Yamaha RST90G Page 107 Owner'S Manual Download

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Periodic maintenance and adjustment

101

Loosen the joint clamp bolts.

Slide the oil tank breather hose clamp
away from the air filter case, and then
disconnect the oil tank breather hose.

Slide the crankcase breather hose clamp
(crankcase side) up, and then disconnect
the crankcase breather hose from the
engine.

Lift up the air filter case, slide the crank-
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.

Disconnect the negative battery lead.

Replace the blown fuse with one of the
proper amperage.

1. Air filter case fastener

1. Joint clamp bolt

1. Oil tank breather hose clamp
2. Oil tank breather hose

1. Crankcase breather hose clamp (crankcase

side)

2. Crankcase breather hose

1. Crankcase breather hose clamp (air filter

case side)

U8JV70E0.book Page 101 Monday, April 6, 2015 11:49 AM

Summary of Contents for RST90G

Page 1: ...DIC183 OWNER S MANUAL Read this manual carefully before operating this vehicle RST90G RST90TFG RST90TFLG RST90TFYG 8JV 28199 70 ESU10012 LIT 12628 03 24 ...

Page 2: ...nnues dans l État de Californie pour provoquer des cancers des malformations congénitales et des troubles de la reproduction Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U8JV70E0 book Page 1 Monday April 6 2015 11 49 AM ...

Page 3: ...ime of print ing there may be minor discrepancies between your snowmobile and this manual If there is any question concerning this manual please consult a Yamaha dealer WARNING EWS00671 Please read this manual carefully before operating this snowmobile Do not at tempt to operate this snowmobile until you have attained adequate knowledge of its controls and operating features Regular inspections an...

Page 4: ...fety messages that follow this symbol to avoid possible injury or death WARNING EWS00022 A WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE ECS00012 A NOTICE indicates special precautions that must be taken to avoid damage to the snowmobile or other property TIP A TIP provides key information to make pro cedures easier or clearer U8JV70E0...

Page 5: ...umb warmer adjusting switch 23 Auxiliary DC jack 24 Helmet shield heater jack RST90TF RST90TFL RST90TFY 25 Brake lever 25 Parking brake lever 26 Shift lever 26 Drive guard 27 V belt holders 28 Passenger grips RST90TF RST90TFL RST90TFY 29 Passenger grip warmer switch 29 Passenger footrests 30 Backrest 30 Storage compartment RST90TF RST90TFL RST90TFY 31 Storage areas RST90 32 Tow hitch RST90TF RST90...

Page 6: ...ive chain housing 82 Brake and parking brake 83 Extrovert drive sprocket RST90TF RST90TFL RST90TFY 86 Skis and ski runners 86 Steering system 87 Drive track and slide runners 89 Lubrication 92 Replacing a headlight bulb 93 Adjusting the headlight beams 95 Fittings and fasteners 96 Battery 96 Replacing a fuse 97 Troubleshooting 103 Storage 108 Specifications 110 Consumer information 112 Identificat...

Page 7: ...nt information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 3 7 2 6 5 4 6 5 4 3 2 1 7 RST90TF RST90TFL RST90TFY RST90 U8JV70E0 book Page 1 Monday April 6 2015 11 49 AM ...

Page 8: ...Location of the important labels 2 8 10 8 9 13 16 11 12 9 16 12 15 13 16 15 14 16 11 10 RST90TF RST90TFL RST90TFY RST90 14 U8JV70E0 book Page 2 Monday April 6 2015 11 49 AM ...

Page 9: ...e l accélérateur et de la direction Le frein de sécurité doit être appliqué lors du démarrage Ne pas rouler avec le frein de sécurité actionné En cas d urgence utiliser l interrupteur d arrêt du moteur Ne pas laisser tourner le moteur sans la courroie ou sans son garde S assurer que le bouchon du réservoir soit bien refermé après le remplissage Afin d éviter tout risque de collision ne pas rouler ...

Page 10: ...uel du propriétaire 8FA E0 8FA 2389C E0 NEVER stand behind or near a rotating track Debris or a broken track could be thrown back with great force which could cause severe leg or other injuries or death Ne JAMAIS se tenir à proximité ou à l arrière d une chenille en mouvement Des débris ou une chenille cassée pourraient être projetés violemment et entraîner des blessures sévères aux jambes ou autr...

Page 11: ...ure open doing so may cause explosion and result in serious injury See Owner s manual L unité contient de I azote sous haute pression Ne pas lncinérer perforer ouvrir car ceci pourrait causer une explosion et de graves blessures Voir le Manuel utilisateur K7R 22259 00 15 RST90TFL 16 U8JV70E0 book Page 5 Monday April 6 2015 11 49 AM ...

Page 12: ...rake before starting the engine Never drive the snowmobile with the parking brake applied This may over heat the brake disc and reduce braking ability While using your snowmobile This snowmobile was not manufactured for use on public streets roads or highways Such use is prohibited by law and you could collide with another vehicle Be careful where you ride There may be obstacles hidden beneath the...

Page 13: ...ture parts and accessories or offer other modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket companies produce Therefore Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifica tions not specifically recommended by Yamaha even if sold and installed by a Yamaha dealer Maintenance and storage When laying th...

Page 14: ...servoir 7 Passenger grip warmer switch 8 Passenger grip 9 Backrest 10 Storage compartment 11 Storage pouch RST90TF RST90TFL RST90TFY 12 Tool kit 13 Tail brake light 14 Tow hitch RST90TF RST90TFL RST90TFY tow hitch bracket RST90 15 Slide rail suspension 16 Drive track 17 V belt holder 18 Solo touring storage area RST90 19 Rear carrier RST90 20 Throttle stop screw RST90 U8JV70E0 book Page 8 Monday A...

Page 15: ...13 8 10 4 7 6 9 12 12 RST90TF RST90TFL RST90TFY RST90 1 Brake lever 2 Parking brake lever 3 Grip warmer adjusting switch 4 Thumb warmer adjusting switch 5 Helmet shield heater jack RST90TF RST90TFL RST90TFY 6 Engine stop switch 7 Throttle lever 8 Main switch 9 Shift lever 10 Auxiliary DC jack 11 Headlight beam switch 12 Shroud latch RST90 13 Starter choke lever RST90 U8JV70E0 book Page 9 Monday Ap...

Page 16: ... taillights come on after the engine is start ed ESU10302 Starter choke lever RST90 Use the starter choke lever when starting and warming up a cold engine TIP Refer to the Starting the engine section on page 45 for proper operation ESU10313 Throttle lever Once the engine is running cleanly squeez ing the throttle lever will increase the engine speed and cause engagement of the drive train Regulate...

Page 17: ...sition when the throttle lever is released See page 110 for the clutch engagement speed TIP If the T O R S is activated the warning light and engine trouble warning indicator flash and the two digit code 84 displays RST90TF RST90TFL RST90TFY or flash es RST90 in the meter display If this occurs have a Yamaha dealer check the system as soon as possible RST90TF RST90TFL RST90TFY RST90 ESU14851 Multi...

Page 18: ...eter and tripmeter modes Odometer shows the total distance that the vehicle has run Tripmeter A and tripmeter B show the dis tance traveled since they last reset Fuel reserve tripmeter shows the distance traveled since the fuel level warning indicator and warning light came on Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP A and TRIP B in ...

Page 19: ...nting the distance traveled from that point When this occurs change the en gine oil as soon as possible See page 71 for the oil change procedure TIP The oil change tripmeter will flash only when the snowmobile is stopped To return to the previous display mode push the SELECT button To display the oil change tripmeter again turn the key to the off position then back to the on posi tion After changi...

Page 20: ... the clock 1 Turn the key to the on position 2 Push the SELECT button and RESET button simultaneously until the hour dig its start flashing 3 Push the RESET button to change the hour setting and then push the SE LECT button The minute digits will start flashing 4 Push the RESET button to change the minute setting and then push the SE LECT button The clock starts when the SELECT button is released ...

Page 21: ...achometer needle makes one sweep and the low cool ant temperature indicator light the warning light and all segments of the meter unit dis play come on and go off The grip warmer level is initially displayed for 5 seconds then the display switches to the fuel meter TIP To switch the speedometer odometer and tripmeter displays between kilometers and miles select the odometer mode ODO and then push ...

Page 22: ...his mode offers a sportier engine response compared to the other modes Touring mode T This mode allows the rider to enjoy smooth drivability from the low speed range to the high speed range Entry mode E This mode offers a reduction of engine power compared to the other modes and is suitable for the entry level rider Push the MODE button to switch between modes WARNING EWS00840 Do not change the D ...

Page 23: ...t the engine RST90 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 engine trou ble warning indicator flash and the two digit code 86 flashes in the error code display When this occurs maximum en gine speed is reduced to protect the en gine ESU10428 Fuel meter and grip thumb warmer level indicator The fu...

Page 24: ...e snowmobile must be stopped on a level surface to obtain an accurate fuel meter reading since the reading changes accord ing to the movement and inclination of the snowmobile Grip thumb warmer level indicator When the grip warmer adjusting switch is pressed the grip warmer indicator comes on and the display switches to the grip warmer level 1 Fuel meter and grip thumb warmer level in dicator 1 Fu...

Page 25: ...RST90TFY RST90 RST90TF RST90TFL RST90TFY RST90 TIP The grip thumb warmer level is displayed for 5 seconds after releasing the grip thumb warmer adjusting switch then the display switches to the fuel meter 1 Grip warmer indicator 2 Thumb warmer indicator 1 Grip warmer indicator 2 Thumb warmer indicator 1 Grip warmer adjusting switch 1 Grip warmer adjusting switch 1 Thumb warmer adjusting switch 1 1...

Page 26: ...nnected coupler broken lead or short circuit is detected by the self diagnosis device of the snowmobile to warn the rider of any of the above problems If this occurs have a Yamaha dealer inspect the snowmobile as soon as possible RST90TF RST90TFL RST90TFY RST90 ESU10464 Oil level warning indicator RST90 The oil level warning indicator and the warn ing light come on when the engine oil level is low...

Page 27: ...warning indicator and the warning light do not go off check the engine oil level in the oil tank see page 71 for engine oil level checking procedures and add engine oil if necessary If the warning indicator and the warning light still remain on have a Yamaha dealer check the snowmobile Oil pressure warning The warning indicator comes on and OP LO oil pressure low appears in the odome ter display i...

Page 28: ... the EPS system may not be working correctly When this occurs have a Yamaha dealer check the EPS system TIP If the steering load is too heavy i e exces sive steering use when the snowmobile is traveling at a slow speed the power assist is reduced to protect the EPS motor from over heating ESU13772 Self diagnosis device This model is equipped with a self diagnosis device for various electrical circ...

Page 29: ...the stop switch so that you can react quickly in an emergency ESU10662 Headlight beam switch LIGHTS Push the headlight beam switch to change the headlight to high beam HI or to low beam LO ESU12655 Grip thumb warmer adjusting switch The grip warmer adjusting switch and the thumb warmer adjusting switch control the electrically heated handlebar grips and throt tle lever respectively 1 Warning light...

Page 30: ...iary DC jack is located in the front panel and can be used for accessories TIP The auxiliary DC jack can only be used if the engine is 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 RST90TF RST90TFL RST90TFY RST90 1 Grip warmer adjusting switch 1 Grip warmer adjusting switch 1 Thumb warmer adjusting sw...

Page 31: ...gine is running To use the helmet shield heater jack 1 Start the engine 2 Open the helmet shield heater jack cap and then insert the power plug of the hel met shield heater into the jack 3 After using the helmet shield heater be sure to remove its power plug from the jack and to close the jack cap NOTICE ECS00893 To avoid circuit overload and a possible fuse blowing do not use a helmet shield heat...

Page 32: ...g 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 ESU10594 Shift lever 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 RST90TF RST90TFL RST90TFY 1 Brake le...

Page 33: ...alled securely before operating the snowmobile to protect against severe injury or death from a broken V belt or other part should it come off the snow mobile while it is in operation NOTICE ECS00931 Never run the engine with the V belt re moved Clutch components can be damaged Be careful not to scratch the windshield when removing or installing the drive guard 1 Pull out 2 Slide to REV reverse 3 ...

Page 34: ...r 2 Lift up the rear of the drive guard as shown and then pull the guard rearward to remove it To install the drive guard 1 Fit the front slots in the drive guard over the projections on the drive guard front holder 2 Align the slots in the rear of the drive guard with the projections on the drive guard rear holder and then insert the drive guard locking pin into the holder as shown ESU10762 V bel...

Page 35: ...p adjusting knob by turning it counterclockwise 2 Move the passenger grip to the desired position 3 Install the adjusting knob by turning it clockwise WARNING EWS00781 Make sure that the passenger grip adjust ing knobs are securely tightened after changing the positions of the passenger grips ESU10682 Passenger grip warmer switch The passenger grip warmer switch controls the electrically heated pa...

Page 36: ...rely after changing the position of the footrests Do not overtighten the screws other wise the footrest may be damaged ESU14131 Backrest WARNING EWS00132 Do not sit on the backrest Otherwise you could lose your balance fall and be in jured The angle and position RST90TF RST90TFL RST90TFY of the backrest are adjustable To adjust the backrest angle Turn the backrest adjusting knob until the backrest...

Page 37: ...ompartment NOTICE ECS00901 The bottom of the storage compartment may be hot during or immediately after op erating the snowmobile It can cause burns if it becomes extremely hot Further more heat in the storage compartment can affect the quality of food items and deform and discolor plastic items The storage compartment is located behind the seat Use the storage compartment to store the storage pou...

Page 38: ...0782 Before starting the engine make sure that the tool kit is securely fastened and that the storage pouch zipper is completely closed ESU10824 Storage areas RST90 This snowmobile is equipped with a storage compartment rear storage area and rear carrier Storage compartment The storage compartment is located under the shroud Open the storage compartment by unhook ing the fasteners to store the too...

Page 39: ...e rear carrier 2 Slide both the backrest and the rear car rier forward until they stop and then re move them 3 Remove the passenger seat lock knob and then remove the passenger seat 4 Align the holes in the rear carrier with the bolts on the carrier lock bracket and then place the rear carrier on the carrier lock bracket 1 Rear storage area 2 Rear carrier Maximum load limit Rear storage area 20 kg...

Page 40: ...tall the passenger seat and then in stall the passenger seat lock knob 3 Align the holes in the backrest bracket with the bolts on the carrier lock bracket and then place the backrest on the carri er lock bracket 4 Align the holes in the rear carrier with the bolts on the carrier lock bracket and then place the rear carrier on the carrier lock bracket 5 Slide both the backrest and the rear car rie...

Page 41: ...ha dealer ESU14870 Fuel WARNING EWS00072 Gasoline and gasoline vapors are ex tremely flammable To avoid fires and ex plosions and to reduce the risk of injury when refueling follow these instructions Make sure there is sufficient gasoline in the tank 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 op...

Page 42: ...ine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher NOTICE ECS01100 RST90 Oxygenated fuels gasohol con taining a maximum 10 of ethanol E10 can be used although richer jetting may be required to prevent engine damage Consult a Yamaha dealer Gasohol con taining methanol is not recommended RST90TF RST90TFL ...

Page 43: ...the cylinders in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber yourself Take the shock absorber to a Yamaha dealer for any service TIP A special wrench can be obtained at a Yamaha dealer ESU10895 Adjusting the spring preload of the front shock absorbers WARNING EWS00721 The spring preload of the left and right shock absorbers...

Page 44: ...A is the lower the spring preload 3 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten the locknut to the speci fied torque ECS00861 Spring preload setting Minimum soft 161 0 mm 6 34 in RST90 160 0 mm 6 30 in RST90TF RST90TFL RST90TFY Standard 162 0 mm 6 38 in RST90 163 0 mm 6 42 in RST90TF RST90TFL RST90TFY Maximum hard 172 0 m...

Page 45: ...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 chang ing 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 Ins...

Page 46: ...usted 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 injury ...

Page 47: ...adjusted by turning the adjusting nuts To increase the spring preload turn the ad justing nut in direction a To decrease the spring preload turn the adjusting nut in direc tion b TIP The spring preload setting is determined by measuring distance A shown in the illustra tion The longer distance A is the higher the spring preload the shorter distance A is the lower the spring preload 1 Locknut 2 Con...

Page 48: ...e due to exces sive gas pressure Do not deform or damage the cylinders in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out damper yourself Take the damper to a Yamaha dealer for any service NOTICE ECS01110 Yamaha Performance Dampers are preci sion instruments and are not serviceable in any way The mishandling of a removed damper can easily bre...

Page 49: ... specified level Check vehicle for oil leakage 71 Coolant Check coolant level Add if necessary 76 V belt Check for wear and damage Replace if necessary 79 Drive guard Make sure the drive guard is installed securely Check the drive guard mounts for damage 27 Brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check brake pads for wear Replace if necessary Check fluid ...

Page 50: ...rs 89 Steering Check for excessive free play 87 Lights signals and switch es Check operation Correct if necessary 23 23 93 95 Throttle lever Make sure that operation is smooth and spring back to its original position when released 10 Throttle override system T O R S Check the T O R S for proper operation If system is not functioning properly have Yamaha dealer check vehicle 66 ITEM CHECKS PAGE U8J...

Page 51: ... it stops again ask a Yamaha dealer to inspect the snowmobile an engine overheating prevention system which prevents overheating when the en gine is idling When the engine has been idling for 3 minutes or longer and the cool ant temperature has risen above 100 C 212 F the engine automatically stops to prevent overheating The engine can be started after it stops ESU13971 Starting the engine RST90TF...

Page 52: ...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 crank the engine more than 10...

Page 53: ...of operation the engine oil must be changed and the oil filter cartridge replaced If any engine trouble should occur dur ing the engine break in period immedi ately have a Yamaha dealer check the snowmobile ESU11334 Riding your snowmobile Getting to know your snowmobile WARNING EWS00212 To avoid severe injury or death Keep both hands on the handlebar dur ing operation Never put your feet outside t...

Page 54: ...page 45 to start the engine Once the engine has warmed up you are ready to be gin riding your snowmobile To start out and accelerate 1 With the engine idling release the park ing brake 2 Apply the throttle slowly and smoothly The V belt clutch will engage and you will start to accelerate WARNING Do not allow anyone to stand behind the snowmobile when starting the engine A broken track track fittin...

Page 55: ...keep your weight on the uphill side at all times On climbs straight up the hill this can be accomplished by leaning forward and on steeper inclines standing on the running boards and leaning forward over the handlebar Also see Traversing a slope Slow down as you reach the crest of the hill and be prepared to react to obstacles sharp drops or other vehicles or people which may be on the other side ...

Page 56: ... again in the direction you wish to travel If your snowmobile starts to tip steer down the hill to regain balance WARNING If you are unable to maintain correct balance and your snowmobile is going to tip over dismount your snowmobile immediately on the uphill side to avoid being hit or caught under the snowmobile as it tips over EWS00262 Ice or icy surface WARNING EWS00271 When you have to operate...

Page 57: ...tial break in the new drive track will tend to stretch quickly as the track settles Be sure to correct the track tension and align ment frequently See page 89 for adjustment procedures A loose track can slip ratchet derail or catch on suspension parts causing severe damage Do not overtighten the drive track otherwise it may increase the friction between the track and the slide runners re sulting i...

Page 58: ...ops completely and only while the engine is idling Make sure that the area behind the snowmobile is clear before reversing Watch behind Reduce speed and avoid sharp turning when operating the snowmobile in re verse TIP Make sure that the engine is warmed up enough before riding 1 To select the desired operating position pull the shift lever out slide it to FWD or to REV until it stops and then rel...

Page 59: ...cy ESU13781 Transporting When transporting your snowmobile on a trailer or in a truck observe the following rec ommendations to help protect it from dam age RST90 Make sure that the fuel level in the fuel tank is lower than the bottom of the carburetors Otherwise the vibration and bumps from the road surface could make it possible for fuel to flow through the carbu retors into the cylinders This c...

Page 60: ... vents and also help protect the snowmobile against damage from debris on the road If transporting the snowmobile in an open trailer or truck in areas where road salt is used coat metal suspension surfaces lightly with oil or another protectant This will help protect against corrosion Be sure to clean the snowmobile when you get to your destination to remove any corrosive salts U8JV70E0 book Page ...

Page 61: ...cing can lead to eye injury burns fire or carbon mon oxide poisoning possibly leading to death See page 6 for more information about carbon monoxide WARNING EWS00791 Brake discs calipers and linings can become very hot during use To avoid possible burns let brake components cool before touching them Maintenance replacement or repair of the emission control devices and systems may be performed by a...

Page 62: ...clear ance when engine is cold Every 40000 km 25000 mi 70 Crankcase breath er system Check breather hose for cracks or damage Replace if necessary Fuel filter RST90 Check condition Replace if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Idle speed RST90 Check and adjust idle speed 64 Fuel injection RST90TF RST90TFL RST90TFY Check synchronization Adjust if necessary...

Page 63: ...Inspect weights rollers and bushings for wear for primary Inspect ramp shoes bushings for wear for secondary Replace if necessary Lubricate with specified grease Drive chain Check chain slack Adjust if necessary Initial at 500 km 300 mi and every 800 km 500 mi thereafter 82 Drive chain oil Check oil level 82 Change 82 Shift lever Lubricate with specified grease Brake and parking brake Adjust free ...

Page 64: ...s Check for wear and damage Replace if necessary 86 Steering system Check toe out Adjust if necessary 87 Steering bearings Check bearing assemblies for looseness Lubricate with specified grease Skis and front shock absorbers Lubricate with specified grease 92 Suspension compo nent Lubricate with specified grease 92 Drive track Check the deflection Adjust if necessary Initial at 500 km 300 mi and e...

Page 65: ...90TFL RST90TFY The owner s tool kit is located in the storage pouch See page 31 for information on how to access the storage compartment The service information included in this man ual and the tools provided in the owner s tool kit are intended to assist you in the perfor mance of preventive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform...

Page 66: ...ud and covers are secured before operation A loose shroud or cover could move and cause loss of control Shroud To remove the shroud Loosen the fasteners slowly raise the shroud and then unhook the shroud from the shroud stay To install the shroud Hook the end of the shroud onto the shroud stay slowly lower it to the original position and then tighten the fasteners Left and right side covers To rem...

Page 67: ...en the fasteners 4 Install the shroud Top cover To remove the top cover 1 Remove the shroud and the left side cov er See the above procedures 2 Disconnect the auxiliary DC jack coupler 3 Remove the screws and then remove the cable guide 4 Pull the windshield stay rubber covers upward 1 Fastener 2 Left side cover 1 2 1 Auxiliary DC jack coupler 1 Screw 2 Cable guide 1 1 2 U8JV70E0 book Page 61 Mond...

Page 68: ...through the cable guide place the cable guide in the original position and then in stall the screws 6 Connect the auxiliary DC jack coupler 7 Install the left side cover and the shroud NOTICE ECS00373 Make sure that all cables hoses and leads are routed properly before install ing the shroud and covers When installing the shroud and covers be sure to tighten the fasteners secure ly ESU14770 Openin...

Page 69: ... important engine com ponents and are easy to inspect The condi tion of the spark plugs can indicate 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 light tan color for a snowmobile that is being ridden normally If any spark plug shows a distinctly different color there could be somethin...

Page 70: ...hickness gauge and adjust to specification 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 NOTICE ECS00383 Make sure that the spark plug caps are se curely installed Otherwise the spark plug caps could be damaged due to engine vi bration ESU11796 Adjusting the engine idling speed RST90 1 Place the...

Page 71: ... the top cover See page 60 for removal procedures 3 Remove the headlight unit bolt and the windshield stay bolts on each side of the snowmobile 4 Unhook the headlight unit as shown then lift it up and move it forward away from the handlebar NOTICE Be careful not to scratch the snowmobile when moving the headlight unit ECS00921 5 Loosen the locknut 6 To increase the throttle lever free play turn th...

Page 72: ...O R S WARNING EWS00353 When checking the T O R S take precau tions to avoid snowmobile movement which could cause an accident Make sure that the throttle lever moves smoothly with the engine off before checking the T O R S Make sure that the parking brake is ap plied Do not rev the engine to the point that the clutch engages 1 Locknut 2 Throttle lever free play adjusting bolt 3 Throttle lever free...

Page 73: ...e limited to less than the clutch engagement speed See page 110 for the clutch engagement speed WARNING If the engine speed does not decrease to less than the clutch engagement speed stop the engine by turning the main switch to the off position and consult a Yamaha dealer Operating the snowmobile with a mal functioning T O R S could result in loss of control EWS00363 ESU14920 Checking the air fil...

Page 74: ...attach the air filter case by hooking all the fas teners 7 Close the shroud RST90TF RST90TFL RST90TFY 1 Place the snowmobile on a level surface and apply the parking brake 2 Remove the shroud and the top cover See page 60 for removal procedures 3 Remove the headlight unit bolt and the windshield stay bolts on each side of the snowmobile 4 Unhook the headlight unit as shown then lift it up and move...

Page 75: ...t 7 Place the air filter element frame in the original position and then install the air filter case cover by hooking the fasten ers 8 Install the headlight unit making sure to fit the slots on its bottom onto the projec tions on its stay 9 Fit the weatherstrip on the headlight unit into the recess in the top of the air filter case cover 1 Headlight unit 1 Air filter case cover fastener 1 Air filt...

Page 76: ... poor performance Common problems are hard starting bogging and plug fouling Proper carburetion adjustments will correct the air fuel ratio Be sure to have a Yamaha dealer make these adjustments Remember Less air at higher altitude means there is less horsepower available even with the optimal air fuel ratio Expect acceleration and top speed to be reduced at higher altitudes To overcome operating ...

Page 77: ...ine will wear quickly The oil filter cartridge should be re placed after the first 800 km 500 mi of operation and every 20000 km 12000 mi of operation thereafter To check the engine oil level 1 Place the snowmobile on a level surface and apply the parking brake 2 Start the engine warm it up for 10 15 minutes and then turn it off TIP The engine can also be warmed up by driv ing the snowmobile for 1...

Page 78: ...H level mark See page 110 for the recom mended oil NOTICE When adding the engine oil be careful not to fill above the H level mark on the dipstick Use only the recommended oil See page 110 Make sure that no foreign mate rial enters the engine oil tank ECS00463 7 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 8 Connect the oil level gauge coupler 9 Install the righ...

Page 79: ...ove the right side cover RST90 see page 62 for the procedures 4 Remove the screws and the bolts and then pull the right lower cover outward to remove it RST90TF RST90TFL RST90TFY RST90TF RST90TFL RST90TFY 5 Remove the bottom panel by removing the bolts 6 Place an oil pan under the oil tank to col lect the used oil 7 Disconnect the oil level gauge coupler RST90TF RST90TFL RST90TFY RST90 1 Screw 2 B...

Page 80: ...sket to drain the oil from the crank case TIP A mark is stamped on the crankcase near the engine oil drain bolt for easy iden tification Dispose of used oil according to local reg ulations Skip steps 11 13 if the oil filter cartridge is not being replaced 11 Remove the oil filter cartridge with an oil filter wrench 1 Cylinder head cap 1 Cylinder head cap 1 Engine oil drain bolt oil tank 2 Gasket 1...

Page 81: ...d cap 16 Start the engine warm it up for several minutes and then turn it off 17 Remove the oil filler cap and then add sufficient oil of the recommended type to raise it to the H level mark on the dip stick NOTICE When adding the en gine oil be careful not to fill above the H level mark on the dipstick Use only the recommended oil See page 110 Make sure that no foreign mate rial enters the engine...

Page 82: ...over the right side cover and the shroud or install the right side cover and close the shroud ESU14930 Cooling system The coolant level should be checked before each ride In addition the cooling system must be bled at the intervals specified in the periodic maintenance and lubrication chart WARNING EWS00381 Do not remove the coolant reservoir cap when the engine is hot Scalding hot fluid and steam...

Page 83: ...D LEVEL mark See the following section Replenishing the coolant for more details NOTICE If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has been used instead of coolant replace it with coolant as soon as possible other wise the cooling system will not be protected against frost and corrosion If...

Page 84: ...arking brake 2 Remove the shroud the right side cover and the top cover RST90TF RST90TFL RST90TFY see page 60 for the procedures or open the shroud RST90 see page 62 for the proce dures 3 Remove the coolant reservoir cap and add coolant until it reaches the COLD LEVEL mark RST90 RST90TF RST90TFL RST90TFY RST90 RST90TF RST90TFL RST90TFY 1 COLD LEVEL mark 2 Coolant reservoir cap 1 COLD LEVEL mark 2 ...

Page 85: ...ts can be dam aged The V belt should be checked before each ride To check the V belt 1 Remove the shroud and the left side cov er RST90TF RST90TFL RST90TFY or open the shroud RST90 and then re move the drive guard See page 27 for drive guard removal procedures 2 Check the V belt for wear and damage Replace if necessary 3 Install the drive guard and then install the left side cover and the shroud o...

Page 86: ...t it separates from the secondary fixed sheave 5 Pull the V belt up over the secondary fixed sheave 6 Remove the V belt from the secondary sheave assembly and primary sheave assembly 7 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 sheaves the secondary sliding and fixed sheaves must touch each other...

Page 87: ...he original position and then install the screws and the bolts RST90TF RST90TFL RST90TFY Standard V belt position From 1 5 mm 0 06 in above the edge of the secondary sheave as sembly to 0 5 mm 0 02 in below the edge 1 V belt position adjusting bolt 2 Spacer V belt position Adjustment More than 1 5 mm 0 06 in above the edge Remove a spacer From 1 5 mm 0 06 in above the edge to 0 5 mm 0 02 in below ...

Page 88: ...0 see page 62 for the procedures 3 Remove the dipstick wipe it off with a clean rag and then insert it back into the filler hole RST90TF RST90TFL RST90TFY RST90 4 Remove the dipstick and check that the oil is between the maximum and mini mum level marks on the REVERSE side of the dipstick If the oil is below the min imum level mark add sufficient oil of the recommended type to raise it to the maxi...

Page 89: ...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 NOTICE ECS00061 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 ...

Page 90: ...ar by measuring the thickness of the pads If the parking brake pads reach the wear limit ask a Yamaha dealer to replace them 3 Install the right side cover and the shroud or close the shroud To adjust the parking brake As the parking brake pads wear adjustment may be necessary to ensure proper brake performance 1 Remove the shroud and the right side cover RST90TF RST90TFL RST90TFY see page 60 for ...

Page 91: ...g brak ing performance Clean the filler cap before removing Use only DOT 4 brake fluid from a sealed container Use only the specified brake fluid other wise the rubber seals may deteriorate causing leakage Refill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reac tion 1 Parking brake pad adjusting bolt locknut 2 Parking brake pad adjusting...

Page 92: ...id replacement is necessary when the following components are replaced dur ing the periodic maintenance or if they are damaged or leaking All oil seals of the master cylinder and cali per cylinder The brake hose ESU14271 Extrovert drive sprocket RST90TF RST90TFL RST90TFY Check the extrovert drive sprocket for wear and damage Replace if necessary To measure the drive sprocket wear Measure the drive...

Page 93: ...k the handlebar for excessive free play To check the handlebar 1 Push the handlebar 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 RST90 To adjust the handlebar height 1 Remove the handlebar cover 1 Ski wear limit front 2 Ski runner 3 Ski wear limit rear Ski runner wear limit 8 0 mm 0 31 in Ski wear limit fr...

Page 94: ...ten the front handlebar bolts to the specified torque and then tighten the rear handlebar bolts to the specified torque NOTICE Make sure each han dlebar holder is installed so that the smaller gap is facing forward ECS00583 5 Install the handlebar cover 1 Handlebar cover 1 Handlebar bolt 1 Area where projection cannot be installed 1 Forward 2 Small gap Handlebar bolt tightening torque 23 Nm 2 3 m ...

Page 95: ...s of braking ability and snowmobile control which could cause an accident Checking the drive track WARNING EWS00491 Do not operate the snowmobile if you find damage to the drive track or if it has been maladjusted Drive track damage or failure could result in loss of braking ability and snowmobile control which could cause an accident Check the drive track alignment and deflec tion and check the t...

Page 96: ...the drive track off the ground 3 Start the engine and rotate the drive track one or two turns Stop the engine 4 Align the drive track by turning the left and right adjusting nuts 1 Spring scale 1 Drive track deflection 2 Slide runner Standard drive track deflection 30 0 35 0 mm 1 18 1 38 in 2 1 Rear axle nut Drive track alignment Shifted to right Shifted to left Left adjusting nut Turn out Turn in...

Page 97: ...runners for wear and dam age If the slide runners reach the wear limit they should be replaced RST90 RST90TF RST90TFL RST90TFY 1 Forward 2 Gap 3 Slide runner 4 Drive track 5 Slide metal 1 Forward 2 Gap 3 Slide runner 4 Drive track 5 Slide metal Drive track deflection More than specified Less than specified Left adjusting nut Turn in Turn out Right adjust ing nut Turn in Turn out Rear axle nut tigh...

Page 98: ... WARNING EWS00512 Do not grease the throttle cable because it could become frozen which could cause loss of control Apply a dab of grease onto the cable end only TIP For parts equipped with a grease nipple use a grease gun Lubricants Brake lever Silicone grease Other lubrication points Low temperature grease 1 Lubrication point 1 1 Throttle cable end 1 Grease nipple 1 Grease nipple 1 U8JV70E0 book...

Page 99: ...ass part of the bulb or its life and illumination will be affect ed If the glass is oil stained thorough ly clean it with a cloth moistened with alcohol or lacquer thinner ECS00622 6 Install the bulb holder cover and then connect the headlight coupler 7 Close the shroud RST90TF RST90TFL RST90TFY 1 Remove the shroud and the top cover See page 60 for removal procedures 1 Grease nipple 1 Grease nippl...

Page 100: ...the bulb holder cover 6 Unhook the bulb holder and then re move the burnt out bulb 7 Install a new bulb 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 thorough ly clean it with a cloth moistened with alcohol or lacquer thinner ECS00622 1 Headlight un...

Page 101: ... ESU14151 Adjusting the headlight beams RST90TF RST90TFL RST90TFY 1 Remove the top cover See page 60 for removal procedures 2 Use a Phillips screwdriver to turn the headlight beam adjusting screw and ad just the headlight beams To lower the headlight beams turn the headlight beam adjusting screw in direction a To raise the headlight beams turn the head light beam adjusting screw in direction b 1 D...

Page 102: ...e 97 This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the electrolyte or to add dis tilled water However the battery lead con nections need to be checked and if necessary tightened WARNING EWS00541 Battery electrolyte is poisonous and dan gerous It contains sulfuric acid and can cause severe burns Avoid contact with skin eyes or clothing ANTIDOTE EXTER...

Page 103: ...are tight NOTICE ECS00844 To charge a VRLA Valve Regulated Lead Acid battery a special constant voltage battery charger is required Us ing a conventional battery charger will damage the battery Do not charge the battery quickly ESU14950 Replacing a fuse WARNING EWS00551 Be sure to use the specified fuse A wrong fuse could cause electrical system dam age or A FIRE HAZARD NOTICE ECS00632 Be sure to ...

Page 104: ... case and then disconnect the oil tank breather hose 7 Lift up the air filter case disconnect the cylinder head breather hose from the case and then remove the case 8 Unhook the battery band and then re move the battery cover 1 Headlight unit 1 Air filter case fastener 2 Air temperature sensor coupler 1 Joint clamp bolt 1 1 2 1 1 Oil tank breather hose clamp 2 Oil tank breather hose 1 Cylinder hea...

Page 105: ...1 Negative battery lead 2 Bolt 1 Spare fuse 2 Fuel injection system fuse 3 Main fuse 4 EPS fuse 1 2 1 2 3 4 1 IGN ignition fuse 2 ETV electronic throttle valve fuse 3 Spare fuse 4 HEAD headlight fuse 5 SIG signaling system fuse 6 DC auxiliary DC jack fuse 7 S H helmet shield heater jack fuse 3 7 1 6 5 4 3 2 U8JV70E0 book Page 99 Monday April 6 2015 11 49 AM ...

Page 106: ...P If the fuse immediately blows again ask a Yamaha dealer to inspect the snowmobile RST90 The main fuse is located under the air filter case The fuse box which contains the fuses for the individual circuits is located behind the right side cover 1 Open the shroud 2 Remove the right side cover See page 60 for removal procedures 3 Unhook the air filter case fastener Specified fuses Main fuse 40 0 A ...

Page 107: ... slide the crank 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 Air filter case fastener 1 Joint clamp bolt 1 Oil tank breather hose clamp 2 Oil tank breather hose 1 Crankcase breather hose clamp cr...

Page 108: ...ght side cover and close the shroud TIP If the fuse immediately blows again ask a Yamaha dealer to inspect the snowmobile 1 Main fuse 2 Spare main fuse 1 Fuse box 2 HEAD headlight fuse 3 SIG signaling system fuse 4 DC TERM auxiliary DC jack fuse 5 C W carburetor warmer fuse 6 IGN ignition fuse 7 Spare fuse 1 7 2 3 4 5 6 Specified fuses Main fuse 30 0 A Spare main fuse 30 0 A Headlight fuse 20 0 A ...

Page 109: ...ical system Poor spark or no spark Spark plugs are dirty with carbon or are wet Remove carbon or wipe spark plugs dry Replace if necessary Faulty ignition system Ask a Yamaha dealer to check T O R S malfunction Disconnect throttle switch connec tors and connect wire harness con nectors together to bypass T O R S WARNING Before bypassing the T O R S make sure that the throt tle returns properly to ...

Page 110: ...obile This can cause electrical system damage or A FIRE HAZARD Be sure to pull the lead covers back over the terminals completely If the termi nals are exposed they could come into contact with the frame or a metal part of the snowmobile and this can cause electrical system damage or A FIRE HAZARD NOTICE ECS00651 Use the connecting leads to jump start the snowmobile only Do not use the con necting...

Page 111: ...sconnect the black jumper cable from the negative terminal of the bat tery used to jump start the engine 11 Disconnect the red jumper cable from the positive terminal of the battery used to jump start the engine 12 Disconnect the red jumper cable from the red connecting lead and then pull the cover completely over the lead termi nal 13 Install the red connecting lead into the lead holder 14 Instal...

Page 112: ...dealer to check Snowmobile does not move Malfunctioning V belt clutch Ask a Yamaha dealer to check Drive track does not move Foreign object is caught in drive track or slide runners have melted to slide metal due to lack of lu brication Tight loose or broken drive chain Ask a Yamaha dealer to check V belt twists Improper V belt Replace with correct V belt Incorrect V belt clutch offset Ask a Yamah...

Page 113: ...Troubleshooting 107 Worn or damaged drive track Ask a Yamaha dealer to check U8JV70E0 book Page 107 Monday April 6 2015 11 49 AM ...

Page 114: ...en part of the windshield to make sure 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 lubri cant Proper lubrication fights corrosion while it reduces frict...

Page 115: ...y can cause permanent battery damage ECS00692 Drive track Loosen the drive track and block up the chassis so that the track is suspended above the ground V belt Remove the V belt and store separately Storage Store the snowmobile in a dry well ventilated 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 con...

Page 116: ...l injection ID mark 8JU1 00 RST90TF RST90TFL RST90TFY Fuel Recommended fuel REGULAR UNLEADED GASOLINE ONLY Minimum pump octane R M 2 86 Starting system Electric starter Chassis Drive track Material Molded rubber fiberglass rod reinforced Type Extrovert drive type RST90TF RST90TFL RST90TFY Internal drive type RST90 Width 381 mm 15 0 in Deflection 30 0 35 0 mm 1 18 1 38 in Length on ground 1074 mm 4...

Page 117: ...RST90 3 1 L 3 28 US qt 2 73 Imp qt RST90TF RST90TFL RST90TFY Total amount 3 7 L 3 91 US qt 3 26 Imp qt RST90 4 0 L 4 23 US qt 3 52 Imp qt RST90TF RST90TFL RST90TFY Brake Type Hydraulic disc type ventilated disc Operation Handle lever left hand operated Throttle Operation Handle lever right hand operated Electrical system Ignition system TCI Spark plug Manufacturer NGK Model CR8E Gap 0 7 0 8 mm 0 0...

Page 118: ... 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 RST90TF RST90TFL RST90TFY RST90 Key identification number The key identification number is stamped in the location as shown 1 Frame serial number 1 Engine serial numbe...

Page 119: ...rol Information la bel is affixed at the location in the illustration This label shows specifications related to ex haust emissions as required by federal law state law and Environment Canada 1 Vehicle Emission Control Information label 1 Vehicle Emission Control Information label 1 1 U8JV70E0 book Page 113 Monday April 6 2015 11 49 AM ...

Page 120: ...r it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha snowmobile dealer in the country of residence of the original purchaser In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after ownership transfer All new Yamaha snowmobiles purchased from an authorized Yamaha dealer in the customer s...

Page 121: ... Owner s Manual that failure may not be covered under warranty Q Under what conditions is the clutch not covered by warranty A Clutches as well as clutch components wear with use Normal wear is not covered under warranty such service is the customer s responsibility Abnormal wear is however covered for one 1 year from the date of purchase Your Yamaha snowmobile dealer possesses criteria as to what...

Page 122: ...rst contact the owner of the dealership 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 FOR U S A CUSTOMERS CUSTOMER SERVICE The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers agains...

Page 123: ...Consumer information 117 ESU12514 YAMAHA EXTENDED SERVICE Y E S FOR U S A CUSTOMERS U8JV70E0 book Page 117 Monday April 6 2015 11 49 AM ...

Page 124: ...will be there whether your repair expense is a few dollars or a few thousand Under the Yamaha Protection Plus program Yamaha picks up the entire cost of parts and labour to repair every applicable mechanical defect Yamaha s computerized warranty system is updated as soon as you buy coverage so Yamaha Protection Plus takes over automatically and immediately when your factory warranty expires You ca...

Page 125: ...ams adjusting 95 Headlight bulb replacing 93 Helmet shield heater jack RST90TF RST90TFL RST90TFY 25 High beam indicator light 16 High altitude settings 70 I Identification numbers 112 L Location of the important labels 1 Low coolant temperature indicator light 17 Lubrication 92 M Main switch 10 Multi function meter unit 11 O Oil level warning indicator RST90 20 Oil level pressure warning indicator...

Page 126: ... Throttle lever 10 Throttle lever free play adjusting 65 Throttle override system T O R S 11 Throttle override system T O R S checking 66 Tool kit 59 Tow hitch RST90TF RST90TFL RST90TFY and tow hitch bracket RST90 35 Transporting 53 Troubleshooting 103 Two up 2 up adjusting blocks adjusting RST90 39 V Valve clearance 70 V belt 79 V belt holders 28 Vehicle Emission Control Information label 113 W W...

Page 127: ...rm right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out GenuineYamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service man...

Page 128: ...Printed on recycled paper Printed in Japan 2015 04 0 5 1 CR U8JV70E0 book Page 1 Monday April 6 2015 11 49 AM ...

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