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Yamaha VK540EG Owner'S Manual Download Page 47

8-6

ESU00147

THROTTLE CABLE ADJUSTMENT

CAUTION:

Be sure the engine idle speed is adjusted first.

1. Loosen the adjuster locknut.
2. Turn the adjuster in or out until proper throttle lever free

play is achieved.

Throttle lever free play 

1

:

1.0 ~ 2.0 mm (0.04 ~ 0.08 in)

2

Locknut

3

Adjuster

3. Tighten the locknut.

816-017

ESU00149

OIL PUMP CABLE ADJUSTMENT

CAUTION:

Be sure the throttle cable is adjusted first.

1. Loosen the adjuster locknut.
2. Pull the oil pump outer cable and adjust the free play

between the adjuster and outer cable by turning the
adjuster in or out.

Pump cable free play 

1

:

25 

±

 1 mm (0.98 

±

 0.04 in)

2

Locknut

3

Adjuster

3. Tighten the locknut.

800-008

Summary of Contents for VK540EG

Page 1: ...L SNOWMOBILE VK540EG 8AC 28199 18 ...

Page 2: ......

Page 3: ...n the spaces provided to assist you in ordering spare parts from your Yamaha dealer 1 The frame number is the seventeen digit number stamped on the frame of the machine See Fig Å 2 The engine number is stamped in the location as shown See Fig ı 3 Key number See Fig Ç Also record and keep these I D numbers in a separate place in case your machine is stolen C A 860 002 861 011 B 861 002 ...

Page 4: ...ned to acquaint you with the operation of this snowmo bile and minor maintenance required for satisfactory ser vice Should major repairs ever be required you are advised to consult a nearby Yamaha dealer who has the techniques tools and parts to ensure your satisfaction We hope that the information within this booklet will help you enjoy many hours of pleasure with your Yamaha snowmobile VK540EG O...

Page 5: ...is manual should be considered a permanent part of thismachineandshouldremainwiththismachinewhen 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 machine operator a by stander or...

Page 6: ...ITCH 5 7 PRE OPERATION CHECKS 6 1 FUEL 6 1 ENGINE OIL 6 2 THROTTLE LEVER 6 2 MANUAL STARTER 6 2 THROTTLE OVERRIDE SYSTEM T O R S CHECK 6 3 BRAKE 6 4 V BELT 6 4 DRIVE V BELT GUARD 6 5 DRIVE TRACK 6 5 SLIDE RUNNERS 6 5 SKI SKI RUNNER 6 6 STEERING SYSTEM 6 6 LIGHTS 6 6 BATTERY 6 6 FITTINGS FASTENERS 6 6 SERVICE TOOLS AND SPARE PARTS 6 7 OPERATION 7 1 STARTING THE ENGINE 7 1 EMERGENCY ENGINE STARTING ...

Page 7: ...TUDE ADJUSTMENTS 8 9 FAN BELT 8 10 DRIVE V BELT REPLACEMENT 8 11 DRIVE CHAIN HOUSING 8 13 BRAKE PARKING BRAKE 8 14 SUSPENSION 8 15 FULL RATE ADJUSTER 8 17 TRACK ADJUSTMENT 8 18 SKI ALIGNMENT 8 20 HANDLEBAR ADJUSTMENT 8 21 LUBRICATION 8 22 HEADLIGHT 8 23 BATTERY 8 24 FUSE REPLACEMENT 8 25 TROUBLESHOOTING 9 1 STORAGE 10 1 SPECIFICATIONS 11 1 DIMENSIONS 11 1 ENGINE 11 1 CHASSIS 11 1 ELECTRIC 11 2 WIR...

Page 8: ...ced due to normal wear or routine maintenance including oil spark plugs clutch drive belts slide runners and track THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the snowmobile as specified in the appropriate Owner s Manual 2 Give notice to an authorized Yamaha snowmobile dealer of any and all apparent defects within ten 10 days after discovery and make the ma...

Page 9: ...ear is however covered for one 1 year from the date of purchase Your Yamaha snowmobile dealer possesses criteria as to what constitutes abnormal wear Q Will the warranty be void or canceled if I do not operate or maintain my new Yamaha exactly as specified in the Owner s Manual A No The warranty on a new Yamaha cannot be voided or canceled However ifaparticularfailure is caused by operation or mai...

Page 10: ...ha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new snowmobile please advise us of your new address by sending a postcard listing your snowmobile model name engine serial number dealer number or dealer s name as it is shown on your warranty registration identification your name and new mailing address Mail to YAMAHA MOT...

Page 11: ...e expenses you incur because your Yamaha needs covered service replace ment vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb cov erage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your en tire Y E S plan period Y E S coverage is honored at any autho rized Yamaha dealer natio...

Page 12: ...on and adequate clothing for snowmobiling Check lever position Drive Reverse or Low before moving AFIN D ÉVITER TOUT RISQUE DE BLESSURE SÉRIEUSE OU MÊME MORTELLE VEUILLEZ SUIVRE LES RECOMMANDATIONS SUIVANTES Avant d utiliser ce véhicule lire le manuel du propriétaire et toutes les étiquettes Avant de démarrer le moteur vérifier l opération du frein de l accélérateur et de la direction Le frein de ...

Page 13: ...drinking alcohol or taking drugs Your ability to operate the machine is reduced by the influence of alcohol or drugs 4 For safety and proper care of the machine always perform the pre operation checks on page 6 1 6 7 before starting the engine Check the throttle steer ing and brake operation every time before starting the engine Be sure the throttle lever moves freely and it returns to the idle po...

Page 14: ...r skin or clothing immediately wash your skin with soap and water and change your clothes 9 Wear protective clothing Wear an approved helmet and a face shield or goggles Also wear a good quality snowmobile suit boots and a pair of snowmobile gloves or mittens that will permit use of your thumbs and fingers for operation of the controls Operation 1 Do not run the engine indoors except when starting...

Page 15: ...ances Be alert plan ahead and begin decelerating early The best braking method on most surfaces is to release the throttle and apply the brake gently not suddenly Maintenance and Storage 1 Modifications made to the machine not approved by Yamaha or the removal of original equipment may render your machine unsafe for use and may cause severe personal injury Modifications may also make your machine ...

Page 16: ...ion 8 Steering ski 9 Headlight 0 Front baffle plate A Shroud B Tail brake light C Flap D Tow hitch E Luggage box F Headlight adjusting knob G Engine stop switch H Throttle lever I Drive select lever Shift lever J Main switch K Starter handle L Starter lever M Grip warmer switch N Headlight beam switch O Brake lever P Parking brake button ...

Page 17: ... be started 3 START Starting circuit is switched on The starter motor starts NOTE The lights will come on after the engine starts CAUTION Releasetheswitchimmediatelyaftertheenginestarts 831 004 815 001 ESU00020 STARTER LEVER CHOKE Use this lever when starting and warming up a cold engine 1 Starter lever choke 2 When starting a cold engine 3 Warming up 4 When the engine is warm NOTE Refer to STARTI...

Page 18: ...ing MODE Run Trouble SWITCH OFF ON RUN Throttle switch Carburetor switch Engine A B C ESU00025 THROTTLE OVERRIDE SYSTEM T O R S If the carburetor or throttle cable should malfunction during operation release the throttle lever The T O R S is de signed to interrupt the ignition and stop the engine if the carburetor fails to return to idle when the lever is released WARNING If T O R S stops the engi...

Page 19: ...tch while driving so that you can react quickly in an emergency 831 008 ESU00032 BRAKE LEVER The machine is stopped by braking the entire drive system Squeeze the brake lever towards the handlebar to stop the machine 1 Brake lever 2 Brake lever end 3 Handlebar end NOTE When the brake is operated the brake light will illuminate CAUTION Be sure the brake lever end does not project out over the handl...

Page 20: ...ed This may overheat the brake disc and reduce brak ing ability 818 001 817 003 817 005 ESU00037 DRIVE SELECT LEVER SHIFT LEVER The drive select lever is used to shift your machine into drive low or reverse After coming to a complete stop squeeze the stopper underneath the lever and move the lever to the desired position 1 Drive select lever Shift lever 2 Stopper Lever position Machine movement 3 ...

Page 21: ...EADLIGHT ADJUSTING KNOB Use the knob to adjust the headlight vertical position 1 Up 2 Down 832 018 831 020 ESU00042 GRIP AND THUMB WARMER SWITCH This switch controls the electrically heated handlebar grips and throttle lever 1 Grip and thumb warmer switch 2 ON 3 OFF 833 004 ESU00046 TRIP ODOMETER RESET KNOB Use knob to reset the trip odometer 1 Reset knob 2 Turn counterclockwise ...

Page 22: ...achine with the shroud open or unlatched or with the shroud 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 845 014 ESU00052 V BELT GUARD The V belt guard is designed to cover the clutch and V belt in case parts break or come loose WARNING Be sure the V belt guard is tight...

Page 23: ...0 847 005 ESU00071 TOW HITCH Use the tow point within the specified weight limits 1 Tow point Tow weight 120 kg 265 lb Vertical weight 15 kg 33 1 lb CAUTION Avoid towing for a long time under the 10 km h 0 6 mph speed to prevent early wear of the drive V belt ESU00069 LUGGAGE BOX Luggage box is located under the seat The seat can be opened left side by unhooking the latches on the right side seat ...

Page 24: ... 88 or higher 2 Fuel tank capacity Total 31 0 L 6 8 Imp gal 8 2 US gal WARNING Fuel is highly flammable and poisonous Check SAFETY INFORMATION see page 3 2 carefully before refueling Do not fill the fuel tank all the way to the top When the machine is tilted this could cause the fuel to overflow Make sure that the fuel tank cap is closed securely after refueling Leaking fuel can catch fire CAUTION...

Page 25: ...U00084 ENGINE OIL Make sure there is sufficient oil in the oil tank 1 Lower level 2 Upper level Oil tank capacity 2 5 L 2 2 Imp qt 2 6 US qt Recommended oil YAMALUBE 2 cycle oil 800 006 816 025 815 006 ESU00088 MANUAL STARTER Check for proper operation Check the rope for damage ESU00087 THROTTLE LEVER Check the throttle lever operation before starting the en gine It must open smoothly and spring b...

Page 26: ...ccident 1 Start the engine NOTE Refer to STARTING THE ENGINE 2 Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb above and fore finger below between the throttle lever pivot 1 and stop switch housing 2 While holding as described above press the throttle lever 3 gradually The engine should stop immediately WARNING If the engine does not stop stop the eng...

Page 27: ...ing ability which could lead to an accident CAUTION Be sure the brake lever end should not project out over the handlebar end for preventing brake lever damage when the machine is placed on its side ESU00094 V BELT Open the shroud and remove the V belt guard Check the V belt for wear and damage Replace if neces sary Wear limit 1 32 0 mm 1 26 in WARNING Be sure the V belt guard is tightened securel...

Page 28: ...rol which could cause an accident ESU00095 DRIVE V BELT GUARD Check the drive belt guard mounts for damage and check the tightness of the wing bolt Make sure the drive belt guard is firmly in place 820 123 805 808 ESU00098 SLIDE RUNNERS Check wear and damage If the slide runners reach the wear limit they should be replaced 1 Slide runners 2 Wear limit Wear limit height 10 mm 0 39 in CAUTION Be sur...

Page 29: ... 2 Turn the handlebar slightly to the right and left 2 If excessive free play is noticed consult a Yamaha dealer ESU00104 LIGHTS Check the lights Replace any burned out bulbs ESU00106 BATTERY See page 8 24 for more details Check the fluid level and top up if necessary Use only distilled water if refilling is necessary 830 007 ESU00110 FITTINGS FASTENERS Check the tightness of fittings fasteners Ti...

Page 30: ...can be done by yourself The following should be carried in the luggage box Tool kit Flashlight Roll of plastic tape Steel wire Tow rope Emergency starter rope In addition to these it is advisable to have the following spare parts Drive belt Light bulbs Spark plugs When you start out for a long distance trip extra fuel and oil should be carried ...

Page 31: ...n the engine is warm Put the starter lever in the Close position 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 Close position 1 START CAUTION Release the switch immediately after the engine starts If the engine fai...

Page 32: ...ion in wet snow If any abnormal condition is noticed such as excessive vibration or noise consult a Yamaha dealer ESU00120 EMERGENCY ENGINE STARTING 1 Proceed with the STARTING THE ENGINE item 1 2 Turn the main switch to the ON position 1 ON 3 Pull slowly on the recoil starter until it is engaged then pull it briskly After the engine starts put the starter lever choke in the Half open position War...

Page 33: ...lease read all warning and caution labels on your snow mobile Also read the Snowmobiler s Safety Handbook originally supplied with your machine LEARNING TO RIDE YOUR SNOWMOBILE Before you ride always perform the pre operation checks listed on page 8 1 8 3 The short time spent checking the condition of the machine will be rewarded with added safety and a more reliable snowmobile Always wear the pro...

Page 34: ...ly not suddenly WARNING Many surfaces such as ice and hard packed snow require much longer stopping distances Be alert plan ahead and begin decelerating early Improper use of the brake can cause the drive track to lose traction reducing control and increasing the possibility of an accident TURNING For most snow surfaces body English is the key to turning As you approach a curve slow down and begin...

Page 35: ...ack 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 accom plished by leaning forward and on steeper inclines stand ing on the running boards and leaning forward over the handlebars Also see CROSSING A SLOPE Slow down as you reach the crest of the hill and be prepared to react to obstacles sharp drops or other people or ve...

Page 36: ... to maintain proper balance As you travel across the slope lean your body to position your weight towards the uphill side A recommended riding position is to kneel with the knee of the downhill leg on the seat and the foot of the uphill leg on the running board This position will make it easier for you to shift your body weight as needed Snow and ice are slippery so be prepared for the possibil it...

Page 37: ...e or result in rapid wear of ski runners drive track slide runners and drive sprockets Operation of the machine under the following conditions should be avoided at all costs 1 Dirt 2 Sand 3 Rocks 4 Grass 5 Bare pavement Other conditions that should be avoided for the sake of drive track and slide runner life are 1 Glare ice surfaces 2 Snow mixed with a lot of dirt and sand All the above conditions...

Page 38: ...ettles Be sure to correct the track tension and alignment fre quently See pages 8 18 8 20 for adjustment proce dures A loose track can slip ratchet derail or catch on suspension parts causing severe damage Do not over tighten the drive track otherwise it may increase the friction between the track and the slide runners resulting in the rapid wear of both components Also this may put an excessive l...

Page 39: ... the drive track Studs may catch on an object and pull out of the track leaving tears and damage around the already weakened area To minimize possible damage consult your stud manufacturer for installation and stud pattern recommendations Yamaha does not recommend track studding ESU00131 DRIVING WARNING Besuretoread SAFETYINFORMATION and RIDING YOUR SNOWMOBILE carefully before operating the machin...

Page 40: ...ing the brake lever 3 Press the throttle lever slowly to move the machine 4 Turn the handlebar in the desired direction 5 Squeeze the brake lever to stop the machine 6 Apply parking brake squeeze the brake lever and push down the button then pinch it in place by releasing the brake lever 831 007 831 021 ESU00136 STOPPING THE ENGINE 1 Turn the main switch to the OFF position to stop the engine 1 OF...

Page 41: ...m hydro static lock When possible the fuel tank should be empty during transportation especially if the trip will be 30 minutes or longer If transporting the machine in an open trailer or truck put a tight fitting cover on the machine A cover specifi cally 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 machi...

Page 42: ... if necessary Check fuel hose for cracks or damage Replace if necessary Check oil hose for cracks or damage Replace if necessary Check throttle lever operation Adjust the jets Check wear and damage Replace if necessary Adjust fan belt if necessary Check operation and rope damage Replace if necessary Check operation Repair if necessary Check operation Repair if necessary Spark plug Engine oil Oil f...

Page 43: ...y Check cracks bends or damage Replace if necessary Check wear and damage Replace if necessary Check deflection wear and damage Adjust replace if neces sary Check wear and damage Replace if necessary Check operation Adjust free play and or replace pads if necessary Check oil level Replace Check deflection Adjust if necessary Check wear and damage Replace if necessary Check operation Adjust toe out...

Page 44: ...ar for primary Inspect ramp shoes bushings for wear for secondary Replace if necessary Lubricate with specified grease Lubricate with specified grease Lubricate with specified grease Lubricate with specified grease Lubricate with specified grease Check cable damage Replace if necessary Make sure the shroud latches are hooked Check tightness Repair if necessary Check proper placement Battery Primar...

Page 45: ...ly 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 indicate an intake track air leak or carburetion problem for that cylinder Do not attempt to diagnose such problems yourself Instead take the machine to your Yamaha dealer You should periodically remove and in spect the spark plug beca...

Page 46: ...ng the plug always clean the gasket surface Wipe off any grime from the threads and torque the spark plug properly Spark plug torque 20 Nm 2 0 m kg 14 ft lb 834 001 ESU00146 ENGINE IDLE SPEED ADJUSTMENT CAUTION Be sure this adjustment is serviced by a Yamaha dealer Be sure the throttle lever moves smoothly 1 Start the engine NOTE Refer to STARTING THE ENGINE 2 Turn the throttle stop screw 1 in or ...

Page 47: ...e play 1 1 0 2 0 mm 0 04 0 08 in 2 Locknut 3 Adjuster 3 Tighten the locknut 816 017 ESU00149 OIL PUMP CABLE ADJUSTMENT CAUTION Be sure the throttle cable is adjusted first 1 Loosen the adjuster locknut 2 Pull the oil pump outer cable and adjust the free play between the adjuster and outer cable by turning the adjuster in or out Pump cable free play 1 25 1 mm 0 98 0 04 in 2 Locknut 3 Adjuster 3 Tig...

Page 48: ...es use of alcohol oxygenated fuels etc and should be done by an authorized Yamaha dealer CAUTION The drive chain gears and V belt clutch should be adjusted when operating over 900 m 3000 ft high altitude Consult a Yamaha dealer Pilot Screw Adjustment Turn the pilot screw in or out to adjust low speed tuning Standard pilot screw position 1 1 4 turns out from the seated position Warmer weather Highe...

Page 49: ...er to catch any spilled fuel Handle fuel with care it is highly flammable Standard main jet 141 3 1 Loosen the carburetor clamps and turn over the carbu retor 2 Pinch the fuel hose to prevent fuel flowing 3 Remove the drain plug and install the proper main jet 4 Assemble by reversing the removal steps WARNING Be sure the throttle outer cable is firmly seated in the holderandthethrottleoperatessmoo...

Page 50: ...authorized Yamaha dealer care fully Proper carburetion adjustments will correct the fuel air ratio Remember less air at higher altitude means there is less horsepower available even with proper carburetion Ex pect 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 clutch and driveline setti...

Page 51: ...he fan cover 2 Measure the fan belt deflection by applying 50 N 5 kg 11 lb of force at the center of belt 1 Deflection 2 50 N 5 kg 11 lb Standard belt deflection 8 mm 0 31 in 50 N 5 kg 11 lb Ifthedeflectionexceedsthespecification consultaYamaha dealer 805 074 ...

Page 52: ...heave should be serviced by a Yamaha dealer Serious injury can occur from sudden release of spring tension during sheave disassembly CAUTION To ensure proper clutch performance the spacers in the secondary clutch must be repositioned as the V belt wears For this adjustment consult a Yamaha dealer 805 030 35 mm 1 38 in 2 spacers between sheaves 34 mm 1 34 in 1 spacer between sheaves 33 mm 1 30 in N...

Page 53: ... 4 Remove the belt from the secondary sheave and pri mary sheave 5 Install the new belt over the primary sheave 6 Rotate the secondary sliding sheave clockwise 4 and push 5 it so that it separates from the fixed sheave 7 Install the belt 6 between the secondary sliding and fixed sheaves 8 Install the drive V belt guard WARNING Never run the engine without the drive V belt or with the drive V belt ...

Page 54: ...l Slight flow CORRECT No flow Insufficient 1 Level bolt 2 Filler cap 2 Add chain oil until it begins to flow out from the level hole Drive chain oil API GL 3 SAE 75 or 80 CAUTION Be sure no foreign material enters the gearcase 3 Check the level hole bolt gasket and filler cap O ring If damaged replace it 4 Install the level hole bolt and filler cap 807 012 ...

Page 55: ...Locknut 4 Adjuster bolt 4 Tighten the locknut 5 Install the cap 807 013 818 028 ESU00176 BRAKE PARKING BRAKE Checking Pad Wear Check pad wear by measuring the thickness of the brake pad If the pad reaches the wear limit consult a Yamaha dealer for replacement Wear limit 1 9 5 mm 0 37 in Adjustment This machine has a self adjusting brake caliper No adjust ment is necessary under normal conditions I...

Page 56: ... 2 3 4 5 Softer Harder 3 Spring adjuster position Preload Å Standard Front 1 2 3 4 5 6 7 Softer Harder 4 Spring adjuster position Preload ı Standard Rear B A WARNING This shock absorber contains highly pressurized ni trogen gas It could explode by improper handling causing injury or property damage Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock absorber ...

Page 57: ...load Adjust the spring preload by turning the adjuster 1 Adjuster Turn in Turn out Preload Harder Softer Snow condition Icy Soft 2 Standard length 16 mm 0 63 in CAUTION Be sure the left and right spring preload is same 820 049 ...

Page 58: ...e this adjustment when there is no load rider or cargo on the snowmobile 1 Loosen the nut 1 1 2 or 3 4 turns while holding the adjusting bolt 2 securely with a wrench so it does not move CAUTION Neverallowtheadjustingbolt2tomovewhileloosen ing the nut 2 Turn the adjusting bolt 2 to the desired position CAUTION Be sure the adjusting bolt ends are set at the same position on each side 3 Whileholding...

Page 59: ...near a rotating track Inspect track condition frequently Replace dam aged track guide clips Replace the track if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken Oth erwise track damage and or failure could result in loss of braking ability and machine control which could cause an accident Never install studs cleats closer than three inches from ...

Page 60: ...table stand before working underneath the machine Operate the engine in a well ventilated area 1 Lift the rear of the machine onto a suitable stand to raise the track off the ground 2 Loosen the rear axle nut 1 NOTE It is not necessary to remove the cotter pin 2 3 Start the engine and rotate the track one or two turns Stop the engine 4 Check the track alignment with the slide runner 3 If the align...

Page 61: ...ad 2 Check the following for ski alignment 1 Ski is facing forward 2 Ski toe out 1 2 is within specification Ski toe out 1 2 0 15 mm 0 0 6 in 3 If alignment is not correct consult a Yamaha dealer 819 001 8 Slide runner 9 Track 0 Track metal A Gap B Forward 5 Adjust track deflection to the specified amount CAUTION The adjusters should be turned an equal amount 6 Recheck alignment and deflection If ...

Page 62: ...e handlebar assembly up or down to adjust the handlebar height to the desired position 3 Tighten the handlebar bolts and install the handlebar cover Handlebar bolt tightening torque 15 Nm 1 5 m kg 11 ft lb CAUTION Be sure the small gap 1 side of the holder faces forward 2 845 026 819 040 845 012 819 077 ...

Page 63: ... temperature grease 1 Brake Throttle cable ends 2 Front suspension 3 Rear suspension WARNING Apply a dab of grease to the cable end only Do not grease the brake throttle cables themselves becausetheycouldbecomefrozen whichcouldcause loss of control 818 026 819 046 820 092 ...

Page 64: ...until it cools down 5 Install the new bulb Bulb type 12 V 60 55 W CAUTION Keepoiloryourhandsawayfromtheglasspartofbulb 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 6 Set the spring and install the secket cover Reconnect the bulb coupler Beam Adjustment 1 Turn the adjuster 1 in or out to adjust t...

Page 65: ... dangerous It contains sulfuric acid and can cause severe burns Avoid contact with 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 Batteriesproduceexplosivegases Keepsparks flame cigarette...

Page 66: ...use electrical system damage and A FIRE HAZARD CAUTION Be sure the main switch is turned off to prevent accidental short circuiting 1 Lift up the shroud 2 Replace the blown fuse with one of proper amperage NOTE If the fuse immediately blows again consult Yamaha dealer Fuse type 10 A 835 003 ...

Page 67: ...ot correct for altitude and or conditions Consult dealer E Engine constantly backfires or mis fires 1 Faulty spark plug s Replace spark plug s 2 Fuel system clogged See A 1 above 3 T O R S malfunction See T O R S in A 2 above ESU00277 TROUBLESHOOTING A Engine turns over but doesn t start 1 Fuel system No fuel supplied to combustion chamber No fuel in tank Supply fuel Clogged fuel line Clean fuel l...

Page 68: ... burns 1 Belt or sheave surface oily or dirty clean 2 Problem with drive line See F above I Engine does not upshift or downshift properly engages harshly 1 Drive belt worn replace belt or consult dealer 2 Clutch settings incorrect for altitude con ditions Consult dealer 3 Primary clutch worn or sticking Consult dealer 4 Secondary clutch worn or sticking Consult dealer J Noise or excessive vibratio...

Page 69: ...ases the chance for water to enter the engine Use Yamaha Stor Rite Fogging Oil or an equivalent to protect both combustion chamber and crank shaftfromcorrosion Analternatemethod is to remove the airbox and squirt oil into the carburetor throats while the engine is running CAUTION Do not attempt to store the machine by simply starting the engine occasionally duringthestorageperiod Thiscancause more...

Page 70: ...uld be trapped underneath which could increase the chance of rust ing RETURN TO SERVICE AFTER STORAGE When returning your machine to service reinstall the drive belt and adjust the track Reinstall the battery and make sure the battery vent tube is properly reinstalled and is not kinked Remove the spark plugs and clean them or replace them Perform all other pre opera tion and seasonal maintenance l...

Page 71: ...em VK540E Axial fan cooled 2 stroke 7 port Parallel 2 cylinders 535 cm3 73 0 64 0 mm 2 87 2 52 in 1200 100 r min YAMALUBE 2 cycle oil MIKUNI B38 34 1 Unleaded gasoline Pump octane R M 88 or higher 2 Electric and manual with recoil starter ESU00231 CHASSIS VK540E Molded rubber fiber glass rod reinforced 500 mm 19 7 in 35 45 mm 1 38 1 77 in 100 N 10 kg 22 lb 1204 mm 47 4 in Slide rail suspension Tri...

Page 72: ...le lever right hand operated Transmission Type Sheave distance Sheave offset Engagement speed Shift speed Drive chain Reduction ratio Fuel tank Tank capacity Oil tank Tank capacity Brake Type Operation Throttle Operation Subject to change according to elevation settings ESU00232 ELECTRIC VK540E Ignition system Spark plug Type Gap Battery Capacity Maximum charge rate Headlight Bulb Quantity Tail br...

Page 73: ... Back buzzer 2 Speedometer light 3 Tachometer light option 4 Tachometer option 5 Gear position switch 6 Thumb warmer 7 Grip warmer 8 Grip warmer switch 9 Main switch 0 Fuse A Rectifier B Starter relay C Battery D Tail brake light E Spark plug F Ignition coil G Starter motor H CDI unit I CDI magneto J Voltage regulator K Frame ground L Brake light switch M Carburetor switch N Headlight beam switch ...

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