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Yamaha SR10ALLG, Owner'S Manual

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19

Lubrication

Chain Case

Checking Lubricant Level

NOTE: The snowmobile must be

on a level surface for this proce-
dure.

1. Check the lubricant level in the

chain case by using the sight glass.

0746-115

NOTE: The correct level is when

the lubricant is at least halfway up
in the sight glass.

NOTE: Adding lubricant can be

done by the snowmobile owner if
qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized
Yamaha Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner

.

2. If the lubricant level is low, remove

the three screws securing the shift

actuator to the chain case, discon-

nect the actuator wiring harness, and

remove the actuator w/extension,

detent, and spring; then add appro-

priate amount of Synthetic Chain

Lube through the shift actuator

opening. When the lubricant is half-

way up the sight glass, install the

shift actuator w/extension, detent,

and spring and connect the actuator

wiring harness. Tighten screws to

0.4 kg-m (36 in.-lb).

0748-259

3. Start the engine and verify proper

reverse and forward operation by shift-

ing in and out of reverse three times.

NOTE: If excessive build-up of

moisture or discolored oil is
detected in the chain case, it may
be necessary to replace the lube.

Replacing Lubricant

NOTE: Replacing the lubricant

can be done by the snowmobile
owner if qualified to do so. If the
owner does not feel qualified, take
the snowmobile to an authorized
Yamaha Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner

.

NOTE: The side panels, hood,

and exhaust resonator must be
removed for this procedure.

1. Place a drain pan under the chain

case; then loosen the eleven screws

securing the chain case cover/oil tank

assembly to the chain case housing

starting with the bottom screws first.

NOTE: It is critical that the snow-

mobile is on a level surface to
ensure the lubricant drains prop-
erly and completely.

NOTE: Inspect the chain case

cover seal for nicks or damage.

Full Level

CAUTION

When installing the shift actuator,
rotate the actuator back and forth
to properly align it with the exten-
sion gear. Failure to do so could
cause component damage.

Wire Harness

Detent Block

Spring

Shift Actuator

Extension

Screw

(Qty 3)

U8JRS2E0.book  Page 19  Thursday, May 7, 2015  2:25 PM

Summary of Contents for SR10ALLG

Page 1: ...isesti ennen moottorikelkan käyttöä Läs den här instruktionsboken noga innan snöskotern används Leggere attentamente questo manuale prima di utilizzare questo veicolo Read this manual carefully before operating this vehicle Il convient de lire attentivement ce manuel avant la première utilisation du véhicule SR10AM53G SR1AMS53G SR1AML53G SR10AM62G SR1AML62G SR10ARLG SR10ALLG SR1ASD37G SR1ASD46G SR...

Page 2: ...DIC183 PRINTED IN U S A ESU12520 Original instructions Notice originale Istruzioni originali Bruksanvisning i original Alkuperäiset ohjeet Opprinnelige instruksjoner ...

Page 3: ...fully before operating this vehicle OWNER S MANUAL SR10ARLG SR10ALLG SR1ASD37G SR1ASD46G SR10AXLG SR1AMS41G SR10AM53G SR1AMS53G SR1AML53G SR10AM62G SR1AML62G 8KS F8199 S1 E0 U8KSS1E0 book Page 1 Thursday May 7 2015 5 00 PM ...

Page 4: ...forms to the essential health and safety requirements of Directive 2006 42 EC and to the other relevant Directive of EEC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted If applicable If applicable Title and or number and date of issue of standards and or specificatio...

Page 5: ...Starting and Stopping Engine 15 Braking 16 Emergency Stopping 17 Throttle Ignition Monitor Switch 17 Varying Altitude Operation 18 Lubrication 19 20 Chain Case 19 Rear Suspension 20 Maintenance 21 42 Periodic Maintenance Checklist 21 Fuel System 22 Checking Engine Oil Level 22 Changing Engine Oil Filter 22 Coolant Level 24 Spark Plugs 24 Checking Adjusting Valve Clearance 25 Battery 25 Fuses 27 Br...

Page 6: ...Handbook Failure to follow this warning could result in personal injury to yourself or others Personal Injury To avoid injury to yourself and others NEVER operate the snowmobile with out first reading and understanding this manual and the Snowmobile Safety Handbook then follow the instructions and heed the warnings given USE COMMON SENSE DON T DRINK and DRIVE STAY IN CONTROL at ALL TIMES TELL YOUR...

Page 7: ...elated maintenance operating instructions and off sea son storage instructions If major repair or service is ever required contact an autho rized Yamaha Snowmobile dealer for professional service At the time of publication all information and illustrations were technically correct Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual condit...

Page 8: ... parts service accessories or warranty If the complete engine must be replaced ask the dealer to notify Yamaha for cor rect registration information Control Locations Shown are the typical control locations for Yamaha snowmobiles Location of a specific control will vary according to model SR10 Models 0749 256 SR10 Long Track Models 0749 257 VIN Accessory Outlet Emergency Stop Switch Reverse Switch...

Page 9: ...then moved to a warm area Also if the snowmobile is to remain on a trailer after filling the gas tank the bed of the trailer must be maintained level to prevent gasoline from draining out through the gas tank vent hose The SR10SD46 features a 15 9 L 4 2 US gallon auxiliary gas tank A separate gas tank cap is located beneath the cowling just behind the operator seat The auxil iary tank is plumbed d...

Page 10: ...ph the exposed cord on the side of a new belt will be worn down This will allow the drive belt to gain its optimum flexibility and will extend drive belt life NOTE Before starting the snow mobile in extremely cold tempera tures the drive belt should be removed and warmed up to room temperature Once the drive belt is at room temperature install the drive belt Cold Drive Away Function There is a col...

Page 11: ...the mode selected F Fuel Level Display This display shows the approximate amount of gas remaining in the gas tank G RPM Speed Clock Altimeter Press the Upper Left Button to cycle the left screen between RPM and speed NOTE When RPM is displayed on the left screen the right screen will display speed clock or altimeter When speed is displayed on the left screen the right screen will display RPM clock...

Page 12: ...uit high P0112 Intake air temp sensor circuit low P0113 Intake air temp sensor circuit high P0115 Engine coolant temp sensor 1 circuit P0117 Engine coolant temp sensor 1 circuit low P0118 Engine coolant temp sensor 1 circuit high P0120 Throttle position sensor circuit P0122 Throttle position sensor circuit low P0123 Throttle position sensor circuit high P0130 O2 sensor circuit P0131 O2 sensor circ...

Page 13: ...of the silencer is to quiet the intake of fresh air Since the fuel intake system is calibrated with the air intake silencer in place the engine must never be run with the silencer removed Performance will not be improved if the air intake silencer is removed In con trast severe engine damage will occur WARNING Tighten the cap screws according to specifications to prevent unex pected movement of th...

Page 14: ...dead battery but rather to remove the battery service it and correctly charge it however in an emergency it may be necessary to jump start a snowmobile If so use the following procedure to care fully and safely complete this pro cedure NOTE To access the battery the seat must be removed 1 For the snowmobile to be jump started slide any terminal boots away 2 Inspect the battery for any signs of ele...

Page 15: ...ith the good battery Allow the vehicle to run for several minutes applying some charge to the dead battery 9 Start the snowmobile with the dead battery and allow it to run for several minutes before disconnecting the jumper cables 10 Remove the jumper cables in oppo site order of hook up 4 3 2 1 Be careful not to short cables against bare metal NOTE Have the battery and elec trical system checked ...

Page 16: ...e is at the discre tion and expense of the snowmobile owner NOTE When the snowmobile is operated in extremely cold weather 23 C 10 F or colder a small amount of leakage may be present Unless the leakage is excessive replacement is not nec essary NOTE The frequency of servic ing rebuildable shock absorbers will vary according to the types of conditions and terrain the snow mobile has been subjected...

Page 17: ... function to operate prop erly If the belt is too tight difficulty in engaging reverse will be experi enced 1 Always warm up the engine for 2 3 minutes prior to shifting into reverse 2 With the engine at idle under 2500 RPM and the snowmobile at a com plete stop press and release the reverse switch button NOTE The snowmobile must be at a complete stop and the engine running under 2500 RPM before t...

Page 18: ...ng procedure 1 Position the hood onto the snowmo bile and connect the hood harness connector making sure the harness does not become pinched 2 Secure the hood with torx head screws and tighten securely 3 Install the access panel onto the lower console then close the access panel and secure with the hairpin clip Install the intake panel Removable Seat To remove the seat remove the torx head screw f...

Page 19: ...748 419 Towing If the snowmobile is to be towed by another snowmobile do not tow using the loops in the skis The tow rope should be attached to the spindles U8JRS2E0 book Page 14 Thursday May 7 2015 2 25 PM ...

Page 20: ...proved DOT 4 brake fluid until the fluid is at the recommended level Install and secure the reservoir cover Do not allow moisture to con taminate the brake system 4 Test the throttle control lever by completely compressing and releas ing it several times The lever MUST return to the idle position quickly and completely 5 Move the emergency stop switch to the UP or RUN position WARNING Engine start...

Page 21: ...of brakes If this occurs the brake fluid requires a cool down period before the brakes will again function properly This cool down period will vary depending upon the ambient air tem perature and the temperature of the brake fluid If loss of brakes has occurred because of high fluid temper atures do not operate the snowmobile until the cool down period has expired and brake lever firmness has retu...

Page 22: ...gine stops abruptly when the throttle control lever is released and the activation of the monitor switch is suspected use the following proce dure 1 Rotate the ignition key to the OFF position 2 Remove ice and snow from the throttle system and wait 5 10 minu tes for the engine heat to thaw ice from the throttle system 3 Test the throttle control lever by compressing and releasing it several times ...

Page 23: ...obile owner NOTE The monitor switch is now bypassed All other ignition electri cal features ignition switch emer gency stop switch headlight taillight and brakelight will operate properly Varying Altitude Operation Operating a snowmobile at varying alti tudes requires changes in performance components These changes affect drive train components Have a Yamaha dealer perform altitude related service...

Page 24: ...rify proper reverse and forward operation by shift ing in and out of reverse three times NOTE If excessive build up of moisture or discolored oil is detected in the chain case it may be necessary to replace the lube Replacing Lubricant NOTE Replacing the lubricant can be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an authorized Yam...

Page 25: ...hed between the actuator and the case 4 Install and secure the exhaust reso nator 5 Start the engine and verify proper reverse and forward operation by shifting in and out of reverse three times Rear Suspension This procedure should be done every 40 operating hours NOTE Yamaha recommends that All Temp Grease be used for this procedure 1 Using Handlebar Stand or Steering Post Stand or a suitable su...

Page 26: ...or wear damage and tight connections Exhaust System Weekly 8 Check for damage leakage and obstructions Nuts Bolts Fasteners Weekly Check tightness Shock Absorbers Weekly 11 35 Check for fluid leakage and damage and air pres sure Fox Air Shocks Spark Plugs 4000 km 2500 Mi Seasonal 24 Check center electrode insulator color carbon and gap Valve Clearance 40000 km 25000 Mi 25 Check adjust Crankcase Br...

Page 27: ...nd expense of the snowmobile owner 0747 833 Checking Engine Oil Level NOTE The snowmobile must be on a level surface for this proce dure 1 Start the engine and let it idle and warm up until the fan on the radiator turns on or if the snowmobile was operated allow the engine to idle for approximately 30 seconds 2 Shut the engine off then allow the engine to cool Remove the oil level stick from the o...

Page 28: ...sition remove the drain plug from the oil tank 746 121A NOTE To aid in draining the oil from the tank position a funnel between the tank and the opening of the tunnel running board 9 After the oil has drained completely install the drain plug with a new O ring and tighten to 2 2 kg m 16 ft lb 10 Pour 2 8 L 3 US quarts of engine oil into the oil tank 11 Without starting the engine place the handleb...

Page 29: ...iate specifications sheet for correct spark plug gap 1 Disconnect the main harness from the ignition coils then remove the ignition coils from the cylinder head cover 2 Remove the three spark plugs NOTE Prior to installing the spark plugs check the gap between the electrode and ground strap The clearance should be 0 7 0 8 mm 0 028 0 031 in 3 Install new spark plugs Tighten to 1 3 kg m 9 4 ft lb 4 ...

Page 30: ...battery bracket solenoid to the seat base then move the bracket up and out of the way and remove the battery 0747 528 4 Thoroughly wash the battery with soap and water then using a wire brush clean the battery posts and cable ends removing all corrosive buildup Replace damaged cables or cable ends CAUTION It is critical that the checking adjusting valve clearance be done at the recommended interva...

Page 31: ...move the battery charger and allow the battery to sit for 1 2 hours 8 Connect the multimeter and test the battery voltage The meter should read no less than 12 5 DC Volts If the voltage is as specified the bat tery is ready for service NOTE If voltage in step 8 is below specifications charge the battery an additional 1 5 hours then retest The battery is ready for service 9 Place the battery into p...

Page 32: ...e to check has been deter mined perform the following steps 1 Locate the fuse block and remove the fuse block cover NOTE The fuse block is behind the coolant overflow bottle XM124A NOTE There are spare fuses beneath the fuse block cover 2 Remove the suspected fuse NOTE Fuse function descrip tions are next to the fuse contacts in the fuse block 3 Look through the clear side of the fuse to see if th...

Page 33: ...aha Snowmobile dealer for this service This service is at the dis cretion and expense of the snowmobile owner Checking Brake Lever Travel Before each use check the brake lever travel using the following procedure 1 Compress the brake lever fully NOTE Do not pump the brake lever as it will produce an inaccu rate reading 2 Measure the distance between the brake lever and the handlebar The distance m...

Page 34: ...les NOTE It may be necessary to refill the reservoir during the bleed ing process Never allow the brake fluid to go below the low brake fluid mark in the reservoir 5 When the brake fluid is free of all air and the brake lever feels firm when compressed fill the reservoir to the high brake fluid mark then install and secure the cover Remove the tube from the bleeder valve Checking Changing Brake Pa...

Page 35: ...per 8 Position the outer brake pad into the caliper then install the hair pin clip into the caliper assembly 9 Repeat steps 5 8 for the inner pad then secure the pad with the hairpin clip 10 Remove the reservoir cover and remove the remaining fluid then fill the reservoir with fresh fluid and install the cover 11 Pump the brake lever to ensure cor rect positioning of the brake pads and proper brak...

Page 36: ...etched maxi mum power will not be transmitted and the belt could also fail and therefore must be replaced Periodic checks at least once a month under normal usage of two drive belt specifications are essential 1 Measure the outside circumference of the drive belt The belt should be within 1118 1126 mm 44 0 44 3 in 2 Measure the outside width of the drive belt The belt should be at least 34 5 mm 1 ...

Page 37: ... lock 2 Open the left side access panel and remove the belt guard assembly 3 Rotate the driven clutch sliding sheave clockwise 1 then push towards the engine 2 so it will sep arate from the fixed sheave 4 Remove the drive belt by pulling it up and over the fixed sheave SNO 336 Installing Drive Belt NOTE Before installing the drive belt use a suitable cleaning sol vent to thoroughly clean the sheav...

Page 38: ...2 0 in 746 788A NOTE Measurement is from the bottom of the wear strip at the point of the shock pad on the slide rail NOTE Only tighten track until the track does not ratchet Too tight of a track will cause the rear suspen sion to not work properly Adjusting Track Tension NOTE To ensure proper track tension adjustment perform all adjustments on both sides of the snowmobile 1 Loosen the idler wheel...

Page 39: ... relationship of the rear idler wheels and the inner track drive lugs If the rear idler wheels are centered between the inner track drive lugs no adjustment is necessary 0745 809 5 If the idler wheels are not centered between the inner track drive lugs an adjustment is necessary Adjusting Track Alignment 1 On the side of the track which has the inner track drive lugs closer to the rear idler wheel...

Page 40: ...ng Additional ski pressure can be obtained by tightening the spring tension ski pressure can be decreased by relaxing spring tension NOTE Equal adjustments should be maintained on both sides of the snowmobile Front ski shock spring pre load adjust ment is accomplished by loosening the adjuster nut locking collar B from the adjuster nut A and using the Spring Adjuster Tool from the tool kit rotatin...

Page 41: ...rees The fol lowing settings are recommended but vary on rider preference or style NOTE Care should be taken to have equal pressure in the front ski shocks before operating the snow mobile To increase or decrease air pressure use the following procedure NOTE When adjusting air pres sure all weight must be removed from the suspension and the shock absorbers must be fully extended 1 Remove the air v...

Page 42: ...g the amount of ski pressure be sure to adjust both straps equally and do not over adjust the limiter straps to adversely affect steering and operator control of the snowmobile Some experimentation may be required until the proper adjustment for the opera tor s individual style is obtained NOTE If the limiter straps are adjusted it is highly recommended that at least a minimum of 3 2 mm 1 8 in pre...

Page 43: ...e bracket SNO 511 3 Connect the taillight harness connec tor then secure the taillight to the bracket with the two screws Removing Installing Headlight Bulb NOTE The bulb portion of head light is fragile HANDLE WITH CARE When replacing the headlight bulb the bulb assembly must first be removed from the housing Do not touch the glass portion of the bulb If the glass is touched it must be cleaned wi...

Page 44: ...and long extension until correct aim is obtained Shut the engine off then disengage the brake lever lock 0746 807 Ski Wear Bars The ski wear bar is a replaceable bar attached to the underside of the ski The purpose of the wear bar is to assist in turn ing the snowmobile to minimize ski wear and to maintain good steering control If the snowmobile is operated primarily in deep snow ski wear bar wear...

Page 45: ...ts the ski to see if it is within the wear limit of 13 mm 0 51 in A and 8 mm 0 31 in B Replace as necessary SNO 442A Installing Dual 1 Position the wear bar with the car bide A on the inside of ski and loosely secure using the existing spacer washer and nut then posi tion the wear bar without the carbide B on the outside of the ski and loosely secure using the existing spacer washer and nut SNO 44...

Page 46: ...move the ski Account for the rubber damper inserts and washers 3 To increase ski stance place ski stance spacer to the outside of the spindle and adjust the damper 4 To decrease ski stance place ski stance spacer to the inside of the spindle and adjust the damper 0748 290 0749 261 5 Apply an all temperature grease to the non threaded portion of the cap screw then slide the cap screw through the sk...

Page 47: ... then immediately drive into deep snow and allow the wear strips to cool Repeat the procedure warming up the wear strips then cooling them down two or three times NOTE The rail wear strips will wear rapidly if the snowmobile is operated on terrain on which the snow cover is minimal Loose snow is required to cool and lubri cate the wear strips and prevent accelerated wear NOTE Two Wheel Kit and Fou...

Page 48: ...m 0 06 in above the edge of the driven clutch sheaves to 0 5 mm 0 02 in below the edge SNO 337 3 Adjust the position by removing or adding a spacer on each adjusting bolt SNO 338 Spacer Part Numbers 90201 061H1 0 5 mm 0 02 in 90201 06037 1 0 mm 0 04 in 4 Close the access panel DRIVE CLUTCH AND DRIVEN CLUTCH Keeping the drive clutch and driven clutch clean should be the primary con sideration of th...

Page 49: ...e must extend beyond the front edge of the drive clutch 4 If offset adjustment needs to be made remove the driven clutch and add shims p n 8JP RA449 00 2 mm 8JP RA448 00 1 mm to increase the offset or remove shims to decrease the offset 5 Once the correct offset is reached install driven clutch and tighten cap screw to 6 4 kg m 46 ft lb NOTE When adjusting the driven clutch the clutch free play cl...

Page 50: ...the upper steering post bushing and shafts of the shock absorbers 10 Lubricate the rear suspension with all temperature grease 11 Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely Make sure all rivets hold ing the components together are tight Replace all loose rivets 12 Clean and polish the hood console and chassis DO NOT USE SOL VENTS THE PROP...

Page 51: ...connect the battery cables making sure to connect the positive cable first Test the electric start system 9 Inspect the entire brake system all controls headlight taillight brake light ski wear bars and headlight aim adjust or replace as necessary 10 Adjust the track to the proper tension and alignment Noise level and vibration level Noise level 77 311 EEC 92 dB A 4375 r min Uncertainty of measure...

Page 52: ...47 Snowmobile Safety Rules U8JRS2E0 book Page 47 Thursday May 7 2015 2 25 PM ...

Page 53: ...48 U8JRS2E0 book Page 48 Thursday May 7 2015 2 52 PM ...

Page 54: ...PRINTED IN U S A U8JRS2E0 book Page 1 Thursday May 7 2015 2 25 PM ...

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