Loading...YAMAHA RS90K, RS90RK, RSG90K, RS90MK, RST90K SERVICE MANUAL
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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!
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.
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.
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
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.
1 |
2 |
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INFO |
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CHAS |
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POWR |
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TR |
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ENG |
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COOL |
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CARB |
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ELEC – |
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SPEC |
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LT |
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ILLUSTRATED SYMBOLS (Refer to the illustration)
Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content.
1General information
2Periodic inspection and adjustment
3Chassis
4Power train
5Engine
6Cooling system
7Carburetion
8Electrical
9Specifications
Illustrated symbols 0 to F are used to identify the specifications which appear.
0 Filling fluid
ALubricant
BTightening
CWear limit, clearance
DEngine speed
ESpecial tool
FΩ, V, A
Illustrated symbols G to O in the exploded diagram indicate grade of lubricant and location of lubrication point.
GApply locking agent (LOCTITE®)
HApply Yamabond No.5®
IApply engine oil
JApply gear oil
KApply molybdenum disulfide oil
LApply wheel bearing grease
MApply low-temperature lithium-soap base grease
NApply molybdenum disulfide grease
OUse new one
INDEX
INDEX
INNEHÅLLSFÖRTECKNING
GENERAL INFORMATION |
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RENSEIGNEMENTS GENERAUX |
GEN |
1 |
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ALLMÄN INFORMATION |
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INFO |
PERIODIC INSPECTION AND ADJUSTMENT
INSPECTIONS ET REGLAGES PERIODIQUES
PERIODISK INSPEKTION OCH JUSTERING
INSP |
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ADJ |
CHASSIS |
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CHASSIS |
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CHAS |
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CHASSI |
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POWER TRAIN |
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TRAIN DE ROULEMENT |
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POWR |
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DRIVENHET |
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TR |
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ENGINE |
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MOTEUR |
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ENG |
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MOTOR |
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COOLING SYSTEM |
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SYSTEME DE REFROIDISSEMENT |
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COOL |
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KYLSYSTEM |
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CARBURETION |
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CARBURATION |
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CARB |
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FÖRGASNING |
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ELECTRICAL |
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PARTIE ELECTRIQUE |
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ELEC |
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ELSYSTEM |
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SPECIFICATIONS |
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CARACTERISTIQUES |
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SPEC |
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SPECIFIKATIONER |
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CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION............................ |
1-1 |
FRAME SERIAL NUMBER ......................... |
1-1 |
ENGINE SERIAL NUMBER........................ |
1-1 |
IMPORTANT INFORMATION .......................... |
1-2 |
PREPARATION FOR REMOVAL AND |
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DISASSEMBLY........................................... |
1-2 |
ALL REPLACEMENT PARTS..................... |
1-2 |
GASKETS, OIL SEALS, AND O-RINGS..... |
1-3 |
LOCK WASHERS/PLATES |
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AND COTTER PINS ................................... |
1-3 |
BEARINGS AND OIL SEALS ..................... |
1-3 |
CIRCLIPS ................................................... |
1-3 |
LOCTITE® ................................................... |
1-3 |
SPECIAL TOOLS ............................................. |
1-4 |
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 |
CHAPTER 2.
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION............................................... |
2-1 |
PERIODIC MAINTENANCE CHART................ |
2-1 |
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 |
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ADJUSTMENT.......................................... |
2-15 |
THROTTLE OVERRIDE SYSTEM |
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(T.O.R.S.) CHECK .................................... |
2-16 |
COMPRESSION PRESSURE |
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MEASUREMENT ...................................... |
2-17 |
ENGINE OIL LEVEL INSPECTION .......... |
2-18 |
ENGINE OIL REPLACEMENT ................. |
2-20 |
CRANKCASE BREATHER HOSE |
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INSPECTION ............................................ |
2-23 |
CARBURETOR JOINTS INSPECTION .... |
2-23 |
CHECKING THE AIR FILTER |
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ELEMENT ................................................. |
2-23 |
EXHAUST SYSTEM INSPECTION .......... |
2-24 |
POWER TRAIN............................................... |
2-25 |
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 |
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SYSTEM) .................................................. |
2-32 |
DRIVE CHAIN ........................................... |
2-33 |
TRACK TENSION ADJUSTMENT............ |
2-35 |
SLIDE RUNNER INSPECTION ................ |
2-37 |
MAXIMIZING DRIVE TRACK LIFE ........... |
2-37 |
CHASSIS ........................................................ |
2-39 |
SKI/SKI RUNNER ..................................... |
2-39 |
STEERING SYSTEM ................................ |
2-40 |
LUBRICATION .......................................... |
2-41 |
ELECTRICAL ................................................. |
2-44 |
HEADLIGHT BEAM ADJUSTMENT ......... |
2-44 |
BATTERY INSPECTION........................... |
2-44 |
FUSE INSPECTION.................................. |
2-52 |
SPEEDOMETER UNIT INSPECTION ...... |
2-54 |
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 ........................................................ |
3-1 |
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”/ |
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RST90TF................................................... |
3-13 |
RS90M ...................................................... |
3-14 |
RST90 “USA/Canada”............................... |
3-15 |
INSPECTION ............................................ |
3-16 |
INSTALLATION |
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(RST90 “USA/Canada”) ............................ |
3-17 |
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 |
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 |
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CHAIN HOUSING INSTALLATION .......... |
4-32 |
BRAKE ........................................................... |
4-34 |
BRAKE PAD REPLACEMENT ................. |
4-35 |
BRAKE CALIPER DISASSEMBLY ........... |
4-38 |
BRAKE CALIPER INSPECTION |
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AND REPAIR ............................................ |
4-38 |
BRAKE CALIPER ASSEMBLY ................. |
4-39 |
BRAKE CALIPER INSTALLATION........... |
4-39 |
INSPECTION ............................................ |
4-41 |
BRAKE MASTER CYLINDER |
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ASSEMBLY............................................... |
4-41 |
INSTALLATION ........................................ |
4-41 |
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 |
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 |
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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 |
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AND BALANCER SHAFT ......................... |
5-52 |
REMOVAL ................................................ |
5-54 |
INSPECTION ............................................ |
5-56 |
INSTALLATION ........................................ |
5-67 |
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.) |
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INSPECTION AND ADJUSTMENT .......... |
7-11 |
INSPECTION ............................................ |
7-12 |
INSTALLATION ........................................ |
7-13 |
CHAPTER 8.
ELECTRICAL
SWITCH INSPECTION ..................................... |
8-1 |
SWITCH INSPECTION ............................... |
8-1 |
INSPECTING A SWITCH SHOWN |
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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 |
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(T.O.R.S.).................................................... |
8-7 |
ENGINE STOP SWITCH ............................ |
8-7 |
THROTTLE SWITCH .................................. |
8-8 |
MAIN SWITCH ............................................ |
8-8 |
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 |
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(RS90R/RSG90/RST90/RST90TF)........... |
8-32 |
DC BACK BUZZER |
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(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 |
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SWITCH.................................................... |
8-39 |
GRIP WARMER ADJUSTMENT |
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SWITCH.................................................... |
8-40 |
PASSENGER GRIP WARMER |
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(RST90/RST90TF).................................... |
8-40 |
PASSENGER GRIP WARMER SWITCH |
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(RST90/RST90TF).................................... |
8-41 |
PASSENGER GRIP WARMER RELAY |
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(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 |
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GEN |
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MACHINE IDENTIFICATION INFO |
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GENERAL INFORMATION |
1 |
MACHINE IDENTIFICATION |
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FRAME SERIAL NUMBER |
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The frame serial number 1 is located on the right-hand side of the frame |
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(just below the front of the seat). |
1 |
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.
1-1
GEN
IMPORTANT INFORMATION INFO 
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”.
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 INFO 
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.
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.
4 Shaft
LOCTITE®
After installing fasteners that have LOCTITE® applied, wait 24 hours before using the machine. This will give the LOCTITE® time to dry properly.
1-3
SPECIAL TOOLS
SPECIAL TOOLS
GEN 
INFO 
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.
• 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
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.
GEN 
INFO 
•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.
•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
GEN
SPECIAL TOOLS INFO 
•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.
• 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 INFO 
•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.
•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 INFO 
• 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).
• Drive gear socket P/N: YS-01490
90890-01490
Remove and install drive chain sprocket nut (36 × 100 mm (1.4 × 4 in) 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
INTRODUCTION/ PERIODIC MAINTENANCE CHART
INSP ADJ
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.
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Initial |
Every |
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Pre-opera- |
1 month or |
Seasonally |
Item |
Remarks |
tion check |
800 km |
or 3,200 km |
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(Daily) |
(500 mi) |
(2,000 mi) |
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(40 hr) |
(160 hr) |
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Check condition. |
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Spark plugs |
Adjust gap and clean. |
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Replace if necessary. |
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Valve clearance |
Check clearance. |
Every 40,000 km (25,000 mi) |
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Adjust clearance when engine is cold. |
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Engine oil |
Check oil level. |
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Replace. |
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Every |
Engine oil filter cartridge |
Replace. |
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20,000 km |
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(12,000 mi) |
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Fuel |
Check fuel level. |
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Fuel filter |
Check condition. |
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Replace if necessary. |
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Fuel line |
Check fuel hose for cracks or damage. |
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Replace if necessary. |
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Check coolant level. |
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Engine coolant |
Air bleed the cooling system if necessary. |
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The coolant should be changed at least every season. |
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Check throttle lever operation. |
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Carburetor |
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Adjust the jets. |
Whenever operating condition (elevation/tem- |
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perature) is changed. |
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Engine stop switch |
Check operation. |
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Repair if necessary. |
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Throttle override system |
Check operation. |
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(T.O.R.S.) |
Repair if necessary. |
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Throttle lever |
Check operation. |
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Repair if necessary. |
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Exhaust system |
Check for leakage. |
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Tighten or replace gasket if necessary. |
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Drive guard |
Check for cracks, bends or damage. |
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Replace if necessary. |
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V-belt |
Check for wear and damage. |
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Replace if necessary. |
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Drive track and idler wheels |
Check deflection, and for wear and damage. |
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Adjust/replace if necessary. |
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Slide runners |
Check for wear and damage. |
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Replace if necessary. |
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Check operation and fluid leakage. |
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Brake and parking brake |
Adjust free play and/or replace pads if necessary. |
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Replace brake fluid. |
See NOTE on page 2-2. |
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Check for slight free play. |
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Every |
Disc brake installation |
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1,600 km |
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Lubricate shaft with specified grease as required. |
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(1,000 mi) |
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2-1
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PERIODIC MAINTENANCE CHART |
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INSP |
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ADJ |
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Initial |
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Every |
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Pre-opera- |
1 month or |
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Seasonally |
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Item |
Remarks |
tion check |
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800 km |
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or 3,200 km |
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(Daily) |
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(500 mi) |
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(2,000 mi) |
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(40 hr) |
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(160 hr) |
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Drive chain oil |
Check oil level. |
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Replace. |
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Drive chain |
Check deflection. |
Initial at 500 km (300 mi) and every 800 km |
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Adjust if necessary. |
(500 mi) thereafter. |
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Check for wear and damage.
Skis and ski runners
Replace if necessary.
Check operation.
Steering system
Adjust toe-out if necessary.
Strap (RS90M)
Check for damage.
Replace if necessary.
Lights
Check operation.
Replace bulbs if necessary.
Battery
Check condition.
Charge if necessary.
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Check engagement and shift speed. |
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Adjust if necessary. |
Whenever operating elevation is changed. |
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Primary and secondary |
Inspect sheaves for wear/damage. |
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Inspect weights/rollers and bushings for wear-for primary. |
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clutches |
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Inspect ramp shoes/bushings for wear-for secondary. |
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Replace if necessary. |
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Lubricate with specified grease. |
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Steering column bearing |
Lubricate with specified grease. |
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Ski and front suspension |
Lubricate with specified grease. |
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Suspension component |
Lubricate with specified grease. |
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Parking brake cable end and |
Lubricate with specified grease. |
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Check cable damage. |
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lever end/throttle cable end |
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Replace if necessary. |
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Shroud latches |
Make sure that the shroud latches are hooked. |
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Fittings and fasteners
Check tightness.
Repair if necessary.
Tool kit and recommended
Check for proper placement.
equipment
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
2 |
SPARK PLUGS/FUEL LINE INSPECTION
ENGINE
SPARK PLUGS
INSP ADJ
1
2
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)
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 b it to specification.
FUEL LINE INSPECTION
1.Inspect:
•Fuel hoses 1
•Fuel delivery hoses 2
Cracks/damage → Replace.
2-3
INSP
COOLING SYSTEM ADJ
COOLING SYSTEM
Coolant replacement
NOTE:
The coolant should be changed at least every season.
1. Place the machine on a level surface.
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2. Make sure that the carburetor coolant shut-off |
1 |
lever 1 is turned to “ON” a. |
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(for RS90M) |
a
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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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COOLING SYSTEM |
INSP |
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ADJ |
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7. Remove: |
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• Rear bumper cover 1 |
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8. Disconnect: |
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• Coolant hoses 2 |
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9. Drain the coolant. |
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NOTE: |
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1 |
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Lift up the front of the machine to drain the coolant |
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completely. |
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WARNING |
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Coolant is poisonous. It is harmful or fatal if |
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swallowed. |
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• If coolant is swallowed, induce vomiting |
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immediately and get immediate medical atten- |
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tion. |
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• If coolant splashes in your eyes, thoroughly |
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wash them with water and consult a doctor. |
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• If coolant splashes on your skin or clothes, |
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quickly wash it away with soap and water. |
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10. Connect: |
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• Front coolant hoses |
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11. Connect: |
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• Rear coolant hoses |
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12. Fill: |
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• Cooling system |
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Recommended coolant: |
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High quality silicate-free ethylene |
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glycol antifreeze containing corro- |
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sion inhibitors |
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Coolant mixing ratio (coolant:water): |
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3:2 (60%:40%) |
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Total amount: |
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RS90/RS90R/RSG90 |
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4.8 L (4.22 Imp qt, 5.07 US qt) |
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RS90M |
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6.3 L (5.55 Imp qt, 6.66 US qt) |
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RST90 “USA/Canada”/RST90TF |
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“Canada” |
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5.2 L (4.58 Imp qt, 5.50 US qt) |
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RST90 “Europe”/RST90TF |
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“Europe” |
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5.4 L (4.75 Imp qt, 5.71 US qt) |
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CAUTION: |
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• Hard water or salt water is harmful to engine |
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parts. If soft water is not available, use boiled |
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or distilled water. |
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• Do not use water containing impurities or oil. |
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13. Bleed the air from the cooling system. |
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2-5
INSP
COOLING SYSTEM ADJ
2
3
1
1
1
14.Inspect:
•Cooling system
Decrease of pressure (leaks) → Repair as required.
Inspection steps:
•Attach the cooling system tester 1 and adapter 2 to the coolant filler 3.
Cooling system tester: 90890-01325, YU-24460-01
Adapter:
90890-01352, YU-33984
•Apply 100 kPa (1.0 kg/cm2, 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 a.
2-6
INSP
COOLING SYSTEM/VALVE CLEARANCE ADJUSTMENT ADJ
1 |
a |
•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.
3.Install:
• Rear bumper cover
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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INSP |
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VALVE CLEARANCE ADJUSTMENT ADJ |
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4. Remove: |
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• Cylinder head cover |
1 |
2 |
Refer to “CAMSHAFTS” in CHAPTER 5. |
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• Timing mark accessing screw 1 |
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• 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 a on the A.C. magneto rotor with the mark b on the A.C. magneto cover.
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
INSP
VALVE CLEARANCE ADJUSTMENT ADJ
ÈFront
For each cylinder, starting with cylinder #3 at TDC, turn the crankshaft clockwise as specified in the fol-
lowing table.
É Degrees that the crankshaft is turned clockwise Ê Cylinder
Ë Combustion cycle
#2 Cylinder |
120° |
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#1 Cylinder |
240° |
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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 2 with a valve lapper 3.
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 1 and valve pad 2 so that they can be installed in the correct place.
2-9
INSP
VALVE CLEARANCE ADJUSTMENT ADJ
•Select the proper valve pad from the following table.
Valve pad thickness |
Available valve pads |
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range |
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1.20 ~ |
25 thicknesses in |
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Nos. |
2.40 mm |
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0.05 mm (0.0020 in) |
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120 ~ 240 |
(0.047 ~ |
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increments |
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0.094 in) |
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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 |
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0 or 2 |
0 |
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5 |
5 |
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8 |
10 |
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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
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VALVE CLEARANCE ADJUSTMENT |
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INSP |
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ADJ |
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VALVE PAD SELECTION TABLE |
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INTAKE |
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Measured |
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INSTALLED PAD NUMBER |
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clearance |
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↓ |
120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
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215 |
220 |
225 |
230 |
235 |
240 |
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0.00 ~ 0.04 |
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120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
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200 |
205 |
210 |
215 |
220 |
225 |
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0.05 ~ 0.09 |
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120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
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205 |
210 |
215 |
220 |
225 |
230 |
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0.10 ~ 0.14 |
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120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
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210 |
215 |
220 |
225 |
230 |
235 |
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0.15 ~ 0.22 |
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Specification |
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exa |
0.23 ~ 0.27 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
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220 |
225 |
230 |
235 |
240 |
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→ |
0.28 ~ 0.32 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
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225 |
230 |
235 |
240 |
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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 |
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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 |
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0.43 ~ 0.47 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.48 ~ 0.52 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.53 ~ 0.57 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.58 ~ 0.62 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.63 ~ 0.67 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.68 ~ 0.72 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.73 ~ 0.77 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.78 ~ 0.82 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.83 ~ 0.87 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.88 ~ 0.92 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.93 ~ 0.97 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.98 ~ 1.02 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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1.03 ~ 1.07 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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EXAMPLE: |
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1.08 ~ 1.12 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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VALVE CLEARANCE: |
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1.13 ~ 1.17 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) |
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1.18 ~ 1.22 |
220 |
225 |
230 |
235 |
240 |
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Installed is 150 |
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1.23 ~ 1.27 |
225 |
230 |
235 |
240 |
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Measured clearance is 0.25 mm (0.0098 in) |
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1.28 ~ 1.32 |
230 |
235 |
240 |
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Replace 150 pad with 160 pad |
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1.33 ~ 1.37 |
235 |
240 |
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1.38 ~ 1.42 |
240 |
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EXHAUST |
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Measured |
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INSTALLED PAD NUMBER |
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clearance |
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↓ |
120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
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215 |
220 |
225 |
230 |
235 |
240 |
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0.00 ~ 0.02 |
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120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
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190 |
195 |
200 |
205 |
210 |
215 |
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0.03 ~ 0.07 |
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120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
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195 |
200 |
205 |
210 |
215 |
220 |
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0.08 ~ 0.12 |
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120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
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200 |
205 |
210 |
215 |
220 |
225 |
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0.13 ~ 0.17 |
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120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
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205 |
210 |
215 |
220 |
225 |
230 |
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0.18 ~ 0.20 |
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120 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
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210 |
215 |
220 |
225 |
230 |
235 |
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0.21 ~ 0.25 |
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Specification |
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exa |
0.26 ~ 0.30 |
125 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
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220 |
225 |
230 |
235 |
240 |
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→ |
0.31 ~ 0.35 |
130 |
135 |
140 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
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225 |
230 |
235 |
240 |
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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 |
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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 |
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0.46 ~ 0.50 |
145 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.51 ~ 0.55 |
150 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.56 ~ 0.60 |
155 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.61 ~ 0.65 |
160 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.66 ~ 0.70 |
165 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.71 ~ 0.75 |
170 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.76 ~ 0.80 |
175 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.81 ~ 0.85 |
180 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.86 ~ 0.90 |
185 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.91 ~ 0.95 |
190 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.96 ~ 1.00 |
195 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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1.01 ~ 1.05 |
200 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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1.06 ~ 1.10 |
205 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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EXAMPLE: |
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1.11 ~ 1.15 |
210 |
215 |
220 |
225 |
230 |
235 |
240 |
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VALVE CLEARANCE: |
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1.16 ~ 1.20 |
215 |
220 |
225 |
230 |
235 |
240 |
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0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) |
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1.21 ~ 1.25 |
220 |
225 |
230 |
235 |
240 |
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Installed is 175 |
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1.26 ~ 1.30 |
225 |
230 |
235 |
240 |
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Measured clearance is 0.35 mm (0.0138 in) |
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Replace 175 pad with 185 pad |
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1.31 ~ 1.35 |
230 |
235 |
240 |
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1.36 ~ 1.40 |
235 |
240 |
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1.41 ~ 1.45 |
240 |
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2-11
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