Yamaha RS90GTW Owner'S Manual Download | Manualshive

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ESU00355

Battery

This snowmobile is equipped with a sealed-type (MF)
battery, which does not require any maintenance. There
is no need to check the electrolyte or to add distilled
water.

To charge the battery

Have a Yamaha dealer charge the battery as soon as
possible if it seems to have discharged. Keep in mind
that the battery tends to discharge more quickly if the
snowmobile is equipped with electrical accessories.

WARNING

@

Battery electrolyte is poisonous and dangerous. It
contains sulfuric acid and can cause severe burns.
Avoid contact with skin, eyes, or clothing.
ANTIDOTE:

●

EXTERNAL: Flush with water.

●

INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg,
or vegetable oil. Call 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. Always shield your
eyes when working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.

@

ESU04232

Replacing a fuse

WARNING

@

Be sure to use the specified fuse. A wrong fuse
could cause electrical system damage or A FIRE
HAZARD.

@

CAUTION:

@

Be sure to turn the main switch off and disconnect
the negative battery lead to prevent accidental short-
circuiting.

@

E_8gg.book Page 37 Thursday, March 16, 2006 4:23 PM

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Summary of Contents for RS90GTW

Page 1: ...OWNER S MANUAL SNOWMOBILE RS90NW RS90RW RS90NRW RS90MW RS90MSW RS90GTW ...

Page 2: ......

Page 3: ...e 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 E_8gg book Page 1 Thursday March 16 20...

Page 4: ...ion 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 RS90NW RS90RW RS90NRW RS90MW RS90MSW RS90GTW RSG90W RSG90GTW OWNER S MANUAL 2006 by Yamaha Motor Corp...

Page 5: ... 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 bystander or a person insp...

Page 6: ...ht 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 Rear carrier 5 13 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 fluid ...

Page 7: ...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 track 8 31 Aligni...

Page 8: ...ormal 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 avail ...

Page 9: ...ark 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 and s...

Page 10: ...arranty 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 OF A...

Page 11: ...1 4 ESU04280 YAMAHA EXTENDED SERVICE Y E S CW 06E E_8gg book Page 4 Thursday March 16 2006 4 23 PM ...

Page 12: ... following labels carefully before operat ing this snowmobile NOTE Maintain or replace safety and instruction labels as nec essary 1 RS90N RS90M RS90MS 1 RS90R RS90NR RS90GT RSG90 RSG90GT 2 8EK 77761 E0 8FB 77761 E0 E_8gg book Page 1 Thursday March 16 2006 4 23 PM ...

Page 13: ...rvice 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 22259 70 8ED ...

Page 14: ...8 RS90M RS90MS RSG90 RSG90GT 9 RS90MS 8FS 24875 E0 Do not use the carrier to lift the snowmobile Ne pas soulever la motoneige en tirant sur le porte bagages E_8gg book Page 3 Thursday March 16 2006 4 23 PM ...

Page 15: ...2 4 NOTE The following suspension adjustment charts are included with the Owner s Manual RS90N RS90NR RS90M RS90MS RS90R RS90GT RSG90 RSG90GT E_8gg book Page 4 Thursday March 16 2006 4 23 PM ...

Page 16: ...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 starting the engine Check th...

Page 17: ... 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 your thumbs and fingers ...

Page 18: ...lease 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 personal injury Modifications ...

Page 19: ...4 1 ESU00012 4 DESCRIPTION RS90N RS90NR RS90M RSG90 RSG90GT RS90R RS90GT RS90MS E_8gg book Page 1 Thursday March 16 2006 4 23 PM ...

Page 20: ...humb warmer adjustment switch L Throttle lever M Shift lever RS90R RS90NR RS90GT RSG90 RSG90GT N Shroud latch O Main switch P Auxiliary DC jack RS90GT RSG90GT Q Starter lever R Tachometer S Low coolant temperature indicator light T High beam indicator light U Warning light V Self diagnosis warning indicator W Coolant temperature warning indicator X Fuel level warning indicator Y Oil level warning ...

Page 21: ...he 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 E_8gg book Page 1 Thursday March 16 2006 4 23 PM ...

Page 22: ...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 overheating when the engine is ...

Page 23: ...thout 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 diagnosis warning indicator ...

Page 24: ...nd 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 the tripmeter is displaye...

Page 25: ...2 control the electrically heated handlebar grips and throttle lever respectively To raise the temperature press the respective switch to HI To lower the temperature press the 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 switches to th...

Page 26: ...e 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 temperature is low and informs th...

Page 27: ...he 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 to cool off Then check th...

Page 28: ...e 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 RSG90GT The brake lever is equipped with a position adjuster ...

Page 29: ...arking brake applied This may overheat the brake disc and reduce braking ability ESU03411 Shift lever For RS90R RS90NR RS90GT RSG90 RSG90GT 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 Slide to REV Reverse 5...

Page 30: ...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 37 8 39 for the specified amper...

Page 31: ...ay 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 with the V belt or drive gua...

Page 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 RSG90GT Turn the remote adjustment dial to adjust the rear sus pension damping force See page 8 27 for adjustment procedures 1 Rear suspension damping force remote adjustmen...

Page 33: ...cated at the rear of the snowmobile 1 Rear carrier WARNING Do not use the rear carrier to lift the snowmobile The snowmobile could fall which could result in severe injury or death Maximum load limit 10 kg 22 lb E_8gg book Page 13 Thursday March 16 2006 4 23 PM ...

Page 34: ...nk 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 or if the ambient temperature rises causing the fuel to warm up and expand Make sure that the fuel tank cap is closed securely after refueling Leaking fuel can ...

Page 35: ...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 40 60 F SAE 0W 30 40 29 ...

Page 36: ...he 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 H 3 and L 4 level marks on the oil ...

Page 37: ...vel 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 temporarily in an emer gency E_8gg...

Page 38: ...orward 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 throttle lever 3 gradually The...

Page 39: ...rake 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 2 Brake fluid Check the ...

Page 40: ...y 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 guard mounts for damage ...

Page 41: ...le pattern drive track For RS90M RS90MS 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 Operation on areas with lig...

Page 42: ...i 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 RSG90GT Ski runner wear limit a 8 mm 0 31 in Ski wear limit b 12 mm 0 47 in For...

Page 43: ... 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 posi tion and then instal...

Page 44: ... 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 E_8gg book Page 11 Thursday M...

Page 45: ...E 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 CAUTION Release the switch...

Page 46: ... 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 800 km 500 mi of operatio...

Page 47: ... 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 characteristics Set the parking brake...

Page 48: ...th 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 hill this can be accompli...

Page 49: ...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 balance gradually steer agai...

Page 50: ...t 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 the drive track will be ...

Page 51: ... 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 logs etc If snow coverag...

Page 52: ... 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 not use the strap to...

Page 53: ...e parking brake lever to the left For RS90R RS90NR RS90GT RSG90 RSG90GT 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 Be sure to slide t...

Page 54: ...wmo 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 removed from the main switc...

Page 55: ...ssible 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 snowmobile against damage f...

Page 56: ...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 maintenance chart for the emissi...

Page 57: ...ne 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 Repair if necessary 5 3 6 5 ...

Page 58: ...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 RS90M RS90MS Check for damage...

Page 59: ...ce if necessary Lubricate with specified grease Steering column bearing Lubricate with specified grease Ski and front suspension Lubricate with specified grease 8 35 Suspension component Lubricate with specified grease 8 35 Parking brake cable end and lever end throttle cable end Lubricate with specified grease 8 35 Check cable damage Replace if necessary Shroud latches Make sure that the shroud l...

Page 60: ...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 center electrode por...

Page 61: ...park 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 Otherwise the spark plug caps co...

Page 62: ...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 adjustments should be left to...

Page 63: ... 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 sure to consult a Yamaha...

Page 64: ...ation 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 level gauge coupler 3 6 Rem...

Page 65: ...d 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 ft lb Recommended engine...

Page 66: ... 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 engine is running immediate...

Page 67: ...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 coolant until it reaches the COLD LE...

Page 68: ...ant 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 E_8gg book Page 13 Thursday March 16 2006 4 23 PM ...

Page 69: ...aler 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 Remove the drive guard 2 Rotat...

Page 70: ...just 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 below the edge Not necessa...

Page 71: ...lt or drive guard removed ESU03514 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 surface 2 Remove the dipsti...

Page 72: ...R RS90NR RS90GT RSG90 RSG90GT 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 adjusting bolt in p...

Page 73: ...arking 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 ...

Page 74: ... 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 suspension can be adjusted...

Page 75: ...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 76: ...ure For RS90N RS90NR This snowmobile is equipped with FOX shock absorbers as standard equipment The air pressure of the shock absorbers can be adjusted using the special pump 1 included with your snowmo bile NOTE The following procedure applies to both shock absorb ers 1 Place the snowmobile on a level surface and apply the parking brake 2 Lift the front of the snowmobile onto a suitable stand to ...

Page 77: ...s rapidly check to make sure that the pump is properly connected and tightened onto the air valve To decrease the air pressure push the black bleed valve button 4 NOTE To allow pressure to escape from the pump and the shock absorber push the button halfway down and hold it To allow only a small amount of pressure to escape push the button all the way down and quickly release it 6 Remove the hose c...

Page 78: ...ers must be set to the same setting Uneven settings can cause poor handling and 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 exp...

Page 79: ...s even if the adjusting knobs are turned out more than the minimum settings CAUTION The damping forces for the left and right ski shock absorbers must be adjusted to the same settings Uneven settings can cause poor handling and loss of stability Adjusting knob position Turns out b Turns in a Damping Soft Hard With the adjuster fully turned in direction a 12 clicks out out Minimum Standard 7 clicks...

Page 80: ...U04045 Adjusting the rear suspension spring preload The rear suspension spring preload can be adjusted by turning the spring preload adjuster 1 on the shock absorber RS90R RS90GT RSG90 RSG90GT or each shock absorber RS90N RS90NR RS90M RS90MS For RS90N RS90NR CD 17E For RS90M RS90MS CD 13E A Spring seat length Standard Increased Decreased Preload Harder Softer È a Length front Maximum 123 5 mm 4 86...

Page 81: ...t 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 absorber by yourself Take the unit to a Yamaha dealer C Spring adj...

Page 82: ...e 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 explode Do not deform o...

Page 83: ...ARNING 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 worn or damaged shoc...

Page 84: ...wner 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 rod beyond the range of...

Page 85: ...re 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 paint 3 c Adjustable ran...

Page 86: ... 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 scale Pull at the center of the dr...

Page 87: ...wo 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 adjuster Turn out Turn in 4...

Page 88: ...n 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 RSG90GT 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 0 15 mm 0 0 59 in E_...

Page 89: ...re 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 E_8gg book Page 34 Thursday March 16 2006 4 23 PM ...

Page 90: ...ble 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 3 E_8gg book Page 35 Thursday March 16 2006 4 23 PM ...

Page 91: ...l 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 into the hole under the shro...

Page 92: ...thing 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 Always shield your eyes when w...

Page 93: ...ase 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 first and then connect it ...

Page 94: ...pare 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 E_8gg book Page 39 Thursday March 16 2006 4 23 PM ...

Page 95: ...he 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 battery is discharged ...

Page 96: ...d 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 Pull the black lead cover...

Page 97: ...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 to expel excess fuel Ask ...

Page 98: ...riveline 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 assembly Ask a Yamaha dealer ...

Page 99: ...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 attempt to store the snowm...

Page 100: ...ect 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 clean or replace them if...

Page 101: ...8 in RS90R RS90GT RSG90 RSG90GT 1 185 mm 46 7 in RS90M RS90MS Dry weight 245 kg 540 lb RS90N 250 kg 551 lb RS90R RS90GT 249 kg 549 lb RS90NR 266 kg 586 lb RS90M 270 kg 595 lb RS90MS 260 kg 573 lb RSG90 261 kg 575 lb RSG90GT Ski stance 1 086 mm 42 8 in RS90N RS90R RS90NR RS90GT RSG90 RSG90GT 980 mm 38 6 in RS90M RS90MS RS90N RS90R RS90NR RS90M RS90MS RS90GT RSG90 RSG90GT Type Liquid cooled 4 stroke...

Page 102: ...30 35 mm 1 18 1 38 in 100 N 10 kg 22 lb RS90N RS90R RS90NR RS90M RS90MS RS90GT 25 30 mm 0 98 1 18 in 100 N 10 kg 22 lb RSG90 RSG90GT Length on ground 723 mm 28 5 in RS90N RS90NR 768 mm 30 2 in RS90R RS90GT 1 068 mm 42 0 in RS90M 1 201 mm 47 3 in RS90MS 960 mm 37 8 in RSG90 RSG90GT Suspension type Slide Rail Suspension Drive sprocket Quadruple polyethylene 9 teeth RS90N RS90R RS90NR RS90GT RSG90 RS...

Page 103: ... 40 20 2 00 RS90M 40 18 2 22 RS90MS 39 22 1 77 RSG90 RSG90GT 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 Throttle ...

Page 104: ... 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 E_8gg book Page 4 Thursday March 16 2006 4 23 PM ...

Page 105: ... MEMO E_8gg book Page 5 Thursday March 16 2006 4 23 PM ...

Page 106: ...ACK 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 R Br Y R W L R Dg Br Y W R W G Gy B Br W Br BLACK B L BLACK B Y Ch BLACK B Y Br Br W BLACK B R B B B B L B Y Lg Br Y Y R Gy O Br W Y L L Y B Br L B Y W Ch Lg ...

Page 107: ...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 RSG90GT d Headlight beam switch e Headlight relay f Headlight g Jumper leads È RS90R RS90GT RSG90 RSG90GT É RS90N RS90NR RS90M RS90MS Ê RS90N RS90R RS90NR RS90M RS90GT RSG90 RSG90GT Ë RS90MS COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G G...

Page 108: ... MEMO E_8gg book Page 3 Thursday March 16 2006 4 23 PM ...

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