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Yamaha RST90K, Owner'S Manual

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Yamaha RST90K Owner'S Manual Download Page 7

Maximizing drive track life ...............7-7
Driving .............................................7-8
Stopping the engine.........................7-9
Transporting ..................................7-10

PERIODIC MAINTENANCE

...............8-1

Periodic maintenance chart .............8-1
Tool kit .............................................8-4
Spark plug inspection ......................8-4
Engine idle speed adjustment .........8-6
Throttle cable adjustment ................8-6
Carburetor adjustment.....................8-7
High altitude adjustments ................8-9
Adjusting the valve clearance..........8-9
Changing the engine oil.................8-10
Cooling system ..............................8-13
V-belt replacement ........................8-15
Checking the drive chain 
housing oil level and the drive 
chain tension .................................8-17
Checking the brake pads ...............8-19
Checking the parking brake 
pads...............................................8-19
Checking the brake fluid level........8-20
Brake fluid replacement .................8-20
Suspension....................................8-20
Drive track adjustment...................8-25
Ski alignment .................................8-27
Handlebar adjustment ...................8-27
Lubrication .....................................8-29
Headlight bulb replacement...........8-30
Headlight beam adjustment...........8-30
Battery ...........................................8-31
Fuse replacement ..........................8-31

TROUBLESHOOTING

.......................9-1

STORAGE

........................................10-1

SPECIFICATIONS

............................11-1

Dimensions....................................11-1
Engine ...........................................11-1
Chassis..........................................11-2
Electric ...........................................11-3

WIRING DIAGRAM

..........................12-1

U8ET10.book  Page 2  Monday, June 14, 2004  5:42 PM

Summary of Contents for RST90K

Page 1: ...OWNER S MANUAL SNOWMOBILE RST90K ...

Page 2: ......

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

Page 4: ...bile If you have any questions concerning the operation or maintenance of your snowmobile please consult a Yamaha dealer To maintain the high quality and performance of this snowmobile it is important that you and your Yamaha dealer pay close attention to the recommended mainte nance schedules and operating instructions contained within this manual RST90K OWNER S MANUAL 2004 by Yamaha Motor Corpor...

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

Page 6: ...light beam switch 5 10 Auxiliary DC jack 5 10 Passenger grip warmer switch 5 11 Shroud latches 5 12 Drive guard 5 12 V belt holders 5 13 Storage areas 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 leakage 6 7 V belt 6 7 Drive guard 6 7 Drive track 6 8 Slide runners 6 8 Skis and sk...

Page 7: ...ystem 8 13 V belt replacement 8 15 Checking the drive chain housing oil level and the drive chain tension 8 17 Checking the brake pads 8 19 Checking the parking brake pads 8 19 Checking the brake fluid level 8 20 Brake fluid replacement 8 20 Suspension 8 20 Drive track adjustment 8 25 Ski alignment 8 27 Handlebar adjustment 8 27 Lubrication 8 29 Headlight bulb replacement 8 30 Headlight beam adjus...

Page 8: ...1 1 ESU00004 1 YAMAHA MOTOR CORPORATION U S A SNOWMOBILE LIMITED WARRANTY CW 01E ...

Page 9: ...1 2 CW 02E ...

Page 10: ...1 3 CW 03E ...

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

Page 12: ...2 1 ESU04050 2 LOCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operat ing this snowmobile NOTE Maintain or replace safety and instruction labels as nec essary 1 2 ...

Page 13: ...2 2 NOTE The following suspension adjustment charts are included with the Owner s Manual ...

Page 14: ...lcohol or taking drugs Your ability to operate the snowmo bile is reduced by the influence of alcohol or drugs 4 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 the throttle brake and steering for proper operation every time before starting the engine Make sure that the throttle lever moves freely and it return...

Page 15: ...ine spills on your skin or clothing immediately wash your skin with soap and water and change your clothes 9 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 for operation of the controls Operation 1 Do not run the engine indoors except when ...

Page 16: ...n most surfaces is to release the throttle and apply the brake gently not suddenly Maintenance and storage 1 Do not leave the snowmobile on its left side for an extended period of time Fuel may leak out from the fuel breather hose 2 Modifications made to the snowmobile not approved by Yamaha or the removal of original equipment may render your snowmobile unsafe for use that may cause severe person...

Page 17: ...PTION 1 Windshield 2 Steering handlebar 3 Seat 4 Passenger grip warmer switch 5 Large solo touring storage area 6 Rear carrier 7 Frame 8 Slide rail suspension 9 Drive track 0 Skis A Headlights B Shroud C Storage compartment ...

Page 18: ...tch P Main switch Q Auxiliary DC jack R Starter lever S Tachometer T Low coolant temperature indicator light U High beam indicator light V Warning light W Self diagnosis warning indicator X Coolant temperature warning indicator Y Fuel level warning indicator Z Oil level warning indicator Speedometer Grip warmer indicator Select reset button _ Thumb warmer indicator a Fuel meter and grip thumb warm...

Page 19: ...ircuit is switched off The key can be removed only in this position 2 ON The ignition circuit is switched on 3 START The starting circuit is switched on The starter motor starts CAUTION Release the switch immediately after the engine starts NOTE The headlights meter lights and taillights come on after the engine starts ...

Page 20: ...he snowmobile by varying the throttle position Because the throttle is spring loaded the snowmobile will deceler ate and the engine will return to idle when it is released b WARNING Check the throttle brake and steering for proper operation before starting the engine ESU00361 Engine overheating prevention system This model is equipped with an engine overheating pre vention system to prevent overhe...

Page 21: ...ngine can be operated without a prob lem before restarting the engine Be sure to use the specified spark plug and spark plug cap Otherwise the T O R S will not work properly CA 19E È Idling starting É Running Ê Trouble 1 Throttle position sensor throttle valve position 2 Throttle switch 3 Throttle cable a On b Off c Open d Closed NOTE When the T O R S is activated the warning light 4 and self diag...

Page 22: ...t 2 the warning light 3 and all segments of the meter 4 turn on and off once The grip warmer level is initially displayed for 5 seconds then switches to the fuel meter display Odometer and tripmeter modes Pushing the select reset button 5 switches the display between the odometer mode ODO and the tripmeter mode TRIP To reset the tripmeter push the select reset button for at least one second while ...

Page 23: ...rmer adjustment switch 2 control the electrically heated handlebar grips and throttle lever respectively To raise the temperature press each switch to HI To lower the temperature press each switch to LO NOTE The grip warmer indicator 3 comes on and the dis play switches to the grip warmer level when the grip warmer adjustment switch is pressed The thumb warmer indicator 4 comes on and the display ...

Page 24: ...g light go off the engine oil level is sufficient however it is getting low Add engine oil as soon as possible If the oil level warning indicator and the warning light do not go off check the engine oil level in the oil tank see page 6 3 and add engine oil if necessary ESU04171 Low coolant temperature indicator light The low coolant temperature indicator light 1 comes on when the coolant temperatu...

Page 25: ... warning light 1 and the self diagnosis warning indicator 2 will flash and then an error code e g Er_1 Er_2 16 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 ...

Page 26: ... switch so that you can react quickly in an emergency ESU00320 Brake lever The snowmobile is stopped by braking the entire drive system Squeeze the brake lever towards the handlebar grip to stop the snowmobile 1 Brake lever 2 Brake lever end 3 Handlebar end NOTE When the brake lever is operated the brake light will illu minate CAUTION Make sure that the brake lever end does not project out over th...

Page 27: ...e engine Never run the snowmobile with the parking brake applied This may overheat the brake disc and reduce braking ability ESU00341 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 1 Shift lever 2 Pull out 3 Slide to FWD Forward 4 Slide to REV Rev...

Page 28: ...xiliary DC jack cap 1 and then insert the accessory power plug into the jack 2 NOTE After using the auxiliary DC jack be sure to remove the accessory power plug from the jack and close the auxil iary DC jack cap CAUTION Do not use accessories requiring more than the maximum rated capacity for the auxiliary DC jack This may overload the circuit and cause the fuse to blow See pages 8 31 8 32 for the...

Page 29: ...ow ESU04311 Footrests The footrests can be installed in two locations to suit pas senger preference To change the location of a footrest remove the screws place the footrest in the desired location and then install and tighten the screws 1 Footrest 2 Screws CAUTION Make sure that the footrest screws are tightened securely after changing the installation location of the footrests ...

Page 30: ...shroud WARNING Do not drive the snowmobile with the shroud open unlatched or removed Keep your body and clothing away from rotating parts when servicing with the shroud open Do not touch the hot muffler and engine during or immediately after operation ESU00521 Drive guard The drive guard is designed to cover the V belt clutch and V belt in case parts break or come loose WARNING Make sure that the ...

Page 31: ... ment rear storage area and rear carrier Storage compartment The storage compartment is located under the shroud Open the storage compartment to store the tool kit spare parts or other small items Rear storage area and rear carrier The rear storage area and the rear carrier are located at the rear of the snowmobile The rear storage area can be used when the passenger seat is removed Maximum load l...

Page 32: ... remove them 3 Remove the passenger seat lock knob 4 and then remove the passenger seat 5 CAUTION When using the rear storage area do not load any cargo that is too large for it In addition cargo must not project from the edges of the rear storage area To install the passenger seat backrest and rear car rier NOTE If loading cargo on both the rear storage area and the rear carrier follow steps 3 5 ...

Page 33: ...on the carrier lock bracket 3 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 4 Slide both the backrest and the rear carrier backward until they stop 5 Pull the carrier lock lever 3 up to lock the backrest and the rear carrier in place Then place the lever under the rear carrier and secure it with the holder...

Page 34: ...uel in the fuel tank WARNING Fuel is HIGHLY FLAMMABLE and poisonous Check the SAFETY INFORMATION section carefully before refueling See page 3 2 Do not fill the fuel tank above the bottom of the filler tube 1 Fuel could overflow if the snowmo bile is tilted on its side or if the ambient tempera ture rises causing the fuel to warm up and expand Make sure that the fuel tank cap is closed securely af...

Page 35: ...th oxygenated fuel The fuel tank should be filled with straight gaso line as specified ESU04030 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 Engine oil also lubricates the starter clutch In order to prevent clutch slippage do not mix any chemical additives with the oil or use oils of a higher gr...

Page 36: ...ning it off 3 Disconnect the oil level gauge coupler 1 CAUTION Disconnect the oil level gauge coupler before remov ing the oil level gauge dipstick Otherwise the cable can twist and break 4 Remove the oil level gauge dipstick 2 wipe it clean insert it back into the filler hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the F 3 and E...

Page 37: ...s cold If the coolant level is below the COLD LEVEL mark add soft water until it reaches the COLD LEVEL mark See pages 8 13 8 14 for more details 1 COLD LEVEL mark WARNING Do not remove the coolant reservoir cap when the engine is hot CAUTION Hard water or salt water is harmful to the engine parts You may use boiled or distilled water if soft water is not available Tap water can be used temporaril...

Page 38: ...ile could start moving forward unexpectedly which could cause an accident 1 Start the engine NOTE Refer to the Starting the engine section 2 Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb above and forefinger below between the throttle lever pivot 1 and the engine stop switch housing 2 While holding the pivot point as described above press the thrott...

Page 39: ...cates a failure in the brake system Do not operate the snowmobile if you find any problems in the brake system You could lose braking ability which could lead to an accident Ask a Yamaha dealer to inspect and repair the brake system CAUTION Make sure that the brake lever end does not project out over the handlebar end This is to prevent brake lever damage when the snowmobile is placed on its side ...

Page 40: ... tic parts Never spill any brake fluid If any is spilled clean it up immediately ESU00941 V belt Open the shroud and remove the drive guard Check the V belt for wear and damage Replace if neces sary WARNING Make sure that the drive guard is tightened securely before operating the snowmobile Never run the engine without the V belt or with the drive guard removed ESU00096 Drive guard Check the drive...

Page 41: ...aladjusted Drive track damage or failure could result in loss of brak ing ability and snowmobile control which could cause an accident ESU00982 Slide runners Check the slide runners for wear and damage If the slide runners reach the wear limit they should be replaced 1 Slide runners a Wear limit CAUTION Ride on fresh snow frequently Operating on ice or hard packed snow will rapidly wear the slide ...

Page 42: ... This will wear or damage the skis ESU00103 Steering system Check the handlebar for excessive free play 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 noticed consult a Yamaha dealer ESU00378 Lights Check the lights Replace any burned out bulbs CAUTION Avoid using a scraper or hot water for cleaning the plastic lens...

Page 43: ... the air filter element remove the snow Then install the air filter element beneath the holding guides on the case and install the air filter case cover NOTE After riding the snowmobile make sure that there is no snow under the air filter element ESU00110 Fittings and fasteners Check the tightness of the fittings and fasteners Tighten in proper sequence and torque if necessary ...

Page 44: ...pment with you while riding the snowmobile so that minor repairs can be done if neces sary The following should be carried at all times Tool kit Flashlight Roll of plastic tape Steel wire Towrope Jumper cables V belt Light bulbs Spark plugs When you start out for a long distance trip extra fuel and oil should be carried as well ...

Page 45: ... warm engine starting NOTE The starter lever choke is not required when the engine is warm Put the starter lever choke in the closed posi tion 2 Turn the main switch to the START position After the engine starts put the starter lever choke in the half open position Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the closed position 1 START C...

Page 46: ...ll throttle operation or any condition that might result in engine overheating must be avoided Operating your snowmobile for the first time Start the engine and let it idle for 15 minutes 0 160 km 0 100 mi Avoid prolonged operation above 6 000 r min 160 500 km 100 300 mi Avoid prolonged operation above 8 000 r min 500 km 300 mi and beyond The snowmobile can now be operated normally CAUTION After 8...

Page 47: ...ded with added safety and a more reliable snowmobile Always wear the proper cloth ing for both warmth and to help protect you from injury if an accident occurs Become familiar with operating your snow mobile at low speeds even if you are an experienced rider Do not attempt to oper ate at maximum performance until you are totally familiar with the snowmobile s han dling and performance characterist...

Page 48: ... thor oughly familiar with the operation of your snowmobile Riding uphill You should practice first on gentle slopes Try more difficult climbs only after you have developed your skill As you approach a hill accelerate before you start the climb and then reduce the throttle to prevent track slippage It is also important to keep your weight on the uphill side at all times On climbs straight up the h...

Page 49: ...our downhill leg on the seat and the foot of your uphill leg on the running board This position will make it easier for you to shift your body weight as needed Snow and ice are slippery so be prepared for the possibility that your snowmobile could begin to slip sideways on the slope If this happens steer in the direction of the slide if there are no obstacles in your path As you regain proper bala...

Page 50: ...es 2 Snow mixed with a lot of dirt and sand All of the above surfaces have one thing in common in regard to drive track and slide runners little or no lubricating ability Drive track and all slide rail systems require lubrication snow or water between the slide runners and the slide metal In the absence of lubrication the slide runners will rapidly wear and in severe cases liter ally melt away and...

Page 51: ...erheating avoid sustained high speed usage in areas such as icy trails frozen lakes and rivers that have minimal snow coverage An overheated track will be weakened internally which may cause fail ure or damage Off trail riding Avoid off trail riding until there is sufficient snow cover age It generally takes several feet of snow to provide a good overall base to properly cover debris such as rocks...

Page 52: ...se 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 the shift lever to FWD or REV until it stops 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 reverse C...

Page 53: ... 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 switch whenever the operator leaves the snow mobile to prevent accidental start...

Page 54: ... hydrostatic lock When possible the fuel tank should be empty during transportation especially if the trip takes longer than 30 minutes If transporting the snowmobile in an open trailer or truck put a tight fitting cover on the snowmobile A cover specifically designed for your snowmobile is best This will help keep foreign objects out of the cooling vents in the shroud and also help protect the sn...

Page 55: ...e Every 20 000 km 12 000 mi 8 10 8 12 Fuel Check fuel level 6 1 6 2 Fuel filter Check condition Replace if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Engine coolant Check coolant level 6 4 8 13 8 14 Air bleed the cooling system if necessary 8 13 Carburetor Check throttle lever operation 5 2 6 5 Adjust the jets Whenever operating condition elevation temperature is...

Page 56: ... installation Check for slight free play Lubricate shaft with specified grease as required Every 1 600 km 1 000 mi Drive chain oil Check oil level 8 17 8 18 Replace Drive chain Check deflection Adjust if necessary Initial at 500 km 300 mi and every 800 km 500 mi thereafter 8 18 Skis and ski runners Check for wear and damage 6 9 Replace if necessary Steering system Check operation 6 9 Adjust toe ou...

Page 57: ...es bushings for wear for secondary Replace if necessary Lubricate with specified grease Steering column bearing Lubricate with specified grease Ski and front suspension Lubricate with specified grease 8 34 Suspension component Lubricate with specified grease 8 34 Parking brake cable end and lever end throttle cable end Lubricate with specified grease 8 34 Check cable damage Replace if necessary Sh...

Page 58: ...ate 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 porcelain color could indi cate...

Page 59: ...ber hot spots and thread damage Always use a spark plug with the speci fied reach Before installing any spark plug measure the electrode gap with a wire thickness gauge and adjust to specifica tion When installing the spark plug always clean the gasket surface Wipe off any grime from the threads and tighten the spark plug to the specified torque CAUTION Make sure that the spark plug caps are secur...

Page 60: ...efer to the Starting the engine section 2 Turn the throttle stop screw 1 in or out to adjust the engine idle speed ESU01471 Throttle cable adjustment CAUTION Be sure to adjust the engine idle speed first 1 Loosen the locknut 2 Turn the adjuster in or out until the proper throttle lever free play is achieved 1 Locknut 2 Adjuster 3 Tighten the locknut Standard engine idle speed 1 400 100 r min Throt...

Page 61: ...vation changes use of alcohol oxygenated fuels etc and should be set by a Yamaha dealer CAUTION The drive chain gears and V belt clutch should be adjusted when operating over a high altitude of 900 m 3 000 ft Consult a Yamaha dealer Pilot screw adjustment Turn the pilot screw in or out to adjust low speed tuning CD 02E Standard pilot screw position 2 turns out from the seated position Pilot screw ...

Page 62: ...ug or float chamber to catch any spilled fuel Handle fuel with care it is HIGHLY FLAMMABLE CD 04E 1 Loosen the carburetor clamps and remove all hoses and cables and then remove the carburetor 2 Pinch the fuel hose to prevent fuel flowing 3 Remove the float chamber and install the proper main jet 4 Assemble by reversing the removal steps WARNING Make sure that all hoses and clamps are properly inst...

Page 63: ...horsepower available even with proper carburetion Expect acceleration and top speed to be reduced at higher altitudes To overcome operating with less power at high altitudes your snowmobile may also require different settings for the drive chain gears and V belt clutch to avoid poor per formance and rapid wear If you plan to operate your snowmobile at an altitude different from the area where you ...

Page 64: ... 20 000 km 12 000 mi of operation To change the engine oil with or without oil filter cartridge replacement 1 Place the snowmobile on a level surface and apply the parking brake 2 Remove the bottom panel 1 and right side cover 2 3 Start the engine warm it up for several minutes and then turn it off 4 Place oil pans under both the engine and the oil tank to collect the used oil 5 Disconnect the oil...

Page 65: ... US qt of the recom mended engine oil to the oil tank and then install and tighten the oil level gauge dipstick and the cylinder head cap 12 Start the engine warm it up for several minutes and then turn it off Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lb Tightening torques Crankcase engine oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lb Oil tank engine oil drain bolt 16 Nm 1 6 m kgf 11...

Page 66: ... min utes while checking it for oil leakage If oil is leaking immediately turn the engine off and make sure the engine oil drain bolts cylinder head cap and oil level gauge dipstick are installed correctly 15 Turn the engine off connect the oil level gauge cou pler and then install the bottom panel and right side cover CAUTION If oil is leaking or the oil level warning indicator comes on when the ...

Page 67: ...and slowly rotate the cap counterclockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counter clockwise and remove it The cooling system must be bled of air if the coolant reservoir becomes empty if air can be seen in the cooling system or if there is a cooling system leak Consult a Yamaha dealer CAUTIO...

Page 68: ...l 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 Recommended coolant High quality ethylene glycol antifreeze containing corro sion inhibitors Antifreeze and water mixing ratio 60 40 Total amount 5 2 L 4 58 Im...

Page 69: ...ng bolt Have a Yamaha dealer make this adjustment CAUTION As the V belt wears adjustment may be necessary To ensure proper clutch performance the V belt position should be adjusted by adding a spacer on each adjusting bolt when the V belt position reaches 1 5 mm 0 06 in below the edge Have a Yamaha dealer make this adjustment CD 05E NOTE Apply the parking brake before replacing the V belt 1 Remove...

Page 70: ...position is incorrect adjust the V belt position by removing or adding a spacer 4 on each adjusting bolt 5 CD 06E 7 Tighten each adjusting bolt Standard V belt position a From 1 5 mm 0 06 in above the edge of the second ary sheave to 0 5 mm 0 02 in below the edge V belt position Adjustment More than 1 5 mm 0 06 in above the edge Remove spacer From 1 5 mm 0 06 in above the edge to 0 5 mm 0 02 in be...

Page 71: ...ver run the engine with the V belt or drive guard removed ESU03511 Checking the drive chain housing oil level and the drive chain tension Oil level check WARNING The engine oil tank brake disc and coolant hoses will be very hot after the engine has been run Avoid contact while they are still hot with any part of your body or clothing during inspection or repair 1 Place the snowmobile on a level su...

Page 72: ... CAUTION Make sure that no foreign material enters the drive chain housing 4 Install the dipstick and align the notch 4 of the dip stick handle with the projection 5 of the drive chain housing Chain tension adjustment 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 place while tightening the locknut 1 Locknu...

Page 73: ...rking brake pads wear adjustment may be nec essary to ensure proper brake performance WARNING Be sure to have a Yamaha dealer make this adjust ment 1 Loosen the locknut 1 and the adjusting bolt 2 2 Loosen the cable locknut 3 3 Turn the cable adjuster 4 in or out to adjust the cable length 4 Tighten the cable locknut 5 Turn the adjusting bolt in or out to adjust the clear ance between the parking b...

Page 74: ...ed clean it up immediately ESU00181 Brake fluid replacement Brake fluid replacement is necessary when the following components are replaced during the periodic mainte nance or if they are damaged or leaking a All oil seals of the master cylinder and caliper cylinder b The brake hose WARNING Make sure that the brake fluid and the above parts are replaced by a Yamaha dealer ESU00183 Suspension The s...

Page 75: ... be adjusted by turning the spring preload adjuster 1 CD 10E CAUTION The left and right ski spring preload must be set to the same setting Uneven settings can cause poor handling and loss of stability Spring adjuster position 5 4 3 2 1 Preload 2 Hard Soft 3 Standard 1 ...

Page 76: ...he front 1 and the other is in the rear 2 of the rear suspen sion assembly The spring preload can be adjusted by turning the spring preload adjuster 3 on the front and rear shock absorb ers WARNING Be sure to have a Yamaha dealer make this adjust ment CD 13E CD 23E A Spring adjuster position 1 2 3 4 5 Preload Soft Hard È Standard front 3 B Spring adjuster position S M H Preload Soft Medium Hard É ...

Page 77: ...lace CAUTION When using the two wrenches included in the owner s tool kit make sure that they are situated at a right angle to the control rod as shown and that they are tightly fitted to the locknut and the control rod adjusting nut The left and right adjusting nuts must be set to the same position Uneven settings can cause poor handling and loss of stability WARNING Never adjust the control rods...

Page 78: ...der or cargo on the snowmobile 1 Install the special tools 1 and 2 included in the owner s tool kit to the 2 up adjusting block 3 2 Pull the lock lever 4 and turn the special tool 2 to change the block position 3 Release the lock lever CAUTION Make sure that the 2 up adjusting blocks are installed in the same position on both sides of the snowmobile a 2 up position rider and passenger b Solo rider...

Page 79: ...he drive track condition frequently Replace damaged slide metal Replace the drive track if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken Otherwise track damage or failure could result in loss of braking ability and snow mobile control which could cause an accident Drive track deflection measurement 1 Lay the snowmobile on its side 2 Measure th...

Page 80: ...he drive track one or two turns Stop the engine 4 Check the drive track alignment with the slide runners 2 If the alignment is incorrect align the drive track by turning the left and right adjusters CD 08E 7 Slide runners 8 Drive track 9 Slide metal a Gap b Forward 5 Adjust the drive track deflection to specification CD 09E 5 6 Drive track alignment 5 Shifted to right 6 Shifted to left 3 Left adju...

Page 81: ...SU00200 Ski alignment 1 Turn the handlebar so the skis face straight ahead 2 Check the following for ski alignment a Skis are facing forward b Ski toe out 1 2 is within specification 3 If the alignment is not correct consult a Yamaha dealer ESU03541 Handlebar adjustment 1 Remove the handlebar cover 1 2 Loosen the handlebar bolts Rear axle tightening torque 75 Nm 7 5 m kgf 54 ft lb Ski toe out 1 2 ...

Page 82: ...TION Make sure that the projection on the handlebar is not installed into the area a shown 4 Tighten the handlebar bolts and install the handlebar cover CAUTION Make sure that the small gap b side of the handlebar holders faces forward c Handlebar bolt tightening torque 14 5 Nm 1 45 m kgf 11 ft lb ...

Page 83: ...a dab of grease onto the cable end only Do not grease the throttle cable because it could become frozen which could cause loss of control 2 Front suspension 3 Rear suspension WARNING Be sure to have a Yamaha dealer lubricate the front and rear suspensions 2 2 Lubricant Low temperature grease 3 ...

Page 84: ...down 6 Install the new bulb CAUTION Keep oil or 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 ESU00372 Headlight beam adjustment 1 Lift up the shroud 2 Insert a Phillips screwdriver into the hole under the shroud to access the headlight beam adjuste...

Page 85: ...act with skin eyes or clothing ANTIDOTE EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Alway...

Page 86: ...own disconnect the crankcase breather hose from the air filter case and then remove the air filter case 8 Disconnect the negative battery lead 9 Replace the blown fuse with one of the proper amperage 10 Connect the negative battery lead 11 Install the air filter case by reversing the removal steps NOTE When installing the air filter case connect the crankcase breather hose to the air filter case f...

Page 87: ...es 20 A 10 A 15 A 3 A F Spare main fuse Specified fuses 9Main fuse 30 A 0 HEAD Headlight fuse 20 A A SIG Signal fuse 10 A B DC TERM Auxiliary DC jack fuse 3 A C C W Carburetor warmer fuse 20 A D IGN Ignition fuse 15 A ...

Page 88: ... 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 the engine can be started using a 12 volt battery and jumper cables Two connecting leads hav...

Page 89: ...lack jumper cable to the negative terminal of the booster battery 7 Pull the black lead cover to expose the terminal through the slit in the cover and then connect the black jumper cable to the black terminal of the discharged battery 8 Start the engine 9 Disconnect the black jumper cable from the black connecting lead and then pull the cover completely over the lead terminal 10 Disconnect the bla...

Page 90: ...plugs Clean or replace the spark plugs 3 Incorrect jetting for altitude or tempera ture Carburetor Ask a Yamaha dealer to inspect 4 Improper fuel flow See A 1 above 5 Incorrect V belt clutch settings for alti tude or conditions Ask a Yamaha dealer to inspect E Engine constantly backfires or mis fires 1 Faulty spark plugs Replace the spark plugs 2 Clogged fuel system See A 1 above 3 Malfunctioning ...

Page 91: ...assembly Ask a Yamaha dealer to inspect 4 Worn or sticking secondary sheave assembly Ask a Yamaha dealer to inspect K Noise or excessive vibration in drive chain and sprockets 1 Broken V belt clutch components Ask a Yamaha dealer to inspect 2 Worn or damaged bearings Ask a Yamaha dealer to inspect 3 Worn or damaged V belt with flat spots Replace 4 Worn or damaged idler wheels or shafts Ask a Yamah...

Page 92: ...oxygenated fuel gasohol is used because the alcohol content in the fuel increases the chance for water to enter the engine Use Yamaha Stor Rite Engine Fogging Oil or an equiva lent fogging oil to protect both the com bustion chamber and crankshaft from corrosion An alternate method is to remove the carburetor silencer and squirt oil into the carburetor throats while the engine is running CAUTION D...

Page 93: ...enti lated place out of direct sunlight Put a fab ric cover over the snowmobile preferably one that is designed for it Do not use a plastic or vinyl cover condensation could be trapped underneath which could increase the chances of rusting Returning to service after storage When returning your snowmobile to ser vice install the V belt and battery and adjust the drive track Remove the spark plugs a...

Page 94: ...y weight 272 kg 600 lb Ski stance 1 086 mm 42 8 in RST90 Type Liquid cooled 4 stroke 12 valves Cylinder arrangement Parallel 3 cylinder Displacement 973 cm3 Bore Stroke 79 0 66 2 mm 3 11 2 61 in Idle speed 1 400 100 r min Engine oil type API SE SF SG or higher SAE 0W 30 Carburetor type KEIHIN CVK40 3 Fuel Unleaded gasoline Pump octane 88 or higher Starting system Electric starter R M 2 ...

Page 95: ...mm 0 59 in Engagement speed 1 Approx 3 200 r min Shift speed 1 Approx 8 500 r min 2 Drive chain Silent chain enclosed in oil bath Reduction ratio 39 22 1 77 Fuel tank Tank capacity 38 0 L 8 4 lmp gal 10 0 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 Br...

Page 96: ...K Gap 0 7 0 8 mm 0 028 0 031 in Battery Capacity YTX20L BS 12 V 18 A h Maximum charge rate 1 8 Amperes hr for 10 hrs Headlight Bulb Quantity 12 V 60 55 W 2 Tail brake light Bulb Quantity 12 V 5 21 W 2 Meter light Bulb Quantity 14 V 50 mA 6 Indicator light Bulb Quantity 14 V 80 mA 3 ...

Page 97: ...W Y B G B R B R B R B R B G B Ch Ch C G G C L R L R D G G D L R L R D B B C B B B Lg B W L R O B L R Y R L Br Br L R Y R W O BLACK Br O Br Gy BLACK Br Gy Br L W Y B L W BLACK Br W G L R B L Y B Gy W L W Y B Lg G Br L Y B Y R Br Y B Y Br W W R W G B L L G B W Y W Y L Lg W Lg L Ch B B Y R Lg B W L G G R G L R B B Y L Y L G R G R O B O B Y L R L R B Y L G R Y L O B BLACK G R Y L O B BLACK G Y B G R Y...

Page 98: ... Warning light Low coolant temperature indicator light Multi function meter Meter light _ High beam indicator light a Auxiliary DC jack fuse b HEAD Headlight fuse c SIG Signal fuse d C W Carburetor warmer fuse e IGN Ignition fuse f Auxiliary DC jack g Headlight beam switch h Headlight relay i Headlight COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue Lg Light green O O...

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