YAMAHA RS90K, RS90RK, RSG90K, RS90MK, RST90K SERVICE MANUAL
...
SERVICE MANUAL
MANUEL D’ATELIER
INSTRUKTIONSBOK
RS90K
RS90RK
RSG90K
RS90MK
RST90K
RST90TFK
8FJ-28197-J0
981097
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!
WARNI NG
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.
RS90K, RS90RK, RSG90K,
RS90MK, RST90K, RST90TFK
SERVICE MANUAL
©2004 by Yamaha Motor Co., Ltd.
1st Edition, July 2004
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
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 Carburetion
8 Electrical
9 Specifications
CARB
9
ELEC
–+
SPEC
0AB
T
.
R
.
CDE
FGH
LT
IJK
E
LMN
B
G
LS
5
M
M
Illustrated symbols 0 to F are used to identify the
specifications which appear.
0
Filling fluid
A Lubricant
B Tightening
C Wear limit, clearance
D Engine speed
E Special tool
FΩ, V, A
Illustrated symbols G to O 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 wheel bearing grease
M Apply low-temperature lithium-soap base grease
N Apply molybdenum disulfide grease
O Use new one
®
®
)
O
New
INDEX
INDEX
INNEHÅLLSFÖRTECKNING
GENERAL INFORMATION
RENSEIGNEMENTS GENERAUX
ALLMÄN INFORMATION
PERIODIC INSPECTION AND ADJUSTMENT
INSPECTIONS ET REGLAGES PERIODIQUES
PERIODISK INSPEKTION OCH JUSTERING
CHASSIS
CHASSIS
CHASSI
POWER TRAIN
TRAIN DE ROULEMENT
DRIVENHET
ENGINE
MOTEUR
MOTOR
GEN
INFO
INSP
ADJ
CHAS
POWR
TR
ENG
1
2
3
4
5
COOLING SYSTEM
SYSTEME DE REFROIDISSEMENT
KYLSYSTEM
CARBURETION
CARBURATION
FÖRGASNING
ELECTRICAL
PARTIE ELECTRIQUE
ELSYSTEM
SPECIFICATIONS
CARACTERISTIQUES
SPECIFIKATIONER
COOL
CARB
– +
ELEC
SPEC
6
7
8
9
CHAPTER 1.
GENERAL INFORMATION
MACHINE 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 CARBURETION SERVICE ................ 1-8
FOR ELECTRICAL SERVICE .................... 1-8
®
................................................... 1-3
............................................. 1-4
............................ 1-1
.......................... 1-2
POWER TRAIN
SHEAVE OFFSET ADJUSTMENT ........... 2-25
DRIVE V-BELT.......................................... 2-27
ENGAGEMENT SPEED CHECK.............. 2-29
PARKING BRAKE ADJUSTMENT............ 2-30
BRAKE FLUID LEVEL INSPECTION ....... 2-30
BRAKE PAD INSPECTION....................... 2-31
BRAKE HOSE INSPECTION.................... 2-31
AIR BLEEDING (HYDRAULIC BRAKE
SYSTEM) .................................................. 2-32
DRIVE CHAIN ........................................... 2-33
TRACK TENSION ADJUSTMENT............ 2-35
SLIDE RUNNER INSPECTION ................ 2-37
MAXIMIZING DRIVE TRACK LIFE ........... 2-37
CHASSIS
SKI/SKI RUNNER ..................................... 2-39
STEERING SYSTEM ................................ 2-40
LUBRICATION .......................................... 2-41
ELECTRICAL
HEADLIGHT BEAM ADJUSTMENT ......... 2-44
BATTERY INSPECTION........................... 2-44
FUSE INSPECTION.................................. 2-52
SPEEDOMETER UNIT INSPECTION ...... 2-54
............................................... 2-25
........................................................ 2-39
................................................. 2-44
CHAPTER 2.
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION
PERIODIC MAINTENANCE CHART
ENGINE
............................................................ 2-3
SPARK PLUGS........................................... 2-3
FUEL LINE INSPECTION........................... 2-3
COOLING SYSTEM.................................... 2-4
VALVE CLEARANCE ADJUSTMENT ........ 2-7
CARBURETOR SYNCHRONIZATION ..... 2-13
ENGINE IDLE SPEED ADJUSTMENT..... 2-14
THROTTLE CABLE FREE PLAY
ADJUSTMENT.......................................... 2-15
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK .................................... 2-16
COMPRESSION PRESSURE
MEASUREMENT ...................................... 2-17
ENGINE OIL LEVEL INSPECTION .......... 2-18
ENGINE OIL REPLACEMENT ................. 2-20
CRANKCASE BREATHER HOSE
INSPECTION ............................................ 2-23
CARBURETOR JOINTS INSPECTION .... 2-23
CHECKING THE AIR FILTER
ELEMENT ................................................. 2-23
EXHAUST SYSTEM INSPECTION .......... 2-24
............................................... 2-1
................ 2-1
TUNING
.......................................................... 2-55
CARBURETOR TUNING .......................... 2-55
CLUTCH.................................................... 2-62
GEAR SELECTION................................... 2-67
HIGH ALTITUDE TUNING ........................ 2-73
FRONT SUSPENSION ............................. 2-74
REAR SUSPENSION................................ 2-75
CHAPTER 3.
CHASSIS
STEERING
RS90/RS90R/RSG90/RST90/RST90TF..... 3-1
RS90M ........................................................ 3-3
REMOVAL................................................... 3-7
INSPECTION .............................................. 3-7
INSTALLATION........................................... 3-8
SKI
.................................................................. 3-12
RS90/RS90R/RSG90 “USA/Canada” ....... 3-12
RSG90 “Europe”/RST90 “Europe”/
RST90TF................................................... 3-13
RS90M ...................................................... 3-14
RST90 “USA/Canada”............................... 3-15
INSPECTION ............................................ 3-16
INSTALLATION
(RST90 “USA/Canada”) ............................ 3-17
........................................................ 3-1
FRONT SUSPENSION ................................... 3-18
HANDLING NOTES .................................. 3-20
INSPECTION ............................................ 3-20
INSTALLATION ........................................ 3-21
CHAPTER 4.
POWER TRAIN
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 ................................. 4-10
DISASSEMBLY......................................... 4-12
INSPECTION ............................................ 4-12
ASSEMBLY............................................... 4-13
INSTALLATION ........................................ 4-15
SLIDE RAIL SUSPENSION............................ 4-42
RS90/RS90R............................................. 4-42
RSG90 ...................................................... 4-48
RS90M ...................................................... 4-53
RST90 ....................................................... 4-59
RST90TF................................................... 4-65
REMOVAL................................................. 4-72
INSPECTION ............................................ 4-72
ASSEMBLY............................................... 4-73
INSTALLATION......................................... 4-75
FRONT AXLE AND TRACK ........................... 4-78
INSPECTION ............................................ 4-79
INSTALLATION......................................... 4-79
CHAPTER 5.
ENGINE
SEAT AND FUEL TANK................................... 5-1
RS90/RS90R/RSG90/RS90M ..................... 5-1
DRIVE CHAIN HOUSING ............................... 4-16
WITHOUT REVERSE MODEL ................. 4-16
REMOVAL ................................................ 4-18
INSPECTION ............................................ 4-18
INSTALLATION ........................................ 4-20
WITH REVERSE MODEL......................... 4-21
REMOVAL ................................................ 4-24
INSPECTION ............................................ 4-24
INSTALLATION ........................................ 4-25
SECONDARY SHAFT .................................... 4-27
REMOVAL ................................................ 4-28
INSPECTION ............................................ 4-29
INSTALLATION ........................................ 4-29
SECONDARY SHAFT AND DRIVE
CHAIN HOUSING INSTALLATION .......... 4-32
BRAKE ........................................................... 4-34
BRAKE PAD REPLACEMENT ................. 4-35
BRAKE CALIPER DISASSEMBLY ........... 4-38
BRAKE CALIPER INSPECTION
AND REPAIR ............................................ 4-38
BRAKE CALIPER ASSEMBLY ................. 4-39
BRAKE CALIPER INSTALLATION........... 4-39
INSPECTION ............................................ 4-41
BRAKE MASTER CYLINDER
ASSEMBLY............................................... 4-41
INSTALLATION ........................................ 4-41
BACKREST AND PASSENGER SEAT ........... 5-2
RST90/RST90TF ........................................ 5-2
RIDER SEAT AND FUEL TANK ...................... 5-3
RST90/RST90TF ........................................ 5-3
REMOVAL................................................... 5-4
INSTALLATION........................................... 5-4
OIL TANK ......................................................... 5-5
ENGINE ASSEMBLY ....................................... 5-6
HOSE AND LEADS..................................... 5-6
ENGINE ASSEMBLY .................................. 5-8
REMOVAL................................................... 5-9
INSTALLATION........................................... 5-9
EXHAUST PIPE AND MUFFLER ................... 5-11
INSTALLATION......................................... 5-12
CAMSHAFTS.................................................. 5-14
CYLINDER HEAD COVER ....................... 5-14
CAMSHAFTS ............................................ 5-15
REMOVAL................................................. 5-16
INSPECTION ............................................ 5-17
INSTALLATION......................................... 5-20
CYLINDER HEAD........................................... 5-24
REMOVAL................................................. 5-25
INSPECTION ............................................ 5-25
INSTALLATION......................................... 5-26
VALVES AND VALVE SPRINGS ................... 5-28
REMOVAL................................................. 5-29
INSPECTION ............................................ 5-30
INSTALLATION......................................... 5-34
A.C. MAGNETO ROTOR
AND STARTER CLUTCH............................... 5-37
REMOVAL ................................................ 5-38
INSPECTION ............................................ 5-39
INSTALLATION ........................................ 5-40
OIL PAN AND OIL PUMP .............................. 5-42
REMOVAL ................................................ 5-45
INSPECTION ............................................ 5-45
INSTALLATION ........................................ 5-47
CRANKCASE ................................................. 5-49
CRANKCASE............................................ 5-49
CONNECTING RODS AND PISTONS ..... 5-51
CRANKSHAFT
AND BALANCER SHAFT ......................... 5-52
REMOVAL ................................................ 5-54
INSPECTION ............................................ 5-56
INSTALLATION ........................................ 5-67
CHAPTER 8.
ELECTRICAL
SWITCH INSPECTION ..................................... 8-1
SWITCH INSPECTION ............................... 8-1
INSPECTING A SWITCH SHOWN
IN THE MANUAL ........................................ 8-1
IGNITION SYSTEM .......................................... 8-2
CIRCUIT DIAGRAM.................................... 8-2
TROUBLESHOOTING ................................ 8-3
IGNITION SPARK GAP .............................. 8-5
IGNITION COIL........................................... 8-5
PICKUP COIL ............................................. 8-6
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.).................................................... 8-7
ENGINE STOP SWITCH ............................ 8-7
THROTTLE SWITCH .................................. 8-8
MAIN SWITCH ............................................ 8-8
CHAPTER 6.
COOLING SYSTEM
HEAT EXCHANGER ........................................ 6-1
INSPECTION .............................................. 6-4
INSTALLATION .......................................... 6-5
THERMOSTAT ................................................. 6-6
INSPECTION .............................................. 6-7
INSTALLATION .......................................... 6-7
WATER PUMP.................................................. 6-9
REMOVAL ................................................ 6-11
DISASSEMBLY......................................... 6-11
INSPECTION ............................................ 6-12
ASSEMBLY............................................... 6-12
INSTALLATION ........................................ 6-13
CHAPTER 7.
CARBURETION
CARBURETORS AND FUEL PUMP................ 7-1
INSPECTION .............................................. 7-6
ASSEMBLY................................................. 7-8
INSTALLATION .......................................... 7-9
FUEL LEVEL ADJUSTMENT ................... 7-10
THROTTLE POSITION SENSOR (T.P.S.)
INSPECTION AND ADJUSTMENT .......... 7-11
INSPECTION ............................................ 7-12
INSTALLATION ........................................ 7-13
ELECTRICAL STARTING SYSTEM ................ 8-9
CIRCUIT DIAGRAM.................................... 8-9
TROUBLESHOOTING .............................. 8-10
STARTER MOTOR ................................... 8-12
CHARGING SYSTEM ..................................... 8-17
CIRCUIT DIAGRAM.................................. 8-17
TROUBLESHOOTING .............................. 8-18
BATTERY.................................................. 8-19
A.C. MAGNETO ........................................ 8-19
LIGHTING SYSTEM ....................................... 8-20
CIRCUIT DIAGRAM.................................. 8-20
TROUBLESHOOTING .............................. 8-21
BULB(S) .................................................... 8-23
HEADLIGHT BEAM SWITCH ................... 8-23
HEADLIGHT RELAY................................. 8-23
LOAD CONTROL RELAY ......................... 8-24
SIGNAL SYSTEM ........................................... 8-25
CIRCUIT DIAGRAM.................................. 8-25
TROUBLESHOOTING .............................. 8-26
BRAKE LIGHT SWITCH ........................... 8-32
GEAR POSITION SWITCH
(RS90R/RSG90/RST90/RST90TF)........... 8-32
DC BACK BUZZER
(RS90R/RSG90/RST90/RST90TF)........... 8-32
COOLANT TEMPERATURE SENSOR .... 8-33
OIL LEVEL SWITCH ................................. 8-34
FUEL SENDER ......................................... 8-34
SPEED SENSOR...................................... 8-35
GRIP WARMER SYSTEM .............................. 8-36
CIRCUIT DIAGRAM.................................. 8-36
TROUBLESHOOTING.............................. 8-37
GRIP AND THUMB WARMER COIL ........ 8-39
THUMB WARMER ADJUSTMENT
SWITCH.................................................... 8-39
GRIP WARMER ADJUSTMENT
SWITCH.................................................... 8-40
PASSENGER GRIP WARMER
(RST90/RST90TF).................................... 8-40
PASSENGER GRIP WARMER SWITCH
(RST90/RST90TF).................................... 8-41
PASSENGER GRIP WARMER RELAY
(RST90/RST90TF).................................... 8-41
CARBURETOR HEATER SYSTEM ............... 8-42
CIRCUIT DIAGRAM.................................. 8-42
TROUBLESHOOTING.............................. 8-43
CARBURETOR HEATER RELAY ............ 8-44
CARBURETOR HEATER ......................... 8-44
SELF-DIAGNOSIS.......................................... 8-45
SELF-DIAGNOSIS CODE ........................ 8-46
CHAPTER 9.
SPECIFICATIONS
GENERAL SPECIFICATIONS ......................... 9-1
MAINTENANCE SPECIFICATIONS ................ 9-4
ENGINE ...................................................... 9-4
POWER TRAIN........................................... 9-9
CHASSIS .................................................. 9-15
ELECTRICAL............................................ 9-17
HIGH ALTITUDE SETTINGS.................... 9-19
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 .......................................... 9-27
1
1
GEN
MACHINE IDENTIFICATION
GENERAL INFORMATION
MACHINE 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
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”.
INFO
3. When disassembling the machine, 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 machine, 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.
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’s 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 lightweight lithium base 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 machine. This will give the LOCTITE
erly.
®
®
time to dry prop-
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-”,
“YS-” or “ACC-”.
• For others, use part number starting with “90890-”.
FOR TUNE UP
• Dial gauge
P/N: YU-03097
90890-03097
This gauge is used for run out measurement.
INFO
• Fuel level gauge
P/N: YM-01312-A
90890-01312
This gauge is used to measure the fuel level in the float chamber.
• Angle gauge
Use goods on the market.
This tool is used to tightening the torque.
• Steering linkage alignment plate
P/N: YS-01487
90890-01487
Locks steering relay arms in place while adjusting the steering linkage for
front-end alignment.
FOR ENGINE SERVICE
• Piston pin puller
P/N: YU-01304
90890-01304
This tool is used to remove the piston pin.
1-4
GEN
SPECIAL TOOLS
• Rotor holding puller
P/N: YU-33270-B
90890-01362
• Flywheel puller attachment
P/N: YM-33282
90890-04089
These tools are used to remove the magneto rotor.
• Cooling system tester
P/N: YU-24460-01
90890-01325
• Adapter
P/N: YU-33984
90890-01352
This tester and its adapter are used for checking the cooling system.
INFO
• Oil filter wrench
P/N: YM-01469
90890-01469
This tool is needed to loosen or tighten the oil filter cartridge.
• Vacuum gauge
P/N: YU-44456
90890-03094
This guide is used to synchronize the carburetors.
• Compression gauge set
P/N: YU-33223 (compression gage)
90890-03081
P/N: YU-33223-4 (adapter)
90890-04136
These tools are used to measure engine compression.
• Valve spring compressor set
P/N: YM-04019 (valve spring compressor)
90890-04019
P/N: YM-04108 (attachment)
90890-04108
These tools are used to remove or install the valve assemblies.
1-5
SPECIAL TOOLS
• 40 and 50 mm bearing driver
P/N: YM-04058
90890-04058
• Mechanical seal installer
P/N: YM-04145
90890-04145
These tools are used to install the water pump seal.
• Rotor holding tool
P/N: YU-01235
90890-01235
This tool is used to hold the camshaft sprocket.
GEN
INFO
• Valve guide remover (ø5)
P/N: YM-04097
90890-04097
This tool is used to remove or install the valve guides.
• Valve guide installer (ø5)
P/N: YM-04098
90890-04098
This tool is used to install the valve guides.
• Valve guide reamer (ø5)
P/N: YM-04099
90890-04099
This tool is used to rebore the new valve guides.
• 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
• Dynamic spark tester
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-01489
90890-01489
Used to turn the engine mounting bolts when removing/installing engine.
INFO
• Quick gasket
P/N: ACC-QUICK-GS-KT
• Yamaha bond No. 1215
P/N: 90890-85505
This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces.)
®
FOR POWER TRAIN SERVICE
• Sheave holder
P/N: YS-01880-A
90890-01701
This tool is used to hold the primary sheave and A.C. 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
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
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.
• Secondary shaft slide & holder
P/N: YS-01492
90890-01492
Remove and install secondary shaft bearing tapered collar.
Also used to hold the secondary shaft when used with the drive gear
socket (YS-01490/90890-01490).
INFO
• Drive gear socket
P/N: YS-01490
90890-01490
Remove and install drive chain sprocket nut (36 × 100 mm (1.4 × 4in)
deep well socket).
• Ring nut wrench
P/N: YU-01268
90890-01268
Remove and install secondary shaft bearing nut.
FOR CARBURETION SERVICE
• Mity vac
P/N: YS-42423
90890-06756
This tool is used to check the fuel pump.
FOR ELECTRICAL SERVICE
• Pocket tester
P/N: YU-03112-C
90890-03112
This instrument is necessary for checking the electrical components.
• Electro tester
P/N: YU-33260-A
90890-03021
This instrument is invaluable for checking the electrical system.
1-8
SPECIAL TOOLS
• Engine tachometer
P/N: YU-08036-C
90793-80009
This tool is used to check engine speed.
GEN
INFO
1-9
INSP
ADJ
INTRODUCTION/
PERIODIC MAINTENANCE CHART
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 machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to
machines already in service as well as new machines that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART
Regular maintenance is most important for best performance and safe operation.
Item Remarks
Check condition.
Spark plugs
Valve clearance
Engine oil
Engine oil filter cartridge Replace.
Fuel Check fuel level.
Fuel filter
Fuel line
Engine coolant
Carburetor
Engine stop switch
Throttle override system
(T.O.R.S.)
Throttle lever
Exhaust system
Drive guard
V-belt
Drive track and idler wheels
Slide runners
Brake and parking brake
Disc brake installation
Adjust gap and clean.
Replace if necessary.
Check clearance.
Adjust clearance when engine is cold.
Check oil level.
Replace.
Check condition.
Replace if necessary.
Check fuel hose for cracks or damage.
Replace if necessary.
Check coolant level.
Air bleed the cooling system if necessary.
The coolant should be changed at least every season.
Check throttle lever operation.
Adjust the jets.
Check operation.
Repair if necessary.
Check operation.
Repair if necessary.
Check operation.
Repair if necessary.
Check for leakage.
Tighten or replace gasket if necessary.
Check for cracks, bends or damage.
Replace if necessary.
Check for wear and damage.
Replace if necessary.
Check deflection, and for wear and damage.
Adjust/replace if necessary.
Check for wear and damage.
Replace if necessary.
Check operation and fluid leakage.
Adjust free play and/or replace pads if necessary.
Replace brake fluid. See NOTE on page 2-2.
Check for slight free play.
Lubricate shaft with specified grease as required.
Initial
Pre-opera-
tion check
(Daily)
1 month or
800 km
(500 mi)
(40 hr)
Every 40,000 km (25,000 mi)
Whenever operating condition (elevation/temperature) is changed.
Every
Seasonally
or 3,200 km
(2,000 mi)
(160 hr)
Every
20,000 km
(12,000 mi)
Every
1,600 km
(1,000 mi)
2-1
INSP
ADJ
PERIODIC MAINTENANCE CHART
Item Remarks
Drive chain oil
Drive chain
Skis and ski runners
Steering system
Strap (RS90M)
Lights
Battery
Primary and secondary
clutches
Steering column bearing Lubricate with specified grease.
Ski and front suspension Lubricate with specified grease.
Suspension component Lubricate with specified grease.
Parking brake cable end and
lever end/throttle cable end
Shroud latches Make sure that the shroud latches are hooked.
Fittings and fasteners
Tool kit and recommended
equipment
Check oil level.
Replace.
Check deflection.
Adjust if necessary.
Check for wear and damage.
Replace if necessary.
Check operation.
Adjust toe-out if necessary.
Check for damage.
Replace if necessary.
Check operation.
Replace bulbs if necessary.
Check condition.
Charge if necessary.
Check engagement and shift speed.
Adjust if necessary.
Inspect sheaves for wear/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.
Lubricate with specified grease.
Check cable damage.
Replace if necessary.
Check tightness.
Repair if necessary.
Check for proper placement.
Initial
Pre-opera-
tion check
(Daily)
Initial at 500 km (300 mi) and every 800 km
(500 mi) thereafter.
Whenever operating elevation is changed.
1 month or
800 km
(500 mi)
(40 hr)
Every
Seasonally
or 3,200 km
(2,000 mi)
(160 hr)
2
NOTE:
Brake fluid replacement:
1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the
brake fluid level and add the fluid as required.
2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3.Replace the brake hose every four years, or if cracked or damaged.
2-2
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SPARK PLUGS/FUEL LINE INSPECTION
ENGINE
SPARK PLUGS
1. Remove:
• Spark plug caps
• Spark plugs
2. Inspect:
• Electrodes 1
Damage/wear → Replace the spark plug.
• Insulator color 2
3. 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 R CR8E (NGK)
Before installing a spark plug, clean the gasket surface and spark plug surface.
4. 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. Inspect:
• Fuel hoses 1
• Fuel delivery hoses 2
Cracks/damage → Replace.
2
2-3
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1
COOLING SYSTEM
COOLING SYSTEM
Coolant replacement
NOTE:
The coolant should be changed at least every season.
1. Place the machine on a level surface.
2. Make sure that the carburetor coolant shut-off
lever 1 is turned to “ON” a.
(for RS90M)
a
1
1
3. Remove:
• Coolant filler cap 1
WARNING
Do not remove the coolant filler cap 1 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
coolant filler 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 coolant
hoses.
5. Disconnect:
• Coolant hoses 1
6. Drain the coolant.
NOTE:
Lift up the tail of the machine to drain the coolant.
2-4
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2
1
2
COOLING SYSTEM
7. Remove:
• Rear bumper cover 1
8. Disconnect:
• Coolant hoses 2
9. Drain the coolant.
NOTE:
Lift up the front of the machine to drain the coolant
completely.
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.
10. Connect:
• Front coolant hoses
11. Connect:
• Rear coolant hoses
12. Fill:
• Cooling system
Recommended coolant:
High quality silicate-free ethylene
glycol antifreeze containing corrosion inhibitors
Coolant mixing ratio (coolant:water):
3:2 (60%:40%)
Total amount:
RS90/RS90R/RSG90
4.8 L (4.22 Imp qt, 5.07 US qt)
RS90M
6.3 L (5.55 Imp qt, 6.66 US qt)
RST90 “USA/Canada”/RST90TF
“Canada”
5.2 L (4.58 Imp qt, 5.50 US qt)
RST90 “Europe”/RST90TF
“Europe”
5.4 L (4.75 Imp qt, 5.71 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.
13. Bleed the air from the cooling system.
2-5
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1
2
3
COOLING SYSTEM
14. Inspect:
• Cooling system
Decrease of pressure (leaks) → Repair as
required.
Inspection steps:
• Attach the cooling system tester 1 and adapter
to the coolant filler 3.
2
Cooling system tester:
90890-01325, YU-24460-01
Adapter:
90890-01352, YU-33984
1
1
• Apply 100 kPa (1.0 kg/cm
2
, 14 psi).
• Measure the pressure with the gauge.
Air bleeding
1. Remove:
• Rear bumper cover 1
2. Bleed air from the cooling system.
Air bleeding steps:
• Lift up the tail of the machine.
• Remove the bleed bolt 1 on the heat
exchanger.
• While slowly adding coolant to the coolant filler,
drain the coolant until no more air bubbles
appear.
• Tighten the bleed bolt 1.
Bleed bolt:
13 Nm (1.3 m · kg, 9.4 ft · lb)
T
.
R
.
• Add coolant to the coolant cold level
2-6
a.
INSP
ADJ
COOLING SYSTEM/VALVE CLEARANCE ADJUSTMENT
• Install the coolant filler cap.
Apply and lock the parking brake. Start the
engine and run it at approximately 2,500 ~
2,700 r/min until the coolant circulates (approximately 3 ~ 5 minutes). The rear heat exchanger
will be warm to the touch.
WARNING
To avoid severe injury or death:
• Make sure the machine is securely supported
with a suitable stand.
• Do not exceed 2,800 r/min. Drive line damage
and excessive V-belt wear could occur, or the
machine could unexpectedly move forward if
the clutch engages.
• Operate the engine only in a well-ventilated
area.
• Remove the coolant filler cap and bleed the
cooling system again, as described above.
No air bubbles → OK.
• Pour coolant into the coolant reservoir 1 until
the coolant level reaches the “COLD LEVEL”
level mark a.
1
3. Install:
• Rear bumper cover
a
Rear bumper cover bolt:
4 Nm (0.4 m · kg, 2.9 ft · lb)
T
.
R
.
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:
• Coolant
Refer to “COOLING SYSTEM”.
2. Drain:
• Engine oil
Refer to “ENGINE OIL REPLACEMENT”.
3. Remove:
• Oil tank
Refer to “A.C. MAGNETO ROTOR AND
STARTER CLUTCH” in CHAPTER 5.
2-7
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1
VALVE CLEARANCE ADJUSTMENT
4. Remove:
• Cylinder head cover
2
Refer to “CAMSHAFTS” in CHAPTER 5.
• Timing mark accessing screw 1
• Crankshaft end accessing screw 2
b
a
1
5. 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
neto rotor with the mark b on the A.C. magneto
cover.
a on the A.C. mag-
NOTE:
TDC on the compression stroke can be found when
the camshaft lobes are turned away from each
other.
• 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.
Valve clearance measuring sequence
Cylinder #3 → #2 → #1
2-8
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VALVE CLEARANCE ADJUSTMENT
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
#2 Cylinder 120°
#1 Cylinder 240°
6. Loosen:
• Timing chain tensioner cap bolt
Refer to “CAMSHAFTS” in chapter 5.
7. 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.
8. Adjust:
• Valve clearance
Adjustment steps:
• Remove the valve lifter 1 and the valve pad
with a valve lapper 3.
2
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.
1
2-9
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
• Select the proper valve pad from the following
table.
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
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
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VALVE CLEARANCE ADJUSTMENT
VALVE PAD SELECTION TABLE
INTAKE
Measured
clearance
0.00 ~ 0.04 120 125 130
0.05 ~ 0.09 120 125 130 135
0.10 ~ 0.14 120 125 130 135 140
0.15 ~ 0.22 Specification
exa 0.23 ~ 0.27 125 130 135 140 145 150
→
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
135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
VALVE CLEARANCE:
0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in)
Installed is 150
Measured clearance is 0.25 mm (0.0098 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
0.08 ~ 0.12 120 125 130 135 140 145 150 155
0.13 ~ 0.17 120 125 130 135 140 145 150 155 160
0.18 ~ 0.20 120 125 130 135 140 145 150 155 160 165
0.21 ~ 0.25 Specification
exa 0.26 ~ 0.30 125 130 135 140 145 150 155 160 165 170 175
→
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
155 160 165 170 175 180 185 190 195 200 205 210 215 220
160 165 170 175 180 185 190 195 200 205 210 215 220 225
165 170 175 180 185 190 195 200 205 210 215 220 225 230
170 175 180 185 190 195 200 205 210 215 220 225 230 235
180 185 190 195 200 205 210 215 220 225 230 235 240
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
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