 3 Slide runner 4 Drive track 5 Slide metal 1 Forward 2 Gap 3 Slide runner 4 Drive track 5 Slide metal Drive track d...

Page 77: ...e slide runners ESU12199 Lubrication Lubricate the following points with the speci fied grease WARNING EWS00512 Do not grease the throttle cable because it could become frozen which could cause loss of control Apply a dab of grease onto the cable end only TIP For parts equipped with a grease nipple use a grease gun Rear axle nut tightening torque 75 Nm 7 5 m kgf 54 ft lbf 1 Slide runner 2 Wear lim...

Page 78: ...nd then hook the bulb holder onto the headlight unit NOTICE Keep oil and your hands away from the glass part of the bulb or its life and illumination will be affect ed If the glass is oil stained thorough ly clean it with a cloth moistened with alcohol or lacquer thinner ECS00622 1 Grease nipple 1 Grease nipple 1 Grease nipple 1 1 1 1 1 Headlight coupler 2 Bulb holder cover 1 Bulb holder 1 2 U8JES...

Page 79: ...ence and torque if necessary ESU14021 Battery The battery is located under the air filter case See page 72 This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the electrolyte or to add dis tilled water However the battery lead con nections need to be checked and if necessary tightened WARNING EWS00541 Battery electrolyte is poisonous and dan gerous It con...

Page 80: ...e battery to or discon nect it from the snowmobile while it is being charged Sparks may ignite the hydrogen gas created by the battery Make sure that the battery terminals are tight NOTICE ECS00844 To charge a VRLA Valve Regulated Lead Acid battery a special constant voltage battery charger is required Us ing a conventional battery charger will damage the battery Do not charge the battery quickly ...

Page 81: ...ive battery lead 7 Replace the blown fuse with one of the proper amperage 1 Oil tank breather hose clamp 2 Oil tank breather hose 3 Crankcase breather hose clamp air filter case side 4 Crankcase breather hose 1 Main fuse 2 Spare main fuse 1 HEAD headlight fuse 2 SIG signaling system fuse 3 DC TERM auxiliary DC jack fuse 4 C W carburetor warmer fuse 5 IGN ignition fuse 6 FAN radiator fan fuse 7 Spa...

Page 82: ...case ECS00642 10 Close the shroud TIP If the fuse immediately blows again ask a Yamaha dealer to inspect the snowmobile Specified fuses Main fuse 30 0 A Spare main fuse 30 0 A Headlight fuse 20 0 A Signaling system fuse 10 0 A Auxiliary DC jack fuse 3 0 A Carburetor warmer fuse 20 0 A Ignition fuse 15 0 A Radiator fan fuse 15 0 A Spare fuses 20 0 A 15 0 A 10 0 A 3 0 A U8JES2E0 book Page 74 Friday ...

Page 83: ...hrot tle returns properly to the fully closed position The T O R S is an important safety device in the case of a malfunction take the snowmobile to a Yamaha dealer immediately for repair EWS00562 3 Compression Insufficient Loose cylinder head nuts Tighten nuts properly Worn or damaged gasket Replace gasket Worn or damaged piston and cylin der Ask a Yamaha dealer to check Discharged battery If the...

Page 84: ...er purpose To start the engine using the booster battery 1 Apply the parking brake and turn the key to the off position 2 Open the shroud 3 Remove the red connecting lead from the lead holder and move it away from the black connecting lead NOTICE Be sure to connect the red jumper cable to the red connecting lead and the black jumper cable to the black connecting lead Do not re verse the connection...

Page 85: ...tarter does not operate or operates slowly Engine stop switch is pushed in Pull it out Faulty wire connections Check connec tions or ask a Yamaha dealer to check Discharged battery Charge battery or see Discharged battery above Seized engine Seizure is caused by poor lubrication inadequate fuel or an air leak Ask a Yamaha dealer to check Hydrostatic lock occurs when fuel has filled cylinders durin...

Page 86: ...en engine mount s Ask a Yamaha dealer to check V belt slips or becomes extremely hot Oily or dirty V belt or primary and second ary sheave assembly surfaces Clean Problem with driveline See V belt twists above Engine does not upshift or downshift properly or engages harshly Worn or damaged V belt Replace V belt or ask a Yamaha dealer to check Incorrect V belt clutch settings for altitude or condit...

Page 87: ... and apply a rust inhibitor 4 Store the snowmobile in a dry well ven tilated place with a porous cover placed over it 5 Keep the snowmobile on a level surface during storage or while transporting NOTICE ECS00871 Improper cleaning can damage plastic parts such as shroud covers wind shields headlight lenses meter lenses etc Use only a soft clean cloth or sponge with mild detergent and water to clean...

Page 88: ...C 90 F Check the condition of the battery once a month and charge it as necessary NOTICE Always keep the battery charged Storing a dis charged battery can cause permanent battery damage ECS00692 TIP Before installing the battery have a Yamaha dealer inspect and fully charge it U8JES2E0 book Page 80 Friday March 28 2014 11 06 AM ...

Page 89: ...r min FIN SWE A weighted sound power level 99 dB A 4250 r min FIN SWE Vibration on seat EN1032 ISO 5008 Not exceed 0 5 m s FIN SWE Vibration on handlebar EN1032 ISO 5008 Not exceed 2 5 m s FIN SWE Chassis Drive track Material Molded rubber fiberglass rod reinforced Type Extrovert drive type Width 500 mm 19 7 in Deflection 30 0 35 0 mm 1 18 1 38 in Length on ground 1104 mm 43 5 in Rear suspension T...

Page 90: ...en hour rate amperage 1 8 A Bulb voltage wattage quantity Headlight 12 V 60 55 W 2 Headlight bulb type Halogen bulb Tail brake light 12 V 5 21 W 1 Meter lighting 14 V 50 mA 6 High beam indicator light 14 V 80 mA 1 Warning light 14 V 80 mA 1 Low coolant temperature indicator light 14 V 80 mA 1 ESU14251 For EUR only The figures quoted are emission levels and are not necessarily safe working levels W...

Page 91: ...s is especially impor tant during the warranty period as unauthor ized haphazard or improper repairs can void the warranty Remember that your authorized Yamaha dealer has the special tools tech niques and spare parts necessary for proper repair of your snowmobile Always consult your Yamaha dealer if you are in doubt as to proper specifications and or maintenance procedures Occasionally printing er...

Page 92: ...gh beam indicator light 15 High altitude settings 50 I Identification numbers 83 L Location of the important labels 1 Louvers 23 Low coolant temperature indicator light 15 Lubrication 69 M Main switch 13 Multi function meter unit 14 O Oil level warning indicator 18 P Parking brake lever 21 Part locations 11 Passenger grip warmer switch 23 Periodic maintenance chart for the emission control system ...

Page 93: ...usting 47 Throttle override system T O R S 14 Throttle override system T O R S checking 48 Tool kit 45 Tow hitch bracket 25 Transporting 39 Troubleshooting 75 V Valve clearance 50 V belt 56 V belt holders 22 U8JES2E0 book Page 85 Friday March 28 2014 11 06 AM ...

Page 94: ...Printed on recycled paper Printed in Japan 2014 04 0 3 1 CR U8JES2E0 book Page 1 Friday March 28 2014 11 06 AM ...

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Yamaha GCH I 237, Owner'S Manual

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