Yamaha RX10J Owner'S Manual Download Page 3

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ESU00286

MACHINE IDENTIFICATION

Identification number records

A. FRAME NUMBER:

CZ-01E

B. ENGINE NUMBER (PRIMARY ID):

CZ-01E

C. KEY NUMBER:

CZ-01E

Record the frame number, engine number (Primary ID),
and key number in the spaces provided for assistance
when ordering spare parts from a Yamaha dealer.

The

frame number

is the seventeen-digit number

stamped on the frame of the snowmobile. (See
fig.

The

engine number

is stamped in the location as

shown. (See fig.

Key number

(See fig.

Also, record and keep the ID numbers in a separate
place in case the snowmobile is stolen.

U8FA11.book Page 1 Thursday, April 3, 2003 4:09 PM

Summary of Contents for RX10J

Page 1: ...OWNER S MANUAL SNOWMOBILE RX10J RX10SJ RX10MJ RX10MSJ RX10RJ RX10RSJ RXW10J RXW10SJ 8FA 28199 11 LIT 12628 02 33 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003 04 2 0 1 CR E YAMAHA MOTOR CO LTD ...

Page 2: ......

Page 3: ...e spaces provided for assistance when ordering spare parts from a Yamaha dealer 1 The frame number is the seventeen digit number stamped on the frame of the snowmobile See fig È 2 The engine number is stamped in the location as shown See fig É 3 Key number See fig Ê Also record and keep the ID numbers in a separate place in case the snowmobile is stolen A B C U8FA11 book Page 1 Thursday April 3 20...

Page 4: ...ation 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 RX10J RX10SJ RX10MJ RX10MSJ RX10RJ RX10RSJ RXW10J RXW10SJ OWNER S MANUAL 2003 by Yamaha Motor Corpo...

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

Page 6: ...11 Shift lever 5 11 Headlight beam switch 5 12 Shroud latches 5 12 Drive guard 5 12 V belt holders 5 13 Storage compartment 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 51 mm 2 0 in high profile pattern drive track 6 8 Slide ...

Page 7: ...il 8 11 Cooling system 8 13 V belt replacement 8 15 Checking the oil level of the drive chain housing 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 28 Ski alignment 8 30 Handlebar adjustment 8 30 Lubrication 8 32 Headlight bulb replacement 8 33 Headlight beam adjustmen...

Page 8: ...1 1 ESU00004 1 YAMAHA MOTOR CORPORATION U S A SNOWMOBILE LIMITED WARRANTY CW 01E U8FA11 book Page 1 Thursday April 3 2003 4 09 PM ...

Page 9: ...1 2 CW 02E U8FA11 book Page 2 Thursday April 3 2003 4 09 PM ...

Page 10: ...1 3 CW 03E U8FA11 book Page 3 Thursday April 3 2003 4 09 PM ...

Page 11: ...any reasonable expenses you incur because your Yamaha needs cov ered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any war ranty repairs as well as covered repairs dur ing your entire Y E S plan period Y E S coverage is honored at any authorized Yamaha ...

Page 12: ...ease read the following labels carefully before operat ing this snowmobile NOTE Maintain or replace safety and instruction labels as nec essary 1 RX10J RX10S RX10M RX10MS 1 RX10R RX10RS RXW10 RXW10S 2 3 U8FA11 book Page 1 Thursday April 3 2003 4 09 PM ...

Page 13: ...2 2 4 RX10M RX10MS 5 RX10M RX10MS 6 7 RXW10 RXW10S 8 RX10M RX10MS RXW10 RXW10S U8FA11 book Page 2 Thursday April 3 2003 4 09 PM ...

Page 14: ...to carry the OPERA TOR ONLY Passengers are prohibited Carrying a passenger can cause loss of control 4 Do not operate the snowmobile after drinking alcohol or taking drugs Your ability to operate the snowmo bile is reduced by the influence of alcohol or drugs 5 For safety and proper care of the snowmobile always perform the pre operation checks on pages 6 1 6 10 before starting the engine Check th...

Page 15: ... vapor or get some gasoline into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash your skin with soap and water and change your clothes 10 Wear protective clothing Wear an approved helmet and a face shield or goggles Also wear a good qual ity snowmobile suit boots and a pair of gloves or mit tens that will permit use of your thumbs and fingers ...

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

Page 17: ...ndshield 2 Steering handlebar 3 Seat 4 Frame 5 Slide rail suspension 6 Drive track 7 Skis 8 Headlights 9 Shroud 0 Storage compartment RX10 RX10S RX10R RX10RS RX10M RX10MS RXW10 RXW10S U8FA11 book Page 1 Thursday April 3 2003 4 09 PM ...

Page 18: ...ch M Main switch N Starter lever O Tachometer P Low coolant temperature indicator light Q High beam indicator light R Warning light S Self diagnosis warning indicator T Coolant temperature warning indicator U Fuel level warning indicator V Oil level warning indicator W Speedometer X Grip warmer indicator Y Select reset button Z Thumb warmer indicator Fuel meter and grip thumb warmer heat level ind...

Page 19: ...he key can be removed only in this position 2 ON The ignition circuit is switched on 3 START The starting circuit is switched on The starter motor starts CAUTION Release the switch immediately after the engine starts NOTE The headlights meter lights and taillights come on after the engine starts U8FA11 book Page 1 Thursday April 3 2003 4 09 PM ...

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

Page 21: ...R S is activated make sure that the cause of the malfunction has been corrected and that the engine 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 01E È Idle or starting É Run Ê Trouble 1 Carburetor switch 2 Throttle switch 3 Throttle cable 4 Throttle valve a On b Off A B C M...

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

Page 23: ...umb warmer adjustment switch 2 control the electrically heated handlebar grips and throttle lever 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 heat level when the grip warmer adjustment switch is pressed The thumb warmer indicator 4 comes on and the dis play s...

Page 24: ...rning indicator 1 and the warning light 2 come on when the engine oil level is low If the oil level warning indicator and the warning light come on place the snowmobile on a level surface and allow it to idle for one minute If the oil level warning indicator and the warning 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...

Page 25: ... warning light 2 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 6 4 CAUTION Do not operate the engine if it overheats The coolant temperature warning indicator indicates a malfunctioning sensor disconnected coupler broken lead or short circuit when detected by the self diagnosis device of the...

Page 26: ...lash patterns WARNING If the self diagnosis warning indicator and warn ing light flash continuously during operation there may be some problem with the electrical circuit lead couplers etc See page 5 9 for warn ing indicator and warning light flash pattern num bers 1 6 Stop the engine and allow it to cool off Then check that the wire harness couplers are con nected properly in the engine compartme...

Page 27: ...and warning light flash continuously in this pattern 4 Warning indicator and warning light flash continuously in this pattern 5 Warning indicator and warning light flash continuously in this pattern 6 Warning indicator and warning light flash continuously in this pattern On Off s Second 0 75 s 0 25 s 4 s 0 75 s 2 5 s 0 75 s 0 25 s 3 5 s 0 75 s 0 25 s 4 5 s 0 75 s 0 25 s 5 5 s 0 75 s 0 25 s 6 5 s U...

Page 28: ... grip to stop the snowmobile 1 Brake lever 2 Brake lever end 3 Handlebar end NOTE When the brake lever is operated the brake light will illu minate CAUTION Make sure that the brake lever end does not project out over the handlebar end This will help prevent brake lever damage when the snowmobile is placed on its side for service The brake lever is equipped with a position adjuster To adjust the br...

Page 29: ...he parking brake applied This may overheat the brake disc and reduce braking ability ESU00341 Shift lever For RX10R RX10RS RXW10 RXW10S The shift lever is used to put the snowmobile into forward or reverse After coming to a complete stop pull the shift lever out slide it to FWD or to REV until it stops and then release it 1 Shift lever 2 Pull out 3 Slide to FWD Forward 4 Slide to REV Reverse 5 Rel...

Page 30: ...hat all cables and wires are in place when closing the 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 ESU00052 Drive guard The drive guard is designed to cover the V belt clutch and V belt in cas...

Page 31: ...lders provided CAUTION Make sure that the V belt is installed securely in the holders ESU00342 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 U8FA11 book Page 13 Thursday April 3 2003 4 09 PM ...

Page 32: ...ING 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 after refueling Leaking fue...

Page 33: ...uel tank should be filled with straight gaso line as specified ESU00343 Engine oil Use a combination of the recommended SAE and API oil classifications shown in the chart below CB 01E 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 grade than CD In addition ...

Page 34: ...ome severed 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 4 level marks on the oil level gauge dipstick 5 If the engine oil is below the E level mark add suffi cient oil of the recommended type to raise it to the F level mark See pag...

Page 35: ...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 temporarily in an emer gency U8FA11 book Page 4 Thursday April 3 2003 4 09 PM ...

Page 36: ...orward unexpectedly which could cause an accident 1 Start the engine NOTE Refer to the Starting the engine section 2 Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb above and forefinger below between the throttle lever pivot 1 and the engine stop switch housing 2 While holding the pivot point as described above press the throttle lever 3 gradually The...

Page 37: ...rake system Do not operate the snowmobile if you find any problems in the brake system You could lose braking ability which could lead to an accident Ask a Yamaha dealer to inspect and repair the brake system CAUTION Make sure that the brake lever end does not project out over the handlebar end This is to prevent brake lever damage when the snowmobile is placed on its side 2 Brake fluid Check the ...

Page 38: ...y brake fluid If any is spilled clean it up immediately ESU00094 V belt Open the shroud and remove the drive guard Check the V belt for wear and damage Replace if neces sary WARNING Make sure that the drive guard is tightened securely before operating the snowmobile Never run the engine without the V belt or with the drive guard removed ESU00096 Drive guard Check the drive guard mounts for damage ...

Page 39: ... in deep snow riding conditions Therefore avoid prolonged operation on hard surfaces such as ice hard packed snow dirt etc to extend the life of the track and slide runners CAUTION Only use in deep snow riding conditions Operation on areas with light snowfall ice hard packed snow dirt or grass will result in rapid wear or damage to the track and slide runners from lack of snow which serves as a lu...

Page 40: ...e 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 lenses 1 Ski runner wear lim...

Page 41: ...0110 Fittings and fasteners Check the tightness of the fittings and fasteners Tighten in proper sequence and torque if necessary ESU00345 Tool kit and recommended equipment It is good practice to carry the tool kit spare parts and other necessary equipment with you while riding the snowmobile so that minor repairs can be done if neces sary The following should be carried at all times Tool kit Flas...

Page 42: ...E The starter lever choke is not required when the engine is warm Put the starter lever choke in the closed posi tion 2 Turn the main switch to the START position After the engine starts put the starter lever choke in the half open position Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the closed position 1 START CAUTION Release the switch...

Page 43: ... any condition that might result in engine overheating must be avoided Operating your snowmobile for the first time Start the engine and let it idle for 15 minutes 0 160 km 0 100 mi Avoid prolonged operation above 6 000 r min 160 500 km 100 300 mi Avoid prolonged operation above 8 000 r min 500 km 300 mi and beyond The snowmobile can now be operated normally CAUTION After 800 km 500 mi of operatio...

Page 44: ...y 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 characteristics Set the parking ...

Page 45: ...eration 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 opening to prevent track slippage It is also important to keep your weight on the uphill side at all times On climbs straight up the hill this can be accomplis...

Page 46: ...seat and the foot of the uphill leg on the running board This posi tion will make it easier for you to shift your body weight as needed Snow and ice are slippery so be prepared for the possibility that your snowmobile could begin to slip sideways on the slope If this happens steer in the direction of the slide if there are no obstacles in your path As you regain proper balance gradually steer agai...

Page 47: ... lot of dirt and sand All the above conditions have one thing in common in regard to drive track and slide runners little or no lubricating ability Drive track and all slide rail systems require lubrication snow or water between the slide runners and the slide metal In the absence of lubrication the slide runners will rapidly wear and in severe cases liter ally melt away and the drive track will b...

Page 48: ... high speed usage in areas such as icy trails frozen lakes and rivers that have minimal snow coverage An overheated track will be weakened internally which may cause fail ure or damage Off trail riding Avoid off trail riding until there is sufficient snow cover age It generally takes several feet of snow to provide a good overall base to properly cover debris such as rocks logs etc If snow coverag...

Page 49: ... traverse side hill riding Only experi enced operators should traverse slopes steep enough to require strap use Keep the right hand on the right handlebar grip for steering and grip the strap with the left hand to shift weight uphill for balance during traverse riding Ride cautiously while using the strap Do not accelerate or decelerate abruptly while holding onto the strap Do not use the strap to...

Page 50: ...ing the parking brake lever to the left For RX10R RX10RS RXW10 RXW10S 1 To select the desired operating position pull the shift lever out slide it to FWD or to REV until it stops and then release it 1 Pull out 2 Slide to FWD Forward 3 Slide to REV Reverse 4 Release WARNING Make sure that the throttle lever is fully released and the snowmobile is at a full stop before shift ing Be sure to slide the...

Page 51: ...wmo bile 4 Turn the handlebar in the desired direction 5 Squeeze the brake lever to stop the snowmobile 6 Apply the parking brake by moving the parking brake lever to the left ESU00136 Stopping the engine Turn the main switch to the OFF position to stop the engine 1 OFF WARNING Push down the engine stop switch to stop the engine in an emergency Make sure that the key is removed from the main switc...

Page 52: ...ssible the fuel tank should be empty during transportation especially if the trip takes longer than 30 minutes If transporting the snowmobile in an open trailer or truck put a tight fitting cover on the snowmobile A cover specifically designed for your snowmobile is best This will help keep foreign objects out of the cooling vents in the shroud and also help protect the snowmobile against damage f...

Page 53: ... 000 mi 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 changed Engine stop switch Ch...

Page 54: ...ght 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 out if necessary Strap RX10M ...

Page 55: ...condary Replace if necessary Lubricate with specified grease Steering column bearing Lubricate with specified grease 8 32 Ski and front suspension Lubricate with specified grease 8 32 Suspension component Lubricate with specified grease 8 32 Parking brake cable end and lever end throttle cable end Lubricate with specified grease 8 32 Check cable damage Replace if necessary Shroud latches Make sure...

Page 56: ...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 an intake track air leak...

Page 57: ... damage Always use a spark plug with the speci fied reach Before installing any spark plug measure the electrode gap with a wire thickness gauge and adjust to specifica tion When installing the spark plug always clean the gasket surface Wipe off any grime from the threads and tighten the spark plug to the specified torque CAUTION Make sure that the spark plug caps are securely installed Otherwise ...

Page 58: ... engine section 2 Turn the throttle stop screw 1 in or out to adjust the engine idle speed ESU00147 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 1 350 100 r min Throttle lever free play a 2 ...

Page 59: ...ohol 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 1 Mixture Condition Turn ...

Page 60: ...versing the removal steps Main jet replacement Replace the main jet according to the setting chart which is available at a Yamaha dealer WARNING Never remove the drain plug or the float chamber while the engine is hot Fuel will flow out from the float chamber which could ignite and cause injury Place a rag under the carburetor before removing the drain plug or float chamber to catch any spilled fu...

Page 61: ...g 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 installed Standard main jet 135 Main jet 1 Mixture Condition Small No Lean Warm weather High altitude Large No Rich Cold weather Low altitude U8FA11 book Page 9 Thursday April 3 2003 4 09 PM ...

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

Page 63: ... mi of operation Have a Yamaha dealer replace the oil filter cartridge To change the engine oil 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 ...

Page 64: ...g immediately turn the engine off and make sure the engine oil drain bolts and oil level gauge dipstick are installed correctly 12 Turn the engine off and then install the bottom cover and right side cover CAUTION If oil is leaking or the oil level warning indicator comes on when the engine is running immediately turn the engine off and have a Yamaha dealer check the snow mobile Continuing to oper...

Page 65: ... counterclockwise to the detent This pro cedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it The cooling system must be bled of air if the coolant reservoir becomes empty if air can be seen in the cooling system or if there is a cooling system leak Consult a Yamaha dealer CAUTION Operating the engine wi...

Page 66: ...nd then stop the engine 3 Fill the coolant reservoir with coolant to 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 Coolant and water mixed ratio 60 40 Total amount 4 7 L 4 14 Imp qt 4 97 US qt U8FA11 book Page 14 Th...

Page 67: ...ler make this adjustment CAUTION As the V belt wears adjustment may be necessary To ensure proper clutch performance the V belt position should be adjusted by adding a spacer on each adjusting bolt when the V belt position reaches 1 5 mm 0 06 in below the edge Have a Yamaha dealer make this adjustment CD 05E NOTE Apply the parking brake before replacing the V belt 1 Remove the drive guard 2 Rotate...

Page 68: ...ust the V belt position by removing or adding a spacer 4 on each adjusting bolt 5 CD 06E 7 Tighten each adjusting bolt Standard V belt position a From 1 5 mm 0 06 in above the edge of the second ary sheave to 0 5 mm 0 02 in below the edge V belt position Adjustment More than 1 5 mm 0 06 in above the edge Remove spacer From 1 5 mm 0 06 in above the edge to 0 5 mm 0 02 in below the edge Not necessar...

Page 69: ... the engine with the V belt or drive guard removed ESU00351 Checking the oil level of the drive chain hous ing WARNING The engine oil tank brake disc and coolant hoses will be very hot after the engine has been run Avoid contact while they are still hot with any part of your body or clothing during inspection or repair 1 Place the snowmobile on a level surface 2 Remove the dipstick 1 and wipe it o...

Page 70: ...hat 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 chain adjuster locknut 2 Turn the adjuster bolt clockwise until it is finger tight 3 Hold the adjuster bolt in place while tightening the chain adjuster locknut 1 Chain adjuster locknut 2 A...

Page 71: ...ustment 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 brake pads 5 and the brake...

Page 72: ...y 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 suspension can be adjusted...

Page 73: ...gs can cause poor handling and loss of stability Spring seat length Standard Long Short Preload Hard Soft a Length Maximum 156 6 mm 6 17 in 148 6 mm 5 85 in Minimum 146 6 mm 5 77 in Spring seat length Standard Long Short Preload Hard Soft a Length Maximum 144 6 mm 5 69 in 134 6 mm 5 30 in Minimum 134 6 mm 5 30 in Spring seat length Standard Long Short Preload Hard Soft a Length Maximum 158 6 mm 6 ...

Page 74: ...e or other high heat source which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose of a worn or damaged shock absorber by yourself Take the unit to a Yamaha dealer ESU03240 Rear suspension spring preload adjustment The rear suspension is equipped with two shock absorb ers One is in the front 1 and the other is in the rear 2 of the rear suspension assem...

Page 75: ...10S CD 14E A Spring seat length Standard Long Short Preload Hard Soft È a Length front Maximum 107 0 mm 4 21 in 97 0 mm 3 82 in Minimum 97 0 mm 3 82 in Spring seat length Standard Long Short Preload Hard Soft È a Length front Maximum 127 0 mm 5 0 in 117 0 mm 4 61 in Minimum 117 0 mm 4 61 in B Spring adjuster position 1 2 3 4 5 6 7 Preload Soft Hard É Standard rear 4 U8FA11 book Page 23 Thursday Ap...

Page 76: ...shock absorber Do not subject the shock absorber to an open flame or other high heat sources which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose of a worn or damaged shock absorber by yourself Take the unit to a Yamaha dealer C Spring adjuster position 1 2 3 4 5 Preload Soft Hard Ê Standard front 3 D Spring adjuster position 1 2 3 4 5 6 7 Preload So...

Page 77: ... there is a click WARNING This shock absorber contains highly pressurized nitrogen gas It could explode by improper handling causing injury or property damage Do not tamper with or attempt to open the shock absorber Do not subject the shock absorber to an open flame or other high heat source which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose of a w...

Page 78: ...usting bolt 2 securely with a wrench so it does not move CAUTION Never allow the adjusting bolt 2 to move while loos ening the nut 2 Turn the adjusting bolt 2 to the desired position CAUTION Make sure that the adjusting bolt ends are set at the same position on each side 3 While holding the adjusting bolt securely tighten the full rate adjusting nut 1 CAUTION Never allow the adjusting bolt to move...

Page 79: ... mm wrenches included in the 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 adjust ing nut The left and right adjusting nuts must be set to the same position Uneven settings can cause poor han dling and loss of stability WARNING Never adjust the control rods beyond the maximum range indicate...

Page 80: ...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 the drive track deflection ...

Page 81: ... turns Stop the engine 4 Check the drive track alignment with the slide runners 2 If the alignment is incorrect align the drive track by turning the left and right adjusters CD 08E 7 Slide runners 8 Drive track 9 Slide metal a Gap b Forward 5 Adjust the drive track deflection to specification CD 09E 5 6 Drive track alignment 5 Shifted to right 6 Shifted to left 3 Left adjuster Turn out Turn in 4 R...

Page 82: ...r 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 ESU00354 Handlebar adjustment 1 Remove the handlebar cover 1 È RX10 RX10S RX10R RX10RS RXW10 RXW10S É RX10M RX10MS Rear axle tightening torque 75 Nm 7 5 m kgf 54 2 ft lb Ski toe out 1 2 0 15 mm 0 0 59...

Page 83: ...10M RX10MS CAUTION Make sure that the projection on the handlebar is not installed into the area a shown 4 Tighten the handlebar bolts and install the handlebar cover CAUTION Make sure that the small gap b side of the handlebar holders faces forward c A B Handlebar bolt tightening torque 14 5 Nm 1 45 m kgf 10 5 ft lb U8FA11 book Page 31 Thursday April 3 2003 4 09 PM ...

Page 84: ...able 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 2 3 Lubricant Low temperature grease U8FA11 book Page 32 Thursday April 3 2003 4 09 PM ...

Page 85: ...lb 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 adjuster 1 3 Turn the headlight ...

Page 86: ...skin eyes or clothing ANTIDOTE EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield ...

Page 87: ... fuse with one of proper amperage 6 Install the air filter case by reversing the removal steps NOTE If the fuse immediately blows again ask a Yamaha dealer to inspect the snowmobile 9 Spare fuses 20 A 10 A 0 Spare main fuse Specified fuses 4Main fuse 30 A 5 HEAD Headlight fuse 20 A 6 SIG Signal fuse 10 A 7 C W Carburetor Warmer fuse 20 A 8 IGN Ignition fuse 10 A U8FA11 book Page 35 Thursday April ...

Page 88: ...ately 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 have been provided for jum...

Page 89: ... 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 black jumper cable from the...

Page 90: ...e 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 T O R S system See A 2 ab...

Page 91: ...ler 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 Yamaha dealer to inspect 5 Wor...

Page 92: ...l is used because the alcohol content in the fuel increases the chance for water to enter the engine Use Yamaha Stor Rite Engine Fogging Oil or an equiva lent fogging oil to protect both the com bustion chamber and crankshaft from corrosion An alternate method is to remove the carburetor silencer and squirt oil into the carburetor throats while the engine is running CAUTION Do not attempt to store...

Page 93: ... a dry well venti 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 reinstall the V belt and adjust the drive track and install the batte...

Page 94: ...b RX10 RX10S 264 kg 581 lb RX10M RX10MS RXW10 RXW10S 254 kg 560 lb RX10R RX10RS Ski tread 1 068 mm 42 0 in RX10 RX10S RX10R RX10RS RXW10 RXW10S 980 mm 38 6 in RX10M RX10MS RX10 RX10S RX10M RX10MS RX10R RX10RS RXW10 RXW10S Type Liquid cooled 4 stroke 20 valves Cylinder arrangement Parallel 4 cylinder Displacement 998 cm3 Bore Stroke 74 0 58 0 mm 2 91 2 28 in Idle speed 1 350 100 r min Engine oil ty...

Page 95: ...RXW10S Quadruple polyethylene 8 teeth RX10M RX10MS Transmission Type Automatic centrifugal engagement infinite ly variable 3 8 1 1 1 Sheave distance Approx 268 5 mm 10 57 in Sheave offset Approx 15 mm 0 59 in Engagement speed 1 Approx 3 600 r min RX10 RX10S RX10R RX10RS RXW10 RXW10S Approx 4 200 r min RX10M RX10MS Shift speed 1 Approx 10 250 r min 2 Drive chain Silent chain enclosed in oil bath Re...

Page 96: ... hand operated Throttle Operation Handle lever right hand operated RX10 RX10S RX10M RX10MS RX10R RX10RS RXW10 RXW10S Ignition system DC CDI Spark plug Type R CR9E NGK Gap 0 7 0 8 mm 0 028 0 031 in Battery Capacity YTX20L BS 12 V 18 A h Maximum charge rate 1 8 Amperes hr for 10 hrs Headlight Bulb Quantity 12 V 60 55 W 2 Tail brake light Bulb Quantity 12 V 5 21 W 2 Meter light Bulb Quantity 14 V 50 ...

Page 97: ... MEMO U8FA11 book Page 4 Thursday April 3 2003 4 09 PM ...

Page 98: ... G B B B G G G L R L R L R L Y B P P R R R B B B L B R W L R B L W Y W Y Y L Y L B W Y W Y W B Y B L Br W Br Br W B Y B Br OFF OPEN B Y B L B Y L R RUN OFF Br W B W R W B L RUN IDLE Br W L Br R B B B Lg Y R A G G B B B Y B Y B A Lg B Lg B Lg B Y G Y G Y G B B A G R G R A R B R B C C Y Y A B G B G B G BLACK B W L R BLACK W Y B L L Y W Y W Lg L Lg L Lg W Lg W B L B L B L Y L Y L B L BLACK BLACK BLAC...

Page 99: ...light Y Multi function meter Z Warning light Self diagnosis system High beam indicator light Headlight _ Headlight relay a Headlight beam switch b HEAD Headlight fuse c SIG Signal fuse d C W Carburetor Warmer fuse e IGN Ignition fuse f Load control relay COLOR CODE B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B G Black Green B L Black Bl...

Page 100: ... MEMO Memo fm Page 1 Friday April 4 2003 4 56 PM ...

Page 101: ...OWNER S MANUAL SNOWMOBILE RX10J RX10SJ RX10MJ RX10MSJ RX10RJ RX10RSJ RXW10J RXW10SJ 8FA 28199 11 LIT 12628 02 33 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003 04 2 0 1 CR E YAMAHA MOTOR CO LTD ...

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Yamaha RX10J, Owner'S Manual

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