Yamaha RX10K Assembly Manual Download

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RX10K

RX10RK/RX10RSK

RXW10K/RXW10SK

RX10MK/RX10MSK

LIT-12668-02-39

ASSEMBLY MANUAL

8FV-28107-10

981094

Summary of Contents for RX10K

Page 1: ...RX10K RX10RK RX10RSK RXW10K RXW10SK RX10MK RX10MSK LIT 12668 02 39 ASSEMBLY MANUAL 8FV 28107 10 981094...

Page 2: ...ked in the crate against a hard object or subject it to heavy shocks during transportation or in the service shop PREPARATION To assemble the machine correctly supplies and working space are required...

Page 3: ...cates correct upright position of the transport package Transport package must be kept away from rain Up to 9 of the transport packages can be piled up Only stack this unit with transport packages of...

Page 4: ...V BELT HEIGHT AND INSTALLATION 3 3 ENGINE OIL 3 4 ENGINE OIL LEVEL 3 4 BREAK IN 3 5 COOLANT LEVEL 3 6 DRIVE CHAIN HOUSING OIL LEVEL INSPECTION 3 7 DRIVE CHAIN TENSION ADJUSTMENT 3 8 THROTTLE CABLE ADJ...

Page 5: ...ONTROL ROD ADJUSTMENT RXW10K RXW10SK 3 27 CONTROL ROD ADJUSTMENT RX10MK RX10MSK 3 28 BRAKE FLUID LEVEL 3 29 BRAKE FLUID REPLACEMENT 3 29 HYDRAULIC BRAKE AIR BLEEDING 3 30 BATTERY INSPECTION 3 31 APPEN...

Page 6: ...A for shipment B Carton box C Carton box D Vinyl bag E Vinyl bag For RX10MK RX10MSK F Windshield G Flap H Tool box I Owner s manual The storage location after machine assembly is shown in the illustra...

Page 7: ...MK RX10MSK 6 Carton box B Ski assembly 1 Carton box C Rear bumper Rear bumper bracket For RX10MK RX10MSK 9 8 Steering pad assembly Except for RX10MK RX10MSK 7 Left Right Side cover For RX10MK RX10MSK...

Page 8: ...22 2 pcs 10 Windshield F Key Upper handle holder Lower handle holder Bolts Clamp 1 1 2 3 4 Handlebar joint 5 Screw driver bit 5 Wrench 3 6 Spark plug box wrench 16 7 Box wrench 14 8 For RX10K For RX10...

Page 9: ...Owner s manual I Safety hand book J Suspension setting card Except for RXW10K RXW10SK K 1 4...

Page 10: ...3 Remove the bolts 2 and then remove the top of the crate 3 4 Remove the bolts 4 and then remove the sides of the crate 5 Remove the carton box 6 Remove the bolts 5 and then remove the brackets 6 The...

Page 11: ...installed on the right side are not used for installation 12 Remove the bracket 13 The braket 13 installed on the right side are not used for installation 13 Remove the bolt 14 and nut 15 Left side T...

Page 12: ...l bag 1 M6 1 0 L 14 mm 0 55 in Nut spring 2 in the vinyl bag 4 L 19 mm 0 75 in Screw 3 in the vinyl bag 1 M5 0 8 L 18 mm 0 71 in Nut 3 in the vinyl bag 1 Headlight cover 1 in the carton box Fairing 2...

Page 13: ...Name Qty Location Remark Nut spring 2 in the vinyl bag 4 L 19 5 mm 0 77 in Bolt 2 in the vinyl bag 4 M6 1 0 L 16 mm 0 63 in Bolt 3 in the vinyl bag 1 L 15 mm 0 59 in Self tapping screw 2 in the vinyl...

Page 14: ...Location Remark Ski assembly 2 in the carton box Bolt 2 in the vinyl bag 2 for RX10K RX10RK RX10RSK M10 1 25 L 130 mm 5 12 in Bolt 2 in the vinyl bag 2 for RXW10K RXW10SK M10 1 25 L 115 mm 4 53 in Nut...

Page 15: ...SK Parts List No Parts Name Qty Location Remark Ski assembly 2 in the carton box Bolt 2 in the vinyl bag 2 M10 1 25 L 153 mm 6 02 in Nut 2 in the vinyl bag 2 M10 1 25 Split pin 2 in the vinyl bag 2 St...

Page 16: ...me Qty Location Remark Shock absorber 2 in the carton box Nut 4 in the vinyl bag 2 M10 1 25 Washer plate 4 in the vinyl bag 2 d 10 mm 0 4 in D 25 mm 0 98 in Bolt 2 in the vinyl bag 2 M10 1 25 L 60 mm...

Page 17: ...ts List No Parts Name Qty Location Remark Under cover 1 in the carton box Bolt 8 in the vinyl bag 1 M6 1 0 L 18 mm 0 71 in Nut spring 6 in the vinyl bag 1 L 19 mm 0 75 in Front bumper 1 in the carton...

Page 18: ...7 1 2 C 3 0 4 Nm 0 04 mSkg 0 3 ftSlb SIDE COVER For RX10MK RX10MSK Parts List No Parts Name Qty Location Remark Side cover 2 in the carton box Screw 8 in the vinyl bag 1 M5 Nut 8 in the vinyl bag 1 M...

Page 19: ...vinyl bag Clamp 1 in the vinyl bag Bolt with washer 4 in the vinyl bag M8 1 25 L 55 mm 2 17 in Steering pad assembly 1 in the carton box Set up point 1 Position tab A toward the left and install the l...

Page 20: ...older 2 in the vinyl bag Clamp 1 in the vinyl bag M8 1 25 L 165 mm 6 50 in Bolt with washer 4 in the vinyl bag Steering pad assembly 1 in the carton box Set up point 1 Position tab A toward the left a...

Page 21: ...the holder faces forward B a 0 mm 0 in D Center the match mark 1 on the handle bar C between the lower handlebar hold ers D 2 Pass all leads and cables through the clamp 1 Except for brake hose and pa...

Page 22: ...he vinyl bag 3 Rear bumper bracket 1 in the carton box Bolt 4 in the vinyl bag 3 M8 1 25 L 16 mm 0 63 in Rear bumper 1 in the carton box Flange bolt 4 in the vinyl bag 3 M6 1 0 L 15 5 mm 0 61 in Nut s...

Page 23: ...bag 3 M6 1 0 L 15 5 mm 0 61 in Nut spring 4 in the vinyl bag 3 L 19 mm 0 75 in Reflector 2 in the vinyl bag 5 Washer 2 in the vinyl bag 5 Nut 2 in the vinyl bag 5 M5 Bolt 4 in the vinyl bag 3 M8 1 25...

Page 24: ...vinyl bag 6 M6 1 0 L 15 5 mm 0 61 in Nut spring 4 in the vinyl bag 6 L 19 mm 0 75 in Reflector 2 in the vinyl bag 4 Washer 2 in the vinyl bag 4 Nut 2 in the vinyl bag 4 M5 Bolt 4 in the vinyl bag 6 M...

Page 25: ...2 14...

Page 26: ...er SHEAVE OFFSET ADJUSTMENT 1 Open the shroud 2 Remove SDrive V belt guard SDrive V belt 3 Measure SSheave offset a Use the sheave gauge Out of specification Adjust Sheave offset 15 1 5 mm 0 59 0 06 i...

Page 27: ...ftSlb SRecheck the sheave offset If out of specifica tion repeat the above steps When adjusting the sheave offset the second ary sheave free play clearance should be ad justed 5 Measure SSecondary she...

Page 28: ...that it separates from the fixed sheave 5 Install the belt 3 between the secondary sliding and fixed sheave 6 Measure the V belt height a Make sure secondary clutch is all the way together be fore mea...

Page 29: ...ore each use Do not run the engine with too much or not enough oil in the oil tank Oil could flow into the air filter case and the engine could be damaged Checking the engine oil level 1 Place the sno...

Page 30: ...500 km 300 mi For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 500 km 300 mi The various parts in the en...

Page 31: ...ounterclockwise and remove it D The cooling system must be bled of air if the reservoir tank becomes empty if air can be seen in the cooling system or if there is a cooling system leak Operating the e...

Page 32: ...ositioned straight up when checking the oil level 2 Remove the oil level gauge 1 3 Check the oil level gauge If not add oil until upper level a Upper level b Lower level A Without reverse B With rever...

Page 33: ...8 DRIVE CHAIN TENSION ADJUSTMENT 1 Loosen the locknut 1 2 Turn the adjuster bolt 2 clockwise until it is finger tight 3 Hold the adjuster bolt 2 in place while tight ening the chain adjuster locknut...

Page 34: ...08 X 0 12 in Adjust if out of specification 2 Loosen the locknut 1 3 Turn the adjuster 2 in or out to adjust the throttle cable free play Clockwise Free play is increased Counterclockwise Free play i...

Page 35: ...rging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN D Always keep the battery charged Storing a discharged battery can cause perma nent batter...

Page 36: ...es to the ground of the insulator plate on the muffler when tightening terminal nuts Insulate wrench with tape D Never hammer the battery terminals when connecting the cable terminals to the bat tery...

Page 37: ...ever allow anyone to hold the rear of the machine off the ground to allow the track to spin Never allow anyone near a rotating track D Inspect track condition frequently Re place the track if it is da...

Page 38: ...adjust Track alignment Shifted to right Shifted to left Left adjuster nut Turn out Turn in Right adjuster nut Turn in Turn out 5 Slide runner 6 Track 7 Track metal a Gap C Forward c Adjust track defl...

Page 39: ...e machine apply the parking brake start the engine and let it idle 5 Turn the headlight to high beam and check the headlight projection height on the wall The projection should be at the parallel mark...

Page 40: ...ification Adjust Brake pad clearance 1 5 X 2 0 mm 0 059 X 0 079 in 2 Adjust SBrake pad clearance Adjustment steps SLoosen the locknut 1 STurn the adjuster 2 in or out to until the speci fied clearance...

Page 41: ...42 0 in 2 Adjust SSki toe out Adjustment steps SLoosen the locknuts tie rod 1 STurn the tie rods 2 in or out until the specified toe out is obtained STighten the locknuts tie rod 1 Locknut rod end 25...

Page 42: ...and right spring pre loads are the same 1 Loosen the lock nut 1 2 Adjust the spring preload by turning the spring seat 2 Check the rear suspension spring preload and adjust if needed RX10K RX10RK RX1...

Page 43: ...e rear suspension stopper band are adjusted evenly RX10MK RX10MSK This adjustment affects the handling character istics of the machine Adjuster Thread Length RX10K RX10RK RX10RSK z RX10MK RX10MSK z Lo...

Page 44: ...the rear suspension stopper band are adjusted evenly This adjustment affects the handling character istics of the machine Adjuster Thread Length 15 0 5 mm 0 59 0 02 in Maximum 35 mm 1 37 in Minimum 10...

Page 45: ...urized nitrogen gas Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock absorber assem bly to flames or high heat which could cause it to explode Turn the adjust...

Page 46: ...uld cause it to explode Front shock absorber 1 Loosen the locknut 1 2 Adjust the spring preload by turning the spring seat 2 Check the rear suspension spring preload and adjust if needed Spring seat d...

Page 47: ...sorber Turn the adjusting ring 1 to the proper position Spring adjuster position 1 2 3 4 5 Preload Softer z Harder Front Standard 3 Rear shock absorber Turn the adjusting hook 2 to the proper posi tio...

Page 48: ...DAMPING FORCE RX10K RX10RK RX10RSK Never go beyond the maximum or minimum adjustment positions Turn the adjusting handle 1 in direction a or b Maximum 11 clicks Adjustment dial turning direction S H D...

Page 49: ...clicks 1 click out out out Minim m Standard Maxim m force adjuster position Minimum Standard Maximum Turns out z Turns in Damping force Softer z Harder With the adjuster fully turned lightly in direct...

Page 50: ...Be sure the left and right positions are aligned Rotating the track will help to move the shock absorber assembly 3 Tighten the nut 1 Nut 49 Nm 4 9 mSkg 35 ftSlb Never allow the adjusting bolt to mov...

Page 51: ...he scale on the special wrench 2 included in the owner s tool kit 3 Turn the adjusting rod 3 in direction a or b to adjust the control rod stroke Adjusting position MIN STD MAX Effect Decrease pitchin...

Page 52: ...Decrease weight transfer pitching Standard 3 3 Tighten the locknut Locknut 25 Nm 2 5 mSkgf 18 1 ftSlb D When using the two 22 mm spanners in cluded in the tool kit make sure that they are situated at...

Page 53: ...n the lock nut 1 2 Turn the adjusting nut 2 in or out to adjust the control rod stroke Adjusting position 1 2 3 Effect Increase weight transfer Decrease pitching Standard 2 Never adjust the control ro...

Page 54: ...d may result in vapor lock If the brake fluid level goes down consult a Yamaha dealer Brake fluid may deteriorate painted sur faces or plastic parts Never spill any fluid If any is spilled clean it up...

Page 55: ...the caliper bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake lever several time f Pull the lever in Hold the lever in position g Loosen the bleed screw and al...

Page 56: ...electrolyte other than spe cified The specific gravity of the MF battery elec trolyte is 1 320 68 _F 20 _C the specific gravity of the general type battery electro lyte is 1 280 If the electrolyte wh...

Page 57: ...ined from the container g Leave the container in this position for 20 minutes or longer to allow proper chemical reaction SMake sure air bubbles are rising from all six fill er ports SIf air bubbles a...

Page 58: ...s produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near bat teries KEEP OUT OF REACH OF CHILDREN 2 Check...

Page 59: ...mounted on the snowmobile disconnect the negative lead from the battery terminal STo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the...

Page 60: ...f the current does not exceed the standard charging current after 5 minutes replace the battery If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5...

Page 61: ...This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 1...

Page 62: ...4 1...

Page 63: ...RADE OF LUBRICANT Front and rear suspension 1 Use a grease gun to inject grease into the nipples 1 2 Apply grease 2 Recommended lubricant Esso Beacon 325 Grease or Aeroshell Grease 7A A Front B Rear R...

Page 64: ...6 1 CABLE ROUTING for RX10K RX10MK RX10MSK...

Page 65: ...s Clamp the vacuum hose 2 Clamp the ignition coil lead Connectors To the heat exchanger Main switch Set the coupler in the rear space of the instrument panel Tail brake light lead coupler Throttle cab...

Page 66: ...6 3...

Page 67: ...le position sensor lead coupler under the vacuum hose Drive guard bracket Connect the battery negative lead to the starter motor mount ing bolt Clamp the throttle position switch lead and carburetor s...

Page 68: ...6 5...

Page 69: ...ght wire harness Align it with the positioning tape of the headlight wire harness Meter coupler Securely fit in the rubber cover Put the boots of the meter cou pler in the boss root on the side of the...

Page 70: ...6 7...

Page 71: ...ch Speed sensor lead coupler Fuel sender lead cover Route the fuel tank breather hose along the frame cross member Clamp the speed sensor lead only Clamp the fuel tank breather hose Clamp the compress...

Page 72: ...6 9...

Page 73: ...rness Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side Right handlebar switch Push into the end of clamp be tween frame cross member and fuel tank Less than 50 mm 2 0 i...

Page 74: ...6 11...

Page 75: ...and frame together Bracket Connect the gear position switch lead For model with the reverse Fold back the gear position switch lead and clamp it For model without reverse Wire harness Fuse box Coolan...

Page 76: ...6 13...

Page 77: ...ank Point the pawl of clip to the up ward Clamp the fuel tank breather hose and speed sensor lead Tighten the frame cross mem ber and frame Wire harness clamp Rivets Speed sensor Nylon nuts Point the...

Page 78: ...6 15...

Page 79: ...arter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat CDI unit bracket Latch Battery band Battery cover To the carburetor 0 X...

Page 80: ...6 17 CABLE ROUTING for RX10RK RX10RSK RXW10K RXW10SK...

Page 81: ...leads Clamp the vacuum hose 2 Clamp the ignition coil lead Connectors To the heat exchanger Main switch Set the coupler in the rear space of the instrument panel Tail brake light lead coupler Throttl...

Page 82: ...6 19...

Page 83: ...under the vacuum hose Drive guard bracket Connect the battery negative lead to the starter motor mount ing bolt Clamp the throttle position switch lead and carburetor switch lead Voltage regulator Car...

Page 84: ...6 21...

Page 85: ...ght wire harness Align it with the positioning tape of the headlight wire harness Meter coupler Securely fit in the rubber cover Put the boots of the meter cou pler in the boss root on the side of the...

Page 86: ...6 23...

Page 87: ...tch Speed sensor lead coupler Fuel sender lead cover Route the fuel tank breather hose along the frame cross member Clamp the speed sensor lead only Clamp the fuel tank breather hose Clamp the compres...

Page 88: ...6 25...

Page 89: ...rness Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side Right handlebar switch Push into the end of clamp be tween frame cross member and fuel tank Less than 50 mm 2 0 i...

Page 90: ...6 27...

Page 91: ...and frame together Bracket Connect the gear position switch lead For model with the reverse Fold back the gear position switch lead and clamp it For model without reverse Wire harness Fuse box Coolan...

Page 92: ...6 29...

Page 93: ...ank Point the pawl of clip to the up ward Clamp the fuel tank breather hose and speed sensor lead Tighten the frame cross mem ber and frame Wire harness clamp Rivets Speed sensor Nylon nuts Point the...

Page 94: ...6 31...

Page 95: ...arter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat CDI unit bracket Latch Battery band Battery cover To the carburetor 0 X...

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Page 98: ...PRINTED ON RECYCLED PAPER PRINTED IN U S A 2004 06 ITP E...

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Yamaha RX10K, Assembly Manual

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