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Table of Contents

Foreword.......................................................2

General Information ................................ 3-16

Snowmobile Identification .........................3

Control Locations .......................................3

Gasoline — Oil...........................................4

Engine Break-In .........................................4

Drive Belt Break-In.....................................5

Deluxe Digital Gauge .................................5

Standard Gauge.........................................7

Diagnostic Codes.......................................8

Handlebar Tilt.............................................9

Exhaust System .........................................9

Air-Intake Silencer......................................9

Cooling System..........................................9

Battery (Electric Start)..............................10

Drive Clutch and Driven Clutch................ 11

Drive Clutch/Driven Clutch Alignment ...... 11

Fuel Pump................................................ 11

Track/Track Studs ....................................12

Paddle Track (on equipped models) ........12

Reverse Operation...................................12

Access Panel/Hood..................................13

Removable Seat ......................................14

Towing......................................................15

Exhaust Power Valve System ..................15

Exhaust-Controlled Timing (ECT) System

.16

Operating Instructions........................... 17-21

Pre-Start ...................................................17

Starting and Stopping Engine ...................18

Braking......................................................19

Emergency Stopping.................................20

Throttle/Ignition Monitor Switch.................20

Varying Altitude Operation.........................21

Lubrication.................................................. 22

Chain Case ...............................................22

Rear Suspension.......................................23

Maintenance.......................................... 24-47

Periodic Maintenance Checklist................24

Fuel System ..............................................25

Checking/Adding Engine Oil .....................25

Why Yamalube ..........................................25

Coolant Level ............................................26

Spark Plugs...............................................26

Checking/Adjusting Exhaust Power Valve

Cables (800).........................................26

Battery (Electric Start)...............................28

Fuses ........................................................32

Brake System............................................33

Burnishing Brake Pads .............................35

Drive Belt ..................................................36

Track Tension............................................37

Track Alignment ........................................40

Suspension ...............................................41

Lights ........................................................44

Ski Wear Bars ...........................................45

Adjusting Ski Stance .................................46

Rail Wear Strips ........................................47

Preparation for Storage.............................. 48

Preparation after Storage........................... 50

Snowmobile Safety Rules .......................... 51

Consumer Information................................ 52

Reference Information................................ 58

Содержание SXV4NP

Страница 1: ...Read this manual carefully before operating this vehicle SXV4NP SXV4NMP TR4NTP TRT4NP TR8NTSP MM8N54EP MM8N54P MM8N65EP OPERATOR S MANUAL LIT 12628 03 91 8NT F8199 72 ...

Страница 2: ...ation information FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH The Operator s Manual snowmobile decals and the Go Snowmobiling website all display import ant information California Proposition 65 The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED WARNING WARNING identifies personal safety related informa tion Follow the directi...

Страница 3: ...iming ECT System 16 Operating Instructions 17 21 Pre Start 17 Starting and Stopping Engine 18 Braking 19 Emergency Stopping 20 Throttle Ignition Monitor Switch 20 Varying Altitude Operation 21 Lubrication 22 Chain Case 22 Rear Suspension 23 Maintenance 24 47 Periodic Maintenance Checklist 24 Fuel System 25 Checking Adding Engine Oil 25 Why Yamalube 25 Coolant Level 26 Spark Plugs 26 Checking Adjus...

Страница 4: ... in this manual are used for clarity purposes only and are not designed to depict actual conditions Because Yamaha constantly refines and improves its products no retroactive obligation is incurred This Operator s Manual should be considered a permanent part of the snowmobile and must remain with the snowmobile at the time of resale If the snowmobile changes own ership more than once contact Yamah...

Страница 5: ...se numbers are required by the dealer to complete warranty claims properly No warranty will be allowed by Yamaha if the engine serial number or VIN is removed or mutilated in any way Always provide the snowmobile name VIN and ESN when contacting an autho rized Yamaha Snowmobile dealer for parts service accessories or warranty If the complete engine must be replaced ask the dealer to notify Yamaha ...

Страница 6: ...and deliver a richer fuel oil ratio during the engine break in period 800 The break in period occurs in two stages Stage One occurs during the first 18 min utes of a new engine s run time where the ECM will provide additional fuel and oil to the engine Stage Two occurs after the completion of Stage One However Stage Two still provides additional fuel and oil to the engine for the remainder of 6 ho...

Страница 7: ...se flashing and will remain con tinuously illuminated B High Beam Indicator The indicator is on whenever the high beam mode is selected by the headlight switch C Low Oil Indicator The indicator is designed to alert the snowmobile operator when the oil in the oil injection tank gets below a prescribed level Once the indicator illuminates during operation of the snowmobile the operator must periodic...

Страница 8: ...en speed is displayed on the left screen the right screen will display RPM clock or altimeter Press the Upper Right Button to cycle the right screen between speed RPM clock and altimeter Press and hold the Upper Button on the speed side of the gauge to shift between standard mph miles and Fahrenheit and metric km h kilometers and Celsius Press and hold the Upper Button on the RPM side to view maxi...

Страница 9: ...press and hold the Left Button to shift between standard mph miles Fahrenheit and metric km h kilometers Celsius 5 Engine Hour Meter Odometer Trip Meter Speedometer Tachometer Clock Display Displays engine hours odometer trip meter speed ometer tachometer and clock Press the Middle Button to change which parameter is being displayed The Engine Hour Meter and Odometer cannot be reset To reset the t...

Страница 10: ...s at the discretion and expense of the snowmobile owner CAUTION If the indicator is illuminated stop the engine immediately and allow it to cool down If unable to either determine or remedy the problem take the snowmo bile to an authorized Yamaha Snowmo bile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner Code Trouble C1600 Thumb Warme...

Страница 11: ...e checked daily If leakage or damage is detected take the snowmobile to an authorized Yamaha Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snow mobile owner When filling the cooling system use an ethylene glycol based coolant water mix ture which will satisfy the coldest antici pated weather conditions of your area in accordance with the c...

Страница 12: ...Make sure all switches on the snowmobile to be jump started are turned OFF 5 Disconnect all external accessories such as cell phones GPS units and radios on both vehicles 6 Attach one clamp of the positive red cable to the positive termi nal 1 of the dead battery C being careful not to touch any metal with the other clamp then attach the other clamp of the positive red cable to the positive termin...

Страница 13: ...nowmobile dealer for further information Drive Clutch Driven Clutch Alignment The alignment between the drive clutch and driven clutch is set at the factory Normally no adjustment is necessary as long as neither the drive clutch nor the driven clutch is removed or disassembled However if pre mature drive belt wear is experienced or if the drive belt turns over the drive clutch driven clutch alignm...

Страница 14: ...d snow conditions is NOT covered under Yamaha warranty policy Never exceed the maximum sustained speeds for the specific deep lug tracks NOTE If operating on ice or hard packed snow conditions it is recom mended that Ice Scratchers be used to reduce wear strip wear and engine overheating Reverse Operation The engine reverse function offers the oper ator the convenience of being able to back up the...

Страница 15: ...m the skid plate Pull the top of the side panel out and up and off the skid plate 2 Remove the Torx screw securing the front of the hood to the chassis then loosen the two quarter turn fasteners securing the hood Disconnect the hood harness and remove the hood 0752 484 ONS 305 To install the hood and access panels use the following procedure 1 Position the hood onto the snowmobile and connect the ...

Страница 16: ...t then remove the four tabs from the seat base from the lower console Pull back and remove the seat cover and foam 0747 530 To install the seat use the following pro cedure 1 Position the seat foam into the seat cover by first aligning the front of the foam with the front of the seat base cover then wrap the rear of the seat base cover over the rear of the seat foam Cover the sides of the seat foa...

Страница 17: ...two black machine screws M6 x 35 mm and two M6 black flange nyloc nuts Tighten to 1 1 kg m 96 in lb Secure the seat frame to the two side tun nel brackets using two black machine screws M6 x 25 mm and two M6 black flange nyloc nuts Tighten to 1 1 kg m 96 in lb 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...

Страница 18: ...lled Timing ECT System This system automatically adjusts the ignition timing to provide maximum performance through a variety of operating conditions The ECM receives input on engine RPM demand and exhaust pipe temperature engine condi tion and adjusts the ignition timing accord ingly This system is not adjustable and is maintenance free If a system fault is suspected use an ohm meter to check con...

Страница 19: ...e 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 is turn ing over at a sufficient R...

Страница 20: ...nction is active until the engine reaches operating temperature 7 Flooding If the engine does not start but seems ready to start engage the brake lever lock then compress the throttle control lever fully and try to start the engine When the engine starts release the throttle control lever immediately After the warm up release the brake lever lock NOTE If the engine fails to start during the attemp...

Страница 21: ...pes or grades of brake fluid 3 Never ride the brake Even main taining minimal pressure on the brake lever will cause the brake pads to drag on the disc and may overheat the brake fluid 4 The brake lever lock is not a parking brake and should not be applied for periods exceeding 5 minutes NEVER OPERATE THE SNOW MOBILE WITH THE BRAKE LEVER LOCK ENGAGED 5 Pumping the brake lever is permissible howeve...

Страница 22: ...mobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner 4 If the throttle control lever operates properly rotate the ignition key to the RUN position and go through normal starting procedures NOTE If the throttle control lever operates properly and the engine does not start a malfunctioning monitor switch may be the problem Take the sno...

Страница 23: ...r The Mountain Max 800 models are ini tially set up at the factory for operation at an elevation of 1800 2440 m 6000 8000 ft NOTE Drivetrain changes can be made by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Yamaha Snow mobile dealer for this service This service is at the discretion and expense of the snowmobile owner WARNI...

Страница 24: ...gh the fill plug hole When the lube is halfway up the sight glass install the plug Checking Lubricant Level Models with a level plug NOTE The snowmobile must be on a level surface for this procedure 1 Remove the level plug from the chain case cover The lubricant should be level with the bottom threads of the level plug hole If the lubricant level is correct install the level plug Tighten to 0 7 kg...

Страница 25: ...TE Replacing the lubricant can be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an authorized Yamaha Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner 1 Place the snowmobile on a level sur face Remove both access panels and the hood then remove the exhaust resonator 2 Place a dra...

Страница 26: ... 37 Check adjust Electrical Wiring Weekly Check for wear damage and tight connections Exhaust System Weekly 9 Check for damage leakage and obstructions Fuel System Tank Pump In Line Filter Vent Hose Weekly Check for damage wear obstructions and leak age Nuts Bolts Fasteners Weekly Check tightness Recoil Starter Weekly Check rope for wear fraying and proper operation Shock Absorbers Weekly 41 Check...

Страница 27: ...indicator light illuminates on the gauge The oil tank when filled to the bottom of the filler neck has a capacity of 3 08 L 3 25 quarts The low oil indicator light will illu minate when the oil level is down to 1 09 L 1 15 quarts If the oil level reaches 0 63 L 0 67 quart air can be introduced into the oil pump cavity during vehicle operation causing the risk of engine seizure SNO 874M 1 Park the ...

Страница 28: ...old and resonator 2 Move the expansion chamber out of the way to access the spark plugs 3 Remove the spark plug caps from the plugs 4 Using a spark plug wrench remove the plugs 5 Install the plugs and finger tighten 6 Tighten the spark plugs to 2 6 kg m 19 ft lb then install the spark plug caps 7 Place the expansion chamber into position and secure to the exhaust manifold and resonator with the sp...

Страница 29: ...hen measure the amount of exposed cable from the cable housing to the end of the cable cable drum 0735 516 NOTE The two cable measure ments must be equal in length or less than 0 5 mm 0 020 in differ ence in length from each other NOTE Repeat steps 4 and 5 for each cable then compare the measure ments to the Exhaust Power Valve Cable Length chart NOTE The measurements must be within the specificat...

Страница 30: ... 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 NOTE If battery posts or cable ends have a build up of white green powder residue apply water and baking soda to neutralize acid then flush off with warm soapy water 5 Using a multimeter test the battery voltage The meter must read no less than 12 8 DC ...

Страница 31: ...ery 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 battery posts and cable ends with a light coat of multi purpose grease 10 Secure the red positive cable to the positive terminal on the battery using a cap screw lock washer and a flat washer Tighten securely 11 Secure the main black negative cable and the smal...

Страница 32: ...e both the expansion chamber and the resonator ZR 387 3 Remove the negative battery cable and ground wire then remove the positive cable ZR 386 4 Remove the screw securing the bat tery hold down bracket then remove the battery from the snow mobile 5 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 ...

Страница 33: ...ry to sit for 1 2 hours 9 Connect the multimeter and test the battery voltage The meter should read no less than 12 8 DC Volts If the voltage is as specified the bat tery is ready for service NOTE If voltage in step 9 is below specifications charge the battery an additional 1 5 hours then retest The battery is ready for service 10 Place the battery into position in the snowmobile then coat the bat...

Страница 34: ...Locate the fuse block and remove the fuse block cover NOTE Open the right side access panel the fuse block is on the upper spar ZR 372 ZR 394 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 ...

Страница 35: ...s first Take the snowmobile to an authorized Yamaha Snowmobile dealer for this service This service is at the dis cretion and expense of the snowmobile owner Checking Brake Lever Travel Before each use check the brake lever travel using the following procedure 1 Compress the brake lever fully NOTE Do not pump the brake lever as it will produce an inaccurate reading 2 Measure the distance between t...

Страница 36: ...uid flows free of air bubbles NOTE It may be necessary to refill the reservoir during the bleeding process Never allow the brake fluid to go below the low brake fluid mark in the reservoir 5 When the brake fluid is free of all air and the brake lever feels firm when compressed fill the reservoir to the high brake fluid mark then install and secure the cover Remove the tube from the bleeder valve C...

Страница 37: ...nd remove the remaining fluid then fill the reservoir with fresh fluid and install the cover 9 Pump the brake lever to ensure cor rect positioning of the brake pads and proper brake lever travel then release NOTE If brake lever travel is not within specification bleed the brake system 10 Remove the reservoir cover and fill the reservoir if necessary to the proper level with fresh brake fluid then ...

Страница 38: ...ature install the drive belt Also new drive belts have a break in period of 40 km 25 miles After install ing a new drive belt drive the snowmo bile for 40 km 25 miles at 3 4 throttle or less By revving the engine up and down but not exceeding 100 km h 60 mph the exposed cord on the side of a new belt will be worn down This allows the drive belt to gain its optimum flexibility and will extend drive...

Страница 39: ...ee of the driven clutch 4 When the belt is free of driven clutch remove the belt from the drive clutch Installing 400 1 Place the belt so the arrow is point ing toward the front of the snowmo bile between the sheaves of the drive clutch 2 With the driven clutch sheaves fully apart roll the belt over the stationary sheave 3 With the drive belt properly posi tioned in the drive clutch and driven clu...

Страница 40: ...y stand high enough to use a spring scale 3 At the midpoint of the track shock pad hook a spring scale around a track clip then pull down on the scale to 9 kg 20 lb Measure the deflection distance between the bottom of the wear strip and the inside surface of the track clip Mea surement should be 50 mm 2 0 in 0753 172 ONS 095 NOTE Measurement is from the bottom of the wear strip at the point of th...

Страница 41: ...of the track clip exceeds specifications tighten the adjusting bolt s to take up excessive slack in the track 3 If the distance between the bottom of the wear strip and the inside surface of the track clip is less than specified loosen the adjusting bolts to increase the slack in the track 4 Check track alignment 5 After proper track tension is obtained tighten the idler wheel axle cap screws to 4...

Страница 42: ...are an equal length from the outside of the track no adjust ment is necessary 0755 003 5 If the idler wheels are not centered an adjustment is necessary Adjusting Track Alignment 1 On the side of the track which has the outside of the track closer to the rear idler wheel loosen the idler wheel axle cap screw then rotate the adjusting bolt clockwise 1 to 1 1 2 turns 2 Check track alignment and cont...

Страница 43: ...y Take the snow mobile to an authorized Yamaha Snowmo bile dealer for this service 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 individu ally 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...

Страница 44: ... front of the skid frame and the skis Tightening the limiter strap shortening the strap will pull up on the front of the skid frame and will increase ski pressure Loosening the lim iter strap lengthening the strap lowers the front of the skid frame and decreases ski pressure When customizing the amount of ski pressure be sure to adjust both straps equally and do not over adjust the limiter straps ...

Страница 45: ...te the knob and adjust ment block up and forward until it locks into the upper mounting hole 0755 183 0755 182 Overload Springs NOTE Yamaha recommends that the overload springs be engaged whenever a load on the snowmobile operator cargo exceeds 136 kg 300 lb To either engage or disengage the spring tension blocks use a spark plug socket and a screwdriver to adjust the spring block to the desired p...

Страница 46: ...measurement obtained in step 2 make a horizontal mark on the aiming surface directly in front of the headlight 4 Make a vertical mark which inter sects the horizontal mark on the aim ing surface directly in front of the headlight 5 Engage the brake lever lock and start the engine Move the headlight dim mer switch to the LOW beam posi tion DO NOT USE HIGH BEAM 6 Observe the headlight beam aim Prope...

Страница 47: ...e lever lock 0752 957 Ski Wear Bars The ski wear bar is a replaceable bar attached to the underside of the ski The purpose of the wear bar is to assist in turn ing the snowmobile to minimize ski wear and to maintain good steering control If the snowmobile is operated primarily in deep snow ski wear bar wear will be mini mal however if the snowmobile is oper ated on terrain where the snow cover is ...

Страница 48: ...obile 2 Remove the cotter pin then remove the nut and cap screw securing the ski assembly to the spindle Remove the ski Account for the ski damper inserts spacer and washers NOTE Illustration below shows the spacer on the inside narrow ski stance 0750 103 0755 002 3 To increase ski stance place ski stance spacer to the outside of the spindle and adjust the damper 4 To decrease ski stance place ski...

Страница 49: ...e snowmobile owner Each time a new set of wear strips are installed they should be tempered Tem per the wear strips by driving the snow mobile for approximately a mile on a hard pack trail then immediately drive into deep snow and allow the wear strips to cool Repeat the procedure warming up the wear strips then cooling them down two or three times NOTE The rail wear strips will wear rapidly if th...

Страница 50: ...l starter handle slowly about 10 times C Install the spark plugs and con nect the high tension leads 8 Fill the gas tank to its rated capacity then add Fuel Stabilizer to the gas tank following directions on the con tainer for the stabilizer gasoline ratio Tighten the gas tank cap securely 9 With the snowmobile level check the lubricant level in the chain case If low add chain lube through the fil...

Страница 51: ...ct it from dirt and dust 18 If the snowmobile must be stored out doors position the snowmobile out of direct sunlight then block the entire snowmobile off the ground making sure the snowmobile is secure Loosen the track adjusting bolts to reduce track tension Cover with a machine cover or a heavy tarpaulin to protect it from dirt dust and rain CAUTION Avoid storing in direct sunlight and using a p...

Страница 52: ...wmobile as a spare in case of emergency 5 Inspect all fuel hoses and oil hoses for deterioration or cracks replace if nec essary Make sure all connections are tight then fill the oil injection reservoir with the recommended 2 cycle oil 6 Inspect the spark plugs Replace gap or clean as necessary 7 Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely...

Страница 53: ...51 Snowmobile Safety Rules ...

Страница 54: ...and if it finds that a safety defect exists in a group of vehi cles it may order a recall and remedy campaign However Transport Canada cannot become involved in individual 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...

Страница 55: ...Competition or racing 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 warranty shall include parts replaced due to normal wear or routine ...

Страница 56: ...ay 1 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 ...

Страница 57: ...problem arises regarding warranty first contact the owner of the dealership Since all warranty mat ters 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 assistance please write U S A CUSTOMERS Yamaha Motor Corporation U S A Customer Relations Department P O Box 6555 Cypress California 90630 CANADIAN CUSTOMERS Yama...

Страница 58: ...ce replacement vehicle rental 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 ...

Страница 59: ...der the Yamaha Motor Protection Plan 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 Motor Pro tection Plan takes over automati cally and immediately when your factory warranty expires You can even get Yamaha Motor Protection Plan coverage on many pre owne...

Страница 60: ...sories will fit right and perform right 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 Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your autho ri...

Страница 61: ...Printed on recycled paper Printed in U S A 2022 xx x x 1 AC U8HK75E0 book Page 1 Wednesday May 1 2013 2 07 PM ...

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