YAMAHA FX10X, FX10RTX, FX10RTRX, FX10RTRAX, FX10MTX SERVICE MANUAL
...
SERVICE MANUAL
2008
FX10X
FX10RTX
FX10RTRX
FX10RTRAX
FX10MTX
FX10MTRX
FX10MTRAX
LIT-12618-02-69 8GL-28197-10
NOTICE
This manual was written by the Yamaha Motor
Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to put an
entire mechanic’s education into one manual, so it
is assumed that persons using this book to perform
maintenance and repairs on Yamaha snowmobiles
have a basic understanding of the mechanical concepts and procedures inherent in snowmobile
repair. Without such knowledge, attempted repairs
or service to this model may render it unfit and/or
unsafe to use. Yamaha Motor Company, Ltd. is
continually striving to improve all models manufactured by Yamaha. Modifications and significant
changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will,
where applicable, appear in future editions of this
manual.
HOW TO USE THIS MANUAL
Particularly important information is distinguished in
this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BE
ALERT! YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result
in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing
the snowmobile.
CAUTION:
A CAUTION indicates special precautions that
must be taken to avoid damage to the snowmobile.
NOTE:
A NOTE provides key information that can make
procedures easier or clearer.
FX10X, FX10RTX, FX10RTRX, FX10RTRAX,
FX10MTX, FX10MTRX, FX10MTRAX
SERVICE MANUAL
©2007 by Yamaha Motor
Corporation, U.S.A.
1st Edition, July 2007
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N.LIT-12618-02-69
MANUAL FORMAT
All of the procedures in this manual are organized
in a sequential, step-by-step format. The information has been compiled to provide the mechanic
with an easy to read, handy reference that contains
comprehensive explanations of all inspection,
repair, assembly, and disassembly operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required to correct the problem will
follow the symbol, e.g.,
• Bearings
Pitting/damage → Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before
each disassembly section to facilitate correct disassembly and assembly procedures.
1 2
GEN
INFO
34
INSP
ADJ
POWR
CHAS
TR
56
ENG
78
COOL
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 9 are designed as thumb
tabs to indicate the chapter’s number and content.
1 General information
2 Periodic inspection and adjustment
3 Chassis
4 Power train
5 Engine
6 Cooling system
7 Fuel injection system
8 Electrical
9 Specifications
–+
9
FI
ELEC
SPEC
0AB
T
.
R
.
CDE
FGH
LT
IJKL
E
MNO
B
PQR
G
LS
M
5
BF
M
Illustrated symbols 0 to F are used to identify the specifications which appear.
0
Filling fluid
A Lubricant
B Tightening torque
C Wear limit, clearance
D Engine speed
E Special tool
F Electrical data (Ω, V, A)
Illustrated symbols G to R in the exploded diagram
indicate grade of lubricant and location of lubrication point.
G Apply locking agent (LOCTITE
H Apply Yamabond No.5
I Apply engine oil
J Apply gear oil
K Apply molybdenum disulfide oil
L Apply brake fluid
M Apply wheel bearing grease
N Apply low-temperature lithium-soap-based grease
O Apply molybdenum disulfide grease
P Apply silicone grease
Q ESSO beacon 325 grease or Aeroshell grease #7A
R Use new one
®
®
)
S
New
INDEX
GENERAL INFORMATION
PERIODIC INSPECTION AND
ADJUSTMENT
CHASSIS
POWER TRAIN
ENGINE
GEN
INFO
INSP
ADJ
CHAS
POWR
TR
ENG
1
2
3
4
5
COOLING SYSTEM
FUEL INJECTION SYSTEM
ELECTRICAL
SPECIFICATIONS
COOL
FI
– +
ELEC
SPEC
6
7
8
9
CHAPTER 1.
GENERAL INFORMATION
SNOWMOBILE IDENTIFICATION
FRAME SERIAL NUMBER ......................... 1-1
ENGINE SERIAL NUMBER........................ 1-1
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY........................................... 1-2
ALL REPLACEMENT PARTS..................... 1-2
GASKETS, OIL SEALS, AND O-RINGS..... 1-3
LOCK WASHERS/PLATES AND COTTER
PINS............................................................ 1-3
BEARINGS AND OIL SEALS ..................... 1-3
CIRCLIPS ................................................... 1-3
LOCTITE
SPECIAL TOOLS
FOR TUNE UP............................................ 1-4
FOR ENGINE SERVICE............................. 1-4
FOR POWER TRAIN SERVICE ................. 1-7
FOR FUEL INJECTION SERVICE ............. 1-8
FOR ELECTRICAL SERVICE .................... 1-8
®
................................................... 1-3
............................................. 1-4
................... 1-1
.......................... 1-2
CHAPTER 2.
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION
PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM
GENERAL MAINTENANCE AND
LUBRICATION CHART
............................................... 2-1
.............. 2-1
.................................... 2-2
THROTTLE BODY JOINTS
INSPECTION ............................................ 2-23
CHECKING THE AIR FILTER
ELEMENT ................................................. 2-23
EXHAUST SYSTEM INSPECTION .......... 2-25
POWER TRAIN
SHEAVE OFFSET ADJUSTMENT ........... 2-26
DRIVE V-BELT.......................................... 2-28
ENGAGEMENT SPEED CHECK.............. 2-30
PARKING BRAKE PAD INSPECTION ..... 2-31
PARKING BRAKE ADJUSTMENT............ 2-31
BRAKE FLUID LEVEL INSPECTION ....... 2-32
BRAKE PAD INSPECTION....................... 2-33
BRAKE HOSE INSPECTION.................... 2-33
AIR BLEEDING (HYDRAULIC BRAKE
SYSTEM) .................................................. 2-34
DRIVE CHAIN ........................................... 2-35
TRACK TENSION ADJUSTMENT............ 2-37
SLIDE RUNNER INSPECTION ................ 2-39
MAXIMIZING DRIVE TRACK LIFE ........... 2-39
CHASSIS
SKI/SKI RUNNER ..................................... 2-41
STEERING SYSTEM ................................ 2-41
BRAKE LEVER ADJUSTMENT ................ 2-43
LUBRICATION .......................................... 2-43
ELECTRICAL
HEADLIGHT BULB REPLACEMENT ....... 2-45
HEADLIGHT BEAM ADJUSTMENT ......... 2-46
BATTERY INSPECTION........................... 2-46
FUSE INSPECTION.................................. 2-52
TUNING
CLUTCH.................................................... 2-54
GEAR SELECTION................................... 2-56
FRONT SUSPENSION ............................. 2-63
REAR SUSPENSION................................ 2-67
............................................... 2-26
........................................................ 2-41
................................................. 2-45
.......................................................... 2-54
ENGINE
............................................................ 2-3
SPARK PLUGS........................................... 2-3
FUEL LINE INSPECTION........................... 2-3
COOLING SYSTEM.................................... 2-4
VALVE CLEARANCE ADJUSTMENT ........ 2-7
THROTTLE BODY
SYNCHRONIZATION ............................... 2-12
THROTTLE CABLE FREE PLAY
ADJUSTMENT.......................................... 2-14
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK .................................... 2-16
COMPRESSION PRESSURE
MEASUREMENT ...................................... 2-17
ENGINE OIL LEVEL INSPECTION .......... 2-19
ENGINE OIL REPLACEMENT ................. 2-20
CYLINDER HEAD BREATHER HOSE
INSPECTION ............................................ 2-23
CHAPTER 3.
CHASSIS
COVERS
STEERING
SKI
........................................................... 3-1
INSTALLATION........................................... 3-3
........................................................ 3-4
FX10............................................................ 3-4
FX10RT/FX10RTR/FX10RTRA .................. 3-6
FX10MT/FX10MTR/FX10MTRA ................. 3-8
REMOVAL................................................. 3-11
INSPECTION ............................................ 3-11
INSTALLATION......................................... 3-12
.................................................................. 3-16
FX10/FX10RT/FX10RTR/FX10RTRA....... 3-16
FX10MT/FX10MTR/FX10MTRA ............... 3-17
INSPECTION ............................................ 3-18
FRONT SUSPENSION ................................... 3-19
FX10/FX10RT/FX10RTR/FX10RTRA....... 3-19
FX10MT/FX10MTR/FX10MTRA ............... 3-21
HANDLING NOTES .................................. 3-23
INSPECTION ............................................ 3-23
INSTALLATION ........................................ 3-24
CHAPTER 4.
POWER TRAIN
SLIDE RAIL SUSPENSION............................ 4-43
FX10.......................................................... 4-43
FX10RT/FX10RTR/FX10RTRA ................ 4-49
FX10MT/FX10MTR/FX10MTRA ............... 4-55
HANDLING NOTES .................................. 4-61
REMOVAL................................................. 4-61
INSPECTION ............................................ 4-61
ASSEMBLY............................................... 4-62
INSTALLATION......................................... 4-66
FRONT AXLE AND TRACK ........................... 4-67
INSPECTION ............................................ 4-68
INSTALLATION......................................... 4-68
PRIMARY SHEAVE AND DRIVE V-BELT ....... 4-1
REMOVAL .................................................. 4-3
DISASSEMBLY........................................... 4-3
INSPECTION .............................................. 4-4
ASSEMBLY................................................. 4-6
INSTALLATION .......................................... 4-9
SECONDARY SHEAVE ................................. 4-11
DISASSEMBLY......................................... 4-13
INSPECTION ............................................ 4-13
ASSEMBLY............................................... 4-14
INSTALLATION ........................................ 4-16
DRIVE CHAIN................................................. 4-17
WITHOUT REVERSE MODEL ................. 4-17
REMOVAL ................................................ 4-19
INSPECTION ............................................ 4-19
INSTALLATION ........................................ 4-21
WITH REVERSE MODEL......................... 4-22
REMOVAL ................................................ 4-25
INSPECTION ............................................ 4-25
INSTALLATION ........................................ 4-26
SECONDARY SHAFT .................................... 4-28
INSPECTION ............................................ 4-29
SECONDARY SHAFT AND DRIVE
CHAIN COVER INSTALLATION .............. 4-30
BRAKE ........................................................... 4-32
BRAKE PAD ............................................. 4-32
BRAKE PAD REPLACEMENT ................. 4-33
BRAKE CALIPER AND
PARKING BRAKE..................................... 4-35
BRAKE CALIPER DISASSEMBLY ........... 4-37
BRAKE CALIPER INSPECTION
AND REPAIR ............................................ 4-37
BRAKE CALIPER ASSEMBLY ................. 4-38
BRAKE CALIPER INSTALLATION........... 4-38
BRAKE MASTER CYLINDER................... 4-39
INSPECTION ............................................ 4-41
BRAKE MASTER CYLINDER
ASSEMBLY............................................... 4-41
INSTALLATION ........................................ 4-42
CHAPTER 5.
ENGINE
SEAT AND FUEL TANK................................... 5-1
REMOVAL................................................... 5-3
INSTALLATION........................................... 5-4
EXHAUST PIPE AND MUFFLER ..................... 5-5
INSTALLATION........................................... 5-7
OIL TANK ......................................................... 5-9
ENGINE ASSEMBLY ..................................... 5-10
HOSES AND LEADS ................................ 5-10
ENGINE ASSEMBLY ................................ 5-12
REMOVAL................................................. 5-13
INSTALLATION......................................... 5-13
CAMSHAFTS.................................................. 5-15
CYLINDER HEAD COVER ....................... 5-15
CAMSHAFTS ............................................ 5-16
REMOVAL................................................. 5-17
INSPECTION ............................................ 5-18
INSTALLATION......................................... 5-22
CYLINDER HEAD........................................... 5-26
REMOVAL................................................. 5-27
INSPECTION ............................................ 5-27
INSTALLATION......................................... 5-28
VALVES AND VALVE SPRINGS ................... 5-30
REMOVAL................................................. 5-31
INSPECTION ............................................ 5-32
INSTALLATION......................................... 5-36
AC MAGNETO ROTOR AND STARTER
CLUTCH ......................................................... 5-39
REMOVAL................................................. 5-40
INSPECTION ............................................ 5-41
INSTALLATION......................................... 5-42
OIL PAN AND OIL PUMP .............................. 5-44
REMOVAL ................................................ 5-47
INSPECTION ............................................ 5-47
INSTALLATION ........................................ 5-49
CRANKCASE ................................................. 5-51
REMOVAL ................................................ 5-53
INSPECTION ............................................ 5-53
INSTALLATION ........................................ 5-54
CONNECTING RODS AND PISTONS ........... 5-57
REMOVAL ................................................ 5-58
INSPECTION ............................................ 5-59
INSTALLATION ........................................ 5-65
CRANKSHAFT AND BALANCER SHAFT .... 5-68
REMOVE .................................................. 5-70
INSPECTION ............................................ 5-71
INSTALLATION ........................................ 5-74
ISC (IDLE SPEED CONTROL) UNIT........ 7-27
AIR FILTER CASE ......................................... 7-28
THROTTLE BODY.......................................... 7-29
INJECTORS.............................................. 7-30
REMOVAL................................................. 7-32
INSPECTION ............................................ 7-32
FUEL PRESSURE INSPECTION ............. 7-33
INSPECTION AND ADJUSTMENT .......... 7-34
CHAPTER 8.
ELECTRICAL
SWITCH INSPECTION ..................................... 8-1
SWITCH INSPECTION ............................... 8-1
INSPECTING A SWITCH SHOWN IN
THE MANUAL ............................................. 8-1
CHAPTER 6.
COOLING SYSTEM
RADIATOR ....................................................... 6-1
INSPECTION .............................................. 6-3
INSTALLATION .......................................... 6-4
THERMOSTAT ................................................. 6-5
INSPECTION .............................................. 6-6
INSTALLATION .......................................... 6-6
WATER PUMP.................................................. 6-7
REMOVAL .................................................. 6-9
DISASSEMBLY........................................... 6-9
INSPECTION ............................................ 6-10
ASSEMBLY............................................... 6-10
INSTALLATION ........................................ 6-11
OIL COOLER AND HEAT EXCHANGER ...... 6-12
INSPECTION ............................................ 6-14
CHAPTER 7.
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM............................. 7-1
CIRCUIT DIAGRAM.................................... 7-2
ECU SELF-DIAGNOSTIC FUNCTION ....... 7-4
SELF-DIAGNOSTIC FUNCTION TABLE ... 7-4
TROUBLESHOOTING CHART .................. 7-6
DIAGNOSTIC MODE.................................. 7-7
TROUBLESHOOTING DETAILS.............. 7-13
OIL PRESSURE SWITCH ........................ 7-26
INTAKE AIR TEMPERATURE
SENSOR................................................... 7-26
IGNITION SYSTEM .......................................... 8-2
CIRCUIT DIAGRAM.................................... 8-2
TROUBLESHOOTING ................................ 8-4
IGNITION SPARK GAP .............................. 8-6
IGNITION COIL........................................... 8-6
CRANKSHAFT POSITION SENSOR ......... 8-7
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.).................................................... 8-8
ENGINE STOP SWITCH ............................ 8-9
THROTTLE SWITCH .................................. 8-9
MAIN SWITCH .......................................... 8-10
ELECTRICAL STARTING SYSTEM .............. 8-11
CIRCUIT DIAGRAM.................................. 8-11
TROUBLESHOOTING .............................. 8-12
STARTER MOTOR ................................... 8-14
CHARGING SYSTEM ..................................... 8-18
CIRCUIT DIAGRAM.................................. 8-18
TROUBLESHOOTING .............................. 8-19
BATTERY.................................................. 8-20
STATOR COIL .......................................... 8-20
LIGHTING SYSTEM ....................................... 8-22
CIRCUIT DIAGRAM.................................. 8-22
TROUBLESHOOTING .............................. 8-24
BULB(S) .................................................... 8-27
HEADLIGHT BEAM SWITCH ................... 8-27
HEADLIGHT RELAY................................. 8-28
LOAD CONTROL RELAY ......................... 8-28
SIGNAL SYSTEM ........................................... 8-30
CIRCUIT DIAGRAM.................................. 8-30
TROUBLESHOOTING .............................. 8-32
BRAKE LIGHT SWITCH ........................... 8-38
DC BACK BUZZER (FX10/FX10RTR/
FX10RTRA/FX10MTR/FX10MTRA) ......... 8-38
COOLANT TEMPERATURE SENSOR .... 8-39
OIL LEVEL SWITCH................................. 8-40
FUEL SENDER......................................... 8-40
SPEED SENSOR...................................... 8-41
GRIP WARMER SYSTEM .............................. 8-42
CIRCUIT DIAGRAM.................................. 8-42
TROUBLESHOOTING.............................. 8-44
GRIP WARMER AND THUMB
WARMER.................................................. 8-45
GRIP/THUMB WARMER ADJUSTMENT
SWITCH.................................................... 8-45
COOLING SYSTEM........................................ 8-46
CIRCUIT DIAGRAM.................................. 8-46
TROUBLESHOOTING.............................. 8-48
RADIATOR FAN MOTOR......................... 8-49
RADIATOR FAN MOTOR RELAY ............ 8-49
CHAPTER 9.
SPECIFICATIONS
GENERAL SPECIFICATIONS ......................... 9-1
MAINTENANCE SPECIFICATIONS ................ 9-5
ENGINE ...................................................... 9-5
POWER TRAIN......................................... 9-10
CHASSIS .................................................. 9-16
ELECTRICAL............................................ 9-18
TIGHTENING TORQUE.................................. 9-20
ENGINE .................................................... 9-20
POWER TRAIN......................................... 9-22
CHASSIS .................................................. 9-25
GENERAL TORQUE SPECIFICATIONS ....... 9-26
DEFINITION OF UNITS .................................. 9-26
CABLE ROUTING .......................................... 9-28
1
GEN
SNOWMOBILE IDENTIFICATION
GENERAL INFORMATION
SNOWMOBILE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number 1 is located on the right-hand side of the frame
(just below the front of the seat).
ENGINE SERIAL NUMBER
The engine serial number 1 is located on the right-hand side of the crankcase.
NOTE:
Designs and specifications are subject to change without notice.
INFO
1-1
GEN
IMPORTANT INFORMATION
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
INFO
1. Remove all dirt, mud, dust, and foreign material before removal and
disassembly.
While cleaning, take care to protect the electrical parts, such as relays,
switches, motor, resistors, controllers, etc., from high pressure water
splashes.
2. Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling the snowmobile, keep mated parts together. This
includes gears, cylinders, pistons, and other parts that have been
“mated” through normal wear. Mated parts must be reused or replaced
as an assembly.
4. During disassembly of the snowmobile, clean all parts and place them
in trays in the order of disassembly. This will speed up assembly time
and help ensure that all parts are reinstalled correctly.
1
5. Keep all parts away from any source of fire.
6. Be sure to keep to the tightening torque specifications. When tightening bolts, nuts, and screws, start with those that have larger diameters,
and proceed from the inside to the outside in a crisscross pattern.
ALL REPLACEMENT PARTS
We recommend using genuine Yamaha parts for all replacements. Use oil
and grease recommended by Yamaha for assembly and adjustments.
1-2
GEN
IMPORTANT INFORMATION
GASKETS, OIL SEALS, AND O-RINGS
1. All gaskets, seals, and O-rings should be replaced when an engine is
overhauled. All gasket surfaces, oil seal lips, and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply
grease to the oil seal lips.
LOCK WASHERS/PLATES AND COTTER PINS
All lock washers/plates 1 and cotter pins must be replaced if they are
removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the
bolt or nut has been properly tightened.
INFO
BEARINGS AND OIL SEALS
Install the bearings 1 and oil seals 2 with their manufacturer marks or
numbers facing outwards. (In other words, the stamped letters must be on
the side exposed to view.) When installing oil seals, apply a light coating
of low temperature lithium-soap-based grease to the seal lips. Oil the
bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the bearings dry. This causes
damage to the surface of the bearings.
CIRCLIPS
All circlips should be inspected carefully before reassembly. Always
replace piston pin clips after one use. Replace misshapen circlips. When
installing a circlip 1, make sure that the sharp edged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view.
Shaft
4
LOCTITE
After installing fasteners that have LOCTITE® applied, wait 24 hours
before using the snowmobile. This will give the LOCTITE
properly.
®
®
time to dry
1-3
GEN
SPECIAL TOOLS
SPECIAL TOOLS
Some special tools are necessary for a completely accurate tune-up and
assembly. Using the correct special tool will help prevent damage that can
be caused by the use of improper tools or improvised techniques.
NOTE:
• Be sure to use the correct part number when ordering the tool, since the
part number may differ according to country.
• For USA and Canada, use part number starting with “YB-”, “YM-”, “YU-”
or “YS-”.
• For others, use part number starting with “90890-”.
FOR TUNE UP
• Dial indicator gauge
P/N: YU-A8428
• Dial gauge
P/N: 90890-03097
This gauge is used for runout measurements.
INFO
• Angle gauge
Use goods on the market.
This tool is used to tighten to specified angles.
• Steering linkage alignment plate
P/N: YS-01531
90890-01531
Locks steering column and pivot arm in place while adjusting the steering
linkage for front-end alignment.
FOR ENGINE SERVICE
• Piston pin puller
P/N: YU-01304
• Piston pin puller set
P/N: 90890-01304
This tool is used to remove the piston pin.
• Heavy duty puller
P/N: YU-33270-B
• Flywheel puller
P/N: 90890-01362
• Crankshaft protector
P/N: YM-33282
• Flywheel puller attachment
P/N: 90890-04089
These tools are used to remove the magneto rotor.
1-4
GEN
SPECIAL TOOLS
• Radiator pressure tester
P/N: YU-24460-01
• Radiator cap tester
P/N: 90890-01325
This tester is used to check the cooling system.
• Radiator pressure tester adapter
P/N: YU-33984
• Radiator cap tester adapter
P/N: 90890-01352
This adapter is used to check the cooling system.
• Oil filter wrench
P/N: YM-01469
90890-01469
This tool is needed to loosen or tighten the oil filter cartridge.
INFO
• Carburetor synchronizer
P/N: YU-44456
• Vacuum gauge
P/N: 90890-03094
This tool is used to synchronize the throttle bodies.
• Engine compression tester
P/N: YU-33223
• Compression gauge
P/N: 90890-03081
This tool is used to measure engine compression.
• Carburetor angle driver 2
P/N:90890-03173
This tool is used to synchronize the throttle bodies.
• Valve spring compressor
P/N: YM-04019
90890-04019
• Valve spring compressor adapter 19.5 mm
P/N: YM-04114
• Valve spring compressor attachment
P/N: 90890-04114
These tools are used to remove or install the valve assemblies.
1-5
GEN
SPECIAL TOOLS
• Bearing driver 40 mm
P/N: YM-04058
• Middle driven shaft bearing driver
P/N: 90890-04058
• Mechanical seal installer
P/N: 90890-04145
These tools are used to install the water pump seal.
• Universal magneto & rotor holder
P/N: YU-01235
• Rotor holding tool
P/N: 90890-01235
This tool is used to hold the camshaft sprockets and oil pump driven gear.
INFO
• Valve guide remover (4.5 mm)
P/N: YM-04116
• Valve guide remover (ø4.5)
P/N: 90890-04116
This tool is used to remove or install the valve guides.
• Valve guide installer (4.5 mm)
P/N: YM-04117
• Valve guide installer (ø4.5)
P/N: 90890-04117
This tool is used to install the valve guides.
• Valve guide reamer (4.5 mm)
P/N: YM-04118
• Valve guide reamer (ø4.5)
P/N: 90890-04118
This tool is used to rebore the new valve guides.
• Valve lapping tool
P/N: YM-A8998
• Valve lapper
P/N: 90890-04101
This tool is needed to remove and install the valve lifters.
• Piston ring compressor
P/N: YM-08037
90890-05158
This tool is used to compress the piston rings when installing the piston
into the cylinder.
1-6
GEN
SPECIAL TOOLS
• Opama pet-4000 spark checker
P/N: YM-34487
• Ignition checker
P/N: 90890-06754
This tool is used to check the ignition system component.
• Engine mount spacer wrench
P/N: YS-01516
90890-01516
Used to turn the engine mounting bolt spacer when removing/installing
engine.
• Yamaha bond No. 1215
P/N: 90890-85505
(Three Bond No.1215
This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces.)
®
)
INFO
FOR POWER TRAIN SERVICE
• Primary clutch holder
P/N: YS-01880-A
• Sheave holder
P/N: 90890-01701
This tool is used to hold the primary sheave and AC magneto rotor.
• Primary sheave puller (18 mm)
P/N: YS-01881-A 1, YS-01881-1 2
90890-01898
This tool is used for removing the primary sheave.
• Clutch spider separator
P/N: YS-28890-C
90890-01711
This tool is used when disassembling and assembling the primary sheave.
• Clutch separator adapter
P/N: YS-34480
90890-01740
This tool is used when disassembling and assembling the primary sheave.
• YXR clutch bushing jig kit
P/N: YS-39752
90890-01528
This tool is used for removal and installation of primary clutch weight and
roller bushings.
1-7
GEN
SPECIAL TOOLS
• Clutch bushing press
P/N: YS-42424
90890-01529
This tool is used for removing and installing the post bushings (primary
sheave cap bush, sliding sheave bush and torque cam bush).
• Track clip installer
P/N: YS-91045-C
90890-01721
This tool is used for installing the track clip.
FOR FUEL INJECTION SERVICE
• Fuel pressure adapter
P/N: YM-03176
90890-03176
This tool is needed to measure fuel pressure.
INFO
• Pressure gauge
P/N: YU-03153
90890-03153
This tool is used to measure fuel pressure.
FOR ELECTRICAL SERVICE
• Analog pocket tester
P/N: YU-03112-C
• Pocket tester
P/N: 90890-03112
This instrument is necessary for checking the electrical components.
• Engine tachometer
P/N: YU-08036-C
90793-80009
This tool is used to check engine speed.
• Model 88 Multimeter with tachometer
P/N: YU-A1927
• Digital circuit tester
P/N: 90890-03174
This instrument is necessary for checking the electrical components.
1-8
INSP
ADJ
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These
preventive maintenance procedures, if followed, will ensure more reliable snowmobile operation and a longer
service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to
snowmobiles already in service as well as new snowmobiles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
INITIAL EVERY
ITEM REMARKS
• Check condition.
Spark plugs
∗
Valve clearance • Check and adjust valve clearance when engine is cold. Every 40000 km (25000 mi)
Crankcase breather system
∗
Fuel filter
∗
Fuel line
∗
Fuel injection
∗
Exhaust system
∗
∗
It is recommended that these items be serviced by a Yamaha dealer.
• Adjust gap and clean.
• Replace if necessary.
• Check breather hose for cracks or damage.
• Replace if necessary.
• Check condition.
• Replace fuel pump assembly if necessary.
• Check fuel hose for cracks or damage.
• Replace if necessary.
• Check synchronization.
• Adjust if necessary.
• Check for leakage.
• Tighten or replace gasket if necessary.
1 month or
800 km
(500 mi)
(40 hr)
Seasonally
or 4000 km
(2500 mi)
(200 hr)
2-1
INSP
ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
GENERAL MAINTENANCE AND LUBRICATION CHART
ITEM REMARKS
Engine oil • Change (warm engine before draining)
Engine oil filter cartridge • Replace.
∗
Cooling system
∗
• Check coolant level.
• Air bleed the cooling system if necessary.
INITIAL EVERY
1 month or
800 km
(500 mi)
(40 hr)
Seasonally
or 4000 km
(2500 mi)
(200 hr)
Every
20000 km
(12000 mi)
• Check engagement and shift speed.
• Adjust if necessary.
Primary and secondary
∗
clutches
Drive chain
∗
Drive chain oil
∗
Brake and parking brake
∗
Control cables
Disc brake installation
∗
Slide runners
∗
Skis and ski runners
∗
Steering system
∗
Steering bearings
∗
Ski and front suspension • Lubricate with specified grease.
∗
Suspension component • Lubricate with specified grease.
∗
Fittings and fasteners
Battery
∗
∗
It is recommended that these items be serviced by a Yamaha dealer.
• Inspect sheaves for wear and damage.
• Inspect weights/rollers and bushings for wear for primary.
• Inspect ramp shoes/bushings for wear for secondary.
• Replace if necessary.
• Lubricate with specified grease.
• Check chain slack.
• Adjust if necessary.
• Check oil level.
• Change.
• Adjust free play and/or replace pads if necessary.
• Change brake fluid. See NOTE following this chart.
• Make sure that operation is smooth.
• Lubricate if necessary.
• Check for slight free play.
• Lubricate shaft with specified grease as required.
• Check for wear and damage.
• Replace if necessary.
• Check for wear and damage.
• Replace if necessary.
• Check toe-out.
• Adjust if necessary.
• Check bearing assemblies for looseness.
• Lubricate with specified grease.
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
• Check condition.
• Charge if necessary.
Whenever operating elevation
is changed.
Initial at 500 km (300 mi) and
every 800 km (500 mi) thereafter.
Every 1600 km (1000 mi)
2
NOTE:
Brake system:
• After disassembling the master cylinder or caliper cylinder, always change the brake fluid. Regularly check
the brake fluid level and add fluid if necessary.
• Replace the oil seals of the master cylinder and caliper cylinder every two years.
• Replace the brake hose every four years, or if cracked or damaged.
2-2
INSP
ADJ
SPARK PLUGS/FUEL LINE INSPECTION
ENGINE
SPARK PLUGS
1. Remove:
• Left side cover
Refer to “COVERS” in CHAPTER 3.
2. Remove:
• Ignition coils
• Spark plugs
3. Inspect:
• Electrodes 1
Damage/wear → Replace the spark plug.
• Insulator color 2
Abnormal color → Replace the spark plug
Normal color is medium-to-light tan.
4. Measure:
• Spark plug gap a
Out of specification → Regap.
Use a wire thickness gauge.
Spark plug gap:
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
1
If necessary, clean the spark plugs with a spark
plug cleaner.
Standard spark plug:
NGK CR9E (NGK)
Before installing a spark plug, clean the gasket surface and spark plug surface.
5. Install:
• Spark plugs
Spark plug:
13 Nm (1.3 m · kg, 9.4 ft · lb)
T
.
R
.
NOTE:
Finger-tighten a the spark plug before torquing
it to specification.
b
FUEL LINE INSPECTION
1. Remove:
• Fuel tank cover
Refer to “SEAT AND FUEL TANK” in CHAPTER 5.
2. Inspect:
• Fuel hose 1
Cracks/damage → Replace.
2-3
INSP
ADJ
COOLING SYSTEM
COOLING SYSTEM
Coolant replacement
NOTE:
The coolant should be changed at least every season.
1. Place the snowmobile on a level surface.
2. Remove:
• Right lower cover
Refer to “COVERS” in CHAPTER 3.
3. Remove:
• Radiator cap 1
2
1
WARNING
Do not remove the radiator cap when the engine
is hot. Pressurized scalding hot fluid and steam
may be blown out, which could cause serious
injury. When the engine has cooled, place a
thick rag or a towel over the radiator cap.
Slowly turn the cap counterclockwise until it
stop. This allows any residual pressure to
escape. When the hissing sound has stopped,
press down on the cap while turning it counterclockwise to remove it.
4. Place an open container under the thermostat
outlet hose, coolant reservoir hose and, for
FX10MT/FX10MTR/FX10MTRA only, heat
exchanger.
5. Disconnect:
• Thermostat outlet hose 2
• Coolant reservoir hose 3
6. Remove:
• Heat exchanger drain bolt 4
(FX10MT/FX10MTR/FX10MTRA)
7. Drain the coolant.
3
4
NOTE:
Lift up the tail of the snowmobile to drain the coolant.
WARNING
Coolant is poisonous. It is harmful or fatal if
swallowed.
• If coolant is swallowed, induce vomiting
immediately and get immediate medical attention.
• If coolant splashes in your eyes, thoroughly
wash them with water and consult a doctor.
• If coolant splashes on your skin or clothes,
quickly wash it away with soap and water.
2-4
INSP
ADJ
COOLING SYSTEM
3
8. Connect:
• Coolant reservoir hose
• Thermostat outlet hose
9. Fill:
• Cooling system
Recommended coolant:
High quality ethylene glycol antifreeze containing corrosion inhibitors
Coolant mixing ratio (coolant:water):
3:2 (60%:40%)
Total amount:
FX10/FX10RT/FX10RTR/FX10RTRA
3.40 L (2.99 Imp qt, 3.59 US qt)
FX10MT/FX10MTR/FX10MTRA
4.70 L (4.14 Imp qt, 4.97 US qt)
CAUTION:
• Hard water or salt water is harmful to engine
parts. If soft water is not available, use boiled
or distilled water.
• Do not use water containing impurities or oil.
3
1
2
10. Bleed the air from the cooling system.
11. Inspect:
• Cooling system
Decrease of pressure (leaks) → Repair as
required.
Inspection steps:
• Attach the cooling system tester 1 and adapter
to the radiator filler 3.
2
Radiator cap tester:
90890-01325
Radiator pressure tester:
YU-24460-01
Radiator cap tester adapter:
90890-01352
Radiator pressure tester adapter:
YU-33984
• Apply 100 kPa (1.0 kg/cm
• Measure the pressure with the gauge.
2-5
2
, 14 psi).
INSP
ADJ
COOLING SYSTEM
È
1
Air bleeding steps:
NOTE:
For models other than FX10MT/FX10MTR/
FX10MTRA, skip steps 1–3.
• Remove the cap 1 on the heat exchanger pipe.
• While slowly adding coolant to the radiator filler,
drain the coolant until no more air bubbles
appear.
• Install the cap 1.
• Add coolant to the full level a.
• Install the radiator cap.
Apply and lock the parking brake. Start the
engine and run it at less than the clutch engagement speed until the coolant circulates (approximately 3 ~ 5 minutes). The heat exchanger will
be warm to the touch (FX10MT/FX10MTR/
FX10MTRA).
FX10MT/FX10MTR/FX10MTRA
È
WARNING
To avoid severe injury or death:
• Make sure the snowmobile is securely supported with a suitable stand.
• Do not exceed the clutch engagement speed.
Drive line damage and excessive V-belt wear
could occur, or the snowmobile could unexpectedly move forward if the clutch engages.
• Operate the engine only in a well-ventilated
area.
c
b
• Remove the radiator cap and bleed the cooling
system again, as described above.
No air bubbles → OK.
• Check the coolant level in the coolant reservoir
when the engine is cold. If the coolant level is
below the “LOW” mark b, add coolant until it
reaches the “FULL” mark c.
2-6
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
VALVE CLEARANCE ADJUSTMENT
NOTE:
• Valve clearance adjustment should be made on a
cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at the top dead center (TDC) on the compression stroke.
1. Drain:
• Engine oil
Refer to “ENGINE OIL REPLACEMENT”.
2. Remove:
• Fuel tank
Refer to “SEAT AND FUEL TANK” in CHAPTER 5.
• Oil tank
Refer to “OIL TANK” in CHAPTER 5.
b
a
1
2
EX IN
3. Remove:
• Cylinder head cover
Refer to “CAMSHAFTS” in CHAPTER 5.
• Timing mark accessing screw 1
• Crankshaft end accessing screw 2
4. Measure:
• Valve clearance
Out of specification → Adjust.
Valve clearance (cold):
Intake valve:
0.15 ~ 0.22 mm
(0.0059 ~ 0.0087 in)
Exhaust valve:
0.21 ~ 0.25 mm
(0.0083 ~ 0.0098 in)
Checking steps:
• Turn the crankshaft clockwise.
• When piston #3 is at TDC on the compression
stroke, align the TDC mark a on the AC magneto rotor with the mark b on the AC magneto
cover.
NOTE:
TDC on the compression stroke can be found when
the camshaft lobes are turned away from each
other.
2-7
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
• Measure the valve clearance with a thickness
gauge 1.
NOTE:
• If the valve clearance is incorrect, record the
measured reading.
• Measure the valve clearance in the following
sequence.
1
Valve clearance measuring sequence
Cylinder #3 → #2 → #1
È Front
For each cylinder, starting with cylinder #3 at TDC,
turn the crankshaft clockwise as specified in the following table.
É Degrees that the crankshaft is turned clockwise
Ê Cylinder
Ë Combustion cycle
Cylinder #2 120°
Cylinder #1 240°
5. Remove:
• Intake camshaft
• Exhaust camshaft
NOTE:
• Refer to “CAMSHAFTS” in CHAPTER 5.
• When removing the timing chain and camshafts,
fasten a wire to the timing chain to retrieve it if it
falls into the crankcase.
2-8
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
6. Adjust:
• Valve clearance
Adjustment steps:
• Remove the valve lifter 1 and the valve pad
with a valve lapper 3.
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
NOTE:
• Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.
• Make a note of the position of each valve lifter
and valve pad 2 so that they can be installed in
the correct place.
• Select the proper valve pad from the following
table.
2
1
Valve pad thickness
range
1.20 ~
Nos.
120 ~ 240
2.40 mm
(0.047 ~
0.094 in)
Available valve pads
25 thicknesses in
0.05 mm (0.0020 in)
increments
NOTE:
• The thickness a of each valve pad is marked in
hundredths of millimeters on the side that
touches the valve lifter.
• Since valve pads of various sizes are originally
installed, the valve pad number must be rounded
in order to reach the closest equivalent to the
original.
• Round off the original valve pad number
according to the following table.
Last digit Rounded value
0 or 2 0
55
810
2-9
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
EXAMPLE:
Original valve pad number = 148 (thickness =
1.48 mm (0.058 in))
Rounded value = 150
• Locate the rounded number of the original valve
pad and the measured valve clearance in the
valve pad selection table. The point where the
column and row intersect is the new valve pad
number.
NOTE:
The new valve pad number is only an approximation. The valve clearance must be measured again
and the above steps should be repeated if the measurement is still incorrect.
2-10
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
VALVE PAD SELECTION TABLE
INTAKE
Measured
clearance
0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.10 ~ 0.14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.15 ~ 0.22 Specification
exa 0.23 ~ 0.27 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
→
0.28 ~ 0.32 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33 ~ 0.37 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 ~ 0.42 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 ~ 0.47 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 ~ 0.52 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 ~ 0.57 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 ~ 0.62 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 ~ 0.67 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 ~ 0.72 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 ~ 0.77 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 ~ 0.82 180 185 190 195 200 205 210 215 220 225 230 235 240
0.83 ~ 0.87 185 190 195 200 205 210 215 220 225 230 235 240
0.88 ~ 0.92 190 195 200 205 210 215 220 225 230 235 240
0.93 ~ 0.97 195 200 205 210 215 220 225 230 235 240
0.98 ~ 1.02 200 205 210 215 220 225 230 235 240
1.03 ~ 1.07 205 210 215 220 225 230 235 240 EXAMPLE:
1.08 ~ 1.12 210 215 220 225 230 235 240
1.13 ~ 1.17 215 220 225 230 235 240
1.18 ~ 1.22 220 225 230 235 240
1.23 ~ 1.27 225 230 235 240
1.28 ~ 1.32 230 235 240
1.33 ~ 1.37 235 240
1.38 ~ 1.42 240
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
↓
INSTALLED PAD NUMBER
VALVE CLEARANCE:
0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in)
Installed is 150
Measured clearance is 0.30 mm (0.0118 in)
Replace 150 pad with 160 pad
EXHAUST
Measured
clearance
0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.03 ~ 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.08 ~ 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.13 ~ 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.18 ~ 0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.21 ~ 0.25 Specification
exa 0.26 ~ 0.30 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
→
0.31 ~ 0.35 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.36 ~ 0.40 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.41 ~ 0.45 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.46 ~ 0.50 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.51 ~ 0.55 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.56 ~ 0.60 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.61 ~ 0.65 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.66 ~ 0.70 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.71 ~ 0.75 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.76 ~ 0.80 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.81 ~ 0.85 180 185 190 195 200 205 210 215 220 225 230 235 240
0.86 ~ 0.90 185 190 195 200 205 210 215 220 225 230 235 240
0.91 ~ 0.95 190 195 200 205 210 215 220 225 230 235 240
0.96 ~ 1.00 195 200 205 210 215 220 225 230 235 240
1.01 ~ 1.05 200 205 210 215 220 225 230 235 240
1.06 ~ 1.10 205 210 215 220 225 230 235 240 EXAMPLE:
1.11 ~ 1.15 210 215 220 225 230 235 240
1.16 ~ 1.20 215 220 225 230 235 240
1.21 ~ 1.25 220 225 230 235 240
1.26 ~ 1.30 225 230 235 240
1.31 ~ 1.35 230 235 240
1.36 ~ 1.40 235 240
1.41 ~ 1.45 240
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
↓
INSTALLED PAD NUMBER
VALVE CLEARANCE:
0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in)
Installed is 175
Measured clearance is 0.35 mm (0.0138 in)
Replace 175 pad with 185 pad
2-11
INSP
ADJ
2
1
VALVE CLEARANCE ADJUSTMENT/
THROTTLE BODY SYNCHRONIZATION
• Install the new valve pad 1 and the valve lifter
.
2
NOTE:
• Apply molybdenum disulfide oil to the valve pad
and the valve lifter.
• The valve lifter must turn smoothly when rotated
by hand.
• Install the valve lifter and the valve pad in the correct place.
• Install the exhaust and intake camshafts, timing
chain and camshaft caps.
Camshaft cap bolt:
10 Nm (1.0 m · kg, 7.2 ft · lb)
T
.
R
.
NOTE:
• Refer to “CAMSHAFTS” in CHAPTER 5.
• Lubricate the camshaft caps, camshaft lobes,
camshaft journals and camshaft cap bolts.
• Align the camshaft marks with the camshaft cap
marks.
• Rotate the crankshaft clockwise several turns to
seat the parts.
• Measure the valve clearance again.
• If the valve clearance is still out of specification,
repeat all of the valve clearance adjustment
steps until the specified clearance is obtained.
7. Install:
• All removed parts
NOTE:
For installation, reverse the removal procedure.
8. Add:
• Engine oil
Refer to “ENGINE OIL REPLACEMENT”.
THROTTLE BODY SYNCHRONIZATION
NOTE:
Prior to synchronizing the throttle bodies, the valve
clearance should be properly adjusted.
1. Remove:
• Fuel tank
Refer to “SEAT AND FUEL TANK” in CHAPTER 5.
2-12
INSP
ADJ
THROTTLE BODY SYNCHRONIZATION
2. Remove:
• Vacuum caps 1
1
1
1
3. Install:
• Vacuum gauge 1
Vacuum gauge:
90890-03094
Carburetor synchronizer:
YU-44456
4. Install:
• Fuel tank
Refer to “SEAT AND FUEL TANK” in CHAPTER 5.
5. Start the engine and let it warm up for several
minutes, and then let it run at specified engine
idling speed.
Engine idle speed:
1,450 ~ 1,550 r/min
6. Adjust:
• Throttle body synchronization
2-13
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