Yamaha RS90GTL Owner'S Manual Download | Manualshive

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ESU00011

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INTRODUCTION

Congratulations on your purchase of a Yamaha snowmo-
bile. This model is the result of Yamaha’s vast experience
in the production of fine sporting and touring snowmo-
biles. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these
fields.
This manual will give you an understanding of the opera-
tion, inspection, and basic maintenance of this snowmo-
bile. If you have any questions concerning the operation
or maintenance of your snowmobile, please consult a
Yamaha dealer.
To maintain the high quality and performance of this
snowmobile, it is important that you and your Yamaha
dealer pay close attention to the recommended mainte-
nance schedules and operating instructions contained
within this manual.

RS90NL

RS90RL/RS90NRL

RS90ML

RS90GTL

RSG90L

OWNER’S MANUAL

©2005 by Yamaha Motor Corporation, U.S.A.

1st Edition, July 2005

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in Japan

P/N LIT-12628-02-50

E_8gg_Intro0.fm Page 1 Friday, July 22, 2005 1:22 PM

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Summary of Contents for RS90GTL

Page 1: ...OWNER S MANUAL SNOWMOBILE RS90NL ...

Page 2: ......

Page 3: ...y ID and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer 1 The frame number is the seventeen digit number stamped on the frame of the snowmobile See fig È 2 The engine number is stamped in the location as shown See fig É 3 Key number See fig Ê Also record and keep the ID numbers in a separate place in case the snowmobile is stolen A B C ...

Page 4: ...ny questions concerning the operation or maintenance of your snowmobile please consult a Yamaha dealer To maintain the high quality and performance of this snowmobile it is important that you and your Yamaha dealer pay close attention to the recommended mainte nance schedules and operating instructions contained within this manual RS90NL RS90RL RS90NRL RS90ML RS90GTL RSG90L OWNER S MANUAL 2005 by ...

Page 5: ...nual should be considered a permanent part of this snowmobile and should remain with the snow mobile when resold Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator a b...

Page 6: ... Shift lever 5 9 Headlight beam switch 5 10 Auxiliary DC jack 5 10 Shroud latches 5 11 Drive guard 5 11 V belt holders 5 11 Carburetor coolant shut off lever 5 12 Rear suspension damping force remote adjustment dial 5 12 Storage compartment 5 12 PRE OPERATION CHECKS 6 1 Fuel 6 1 Engine oil 6 2 Engine oil level 6 3 Coolant 6 4 Throttle lever 6 5 Throttle override system T O R S 6 5 Brake 6 6 Brake ...

Page 7: ... 8 7 Adjusting the high altitude settings 8 8 Adjusting the valve clearance 8 8 Changing the engine oil 8 9 Cooling system 8 12 Replacing the V belt 8 14 Checking the drive chain housing oil level and the drive chain tension 8 16 Checking the brake pads 8 18 Checking the parking brake pads 8 18 Checking the brake fluid level 8 19 Changing the brake fluid 8 19 Suspension 8 19 Adjusting the drive tr...

Page 8: ...e parts replaced due 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 an...

Page 9: ...amages as well as oil 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 an...

Page 10: ...e dealer ship Since 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...

Page 11: ...1 4 ESU04280 YAMAHA EXTENDED SERVICE Y E S CW 06E ...

Page 12: ...IMPORTANT LABELS Please read the following labels carefully before operat ing this snowmobile NOTE Maintain or replace safety and instruction labels as nec essary 1 RS90N RS90M 1 RS90R RS90NR RS90GT RSG90 2 8EK 77761 E0 8FB 77761 E0 ...

Page 13: ...ter 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 l épurateur d air assurez vous que les brides et les tuyaux sont installès correctement Consultez le manuel d entretien 8ES 14427 00 4AA 22259 60 4AA...

Page 14: ...2 3 8 RS90M RSG90 ...

Page 15: ...2 4 NOTE The following suspension adjustment charts are included with the Owner s Manual RS90M RS90R RS90GT RSG90 ...

Page 16: ...s snowmobile is designed to carry the OPERA TOR ONLY Passengers are prohibited Carrying a passenger can cause loss of control 4 Do not operate the snowmobile after drinking alcohol or taking drugs Your ability to operate the snowmo bile is reduced by the influence of alcohol or drugs 5 For safety and proper care of the snowmobile always perform the pre operation checks on pages 6 1 6 11 before sta...

Page 17: ... inhale a lot of gasoline vapor or get some gasoline into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash your skin with soap and water and change your clothes 10 Wear protective clothing Wear an approved helmet and a face shield or goggles Also wear a good qual ity snowmobile suit boots and a pair of gloves or mit tens that will permit use of...

Page 18: ...n most surfaces is to release the throttle and apply the brake gently not suddenly Maintenance and storage 1 Do not leave the snowmobile on its left side for an extended period of time Fuel may leak out from the fuel breather hose 2 Modifications made to the snowmobile not approved by Yamaha or the removal of original equipment may render your snowmobile unsafe for use that may cause severe person...

Page 19: ...4 1 ESU00012 4 DESCRIPTION RS90N RS90NR RS90M RSG90 RS90R RS90GT ...

Page 20: ...ne stop switch J Thumb warmer adjustment switch K Throttle lever L Shift lever RS90R RS90NR RS90GT RSG90 M Shroud latch N Main switch O Auxiliary DC jack RS90GT P Starter lever Q Tachometer R Low coolant temperature indicator light S High beam indicator light T Warning light U Self diagnosis warning indicator V Coolant temperature warning indicator W Fuel level warning indicator X Oil level warnin...

Page 21: ...ircuit is switched off The key can be removed only in this position 2 ON The ignition circuit is switched on 3 START The starting circuit is switched on The starter motor starts CAUTION Release the switch immediately after the engine starts NOTE The headlights meter lights and taillights come on after the engine starts ...

Page 22: ...he snowmobile by varying the throttle position Because the throttle is spring loaded the snowmobile will deceler ate and the engine will return to idle when it is released b WARNING Check the throttle brake and steering for proper operation before starting the engine ESU00361 Engine overheating prevention system This model is equipped with an engine overheating pre vention system to prevent overhe...

Page 23: ...ngine can be operated without a prob lem before restarting the engine Be sure to use the specified spark plug and spark plug cap Otherwise the T O R S will not work properly CA 19E È Idling starting É Running Ê Trouble 1 Throttle position sensor throttle valve position 2 Throttle switch 3 Throttle cable a On b Off c Open d Closed NOTE When the T O R S is activated the warning light 4 and self diag...

Page 24: ...t 2 the warning light 3 and all segments of the meter 4 turn on and off once The grip warmer level is initially displayed for 5 seconds then switches to the fuel meter display Odometer and tripmeter modes Pushing the select reset button 5 switches the display between the odometer mode ODO and the tripmeter mode TRIP To reset the tripmeter push the select reset button for at least one second while ...

Page 25: ...rmer adjustment switch 2 control the electrically heated handlebar grips and throttle lever respectively To raise the temperature press each switch to HI To lower the temperature press each switch to LO NOTE The grip warmer indicator 3 comes on and the dis play switches to the grip warmer level when the grip warmer adjustment switch is pressed The thumb warmer indicator 4 comes on and the display ...

Page 26: ...g light go off the engine oil level is sufficient however it is getting low Add engine oil as soon as possible If the oil level warning indicator and the warning light do not go off check the engine oil level in the oil tank see page 6 3 and add engine oil if necessary ESU04171 Low coolant temperature indicator light The low coolant temperature indicator light 1 comes on when the coolant temperatu...

Page 27: ...the warning light 1 and the self diagnosis warning indicator 2 will flash and then an error code e g 16 and 81 3 will flash slowly in the tripmeter odometer display WARNING If the self diagnosis warning indicator and warn ing light flash continuously and an error code is displayed during operation there may be some problem with the electrical circuit lead couplers etc Stop the engine and allow it ...

Page 28: ...the handlebar grip to stop the snowmobile 1 Brake lever 2 Brake lever end 3 Handlebar end NOTE When the brake lever is operated the brake light will illu minate CAUTION 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 For RS90N RS90NR RS90GT The brake lever is equipped with...

Page 29: ...run the snowmobile with the parking brake applied This may overheat the brake disc and reduce braking ability ESU00341 Shift lever For RS90R RS90NR RS90GT RSG90 The shift lever is used to put the snowmobile into forward or reverse After coming to a complete stop pull the shift lever out slide it to FWD or to REV until it stops and then release it 1 Shift lever 2 Pull out 3 Slide to FWD Forward 4 S...

Page 30: ...he auxiliary DC jack cap 1 and then insert the accessory power plug into the jack 2 NOTE After using the auxiliary DC jack be sure to remove the accessory power plug from the jack and close the auxil iary DC jack cap CAUTION Do not use accessories requiring more than the maximum rated capacity for the auxiliary DC jack This may overload the circuit and cause the fuse to blow See pages 8 35 8 37 fo...

Page 31: ...your body and clothing away from rotating parts when servicing with the shroud open Do not touch the hot muffler and engine during or immediately after operation ESU00521 Drive guard The drive guard is designed to cover the V belt clutch and V belt in case parts break or come loose WARNING Make sure that the drive guard is tightened securely before operating the snowmobile Never run the engine wit...

Page 32: ...ile in temperatures above 0 C 32 F move the carburetor coolant shut off lever to the OFF position to stop the flow of coolant since the carburetor does not need to be warmed ESU04130 Rear suspension damping force remote adjust ment dial For RS90R RS90GT RSG90 Turn the remote adjustment dial to adjust the rear sus pension damping force See page 8 25 for adjustment procedures 1 Rear suspension dampi...

Page 33: ...uel in the fuel tank WARNING Fuel is HIGHLY FLAMMABLE and poisonous Check the SAFETY INFORMATION section carefully before refueling See page 3 2 Do not fill the fuel tank above the bottom of the filler tube 1 Fuel could overflow if the snowmo bile is tilted on its side or if the ambient tempera ture rises causing the fuel to warm up and expand Make sure that the fuel tank cap is closed securely af...

Page 34: ...at snow or ice does not enter the fuel tank when refueling Do not use alcohol deicers or water absorbing additives with oxygenated fuel The fuel tank should be filled with straight gaso line as specified ESU04031 Engine oil Use a combination of the recommended SAE and API oil classifications shown in the chart below CB 02E CAUTION Use only 4 stroke engine oil SAE API SE SF SG or higher 40 20 0 20 ...

Page 35: ...ning it off 3 Disconnect the oil level gauge coupler 1 CAUTION Disconnect the oil level gauge coupler before remov ing the oil level gauge dipstick Otherwise the cable can twist and break 4 Remove the oil level gauge dipstick 2 wipe it clean insert it back into the filler hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the F 3 and E...

Page 36: ...s cold If the coolant level is below the COLD LEVEL mark add soft water until it reaches the COLD LEVEL mark See pages 8 12 8 13 for more details 1 COLD LEVEL mark WARNING Do not remove the coolant reservoir cap when the engine is hot CAUTION Hard water or salt water is harmful to the engine parts You may use boiled or distilled water if soft water is not available Tap water can be used temporaril...

Page 37: ...ile could start moving forward unexpectedly which could cause an accident 1 Start the engine NOTE Refer to the Starting the engine section 2 Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb above and forefinger below between the throttle lever pivot 1 and the engine stop switch housing 2 While holding the pivot point as described above press the thrott...

Page 38: ...cates 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 CAUTION Make sure that the brake lever end does not project out over the handlebar end This is to prevent brake lever damage when the snowmobile is placed on its side ...

Page 39: ... tic parts Never spill any brake fluid If any is spilled clean it up immediately ESU00941 V belt Open the shroud and remove the drive guard Check the V belt for wear and damage Replace if neces sary WARNING Make sure that the drive guard is tightened securely before operating the snowmobile Never run the engine without the V belt or with the drive guard removed ESU00096 Drive guard Check the drive...

Page 40: ...0243 51 mm 2 0 in high profile pattern drive track For RS90M This snowmobile is originally equipped with a 51 mm 2 0 in high profile pattern drive track specifically for use in deep snow riding conditions Therefore avoid prolonged operation on hard surfaces such as ice hard packed snow dirt etc to extend the life of the track and slide runners CAUTION Only use in deep snow riding conditions Operat...

Page 41: ...ki runners Check the skis and ski runners for wear and damage Replace if necessary CAUTION Avoid scratching the skis when loading and unload ing the snowmobile when riding in areas with little or no snow or on sharp edges such as concrete curbs etc This will wear or damage the skis Wear limit height 10 5 mm 0 41 in For RS90N RS90R RS90NR RS90GT RSG90 Ski runner wear limit a 8 mm 0 31 in Ski wear l...

Page 42: ...here is no snow under the air filter element frame 1 Unhook the air filter case cover fasteners and the latch 2 Remove the air filter case cover 3 Lift up the air filter element frame and check the air filter element If there is any snow on the air filter ele ment remove the element and brush off the snow and then install the air filter element 4 Place the air filter element frame in its original ...

Page 43: ...ractice to carry the tool kit spare parts and other necessary equipment with you while riding the snowmobile so that minor repairs can be done if neces sary The following should be carried at all times Tool kit Flashlight Roll of plastic tape Steel wire Towrope Jumper cables V belt Light bulbs Spark plugs When you start out for a long distance trip extra fuel and oil should be carried as well ...

Page 44: ... warm engine starting NOTE The starter lever choke is not required when the engine is warm Put the starter lever choke in the closed posi tion 2 Turn the main switch to the START position After the engine starts put the starter lever choke in the half open position Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the closed position 1 START C...

Page 45: ...ll throttle operation or any condition that might result in engine overheating 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 operated normally CAUTION After 8...

Page 46: ...ded with added safety and a more reliable snowmobile Always wear the proper cloth ing for both warmth and to help protect you from injury if an accident occurs Become familiar with operating your snow mobile at low speeds even if you are an experienced rider Do not attempt to oper ate at maximum performance until you are totally familiar with the snowmobile s han dling and performance characterist...

Page 47: ... thor oughly familiar with the operation of your snowmobile Riding uphill You should practice first on gentle slopes Try more difficult climbs only after you have developed your skill As you approach a hill accelerate before you start the climb and then reduce the throttle to prevent track slippage It is also important to keep your weight on the uphill side at all times On climbs straight up the h...

Page 48: ...our downhill leg on the seat and the foot of your uphill leg on the running board This position will make it easier for you to shift your body weight as needed Snow and ice are slippery so be prepared for the possibility that your snowmobile could begin to slip sideways on the slope If this happens steer in the direction of the slide if there are no obstacles in your path As you regain proper bala...

Page 49: ...es 2 Snow mixed with a lot of dirt and sand All of the above surfaces have one thing in common in regard to drive track and slide runners little or no lubricating ability Drive track and all slide rail systems require lubrication snow or water between the slide runners and the slide metal In the absence of lubrication the slide runners will rapidly wear and in severe cases liter ally melt away and...

Page 50: ...erheating avoid sustained high speed usage in areas such as icy trails frozen lakes and rivers that have minimal snow coverage An overheated track will be weakened internally which may cause fail ure or damage Off trail riding Avoid off trail riding until there is sufficient snow cover age It generally takes several feet of snow to provide a good overall base to properly cover debris such as rocks...

Page 51: ...intain balance during traverse side hill riding Only experi enced operators should traverse slopes steep enough to require strap use Keep the right hand on the right handlebar grip for steering and grip the strap with the left hand to shift weight uphill for balance during traverse riding Ride cautiously while using the strap Do not accelerate or decelerate abruptly while holding onto the strap Do...

Page 52: ...arking brake by moving the parking brake lever to the left For RS90R RS90NR RS90GT RSG90 1 To select the desired operating position pull the shift lever out slide it to FWD or to REV until it stops and then release it 1 Pull out 2 Slide to FWD Forward 3 Slide to REV Reverse 4 Release WARNING Make sure that the throttle lever is fully released and the snowmobile is at a full stop before shift ing B...

Page 53: ...er slowly to move the snowmo bile 4 Turn the handlebar in the desired direction 5 Squeeze the brake lever to stop the snowmobile 6 Apply the parking brake by moving the parking brake lever to the left ESU00136 Stopping the engine Turn the main switch to the OFF position to stop the engine 1 OFF WARNING Push down the engine stop switch to stop the engine in an emergency Make sure that the key is re...

Page 54: ... hydrostatic lock When possible the fuel tank should be empty during transportation 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 sn...

Page 55: ...CONTROL THESE SER VICES NOT ONLY ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERI ODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES ESU04970 Periodic maintena...

Page 56: ... 4 Replace 8 9 8 11 Engine oil filter cartridge Replace Every 20 000 km 12 000 mi 8 9 8 11 Fuel Check fuel level 6 1 6 2 Engine coolant Check coolant level 6 4 Air bleed the cooling system if necessary 8 12 Throttle lever carburetor side Check throttle lever operation 8 7 Throttle lever handlebar side Check operation Repair if necessary 5 2 6 5 Throttle override system T O R S Check operation Repa...

Page 57: ... slight free play Lubricate shaft with specified grease as required Every 1 600 km 1 000 mi Drive chain oil Check oil level 8 16 8 17 Replace Drive chain Check deflection Adjust if necessary Initial at 500 km 300 mi and every 800 km 500 mi thereafter 8 17 Skis and ski runners Check for wear and damage 6 9 Replace if necessary Steering system Check operation 6 10 Adjust toe out if necessary Strap R...

Page 58: ...wear for secondary Replace if necessary Lubricate with specified grease Steering column bearing Lubricate with specified grease Ski and front suspension Lubricate with specified grease 8 33 Suspension component Lubricate with specified grease 8 33 Parking brake cable end and lever end throttle cable end Lubricate with specified grease 8 33 Check cable damage Replace if necessary Shroud latches Mak...

Page 59: ...ct The condition of the spark plug can indi cate the condition of the engine Check the coloration on the white porcelain insulator around the center electrode The ideal coloration at this point is a medium to a light tan color for a snowmobile that is being ridden normally If a spark plug shows a distinctly different color there could be something wrong with the engine For example a very white cen...

Page 60: ...ad damage Always use a spark plug with the speci fied reach Before installing any spark plug measure the electrode gap with a wire thickness gauge and adjust to specifica tion When installing the spark plug always clean the gasket surface Wipe off any grime from the threads and tighten the spark plug to the specified torque CAUTION Make sure that the spark plug caps are securely installed Otherwis...

Page 61: ...e cable CAUTION Be sure to adjust the engine idle speed first 1 Loosen the locknut 2 Turn the adjuster in or out until the proper throttle lever free play is achieved 1 Locknut 2 Adjuster 3 Tighten the locknut ESU04870 Adjusting the carburetors The carburetors are an important part of the engine and its emission control system which require very sophisti cated adjustment Therefore carburetor adjus...

Page 62: ...vailable even with proper carburetion Expect acceleration and top speed to be reduced at higher altitudes To overcome operating with less power at high altitudes your snowmobile may also require different settings for the drive chain gears and V belt clutch to avoid poor per formance and rapid wear If you plan to operate your snowmobile at an altitude different from the area where you bought it be...

Page 63: ...20 000 km 12 000 mi of operation 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 Remove the bottom panel 1 and right side cover 2 3 Start the engine warm it up for several minutes and then turn it off 4 Place oil pans under both the engine and the oil tank to collect the used oil 5 Disconnect the oil ...

Page 64: ... US qt of the recom mended engine oil to the oil tank and then install and tighten the oil level gauge dipstick and the cylinder head cap 12 Start the engine warm it up for several minutes and then turn it off Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lb Tightening torques Crankcase engine oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lb Oil tank engine oil drain bolt 16 Nm 1 6 m kgf 11...

Page 65: ... min utes while checking it for oil leakage If oil is leaking immediately turn the engine off and make sure the engine oil drain bolts cylinder head cap and oil level gauge dipstick are installed correctly 15 Turn the engine off connect the oil level gauge cou pler and then install the bottom panel and right side cover CAUTION If oil is leaking or the oil level warning indicator comes on when the ...

Page 66: ...counter clockwise and remove it 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 dealer CAUTION Operating the engine with an improperly bled cool ing system can cause overheating and severe engine damage Replenishing the coolant 1 Remove the coolant reservoir cap and add cool...

Page 67: ...dd coolant until the coolant level does not go down and then stop the engine 3 Fill the coolant reservoir with coolant until it reaches the COLD LEVEL mark 4 Install the coolant reservoir cap Check for any cool ant leakage NOTE If you find any leaks consult a Yamaha dealer ...

Page 68: ...ing bolt Have a Yamaha dealer make this adjustment CAUTION As the V belt wears adjustment may be necessary To ensure proper clutch performance the V belt position should be adjusted by adding a spacer on each adjusting bolt when the V belt position reaches 1 5 mm 0 06 in below the edge Have a Yamaha dealer make this adjustment CD 05E NOTE Apply the parking brake before replacing the V belt 1 Remov...

Page 69: ... position is incorrect adjust the V belt position by removing or adding a spacer 4 on each adjusting bolt 5 CD 06E 7 Tighten each adjusting bolt Standard V belt position a From 1 5 mm 0 06 in above the edge of the second ary sheave to 0 5 mm 0 02 in below the edge 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 b...

Page 70: ... the engine with the V belt or drive guard removed ESU03513 Checking the drive chain housing oil level and the drive chain tension Checking the oil level WARNING The engine oil tank brake disc and coolant hoses will be very hot after the engine has been run Avoid contact while they are still hot with any part of your body or clothing during inspection or repair 1 Place the snowmobile on a level su...

Page 71: ...reverse transmissions RS90R RS90NR RS90GT RSG90 CAUTION Make sure that no foreign material enters the drive chain housing 4 Install the dipstick making sure to align the notch 4 in the dipstick handle with the projection 5 on the drive chain housing Adjusting the chain tension 1 Loosen the locknut 2 Turn the adjusting bolt clockwise until it is finger tight and then loosen it 1 4 turn 3 Hold the a...

Page 72: ...rking brake pads wear adjustment may be nec essary to ensure proper brake performance WARNING Be sure to have a Yamaha dealer make this adjust ment 1 Loosen the locknut 1 and the adjusting bolt 2 2 Loosen the cable locknut 3 3 Turn the cable adjuster 4 in or out to adjust the cable length 4 Tighten the cable locknut 5 Turn the adjusting bolt in or out to adjust the clear ance between the parking b...

Page 73: ...d clean it up immediately ESU01811 Changing the brake fluid Brake fluid replacement is necessary when the following components are replaced during the periodic mainte nance or if they are damaged or leaking a All oil seals of the master cylinder and caliper cylinder b The brake hose WARNING Make sure that the brake fluid and the above parts are replaced by a Yamaha dealer ESU00183 Suspension The s...

Page 74: ...n Minimum 155 5 mm 6 12 in The spring seat length changes approximately 1 5 mm 0 06 in with each full turn of the adjuster Spring seat length Standard Increased Decreased Preload Harder Softer a Length Maximum 162 0 mm 6 38 in 152 0 mm 5 98 in Minimum 152 0 mm 5 98 in The spring seat length changes approximately 1 5 mm 0 06 in with each full turn of the adjuster Spring seat length Standard Increas...

Page 75: ... other high heat source which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose of a worn or damaged shock absorber by yourself Take the unit to a Yamaha dealer ESU04750 Adjusting the ski damping forces For RS90GT Compression damping force The compression damping force of each ski shock absorber can be adjusted by turning the compression damping force a...

Page 76: ...loss of stability WARNING This shock absorber contains highly pressurized nitrogen gas It could explode by improper handling causing injury or property damage Do not tamper with or attempt to open the shock absorber Do not subject the shock absorber to an open flame or other high heat source which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose of a w...

Page 77: ...E For RS90R RS90GT RSG90 CD 26E A Spring seat length Standard Increased Decreased Preload Harder Softer È a Length front Maximum 123 5 mm 4 86 in 113 5 mm 4 47 in Minimum 107 5 mm 4 23 in The spring seat length changes approximately 1 5 mm 0 06 in with each full turn of the adjuster B Spring adjuster position 1 2 3 4 5 Preload Soft Hard É Standard front 3 C Spring adjuster position S M H Preload S...

Page 78: ...his shock absorber contains highly pressurized nitrogen gas It could explode by improper handling causing injury or property damage Do not tamper with or attempt to open the shock absorber Do not subject the shock absorber to an open flame or other high heat sources which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose of a worn or damaged shock absor...

Page 79: ...ure to stop the remote adjustment dial at a marked position around the dial where there is a click WARNING This shock absorber contains highly pressurized nitrogen gas It could explode by improper handling causing injury or property damage Do not tamper with or attempt to open the shock absorber Do not subject the shock absorber to an open flame or other high heat source which could cause it to ex...

Page 80: ... where there is a click WARNING This shock absorber contains highly pressurized nitrogen gas It could explode by improper handling causing injury or property damage Do not tamper with or attempt to open the shock absorber Do not subject the shock absorber to an open flame or other high heat source which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose ...

Page 81: ...h 3 included in the owner s tool kit as shown Make sure that the rim d of the control rod body is within the range e of the scale 4 Tighten the locknut while holding the adjuster in place CAUTION When using the special wrench make sure that it is situated at a right angle to the control rod and that it is tightly fitted to the locknut or the control rod adjuster WARNING Never adjust the control ro...

Page 82: ...ner s tool kit make sure that they are situated at a right angle to the control rod as shown and that they are tightly fitted to the locknut and the control rod adjusting nut The left and right adjusting nuts must be set to the same position Uneven settings can cause poor handling and loss of stability WARNING Never adjust the control rods beyond the maximum range indicated on the rods with red pa...

Page 83: ...e damaged slide metal Replace the drive track if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken Otherwise track damage or failure could result in loss of braking ability and snow mobile control which could cause an accident Measuring the drive track deflection 1 Lay the snowmobile on its side 2 Measure the drive track deflection with a spring s...

Page 84: ... the drive track one or two turns Stop the engine 4 Check the drive track alignment with the slide runners 2 If the alignment is incorrect align the drive track by turning the left and right adjusters CD 08E 7 Slide runners 8 Drive track 9 Slide metal a Gap b Forward 5 Adjust the drive track deflection to specification CD 09E 5 6 Drive track alignment 5 Shifted to right 6 Shifted to left 3 Left ad...

Page 85: ...02001 Aligning the skis 1 Turn the handlebar so the skis face straight ahead 2 Check the following for ski alignment a Skis are facing forward b Ski toe out 1 2 is within specification 3 If the alignment is not correct consult a Yamaha dealer ESU03543 Adjusting the handlebar For RS90R RS90GT RSG90 1 Remove the handlebar cover 1 Rear axle tightening torque 75 Nm 7 5 m kgf 54 2 ft lb Ski toe out 1 2...

Page 86: ... position CAUTION Make sure that the projection on the handlebar is not installed into the area a shown 4 Tighten the handlebar bolts and install the handlebar cover CAUTION Make sure that the small gap b side of the handlebar holders faces forward c Handlebar bolt tightening torque 14 5 Nm 1 45 m kgf 10 5 ft lb ...

Page 87: ... dab of grease onto the cable end only Do not grease the throttle cable because it could become frozen which could cause loss of control 2 Front suspension 3 Rear suspension WARNING Be sure to have a Yamaha dealer lubricate the front and rear suspensions 2 2 Lubricant Low temperature grease 3 3 ...

Page 88: ...e headlight unit 7 Install the bulb holder cover and then connect the headlight coupler CAUTION Keep oil and your hands away from the glass part of the bulb or its life and illumination will be affected If the glass is oil stained thoroughly clean it with a cloth moistened with alcohol or lacquer thinner ESU03721 Adjusting the headlight beam 1 Lift up the shroud 2 Insert a Phillips screwdriver int...

Page 89: ...act 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 physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Alway...

Page 90: ...own 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 10 Connect the negative battery lead 11 Install the air filter case by reversing the removal steps NOTE When installing the air filter case connect the crankcase breather hose to the air filter case f...

Page 91: ...es 20 A 10 A 15 A 3 A F Spare main fuse Specified fuses 9Main fuse 30 A 0 HEAD Headlight fuse 20 A A SIG Signal fuse 10 A B DC TERM Auxiliary DC jack fuse 3 A C C W Carburetor warmer fuse 20 A D IGN Ignition fuse 15 A ...

Page 92: ...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 3 Compression Insufficient Loose cylinder head nuts Tighten nuts properly Worn or damaged gasket Replace gasket Worn or damaged piston and cylinder Ask a Yamaha dealer to inspect B Starting the engine with a dis charged battery If the snowmobile batte...

Page 93: ...r cable to the black lead Do not reverse the connections 4 Pull the red lead cover to expose the terminal through the slit in the cover and then connect the red jumper cable to the red terminal of the discharged battery 5 Connect the other end of the red jumper cable to the positive terminal of the booster battery 6 Connect the black jumper cable to the negative terminal of the booster battery 7 P...

Page 94: ...k con nections or ask a Yamaha dealer to inspect 3 Discharged battery Charge battery or see B above 4 Seized engine Seizure is caused by poor lubrication inadequate fuel or an air leak Ask a Yamaha dealer to inspect 5 Hydrostatic lock occurs when fuel has filled the cylinders when the vehicle has been transported Remove the spark plugs and turn the engine over several times with the ignition off t...

Page 95: ...lean 2 Problem with the driveline See H above J Engine does not upshift or down shift properly or engages harshly 1 Worn or damaged V belt Replace the V belt or ask a Yamaha dealer to inspect 2 Incorrect V belt clutch settings for alti tude or conditions Ask a Yamaha dealer to inspect 3 Worn or sticking primary sheave assembly Ask a Yamaha dealer to inspect 4 Worn or sticking secondary sheave asse...

Page 96: ...ed fuel gasohol is used because the alcohol content in the fuel increases the chance for water to enter the engine Use Yamaha Stor Rite Engine Fogging Oil or an equiva lent fogging oil to protect both the com bustion chamber and crankshaft from corrosion An alternate method is to remove the carburetor silencer and squirt oil into the carburetor throats while the engine is running CAUTION Do not at...

Page 97: ...ti lated place out of direct sunlight Put a fab ric cover over the snowmobile preferably one that is designed for it Do not use a plastic or vinyl cover condensation could be trapped underneath which could increase the chances of rusting Returning to service after storage When returning your snowmobile to ser vice install the V belt and battery and adjust the drive track Remove the spark plugs and...

Page 98: ... RSG90 Overall width 1 225 mm 48 2 in RS90N RS90R RS90NR RS90GT RSG90 1 165 mm 45 9 in RS90M Overall height 1 090 mm 42 9 in RS90N RS90NR 1 215 mm 47 8 in RS90R RSG90 1 250 mm 49 2 in RS90M 1 150 mm 45 3 in RS90GT Dry weight 246 kg 542 lb RS90N 250 kg 551 lb RS90R RS90NR RS90GT 266 kg 586 lb RS90M 260 kg 573 lb RSG90 Ski stance 1 086 mm 42 8 in RS90N RS90R RS90NR RS90GT RSG90 980 mm 38 6 in RS90M ...

Page 99: ...her Starting system Electric starter RS90N RS90R RS90NR RS90M RS90GT RSG90 Drive track and suspension Track Molded rubber fiber glass rod reinforced Width 381 mm 15 0 in Track deflection 30 35 mm 1 18 1 38 in 100 N 10 kg 22 lb RS90N RS90R RS90NR RS90M RS90GT 25 30 mm 0 98 1 18 in 100 N 10 kg 22 lb RSG90 Length on ground 723 mm 28 5 in RS90N RS90NR 768 mm 30 2 in RS90R RS90GT 1 068 mm 42 0 in RS90M...

Page 100: ...90NR 38 22 1 73 RS90R RS90GT 40 20 2 00 RS90M 39 22 1 77 RSG90 Fuel tank Tank capacity 39 3 L 8 6 lmp gal 10 4 US gal Oil quantity With oil filter cartridge replacement 3 0 L 2 6 lmp qt 3 2 US qt Without oil filter cartridge replacement 2 8 L 2 5 lmp qt 3 0 US qt Total amount 3 7 L 3 3 lmp qt 3 9 US qt Brake Type Hydraulic disc type ventilated disc Operation Handle lever left hand operated Throttl...

Page 101: ...g Type R CR8E NGK Gap 0 7 0 8 mm 0 028 0 031 in Battery Capacity YTX20L BS 12 V 18 A h Maximum charge rate 1 8 Amperes hr for 10 hrs Headlight Bulb Quantity 12 V 60 55 W 2 Tail brake light Bulb Quantity 12 V 5 21 W 2 Meter light Bulb Quantity 14 V 50 mA 6 Indicator light Bulb Quantity 14 V 80 mA 3 ...

Page 102: ...ACK B W DARK GREEN L G R W Br W R Y Br R Br R W Br W Y B G B R B R B R B R B G B Ch Ch D G G D L R L R D B B B Lg B W R L Br Br L R Y R W O BLACK Br O Br Gy BLACK Br Gy Br L W Y B L W BLACK Br W G L R B L Y B Gy W L W Y B Lg G Br L Y B Y R Br Y B Y Br W W R W G B L L G B W Y W Y L Lg W Lg L Ch B B Y R Lg B W L G G L R B Ch Ch Ch R B Ch Ch L R Y B R BG B W Y L Y BLACK B Br W Br R Br L Br L R W Dg L...

Page 103: ...Y Multi function meter Z Meter light High beam indicator light DC TERM Auxiliary DC jack fuse HEAD Headlight fuse _ SIG Signal fuse a C W Carburetor warmer fuse b IGN Ignition fuse c Auxiliary DC jack RS90GT d Headlight beam switch e Headlight relay f Headlight g Jumper leads È RS90R RS90GT RSG90 É RS90N RS90NR RS90M COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue Lg ...

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