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Yamaha Vector RS90RX 2008, Supplementary Service Manual

The Yamaha Vector RS90RX 2008 comes with a comprehensive user manual, but for additional information and maintenance tips, you can easily access the supplementary service manual. This manual is available for free download from manualshive.com, ensuring you have all the necessary resources to keep your Yamaha Vector RS90RX 2008 in optimal condition.

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RS90RX

RS90GTX

RS90GTAX

RS90LTX

RS90LTGTX

LIT-12618-02-70

SUPPLEMENTARY SERVICE MANUAL

8GM-28197-10

2008

Summary of Contents for Vector RS90RX 2008

Page 1: ...RS90RX RS90GTX RS90GTAX RS90LTX RS90LTGTX LIT 12618 02 70 SUPPLEMENTARY SERVICE MANUAL 8GM 28197 10 2008 ...

Page 2: ...e injury or death to the snowmo bile operator a bystander or a person inspect ing or repairing the snowmobile A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile A NOTE provides key information that can make procedures easier or clearer MANUAL FORMAT All of the procedures in this manual are orga nized in a sequential step by step format The information has ...

Page 3: ...ymbols to are used to iden tify the specifications which appear Filling fluid Lubricant Tightening Wear limit clearance Engine speed Special tool Ω V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and loca tion of lubrication point Apply locking agent LOCTITE Apply Yamabond No 5 Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease ...

Page 4: ...S GENERAL INFORMATION GEN INFO 1 PERIODIC INSPECTION AND ADJUSTMENT INSP ADJ 2 CHASSIS CHAS 3 POWER TRAIN POWR TR 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 CARBURETION CARB 7 ELECTRICAL ELEC 8 SPECIFICATIONS SPEC 9 ...

Page 5: ...ON 17 FRONT SUSPENSION 24 REAR SUSPENSION 26 CHAPTER 3 CHASSIS COWLINGS 30 STEERING 31 FRONT SUSPENSION 35 CHAPTER 4 POWER TRAIN DRIVE CHAIN HOUSING 37 SLIDE RAIL SUSPENSION 40 RS90RX RS90GTX RS90GTAX 40 RS90LTX RS90LTGTX 44 CHAPTER 5 ENGINE SEAT AND FUEL TANK 49 OIL TANK 50 CAMSHAFTS 51 CYLINDER HEAD COVER 51 AC MAGNETO ROTOR AND STARTER CLUTCH 52 CHAPTER 7 CARBURETION CARBURETORS AND FUEL PUMP 5...

Page 6: ...L SYSTEM Item Remarks Initial Every 1 month or 800 km 500 mi 40 hr Seasonally or 4 000 km 2 500 mi 200 hr Spark plugs Check condition Adjust gap and clean Replace if necessary Valve clearance Check and adjust valve clearance when engine is cold Every 40 000 km 25 000 mi Cylinder head oil tank breather system Check breather hose for cracks or damage Replace if necessary Fuel filter Check condition ...

Page 7: ... 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 Drive chain oil Check oil level Change Brake and parking brake Adjust free play and or replace pads if necessary Change brake fluid See NOTE following this chart Control cables Make sure that operation is smooth Lubri...

Page 8: ...tall Engine tachometer near the spark plug 3 Measure Engine idle speed Out of specification Adjust 4 Adjust Engine idle speed Adjustment steps Turn the throttle stop screw in or out until the specified engine idle speed is obtained Turning in Idle speed is increased Turning out Idle speed is decreased NOTE NOTE After adjusting the engine idle speed the throt tle cable free play should be adjusted ...

Page 9: ...out until the specified free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the locknut NOTE NOTE After adjusting the free play turn the handlebar to right and left and make sure that the engine idling does not run faster ENGINE OIL LEVEL INSPECTION 1 Inspect Engine oil level CAUTION Do not run the engine with too much or not enough oil in the oil tan...

Page 10: ...n and then remove it again to check the oil level The engine oil level should be between the maximum level mark and minimum level mark Below the minimum level mark Add the rec ommended engine oil to the proper level CAUTION When adding the engine oil be careful not to fill above the maximum level mark and minimum level mark on the oil level gauge CAUTION Do not allow foreign materials to enter the...

Page 11: ...use oils with a diesel specification of CD or oils of a higher quality than specified CYLINDER HEAD BREATHER HOSE INSPECTION 1 Inspect Cylinder head breather hose Cranks damage Replace Loosen connection Connect properly CAUTION Make sure that the cylinder head breather hose is routed correctly OIL TANK BREATHER HOSE INSPECTION 1 Inspect Oil tank breather hose Cranks damage Replace Loosen connectio...

Page 12: ...n to inject grease into the nipples and Both sides 2 Apply grease Apply grease Apply grease Both sides Apply grease Both sides Front Rear RS90RX RS90GTX RS90GTAX Rear RS90LTX RS90LTGTX Recommended lubricant Esso Beacon 325 Grease or Aeroshell Grease 7A Both sides LUBRICATION ...

Page 13: ... the 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 on the wall to 1 2 down from the mark If not adjust the headlight angle Distance Height Set range 6 Adjust Headlight beam vertically Vertical adjustment Higher Turn the adjusting screw counter clo...

Page 14: ...ways set the main switch to OFF when checking or replac ing a fuse 1 Inspect Continuity Inspection steps Connect the pocket tester to the fuse and check the continuity NOTE NOTE Set the pocket tester selector to Ω 1 If the pocket tester indicates replace the fuse Pocket tester 90890 03112 YU 03112 C FUSE INSPECTION ...

Page 15: ... with an amperage other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the lighting ignition grip warmer signal and meter systems to mal function and could possibly cause a fire Item Amperage Q ty Main fuse 30 A 1 Headlight fuse 20 A 1 Signal fuse 10 A 1 Ignition fuse 20 A 1 Carburetor heater fuse 20 A 1 DC t...

Page 16: ...ould be taken in car buretor setting so that the pistons will not be damaged or will not seize CAUTION Before performing the carburetor tuning make sure that the following items are set to specification Engine idle speed Throttle cable free play Carburetor synchronization Carburetor tuning data Standard specifications Type CVK40 Manufacturer KEIHIN I D Mark 8GM1 00 Main jet M J 148 Pilot jet P J 4...

Page 17: ...rk plug insulator color A medium to light tan color indicates nor mal conditions Distinctly different color Replace the main jet 4 The main jet should be adjusted on the basis of the Main jet selection chart NOTE NOTE By checking the condition of the spark plugs it is easy to get some idea of the condition of the engine This may diagnose potential problems before engine damage occurs High altitude...

Page 18: ...INSP ADJ 13 Guide for carburetion CARBURETOR TUNING ...

Page 19: ...filter and keep it free from obstructions Low speed tuning The carburetors are built so that low speed tuning can be done by adjusting the throttle stop screw CAUTION Never run the engine without the air filter case installed Severe engine damage may result 1 Set the engine idle speed by turning the throttle stop screw in to increase engine speed or out to decrease engine speed 2 If low speed perf...

Page 20: ...O Free length 87 4 mm 3 44 in 86 1 mm 3 39 in 84 2 mm 3 31 in Preload 343 N 35 kg 77 lb Spring rate 24 5 N mm 2 50 kg mm 140 lb in 27 0 N mm 2 75 kg mm 154 lb in 31 9 N mm 3 25 kg mm 182 lb in Wire diameter 5 8 mm 0 228 in 6 2 mm 0 244 in Outside diameter 59 5 mm 2 34 in Weight ID 8ES 17605 00 8ES00 Weight rivet OUT Steel 13 9 Steel 13 3 Steel 10 3 None IN Steel 13 9 Steel 13 3 Steel 10 3 Aluminum...

Page 21: ...in 91 2 mm 3 59 in 87 9 mm 3 46 in Preload 392 N 40 kg 88 lb Spring rate 19 6 N mm 2 00 kg mm 112 lb in 22 1 N mm 2 25 kg mm 126 lb in 27 0 N mm 2 75 kg mm 154 lb in Wire diameter 5 5 mm 0 217 in 5 8 mm 0 228 in 6 0 mm 0 236 in Outside diameter 59 5 mm 2 34 in Weight ID 8ES 17605 00 8ES00 Weight rivet OUT Steel 17 2 Steel 13 3 Steel 10 3 None IN Steel 13 9 Steel 13 3 Steel 10 3 Aluminum 10 3 None ...

Page 22: ...ive driven gear ratio should be increased If the surfaces are fairly smooth or better snow conditions exist decrease the ratio Gear ratio chart The drive and driven gears and the chains shown in the gear ratio chart are available as options The figures containing a decimal point represent the drive driven gear ratios while the bottom numbers designate the number of links in the chain GEAR SELECTIO...

Page 23: ...1 39 teeth 8FB 47580 90 RS90LTX RS90LTGTX 40 teeth 8DW 47587 01 40 teeth 8FB 47580 00 Chain 68 links 94890 09068 RS90RX RS90GTX RS90GTAX 70 links 94890 09070 RS90LTX RS90LTGTX Drive gear 18 teeth 19 teeth 20 teeth 21 teeth 22 teeth 23 teeth 24 teeth Driven gear 37 teeth 1 76 68 links 1 68 68 links 1 61 68 links 1 54 70 links 38 teeth 1 90 68 links 1 81 68 links 1 73 68 links 1 65 70 links 1 58 70 ...

Page 24: ...Silver 5 5 0 217 4 86 75 2 95 69 5 2 736 90508 60012 11876 1211 12 32 1 256 70 34 Pink 6 0 0 236 5 53 75 2 95 69 5 2 736 RS90RX RS90GTX RS90GTAX RS90LTX RS90LTGTX 90508 60007 12654 1290 13 45 1 372 76 84 White 6 0 0 236 5 19 75 2 95 69 5 2 736 Seat Sheave 0 3 6 9 1 10 40 70 100 2 20 50 80 110 3 30 60 90 120 Torque cam secondary spring seat Identification mark Effects Part no Cam angle Identificati...

Page 25: ...92 40 White Green White 5 8 0 228 59 5 2 34 5 25 91 2 3 59 90501 582L7 24 5 2 50 392 40 Yellow Green Yellow 5 8 0 228 59 5 2 34 4 92 89 4 3 52 90501 583L0 19 6 2 00 441 45 Blue White Blue 5 8 0 228 59 5 2 34 5 65 95 9 3 78 90501 583L1 22 1 2 25 441 45 White White White 5 8 0 228 59 5 2 34 5 25 93 4 3 68 90501 583L4 22 1 2 25 343 35 White Silver White 5 8 0 228 59 5 2 34 5 25 89 0 3 50 90501 583L5 ...

Page 26: ...d rivets Shape ID mark Standard 8BU 17605 20 45 41 1 603 8DJ 17605 00 37 77 1 333 8ES 17605 00 54 63 1 928 RS90RX RS90GTX RS90GTAX RS90LTX RS90LTGTX 8FA 17605 10 63 81 2 252 8FP 17605 00 67 81 2 392 8FS 17605 00 65 52 2 311 8FN 17605 00 75 28 2 655 GEAR SELECTION ...

Page 27: ...06 Steel 17 2 0 677 3 6 0 127 with hole 90261 06034 Steel 13 9 0 547 3 6 0 127 IN RS90RX RS90GTX RS90GTAX RS90LTX RS90LTGTX OUT RS90RX RS90GTX RS90GTAX 90261 06019 Steel 13 3 0 524 3 1 0 109 90266 06002 Steel 13 3 0 524 2 44 0 086 with hole 90261 06015 Steel 10 3 0 406 2 44 0 086 90261 06028 Aluminum 10 3 0 406 0 85 0 030 90266 06001 Aluminum 13 3 0 524 0 8 0 028 with hole GEAR SELECTION ...

Page 28: ...86 09001 Grooved Machined Increased force Decreased force 8FG 17624 10 15 0 0 59 VESPEL TP 8549 90386 09001 Grooved 8FG 17624 20 15 6 0 61 VESPEL TP 8549 90386 09001 No Mark RS90RX RS90GTX RS90GTAX RS90LTX RS90LTGTX 8FG 17624 30 16 0 0 63 VESPEL TP 8549 90386 09001 Grooved Grooved 8FG 17624 40 16 5 0 65 VESPEL TP 8549 90386 09001 Machined 1 46 mm 1 46 mm 1 46 mm 1 46 mm 1 46 mm GEAR SELECTION ...

Page 29: ...eload Harder Softer Length Minimum 220 mm 8 66 in 230 mm 9 06 in Maximum 231 mm 9 09 in Spring seat distance Standard Shorter Longer Preload Harder Softer Length Minimum 246 6 mm 9 71 in 256 6 mm 10 10 in Maximum 256 6 mm 10 10 in Spring seat distance Standard Shorter Longer Preload Harder Softer Length Minimum 246 5 mm 9 70 in 256 5 mm 10 10 in Maximum 256 5 mm 10 10 in Locknut 30 Nm 3 0 m kg 22 ...

Page 30: ...by turning the adjuster With the adjuster fully turned lightly in direc tion CAUTION Do not continue to turn the adjuster in direction after it stops The shock absorber can be damaged and rebound damping force adjustments cannot be made Do not turn the adjuster in direction more than 20 clicks Even if the adjuster is continually turned after 20 clicks there will be no change in the rebound damping...

Page 31: ... be made Do not turn the adjuster in direction more than 12 clicks Even if the adjuster is continually turned after 12 clicks there will be no change in the compression damping force Be sure to stop the adjuster at a position where there is a click REAR SUSPENSION Stopper band 1 Adjust Stopper band length NOTE NOTE This adjustment affects the handling character istics of the machine Adjuster posit...

Page 32: ...n can be adjusted to work better in one condition but only at the expense of another Keep this in mind when you adjust the suspension Standard setting No 2 holes Stopper band nut 4 Nm 0 4 m kg 2 9 ft lb No 5 hole shortest No 1 hole longest More weight on skis Heavy steering oversteer More maneuver ability Favors hardpack snow ice smooth trails tight turns Less weight on skis Light steering underst...

Page 33: ...e adjustment dial at a marked position around the dial where there is a click WARNING This shock absorber contains highly pres surized nitrogen gas It could explode by improper handling causing injury or prop erty 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...

Page 34: ... holding the adjuster securely tighten the locknut CAUTION When using the special wrench make sure that it is situated at a right angle to the con trol rod and that it is tightly fitted to the locknut or the control rod adjuster WARNING Never adjust the control rod beyond the range of the scale on the special wrench Adjusting position MIN STD MAX Effect Decrease Pitching Increase weight transfer S...

Page 35: ...he parts in the order listed 1 Shroud 1 2 Side cover left and right 2 3 Side under cover left and right 2 4 Top cover 1 5 Headlight assembly 1 6 Headlight stay 1 7 Air filter case 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 5 1 ft lb 3 Nm 0 3 m kg 2 2 ft lb COWLINGS ...

Page 36: ...lead coupler 2 Disconnect 4 Throttle switch lead coupler 2 Disconnect 5 Engine stop switch lead coupler 1 Disconnect 6 Thumb warmer switch lead coupler 1 Disconnect 7 Thumb warmer lead coupler 1 Disconnect 8 Brake switch lead coupler 1 Disconnect 9 Headlight beam switch lead coupler 1 Disconnect 10 Grip warmer switch lead coupler 1 Disconnect 11 Right handlebar switch cover 1 12 Throttle cable hol...

Page 37: ...er 1 18 Master cylinder assembly 1 NOTE NOTE After installing all parts refer to CABLE ROUTING to check the cable lead and hose routings 19 Handlebar holder 2 20 Cable holder 1 21 Handlebar 1 22 Handlebar joint 1 23 Handlebar lower cover 1 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb 23 Nm 2 3 m kg 17 ft lb STEERING ...

Page 38: ... 5 Shift lever assembly Refer to DRIVE CHAIN HOUSING in CHAPTER 4 1 Clip 6 2 Relay rod 1 3 Cotter pin 7 4 Steering shaft 1 5 Steering column cover 1 6 Lock washer 3 7 Bearing 6 8 Bearing holder 6 9 Plate 3 10 Collar 6 11 Steering column 1 1 35 Nm 3 5 m kg 25 ft lb 67 Nm 6 7 m kg 49 ft lb 25 Nm 2 5 m kg 18 ft lb 30 Nm 3 0 m kg 22 ft lb 23 Nm 2 3 m kg 17 ft lb ESSO beacon 325 grease or Aeroshell gre...

Page 39: ...fter removing the engine 14 Idler arm 1 15 Clip 2 16 Washer 4 17 Washer 2 18 Relay arm 2 19 Bushing 4 20 Collar 2 For installation reverse the removal procedure 35 Nm 3 5 m kg 25 ft lb 67 Nm 6 7 m kg 49 ft lb 25 Nm 2 5 m kg 18 ft lb 30 Nm 3 0 m kg 22 ft lb 23 Nm 2 3 m kg 17 ft lb ESSO beacon 325 grease or Aeroshell grease 7A STEERING ...

Page 40: ... 6 Tie rod 1 Disconnect 7 Steering arm 1 8 Ski column 1 9 Bushing 2 10 Upper arm 1 11 Lower arm 1 12 Bushing 4 13 Connecting rod 1 14 Stabilizer arm 1 11 Nm 1 1 m kg 8 0 ft lb 34 Nm 3 4 m kg 24 ft lb 35 Nm 3 5 m kg 25 ft lb 37 Nm 3 7 m kg 27 ft lb 40 Nm 4 0 m kg 29 ft lb 45 Nm 4 5 m kg 32 ft lb 65 Nm 6 5 m kg 47 ft lb RS90GTAX RS90GTX RS90GTAX RS90LTGTX ESSO beacon 325 grease or Aeroshell grease 7...

Page 41: ...r installation reverse the removal procedure 11 Nm 1 1 m kg 8 0 ft lb 34 Nm 3 4 m kg 24 ft lb 35 Nm 3 5 m kg 25 ft lb 37 Nm 3 7 m kg 27 ft lb 40 Nm 4 0 m kg 29 ft lb 45 Nm 4 5 m kg 32 ft lb 65 Nm 6 5 m kg 47 ft lb RS90GTAX RS90GTX RS90GTAX RS90LTGTX ESSO beacon 325 grease or Aeroshell grease 7A FRONT SUSPENSION ...

Page 42: ... Brake disc 1 5 Straight key 1 6 Spacer 1 7 Drain bolt 1 Drain 8 Chain tension adjusting bolt 1 Loosen 9 Gear position switch connector 2 Disconnect 10 Shift lever assembly 1 Disconnect the gear position switch leads 11 Lever rod 1 12 Shift rod 1 13 Lever 1 6 Nm 0 6 m kg 4 3 ft lb 10 Nm 1 0 m kg 7 2 ft lb 16 Nm 1 6 m kg 11 ft lb 23 Nm 2 3 m kg 17 ft lb 24 Nm 2 4 m kg 17 ft lb 25 Nm 2 5 m kg 18 ft ...

Page 43: ...5 22 Spacer 1 23 Spacer 1 24 Spring 1 25 Reverse driven gear 1 26 Journal 1 27 Washer 1 28 Forward driven sprocket 1 29 Spacer 1 30 Reverse drive gear 1 6 Nm 0 6 m kg 4 3 ft lb 10 Nm 1 0 m kg 7 2 ft lb 16 Nm 1 6 m kg 11 ft lb 23 Nm 2 3 m kg 17 ft lb 24 Nm 2 4 m kg 17 ft lb 25 Nm 2 5 m kg 18 ft lb 43 Nm 4 3 m kg 31 ft lb 55 Nm 5 5 m kg 40 ft lb 90 Nm 9 0 m kg 65 ft lb DRIVE CHAIN HOUSING ...

Page 44: ... 36 Shaft 1 37 Drive chain housing 1 For installation reverse the removal pro cedure 6 Nm 0 6 m kg 4 3 ft lb 10 Nm 1 0 m kg 7 2 ft lb 16 Nm 1 6 m kg 11 ft lb 23 Nm 2 3 m kg 17 ft lb 24 Nm 2 4 m kg 17 ft lb 25 Nm 2 5 m kg 18 ft lb 43 Nm 4 3 m kg 31 ft lb 55 Nm 5 5 m kg 40 ft lb 90 Nm 9 0 m kg 65 ft lb DRIVE CHAIN HOUSING ...

Page 45: ...parts in the order listed below Rear axle nut Loosen Tension adjuster Loosen 1 Shock absorber adjuster assembly 1 2 Slide rail suspension 1 3 Collar 2 For installation reverse the removal procedure 60 Nm 6 0 m kg 43 ft lb 10 Nm 1 0 m kg 7 2 ft lb 84 Nm 8 4 m kg 61 ft lb ESSO beacon 325 grease or Aeroshell grease 7A SLIDE RAIL SUSPENSION ...

Page 46: ...pension wheel 4 Suspension wheel bracket 4 Shaft 1 Front pivot arm bracket 2 Bushing 4 Collar 2 Bushing 4 Collar 2 Guide 1 Slide runner 2 Shaft 1 Collar 2 10 Nm 1 0 m kg 7 2 ft lb 4 Nm 0 4 m kg 2 9 ft lb 30 Nm 3 0 m kg 22 ft lb 60 Nm 6 0 m kg 43 ft lb 49 Nm 4 9 m kg 35 ft lb 72 Nm 7 2 m kg 52 ft lb 74 Nm 7 4 m kg 55 ft lb ESSO beacon 325 grease or Aeroshell grease 7A SLIDE RAIL SUSPENSION ...

Page 47: ... assembly 1 Spacer 2 Collar 1 Oil seal 4 Bearing 2 Rear pivot arm 1 Rear pivot arm bracket 1 Guide wheel 2 Washer 4 Bushing 2 Shaft 1 Shaft 1 Shaft 1 Suspension wheel 2 Suspension wheel bracket 2 60 Nm 6 0 m kg 43 ft lb 49 Nm 4 9 m kg 35 ft lb 72 Nm 7 2 m kg 52 ft lb 74 Nm 7 4 m kg 55 ft lb SLIDE RAIL SUSPENSION ...

Page 48: ...e Part name Q ty Remarks Rear axle shaft 1 Guide wheel 2 Guide wheel 1 Collar 2 Tension adjuster 2 Collar 1 Collar 1 Sliding frame 2 For assembly reverse the disassembly procedure 75 Nm 7 5 m kg 54 ft lb SLIDE RAIL SUSPENSION ...

Page 49: ...elow Rear axle nut Loosen Tension adjuster Loosen 1 Collar 2 2 Shaft 1 3 Guide wheel 2 4 Shock absorber adjuster assembly 1 5 Slide rail suspension 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb 60 Nm 6 0 m kg 43 ft lb 84 Nm 8 4 m kg 61 ft lb ESSO beacon 325 grease or Aeroshell grease 7A SLIDE RAIL SUSPENSION ...

Page 50: ...pension wheel 4 Suspension wheel bracket 4 Shaft 1 Front pivot arm bracket 2 Bushing 4 Collar 2 Bushing 4 Collar 2 Guide 1 Slide runner 2 Shaft 1 Collar 2 10 Nm 1 0 m kg 7 2 ft lb 4 Nm 0 4 m kg 2 9 ft lb 30 Nm 3 0 m kg 22 ft lb 60 Nm 6 0 m kg 43 ft lb 49 Nm 4 9 m kg 35 ft lb 72 Nm 7 2 m kg 52 ft lb 74 Nm 7 4 m kg 55 ft lb ESSO beacon 325 grease or Aeroshell grease 7A SLIDE RAIL SUSPENSION ...

Page 51: ...1 Oil seal 4 Bearing 2 Rear pivot arm 1 Shaft 1 Bushing 2 Shaft 1 Slider 2 Rear pivot arm bracket 1 Shaft 1 Suspension wheel 2 Suspension wheel bracket 2 49 Nm 4 9 m kg 35 ft lb 10 Nm 1 0 m kg 7 2 ft lb 60 Nm 6 0 m kg 43 ft lb 72 Nm 7 2 m kg 52 ft lb 74 Nm 7 4 m kg 55 ft lb ESSO beacon 325 grease or Aeroshell grease 7A SLIDE RAIL SUSPENSION ...

Page 52: ...e Part name Q ty Remarks Rear axle shaft 1 Guide wheel 2 Guide wheel 1 Collar 2 Tension adjuster 2 Collar 1 Collar 1 Sliding frame 2 For assembly reverse the disassembly procedure 75 Nm 7 5 m kg 54 ft lb SLIDE RAIL SUSPENSION ...

Page 53: ... 10 92 150 5 5 93 364 5 365 5 14 350 14 390 RS90RX RS90GTX RS90GTAX 359 5 360 5 14 153 14 193 RS90LTX RS90LTGTX Control rod 2 parts number Washer plate parts number Washer plate thickness mm in Standard 8FU 4745B 00 8FU 47384 10 5 0 0 197 8FU 47384 20 10 0 0 394 8GM 47384 00 7 5 0 295 RS90RX RS90GTX RS90GTAX RS90LTX RS90LTGTX SLIDE RAIL SUSPENSION ...

Page 54: ...tor 2 3 Tail brake light cover 1 4 Tail brake light sub wire harness 1 Disconnect 5 Seat 1 6 Muffler side cover 2 7 Side cover 2 8 Fuel tank cover 1 9 Damper 1 10 Fuel sender coupler 1 Disconnect 11 Fuel hose 2 Disconnect 12 Fuel tank breather hose 1 Disconnect 13 Fuel tank 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 5 1 ft lb 5 Nm 0 5 m kg 3 6 ft lb 10 Nm 1 0 m kg 7 2 ft lb SEA...

Page 55: ... 3 Engine oil Drain Refer to ENGINE OIL REPLACEMENT in CHAPTER 2 1 Oil level switch coupler 1 Disconnect 2 Oil tank inlet hose 1 Disconnect 3 Oil tank breather hose 1 Disconnect 4 Oil tank outlet hose 1 Disconnect 5 Oil tank 1 6 Oil level gauge dipstick 1 For installation reverse the removal procedure 11 Nm 1 1 m kg 8 0 ft lb 10 Nm 1 0 m kg 7 2 ft lb OIL TANK ...

Page 56: ...t hose 4 carburetor heating hose Refer to HEAT EXCHANGER in CHAPTER 6 1 Cylinder head breather hose 1 2 Cylinder head water pipe 1 3 Ignition coil 3 4 Spark plug 3 5 Cylinder head cover 1 6 Cylinder head cover gasket 1 7 Timing chain guide top side 1 For installation reverse the removal procedure 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 13 Nm 1 3 m kg 9 4 ft lb CAMSHAFTS ...

Page 57: ...sket 1 3 Dowel pin 2 4 Pickup coil 1 5 Stator coil 1 6 AC magneto rotor 1 7 Idle gear shaft 1 8 Starter clutch idle gear 1 9 Starter clutch 1 10 Woodruff key 1 11 Starter clutch gear 1 12 Washer 1 For installation reverse the removal procedure i LT E E LT LT LT LT 8 9 12 10 6 7 2 3 1 4 5 New 11 3 E 10 Nm 1 0 m kg 7 2 ft lb 6 Nm 0 6 m kg 4 3 ft lb 130 Nm 13 0 m kg 94 ft lb 12 Nm 1 2 m kg 8 7 ft lb ...

Page 58: ...STEM in CHAPTER 2 1 Air filter case joint clamp screw 3 Loosen 2 Oil tank breather hose 1 Disconnect 3 Cylinder head breather hose 1 Disconnect 4 Air filter case 1 5 Air filter case breather hose 1 6 Throttle position sensor coupler 1 Disconnect 7 Carburetor heater coupler 1 Disconnect 8 Starter cable 1 Loosen the screw 9 Throttle cable 1 10 Fuel delivery hose 2 Disconnect 10 Nm 1 0 m kg 7 2 ft lb...

Page 59: ...Disconnect 12 Carburetor heating outlet hose 1 Disconnect 13 Vacuum hose 2 Disconnect 14 Carburetor assembly 1 15 Carburetor joint 3 16 Fuel hose 2 Disconnect 17 Fuel pump 2 18 Collar 4 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb CARBURETORS AND FUEL PUMP ...

Page 60: ...e type Liquid cooled 4 stroke 12 valves Cylinder type Backward inclined parallel 3 cylinder Displacement 973 0 cm3 59 38 cu in Bore stroke 79 0 66 2 mm 3 11 2 61 in Compression ratio 11 30 1 Maximum horse power r min 84 7 kW 115 2 PS 8 500 r min Maximum torque r min 101 6 Nm 10 4 m kg 7 000 r min Vacuum pressure at engine idling speed 24 0 kPa 0 24 kg cm2 3 41 psi Standard compression pressure at ...

Page 61: ...8 1 0 1 Clutch type Automatic centrifugal engagement Secondary reduction system Chain Secondary reduction ratio 1 73 38 22 RS90RX RS90GTX RS90GTAX 1 77 39 22 RS90LTX RS90LTGTX Reverse system Yes Chassis Frame type Monocoque Caster angle 23 Ski stance center to center 1 086 mm 42 8 in Suspension Front suspension type Independent double wishbone Rear suspension type Slide rail Track Track type Inter...

Page 62: ...ed coil ignition Generator system AC magneto Bulb wattage Quantity Headlight 12 V 60 W 55 W 2 Tail Brake light 12 V 5 W 21 W 2 Meter light 14 V 50 mA 6 High beam indicator light 14 V 80 mA 1 Information indicator light 14 V 80 mA 1 Low coolant temperature light 14 V 80 mA 1 GENERAL SPECIFICATIONS ...

Page 63: ... drive right Camshaft cap inside diameter 24 500 24 521 mm 0 9646 0 9654 in Camshaft journal diameter 24 459 24 472 mm 0 9630 0 9635 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Camshaft dimensions Intake A 33 75 33 85 mm 1 3287 1 3327 in Limit 33 65 mm 1 3248 in B 24 95 25 05 mm 0 9823 0 9862 in Limit 24 85 mm 0 9783 in Exhaust A 33 75 33 85 mm 1 3287 1 3327 in Li...

Page 64: ...ickness D Intake 0 8 1 2 mm 0 0315 0 0472 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake 4 975 4 990 mm 0 1959 0 1965 in Limit 4 945 mm 0 1947 in Exhaust 4 965 4 980 mm 0 1955 0 1961 in Limit 4 935 mm 0 1943 in Valve guide inside diameter Intake 5 000 5 012 mm 0 1969 0 1973 in Limit 5 050 mm 0 1988 in Exhaust 5 000 5 012 mm 0 1969 0 1973 in Limit 5 050 mm 0 1988 in Valve stem to...

Page 65: ...24 488 mm 0 9639 0 9641 in Limit 24 457 mm 0 9629 in Valve lifter hole inside diameter Intake 24 500 24 518 mm 0 9646 0 9653 in Limit 24 548 mm 0 9665 in Exhaust 24 500 24 518 mm 0 9646 0 9653 in Limit 24 548 mm 0 9665 in Piston Piston size D 78 935 78 950 mm 3 1077 3 1083 in Measuring point H 5 0 mm 0 20 in Piston to cylinder clearance 0 050 0 075 mm 0 0020 0 0030 in Limit 0 12 mm 0 0047 in Pisto...

Page 66: ...rkerizing Connecting rod Small end diameter 19 005 19 018 mm 0 7482 0 7487 in Big end diameter 41 000 41 018 mm 1 6142 1 6149 in Crankshaft pin to big end bearing clearance 0 033 0 050 mm 0 0013 0 0020 in Bearing color code 0 White White 1 Blue Blue 2 Black Black 3 Brown Brown 4 Green Green 5 Yellow Yellow Crank pin Crank pin outside diameter 37 976 38 000 mm 1 4951 1 4961 in Crankshaft Measuring ...

Page 67: ... Fuel level below the line on the float chamber 0 2 2 2 mm 0 008 0 087 in Throttle cable free play 2 0 3 0 mm 0 08 0 12 in Engine idle speed 1 300 1 500 r min Fuel pump Type Diaphragm Manufacturer 8GM MIKUNI Oil filter Oil filter type Cartridge paper Bypass valve opening pressure 78 118 kPa 0 78 1 18 kg cm2 11 1 16 8 psi Oil pump Oil pump type Trochoidal Inner rotor to outer rotor tip clearance 0 ...

Page 68: ...ller type Reduction ratio 22 28 0 786 Thermostat Opening temperature 69 0 73 0 C 156 2 163 4 F Valve lift 7 0 mm 0 28 in 85 C 185 F Coolant type High quality ethylene glycol antifreeze containing corro sion inhibitors Coolant mixing ratio coolant water 3 2 60 40 Capacity 4 8 L 4 22 Imp qt 5 07 US qt RS90RX RS90GTX RS90GTAX 5 6 L 4 93 Imp qt 5 92 US qt RS90LTX RS90LTGTX MAINTENANCE SPECIFICATIONS ...

Page 69: ... B 32 5 mm 1 28 in Primary sheave spring Part number 90501 582L1 RS90RX RS90GTX RS90GTAX 90501 552L5 RS90LTX RS90LTGTX Color code Yellow Silver Yellow RS90RX RS90GTX RS90GTAX Blue Green Blue RS90LTX RS90LTGTX Diameter 59 5 mm 2 34 in Wire diameter 5 8 mm 0 228 in RS90RX RS90GTX RS90GTAX 5 5 mm 0 217 in RS90LTX RS90LTGTX Preload 343 N 35 kg 77 lb RS90RX RS90GTX RS90GTAX 392 N 40 kg 88 lb RS90LTX RS...

Page 70: ...90RX RS90GTX RS90GTAX 90261 06033 RS90LTX RS90LTGTX Material Steel Size 13 9 mm 0 547 in RS90RX RS90GTX RS90GTAX 17 2 mm 0 677 in RS90LTX RS90LTGTX Quantity 3 Hole quantity 3 Inner Part number 90261 06034 Material Steel Size 13 9 mm 0 547 in Quantity 3 Hole quantity 3 MAINTENANCE SPECIFICATIONS ...

Page 71: ...X RS90LTGTX Number of links 68 L RS90RX RS90GTX RS90GTAX 70 L RS90LTX RS90LTGTX Secondary reduction ratio 1 73 38 22 RS90RX RS90GTX RS90GTAX 1 77 39 22 RS90LTX RS90LTGTX Maximum 14 link drive chain section length 133 35 mm 5 25 in Limit 137 35 mm 5 41 in Track Part number 8FA 47110 00 RS90RX RS90GTX RS90GTAX 8FG 47110 00 RS90LTX RS90LTGTX Width 381 0 mm 15 0 in Length 3 072 0 mm 120 9 in RS90RX RS...

Page 72: ...383 4 kg 0 3 m s 425 0 845 4 lb 0 3 m s RS90LTX RS90LTGTX Compression 1 370 N 0 3 m s 139 7 kg 0 3 m s 308 0 lb 0 3 m s RS90RX RS90GTX RS90GTAX 1 720 N 0 3 m s 175 4 kg 0 3 m s 386 7 lb 0 3 m s RS90LTX RS90LTGTX Slide runner Thickness 18 3 mm 0 72 in Wear limit 10 5 mm 0 41 in Track sprocket wheel Material Ultra high molecular weight polyethylene Number of teeth 9 T Rear guide wheel Material High ...

Page 73: ...i suspension Front suspension Type Independent double wishbone Travel 219 0 mm 8 62 in Spring type Coil spring Spring rate 29 4 N mm 3 0 kg mm 167 9 lb in RS90RX RS90LTX RS90LTGTX 26 5 N mm 2 7 kg mm 151 4 lb in RS90GTX RS90GTAX Wire diameter 8 8 mm 0 346 in RS90RX RS90GTX RS90GTAX RS90LTX 9 0 mm 0 354 in RS90LTGTX Shock absorber damping force Extension 1 050 N 0 3 m s 107 1 kg 0 3 m s 236 1 lb 0 ...

Page 74: ... 68 F White White Ignitor unit model Manufacturer J4T16172 MITSUBISHI Rectifier regulator Type Short circuit type Model Manufacturer FH001 SHINDENGEN No load regulated voltage DC 14 1 14 9 V Capacity DC 35 A Withstand voltage 40 V Battery Specific gravity 1 32 Manufacture YUASA Type YTX20L BS Battery capacity 12 V 18 Ah Ten hour rate amperage 1 8 A Electric starter system Type Constant mesh type S...

Page 75: ...Coil resistance 94 5 115 5 Ω at 20 C 68 F Grip warmer Heater resistance left 6 12 7 48 Ω at 20 C 68 F right 6 12 7 48 Ω at 20 C 68 F Thumb warmer Heater resistance 37 0 45 2 Ω at 20 C 68 F Coolant temperature sensor Model Manufacturer 8CC MITSUBISHI Resistance 5 21 6 37 kΩ at 0 C 32 F 0 300 0 364 kΩ at 80 C 176 F 0 170 0 208 kΩ at 100 C 212 F Indicator light ON 90 110 C 194 230 F OFF 85 105 C 185 ...

Page 76: ...2 F 10 C 14 F 10 C 50 F Altitude Idling speed r min 0 200 m 0 700 ft MJ PJ 150 50 MJ PJ 148 48 MJ PJ 148 45 1 400 200 1 500 m 700 5 000 ft MJ PJ 148 48 MJ PJ 148 45 MJ PJ 145 45 1 400 1 500 3 000 m 5 000 10 000 ft MJ PJ 148 45 MJ PJ 145 45 MJ PJ 145 40 1 400 MAINTENANCE SPECIFICATIONS ...

Page 77: ...acer 9 0 9 6 5 Engine mounting nut 65 6 5 47 Engine mounting bracket 25 2 5 18 Oil pan 10 1 0 7 2 Oil pan drain bolt 10 1 0 7 2 Oil filter cartridge 17 1 7 12 Oil pump 12 1 2 8 7 Oil pump drive chain guide 10 1 0 7 2 Oil pump housing cover 4 0 4 2 9 Oil pump driven gear 15 1 5 11 Oil tank drain bolt 16 1 6 11 Oil tank and frame bolt 10 1 0 7 2 Oil tank and frame nut 19 1 9 13 Oil gallery bolt 20 2...

Page 78: ...e 120 Parts to be tightened Tightening torque Remarks Nm m kg ft lb Balancer 35 3 5 25 Balancer shaft bearing retainer 10 1 0 7 2 Apply LOCTITE AC magneto rotor 130 13 0 94 Apply the engine oil AC magneto rotor cover bolt M6 1 0 11 12 1 2 8 7 AC magneto rotor cover bolt M6 1 0 1 12 1 2 8 7 Apply LOCTITE Starter clutch 12 1 2 8 7 Apply LOCTITE Stator coil 10 1 0 7 2 Apply LOCTITE Pickup coil 6 0 6 ...

Page 79: ...sing cover 10 1 0 7 2 Lever rod and lever 10 1 0 7 2 Shift rod and lever 10 1 0 7 2 Drive chain housing shaft and shift rod 10 1 0 7 2 Reverse drive gear shaft plate 10 1 0 7 2 Apply LOCTITE Reverse driven gear 55 5 5 40 Apply LOCTITE Counter gear 10 1 0 7 2 Apply LOCTITE Drive chain housing and brake caliper 48 4 8 35 Brake caliper bleed screw 6 0 6 4 3 Brake caliper retaining pin 18 1 8 13 Brake...

Page 80: ...ront pivot arm 49 4 9 35 Front pivot arm and control rod 74 7 4 53 Front pivot arm and front pivot arm bracket 72 7 2 52 Front pivot arm bracket and sliding frame 30 3 0 22 Front pivot arm bracket and shaft 30 3 0 22 Suspension wheel 60 6 0 43 Shock absorber and rear pivot arm 49 4 9 35 Rear pivot arm and rear pivot arm bracket 72 7 2 52 Apply LOCTITE Control rod and rear pivot arm 74 7 4 53 Contr...

Page 81: ...3 0 22 Tie rod and steering arm 35 3 5 25 Idler arm 67 6 7 48 Tie rod end locknut 25 2 5 18 Apply LOCTITE Ski 48 4 8 35 Ski runner 19 1 9 13 Ski and ski handle M8 55 12 1 2 8 7 Ski and ski handle M8 100 17 1 7 12 Shock absorber upper 45 4 5 32 Shock absorber lower 45 4 5 32 Spring seat locknut shock absorber 30 3 0 22 RS90RX RS90LTX 42 4 2 31 RS90GTX RS90GTAX RS90LTGTX Steering arm and ski column ...

Page 82: ...tions call for clean dry threads Components should be at room temperature A nut B bolt General torque specifications Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 Unit Read Definition Measurement mm cm Millimeter Centimeter 10 3 meter 10 2 meter Length Length kg Kilogram 103 gram Weight N Newton 1 k...

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