Yamaha VK540EK Owner'S Manual Download

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OWNER’S MANUAL

SNOWMOBILE

VK540EK

8AC-28199-1B

LIT-12628-02-34

PRINTED ON RECYCLED PAPER

PRINTED IN JAPAN

2004.04-0.3

1 CR

(E)

YAMAHA MOTOR CO., LTD.

Summary of Contents for VK540EK

Page 1: ...OWNER S MANUAL SNOWMOBILE VK540EK ...

Page 2: ......

Page 3: ... ID and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer 1 The frame number is the seventeen digit number stamped on the frame of the snowmobile 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 C ...

Page 4: ...le If you have any questions 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 VK540EK OWNER S MANUAL 2004 by Yamaha Motor Corpora...

Page 5: ...nual should be considered a permanent part of this snowmobile and should remain with the snow mobile when 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 snowmobile operator a b...

Page 6: ...le lever 6 2 Recoil starter 6 2 Throttle override system T O R S 6 3 Brake 6 4 V belt 6 4 Drive guard 6 5 Drive track 6 5 Slide runners 6 5 Skis and ski runners 6 6 Steering system 6 6 Lights 6 6 Battery 6 6 Fittings and fasteners 6 6 Tool kit and recommended equipment 6 7 OPERATION 7 1 Starting the engine 7 1 Emergency engine starting 7 2 Break in 7 2 Riding your snowmobile 7 3 Getting to know yo...

Page 7: ...sing oil level and the drive chain tension 8 13 Checking the brake pads 8 14 Suspension 8 14 Drive track adjustment 8 18 Ski alignment 8 20 Handlebar adjustment 8 21 Lubrication 8 22 Headlight bulb replacement 8 23 Headlight beam adjustment 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 2 Electric 11 3 WIRING DIAG...

Page 8: ...1 1 ESU00040 1 YAMAHA MOTOR CORPORATION U S A SNOWMO BILE LIMITED WARRANTY CW 01E ...

Page 9: ...1 2 CW 02E ...

Page 10: ...1 3 CW 03E ...

Page 11: ...1 4 ESU04280 YAMAHA EXTENDED SERVICE Y E S CW 06E ...

Page 12: ...priétaire et toutes les étiquettes Avant de démarrer le moteur vérifier l opération du frein de l accélérateur et de la direction Le frein de sécurité doit être appliqué lors du démarrage Ne pas rouler avec le frein de sécurité actionné En cas d urgence utiliser l interrupteur d arrêt du moteur Ne pas laisser tourner le moteur sans la courroie ou sans son garde S assurer que le bouchon du réservoi...

Page 13: ...alcohol or taking drugs 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 7 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 return...

Page 14: ...ine spills on your 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 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 ...

Page 15: ...n 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 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 t...

Page 16: ... 8 Skis 9 Headlight 0 Engine compartment plate A Shroud B Tail brake light C Snow flap D Tow hitch E Storage compartment F Headlight adjusting knob G Engine stop switch H Throttle lever I Drive select lever J Main switch K Starter handle L Starter lever M Grip and thumb warmer switch N Headlight beam switch O Brake lever P Parking brake button ...

Page 17: ...e headlight meter lights and taillight will come on after the engine starts 3 START The starting circuit is switched on The starter motor starts CAUTION 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 N...

Page 18: ...he carburetor or throttle cable should malfunction dur ing operation the T O R S will operate when the throttle lever is released The T O R S is designed to interrupt the ignition and stop the engine if the carburetor fails to return to idle when the lever is released WARNING If the T O R S is activated make sure that the cause of the malfunction has been corrected and that the engine can be opera...

Page 19: ... switch so that you 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 NOTE When the brake lever is operated the brake light will illu minate CAUTION Make sure that the brake lever end does not project out over th...

Page 20: ...he parking brake applied This may overheat 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 CAUTION Do not shift from forward to reverse or fro...

Page 21: ...e headlight adjusting knob to adjust the headlight vertically Headlight beam moves 1 Up 2 Down ESU00421 Grip and thumb warmer switch The grip and thumb warmer switch controls the electri cally heated handlebar grips and throttle lever 1 Grip and thumb warmer switch 2 ON 3 OFF ESU00461 Tripmeter reset knob Use the tripmeter reset knob to reset the tripmeter 1 Tripmeter reset knob 2 Turn countercloc...

Page 22: ...hroud 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 ESU00521 Drive guard The drive guard is designed to cover the V belt clutch and V belt in case parts break or come loose WARNING Make sure that the d...

Page 23: ...plates in the belly pan are installed when operat ing the snowmobile in deep snow Open the engine compartment plate in the shroud and remove the engine compartment plates in the belly pan when the ambient temperature is above 5 C 41 5 F ESU00691 Storage compartment The storage compartment is located under the seat To open the seat unhook the latches and then lift the right side of the seat up To c...

Page 24: ...se the tow hitch within the specified weight limits 1 Tow hitch CAUTION Avoid towing for long periods under 10 km h 6 2 mph to prevent early wear of the V belt Tow weight limit 120 kg 265 lb Vertical weight limit 15 kg 33 1 lb ...

Page 25: ...is sufficient fuel in the fuel tank 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 on its side 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 26: ... oxygenated fuel The fuel tank should be filled with straight gaso line as specified ESU00842 Engine oil Make sure that there is sufficient oil in the oil tank 1 Lower level 2 Upper level ESU00870 Throttle lever Check the throttle lever operation before starting the engine The throttle lever must open smoothly and spring back to its home position when released ESU00880 Recoil starter Check the rec...

Page 27: ...accident 1 Start the engine NOTE Refer to the Starting the engine section 2 Hold the pivot point of the throttle lever away from the throttle 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 operate and the engine shou...

Page 28: ...d to an accident Ask a Yamaha dealer to inspect and repair the brake sys tem CAUTION 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 ESU00941 V belt Open the shroud and remove the drive guard Check the V belt for wear and damage Replace if neces sary WARNING Make sure that the drive guard...

Page 29: ...rate the snowmobile if you 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 ESU00980 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 CAUTION Ride on fresh snow...

Page 30: ...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 page 8 24 for more details ESU01100 Fittings and fasten...

Page 31: ...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 Emergency starter 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 ...

Page 32: ... 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 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 closed position 1 START CAUTION Release the switch immediately after ...

Page 33: ... 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 Yamaha dealer NOTE To ensure proper engine bre...

Page 34: ...h ing for both warmth and to help protect you from injury if an accident occurs Become familiar with operating your snow mobile at low speeds even if you are an experienced rider Do not attempt to oper ate at maximum performance until you are totally familiar with the snowmobile s han dling and performance characteristics The beginning operator should select a large flat area to become familiar wi...

Page 35: ...e 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 throttle to prevent track slippage It is also important to keep your we...

Page 36: ...our downhill leg on the seat and the foot of your 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 possibility that your snowmobile could begin to slip sideways on the slope If this happens steer in the direction of the slide if there are no obstacles in your path As you regain proper bala...

Page 37: ...es 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 ability 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 ally melt away and...

Page 38: ...erheating avoid sustained 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...

Page 39: ...fore shift ing Be sure to move the 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 mph 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 NOTE The reverse buzzer beeps while the drive selec...

Page 40: ...the brake lever ESU01360 Stopping the engine Turn the main switch to the OFF position to stop the engine 1 OFF WARNING Push down the engine stop switch to stop the engine in an emergency Make sure that the key is removed from the main switch whenever the operator leaves the snow mobile to prevent accidental starting ...

Page 41: ... hydrostatic lock When possible the fuel tank should be empty during transportation especially if the trip will be longer than 30 minutes If transporting the snowmobile in an open trailer or truck put a tight fitting cover on the snowmobile A cover specifically 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 ...

Page 42: ...e 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 2 8 6 Adjust the jets Whenever operating condition elevation temperature is changed Fan belt Check wear and damage Replace if necessary 8 10 Adjust fan belt if necessary Recoil starter Check operation an...

Page 43: ...nd or replace pads if necessary Drive chain oil Check oil level 8 13 Replace Drive chain Check deflection Adjust if necessary 8 13 Skis and ski runners Check for wear and damage 6 6 Replace if necessary Steering system Check operation 6 6 Adjust toe out if necessary Lights Check operation Replace bulbs if necessary 6 6 8 23 Battery Check fluid level Add only distilled water if nec essary 6 6 8 24 ...

Page 44: ... grease 8 22 Suspension component Lubricate with specified grease 8 22 Brake cable end and lever end throttle cable end Lubricate with specified grease 8 22 Check cable damage Replace if necessary Shroud latches Make sure that the shroud latches are hooked 5 6 Fittings and fasteners Check tightness Repair if necessary 6 6 Tool kit and recom mended equipment Check for proper placement 6 7 Item Rema...

Page 45: ...ug can indi cate the condition 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 co...

Page 46: ...ing 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 ESU01461 Engine idle speed adjustment CAUTION Be sure to have a Yamaha dealer make this adjustment Make sure that the throttle lever moves smoothly ...

Page 47: ...t 2 Adjuster 3 Tighten the locknut ESU01491 Oil pump cable adjustment CAUTION Be sure to adjust the throttle cable 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 Locknut 2 Adjuster 3 Tighten the locknut Throttle lever free play a 1 0 2 0 mm 0 04 0 08 in Pump cable free play a 25 1 mm 0 98 ...

Page 48: ...vation changes use of alcohol oxygenated fuels etc and should be set by a Yamaha dealer CAUTION 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 Pilot screw adjustment Turn the pilot screw in or out to adjust low speed tuning CD 02E Standard pilot screw position 1 1 4 turns out from the seated position Pilot sc...

Page 49: ...to catch any spilled fuel Handle fuel with care it is HIGHLY FLAMMABLE CD 04E 1 Loosen the carburetor clamps and turn over the car buretor 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 Make sure that the throttle outer cable is firmly seated in the holder and throttle operates smoothly after a...

Page 50: ...maha dealer carefully Proper carburetion adjustments will correct the air fuel ratio Remember less air at higher altitude means there is less horsepower available even with proper carburetion Expect 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 settings for the drive chain gears and V ...

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 If the deflection exceeds the specification consult a Yamaha dealer Standard belt deflection 8 mm 0 31 in 50 N 5 kg 11 lb ...

Page 52: ...ixed sheave and the secondary sliding sheave Serious injury can occur from the sudden release of spring tension during sheave disassembly CAUTION 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 Bel...

Page 53: ... fixed sheave 4 Remove the V belt from the secondary 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 th...

Page 54: ...ve chain housing 3 Check the filler cap O ring and the oil level check bolt gasket Replace if damaged 4 Install the oil level check bolt and filler cap Chain tension adjustment 1 Remove the check hole cap and measure the chain deflection by pushing the chain with your finger 1 Check hole cap If the deflection is not within the specified range adjust the chain tension 2 Loosen the locknut 3 Turn th...

Page 55: ... 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 brake system ESU01882 Suspension The suspension can be adjusted to suit rider preference A softer setting for example may provide greater rider comfort while a harder setting may allow more precise handling and control over certain types of terrain or ...

Page 56: ...mper with or attempt to open the shock absorber Do not subject the shock absorber to an open flame or other high heat sources which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose of a worn or damaged shock absorber by yourself Take the unit to a Yamaha dealer A Spring adjuster position 1 2 3 4 5 Preload Soft Hard È Standard front 3 B Spring adjuster ...

Page 57: ...pring preload by turning the adjuster 1 CD 22E CAUTION Be sure the left and right extension spring preloads are the same Uneven settings can cause loss of sta bility Adjuster Turn in Turn out Preload Hard Soft Snow condition Icy Soft a Standard length 16 mm 0 63 in ...

Page 58: ...urn while holding the adjusting bolt 2 securely with a wrench so it does not move CAUTION Never allow the adjusting bolt 2 to move while loos ening the nut 2 Turn the adjusting bolt 2 to the desired position CAUTION Make sure that the adjusting bolt ends are set at the same position on each side 3 While holding the adjusting bolt securely tighten the full rate adjusting nut 1 CAUTION Never allow t...

Page 59: ...he drive track condition frequently Replace 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 failure could result in loss of braking ability and snow mobile control which could cause an accident Drive track deflection measurement 1 Lay the snowmobile on its side 2 Measure th...

Page 60: ...op the engine 4 Check the 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 CAUTION The right and left adjusters should be turned to an equal amount Drive track alignment 5 Shifted to ...

Page 61: ...xle nut ESU02000 Ski alignment 1 Turn the handlebar 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 3 If the alignment is not correct consult a Yamaha dealer Rear axle tightening torque 80 Nm 8 0 m kgf 58 ft lb Ski toe out 1 2 0 15 mm 0 0 6 in ...

Page 62: ...lts Move the handlebar up or down to adjust the handlebar height to the desired position 3 Tighten the handlebar bolts and install the handlebar cover CAUTION Make sure that the small gap a side of the handlebar holders faces forward b Handlebar bolt tightening torque 15 Nm 1 5 m kgf 11 ft lb ...

Page 63: ...throttle cable ends WARNING 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 ...

Page 64: ...own 5 Install the new bulb CAUTION Keep oil or 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 Set the spring and install the socket cover and then connect the lead coupler ESU04000 Headlight beam adjustment 1 Turn the headlight beam adjuster 1 in o...

Page 65: ...ous 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 explosive gases Keep sparks flam...

Page 66: ...cal system damage and A FIRE HAZ ARD CAUTION Make sure that the main switch is turned off to pre vent 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 ask a Yamaha dealer to inspect the snowmobile Fuse type 10 A ...

Page 67: ...mmediately for repair 3 Compression 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 ha...

Page 68: ... 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 I Engine does not upshift or down shift 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 sh...

Page 69: ...components This is more important in areas where oxygenated fuel gasohol is used because the alcohol content in the fuel increases the chance for water to enter the engine Use Yamaha Stor Rite Engine Fogging Oil or an equiva lent fogging oil to protect both the com bustion chamber and crankshaft from corrosion An alternate method is to remove the carburetor silencer and squirt oil into the carbure...

Page 70: ... of direct sunlight Put a fab ric cover over the snowmobile preferably one that is designed for it Do not use a plastic or vinyl cover condensation could be trapped underneath which could increase the chances of rusting Returning to service after storage When returning your snowmobile to ser vice reinstall the V belt and adjust the drive track Before installing the battery have a Yamaha dealer ins...

Page 71: ...289 kg 637 lb Ski tread 960 mm 37 8 in VK540E Type Axial fan cooled 2 stroke 7 port Cylinder arrangement Parallel 2 cylinder Displacement 535 cm3 Bore Stroke 73 0 64 0 mm 2 87 2 52 in Idle speed 1 200 100 r min Engine oil type YAMALUBE 2 cycle oil Carburetor type MIKUNI B38 34 1 Fuel Unleaded gasoline Pump octane 88 or higher Starting system Electric starter and manual with recoil starter R M 2 ...

Page 72: ...iable 3 8 1 0 95 1 Sheave distance Approx 268 5 mm 10 57 in Sheave offset Approx 16 mm 0 63 in Engagement speed Approx 2 600 r min Shift speed Approx 6 700 r min Drive chain Triple roller chain enclosed in oil bath Reduction ratio 39 17 2 29 Low 28 22 28 22 39 17 3 72 Fuel tank Tank capacity 31 0 L 6 8 lmp gal 8 2 US gal Oil tank Tank capacity 2 5 L 2 2 lmp qt 2 6 US qt Brake Type Caliper type sel...

Page 73: ...ark plug Type BR9ES NGK Gap 0 7 0 8 mm 0 028 0 031 in Battery Capacity YB16AL A2 12 V 16 A h Maximum charge rate 1 6 Amperes hr for 10 hrs Headlight Bulb Quantity 12 V 60 55 W 1 Tail brake light Bulb Quantity 12 V 8 23 W 1 Meter light Bulb Quantity 12 V 3 4 W 1 ...

Page 74: ...N OFF LO HI OFF ON G Y L Y G L G Y G G Y Br G B Y B L B L L B G Y L G Y B L P L P P B P B A WIRE HARNESS HEADLIGHT SUB WIRE HARNESS G B Y L P B G Y P L BLACK BLACK B P P P P L B L L G Y B B G Y B B B W B Y B B W W R R W L R R R R R R R R B B W R W Br R R R W B B Ch Ch Y R B B B Y B Y R Y R B Y B Y B W Y B B W W R B Y Ch O O L Br A A A G B B B B Y G Y G Y G Y L G Y B L G Y B L L L A A 10A 1 2 5 4 3...

Page 75: ...er left E Grip warmer right F Thumb warmer G Speedometer H Back buzzer I Gear position switch J Tail brake light K Headlight L Voltage regulator M Headlight beam switch N Brake light switch O Frame ground COLOR CODE B Black Br Brown Ch Chocolate G Green L Blue O Orange P Pink R Red W White Y Yellow B W Black White B Y Black Yellow G Y Green Yellow L W Blue White R W Red White W R White Red Y B Yel...

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