Yamaha RSVECTOR Page 52 Owner'S Manual Download | Manualshive

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Periodic maintenance and adjustment

46

ESU12911

Adjusting the throttle cable free
play

1.

Place the snowmobile on a level surface
and apply the parking brake.

2.

Remove the shroud, the left and right
side covers, and the top cover. (See page
42 for removal procedures.)

3.

Remove the headlight unit bolt 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 mov-
ing the headlight unit.

[ECS00920]

5.

Loosen the locknut.

6.

To increase the throttle cable free play,
turn the adjusting bolt in direction (a). To
decrease the throttle cable free play, turn
the adjusting bolt in direction (b).

7.

Tighten the locknut.

8.

Place the headlight unit in the original po-
sition, making sure to insert the projec-
tions on the headlight unit stay into the
slots on the bottom of the headlight unit.

1. Headlight unit bolt

1. Headlight unit

1

1

1. Locknut

2. Throttle cable free play adjusting bolt
3. Throttle cable free play

Throttle cable free play:

2.0–3.0 mm (0.08–0.12 in)

3

1

2

(a)

(b)

U8JA10E0.book Page 46 Tuesday, May 19, 2009 2:37 PM

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Summary of Contents for RSVECTOR

Page 1: ...OWNER S MANUAL RS90GTZ RS90LTGTZ 8JA 28199 10 LIT 12628 02 91 ESU10012 Read this manual carefully before operating this vehicle DIC183 ...

Page 2: ...ESU10041 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U8JA10E0 book Page 1 Tuesday May 19 2009 2 37 PM ...

Page 3: ... at the time of printing there may be minor discrepancies between your snowmobile and this manual If there is any question concerning this manual please consult a Yamaha dealer WARNING EWS00670 Please read this manual carefully before operating this snowmobile Do not attempt to operate this snowmobile until you have attained adequate knowledge of its con trols and operating features Regular inspec...

Page 4: ...fety messages that follow this symbol to avoid possible injury or death WARNING EWS00021 A WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE ECS00011 A NOTICE indicates special precautions that must be taken to avoid damage to the snowmobile or other property TIP A TIP provides key information to make pro cedures easier or clearer U8JA10E0...

Page 5: ...ration check list 28 Operation 30 Starting the engine 30 Break in 31 Riding your snowmobile 31 Maximizing drive track life 35 Driving 36 Stopping the engine 37 Transporting 37 Periodic maintenance and adjustment 38 Periodic maintenance chart for the emission control system 38 General maintenance and lubrication chart 40 Tool kit 42 Removing and installing the shroud and covers 42 Checking the spar...

Page 6: ...ns 80 Consumer information 82 Identification number records 82 Vehicle Emission Control Information label 83 YAMAHA MOTOR CORPORATION U S A SNOWMOBILE LIMITED WARRANTY 84 YAMAHA EXTENDED SERVICE Y E S 87 U8JA10E0 book Page 2 Tuesday May 19 2009 2 37 PM ...

Page 7: ...contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha deal er 6 5 4 3 2 1 7 11 12 10 9 8 12 U8JA10E0 book Page 1 Tuesday May 19 2009 2 37 PM ...

Page 8: ...RE INFO SEE SERVICE MANUAL FOR THIS MODEL SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE ENTRAÎNEMENT 1 CAPACITÉ D HUILE DU CARTER DE CHAÎNE 2 TYPE D HUILE DU CARTER DE CHAÎNE 3 FLÈCHE DE LA CHENILLE POUR PLUS DE DÉTAIL VOIR LE MANUEL D ATELIER POUR CE MODÈLE LES CARACTÉRISTIQUE TECHNIQUES SONT SUSCEPTIBLES DE CHANGER SANS NOTIFICATION PRÉALABLE 250 cm 8 5 oz GL 3 75W or 80W 30 35 mm 1 18 1 38 in...

Page 9: ...n system meets all requirements of the Canadian Interference Causing Equipment Regulations Ce système d allumage par étincelle de véhicule respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada 3JK 82377 10 88C 77769 00 9 10 8 RS90LTGT 7 U8JA10E0 book Page 3 Tuesday May 19 2009 2 37 PM ...

Page 10: ... connecting procedures refer to Owner s Manual FILS DE BRANCHEMENT DES CÂBLES DE DÉMARRAGE Effectuer le branchement des câbles de démarrage conformément aux instructions du Manuel du propriétaire 8FA E0 8FA 2389C E0 11 12 U8JA10E0 book Page 4 Tuesday May 19 2009 2 37 PM ...

Page 11: ...in the vehicle properly in creases the possibility of an accident or equipment damage See page 28 for a list of pre operation checks Apply the parking brake before starting the engine Never drive the snowmobile with the parking brake applied This may over heat the brake disc and reduce braking abil ity While using your snowmobile This snowmobile was not manufactured for use on public streets roads...

Page 12: ...t decision Genuine Yamaha Ac cessories which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use on your snowmobile Many companies with no con nection to Yamaha manufacture parts and ac cessories 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...

Page 13: ... 2 Main fuse 3 Air filter 4 Oil filler cap 5 Fuse box 6 Coolant reservoir 7 Coolant recovery tank 8 Storage compartment 9 Tool kit 10 Tail brake light 11 Slide rail suspension 12 Rear shock absorber damping force remote adjusting dial 13 Drive track 14 V belt holder U8JA10E0 book Page 7 Tuesday May 19 2009 2 37 PM ...

Page 14: ...RESET button 13 SELECT button 14 Fuel meter and grip thumb warmer level in dicator 15 Fuel meter indicator 16 Self diagnosis warning indicator 17 Coolant temperature warning indicator 18 Grip warmer indicator 19 Fuel level warning indicator 20 Thumb warmer indicator 21 Oil level warning indicator 22 Clock 23 Low coolant temperature indicator light 24 High beam indicator light 25 Warning light 26 S...

Page 15: ...IP The snowmobile you have purchased may differ slightly from those shown in the figures of this manual Design and specifications are subjected to change without notice U8JA10E0 book Page 9 Tuesday May 19 2009 2 37 PM ...

Page 16: ...to idle when it is released ESU13241 Throttle override system T O R S WARNING EWS00041 If the T O R S is activated make sure that the cause of the malfunction has been cor rected and that the engine can be operated without a problem before restarting the engine Continuing to operate with a mal function could cause loss of control or damage If the throttle valves or throttle cable malfunc tions dur...

Page 17: ...ning light which shows warnings to gether with the warning indicators a fuel meter which shows the fuel remain ing in the fuel tank a grip thumb warmer level indicator which shows the grip warmer level or the thumb warmer level a display brightness control function When the key is turned to the on position the tachometer needle makes one sweep and the low coolant temperature indicator light the wa...

Page 18: ...hange tripmeter and OIL flash alternately in the odometer display and the tripmeter starts counting the distance traveled from that point When this occurs change the engine oil as soon as possible See page 50 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 chang...

Page 19: ... 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 TIP The clock must be set again when the battery is disconnected Display brightness control This function allows you to adjust the bright ness of the meter unit display to suit the out door lighting conditions T...

Page 20: ...ESU10433 Fuel meter and grip thumb warmer level indicator The fuel meter and grip thumb warmer level indicator have eight segments which show the amount of fuel remaining in the fuel tank the grip warmer level or the thumb warmer level Fuel meter The display segments of the fuel meter disap pear towards E Empty as the fuel level de creases When only one segment is left near E the fuel level warnin...

Page 21: ...splay switches to the fuel meter When the engine is started the grip thumb warmer levels are set to the levels selected when the engine was last stopped ESU13251 Fuel level warning indicator The fuel level warning indicator indicates a malfunctioning sensor disconnected coupler broken lead or short circuit when detected by the self diagnosis device of the snowmobile The fuel level warning indicato...

Page 22: ...indicator and the warning light come on When this occurs stop the engine immediately and allow the engine to cool down and then check the coolant level in the coolant reservoir See page 54 for checking procedures NOTICE ECS00041 Do not continue to operate the engine if it is overheating ESU13364 Self diagnosis device This model is equipped with a self diagnosis device for various electrical circui...

Page 23: ... grip thumb warmer adjustment switch controls the electrically heated handlebar grips and throttle lever To raise the temperature To raise the grip warmer temperature press the side of the switch To raise the thumb warmer temperature press the side of the switch To lower the temperature Continue to press the switch until the temper ature level returns to the minimum level and then raise the temper...

Page 24: ...ecause the jack can be dam aged ESU13261 Helmet shield heater jack The helmet shield heater jack is located on the left side of the handlebar TIP The helmet shield heater jack can only be used if the engine 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 usi...

Page 25: ...set the brake lever to the desired position 3 Tighten the locknut securely after adjust ing the brake lever ESU10581 Parking brake lever When parking the snowmobile or starting the engine apply the parking brake by moving the parking brake lever to the left To release the parking brake move the park ing brake lever to the right ESU10592 Shift lever The shift lever is used to put the snowmobile int...

Page 26: ...and covers Securely fasten the shroud and covers before operating the snowmobile See page 42 for removal and installation procedures 1 Shift lever 1 Pull out 2 Slide to FWD forward 3 Release 1 Pull out 2 Slide to REV reverse 3 Release 1 2 3 3 2 1 1 Shroud 2 Right side cover 1 Left side cover 1 Top cover 1 U8JA10E0 book Page 20 Tuesday May 19 2009 2 37 PM ...

Page 27: ... drive guard The drive guard is designed to protect the V belt clutch and V belt in case parts break or come loose The drive guard is located behind the left side cover See page 42 for removal procedures To remove the drive guard 1 Pull out the drive guard locking pin from the drive guard rear holder 2 Lift up the rear of the drive guard as shown and then pull the guard rearward to remove it To in...

Page 28: ... 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 open flames or other sources of ignition such as the pilot lights of water heaters and clothes dry ers 2 Do not overfill the fuel tank Stop filling when the fuel reaches the b...

Page 29: ...m 5 of ethanol E5 can be used although richer jetting may be re quired to prevent engine damage Con sult a Yamaha dealer Gasohol containing methanol is not recommend ed Make sure that snow or ice does not en ter the fuel tank when refueling Do not use alcohol deicers or water ab sorbing additives with oxygenated fuel The fuel tank should be filled with the recommended gasoline as specified ESU1087...

Page 30: ...preload can be adjusted by turning the adjusting nuts Adjust the spring preload as follows 1 Loosen the locknut 2 To increase the spring preload and there by harden the suspension turn the ad justing nut in direction a To decrease the spring preload and thereby soften the suspension turn the adjusting nut in di rection b TIP The spring preload setting is determined by measuring distance A shown in...

Page 31: ...d damping force turn the adjusting knob in direction a To de crease the rebound damping force turn the adjusting knob in direction b TIP The damping forces will not decrease past the minimum levels even if the adjusting knobs are turned out more than the minimum set tings ESU10982 Adjusting the spring preload of the rear shock absorber The spring preload can be adjusted by turning the adjusting ri...

Page 32: ...an be adjusted by turning the rear shock absorber damping force remote adjusting dial To increase the rebound damping force turn the adjusting dial in direction a To decrease the rebound damping force turn the adjusting dial in direction b ESU11054 Adjusting the control rod The weight transfer can be adjusted by turn ing the adjuster on the control rod 1 Check the control rod length using the scal...

Page 33: ... and to decrease weight transfer turn it in direction b WARNING Never adjust the control rod beyond the range of the scale on the special wrench otherwise the con trol rod could be damaged which could lead to an accident or injury EWS00181 4 Tighten the locknut while holding the ad juster in place 1 Special wrench 2 Control rod length 3 Scale range 1 Locknut 2 Control rod adjuster 3 1 2 Locknut ti...

Page 34: ...o specified level Check vehicle for oil leakage 50 Coolant Check coolant level Add if necessary 54 V belt Check for wear and damage Replace if necessary 56 Drive guard Make sure that drive guard is tightened securely Check the drive guard mounts for damage 21 Brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check brake pads for wear Replace if necessary Check flui...

Page 35: ...de runners 64 Steering Check for excessive free play 63 Lights signals and switch es Check operation Correct if necessary 17 17 67 68 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 defective have Yamaha dealer check vehicle 47 ITEM CHECKS PAGE U8JA10E0 b...

Page 36: ... it stops again ask a Yamaha dealer to inspect the snow mobile 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 ESU11303 Starting the engine 1 Appl...

Page 37: ... 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 ESU11333 Riding your snowmobile Getting to know your snowmobile WARNING EWS00211 To avoid severe injury or death Keep both hands on the handlebar dur ing operation Never put your feet outside the running boards Avoid...

Page 38: ...armed 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 fittings or debris thrown by the track could be danger ...

Page 39: ...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 If you are unable to con tinue up a hill do not s...

Page 40: ...arts 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 EWS00261 Ice or icy surface WARNING EWS00270 When you have to operate on ice or icy surfaces drive slowly and cautiously Avoid accele...

Page 41: ...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 in the rapid wear of both components Also this may put an excessive load on the suspension components resulting in compo nent failure Marginal snow The drive tr...

Page 42: ... 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 1 To select the desired operating position pull the shift lever out slide it to FWD or to REV until it stops and then release it NOTICE Do not shift from FWD to REV or from REV to FWD while the snowmobile is moving as the drive train could be da...

Page 43: ...m mendations to help protect it from damage 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 and also help protect the snowmo bile against damage from debris on the road If transporting the snowmobile in an open trailer or truc...

Page 44: ...for more information about carbon monoxide Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified if applicable Proper periodic maintenance of your snowmobile is important in order to enjoy long pleasur able use Especially important are the maintenance services related to emission control These cont...

Page 45: ...r cracks or damage Replace if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Fuel injection Check synchronization Adjust if necessary Exhaust system Check for leakage Tighten or replace gasket if necessary ITEM REMARKS INITIAL EVERY PAGE 1 month or 800 km 500 mi 40 hr Seasonally or 4000 km 2500 mi 200 hr U8JA10E0 book Page 39 Tuesday May 19 2009 2 37 PM ...

Page 46: ... 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 59 Drive chain oil Check oil level 59 Change 59 Brake and parking brake Adjust free play and or replace pads if necessary 60 Change brake fluid See TIP following this chart ...

Page 47: ... Adjust if necessary 63 Steering bearings Check bearing assemblies for looseness Lubricate with specified grease Skis and front shock absorbers Lubricate with specified grease 66 Suspension compo nent Lubricate with specified grease 66 Drive track Check the deflection Adjust if necessary Initial at 500 km 300 mi and every 800 km 500 mi thereafter 64 Fittings and fasten ers Make sure that all nuts ...

Page 48: ...ealer to check the torque settings and adjust them if necessary ESU13582 Removing and installing the shroud and covers WARNING EWS00091 Be sure shroud 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 ...

Page 49: ...3 Tighten 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 Loosen the quick fastener screws 1 Fastener 2 Left side cover 1 2 1 Auxiliary DC jack coupler 1 Screw 2 Cable guide 1 1 2 U8JA10E0 book Page 43 Tuesday Ma...

Page 50: ...throttle cable park ing brake cable and wire harness through the cable guide place the cable guide in the original position and then install the screws 5 Connect the auxiliary DC jack coupler 6 Install the left side cover and the shroud NOTICE ECS00372 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 sur...

Page 51: ...spark plug and spark plug cap Otherwise the T O R S may not work properly Spark plugs are produced in several different thread lengths The thread length or reach is the distance from the spark plug gasket seat to the end of the threaded portion If the reach is too long overheating and engine damage may result If the reach is too short spark plug fouling and poor performance may result Al so if the...

Page 52: ...e snowmobile when mov ing the headlight unit ECS00920 5 Loosen the locknut 6 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 7 Tighten the locknut 8 Place the headlight unit in the original po sition making sure to insert the projec tions on the headlight unit stay into the slots on the ...

Page 53: ...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 Check the T O R S for proper operation 1 Start the engine TIP Refer to the Starting the engine section on page 30 2 Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb above and forefi...

Page 54: ...nder the air filter element frame after each ride In addition snow may need to be cleaned during a ride depending on the riding conditions 1 Remove the shroud the left and right side covers and the top cover See page 42 for removal procedures 2 Remove the headlight unit bolt on each side of the snowmobile 3 Unhook the headlight unit as shown then lift it up and move it rearward away from the air f...

Page 55: ...ght unit stay into the slots on the bottom of the headlight unit 8 Fit the weatherstrip on the headlight unit into the recess in the top of the air filter case cover 9 Install the headlight unit bolts and then tighten them to the specified torque 10 Install the top cover the left and right side covers and the shroud ESU11931 High altitude settings Operating at high altitude reduces the perfor manc...

Page 56: ...sult ing in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance chart ESU12936 Engine oil and oil filter cartridge The engine oil level should be checked before each use In addition the oil must be changed and the oil filter cartridge replaced at the inter vals sp...

Page 57: ...page 80 for the recommend ed oil 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 80 Make sure that no foreign material enters the engine oil tank ECS00462 7 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 8 Connect the oil level gauge coupler 9 Install the right side cover and th...

Page 58: ...ine oil drain bolt to drain the oil from the oil tank 9 Place an oil pan under the engine to col lect the used oil 10 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Screw 2 Bolt 3 Right lower cover 1 Bolt 2 Bottom panel 1 Oil level gauge coupler 2 Oil filler cap 1 2 1 3 2 1 2 1 1 Cylinder head cap 1 Engine oil drain bolt oil tank 1 Engine oil drain bolt crankcase 2 mark 1 1...

Page 59: ...f 17 Add sufficient oil of the recommended type to raise it to the H level mark on the dipstick See above for the checking pro cedure 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 80 Make sure that no foreign material enters the engine oil tank ECS00462 18 Start the engine and then let it idle for several minu...

Page 60: ...reservoir cap when the engine is hot Scalding hot fluid and steam may be blown out under pres sure which could cause serious injury When the engine has cooled place a thick rag or towel over the coolant reservoir cap and slowly rotate the cap counter clockwise to the detent This procedure al lows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning...

Page 61: ...em or if there is a cooling system leak Consult a Yamaha deal er NOTICE ECS00500 Operating the engine with an improperly bled cooling system can cause overheat ing and severe engine damage Replenishing the coolant 1 Place the snowmobile on a level surface and apply the parking brake 2 Remove the top cover See page 42 for removal procedures 3 Remove the coolant reservoir cap fill the reservoir with...

Page 62: ...ed before each ride To check the V belt 1 Remove the shroud and the left side cov er and then remove the drive guard See pages 21 and 42 for removal proce dures 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 To replace and adjust the V belt WARNING EWS00411 When installing a new V belt make sure that it is p...

Page 63: ...t so that 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 ea...

Page 64: ...t lower cover in the original position and then install the bolts and screws Standard V belt position From 1 5 mm 0 06 in above the edge of the secondary sheave assembly to 0 5 mm 0 02 in below the edge 1 V belt position adjusting bolt 2 Spacer V belt position Adjustment More than 1 5 mm 0 06 in above the edge Remove spacer From 1 5 mm 0 06 in above the edge to 0 5 mm 0 02 in below the edge Not ne...

Page 65: ...emove 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 minimum level mark add sufficient oil of the recommended type to raise it to the maximum level mark NOTICE Make sure that no foreign material enters the drive chain housing ECS00531 5 Install the dipstick making sure to align the notch in the dipstic...

Page 66: ...lity which could lead to an accident Ask a Yamaha dealer to inspect and repair the brake system Test the brake at a low speed when starting out to make sure that it is working properly If the brake does not provide proper braking performance inspect the brake for wear or brake fluid leakage See the following section for more details Checking the brake pads Check the brake pads for wear according t...

Page 67: ... bolt locknut and the parking brake pad adjusting bolt 3 Loosen the parking brake cable locknut 4 Turn the parking brake cable adjusting bolt in or out to adjust the cable length 5 Tighten the parking brake cable locknut 6 Turn the parking brake pad adjusting bolt in or out to adjust the clearance between the parking brake pads and the brake disc Brake pad wear limit 4 7 mm 0 19 in 1 Parking brake...

Page 68: ... level and replenish when necessary Changing the brake fluid WARNING EWS00471 Make sure that the brake fluid and the fol lowing parts are replaced by a Yamaha dealer Brake fluid replacement is necessary when the following components are replaced during the periodic maintenance or if they are dam aged or leaking All oil seals of the master cylinder and cali per cylinder The brake hose ESU13610 Extr...

Page 69: ...ication TIP Move the front tip of each ski fully inward be fore measuring or aligning 3 If the alignment is not correct consult a Yamaha dealer ESU12151 Steering system Check 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 1 Ski...

Page 70: ...erial is visible or support rods are broken Otherwise track damage or fail ure could result in loss of braking ability and snowmobile control which could cause an accident Checking the drive track WARNING EWS00490 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 con...

Page 71: ... If the alignment is incorrect loosen the locknut on the left and the right sides of the snowmobile then align the drive track by turning the adjusting bolt on each side Shifted to right Standard drive track deflection 30 0 35 0 mm 1 18 1 38 in 1 Rear axle nut 1 Slide runner 1 1 Drive track alignment Shifted to right Shifted to left Left adjusting bolt Turn out Turn in Right adjust ing bolt Turn i...

Page 72: ... packed snow will rapidly wear the slide runners ESU12195 Lubrication Lubricate the following points with the speci fied grease WARNING EWS00511 Do not grease the throttle cable because it could become frozen which could cause loss of control Apply a dab of grease onto the cable end only 1 Forward 2 Gap 3 Slide runner 4 Drive track 5 Slide metal Drive track deflection More than specified Less than...

Page 73: ...emove the top cover See page 42 for removal procedures 2 Remove the screws and then remove the headlight access panel 1 Lubrication point 1 Throttle cable end 1 Lubrication point 1 1 Lubrication point 1 Lubrication point 1 Lubrication point 1 1 1 U8JA10E0 book Page 67 Tuesday May 19 2009 2 37 PM ...

Page 74: ... be affect ed If the glass is oil stained thor oughly clean it with a cloth moistened with alcohol or lacquer thinner ECS00621 8 Install the bulb holder cover and then connect the headlight coupler 9 Install the headlight access panel and the top cover ESU12270 Adjusting the headlight beams 1 Remove the top cover See page 42 for removal procedures 1 Screw 1 Screw 2 Headlight access panel 1 Headlig...

Page 75: ...5 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Venti late when charging or using in an en closed space Always shield your eyes when working near batteries KEEP OUT OF THE REACH OF CHILDREN Charge or have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to dis...

Page 76: ... covers and the top cover See page 42 for removal procedures 2 Remove the headlight unit bolt on each side of the snowmobile 3 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 mov ing the headlight unit ECS00920 4 Loosen the joint clamp bolts 5 Move the headlight unit rearward away from the air filte...

Page 77: ...attery band and then re move the battery cover 10 Disconnect the negative battery lead by removing the bolt 11 Replace the blown fuse with one of the proper amperage 1 Air filter case fastener 2 Air temperature sensor coupler 1 Oil tank breather hose clamp 2 Oil tank breather hose 1 Cylinder head breather hose 2 ISC Idle Speed Control unit inlet hose 1 2 1 2 2 1 1 Battery cover 2 Battery band 1 Ne...

Page 78: ...Fit the weatherstrip on the headlight unit into the recess in the top of the air filter case cover 1 IGN ignition fuse 2 FAN radiator fan fuse 3 S H helmet shield heater jack fuse 4 HEAD headlight fuse 5 SIG signaling system fuse 6 DC auxiliary DC jack fuse 7 Spare fuse 1 2 3 4 5 6 7 Specified fuses Main fuse 40 0 A Fuel injection system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 5 0 A Hea...

Page 79: ... specified torque 18 Install the top cover the left and right side covers and the shroud TIP If the fuse immediately blows again ask a Yamaha dealer to inspect the snowmobile 1 Weatherstrip Tightening torque Headlight unit bolt 3 Nm 0 3 m kgf 2 2 ft lbf 1 U8JA10E0 book Page 73 Tuesday May 19 2009 2 37 PM ...

Page 80: ...ce in the case of a malfunction take the snowmobile to a Yamaha dealer immediately for repair EWS00561 3 Compression Insufficient Loose cylinder head nuts Tighten nuts properly Worn or damaged gasket Replace gasket Worn or damaged piston and cylin der Ask a Yamaha dealer to inspect Discharged battery If the battery is discharged the engine can be started using a fully charged 12 volt battery and j...

Page 81: ...oud and the right side cover See page 42 for removal proce dures 3 Remove the red connecting lead from the lead holder and move it away from the black connecting lead NOTICE Be sure to connect the red jumper cable to the red connecting lead and the black jumper cable to the black connecting lead Do not re verse the connections ECS00661 4 Pull the red connecting lead cover to expose the terminal th...

Page 82: ...charged battery Charge battery or see Discharged battery above Seized engine Seizure is caused by poor lubrication inadequate fuel or an air leak Ask a Yamaha dealer to inspect Engine power is low Low coolant temperature indicator light is flashing Warm the engine up Faulty spark plugs Clean or replace the spark plugs Improper fuel flow See Engine turns over but does not start Fuel system above In...

Page 83: ...t or ask a Yamaha dealer to inspect Incorrect V belt clutch settings for altitude or conditions Ask a Yamaha dealer to in spect Worn or sticking primary sheave assembly Ask a Yamaha dealer to inspect Worn or sticking secondary sheave assem bly Ask a Yamaha dealer to inspect Noise or excessive vibration in drive chain and sprockets Broken V belt clutch components Ask a Yamaha dealer to inspect Worn...

Page 84: ...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 lubricant Proper lubrication fights corrosion while it re duces frict...

Page 85: ...ilated place out of direct sunlight Put a fabric cover over the snowmobile preferably one that is designed for it Do not use a plastic or vinyl cover condensation could be trapped un derneath which could increase the chances of rusting Returning to service after storage When returning your snowmobile to service install the V belt and battery and adjust the drive track Remove the spark plugs and cl...

Page 86: ...1 mm 15 0 in Deflection 30 0 35 0 mm 1 18 1 38 in Length on ground RS90GT 768 mm 30 2 in RS90LTGT 960 mm 37 8 in Rear suspension Type Slide rail suspension Track sprocket wheel Material Polyethylene Number of teeth 9 Transmission Clutch type Automatic centrifugal engagement Overall reduction ratio RS90GT 6 02 1 58 1 RS90LTGT 6 18 1 63 1 Sheave distance 267 0 270 0 mm 10 51 10 63 in Sheave offset 1...

Page 87: ...ver left hand operated Throttle Operation Handle lever right hand operated Electrical system Ignition system T C I Spark plug Manufacturer NGK Model CR8E Gap 0 7 0 8 mm 0 028 0 031 in Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Ten hour rate amperage 1 8 A Bulb voltage wattage quantity Headlight 12 V 60 55 W 2 Headlight bulb type Halogen bulb Tail brake light LED Meter lighting LED High ...

Page 88: ... in a separate place in case the snowmobile is sto len Frame serial number The frame serial number is the seventeen digit number stamped on the frame of the snowmobile Engine serial number Primary ID The engine serial number is stamped in the location as shown Key identification number The key identification number is stamped in the location as shown 1 Frame serial number 1 Engine serial number 1 ...

Page 89: ...ion Control 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 U8JA10E0 book Page 83 Tuesday May 19 2009 2 37 PM ...

Page 90: ...e to normal wear or routine maintenance including oil spark plugs clutch drive belts slide runners and track THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the snowmobile as specified in the appropriate Owner s Manual 2 Give notice to an authorized Yamaha snowmobile dealer of any and all apparent defects within ten 10 days after discovery and make the machine ...

Page 91: ...oil spark plugs clutch drive belts and slide runners Q What are some examples of abnormal strain ne glect or abuse A These terms are general and overlap each other in areas Specific examples include Running the ma chine out of oil hitting an object submerged under snow operation on surfaces other than snow or ice operating the machine with a broken or damaged part which causes another part to fail...

Page 92: ... all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corpora tion U S A be sure to include the model serial number names dates and receipts CHANG...

Page 93: ...Consumer information 87 ESU12510 YAMAHA EXTENDED SERVICE Y E S U8JA10E0 book Page 87 Tuesday May 19 2009 2 37 PM ...

Page 94: ...tant labels 1 Low coolant temperature indicator light 14 Lubrication 66 M Main switch 10 Multi function meter unit 11 O Oil level warning indicator 15 P Parking brake lever 19 Part locations 7 Periodic maintenance chart for the emission control system 38 Pre operation check list 28 R Riding your snowmobile 31 S Safety information 5 Self diagnosis device 16 Shift lever 19 Shock absorber rear adjust...

Page 95: ...Index V Valve clearance 50 V belt 56 V belt holders 22 Vehicle Emission Control Information label 83 U8JA10E0 book Page 2 Tuesday May 19 2009 2 37 PM ...

Page 96: ...A5 tate_Blank fm Page 1 Friday May 16 2003 9 00 AM ...

Page 97: ...A5 tate_Blank fm Page 1 Friday May 16 2003 9 00 AM ...

Page 98: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009 05 0 5 1 CR ESU12520 DIC183 ...

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