Yamaha RS Venture RST90Y Owner'S Manual Download | Manualshive

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Periodic maintenance and adjustment

36

ESU11451

Periodic inspection, adjustment, and lubrication will keep your snowmobile in the safest and
most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The
most important points of vehicle inspection, adjustment, and lubrication are explained on the
following pages.

WARNING

EWS00341

Failure to properly maintain the snowmobile or performing maintenance activities incor-
rectly may increase your risk of injury or death during service or while using the snow-
mobile. If you are not familiar with snowmobile service, have a Yamaha dealer perform
service.

WARNING

EWS00700

Turn off the engine when performing maintenance unless otherwise specified.

●

A running engine has moving parts that can catch on body parts or clothing, and elec-
trical parts that can cause shocks or fires.

●

Running the engine while servicing can lead to eye injury, burns, fire, or carbon mon-
oxide poisoning–possibly leading to death. See page 3 for more information about
carbon monoxide.

Maintenance, replacement, or repair of the emission control devices and systems may
be performed by any repair establishment or individual that is certified (if applicable).

Proper periodic maintenance of your snowmobile is important in order to enjoy long, pleasur-
able use. Especially important are the maintenance services related to emission control. These
controls not only function to ensure cleaner air, but are also vital to proper engine operation and
maximum performance. In the following periodic maintenance charts, the services related to
emission control are grouped separately. These services require specialized data, knowledge,
and equipment. Yamaha dealers are trained and equipped to perform these particular services.

ESU11461

Periodic maintenance chart for the emission control system

Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.

ITEM

REMARKS

INITIAL

EVERY

PAGE

1 month

or 800 km

(500 mi)

(40 hr)

Seasonally

or

4000 km

(2500 mi)

(200 hr)

Spark plugs

• Check condition.
• Adjust gap and clean.
• Replace if necessary.

*

Valve clearance

• Check and adjust valve clear-

ance when engine is cold.

Every 40000 km (25000

mi)

U8ET14E0.book Page 36 Thursday, April 10, 2008 9:47 AM

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Summary of Contents for RS Venture RST90Y

Page 1: ...OWNER S MANUAL RST90Y 8ET 28199 14 LIT 12628 02 72 ESU10012 Read this manual carefully before operating this vehicle ...

Page 2: ...ESU10041 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U8ET14E0 book Page 1 Thursday April 10 2008 9 47 AM ...

Page 3: ...able at the time of printing 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 EWS00670 Please read this manual carefully before operating this snowmobile Do not attempt to operate this snowmobile until you have attained adequate knowledge of its con trols and operating features Regular in...

Page 4: ...ety messages that follow this symbol to avoid possible injury or death WARNING EWS00021 A WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE ECS00011 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 U8ET14E0 ...

Page 5: ...sts 17 Backrest 17 Storage areas 18 Fuel 20 Suspension 21 Pre operation checks 26 Pre operation check list 26 Operation 28 Starting the engine 28 Break in 29 Riding your snowmobile 29 Maximizing drive track life 33 Driving 33 Stopping the engine 34 Transporting 35 Periodic maintenance and adjustment 36 Periodic maintenance chart for the emission control system 36 General maintenance and lubricatio...

Page 6: ... 62 Replacing a fuse 63 Troubleshooting 66 Storage 70 Specifications 72 Consumer information 74 Identification number records 74 YAMAHA MOTOR CORPORATION U S A SNOWMOBILE LIMITED WARRANTY 75 YAMAHA EXTENDED SERVICE Y E S 78 U8ET14E0 book Page 2 Thursday April 10 2008 9 47 AM ...

Page 7: ...rtant 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 deal er ATTENTION 8ET 2815K 10 NOTICE 8ET 2815K 00 2 3 9 10 U8ET14E0 book Page 1 Thursday April 10 2008 9 47 AM ...

Page 8: ... for correct installation after battery service or air box removal See Service Manual Des dommages graves risquent de survenir par suite de fuites d huile résultant d un mauvais branchement des tuyaux de reniflard du carter Après l entretien de la batterie ou après la dépose de I épurateur d air assurez vous que les brides et les tuyaux sont installès correctement Consultez le manuel d entretien 8...

Page 9: ... brake disc and reduce braking abil ity 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 snow Stay on established trails to minimize your expo sure to hazards Ride slowly and cautiously when you ride...

Page 10: ... 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 snowmobile on its side for maintenance use a suitable stand to keep it in a stable and level position Do not leav...

Page 11: ...reservoir 6 Fuse box 7 Throttle stop screw 8 Main fuse 9 Oil filler cap 10 Passenger grip warmer switch 11 Solo touring storage area 12 Backrest 13 Rear carrier 14 Tail brake lights 15 Slide rail suspension 16 Drive track 17 V belt holder U8ET14E0 book Page 5 Thursday April 10 2008 9 47 AM ...

Page 12: ... 8 Shift lever 9 Shroud latch 10 Main switch 11 Auxiliary DC jack 12 Starter choke lever 13 Tachometer 14 Low coolant temperature indicator light 15 High beam indicator light 16 Warning light 17 Self diagnosis warning indicator 18 Coolant temperature warning indicator 19 Fuel level warning indicator 20 Oil level warning indicator 21 Speedometer 22 Grip warmer indicator 23 Select reset button 24 Th...

Page 13: ...rted ESU10300 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 28 for proper operation ESU10312 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 thrott...

Page 14: ... function could cause loss of control or damage If the carburetors or throttle cable malfunc tions during operation the T O R S will oper ate when the throttle lever is released The T O R S is designed to override the igni tion and limit the engine speed to less than the clutch engagement speed if the carburetors fail to return to the idle position when the throt tle lever is released See page 72 ...

Page 15: ...ature fuel level and oil level warnings indicator lights which show high beam and low coolant temperature conditions a warning light which shows warnings to gether with the warning indicators a fuel meter which shows the fuel remain ing in the fuel tank a grip thumb warmer level indicator which shows the grip warmer level or the thumb warmer level After the engine is started the tachometer makes o...

Page 16: ...ature is low and informs the rider that the snowmobile should be warmed up After the engine is started warm it up until the indicator light goes off The snowmobile can be operated normally af ter the indicator light goes off TIP Drive the snowmobile at low speeds when the low coolant temperature indicator light is on If the engine speed is too high the warning light and self diagnosis warning indi...

Page 17: ... movement and inclination of the snowmo bile Grip thumb warmer level indicator When the grip warmer adjustment switch is pressed the grip warmer indicator comes on and the display switches to the grip warmer level When the thumb warmer adjustment switch is pressed the thumb warmer indicator comes on and the display switches to the thumb warmer level See Grip thumb warmer adjustment switch on page ...

Page 18: ...r warning light and all segments of the fuel meter warn the rider of the above problems by flashing con tinuously If this occurs have a Yamaha dealer inspect the snowmobile as soon as possible ESU10460 Oil level warning indicator The oil level warning indicator and the warn ing light come on when the engine oil level is low If the oil level warning indicator and the warn ing light come on place th...

Page 19: ...lay Note the error code and then have a Yamaha dealer inspect the snowmobile as soon as possible NOTICE Do not continue to operate the engine longer than necessary if there is an error code to avoid possible engine damage ECS00820 ESU10531 Engine stop switch The engine stop switch is used to stop the en gine in an emergency Simply push the stop switch to stop the engine To start the engine pull th...

Page 20: ... engine is not running To use the auxiliary DC jack 1 Start the engine 2 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 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 ECS00120 Do not use accessories requiring more than the maximum rated capacity for the auxiliary DC ja...

Page 21: ...is will help prevent brake lever damage when the snowmobile is placed on its side for service ESU10581 Parking brake lever When parking the snowmobile or starting the engine apply the parking brake by moving the parking brake lever to the left To release the parking brake move the park ing brake lever to the right ESU10592 Shift lever The shift lever is used to put the snowmobile into forward or r...

Page 22: ... ESU10751 Drive guard WARNING EWS00401 Coming in contact with the rotating V belt or clutch parts can cause severe in jury or death Never run the engine with the drive guard removed Make sure that the drive guard is tight ened 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 opera...

Page 23: ...The footrests can be installed in two locations to suit passenger preference To change the location of a footrest remove the screws place the footrest in the desired location and then install and tighten the screws NOTICE ECS00130 Make sure that the footrest screws are tightened securely after changing the in stallation location of the footrests ESU12610 Backrest The backrest is adjustable 1 Drive...

Page 24: ...rear carrier The rear storage area and the rear carrier are located at the rear of the snowmobile The rear storage area can be used only when the passenger seat is removed To remove the passenger seat and backrest 1 Pull the carrier lock lever away from the carrier lock bracket and then push it down to unlock the backrest and the rear carrier 2 Slide both the backrest and the rear car rier forward...

Page 25: ...rea do not load any car go that is too large for it In addition cargo must not project from the edges of the rear storage area ECS00211 To install the passenger seat and backrest 1 Remove the rear carrier Refer to steps 1 2 in the To remove the passenger seat and backrest section 2 Install the passenger seat and then in stall the passenger seat lock knob 3 Align the holes in the backrest bracket w...

Page 26: ...ors are ex tremely flammable To avoid fires and ex plosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the engine and be sure that nobody is on the snowmo bile Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dry ers 2 Do not overfil...

Page 27: ... or ice does not en ter the fuel tank when refueling Do not use alcohol deicers or water ab sorbing additives with oxygenated fuel The fuel tank should be filled with straight gasoline as specified ESU10871 Suspension The suspension can be adjusted to suit rider preference A softer setting for example may provide greater rider comfort while a harder setting may allow more precise handling and cont...

Page 28: ...en the locknut 2 To increase the spring preload and there by harden the suspension turn the ad justing nut in direction a To decrease the spring preload and thereby soften the suspension turn the adjusting nut in di rection 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 ...

Page 29: ...sting blocks are installed in the same position on both sides of the snowmobile otherwise poor handling and loss of stability may result The spring force can be adjusted by changing the position of the 2 up adjusting blocks TIP Be sure to make this adjustment when there is no load rider or cargo on the snowmobile Use the special tools included in the own er s tool kit to make the adjustment 1 Inse...

Page 30: ... adjusted by turn ing the adjusting nuts on the control rods 1 Loosen the locknut while holding the ad justing nut 2 To increase weight transfer turn the ad justing nut in direction a and to de crease weight transfer turn it in direction b WARNING Never adjust the con trol rods beyond the maximum set ting indicated by red paint otherwise they could be damaged which could lead to an accident or inj...

Page 31: ... Tighten the locknut while holding the ad justing nut in place 1 Red paint area 2 Adjustable range 3 Standard position Locknut tightening torque 25 Nm 2 5 m kgf 18 ft lbf U8ET14E0 book Page 25 Thursday April 10 2008 9 47 AM ...

Page 32: ...d oil to specified level Check vehicle for oil leakage 44 Coolant Check coolant level Add if necessary 47 V belt Check for wear and damage Replace if necessary 49 Drive guard Make sure that drive guard is tightened securely Check the drive guard mounts for damage 16 Brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check brake pads for wear Replace if necessary Che...

Page 33: ...teering Check for excessive free play 56 Lights signals and switch es Check operation Correct if necessary 13 13 61 62 Throttle lever Make sure that operation is smooth and spring back to its home position when released 7 Throttle override system T O R S Check the T O R S for proper operation If system is defective have Yamaha dealer check vehicle 42 ITEM CHECKS PAGE U8ET14E0 book Page 27 Thursday...

Page 34: ...ever 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 Release the switch immedi ately after the engine starts If the en gine fails to start release the switch wait a few seconds then try again Each attempt should be as short as possible to preserve the battery Do not...

Page 35: ...your feet outside the running boards Avoid higher speeds or more difficult maneuvers until you have become thor oughly familiar with your snowmobile and all of its controls A snowmobile is a rider active vehicle and your riding position and your balance are the two basic factors of maneuvering your snow mobile Riding your snowmobile requires skills ac quired through practice over a period of time ...

Page 36: ...e traction reduce con trol and increase the possibility of an accident When slowing down or stopping release the throttle and apply the brake gently not sud denly Turning For most snow surfaces body English is the key to turning As you approach a curve slow down and be gin to turn the handlebar in the desired direc tion As you do so put your weight on the running board to the inside of the turn an...

Page 37: ...bile from the uphill side Restart the engine release the parking brake and de scend the hill Riding downhill WARNING EWS00240 Use extra caution when applying the brake during a descent Excessive braking will cause the drive track to lock causing a loss of control When riding downhill keep speed to a mini mum It is important to apply just enough throttle to keep the clutch engaged while de scending...

Page 38: ... snow as both the skis and drive track do not have as much traction as when the snowmobile is operated on fresh snow Avoid rapid acceleration turning and braking Operation on surfaces other than snow or ice Operation of your snowmobile on surfaces other than snow or ice should be avoided Op eration under such conditions will damage or result in rapid wear of the ski runners drive track slide runne...

Page 39: ...r nally which may cause failure or damage Off trail riding Avoid off trail riding until there is sufficient snow coverage It generally takes several feet of snow to provide a good overall base to properly cover debris such as rocks logs etc If snow coverage is not sufficient stay on trails to avoid impact damage to the drive track Studded track In general track life will be shortened when studs ar...

Page 40: ...reverse 2 Release the parking brake by moving the parking brake lever to the right 3 Press the throttle lever slowly to move the snowmobile 4 Turn the handlebar in the desired direc tion 5 Squeeze the brake lever to stop the snowmobile 6 Apply the parking brake by moving the parking brake lever to the left ESU11411 Stopping the engine Turn the main switch to the off position to stop the engine Pus...

Page 41: ... possible the fuel tank should be empty during transpor tation especially if the trip takes longer than 30 minutes If transporting the snowmobile in an open trailer or truck put a tight fitting cover on the snowmobile A cover specifically designed for your snowmobile is best This will help keep foreign objects out of the cooling vents in the shroud and also help protect the snowmobile against dama...

Page 42: ...ance replacement or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified if applicable Proper periodic maintenance of your snowmobile is important in order to enjoy long pleasur able use Especially important are the maintenance services related to emission control These controls not only function to ensure cleaner air but a...

Page 43: ...or damage Replace if necessary Idle speed Check and adjust idle speed 41 Carburetors Adjust synchronization Adjust the jets Whenever operating condition elevation tem perature is changed 43 Exhaust system Check for leakage Tighten or replace gasket if necessary ITEM REMARKS INITIAL EVERY PAGE 1 month or 800 km 500 mi 40 hr Seasonally or 4000 km 2500 mi 200 hr U8ET14E0 book Page 37 Thursday April 1...

Page 44: ... 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 52 Drive chain oil Check oil level 52 Change 52 Brake and parking brake Adjust free play and or replace pads if necessary 53 Change brake fluid See TIP following this chart ...

Page 45: ...system Check toe out Adjust if necessary 56 Steering bearings Check bearing assemblies for looseness Lubricate with specified grease Skis and front shock absorbers Lubricate with specified grease 60 Suspension compo nent Lubricate with specified grease 60 Fittings and fasten ers Make sure that all nuts bolts and screws are properly tight ened Tighten if necessary 62 Battery Check condition Charge ...

Page 46: ... a very white center electrode porcelain color could indicate an intake track air leak or car buretion problem for that cylinder Do not at tempt 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 plug because heat and deposits will cause a spark plug to slowly break down and erod...

Page 47: ... Starting the engine section on page 28 2 Turn the throttle stop screw in or out to adjust the engine idling speed ESU11821 Adjusting the throttle cable free play NOTICE ECS00410 Be sure to adjust the engine idling speed first 1 Loosen the locknut 2 Turn the adjusting bolt in or out until the specified throttle cable free play is ob tained 3 Tighten the locknut 1 Spark plug gap 2 Spark plug reach ...

Page 48: ...low between the throttle lever pivot and the engine stop switch housing While holding the pivot point as described above press the throttle lever gradually The T O R S will be activated and the engine speed will be limited to less than the clutch engagement speed See page 72 for the clutch engagement speed WARNING If the engine speed does not decrease to less than the clutch engagement speed stop ...

Page 49: ...e engine about 3 for ev ery 305 m 1000 ft of elevation This is because there is less air as altitude increases Less air means less oxygen available for combustion Your snowmobile can be adjusted to over come most of the problems found in high alti tude riding Carburetor adjustments are the most important Less air at high altitude makes the air fuel ratio too rich which can cause poor performance C...

Page 50: ...g into contact with or getting any engine oil on your clothes could result in burns NOTICE ECS00480 Do not run the engine with too much or not enough oil in the oil tank Oil could spray out or the engine could be dam aged Be sure to change the engine oil after the first 800 km 500 mi of operation and every 4000 km 2500 mi thereafter or at the start of a new season other wise the engine will wear q...

Page 51: ...il See page 72 Make sure that no foreign material enters the engine oil tank ECS00462 7 Insert the dipstick into the oil filler hole and then 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 fil ter cartridge replacement 1 Place the snowmobile on a level surface and apply the parking brake 2 Start the engine warm it up...

Page 52: ...ip 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 12 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque 1 Oil level gauge coupler ...

Page 53: ...gauge coupler NOTICE If oil is leaking or the oil level warning indica tor comes on when the engine is run ning immediately turn the engine off and have a Yamaha dealer check the snowmobile Continuing to operate the engine under such conditions could cause severe engine damage ECS00471 19 Install the bottom panel and the right side cover and then close the shroud ESU12002 Cooling system The coolan...

Page 54: ...f soft water is not available Tap water can be used temporarily in an emergency ECS00491 Bleeding the cooling system The cooling system must be bled of air if the coolant reservoir becomes empty if air can be seen in the cooling system or if there is a cooling system leak Consult a Yamaha deal er NOTICE ECS00500 Operating the engine with an improperly bled cooling system can cause overheat ing and...

Page 55: ...operation NOTICE ECS00830 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 check the V belt 1 Open the shroud and remove the drive guard 2 Check the V belt for wear and damage Replace if necessary 3 Install the drive guard and close the shroud To replace and adjust the V belt WARNING EWS00411 When installing a new V be...

Page 56: ... 2 Rotate the secondary sliding sheave clockwise and push it so that it separates from the secondary fixed sheave 3 Pull the V belt up over the secondary fixed sheave 4 Remove the V belt from the secondary sheave assembly and primary sheave assembly 5 Temporarily install the new V belt on the secondary sheave assembly only and then measure the V belt position Do not force the V belt between the sh...

Page 57: ...dard V belt position From 1 5 mm 0 06 in above the edge of the secondary sheave assembly to 0 5 mm 0 02 in below the edge 1 V belt position adjusting bolt 2 Spacer V belt position Adjustment More than 1 5 mm 0 06 in above the edge Remove 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 spacer V belt p...

Page 58: ...d apply the parking brake 2 Remove the dipstick wipe it off with a clean rag and then insert it back into the filler hole 3 Remove the dipstick and check that the oil is between the maximum and mini mum level marks If the oil is below the minimum level mark add sufficient oil of the recommended type to raise it to the maximum level mark NOTICE Make sure that no foreign material enters the drive ch...

Page 59: ...sk a Yamaha dealer to inspect and repair the brake system NOTICE ECS00060 Make sure that the brake lever end does not project out over the handlebar end This will help prevent brake lever damage when the snowmobile is placed on its side for service Test the brake at a low speed when starting out to make sure that it is working properly If the brake does not provide proper braking performance inspe...

Page 60: ... Tighten the parking brake cable locknut 5 Turn the parking brake pad adjusting bolt in or out to adjust the clearance between the parking brake pads and the brake disc 6 Tighten the parking brake pad locknut Brake pad wear limit 7 5 mm 0 30 in 1 Parking brake pad wear limit Parking brake pad wear limit 1 2 mm 0 047 in 1 Parking brake pad locknut 2 Parking brake pad adjusting bolt 3 Parking brake ...

Page 61: ... Make sure that the brake fluid and the fol lowing parts are replaced by a Yamaha dealer Brake fluid replacement is necessary when the following components are replaced during the periodic maintenance or if they are dam aged or leaking All oil seals of the master cylinder and cali per cylinder The brake hose ESU12142 Skis and ski runners Check the skis and ski runners for wear and damage Replace i...

Page 62: ...ndlebar up and down and back and forth 2 Turn the handlebar 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 ...

Page 63: ...ind the snowmobile when the engine is running When the rear of the snowmobile is raised to allow the drive track to spin a suitable stand must be used to support the rear of the snowmobile Never allow anyone to hold the rear of 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 damaged...

Page 64: ... fol lowing section for more details 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 Measure both sides 3 If the deflection is incorrect adjust the drive track Adjusting...

Page 65: ...the left and right adjusting nuts Shifted to right Shifted to left 1 Rear axle nut 1 Slide runner 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 U8ET14E0 boo...

Page 66: ...snow will rapidly wear the slide runners ESU12193 Lubrication Lubricate the following points with the speci fied grease WARNING EWS00511 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 Drive track deflection More than specified Less than specified Left adjusting nut Turn in Turn out Right adjust ing nut...

Page 67: ... and 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 thor oughly clean it with a cloth moistened with alcohol or lacquer thinner ECS00621 1 Throttle cable end 1 Lubrication point 1 Lubrication point 1 Headlight coupler 2 Bulb holder cover 1 Bulb holder 1 ...

Page 68: ...e and torque if nec essary ESU12303 Battery This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the electrolyte or to add distilled water However the battery lead connections need to be checked and if necessary tight ened WARNING EWS00540 Battery electrolyte is poisonous and dan gerous It contains sulfuric acid and can cause severe burns Avoid contact wit...

Page 69: ...ing the battery Never connect the 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 ECS00842 To charge a VRLA Valve Regulated Lead Acid battery a special constant voltage battery charger is required If you do not have access to a constant voltage battery charger ...

Page 70: ...case breather hose clamp air filter case side down disconnect the crankcase breather hose from the air filter case and then remove the air filter case 8 Disconnect the negative battery lead 9 Replace the blown fuse with one of the proper amperage 1 Joint clamp screw 1 Oil tank breather hose clamp 2 Oil tank breather hose 1 Crankcase breather hose clamp crankcase side 2 Crankcase breather hose 1 Cr...

Page 71: ...ngine 12 Install the right side cover and close the shroud TIP If the fuse immediately blows again ask a Yamaha dealer to inspect the snowmobile 1 HEAD headlight fuse 2 SIG signal fuse 3 DC TERM auxiliary DC jack fuse 4 C W carburetor warmer fuse 5 IGN ignition fuse 6 Spare fuse Specified fuses Main fuse 30 0 A Spare main fuse 30 0 A HEAD headlight fuse 20 0 A SIG signal fuse 10 0 A DC TERM auxili...

Page 72: ...ety de vice in the case of a malfunction take the snowmobile to a Yamaha dealer immediately for repair EWS00561 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 inspect Discharged battery If the battery is discharged the engine can be started using a fully charged 12 volt batt...

Page 73: ... 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 connections ECS00661 4 Pull the red connecting lead cover to expose the terminal through the slit in the cover and t...

Page 74: ... or operates slowly Engine stop switch is pushed in Pull it out Faulty wire connections Check connec tions or ask a Yamaha dealer to inspect 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 inspect Hydrostatic lock occurs when fuel has filled the cylinders when the vehicle has...

Page 75: ... engine mount s Ask a Yamaha dealer to inspect V belt slips or becomes extremely hot Oily or dirty V belt or primary and second ary sheave assembly surfaces Clean Problem with the driveline See V belt twists above Engine does not upshift or downshift properly or engages harshly Worn or damaged V belt Replace the V belt or ask a Yamaha dealer to inspect Incorrect V belt clutch settings for altitude...

Page 76: ...re that it does not leave any marks If the windshield is scratched use a quality plastic polishing com pound after washing Lubrication Lubricate moving parts suspension linkage and pivot points Use the grease or lubricant specified in the MAINTENANCE section or Yamaha Lube Zall general purpose lubricant Proper lubrication fights corrosion while it re duces friction Fuel system Add Yamaha Fuel Stab...

Page 77: ...lated place out of direct sunlight Put a fabric cover over the snowmobile preferably one that is designed for it Do not use a plastic or vinyl cover condensation could be trapped un derneath which could increase the chances of rusting Returning to service after storage When returning your snowmobile to service install the V belt and battery and adjust the drive track Remove the spark plugs and cle...

Page 78: ...th on ground 985 mm 38 8 in Rear suspension Type Slide rail suspension Track sprocket wheel Material Polyethylene Number of teeth 9 Transmission Clutch type Automatic centrifugal engagement Overall reduction ratio 6 74 1 77 1 Sheave distance 267 0 270 0 mm 10 51 10 63 in Sheave offset 13 5 16 5 mm 0 53 0 65 in Engagement speed Subject to change according to elevation settings 3000 3400 r min Shift...

Page 79: ...gnition system T C I Spark plug Manufacturer NGK Model CR8E Gap 0 7 0 8 mm 0 028 0 031 in Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Ten 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 2 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 te...

Page 80: ... in a separate place in case the snowmobile is sto len Frame serial number The frame serial number is the seventeen digit number stamped on the frame of the snowmobile Engine serial number Primary ID The engine serial number is stamped in the location as shown Key identification number The key identification number is stamped in the location as shown 1 Frame serial number 1 Engine serial number 1 ...

Page 81: ...to normal wear or routine maintenance including oil spark plugs clutch drive belts slide runners and track THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the snowmobile as specified in the appropriate Owner s Manual 2 Give notice to an authorized Yamaha snowmobile dealer of any and all apparent defects within ten 10 days after discovery and make the machine av...

Page 82: ...l spark plugs clutch drive belts and slide runners Q What are some examples of abnormal strain ne glect or abuse A These terms are general and overlap each other in areas Specific examples include Running the ma chine out of oil hitting an object submerged under snow operation on surfaces other than snow or ice operating the machine with a broken or damaged part which causes another part to fail a...

Page 83: ...all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corpora tion U S A be sure to include the model serial number names dates and receipts CHANGE...

Page 84: ...Consumer information 78 ESU12510 YAMAHA EXTENDED SERVICE Y E S U8ET14E0 book Page 78 Thursday April 10 2008 9 47 AM ...

Page 85: ...adlight beam switch 13 Headlight bulb replacing 61 High beam indicator light 10 High altitude settings 43 I Identification numbers 74 L Location of the important labels 1 Low coolant temperature indicator light 10 Lubrication 60 M Main switch 7 O Oil level warning indicator 12 P Parking brake lever 15 Part locations 5 Passenger grip warmer switch 17 Periodic maintenance chart for the emission cont...

Page 86: ...Index Tool kit 40 Transporting 35 Troubleshooting 66 V Valve clearance 44 V belt 49 V belt holders 17 U8ET14E0 book Page 2 Thursday April 10 2008 9 47 AM ...

Page 87: ...U8ET14E0 book Page 3 Thursday April 10 2008 9 47 AM ...

Page 88: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2008 04 0 3 1 CR ESU12520 ...

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