Yamaha SR1NRJ Original Instructions Manual Download

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Read this manual carefully

before operating this vehicle.

SR1NRJ

SR1NLDJ

SR1NLJ

SR1NLLJ

SR1NXSJ

OPERATOR’S MANUAL

LIT-12628-03-49

8JR-F8199-74-00

Summary of Contents for SR1NRJ

Page 1: ...Read this manual carefully before operating this vehicle SR1NRJ SR1NLDJ SR1NLJ SR1NLLJ SR1NXSJ OPERATOR S MANUAL LIT 12628 03 49 8JR F8199 74 00 ...

Page 2: ...12 Operating Instructions 13 16 Starting and Stopping Engine 13 Braking 14 Emergency Stopping 15 Throttle Ignition Monitor Switch 15 Varying Altitude Operation 16 Lubrication 17 19 Chain Case 17 Rear Suspension 19 Maintenance 20 39 Periodic Maintenance Checklist 20 Fuel System 21 Checking Engine Oil Level 21 Checking Engine Oil LevelChanging Engine Oil Filter 21 Coolant Level 23 Spark Plugs 23 Che...

Page 3: ...or s Manual and Safety Handbook Failure to follow this warning could result in personal injury to yourself or others Personal Injury To avoid injury to yourself and others NEVER operate the snowmobile without first reading and understanding this manual and the Snowmobile Safety Hand book then follow the instructions and heed the warnings given USE COMMON SENSE DON T DRINK and DRIVE STAY IN CONTROL...

Page 4: ...ge instructions If major repair or service is ever required contact an autho rized Yamaha Snowmobile dealer for professional service At the time of publication all information and illustrations were technically correct Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions Because Yamaha constantly refines and improves its product...

Page 5: ...egistration information Control Locations Shown are the typical control locations for Yamaha snowmobiles Location of a specific control will vary according to model 0749 256C Gasoline Oil Recommended Gasoline The recommended gasoline to use in these snowmobiles is 87 octane regular unleaded In many areas oxygenates are added to the gasoline Oxygenated gaso lines containing up to 10 ethanol are acc...

Page 6: ...60 500 km 100 300 miles Avoid pro longed operation above 8000 RPM 500 km 300 miles and beyond The snowmobile can now be operated nor mally NOTE After 800 km 500 miles of operation the engine oil must be changed and the oil filter replaced If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the snowmobile Drive Belt Break In Drive belts requir...

Page 7: ...or The indicator relates to engine oil pres sure not the oil level however if the oil level is low it may affect oil pressure If oil pressure is lost check the oil level see page 21 If the indicator does not go out or if the engine does not start take the snowmo bile to an authorized Yamaha Snowmo bile dealer If not under warranty this service is at the discretion and expense of the snowmobile own...

Page 8: ...n gauge display H Engine Hour Meter Odometer Trip Meter Clock This display shows engine hours odome ter trip meter or clock Press the Lower Right Button to change which parameter is being displayed The Engine Hour Meter and Odometer cannot be reset To reset the trip meter select the Trip Meter then press and hold the Lower Right But ton until the trip meter display reads 0 NOTE The clock can only ...

Page 9: ...trol system circuit low P0509 Idle air control system circuit high P0511 Idle air control circuit P0522 Engine oil pressure sensor circuit low P0523 Engine oil pressure sensor circuit high P0562 System voltage low P0563 System voltage high P0780 Shift Error P1315 Crankshaft Position out of sync P1338 Crankshaft spike detected P1339 Crankshaft tooth not detected P1685 Main relay open circuit P1686 ...

Page 10: ...e If so use the following procedure to carefully and safely complete this procedure NOTE To access the battery the seat must be removed 1 For the snowmobile to be jump started slide any terminal boots away 2 Inspect the battery for any signs of electrolyte leaks loose terminals or bulging sides Leaking or bulging battery cases may indicate a frozen or shorted battery 3 Inspect the snowmobile to be...

Page 11: ...l away from the dead bat tery and start the vehicle with the good battery Allow the vehicle to run for several minutes applying some charge to the dead battery 9 Start the snowmobile with the dead battery and allow it to run for several minutes before disconnecting the jumper cables 10 Remove the jumper cables in oppo site order of hook up 4 3 2 1 Be careful not to short cables against bare metal ...

Page 12: ...the internal fibers weakening the track Avoid spinning 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 man ufacturer for installation and stud pattern recommendations Yamaha does not rec ommend studding a track Paddle Track On Equipped Models These models are equipped with...

Page 13: ...g procedure 1 Remove the hairpin clip from the pin located at the front of the access panel Remove the thumb screw securing the front left access panel to the front fascia Move the panel up and off the pin then swing the panel all the way out and unhinge the panel from the lower console 2 Remove the torx head screws secur ing the hood located on the underside of the hood above the front tube of th...

Page 14: ...at Models with this option can be adjusted with a HIGH and LOW switch which will be located near the gas tank cap SNO 766 Towing If the snowmobile is to be towed by another snowmobile do not tow using the loops in the skis The tow rope should be attached to the lower A arms CAUTION Prior to removing the seat lift the rear of the seat and disconnect the seat heater harness connector WARNING People ...

Page 15: ...mark add Yamaha approved DOT 4 brake fluid until the fluid is at the recommended level Install and secure the reservoir cover Do not allow moisture to con taminate the brake system 4 Test the throttle control lever by completely compressing and releas ing it several times The lever MUST return to the idle position quickly and completely 5 Make sure the battery is fully charged to ensure the engine...

Page 16: ...or must be familiar with when operating this snowmobile and its hydraulic brake system Important addi tional information on the proper mainte nance of the brake system is found in the Maintenance section 1 Use the brakes wisely Each time the brakes are applied in all hydraulic brake systems including automotive applications heat is transferred to the brake fluid The amount of heat trans ferred dur...

Page 17: ...ety purposes which will stop the engine when a loss of return spring force occurs If ice forms in the throttle system or if there is some other malfunction of the throttle system result ing in a loss of return spring force the monitor switch will stop the engine when the throttle control lever is released WARNING Excessive repetitive use of the hydraulic brake for high speed stops will cause overh...

Page 18: ... control NOTE If disconnection of the throt tle monitor switch is needed to start the engine take the snowmobile to an authorized Yamaha Snowmobile dealer for service as soon as possi ble If not under warranty this service is at the discretion and expense of the snowmobile owner NOTE The monitor switch is now bypassed All other ignition electrical features ignition switch emergency stop switch hea...

Page 19: ...rough the shift actua tor opening NOTE Be sure to add a small amount of white lithium grease to the O rings of the new actuator extension and the shift actuator detent block before installing 4 Install the actuator extension and gently rotate counter clockwise to make sure the shift fork is in the for ward position When the shift fork is in the forward position make sure the notch in the extension...

Page 20: ...ring the chain case cover oil tank assembly to the chain case housing starting with the bottom screws first NOTE Do not remove all eleven screws completely until the chain lube has been completely removed This will help keep debris oil out of the screw holes 4 Remove all eleven screws then swing the chain case out of the way Account for a thrust washer on the countershaft YM 128A 5 Inspect all cha...

Page 21: ...Connect the harness to the gear posi tion sensor then secure the connec tor to the main harness using a cable tie 13 Install the resonator and secure using existing hardware 14 Install the lower console then install the seat hood and both access pan els 15 Start the engine then shift the snow mobile into and out of reverse three times Rear Suspension This procedure should be done every 40 operatin...

Page 22: ...imensions Ski Wear Bars Daily 38 Check for wear and damage Electrical Wiring Weekly Check for wear damage and tight connections Exhaust System Weekly 7 Check for damage leakage and obstructions Nuts Bolts Fasteners Weekly Check tightness Shock Absorbers Weekly 34 Check for fluid leakage and damage and air pres sure Fox Air Shocks Spark Plugs 4000 km 2500 Mi Seasonal 23 Check center electrode insul...

Page 23: ... owner 0747 833 Checking Engine Oil Level NOTE The snowmobile must be on a level surface for this procedure 1 Park the snowmobile on a level sur face then start the engine and let it idle and warm up until the fan on the radiator turns on 2 Shut the engine off then remove the oil level stick from the oil tank and wipe clean Screw in the oil level stick then remove and verify the oil level is withi...

Page 24: ...the tunnel and the support then with a drain pan in position remove the drain plug from the oil tank 746 121A NOTE To aid in draining the oil from the tank position a funnel between the tank and the opening of the tunnel running board 10 After the oil has drained completely install the drain plug with a new O ring and tighten to 2 2 kg m 16 ft lb 11 Install the four screws securing the right side ...

Page 25: ...ct the main harness from the ignition coils then remove the ignition coils from the cylinder head cover 2 Remove the three spark plugs NOTE Prior to installing the spark plugs check the gap between the electrode and ground strap The clearance should be 0 7 0 8 mm 0 028 0 031 in 3 Install new spark plugs Tighten to 1 3 kg m 9 4 ft lb 4 Install the ignition coils onto the cyl inder head cover making...

Page 26: ...wo screws and lock nuts securing the battery bracket solenoid to the seat base then move the bracket up and out of the way and remove the battery 0747 528 4 Thoroughly wash the battery with soap and water then using a wire brush clean the battery posts and cable ends removing all corrosive buildup Replace damaged cables or cable ends CAUTION It is critical that the checking adjust ing valve cleara...

Page 27: ...ery to sit for 1 2 hours 8 Connect the multimeter and test the battery voltage The meter should read no less than 12 5 DC Volts If the voltage is as specified the bat tery is ready for service NOTE If voltage in step 8 is below specifications charge the battery an additional 1 5 hours then retest The battery is ready for service 9 Place the battery into position in the snowmobile then coat the bat...

Page 28: ...XM124A NOTE There are spare fuses beneath the fuse block cover 2 Remove the suspected fuse NOTE Fuse function descriptions are next to the fuse contacts in the fuse block 3 Look through the clear side of the fuse to see if the element inside is burned or separated If it is the fuse is blown and should be replaced with a fuse of the correct amperage rating 4 Install the fuse block cover and close t...

Page 29: ... an inaccurate reading 2 Measure the distance between the brake lever and the handlebar The distance must be greater than 25 4 mm 1 in 0745 816B 3 If the resultant distance is less than specified take the snowmobile to an authorized Yamaha Snowmobile dealer for service If not under war ranty this service is at the discretion and expense of the snowmobile owner WARNING DO NOT operate the snowmobile...

Page 30: ...h brake fluid mark then install and secure the cover Remove the tube from the bleeder valve Checking Changing Brake Pads The condition of the brake pads must be checked daily and changed if worn or damaged To check and change the brake pads use the following procedure NOTE The brake pads may be changed by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snow...

Page 31: ...eservoir if necessary to the proper level with fresh brake fluid then install the cover 13 Secure the brake shield the driven clutch tightened to 20 ft lb and the rear belt guard then close and secure the left side access panel NOTE When new brake pads are installed a burnishing process is required see Burnishing Brake Pads sub section Burnishing Brake Pads After changing brake pads the new brake ...

Page 32: ...manufacturers may not be of the same specifications or quality and therefore usage could result in poor performance and pre mature belt failure NOTE Before starting the snowmo bile in extremely cold temperatures the drive belt should be removed and warmed up to room temperature Once the drive belt is at room tem perature install the drive belt Also new drive belts have a break in period of approxi...

Page 33: ...a week thereafter and adjusted according to need The track will stretch and take a set during break in Track deflection must be maintained within the recommended range Checking Track Tension 1 Remove excess ice and snow buildup from the track track drive sprockets and the inside of the skid frame 2 Elevate the snowmobile on a shielded safety stand high enough to use a spring scale 3 At the mid poi...

Page 34: ...en the rear idler wheels are equal distance from the inner track drive lugs Excessive wear to the idler wheels drive lugs and track will occur if the track is improperly aligned Yamaha recommends that the track alignment be checked once a week or whenever the track tension is adjusted Checking Track Alignment 1 Remove excess ice and snow buildup from the track track drive sprockets and the inside ...

Page 35: ...djusting bolts are snug against the axle housings tighten the idler wheel axle cap screws to 4 7 kg m 34 ft lb 4 Field test the track under actual con ditions 5 After the field test check the align ment of the track If additional adjust ment is necessary repeat Adjusting Track Alignment procedure Suspension The suspension should be adjusted for the operational needs and riding prefer ence of the o...

Page 36: ...If not under warranty this service is at the discretion and expense of the snowmobile owner Adjusting Front Ski Shock Springs The front ski shock springs are individually adjustable for the terrain conditions and driving style of the operator The spring adjuster nut has been set at the factory so the correct amount of threads are exposed between the adjuster nut and the threaded shock body as an i...

Page 37: ...approximately six rotations NOTE As the pump is being attached to the shock the hose will fill with air This will result in a lower gauge pres sure of 0 14 0 35 kg cm2 2 5 psi 3 To decrease air pressure in the shock press the black bleed valve button half way down and hold until desired pressure is attained NOTE Pressing the button fully down and releasing it will allow only a small amount of air ...

Page 38: ...es Rear spring pre load adjustment is accom plished by rotating the adjusting cams Position 3 provides the stiffest ride and position 1 is for the light driver or slow speed trail riding Position 2 is for the average operator under normal conditions Always rotate the cam from the lighter position to the heavier position SNO 595 To rotate an adjusting cam use the spark plug wrench from the tool kit...

Page 39: ...be adjusted for vertical aim of the HIGH LOW beam The geo metric center of HIGH beam zone is to be used for vertical aiming 1 Position the snowmobile on a level floor so the headlight is approxi mately 8 m 25 ft from an aiming surface wall or similar surface NOTE There should be an aver age operating load on the snowmo bile when adjusting headlight aim 2 Measure the distance from the floor to midp...

Page 40: ...e from an authorized Yamaha Snowmobile dealer Removing Dual 1 Using Front End Lift elevate the front of the snowmobile 2 Remove the lock nuts washers and spacers securing the wear bars to the ski 3 Remove the wear bars from the ski NOTE When the wear bars are removed measure the thickness of both wear bars to see if they are within the wear limit of 6 0 mm 0 24 in A and B Replace as necessary SNO ...

Page 41: ...ocedure for the other ski Rail Wear Strips Yamaha recommends that the wear strips be checked weekly and replaced as nec essary Measure the wear strips at 254 mm 10 in intervals Wear strips must be 10 7 mm 0 42 in thick or thicker 0745 807 If wear strip measurements are less than specified replacement of both wear strips is necessary to prevent premature track clip wear and possible track damage Ta...

Page 42: ...lt is posi tioned from 1 5 mm 0 06 in above the edge of the driven clutch sheaves to 0 5 mm 0 02 in below the edge SNO 337 3 Adjust the position by removing or adding a spacer on each adjusting bolt SNO 338 Spacer Part Numbers 90201 061H1 0 5 mm 0 02 in 90201 06037 1 0 mm 0 04 in 4 Close the access panel DRIVE CLUTCH AND DRIVEN CLUTCH Keeping the drive clutch and driven clutch clean should be the ...

Page 43: ...SNO 324 NOTE The straightedge must extend beyond the front edge of the drive clutch 4 If offset adjustment needs to be made remove the driven clutch and add shims p n 8JP RA449 00 2 mm 8JP RA448 00 1 mm to increase the offset or remove shims to decrease the offset 5 Once the correct offset is reached install driven clutch and tighten cap screw to 6 4 kg m 43 ft lb NOTE When adjusting the driven cl...

Page 44: ...utch 9 Apply light oil to the upper steering post bushing and shafts of the shock absorbers 10 Lubricate the rear suspension with all temperature grease 11 Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely Make sure all rivets hold ing the components together are tight Replace all loose rivets 12 Clean and polish the hood console and chassis DO ...

Page 45: ...lace if damaged or worn Install the drive belt NOTE If the old belt is worn but in reasonable condition retain it with the snowmobile as a spare in case of emergency 5 Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely 6 If not done during preparation for storage lubricate the rear suspen sion with all temperature grease 7 Check the coolant level...

Page 46: ...44 Snowmobile Safety Rules ...

Page 47: ...ce by an authorized Yamaha dealer 2 Competition racing or non Yamaha authorized rental use 3 Operation on surfaces other than snow or ice 4 Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts 5 Abnormal strain neglect or abuse 6 Lack of proper maintenance 7 Accident or collision damage 8 Modification to original parts SPECIFIC EXCLUSIONS from this war...

Page 48: ... and November 30 All new Yamaha snowmobiles purchased between May 1 and November 30 will have the warranty extended to November 30 of the following year WARRANTY QUESTIONS AND ANSWERS Q What costs are my responsibility during the warranty period A The customer s responsibility includes all costs of normal mainte nance services non warranty repairs accident and collision damages as well as oil spar...

Page 49: ...oblem arises regarding warranty first contact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assis tance please write U S A CUSTOMERS YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPART MENT P O Box 6555 Cypress California 90630 CANADIAN CUSTOMERS YAMAH...

Page 50: ...maha does with the industry s best warranty coverage and best extended warranty plan Yamaha Protection Plus Yamaha Protection Plus gives you the option to extend your factory warranty by 12 24 months depending on your product and requirements Combine that with Yamaha s unsurpassed reputation for reliability and you ve got the peace of mind you deserve While other plans can confuse you with deducti...

Page 51: ...ine parts and factory authorized service for the full dura tion of your coverage For further information contact your dealer For a dealer near you visit our web site www yamaha motor ca For your best ownership experience think Genuine Yamaha Genuine Yamaha Parts Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle providing you with the performa...

Page 52: ...50 NOTES ...

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Page 54: ...Printed on recycled paper Printed in U S A 2017 xx x x 1 AC U8HK75E0 book Page 1 Wednesday May 1 2013 2 07 PM ...

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