Yamaha VK540V Page 72 Owner'S Manual Download

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9-2

E. Engine constantly backfires or misfires

1. Faulty spark plugs ... Replace the

spark plugs.

2. Clogged fuel system ... See A.1. above.
3. Malfunctioning T.O.R.S. system ... See

A.2. above.

Snowmobile does not move

1. Malfunctioning V-belt clutch ... Ask a

Yamaha dealer to inspect.

2. Drive track does not move ... Foreign

object is caught in the drive track, or
the slide runners have melted to the
slide metal due to lack of lubrication.

3. Tight, loose, or broken drive chain ...

Ask a Yamaha dealer to inspect.

G. V-belt twists

1. Improper V-belt ... Replace with the

correct V-belt.

2. Incorrect V-belt clutch offset ... Ask a

Yamaha dealer to inspect.

3. Loose or broken engine mount ... Ask a

Yamaha dealer to inspect.

H. V-belt slips or burns

1. Oily or dirty V-belt or primary and sec-

ondary sheave assembly surfaces ...
Clean.

2. Problem with the driveline ... See G

above.

Engine does not upshift or downshift
properly or engages harshly

1. Worn or damaged V-belt ... Replace

the V-belt or ask a Yamaha dealer to
inspect.

2. Incorrect V-belt clutch settings for alti-

tude or conditions ... Ask a Yamaha
dealer to inspect.

3. Worn or sticking primary sheave

assembly ... Ask a Yamaha dealer to
inspect.

4. Worn or sticking secondary sheave

assembly ... Ask a Yamaha dealer to
inspect.

Noise or excessive vibration in drive
chain and sprockets

1. Broken V-belt clutch components ...

Ask a Yamaha dealer to inspect.

2. Worn or damaged bearings ... Ask a

Yamaha dealer to inspect.

3. Worn or damaged V-belt with flat spots

... Replace.

4. Worn or damaged idler wheels or

shafts ... Ask a Yamaha dealer to
inspect.

5. Worn or damaged drive track ... Ask a

Yamaha dealer to inspect.

E_8KX.book Page 2 Friday, April 2, 2021 8:52 AM

Summary of Contents for VK540V

Page 1: ...DIC183 OWNER S MANUAL Read this manual carefully before operating this vehicle VK5NFN 8KX 28199 75 LIT 12628 03 83 ...

Page 2: ... véhicule tout terrain peut vous exposer à des produits chimiques y compris les gaz d échappement du mo teur le monoxyde de carbone les phtalates et le plomb qui sont reconnus en Californie comme cause de cancer et de malformations congénitales et d autres problèmes liés à la re production Afin de réduire le plus possible l exposition éviter d inhaler les gaz d échappement ne pas faire tourner le ...

Page 3: ...es provided for assistance when ordering spare parts from a Yamaha dealer 1 The vehicle identification number is the seventeen digit number stamped on the frame of the snowmo bile See fig È 2 The engine number is stamped in the location as shown See fig É 3 Key number See fig Ê Also record and keep the ID numbers in a separate place in case the snowmobile is stolen A B 3 860 004 C E_8KX book Page ...

Page 4: ...stions concerning the operation or maintenance of your snowmobile please consult a Yamaha dealer To maintain the high quality and performance of this snowmobile it is important that you and your Yamaha dealer pay close attention to the recommended mainte nance schedules and operating instructions contained within this manual VK5NFN OWNER S MANUAL 2022 by Yamaha Motor Corporation U S A 1st Edition ...

Page 5: ...s snowmobile and should remain with the snow mobile when resold Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety mes sages that follow this symbol to avoid possible injury or death WARNING A WARNING indicates a hazardous situation which if not av...

Page 6: ...e compartment plates 5 7 Storage compartment 5 7 Rear carrier 5 8 Tow hitch 5 8 PRE OPERATION CHECKS 6 1 Fuel 6 1 Engine oil 6 2 Why Yamalube 6 3 Throttle lever 6 3 Recoil starter 6 3 Throttle override system T O R S 6 4 Brake 6 5 Drive guard 6 5 V belt 6 5 Drive track 6 6 Slide runners 6 6 Skis and ski runners 6 7 Steering system 6 7 Lights 6 7 Battery 6 7 Fittings and fasteners 6 8 Tool kit and ...

Page 7: ...ettings 8 8 Checking the fan belt deflection 8 9 Replacing the V belt 8 10 Adjusting the drive chain tension 8 12 Checking the brake pads 8 12 Suspension 8 13 Checking the extrovert drive sprocket 8 14 Adjusting the drive track 8 15 Ski alignment 8 17 Lubrication 8 18 Replacing a headlight bulb 8 19 Adjusting the headlight beams 8 20 Battery 8 20 Replacing a fuse 8 21 TROUBLESHOOTING 9 1 STORAGE 1...

Page 8: ... defect exists in a group of vehicles it may order a recall and remedy campaign However Transport Canada cannot become involved in indi vidual problems between you your dealer or Yamaha Motor Canada Ltd Canada To contact Transport Canada you may call Defect Investigations and Recall Division at 819 994 3328 or toll free 1 800 333 0510 go to www tc gc ca or email mvs sa tc gc ca or write to Transpo...

Page 9: ...or collision damage 8 Modification to original parts SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance including oil spark plugs clutch drive belts slide runners and tracks THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the snowmobile as specified in the appropriate Owner s Manual It is recommended th...

Page 10: ...s Manual that failure may not be covered under warranty Q Under what conditions is the clutch not covered by warranty A Clutches as well as clutch components wear with use Normal wear is not covered under warranty such service is the customer s responsibility Abnormal wear is however covered for one 1 year from the date of purchase Your Yamaha snowmobile dealer possesses criteria as to what consti...

Page 11: ...led at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write FOR U S A CUSTOMERS YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 FOR CANADA CUSTOMERS YAMAHA MOTOR CANADA LTD CUSTOMER RELATIONS DEPARTMENT 480 GORDON BAKER RD Toronto Ontario M2H 3B4 CHANGE OF AD...

Page 12: ...emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period Y E S coverage is honored at any authorized Yamaha dealer nationwide Y E S coverage is transferable to a new owner if you sell or trade in That can make your...

Page 13: ...otection Plus will be there whether your repair expense is a few dollars or a few thousand Under the Yamaha Protection Plus program Yamaha picks up the entire cost of parts and labour to repair every applicable mechanical defect Yamaha s computerized warranty system is updated as soon as you buy coverage so Yamaha Protection Plus takes over automatically and immediately when your factory warranty ...

Page 14: ...IMPORTANT LABELS Please read the following labels carefully before operat ing this snowmobile TIP Maintain or replace safety and instruction labels as nec essary 4 1 567 2 3 8 0 9 A CD B E_8KX book Page 1 Friday April 2 2021 8 52 AM ...

Page 15: ... CHAIN CASE OIL TYPE 3 TRACK TENSION FOR MORE INFO SEE SERVICE MANUAL FOR THIS MODEL SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE ENTRAÎNEMENT 1 CAPACITÉ D HUILE DU CARTER DE CHAÎNE 2 TYPE D HUILE DU CARTER DE CHAÎNE 3 FLÈCHE DE LA CHENILLE POUR PLUS DE DÉTAIL VOIR LE MANUEL D ATELIER POUR CE MODÈLE LES CARACTÉRISTIQUE TECHNIQUES SONT SUSCEPTIBLES DE CHANGER SANS NOTIFICATION PRÉALABLE 250 cm 8...

Page 16: ...EPTIBLED ÊTRE ASPIRÉPARLESYSTÈMEDEVENTILATION AVERTISSEMENT 8AC 1262A E0 88C 77769 00 C M V S S CANADA N S V A C T RANSPOR T 506 8KM 82377 00 CAN ICES 2 NMB 2 MAX TOWING FORCE FORCE DE REMORQUAGE MAX 1176 N 120 kgf 264 lbf MAX VERTICAL FORCE FORCEVERTICALE MAX 147 N 15 kgf 33 lbf 8GS 2817S E0 NEVER stand behind or near a rotating track Debris or a broken track could be thrown back with great force...

Page 17: ... Your ability to operate the snowmo bile is reduced by the influence of alcohol or drugs 4 For safety and proper care of the snowmobile always perform the pre operation checks on pages 6 1 6 8 before starting the engine Check the throttle brake and steering for proper operation every time before starting the engine Make sure that the throttle lever moves freely and it returns to the home position ...

Page 18: ...r protective clothing Wear an approved helmet and a face shield or goggles Also wear a good qual ity snowmobile suit boots and a pair of gloves or mit tens that will permit use of your thumbs and fingers for operation of the controls Operation 1 Do not run the engine indoors except when starting the engine to transport the snowmobile in or out of the building Open the outside doors exhaust fumes a...

Page 19: ...aying the snowmobile on its side for mainte nance use a suitable stand to keep it in a stable and level position 2 Modifications made to the snowmobile not approved by Yamaha or the removal of original equipment may render your snowmobile unsafe for use that may cause severe personal injury Modifications may also make the snowmobile illegal to use 3 Never store the snowmobile with fuel in the fuel...

Page 20: ...ield 4 Steering handlebar 5 Seat 6 Storage compartment 7 Drive track 8 Slide rail suspension 9 Frame 0 Telescopic strut suspension A Skis B Headlight C Shroud D Engine compartment plate 4 5 6 1 2 3 7 8 9 0 A B C D E_8KX book Page 1 Friday April 2 2021 8 52 AM ...

Page 21: ...ect lever K Main switch L Starter handle M Starter lever choke N Thumb warmer adjusting switch O Grip warmer adjusting switch P Auxiliary DC jack Q Headlight beam switch R Brake lever S Parking brake button T Speedometer E F G T S R Q P O N M H J K I L E_8KX book Page 2 Friday April 2 2021 8 52 AM ...

Page 22: ...d taillight come on after the engine starts 3 START The starting circuit is switched on The starter motor starts NOTICE Release the switch immediately after the engine starts ESU00201 Starter lever choke Use the starter lever choke 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 TIP Refer the Starting the engine ...

Page 23: ... O R S will be activated when the throttle lever is released The T O R S is designed to limit the engine speed to less than the clutch engagement speed if the throttle valve fails to return to the idle position when the throttle lever is released See page 11 2 for the clutch engage ment speed WARNING If the T O R S is activated make sure that the cause of the malfunction has been corrected and tha...

Page 24: ...can react quickly in an emergency ESU00320 Brake lever The snowmobile is stopped by braking the entire drive system Squeeze the brake lever towards the handlebar grip to stop the snowmobile 1 Brake lever 2 Brake lever end 3 Handlebar end TIP When the brake lever is operated the brake light will illu minate NOTICE Make sure that the brake lever end does not project out over the handlebar end This w...

Page 25: ...eat the brake disc and reduce braking ability ESU03371 Drive select lever The drive select lever is used to shift your snowmobile into drive reverse or low After coming to a complete stop squeeze the stopper underneath the lever and move the lever to the desired position 1 Drive select lever 2 Stopper CA 18E NOTICE Do not shift from forward to reverse or from reverse to forward while the snowmobil...

Page 26: ...justing switch 3 OFF 4 LO 5 HI EAU10697 Auxiliary DC jack Open the auxiliary DC jack cap 1 and then insert the accessory power plug into the jack NOTICE To avoid circuit overload and a possible fuse blowing do not use accessories requiring more than the maximum rated capacity for the auxiliary DC jack See pages 8 21 8 22 for the specified fuse amperage Do not use an automotive cigarette lighter or...

Page 27: ...tops When clos ing the shroud slowly lower it to its original position and then hook the shroud latches 1 Shroud latch 2 Shroud WARNING Do not drive the snowmobile with the shroud open unlatched or removed Keep your body and clothing away from rotating parts when servicing with the shroud open Do not touch the hot muffler and engine during or immediately after operation NOTICE Make sure that all c...

Page 28: ...partment plates 1 in the belly pan that can be removed to cool down the engine NOTICE Make sure that the engine compartment plates are installed when operating the snowmobile in deep snow Remove the engine compartment plates when towing Remove the engine compartment plates when the ambient temperature is above 5 C 41 5 F ESU00691 Storage compartment The storage compartment is located under the sea...

Page 29: ...er the seat to its original position and then hook the latches ESU00701 Rear carrier ESU00712 Tow hitch Use the tow hitch within the specified weight limits 1 Tow hitch NOTICE To prevent premature wear of the V belt avoid travel ing under 10 km h 6 mi h when towing for long dis tances or long periods of time 846 012 1 2 849 002 Maximum load limit 20 kg 44 lbs 847 007 1 Tow weight limit 120 kgf 264...

Page 30: ...ufficient fuel in the fuel tank 1 Fuel tank cap WARNING Fuel is HIGHLY FLAMMABLE and poisonous Check the SAFETY INFORMATION section carefully before refueling See page 3 2 Do not fill the fuel tank all the way to the top Fuel could overflow if the snowmobile is tilted or if the ambient temperature rises causing the fuel to warm up and expand Make sure that the fuel tank cap is closed securely afte...

Page 31: ... to face the fuel meter toward the rider Otherwise the fuel tank cap could be damaged or fuel could leak TIP A 50 1 gasoline oil mixture is recommended when the ambient temperature is below 25 C 13 F For example 10 L of gasoline per 0 2 L of oil 1 gal of gasoline per 2 6 oz of oil equals a 50 1 mixing ratio ESU00844 Engine oil Make sure that there is sufficient oil in the oil tank 1 Upper level 2 ...

Page 32: ... to make sure the final oil clears our performance standards Thus Yamalube mineral semisynthetic and synthetic oils have their own distinct characters and value Yamaha s experience gained over many years of research and development into oil since the 1960 s helps make Yamalube the best choice for your Yamaha engine ESU00870 Throttle lever Check the throttle lever operation before starting the engi...

Page 33: ...tle switch by putting your thumb above and forefinger below between the throttle lever pivot 1 and the engine stop switch housing 2 While holding the pivot point as described above press the throttle lever 3 gradually The T O R S will be activated and the engine speed will be limited to less than the clutch engagement speed See page 11 2 for the clutch engagement speed WARNING If the engine speed ...

Page 34: ...t Ask a Yamaha dealer to inspect and repair the brake sys tem NOTICE Make sure that the brake lever end does not project out over the handlebar end This is to prevent brake lever damage when the snowmobile is placed on its side ESU03990 Drive guard Check the drive guard mounts for damage Make sure that the wing bolt is tightened securely and the drive guard is firmly in place ESU00941 V belt Open ...

Page 35: ...find damage to the drive track or if it has been maladjusted Drive track damage or failure could result in loss of brak ing ability and snowmobile control which could cause an accident ESU00982 Slide runners Check the slide runners for wear and damage If the slide runners reach the wear limit they should be replaced 1 Slide runners a Wear limit NOTICE Ride on fresh snow frequently Operating on ice...

Page 36: ...ck the handlebar for excessive free play 1 Push the handlebar up and down and back and forth 2 Turn the handlebar slightly to the right and left If excessive free play is noticed consult a Yamaha dealer ESU01041 Lights Check the lights Replace any burned out bulbs ESU03020 Battery Check the fluid level and fill if necessary Use only distilled water if refilling is necessary See pages 8 20 and 10 2...

Page 37: ...the tool kit spare parts and other necessary equipment with you while riding the snowmobile so that minor repairs can be done if neces sary The following should be carried at all times Tool kit Flashlight Roll of plastic tape Steel wire Tow rope V belt Light bulbs Spark plugs When you start out for a long distance trip extra fuel and oil should be carried as well E_8KX book Page 8 Friday April 2 2...

Page 38: ...ngine starting 3 Half open warm engine up 4 Closed warm engine starting TIP The starter lever choke is not required when the engine is warm Put the starter lever choke in the closed posi tion 2 Turn the main switch to the START position After the engine starts release the switch and put the starter lever choke in the half open position Warm up the engine until it runs smoothly and does not begin t...

Page 39: ...ad on the engine while the engine is being warmed up ESU02486 Emergency engine starting WARNING Be sure to check the SAFETY INFORMATION section carefully before starting the engine Make sure that the parking brake is applied TIP Make sure that the engine stop switch is in the on posi tion 1 Fully open the starter lever choke 1 Starter lever choke 2 Fully open cold engine starting 3 Half open warm ...

Page 40: ... Break in There is never a more important period in the life of your snowmobile than the break in period For the first 10 hours approximately 200 km 125 mi do not put an excessive load on the engine Avoid prolonged full throt tle operation Also avoid lugging the engine such as laborious opera tion in wet snow If any abnormal condition is noticed such as excessive vibration or noise consult a Yamah...

Page 41: ...r clothing for both warmth and to help pro tect you from injury if an accident occurs Become familiar with operating your snowmobile at low speeds even if you are an experienced rider Do not attempt to operate at maximum performance until you are totally familiar with the snowmo bile s handling and performance charac teristics The beginning operator should select a large flat area to become famili...

Page 42: ...y let off on the throttle or steer to the outside of the turn Remember Avoid higher speeds until you are thor oughly familiar with the operation of your snowmobile Riding uphill You should practice first on gentle slopes Try more difficult climbs only after you have developed your skill As you approach a hill accelerate before you start the climb and then reduce the throt tle to prevent track slip...

Page 43: ...ecom mended riding position is to kneel with the knee of your downhill leg on the seat and the foot of your uphill leg on the run ning board This position will make it eas ier for you to shift your body weight as needed Snow and ice are slippery so be pre pared for the possibility that your snow mobile could begin to slip sideways on the slope If this happens steer in the direction of the slide if...

Page 44: ...1 Glare ice surfaces 2 Snow mixed with a lot of dirt and sand All of the above surfaces have one thing in common in regard to drive track and slide runners little or no lubricating abil ity Drive track and all slide rail systems require lubrication snow or water between the slide runners and the slide metal In the absence of lubrication the slide runners will rapidly wear and in severe cases liter...

Page 45: ...ned high speed usage in areas such as icy trails frozen lakes and rivers that have minimal snow coverage An overheated track will be weakened internally which may cause fail ure or damage Off trail riding Avoid off trail riding until there is sufficient snow cover age It generally takes several feet of snow to provide a good overall base to properly cover debris such as rocks logs etc If snow cove...

Page 46: ... drive select lever to forward or reverse until it stops completely while the engine is idling Low must not be used for speeds exceeding 50 km h 30 mi h Make sure that the area behind the snowmobile is clear before reversing Watch behind Reduce speed and avoid sharp turning when operating the snowmobile in reverse TIP The reverse buzzer beeps while the drive select lever is in reverse 2 Release th...

Page 47: ...s lower than the bottom of the carburetors Otherwise the vibration and bumps from the road surface could make it possible for fuel to flow through the carbure tors into the crankcase This can result in hydrostatic lock a condition where the engine cannot rotate because of fuel accumulated in the engine Severe engine damage can result from hydrostatic lock When possible the fuel tank should be empt...

Page 48: ...here road salt is used coat metal suspension surfaces lightly with oil or other protec tant This will help protect against corrosion Be sure to clean the snowmobile when you get to your desti nation to remove any corrosive salts E_8KX book Page 11 Friday April 2 2021 8 52 AM ...

Page 49: ...ce if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Oil line Check oil hose for cracks or damage Replace if necessary Carburetor Check throttle lever operation 5 2 6 3 Adjust the jets Whenever operating condition elevation temperature is changed Fan belt Check wear and damage Replace if necessary 8 9 Adjust fan belt if necessary Recoil starter Check operation and ro...

Page 50: ...et Check for wear and damage Replace if necessary 8 14 Slide runners Check for wear and damage 6 6 Replace if necessary Brake and parking brake Check operation 5 3 6 5 8 12 Adjust free play and or replace pads if necessary Drive chain oil Replace Drive chain Check deflection Adjust if necessary 8 12 Skis and ski runners Check for wear and damage 6 7 Replace if necessary Steering system Check opera...

Page 51: ...s for wear for primary Inspect ramp shoes bushings for wear for secondary Replace if necessary Lubricate with specified grease Ski and front suspension Lubricate with specified grease 8 18 Suspension component Lubricate with specified grease 8 18 Brake cable end and lever end throttle ca ble end Lubricate with specified grease 8 18 Check cable damage Replace if necessary Shroud latches Make sure t...

Page 52: ...on of the engine Check the coloration on the white porcelain insulator around the center electrode The ideal coloration at this point is a medium to a light tan color for a snowmobile that is being ridden normally If a spark plug shows a distinctly different color there could be something wrong with the engine For example a very white center electrode porcelain color could indi cate an intake trac...

Page 53: ...he speci fied reach Before installing any spark plug measure the electrode gap with a wire thickness gauge and adjust to specifica tion When installing the spark plug always clean the gasket surface Wipe off any grime from the threads and tighten the spark plug to the specified torque ESU01462 Adjusting the engine idling speed NOTICE Be sure to have a Yamaha dealer make this adjustment Make sure t...

Page 54: ...justing the oil pump cable free play NOTICE Be sure to adjust the throttle lever free play first 1 Loosen the 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 1 Oil pump outer cable 2 Adjuster 3 Locknut 3 Tighten the locknut 804 027 1 Standard engine idle speed 1 200 1 400 r min 804 030 2 1 a Throttle lever free...

Page 55: ...be adjusted when operating at altitudes above 900 m 3 000 ft See Adjusting the high altitude settings for details Replacing the main jet Replace the main jet according to the setting chart which is available at a Yamaha dealer WARNING Never remove the drain plug or the float chamber while the engine is hot Fuel will flow out from the float chamber and could ignite and cause injury Place a rag unde...

Page 56: ...e engine to about 3 for every 305 m 1 000 ft of elevation This is because there is less air as altitude increases Less air means less oxygen available for com bustion Your snowmobile can be adjusted to overcome most of the problems found in high altitude riding Carburetor adjustments are the most important Less air at high alti tude makes the air fuel ratio too rich which can cause poor performanc...

Page 57: ...aha dealer They can tell you if there are any changes necessary for the altitude where you plan to ride NOTICE The drive chain gears and V belt clutch should be adjusted when operating over a high altitude of 900 m 3 000 ft Consult a Yamaha dealer ESU01623 Checking the fan belt deflection 1 Remove the fan belt cover by removing the bolts 2 Measure the fan belt deflection by applying 50 N 5 kgf 11 ...

Page 58: ...condary sliding sheave Serious injury can occur from the sudden release of spring tension during sheave disassembly NOTICE To ensure proper clutch performance as the V belt wears it is necessary to adjust the gap between the secondary fixed sheave and secondary sliding sheave by changing the positions of the spacers Have a Yamaha dealer make this adjustment CD 21E CD 05E Belt width 34 5 mm 1 36 in...

Page 59: ...dary sheave assembly and primary sheave assembly 5 Install the new V belt over the primary sheave assem bly 6 Rotate the secondary sliding sheave clockwise 4 and push 5 it so that it separates from the secondary fixed sheave 7 Install the V belt 6 between the secondary sliding and secondary fixed sheaves 8 Install the drive guard WARNING Never run the engine with the V belt or drive guard removed ...

Page 60: ... pads for wear by measuring the thick ness of each pad If the brake pads reach the wear limit have a Yamaha dealer replace them Adjustment This snowmobile has a self adjusting brake caliper No adjustment is necessary under normal conditions If free play at the brake lever seems excessive or insufficient inspection of the brake system is necessary WARNING Be sure to have a Yamaha dealer inspect the...

Page 61: ...ese adjust ments Adjusting the spring preload of the center shock absorber and the rear torsion springs The spring preload can be adjusted by turning the adjusting ring 1 on the center shock absorber and the adjusters 2 on the rear torsion springs Adjust the spring preload as follows CD 13E CD 23E 1 820 151 A 2 861 025 B Adjusting ring position 1 2 3 4 5 Preload Soft Hard È Standard center 1 Adjus...

Page 62: ...cking the extrovert drive sprocket Check the extrovert drive sprocket for wear and damage Replace if necessary To measure the drive sprocket wear Measure the drive sprocket tooth width 1 If the tooth width is less than 28 mm 1 10 in replace the drive sprocket a 1 820 049 Adjusting nut Turn in Turn out Preload Hard Soft Snow condition Icy Soft a Spring preload setting Minimum soft 13 mm 0 51 in Sta...

Page 63: ...equently Replace any damaged slide metal Replace the drive track if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken Otherwise track damage or fail ure could result in loss of braking ability and snowmobile control which could cause an acci dent Measuring the drive track deflection 1 Lay the snowmobile on its side 2 Measure the drive track deflec...

Page 64: ... drive track alignment with the slide runners 2 If the alignment is incorrect align the drive track by turning the left and right adjusters CD 08E 7 Slide runners 8 Drive track 9 Slide metal a Gap b Forward 5 Adjust the drive track deflection to specification CD 09E NOTICE The right and left adjusters should be turned an equal amount 820 144 1 Drive track alignment 5 Shifted to right 6 Shifted to ...

Page 65: ...lebar so the skis face straight ahead 2 Check the following for ski alignment a Skis are facing forward b Ski toe out 1 2 is within specification TIP Move the front tip of each ski fully inward before measur ing or aligning 3 If the alignment is not correct consult a Yamaha dealer Rear axle tightening torque 75 N m 7 5 kgf m 55 lb ft Ski toe out 1 2 0 15 0 mm 0 0 6 in E_8KX book Page 17 Friday Apr...

Page 66: ...Apply a dab of grease onto the cable ends only Do not grease the brake and throttle cables themselves because they could become frozen which could cause loss of control 2 Front suspension 3 Rear suspension Lubricant Low temperature grease 820 150 3 E_8KX book Page 18 Friday April 2 2021 8 52 AM ...

Page 67: ... hook the bulb holder onto the headlight unit NOTICE Keep oil and your hands away from the glass part of the bulb or its life and illumination will be affected If the glass is oil stained thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Install the bulb holder cover and then connect the headlight coupler 1 Top mark TOP TIP When installing the bulb holder cover make sure...

Page 68: ...NG Battery electrolyte is poisonous and 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 Batteries produce ...

Page 69: ...nect the negative battery lead by removing the bolt 1 Negative battery lead 2 Bolt 3 Replace the blown fuse with one of the proper amperage 1 Spare fuse 2 Main fuse 1 TERMINAL auxiliary DC jack fuse 2 HEAD headlight fuse 3 SIGNAL signal system fuse 4 CARB WARMER carburetor warmer fuse 5 IGNITION ignition fuse 6 Spare fuse TIP If the fuse immediately blows again ask a Yamaha dealer to inspect the s...

Page 70: ...s Main fuse 30 0 A Auxiliary DC jack fuse 3 0 A Headlight fuse 20 0 A Signaling system fuse 7 5 A Carburetor warmer fuse 15 0 A Ignition fuse 15 0 A Spare fuse 30 0 A 20 0 A 15 0 A 7 5 A 3 0 A E_8KX book Page 22 Friday April 2 2021 8 52 AM ...

Page 71: ...ression Insufficient Loose cylinder head nuts Tighten nuts properly Worn or damaged gasket Replace gasket Worn or damaged piston and cylinder Ask a Yamaha dealer to inspect B Engine does not turn over with the recoil starter 1 Seized engine Seizure is caused by poor lubrication inadequate fuel or an air leak Ask a Yamaha dealer to inspect 2 Hydrolock occurs when fuel has filled the crankcase when ...

Page 72: ...irty V belt or primary and sec ondary sheave assembly surfaces Clean 2 Problem with the driveline See G above I Engine does not upshift or downshift properly or engages harshly 1 Worn or damaged V belt Replace the V belt or ask a Yamaha dealer to inspect 2 Incorrect V belt clutch settings for alti tude or conditions Ask a Yamaha dealer to inspect 3 Worn or sticking primary sheave assembly Ask a Ya...

Page 73: ...eaning compounds for plastic may leave scratches on the windshield Test the product on a small hidden part of the windshield to make sure that it does not leave any marks If the windshield is scratched use a quality plastic polishing compound after washing 2 Lubrication Lubricate moving parts suspension link age and pivot points Use the grease or lubricant specified in the MAINTENANCE section or Y...

Page 74: ...ight and that the battery vent tube is properly routed and is securely attached to the battery NOTICE Do not charge the battery quickly Charge the battery for 10 hours at 1 6 amperes 7 Drive track Loosen the drive track and block up the chassis so that the track is suspended above the ground 8 V belt Remove the V belt and store separately 9 Storage Store the snowmobile in a dry well venti lated pl...

Page 75: ...30 lbs Ski tread 960 mm 37 8 in VK540F Type Air cooled 2 stroke Cylinder arrangement Inline 2 cylinder Displacement 535 cm3 Bore stroke 73 0 64 0 mm 2 87 2 52 in Idle speed 1 200 1 400 r min Engine oil type Yamalube 2 Recommended brand Carburetor type TM33 79 1 Fuel REGULAR UNLEADED GASOLINE OILY Pump octane 86 or higher Starting system Electric and recoil starters R M 2 E_8KX book Page 1 Friday A...

Page 76: ... Sheave distance 267 0 270 0 mm 10 51 10 63 in Sheave offset 14 5 17 5 mm 0 57 0 69 in Engagement speed 2 500 2 900 r min Shift speed 6 200 6 800 r min Drive chain Silent chain enclosed in oil bath Reduction ratio 38 18 2 11 Low 28 22 28 22 38 18 3 42 Drive chain oil quantity 0 25 L 0 26 US qt 0 22 lmp qt Fuel tank Tank capacity 44 0 L 11 62 US gal 9 68 lmp gal Oil tank Tank capacity 2 5 L 2 64 US...

Page 77: ...ES NGK Gap 0 7 0 8 mm 0 028 0 031 in Battery Capacity YB16AL A2 12 V 16 0 Ah Maximum charge rate 1 6 Amperes hr for 10 hrs Headlight Bulb Quantity 12 V 60 55 W 2 Tail brake light Bulb Quantity LED Meter light Bulb Quantity 12 V 3 4 W 1 E_8KX book Page 3 Friday April 2 2021 8 52 AM ...

Page 78: ...E_8KX book Page 4 Friday April 2 2021 8 52 AM ...

Page 79: ...ight right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out GenuineYamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manuals...

Page 80: ...Printed in Japan 2021 04 1 1 1 CR E_8KX book Page 1 Friday April 2 2021 8 52 AM ...

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