Yamaha RST90X, RST90GTX User Manual

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Page 1

OWNER’S MANUAL

RST90X

LIT-12628-02-65

RST90GTX

8ET-28199-13

Page 2

ESU10040

Page 3

ESU10120

Congratulations on your purchase of a Yamaha snowmobile. This model is the result of Yamaha’s vast experience in the production of fine sporting and touring snowmobiles. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this snowmobile. If you have any questions concerning the operation or maintenance of your snowmobile, please consult a Yamaha dealer. To maintain the high quality and performance of this snowmobile, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.

RST90X

RST90GTX

OWNER’S MANUAL

U.S.A.

1st Edition, March 2007

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in Japan.

P/N LIT-12628-02-65

Introduction

Page 4

Important manual information

ESU10150

EWS00010

WARNING

PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE SNOWMOBILE.

NOTE:

● Yamaha continually seeks advancements

in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your snowmobile and this manual. If there is any question concerning this manual, please consult a Yamaha dealer.

● This manual should be considered a per-

manent part of this snowmobile and should remain with the snowmobile when resold.

EWS00020

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.

ECS00010

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Page 5

Safety information ............................1

Location of the important labels ..... 4

Description ........................................ 7

Control functions .............................. 9

Main switch .................................... 9

Starter (choke) lever ....................... 9

Throttle lever .................................. 9

Engine overheating

prevention system ..................... 10

Throttle override system

(T.O.R.S.) .................................. 10

Speedometer unit ......................... 11

High beam indicator light .............. 12

Low coolant temperature

indicator light ............................. 12

Fuel meter and grip/

thumb warmer level indicator .... 13

Fuel level warning indicator .......... 14

Oil level warning indicator ............ 14

Coolant temperature warning

indicator ..................................... 15

Self-diagnosis device ................... 15

Engine stop switch ....................... 15

Headlight beam switch

“LIGHTS” ................................... 16

Grip/thumb warmer

adjustment switch ...................... 16

Auxiliary DC jack .......................... 16

Brake lever ................................... 17

Parking brake lever ...................... 17

Shift lever ..................................... 18

Shroud latches ............................. 18

Drive guard ................................... 19

V-belt holders ............................... 19

Passenger grip warmer switch ..... 19

Footrests ...................................... 20

Backrest ....................................... 20

Storage areas ............................... 20

Fuel .............................................. 23

Suspension .................................. 23

Pre-operation checks ..................... 28

Pre-operation check list ............... 28

Operation ......................................... 30

Starting the engine ....................... 30

Break-in ........................................ 31

Riding your snowmobile ............... 31

Maximizing drive track life ............ 34

Driving .......................................... 35

Stopping the engine ..................... 36

Transporting ................................. 36

Periodic maintenance ..................... 38

Periodic maintenance chart for

the emission control system ..... 38

General maintenance and

lubrication chart ........................ 40

Tool kit ......................................... 42

Checking the spark plugs ............. 42

Adjusting the engine

idling speed ............................... 43

Adjusting the throttle cable

free play .................................... 43

Checking the throttle

override system (T.O.R.S.) ....... 44

Checking the air filter ................... 44

Carburetors .................................. 45

High-altitude settings ................... 45

Valve clearance ........................... 46

Engine oil and oil filter cartridge ... 46

Cooling system ............................ 50

V-belt ............................................ 51

Drive chain housing ..................... 54

Brake and parking brake .............. 55

Skis and ski runners ..................... 57

Steering system ........................... 58

Drive track and slide runners ....... 59

Lubrication ................................... 62

Replacing a headlight bulb ........... 63

Adjusting the headlight beam ....... 64

Fittings and fasteners ................... 64

Battery .......................................... 64

Page 6

Contents

Replacing a fuse .......................... 65

Troubleshooting ............................. 68

Storage ............................................ 72

Specifications ................................. 74

Consumer information.................... 76

Identification number records ....... 76

YAMAHA MOTOR

CORPORATION, U.S.A. SNOWMOBILE

LIMITED WARRANTY ............... 77

YAMAHA EXTENDED SERVICE

(Y.E.S.)....................................... 80

Page 7

Safety information

ESU10200

When you ride your snowmobile, you must know and use the following for your safety. Severe injury or death may result if you ignore any of the following.

Before operating

1. Read the Owner’s Manual and all labels before operating this snowmobile. Become familiar with all of the operating controls and their function. Consult a Yamaha dealer about any control or function you do not understand.

2. This snowmobile was not manufactured for use on public streets, roads, or highways. Such use is prohibited by law, and you could collide with another vehicle.

3. Do not operate the snowmobile after drinking alcohol or taking drugs. Your ability to operate the snowmobile is reduced by the influence of alcohol or drugs.

4. For safety and proper care of the snowmobile, always perform the pre-operation checks on page 28 before starting the engine. Check the throttle, brake, and steering for proper operation every time before starting the engine. Make sure that the throttle lever moves freely and it returns to the home position when it is released.

5. Apply the parking brake before starting the engine. Never drive the snowmobile with the parking brake applied. This may overheat the brake disc and reduce braking ability.

6. Do not allow anyone to stand behind the snowmobile when starting, inspecting, or adjusting the snowmobile. A broken track, track fittings, or debris thrown by the track could be dangerous to the operator or bystanders.

7. Handle fuel with care; it is HIGHLY FLAMMABLE.

● Never add fuel when the engine is run-

ning or hot. Allow the engine to cool for several minutes after running.

● Use an approved fuel container.

● Fill the fuel tank outdoors with extreme

care. Never remove the fuel cap indoors. Never fill the fuel tank indoors.

● Never refuel while smoking or in the vi-

cinity of an open flame.

● Make sure that the fuel tank cap is

closed securely after refueling. Wipe up any spilled fuel immediately.

Page 8

Safety information

8. If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash your skin with soap and water, and change your clothes.

9. Wear protective clothing. Wear an approved helmet, and a face shield or goggles. Also, wear a good quality snowmobile suit, boots, and a pair of gloves or mittens that will permit use of your thumbs and fingers for operation of the controls.

Operation

1. Do not run the engine indoors, except when starting the engine to transport the snowmobile in or out of the building. Open the outside doors; exhaust fumes are dangerous.

2. Be careful where you ride. There may be obstacles hidden beneath the snow. Stay on established trails to minimize your exposure to hazards. Ride slowly and cautiously when you ride off of established trails. Hitting a rock or stump, or running into wires could cause an accident and injury.

3. This snowmobile is not designed for use on surfaces other than snow or ice. Use on dirt, sand, grass, rocks, or bare pavement may cause loss of control and may damage the snowmobile.

4. Avoid operating on glare ice, or on snow which has a lot of dirt or sand mixed in. Operation under such conditions will damage or result in rapid wear of ski runners, drive track, slide runners, and drive sprockets.

5. Always ride with other snowmobilers when going on a ride. You may need help if you run out of fuel, have an accident, or damage your snowmobile.

6. Many surfaces such as ice and hardpacked snow require much longer stopping distances. Be alert, plan ahead and begin decelerating early. The best braking method on most surfaces is to release the throttle and apply the brake gently— not suddenly.

Page 9

Maintenance and storage

1. Do not leave the snowmobile on its left side for an extended period of time. Fuel may leak out from the fuel breather hose.

2. Modifications made to the snowmobile not approved by Yamaha, or the removal of original equipment may render your snowmobile unsafe for use that may cause severe personal injury. Modifications may also make the snowmobile illegal to use.

3. Never store the snowmobile with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters, an open flame, sparks, clothes dryers, and the like. Allow the engine to cool off before storing the snowmobile in an enclosed space.

4. Always refer to the “STORAGE” section on page 72 if the snowmobile is to be stored for an extended period.

5. Maintain or replace safety and instruction labels, as necessary.

Safety information

Page 10

Safety information

ESU10231

Location of the important labels

Please read the following labels carefully before operating this snowmobile.

NOTE:

Maintain or replace safety and instruction labels, as necessary.

Page 11

Safety information

Page 12

Safety information

NOTE:

The following suspension adjustment charts are included with the Owner’s Manual.

Page 13

ESU10260

Description

1. Storage compartment

2. Tool kit

3. Air filter

4. Battery

5. Coolant reservoir

6. Fuse box

7. Throttle stop screw

8. Main fuse

9. Oil filler cap

10. Passenger grip warmer switch

11. Solo touring storage area

12. Backrest

13. Rear carrier

14. Tail/brake lights

15. Slide rail suspension

16. Drive track

17. V-belt holder

Page 14

Description

1. Brake lever

2. Parking brake lever

3. Grip warmer adjustment switch

4. Headlight beam switch

5. Engine stop switch

6. Thumb warmer adjustment switch

7. Throttle lever

8. Shift lever

9. Shroud latch

10. Main switch

11. Auxiliary DC jack

12. Starter (choke) lever

13. Tachometer

14. Low coolant temperature indicator light

15. High beam indicator light

16. Warning light

17. Self-diagnosis warning indicator

18. Coolant temperature warning indicator

19. Fuel level warning indicator

20. Oil level warning indicator

21. Speedometer

22. Grip warmer indicator

23. Select/reset button

24. Thumb warmer indicator

25. Fuel meter and grip/thumb warmer level indicator

26. Odometer/tripmeter

NOTE:

● The snowmobile you have purchased may differ slightly from those shown in the figures of

this manual.

● Design and specifications are subjected to change without notice.

Page 15

ESU10281

Main switch

The main switch controls the ignition and lighting systems. The various positions are described below.

1. Off

2. On

3. Start

Off

The ignition circuit is switched off. The key can be removed only in this position.

The ignition circuit is switched on.

Start

The starting circuit is switched on. The starter motor cranks the engine.

ECS00020

CAUTION:

Release the switch immediately after the engine starts.

NOTE:

The headlights, meter lighting, and taillights come on after the engine is started.

ESU10300

Starter (choke) lever

Use the starter (choke) lever when starting and warming up a cold engine.

Control functions

1. Star ter (choke) lever

NOTE:

Refer to the “Starting the engine” section on page 30 for proper operation.

1. When starting a cold engine.

2. Warming up

3. When the engine is warm.

ESU10310

Throttle lever

Once the engine is running cleanly, squeezing the throttle lever will increase the engine speed and cause engagement of the drive system. Regulate the speed of the snowmobile by varying the throttle position. Because the throttle is spring-loaded, the snowmobile will decelerate, and the engine will return to idle when it is released.

Page 16

Control functions

1. Throttle lever

EWS00030

WARNING

Check the throttle, brake, and steering for proper operation before starting the engine. (See page 28.)

ESU10321

Engine overheating prevention

system

This model is equipped with a system, which prevents overheating when the engine is idling. When the engine has been idling for 3 minutes or longer and the coolant temperature has risen above 100 °C (212 °F), the engine automatically stops to prevent overheating.

If the carburetors or throttle cable malfunctions during operation, the T.O.R.S. will operate when the throttle lever is released. The T.O.R.S. is designed to override the ignition and limit the engine speed to less than the clutch engagement speed if the carburetors fail to return to the idle position when the throttle lever is released. (See page 74 for the clutch engagement speed.)

Idling /

starting

Throttle switch

Throttle position sensor

Engine Run Run

Off On Off

Closed Open Open

Running Trouble

T. O. R .S .

will oper-

ate.

Idling / starting

NOTE:

The engine can be started after it stops.

ESU10331

Throttle override system

(T.O.R.S.)

EWS00040

WARNING

● If the T.O.R.S. is activated, make sure

that the cause of the malfunction has been corrected and that the engine can be operated without a problem before restarting the engine.

● Be sure to use the specified spark plug

and spark plug cap. Otherwise, the T.O.R.S. will not work properly.

1. Throttle position sensor (throttle valve closed position)

2. Throttle cable

3. Throttle switch (off)

Page 17

Running

Control functions

1. Throttle position sensor (throttle valve open position)

2. Throttle switch (on)

Trouble

1. Throttle position sensor (throttle valve open position)

2. Throttle switch (off)

NOTE:

● When the T.O.R.S. is activated, the warn-

ing light and self-diagnosis warning indicator will flash, and the two-digit code “84” will flash in the tripmeter/odometer display.

● The T.O.R.S. monitors the condition of the

throttle position sensor, speedometer assembly, and speed sensor, and will operate if any of the monitored items is disconnected or is malfunctioning.

1. Warning light “”

2. Self-diagnosis warning indicator “”

3. Two-digit code “84”

ESU10351

Speedometer unit

The speedometer unit is equipped with the following:

● a digital speedometer (which shows the

riding speed)

● an odometer (which shows the total dis-

tance traveled)

● a tripmeter (which shows the distance trav-

eled since it was last set to zero)

● warning indicators (which show self-diag-

nosis, coolant temperature, fuel level, and oil level warnings)

● a fuel meter (which shows the fuel remain-

ing in the fuel tank)

● a grip/thumb warmer level indicator (which

shows the grip warmer level or the thumb

warmer level) After the engine is started, the tachometer makes one sweep, and the low coolant temperature indicator light, the warning light, and all segments of the meter display turn on and off once.

Page 18

Control functions

1. Tachometer

2. Low coolant temperature indicator light

“”

3. Warning light “”

4. Meter display

5. Select/reset button

The grip warmer level is initially displayed for 5 seconds, then the display switches to the fuel meter.

Odometer and tripmeter modes

Pushing the select/reset button switches the display between the odometer mode “ODO” and the tripmeter mode “TRIP”. To reset the tripmeter, push the select/reset button for at least one second while the tripmeter is displayed.

NOTE:

To switch the speedometer, odometer, and tripmeter displays between kilometers and miles, select the odometer mode “ODO”, and then push the select/reset button for at least 10 seconds while the snowmobile is stopped.

ESU10410

High beam indicator light “”

The high beam indicator light comes on when the high beams of the headlights are switched on. (See page 16 for headlight beam switch operation.)

1. High beam indicator light “”

ESU10481

Low coolant temperature indi-

cator light “”

The low coolant temperature indicator light comes on when the coolant temperature is low and informs the rider that the snowmobile should be warmed up. After the engine is started, warm it up until the indicator light goes off.

1. Low coolant temperature indicator light

“”

2. Warning light “”

3. Self-diagnosis warning indicator “”

4. Two-digit code “86”

The snowmobile can be operated normally after the indicator light goes off.

NOTE:

Operate the snowmobile at low speeds when the low coolant temperature indicator light is on. If the engine speed is too high, the warning light and self-diagnosis warning indicator will flash and the two-digit code “86” will flash

Page 19

Control functions

in the tripmeter/odometer display. When this occurs, maximum engine speed is reduced to protect the engine.

ESU10421

Fuel meter and grip/thumb

warmer level indicator

The fuel meter and grip/thumb warmer level indicator have eight segments which show the amount of fuel remaining in the fuel tank, the grip warmer level, or the thumb warmer level.

1. Fuel meter and grip/thumb warmer level indicator

Fuel meter

The display segments of the fuel meter disappear towards “E” (Empty) as the fuel level decreases. When only one segment is left near “E”, the fuel level warning indicator and the warning light come on.

If the fuel level warning indicator and the warning light come on, refuel as soon as possible.

NOTE:

The snowmobile must be stopped on a level surface to obtain an accurate fuel meter reading, since the reading changes according to the movement and inclination of the snowmobile.

Grip/thumb warmer level indicator

When the grip warmer adjustment switch is pressed, the grip warmer indicator comes on and the display switches to the grip warmer level. When the thumb warmer adjustment switch is pressed, the thumb warmer indicator comes on and the display switches to the thumb warmer level.

1. Grip warmer indicator “”

2. Thumb warmer indicator “”

1. Fuel level warning indicator “”

2. Warning light “”

1. Grip warmer adjustment switch

Page 20

Control functions

1. Thumb warmer adjustment switch

NOTE:

● The grip/thumb warmer level is displayed

for 5 seconds after releasing the grip/thumb warmer adjustment switch, then the display switches to the fuel meter.

● The top segment of the grip/thumb warmer

level indicator flashes once when the grip/thumb warmer adjustment reaches the maximum level. The bottom segment of the grip/thumb warmer level indicator flashes once when the grip/thumb warmer adjustment reaches the minimum level.

● When the engine is started, the grip/thumb

warmer levels are set to the levels selected when the engine is stopped.

ESU10450

Fuel level warning indicator “”

The fuel level warning indicator indicates a malfunctioning sensor, disconnected coupler, broken lead, or short circuit when detected by the self-diagnosis device of the snowmobile. The fuel level warning indicator, warning light, and all segments of the fuel meter warn the rider of the above problems by flashing continuously. When this occurs, have a Yamaha dealer inspect the snowmobile as soon as possible.

1. Fuel level warning indicator “”

2. Warning light “”

3. Fuel meter

ESU10460

Oil level warning indicator “”

The oil level warning indicator and the warning light come on when the engine oil level is low.

1. Oil level warning indicator “”

2. Warning light “”

If the oil level warning indicator and the warning light come on, place the snowmobile on a level surface and allow it to idle for one minute. If the oil level warning indicator and the warning light go off, the engine oil level is sufficient, however it is getting low. Add engine oil as soon as possible. If the oil level warning indicator and the warning light do not go off, check the engine oil level in the oil tank (see page 46 for engine oil level checking procedures), and add engine oil if necessary.

Page 21

ESU10511

Coolant temperature warning

indicator “”

If the engine overheats, the coolant temperature warning indicator and the warning light come on. When this occurs, stop the engine immediately and allow the engine to cool down, and then check the coolant level in the coolant reservoir. (See page 50 for checking procedures.)

1. Coolant temperature warning indicator “”

2. Warning light “”

ECS00040

CAUTION:

Do not operate the engine if it overheats.

ESU10522

Self-diagnosis device

This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the warning light and the self-diagnosis warning indicator will flash, and a two-digit error code will flash slowly in the tripmeter/odometer display.

Control functions

1. Warning light “”

2. Self-diagnosis warning indicator “”

3. Two-digit error code

EWS00052

WARNING

● If the self-diagnosis warning indicator

and warning light flash continuously, and an error code is displayed during operation, there may be some problem with an electrical circuit, couplers, etc.

● Stop the engine and allow it to cool off.

Then, check that the electrical circuits, couplers, etc. in the engine compartment are connected properly.

● If the self-diagnosis warning indicator,

warning light, and an error code flash after the engine has been restarted, note the error code, and then have a Yamaha dealer inspect the snowmobile as soon as possible.

ESU10530

Engine stop switch “”

The engine stop switch is used to stop the engine in an emergency. Simply push the stop switch to stop the engine. To start the engine, pull the stop switch and proceed with starting the engine. (See pages 30 for engine starting procedures.)

Page 22

Control functions

1. Engine stop switch“”

During the first few rides, practice using the stop switch so that you can react quickly in an emergency.

ESU10661

Headlight beam switch

“LIGHTS”

Push the headlight beam switch to change the headlight to high beam “HI” or to low beam “LO”.

1. Headlight beam switch “LIGHTS”

2. High beam “HI”

3. Low beam “LO”

ESU12650

Grip/thumb warmer adjustment

switch

The grip warmer adjustment switch and the thumb warmer adjustment switch control the electrically heated handlebar grips and throttle lever respectively.

1. Grip warmer adjustment switch

1. Thumb warmer adjustment switch

To raise the temperature, press the respective switch to “HI”. To lower the temperature, press the switch to “LO”.

ESU10690

Auxiliary DC jack

The auxiliary DC jack is located in the front panel and can be used for accessories.

NOTE:

The auxiliary DC jack cannot be used if the engine is not running.

To use the auxiliary DC jack

1. Start the engine.

2. Open the auxiliary DC jack cap, and then insert the accessory power plug into the jack.

Page 23

Control functions

1. Auxiliary DC jack cap

2. Auxiliary DC jack

NOTE:

After using the auxiliary DC jack, be sure to remove the accessory power plug from the jack and close the auxiliary DC jack cap.

ECS00120

CAUTION:

● Do not use accessories requiring more

than the maximum rated capacity for the auxiliary DC jack. This may overload the circuit and cause the fuse to blow. (See page 65 for the specified amperage.)

● Do not use an automotive cigarette light-

er or other accessory with a plug that gets hot because the jack can be damaged.

Maximum rated capacity:

DC 12 V, 2.5 A (30 W)

ESU10550

Brake lever

The snowmobile is stopped by braking the entire drive system. Squeeze the brake lever towards the handlebar grip to stop the snowmobile.

1. Brake lever

NOTE:

When the brake lever is operated, the brake light will illuminate.

ECS00060

CAUTION:

Make sure that the brake lever end does not project out over the handlebar end. This will help prevent brake lever damage when the snowmobile is placed on its side for service.

ESU10580

Parking brake lever

When parking the snowmobile or starting the engine, apply the parking brake by moving the parking brake lever to the left.

1. Parking brake lever

To release the parking brake, move the parking brake lever to the right.

Page 24

Control functions

EWS00060

WARNING

● Always set the parking brake before at-

tempting to start the engine.

● Never run the snowmobile with the park-

ing brake applied. This may overheat the brake disc and reduce braking ability.

ESU10590

Shift lever

The shift lever is used to put the snowmobile into forward or reverse. After coming to a complete stop, pull the shift lever out, slide it to “FWD” or to “REV” until it stops, and then release it.

1. Shift lever

1. Pull out.

2. Slide to “FWD” (forward).

3. Release.

1. Pull out.

2. Slide to “REV” (reverse).

3. Release.

ECS00070

CAUTION:

Do not shift from “FWD” to “REV” or from “REV” to “FWD” while the snowmobile is moving. Otherwise, the drive system could be damaged.

ESU10710

Shroud latches

To open the shroud, unhook the shroud latches, and then slowly raise the shroud forward until it stops. When closing the shroud, slowly lower it to its home position, and then hook the shroud latches.

Page 25

1. Shroud latch

2. Shroud

ECS00140

CAUTION:

Make sure that all cables and wires are in place when closing the shroud.

EWS00080

WARNING

● Do not drive the snowmobile with the

shroud open, unlatched, or removed.

● Keep your body and clothing away from

rotating parts when servicing with the shroud open.

● Do not touch the hot muffler and engine

during or immediately after operation.

ESU10750

Drive guard

The drive guard is designed to cover the Vbelt clutch and V-belt in case parts break or come loose.

Control functions

EWS00400

WARNING

● Make sure that the drive guard is tight-

ened securely before operating the snowmobile.

● Never run the engine with the V-belt or

drive guard removed.

ESU10760

V-belt holders

Keep a spare V-belt for emergency use by placing it into the V-belt holders provided.

1. V-belt holder

ECS00180

CAUTION:

Make sure that the V-belt is installed securely in the holders.

ESU10680

Passenger grip warmer switch

The passenger grip warmer switch controls the electrically heated passenger grips.

1. Drive guard

Page 26

Control functions

1. Passenger grip warmer switch

2. Off

3. “HI” (high)

4. “LO” (low)

ESU10700

Footrests

The footrests can be installed in two locations to suit passenger preference. To change the location of a footrest, remove the screws, place the footrest in the desired location, and then install and tighten the screws.

To adjust the backrest angle, turn the backrest adjusting knob until the backrest reaches the desired position.

1. Backrest adjusting knob

EWS00130

WARNING

Do not sit on the backrest.

ESU10820

Storage areas

This snowmobile is equipped with a storage compartment, rear storage area, and rear carrier.

Storage compartment

The storage compartment is located under the shroud. Open the storage compartment to store the tool kit, spare parts, or other small items.

1. Footrest

2. Screw

ECS00130

CAUTION:

Make sure that the footrest screws are tightened securely after changing the installation location of the footrests.

ESU12610

Backrest

The backrest is adjustable.

1. Storage compartment

Rear storage area and rear carrier

The rear storage area and the rear carrier are located at the rear of the snowmobile.

Page 27

The rear storage area can be used only when the passenger seat is removed.

1. Rear storage area

2. Rear carrier

Maximum load limit:

Rear storage area:

20 kg (44 lb)

Rear carrier:

10 kg (22 lb)

To remove the passenger seat and backrest

1. Pull the carrier lock lever away from the carrier lock bracket, and then push it down to unlock the backrest and the rear carrier.

Control functions

1. Backrest

2. Rear carrier

3. Remove the passenger seat lock knob, and then remove the passenger seat.

1. Passenger seat

2. Passenger seat lock knob

4. Align the holes in the rear carrier with the bolts on the carrier lock bracket, and then place the rear carrier on the carrier lock bracket.

1. Carrier lock lever

2. Slide both the backrest and the rear carrier forward until they stop, and then remove them.

1. Hole

2. Bolt

Page 28

Control functions

5. Slide the rear carrier backward until it stops.

6. Pull the carrier lock lever up to lock the rear carrier in place. Then, place the lever under the rear carrier and secure it with the holder.

1. Carrier lock lever

ECS00210

CAUTION:

When using the rear storage area, do not load any cargo that is too large for it. In addition, cargo must not project from the edges of the rear storage area.

To install the passenger seat and backrest

1. Remove the rear carrier. (Refer to steps 1–2 in the “To remove the passenger seat and backrest” section.)

2. Install the passenger seat, and then install the passenger seat lock knob.

3. Align the holes in the backrest bracket with the bolts on the carrier lock bracket, and then place the backrest on the carrier lock bracket.

1. Hole

1. Bolt

4. Align the holes in the rear carrier with the bolts on the carrier lock bracket, and then place the rear carrier on the carrier lock bracket.

5. Slide both the backrest and the rear carrier backward until they stop.

6. Pull the carrier lock lever up to lock the backrest and the rear carrier in place. Then, place the lever under the rear carrier and secure it with the holder.

1. Carrier lock lever

Page 29

ESU10600

Fuel

Make sure that there is sufficient fuel in the fuel tank.

EWS00070

WARNING

● Fuel is HIGHLY FLAMMABLE and poi-

sonous. Check the “SAFETY INFORMATION” section carefully before refueling. (See page 1.)

● Do not fill the fuel tank above the bottom

of the filler tube. Fuel could overflow if the snowmobile is tilted or if the ambient temperature rises, causing the fuel to warm up and expand.

● Make sure that the fuel tank cap is

closed securely after refueling. Leaking fuel can catch fire.

1. Filler tube

2. Fuel level

Control functions

Recommended fuel:

REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity:

39.3 L (10.38 US gal) (8.65 Imp.gal)

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher.

ECS00080

CAUTION:

● Oxygenated fuels (gasohol) containing

a maximum 5% of ethanol can be used, although richer jetting may be required to prevent engine damage. Consult a Yamaha dealer. Gasohol containing methanol is not recommended.

● Make sure that snow or ice does not en-

ter the fuel tank when refueling.

● Do not use alcohol deicers or water ab-

sorbing additives with oxygenated fuel.

● The fuel tank should be filled with

straight gasoline as specified.

ESU10870

Suspension

The suspension can be adjusted to suit rider preference. A softer setting, for example, may provide greater rider comfort, while a harder setting may allow more precise handling and control over certain types of terrain or riding conditions.

Page 30

Control functions

EWS00150

WARNING

Be sure to have a Yamaha dealer make this adjustment. This shock absorber contains highly pressurized nitrogen gas. It could explode by improper handling, causing injury, or property damage.

● Do not tamper with or attempt to open

the shock absorber.

● Do not subject the shock absorber to an

open flame or other high heat source, which could cause it to explode.

● Do not deform or damage the shock ab-

sorber in any way.

● Do not dispose of a worn or damaged

shock absorber by yourself. Take the unit to a Yamaha dealer.

ESU10900

Adjusting the ski spring preload

ECS00250

CAUTION:

The left and right ski spring preload must be set to the same setting. Uneven settings can cause poor handling and loss of stability.

The spring preload can be adjusted by turning the spring preload adjusting ring.

Spring preload setting (spring seat length or spring preload adjusting ring position):

Minimum (soft):

RST90 162.0 mm (6.38 in) RST90GT 112.0 mm (4.41 in)

Standard:

RST90 162.0 mm (6.38 in) RST90GT 112.0 mm (4.41 in)

Maximum (hard):

RST90 172.0 mm (6.77 in) RST90GT 122.0 mm (4.80 in)

* The spring seat length changes ap-

proximately 1.5 mm (0.06 in) with each full turn of the adjusting ring.

ESU10921

Adjusting the ski damping force(RST90GT)

ECS00260

CAUTION:

The damping forces for the left and right ski shock absorbers must be adjusted to the same settings. Uneven settings can cause poor handling and loss of stability.

Compression damping force

The compression damping force of each ski shock absorber can be adjusted by turning the compression damping force adjusting knob. To increase the compression damping force, turn the adjusting knob in direction (a). To decrease the compression damping force, turn the adjusting knob in direction (b).

1. Spring preload adjusting ring

2. Spring seat length

1. Compression damping force adjusting knob

Page 31

Control functions

Compression damping setting:

Minimum (soft):

12 click(s) in direction (b)*

Standard:

7 click(s) in direction (b)*

Maximum (hard):

2 click(s) in direction (b)*

* With the adjusting knob fully turned in

direction (a)

Rebound damping force

The rebound damping force of each ski shock absorber can be adjusted by turning the rebound damping force adjusting knob. To increase the rebound damping force, turn the adjusting knob in direction (a). To decrease the rebound damping force, turn the adjusting knob in direction (b).

1. Rebound damping force adjusting knob

Rebound damping setting:

Minimum (soft):

20 click(s) in direction (b)*

Standard:

12 click(s) in direction (b)*

Maximum (hard):

3 click(s) in direction (b)*

* With the adjusting knob fully turned in

direction (a)

ESU10960

Adjusting the rear suspension spring preload

The spring preload can be adjusted by turning the spring preload adjusting ring on the center shock absorber and the spring preload adjuster on the rear shock absorber.

1. Spring preload adjusting ring

2. Spring seat length

Spring preload setting at the center shock absorber (spring seat length or spring preload adjusting ring position):

Minimum (soft):

111.5 mm (4.39 in)

Standard:

112.5 mm (4.43 in)

Maximum (hard):

122.5 mm (4.82 in)

* The spring seat length changes ap-

proximately 1.5 mm (0.06 in) with each full turn of the adjusting ring.

NOTE:

The damping forces will not decrease past the minimum levels even if the adjusting knobs are turned out more than the minimum settings.

1. Spring preload adjuster

Page 32

Control functions

Spring preload setting at the rear shock absorber (spring preload adjuster position):

Minimum (soft):

Standard:

Maximum (hard):

Adjusting the 2-up adjusting block spring force

The spring force can be adjusted by changing the position of the 2-up adjusting blocks.

1. 2-up adjusting block

NOTE:

Be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile.

1. Install the special tools included in the owner’s tool kit to the 2-up adjusting block.

2. Pull the lock lever and turn the special tools to change the block position.

1. 2-up position (rider and passenger)

2. Solo rider position

3. Special tool

4. Lock lever

3. Release the lock lever.

ECS00280

CAUTION:

Make sure that the 2-up adjusting blocks are installed in the same position on both sides of the snowmobile.

ESU11030

Adjusting the control rods

The weight transfer can be adjusted by turning the control rod adjusting nut.

1. Loosen the locknut while holding the control rod adjusting nut.

2. Turn the control rod adjusting nut in direction (a) to increase weight transfer or direction (b) to decrease weight transfer.

Page 33

1. Locknut

2. Control rod adjusting nut

EWS00170

WARNING

Never adjust the control rods beyond the maximum range indicated on the rods with red paint.

Control functions

3. Tighten the locknut while holding the control rod adjusting nut in place.

Locknut tightening torque:

25 Nm (2.5 m·kgf, 18 ft·lb)

ECS00310

CAUTION:

● When using the two wrenches included

in the owner’s tool kit, make sure that they are situated at a right angle to the control rod as shown, and that they are tightly fitted to the locknut and the control rod adjusting nut.

● The left and right adjusting nuts must be

set to the same position. Uneven settings can cause poor handling and loss of stability.

1. Red paint area

2. Adjustable range

3. Standard position

Page 34

Pre-operation checks

ESU11070

The condition of a snowmobile is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the snowmobile remains unused (for example, as a result of exposure to the elements). Any damage or fluid leakage could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.

NOTE:

Pre-operation checks should be made each time the snowmobile is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.

EWS00190

WARNING

If any item in the pre-operation check list is not working properly, have it inspected and repaired before operating the snowmobile.

ESU11080

Pre-operation check list

ITEM CHECKS PAGE

Fuel

Engine oil

Coolant

V-bel t

Drive guard

Brake

Air filter

• Check fuel level.

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in engine.

• If necessary, add recommended oil to specified

level.

• Check vehicle for oil leakage.

• Check coolant level.

• Add if necessary.

• Check for wear and damage.

• Replace if necessary.

• Make sure that drive guard is tightened securely.

• Check the drive guard mounts for damage.

• Make sure that the drive guard is firmly in place.

• Check operation.

• If soft or spongy, have Yamaha dealer bleed hy-

draulic system.

• Check brake pads for wear.

• Replace if necessary.

• Check fluid level in master cylinder.

• If necessary, add recommended brake fluid to

specified level.

• Check hydraulic system for leakage.

• Check that there is no snow under the air filter ele-

ment.

• If necessary, brush off the snow.

Page 35

Pre-operation checks

ITEM CHECKS PAGE

Tool kit and recommended equipment

Shroud latches • Make sure that the shroud latches are hooked. 18

Skis and ski runners

Drive track

Slide runners

Steering • Check for excessive free play. 58

Lights, signals and switch-es• Check operation.

Throttle lever

Throttle override system (T.O.R.S.)

• Check for proper placement. 42

• Check for wear and damage.

• If necessary, have Yamaha dealer replace skis or

ski runners.

• Check for deflection, wear and damage.

• If necessary, have Yamaha dealer replace track.

• Check for wear and damage.

• If necessary, have Yamaha dealer replace slide

runners.

• Correct if necessary.

• Make sure that operation is smooth and spring

back to its home position when released.

• Check the T.O.R.S. for proper operation.

• If system is defective, have Yamaha dealer check

vehicle.

16, 15, 63, 64

Page 36

Operation

ESU11290

Starting the engine

EWS00200

WARNING

● Be sure to check the “SAFETY INFOR-

MATION” section carefully before starting the engine.

● Make sure that the parking brake is ap-

plied.

NOTE:

Make sure that the engine stop switch is in the on position. The starter motor cannot be operated when the engine stop switch is in the off position.

1. Star ter (choke) lever

2. Fully open position (cold engine starting)

3. Half-open position (warming engine up)

4. Closed position (warm engine starting)

NOTE:

The starter (choke) lever is not required when the engine is warm. Put the starter (choke) lever in the closed position.

2. Turn the main switch to the start position. After the engine starts, put the starter (choke) lever in the half-open position. Warm up the engine until it does not run roughly or begin to stall when the starter (choke) lever is returned to the closed position.

1. Fully open the starter (choke) lever.

1. Star t

ECS00330

CAUTION:

● Release the switch immediately after the

engine starts.

Page 37

Operation

● If the engine fails to start, release the

switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.

ESU11310

Break-in

There is never a more important period in the life of your engine than the period between 0 and 500 km (300 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 500 km (300 mi). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged fullthrottle operation or any condition that might result in engine overheating must be avoided.

Operating your snowmobile for the first time

Start the engine and let it idle for 15 minutes.

0–160 km (0–100 mi)

Avoid prolonged operation above 6000 r/min.

160–500 km (100–300 mi)

Avoid prolonged operation above 8000 r/min.

500 km (300 mi) and beyond

The snowmobile can now be operated normally.

ECS00340

CAUTION:

● After 800 km (500 mi) of operation, the

engine oil must be changed and the oil filter cartridge replaced.

● If any engine trouble should occur dur-

ing the engine break-in period, immediately have a Yamaha dealer check the snowmobile.

ESU11331

Riding your snowmobile

Getting to know your snowmobile

A snowmobile is a rider active vehicle, and your riding position and your balance are the two basic factors of maneuvering your snowmobile. Riding your snowmobile requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Riding your new snowmobile can be a very enjoyable activity, providing you with hours of pleasure. However, it is essential to familiarize yourself with the operation of the snowmobile to achieve the skill necessary to enjoy riding safely. Before operating the snowmobile, read this Owner’s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on page 1. Please read all warning and caution labels on your snowmobile. Also, read the Snowmobiler’s Safety Handbook that is supplied with your snowmobile.

Learning to ride your snowmobile

Before you ride, always perform the pre-operation checks listed on page 28. The short time spent checking the condition of the snowmobile will be rewarded with added safety and a more reliable snowmobile. Always wear the proper clothing for both warmth and to help protect you from injury if an accident occurs. Become familiar with operating your snowmobile at low speeds, even if you are an experienced rider. Do not attempt to operate at maximum performance until you are totally familiar with the snowmobile’s handling and performance characteristics. The beginning operator should select a large flat area to become familiar with the snowmobile. Make sure that this area is free of obsta-

Page 38

Operation

cles and other traffic. You should practice control of the throttle and brake, and master turning techniques in this area before trying more difficult terrain. Set the parking brake and follow the instructions on page 30 to start the engine. Once the engine has warmed up, you are ready to begin riding your snowmobile.

To start out and accelerate

1. With the engine idling, release the parking brake.

2. Apply the throttle slowly and smoothly. The V-belt clutch will engage and you will start to accelerate.

EWS00210

WARNING

The operator should always keep both hands on the handlebar. Never put your feet outside the running boards. Avoid high speeds until you have become thoroughly familiar with your snowmobile and all of its controls.

Braking

When slowing down or stopping, release the throttle and apply the brake gently—not suddenly.

EWS00220

WARNING

● Many surfaces such as ice and hard-

packed snow require much longer stopping distances. Be alert, plan ahead, and begin decelerating early.

● Improper use of the brake can cause the

drive track to lose traction, reduce control, and increase the possibility of an accident.

Turning

For most snow surfaces, “body English” is the key to turning.

As you approach a curve, slow down and begin to turn the handlebar in the desired direction. As you do so, put your weight on the running board to the inside of the turn and lean your upper body into the turn.

This procedure should be practiced at low speeds many times, in a large flat area with no obstacles. Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. Lean more as the turn gets sharper or is made at higher speeds. Improper riding techniques such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the snowmobile to tip. If your snowmobile begins to tip while turning, lean more into the turn to regain balance. If necessary, gradually let off on the throttle or steer to the outside of the turn.

Remember:

Avoid higher speeds until you are thoroughly familiar with the operation of your snowmobile.

Riding uphill

You should practice first on gentle slopes. Try more difficult climbs only after you have developed your skill. As you approach a hill, accelerate before you start the climb, and then reduce the throttle to prevent track slippage. It is also important to keep your weight on the

Page 39

uphill side at all times. On climbs straight up the hill, this can be accomplished by leaning forward and, on steeper inclines, standing on the running boards and leaning forward over the handlebar. (Also see “Traversing a slope”.)

Slow down as you reach the crest of the hill, and be prepared to react to obstacles, sharp drops, or other vehicles or people which may be on the other side. If you are unable to continue up a hill, do not spin the track. Stop the engine and set the parking brake. Then pull the rear of the snowmobile around to point the snowmobile back down the hill. When the snowmobile is pointed downhill, mount your snowmobile from the uphill side. Restart the engine, release the parking brake, and descend the hill.

EWS00230

WARNING

Side hills and steep slopes are not recommended for a novice snowmobiler.

Operation

EWS00240

WARNING

Use extra caution when applying the brake during a descent. Excessive braking will cause the drive track to lock, causing a loss of control.

Traversing a slope

EWS00250

WARNING

Traversing slopes is not recommended for a novice snowmobiler.

Traversing a slope requires you to properly position your weight to maintain proper balance. As you travel across the slope, lean your body to position your weight towards the uphill side. A recommended riding position is to kneel with the knee of your downhill leg on the seat and the foot of your uphill leg on the running board. This position will make it easier for you to shift your body weight as needed.

Riding downhill

When riding downhill, keep speed to a minimum. It is important to apply just enough throttle to keep the clutch engaged while descending the hill. This will allow you to use engine compression to help slow the snowmobile, and to keep the snowmobile from rolling freely down the hill. Also apply the brake frequently, with light pressure.

Page 40

Operation

Snow and ice are slippery, so be prepared for the possibility that your snowmobile could begin to slip sideways on the slope. If this happens, steer in the direction of the slide if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. If your snowmobile starts to tip, steer down the hill to regain balance.

EWS00260

WARNING

If you are unable to maintain correct balance, and your snowmobile is going to tip over, dismount your snowmobile immediately on the uphill side.

Ice or icy surface

Operating on ice or icy surfaces can be very dangerous. Traction for turning, stopping, and starting is much less than that on snow.

EWS00270

WARNING

When you have to operate on ice or icy surfaces, drive slowly and cautiously. Avoid accelerating, turning, and braking rapidly. Steering is minimal and uncontrolled spins are an ever-present danger.

Hard-packed snow

It can be more difficult to negotiate on hardpacked snow as both the skis and drive track do not have as much traction as when the snowmobile is operated on fresh snow. Avoid rapid acceleration, turning, and braking.

Operation on surfaces other than snow or ice

Operation of your snowmobile on surfaces other than snow or ice should be avoided. Operation under such conditions will damage or result in rapid wear of the ski runners, drive track, slide runners, and drive sprockets. Operation of the snowmobile on the following surfaces should be avoided at all times:

● Dirt

● Sand

● Rocks

● Grass

● Bare pavement

Other surfaces that should be avoided for the sake of drive track and slide runner life are:

● Glare ice surfaces

● Snow mixed with a lot of dirt and sand

All of the above surfaces have one thing in common in regard to drive track and slide runners: little or no lubricating ability. Drive track and all slide rail systems require lubrication (snow or water) between the slide runners and the slide metal. In the absence of lubrication, the slide runners will rapidly wear and in severe cases, literally melt away, and the drive track will be subject to damage or failure. Also traction aids such as studs, cleats, etc., may cause further track damage or failure.

EWS00280

WARNING

Drive track damage or failure could result in loss of braking ability and snowmobile control, which could cause an accident.

● Always check the drive track for damage

or maladjustment before operating the snowmobile.

● Do not operate the snowmobile if you

find damage to the drive track.

ECS00350

CAUTION:

Ride on fresh snow frequently. Operating on ice or hard-packed snow will rapidly wear the slide runners.

ESU11350

Maximizing drive track life

Recommendations Track tension

During initial break-in, the new drive track will tend to stretch quickly as the track settles. Be sure to correct the track tension and align-

Page 41

Operation

ment frequently. (See page 59 for adjustment procedures.) A loose track can slip (ratchet), derail or catch on suspension parts causing severe damage. Do not overtighten the drive track, otherwise it may increase the friction between the track and the slide runners, resulting in the rapid wear of both components. Also, this may put an excessive load on the suspension components, resulting in component failure.

Marginal snow

The drive track and the slide runners are lubricated and cooled by snow and water. To prevent the drive track and slide runners from overheating, avoid sustained high-speed usage in areas such as icy trails, frozen lakes and rivers that have minimal snow coverage. An overheated track will be weakened internally, which may cause failure or damage.

Off-trail riding

Avoid off-trail riding until there is sufficient snow coverage. It generally takes several feet of snow to provide a good overall base to properly cover debris, such as rocks, logs, etc. If snow coverage is not sufficient, stay on trails to avoid impact damage to the drive track.

Studded track

In general, track life will be shortened when studs are installed. Drilling stud holes into the drive track will cut the internal fibers, which weakens the track. Avoid spinning the drive track. Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible damage, consult your stud manufacturer for installation and stud pattern recommendations.

Yamaha does not recommend track studding.

ESU11390

Driving

EWS00300

WARNING

Be sure to read the “SAFETY INFORMATION” section on page 1 and the “Riding your snowmobile” section on page 31 carefully before operating the snowmobile.

NOTE:

Make sure that the engine is warmed up enough before riding.

EWS00310

WARNING

● Make sure that the throttle lever is fully

released and the snowmobile is at a full stop before shifting.

● Be sure to slide the shift lever to “FWD”

or “REV” until it stops completely and only while the engine is idling.

● Make sure that the area behind the

snowmobile is clear before reversing. Watch behind.

● Reduce speed and avoid sharp turning

when operating the snowmobile in reverse.

1. To select the desired operating position, pull the shift lever out, slide it to “FWD” or to “REV” until it stops, and then release it.

1. Pull out.

2. Slide to “FWD” (forward).

3. Release.

Page 42

Operation

1. Pull out.

2. Slide to “REV” (reverse).

3. Release.

ECS00070

CAUTION:

Do not shift from “FWD” to “REV” or from “REV” to “FWD” while the snowmobile is moving. Otherwise, the drive system could be damaged.

NOTE:

The reverse buzzer beeps while the shift lever is in reverse.

2. Release the parking brake by moving the parking brake lever to the right.

6. Apply the parking brake by moving the parking brake lever to the left.

ESU11410

Stopping the engine

Turn the main switch to the off position to stop the engine.

1. Off

EWS00330

WARNING

● Push down the engine stop switch to

stop the engine in an emergency.

● Make sure that the key is removed from

the main switch whenever the operator leaves the snowmobile, to prevent accidental starting.

3. Press the throttle lever slowly to move the snowmobile.

4. Turn the handlebar in the desired direction.

5. Squeeze the brake lever to stop the snowmobile.

ESU11420

Transporting

When transporting your snowmobile on a trailer or in a truck, observe the following recommendations to help protect it from damage:

Page 43

● Make sure that the fuel level in the fuel tank

is lower than the bottom of the carburetors. Otherwise, the vibration and bumps from the road surface could make it possible for fuel to flow through the carburetors into the cylinders. This can result in “hydrostatic lock,” a condition where the engine cannot rotate because of fuel accumulated in the engine. Severe engine damage can result from hydrostatic lock. When possible, the fuel tank should be empty during transportation, especially if the trip takes longer than 30 minutes.

● If transporting the snowmobile in an open

trailer or truck, put a tight fitting cover on the snowmobile. A cover specifically designed for your snowmobile is best. This will help keep foreign objects out of the cooling vents in the shroud, and also help protect the snowmobile against damage from debris on the road.

● If transporting the snowmobile in an open

trailer or truck in areas where road salt is used, coat metal suspension surfaces lightly with oil or another protectant. This will help protect against corrosion. Be sure to clean the snowmobile when you get to your destination to remove any corrosive salts.

Operation

Page 44

Periodic maintenance

ESU11450

Safety is an obligation of the owner. Periodic inspection, adjustment, and lubrication will keep your snowmobile in the safest and most efficient condition possible. The most important points of snowmobile inspection, adjustment, and lubrication are explained on the following pages.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable).

EWS00340

WARNING

If you are not familiar with maintenance work, have a Yamaha dealer do it for you.

PROPER PERIODIC MAINTENANCE OF YOUR SNOWMOBILE IS IMPORTANT IN ORDER TO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSION CONTROL. THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR, BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE. IN THE FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES RELATED TO EMISSION CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE SPECIALIZED DATA, KNOWLEDGE, AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES.

ESU11460

Periodic maintenance chart for the emission control system

INITIAL EVERY

ITEM REMARKS

Spark plugs

* Valve clearance

Crankcase breather

system

* Fuel filter

* Fuel line

* Idle speed • Check and adjust idle speed. 43

• Check condition.

• Adjust gap and clean.

• Replace if necessary.

• Check and adjust valve clear-

ance when engine is cold.

• Check breather hose for cracks or damage.

• Replace if necessary.

• Check condition.

• Replace if necessary.

• Check fuel hose for cracks or

damage.

• Replace if necessary.

1 month

or 800 km

(500 mi)

(40 hr)

Every 40000 km (25000

Seasonally

4000 km

(2500 mi)

(200 hr)

mi)

PAG E

—

Page 45

Periodic maintenance

INITIAL EVERY

ITEM REMARKS

• Adjust synchronization. —

* Carburetors

* Exhaust system

* It is recommended that these items be serviced by a Yamaha dealer.

• Adjust the jets.

• Check for leakage.

• Tighten or replace gasket if

necessary.

1 month

or 800 km

(500 mi)

(40 hr)

Whenever operating

condition (elevation/tem-

perature) is changed.

Seasonally

4000 km

(2500 mi)

(200 hr)

PAG E

—

Page 46

Periodic maintenance

ESU11560

General maintenance and lubrication chart

ITEM REMARKS

Engine oil

Engine oil filter car-

tridge

* Cooling system

Primary and sec-

ondary clutches

* Drive chain

* Drive chain oil

Brake and parking

brake

Control cables

Disc brake installa-

tion

* Slide runners

Skis and ski run-

ners

• Change (warm engine before draining)

• Replace.

• Check coolant level.

• Air bleed the cooling system if

necessary.

• Check engagement and shift speed.

• Adjust if necessary.

• Inspect sheaves for wear and

damage.

• Inspect weights/rollers and bushings for wear for primary.

• Inspect ramp shoes/bushings for wear for secondary.

• Replace if necessary.

• Lubricate with specified

grease.

• Check chain slack.

• Adjust if necessary.

• Check oil level. 54

• Change. 54

• Adjust free play and/or replace

pads if necessary.

• Change brake fluid.

• Make sure that operation is

smooth.

• Lubricate if necessary.

• Check for slight free play.

• Lubricate shaft with specified

grease as required.

• Check for wear and damage.

• Replace if necessary.

• Check for wear and damage.

• Replace if necessary.

INITIAL EVERY

1 month

or 800 km

(500 mi)

(40 hr)

Whenever operating ele-

vation is changed.

Initial at 500 km (300 mi)

and every 800 km (500

See NOTE following this

Every 1600 km (1000

Seasonally

4000 km

(2500 mi)

(200 hr)

Every

20000 km

(12000 mi)

mi) thereafter.

chart.

mi)

PAG E

—

Page 47

Periodic maintenance

INITIAL EVERY

ITEM REMARKS

* Steering system

* Steering bearings

Ski and front sus-

pension

Suspension compo-

nent

Fittings and fasteners

* Battery

* It is recommended that these items be serviced by a Yamaha dealer.

• Check toe-out.

• Adjust if necessary.

• Check bearing assemblies for

looseness.

• Lubricate with specified grease.

• Make sure that all nuts, bolts and screws are properly tightened.

• Tighten if necessary.

• Check condition.

• Charge if necessary.

1 month

or 800 km

(500 mi)

(40 hr)

NOTE:

Brake system:

● After disassembling the master cylinder or caliper cylinder, always change the brake fluid.

Regularly check the brake fluid level and add fluid if necessary.

● Replace the oil seals of the master cylinder and caliper cylinder every two years.

● Replace the brake hose every four years, or if cracked or damaged.

Seasonally

4000 km

(2500 mi)

(200 hr)

PAG E

—

Page 48

Periodic maintenance

ESU11740

Tool kit

The owner’s tool kit has the tools which are sufficient for most periodic maintenance and minor repairs. A torque wrench is also necessary to properly tighten nuts and bolts.

1. Tool kit

ECS00360

CAUTION:

Before starting the engine, make sure that the tool kit is properly seated in its holder and is securely fastened.

NOTE:

If you do not have a torque wrench available during a service operation requiring one, take your snowmobile to a Yamaha dealer to check the torque settings and adjust them if necessary.

ESU11780

Checking the spark plugs

The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. Check the coloration on the white porcelain insulator around the center electrode. The ideal coloration at this point is a medium to a light tan color for a snowmobile that is being ridden normally. If a spark plug shows a distinctly different color, there could be something wrong with the engine. For example, a very white center electrode porcelain color

could indicate an intake track air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the snowmobile to a Yamaha dealer for inspection and possible repairs. You should periodically remove and inspect the spark plug because heat and deposits will cause a spark plug to slowly break down and erode. Consult a Yamaha dealer before changing to a different type of spark plug.

Specified spark plug:

Manufacturer:

NGK

Model:

CR8E

Spark plugs are produced in several different thread lengths. The thread length or reach is the distance from the spark plug gasket seat to the end of the threaded portion. If the reach is too long, overheating and engine damage may result. If the reach is too short, spark plug fouling and poor performance may result. Also, if the reach is too short, carbon will form on the exposed threads resulting in combustion chamber hot spots and thread damage. Always use a spark plug with the specified reach.

Spark plug reach:

19.0 mm (0.75 in)

1. Spark plug gap

2. Spark plug reach

Page 49

Before installing any spark plug, measure the electrode gap with a wire thickness gauge and adjust to specification.

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

When installing the spark plug, always clean the gasket surface. Wipe off any grime from the threads and tighten the spark plug to the specified torque.

Periodic maintenance

1. Throttle stop screw

Spark plug tightening torque:

12.5 Nm (1.25 m·kgf, 9 ft·lb)

ECS00380

CAUTION:

Make sure that the spark plug caps are securely installed. Otherwise the spark plug caps could be damaged due to engine vibration.

ESU11792

Adjusting the engine idling

speed

ECS00390

CAUTION:

● Be sure to have a Yamaha dealer make

this adjustment.

● Make sure that the throttle lever moves

smoothly.

● Make sure that the carburetor is syn-

chronized first.

1. Start the engine and warm it up.

NOTE:

Refer to the “Starting the engine” section on page 30.

2. Turn the throttle stop screw in or out to adjust the engine idling speed.

Standard engine idling speed:

1300–1500 r/min

ESU11821

Adjusting the throttle cable free

play

ECS00410

CAUTION:

Be sure to adjust the engine idling speed first.

1. Loosen the locknut.

2. Turn the adjusting bolt in or out until the specified throttle cable free play is obtained.

1. Locknut

2. Throttle cable free play adjusting bolt

3. Throttle cable free play

Throttle cable free play:

2.0–3.0 mm (0.08–0.12 in)

3. Tighten the locknut.

Page 50

Periodic maintenance

ESU11861

Checking the throttle override

system (T.O.R.S.)

Check the T.O.R.S. for proper operation.

EWS00351

WARNING

When checking the T.O.R.S.:

● Make sure that the parking brake is ap-

plied.

● Make sure that the throttle lever moves

smoothly.

● Do not rev the engine to the point that

the clutch engages, otherwise the snowmobile could start moving, which could cause an accident.

1. Start the engine.

NOTE:

Refer to the “Starting the engine” section on page 30.

2. Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb (above) and forefinger (below) between the throttle lever pivot and the engine stop switch housing. While holding the pivot point as described above, press the throttle lever gradually.

1. Throttle lever pivot

2. Engine stop switch housing

3. Throttle lever

The T.O.R.S. will be activated and the engine speed will be limited to less than the clutch engagement speed. (See page 74 for the clutch engagement speed.)

EWS00361

WARNING

If the engine speed does not decrease to less than the clutch engagement speed, stop the engine by turning the main switch to the off position and consult a Yamaha dealer.

ESU11871

Checking the air filter

Always check that there is no snow under the air filter element frame.

1. Unhook the air filter case cover fasteners.

Page 51

2. Remove the air filter case cover.

3. Lift up the air filter element frame and check the air filter element. If there is any snow on the air filter element, remove the element, brush off the snow, and then install the air filter element.

4. Place the air filter element frame in the original position, and then install the air filter case cover.

5. Install the air filter case cover by hooking the fasteners.

Periodic maintenance

NOTE:

After riding the snowmobile, make sure that there is no snow under the air filter element frame.

ESU11910

Carburetors

The carburetors are an important part of the engine and its emission control system, which require very sophisticated adjustment. Therefore, carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.

ESU11940

High-altitude settings

Operating at high altitude reduces the performance of a gasoline engine about 3% for every 305 m (1000 ft) of elevation. This is because there is less air as altitude increases. Less air means less oxygen available for combustion. Your snowmobile can be adjusted to overcome most of the problems found in high-altitude riding. Carburetor adjustments are the most important. Less air at high altitude makes the air/fuel ratio too rich, which can cause poor performance. Common problems are hard starting, bogging, and plug fouling. Proper carburetion adjustments will correct the air/fuel ratio. Be sure to have a Yamaha dealer make these adjustments.

Remember:

Less air at higher altitude means there is less horsepower available, even with proper carburetion. Expect acceleration and top speed to be reduced at higher altitudes. To overcome operating with less power at high altitudes, your snowmobile may also require different settings for the drive chain gears and V-belt clutch to avoid poor performance and rapid wear. If you plan to operate your snowmobile at an altitude different from the area where you bought it, be sure to con-

Page 52

Periodic maintenance

sult a Yamaha dealer. The dealer can tell you if there are any changes necessary for the altitude where you plan to ride.

ECS00430

CAUTION:

The drive chain gears and V-belt clutch should be adjusted when operating above a high altitude of 900 m (3000 ft). Consult a Yamaha dealer.

ESU11950

Valve clearance

The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance chart.

ESU11972

Engine oil and oil filter cartridge

The engine oil level should be checked before each use. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart.

EWS00370

WARNING

Engine oil is extremely hot immediately after the engine is turned off. Coming into contact with or getting any engine oil on your clothes could result in burns.

ECS00480

CAUTION:

● Do not run the engine with too much or

not enough oil in the oil tank. Oil could spray out or the engine could be damaged.

● Be sure to change the engine oil after

the first 800 km (500 mi) of operation, and every 4000 km (2500 mi) thereafter or at the start of a new season, otherwise the engine will wear quickly.

● The oil filter cartridge should be re-

placed every 20000 km (12000 mi) of operation.

To check the engine oil level

1. Place the snowmobile on a level surface and apply the parking brake.

2. Start the engine, warm it up for 10–15 minutes, and then turn it off.

NOTE:

● The engine can also be warmed up by op-

erating the snowmobile for 10–15 minutes.

● After operating the snowmobile, allow the

engine to idle for at least 10 seconds before turning it off.

3. Open the shroud.

4. Disconnect the oil level gauge coupler.

1. Oil level gauge coupler

2. Oil filler cap

Page 53

Periodic maintenance

ECS00451

CAUTION:

Disconnect the oil level gauge coupler before removing the oil filler cap, otherwise the cable could twist and break.

5. Remove the oil filler cap, wipe the dipstick clean, insert it back into the oil filler hole (without screwing it in), and then remove it again to check the oil level.

1. Oil filler cap

2. Dipstick

NOTE:

The engine oil should be between the “H” and “L” level marks on the dipstick.

ECS00461

CAUTION:

● When adding the engine oil, be careful

not to fill above the “H” level mark on the dipstick.

● Use only 4-stroke engine oil.

● Make sure that no foreign material en-

ters the engine oil tank.

7. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap.

8. Connect the oil level gauge coupler.

9. Close the shroud.

To change the engine oil (with or without oil filter cartridge replacement)

1. Place the snowmobile on a level surface and apply the parking brake.

2. Start the engine, warm it up for several minutes, and then turn it off.

3. Open the shroud.

4. Remove the bottom panel and right side cover.

1. “H” level mark

2. “L” level mark

6. If the engine oil is below the “L” level mark, add sufficient oil of the recommended type to raise it to the “H” level mark. (See page 74 for the recommended oil.)

1. Bottom panel

Page 54

Periodic maintenance

1. Right side cover

5. Place an oil pan under the oil tank to collect the used oil.

6. Disconnect the oil level gauge coupler.

1. Oil level gauge coupler

2. Oil filler cap

7. Remove the oil filler cap, cylinder head cap, and drain bolt to drain the oil from the oil tank.

1. Engine oil drain bolt (oil tank)

8. Place an oil pan under the engine to collect the used oil.

9. Remove the engine oil drain bolt to drain the oil from the crankcase.

1. Engine oil drain bolt (crankcase)

2. “” mark

NOTE:

● A “” mark is stamped on the crankcase

near the engine oil drain bolt.

● Dispose of used oil according to local regu-

lations.

● Skip steps 10–12 if the oil filter cartridge is

not being replaced.

1. Cylinder head cap

10. Remove the oil filter cartridge with an oil filter wrench.

Page 55

Periodic maintenance

Recommended engine oil:

See page 74.

Oil quantity:

With oil filter cartridge replacement:

3.0 L (3.17 US qt) (2.64 Imp.qt)

Without oil filter cartridge replacement:

2.8 L (2.96 US qt) (2.46 Imp.qt)

Total amount:

3.7 L (3.91 US qt) (3.26 Imp.qt)

1. Oil filter cartridge

NOTE:

An oil filter wrench is available at a Yamaha dealer.

11. Apply a thin coat of engine oil to the Oring of the new oil filter cartridge.

12. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque.

Tightening torque:

Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lb)

13. Install the engine oil drain bolts, and then tighten them to the specified torques.

Tightening torques:

Engine oil drain bolt (crankcase):

10 Nm (1.0 m·kgf, 7.2 ft·lb)

Engine oil drain bolt (oil tank):

16 Nm (1.1 m·kgf, 11 ft·lb)

14. Add 2.0 L (2.1 US qt) (1.8 Imp. qt) of the recommended engine oil to the oil tank, and then install and tighten the oil filler cap and the cylinder head cap.

15. Start the engine, warm it up for several minutes, and then turn it off.

16. Add sufficient oil of the recommended type to raise it to the “H” level mark on the dipstick. (See above for the checking procedure.)

ECS00461

CAUTION:

● When adding the engine oil, be careful

not to fill above the “H” level mark on the dipstick.

● Use only 4-stroke engine oil.

● Make sure that no foreign material en-

ters the engine oil tank.

17. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and make sure that the engine oil drain bolt, oil tank drain bolt, cylinder head cap, and the oil filler cap are installed correctly.

18. Turn the engine off, and then connect the oil level gauge coupler.

Page 56

Periodic maintenance

ECS00470

CAUTION:

If oil is leaking or the oil level warning indicator comes on when the engine is running, immediately turn the engine off and have a Yamaha dealer check the snowmobile. Continuing to operate the engine under such conditions could cause severe engine damage.

19. Install the bottom panel and right side cover, and then close the shroud.

ESU12000

Cooling system

The coolant level should be checked before each ride. In addition, the cooling system must be bled of air at the intervals specified in the periodic maintenance and lubrication chart.

EWS00380

WARNING

Do not remove the coolant reservoir cap when the engine is hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick rag or towel over the coolant reservoir cap, and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.

To check the coolant level

1. Open the shroud.

2. Check the coolant level in the coolant reservoir when the engine is cold. If the coolant level is below the “COLD LEVEL” mark, add soft water until it reaches the “COLD LEVEL” mark. (See the following section “Replenishing the coolant” for more details.)

1. “COLD LEVEL” mark

ECS00490

CAUTION:

● Hard water or salt water is harmful to the

engine parts. You may use boiled or distilled water, if soft water is not available.

● Tap water can be used temporarily in an

emergency.

Bleeding the cooling system

The cooling system must be bled of air if the coolant reservoir becomes empty, if air can be seen in the cooling system, or if there is a cooling system leak. Consult a Yamaha dealer.

ECS00500

CAUTION:

Operating the engine with an improperly bled cooling system can cause overheating and severe engine damage.

Replenishing the coolant

1. Remove the coolant reservoir cap and add coolant until it reaches the “COLD LEVEL” mark.

Page 57

Periodic maintenance

ESU12050

EWS00400

WARNING

● Make sure that the drive guard is tight-

ened securely before operating the snowmobile.

● Never run the engine with the V-belt or

drive guard removed.

V-belt

1. “COLD LEVEL” mark

2. Coolant reservoir cap

Recommended antifreeze:

High-quality ethylene glycol antifreeze containing corrosion inhibitors

Antifreeze and water mixing ratio:

3:2

Total amount:

5.20 L (5.50 US qt) (4.58 Imp.qt)

2. Start the engine and add coolant until the coolant level does not go down, and then stop the engine.

3. Fill the coolant reservoir with coolant until it reaches the “COLD LEVEL” mark.

4. Install the coolant reservoir cap.

5. Check for any coolant leakage.

NOTE:

If you find any leaks, consult a Yamaha dealer.

The V-belt should be checked before each ride. To check the V-belt

1. Open the shroud and remove the drive guard.

2. Check the V-belt for wear and damage. Replace if necessary.

1. V-belt wear limit

New V-belt width:

34.1 mm (1.34 in)

V-belt wear limit width:

32.5 mm (1.28 in)

3. Install the drive guard and close the shroud.

To replace and adjust the V-belt

EWS00410

WARNING

● Never run the engine with the V-belt or

drive guard removed.

● When installing the new V-belt, make

sure that it is positioned properly. Otherwise, the V-belt clutch engagement

Page 58

Periodic maintenance

speed will be changed and the snowmobile may move unexpectedly when the engine is started, which could cause an accident.

● Have a Yamaha dealer make this adjust-

ment.

NOTE:

Apply the parking brake before replacing the V-belt.

1. Open the shroud and remove the drive guard.

2. Rotate the secondary sliding sheave clockwise and push it so that it separates from the secondary fixed sheave.

1. Secondary sliding sheave

2. Secondary fixed sheave

3. Pull the V-belt up over the secondary fixed sheave.

1. Edge of the secondary sheave assembly

2. Spacer

ECS00510

CAUTION:

As the V-belt wears, adjustment may be necessary. To ensure proper clutch performance, the V-belt position should be adjusted by adding a spacer on each adjusting bolt when the V-belt position reaches 1.5 mm (0.06 in) below the edge of the secondary sheave assembly. Have a Yamaha dealer make this adjustment.

1. V-belt

4. Remove the V-belt from the secondary sheave assembly and primary sheave assembly.

5. Temporarily install the new V-belt on the secondary sheave assembly only, and then measure the V-belt position. Do not

Page 59

force the V-belt between the sheaves; the secondary sliding and fixed sheaves must touch each other.

1. Edge of the secondary sheave assembly

2. V-belt position

Standard V-belt position:

From 1.5 mm (0.06 in) above the edge of the secondary sheave assembly to

0.5 mm (0.02 in) below the edge.

6. If the V-belt position is incorrect, adjust it by removing or adding a spacer on each V-belt position adjusting bolt.

Periodic maintenance

1. V-belt position adjusting bolt

2. Spacer

V-belt position Adjustment

More than 1.5 mm (0.06 in) above the edge

From 1.5 mm (0.06 in) above the edge to 0.5 mm (0.02 in) below the edge

More than 0.5 mm (0.02 in) below the edge

Remove spacer

Not necessary (It is correct.)

Add spacer

7. Tighten the V-belt position adjusting bolts.

V-belt position adjusting bolt tightening torque:

10 Nm (1.0 m·kgf, 7.2 ft·lb)

8. Install the V-belt over the primary sheave assembly.

Page 60

Periodic maintenance

9. Rotate the secondary sliding sheave clockwise and push it so that it separates from the secondary fixed sheave.

1. Secondary sliding sheave

2. Secondary fixed sheave

10. Install the V-belt between the secondary sliding and fixed sheaves.

2. Remove the dipstick, wipe it off with a clean rag, and then insert it back into the filler hole.

1. Dipstick

3. Remove the dipstick and check that the oil is between the maximum and minimum level marks. If the oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the maximum level mark.

1. V-belt

11. Install the drive guard and close the shroud.

ESU12090

Drive chain housing

EWS00430

WARNING

The engine, oil tank, brake disc, and coolant hoses will be very hot after the engine has been run. Avoid contact while they are still hot with any part of your body or clothing during inspection or repair.

To check the drive chain housing oil level

1. Place the snowmobile on a level surface.

1. Maximum level mark

2. Minimum level mark

Page 61

Periodic maintenance

Recommended drive chain oil:

SAE 75W or 80W API GL-4 Gear oil

ECS00530

CAUTION:

Make sure that no foreign material enters the drive chain housing.

4. Install the dipstick, making sure to align the notch in the dipstick handle with the projection on the drive chain housing.

1. Notch

2. Projection

To adjust the chain tension

1. Loosen the locknut.

2. Turn the chain tension adjusting bolt clockwise until it is finger tight, and then loosen it 1/4 turn.

3. Hold the chain tension adjusting bolt in place while tightening the locknut.

ESU12130

Brake and parking brake

EWS00440

WARNING

● A soft, spongy feeling in the brake lever

indicates a failure in the brake system.

● Do not operate the snowmobile if you

find any problems in the brake system. You could lose braking ability, which could lead to an accident. Ask a Yamaha dealer to inspect and repair the brake system.

ECS00060

CAUTION:

Make sure that the brake lever end does not project out over the handlebar end. This will help prevent brake lever damage when the snowmobile is placed on its side for service.

Test the brake at a low speed when starting out to make sure that it is working properly. If the brake does not provide proper braking performance, inspect the brake for wear or brake fluid leakage. (See the following section for more details.)

Checking the brake pads

Check the brake pads for wear. If the brake pads reach the wear limit, ask a Yamaha dealer to replace them.

1. Locknut

2. Chain tension adjusting bolt

1. Brake pad wear indicator

2. Brake pad wear limit

Page 62

Periodic maintenance

Brake pad wear limit:

7.5 mm (0.30 in)

Checking the parking brake pads

Check the parking brake pads for wear by measuring the thickness of the pads. If the parking brake pads reach the wear limit, ask a Yamaha dealer to replace them.

1. Parking brake pad locknut

2. Parking brake pad adjusting bolt

3. Parking brake cable locknut

4. Parking brake cable adjusting bolt

5. Parking brake cable length

Parking brake cable length:

43.5–46.5 mm (1.713–1.831 in)

1. Parking brake pad wear limit

Parking brake pad wear limit:

1.2 mm (0.047 in)

To adjust the parking brake As the parking brake pads wear, adjustment may be necessary to ensure proper brake performance.

EWS00450

WARNING

Be sure to have a Yamaha dealer make this adjustment.

1. Loosen the parking brake pad locknut and the parking brake pad adjusting bolt.

2. Loosen the parking brake cable locknut.

3. Turn the parking brake cable adjusting bolt in or out to adjust the cable length.

4. Tighten the parking brake cable locknut.

5. Turn the parking brake pad adjusting bolt in or out to adjust the clearance between the parking brake pads and the brake disc.

1. Parking brake pad

2. Brake disc

Parking brake pad to brake disc clearance (a) + (b):

1.5–2.0 mm (0.059–0.079 in)

6. Tighten the parking brake pad locknut.

Page 63

Periodic maintenance

Checking the brake fluid level

EWS00460

WARNING

Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. If the brake fluid level goes down, consult a Yamaha dealer.

ECS00550

CAUTION:

Brake fluid may deteriorate painted surfaces or plastic parts. Never spill any fluid. If any is spilled, clean it up immediately.

Place the snowmobile on a level surface. Check that the brake fluid is above the lower level and replenish when necessary.

● All oil seals of the master cylinder and cali-

per cylinder

● The brake hose

ESU12141

Skis and ski runners

Check the skis and ski runners for wear and damage. Replace if necessary.

1. Ski runner wear limit

1. Lower level

Specified brake fluid:

DOT 4

Changing the brake fluid

EWS00470

WARNING

Make sure that the brake fluid and the above parts are replaced by a Yamaha dealer.

Brake fluid replacement is necessary when the following components are replaced during the periodic maintenance or if they are damaged or leaking.

1. Ski wear limit

Ski runner wear limit:

8 mm (0.31 in)

Ski wear limit:

RST90 24 mm (0.94 in) RST90GT 12 mm (0.47 in)

ECS00560

CAUTION:

Avoid scratching the skis when loading and unloading the snowmobile, when riding in areas with little or no snow, or on sharp edges such as concrete, curbs, etc. This will wear or damage the skis.

Page 64

Periodic maintenance

To align the skis

1. Turn the handlebar so the skis face straight ahead.

2. Check the following for ski alignment:

● Skis are facing forward.

● Ski toe-out (distance A – distance B) is

within specification.

1. Distance A

2. Distance B

Ski toe-out (distance A – distance B):

0.0–15.0 mm (0.00–0.59 in)

3. If the alignment is not correct, consult a

Yamaha dealer.

ESU12161

Steering system

Check the handlebar for excessive free play. To check the handlebar

1. Push the handlebar up and down and back and forth.

2. Turn the handlebar slightly to the right and left.

If excessive free play is felt, consult a Yamaha dealer.

To adjust the handlebar height

1. Remove the handlebar cover.

1. Handlebar cover

2. Loosen the handlebar bolts.

1. Handlebar bolt

3. Move the handlebar up or down to adjust the handlebar height to the desired position.

Page 65

Periodic maintenance

ECS00570

CAUTION:

Make sure that the projection on the handlebar is not installed into the area shown.

1. Area where projection cannot be installed

4. Tighten the handlebar bolts and install the handlebar cover.

Handlebar bolt tightening torque:

23 Nm (2.3 m·kgf, 17 ft·lb)

ECS00580

CAUTION:

Make sure that the small gap side of the handlebar holders faces forward.

1. Forward

2. Small gap

ESU12171

Drive track and slide runners

Drive track

EWS00480

WARNING

A broken track, track fittings or debris thrown by the drive track could be dangerous to an operator or bystanders. Observe the following precautions:

● Do not allow anyone to stand behind the

snowmobile when the engine is running.

● When the rear of the snowmobile is

raised to allow the drive track to spin, a suitable stand must be used to support the rear of the snowmobile. Never allow anyone to hold the rear of the snowmobile off the ground to allow the drive track to spin. Never allow anyone near a rotating drive track.

● Inspect the drive track condition fre-

quently. Replace damaged slide metal. Replace the drive track if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken. Otherwise, track damage or failure could result in loss of braking ability and snowmobile control, which could cause an accident.

Page 66

Periodic maintenance

Checking the drive track

EWS00490

WARNING

Do not operate the snowmobile if you find damage to the drive track, or if it has been maladjusted. Drive track damage or failure could result in loss of braking ability and snowmobile control, which could cause an accident.

Check the drive track for deflection, wear, and damage. Adjust or replace if necessary. (See the following section for more details.)

Measuring the drive track deflection

1. Lay the snowmobile on its side.

2. Measure the drive track deflection with a spring scale. Pull at the center of the drive track with a force of 100 N (10 kg, 22 lb).

NOTE:

Measure the gap between the slide runner and the edge of the track window. Measure both sides.

1. Drive track deflection

Standard drive track deflection:

30.0–35.0 mm (1.18–1.38 in)

3. If the deflection is incorrect, adjust the drive track.

Adjusting the drive track

EWS00500

WARNING

● Be sure to have a Yamaha dealer make

this adjustment.

● Support the snowmobile securely on a

suitable stand before working underneath the snowmobile.

● Operate the engine in a well-ventilated

area.

1. Spring scale

1. Lift the rear of the snowmobile onto a suitable stand to raise the drive track off the ground.

2. Loosen the rear axle nut.

Page 67

Periodic maintenance

1. Rear axle nut

3. Start the engine and rotate the drive track one or two turns. Stop the engine.

4. Check the drive track alignment with the slide runners. If the alignment is incorrect, align the drive track by turning the left and right adjusting nuts.

1. Slide runner

Drive track

alignment

Left adjusting nut

Right adjusting nut

Shifted to

right

Tur n o u t Tur n i n

Turn in Turn out

Shifted to left

1. Left adjusting nut

2. Right adjusting nut

Shifted to right

1. Forward

2. Gap

3. Slide runner

4. Drive track

5. Slide metal

Shifted to left

1. Forward

2. Gap

3. Slide runner

4. Drive track

5. Slide metal

Page 68

Periodic maintenance

5. Adjust the drive track deflection to specification.

Drive track

deflection

Left adjusting nut

Right adjusting nut

ECS00591

More than

specified

Turn in Turn out

Less than

specified

CAUTION:

The right and left adjusting nuts should be turned an equal amount.

6. Recheck alignment and deflection. If necessary, repeat steps 3 to 5 until the proper adjustment is achieved.

7. Tighten the rear axle nut.

Rear axle nut tightening torque:

75 Nm (7.5 m·kgf, 54 ft·lb)

Slide runners

Check the slide runners for wear and damage. If the slide runners reach the wear limit, they should be replaced.

ECS00350

CAUTION:

Ride on fresh snow frequently. Operating on ice or hard-packed snow will rapidly wear the slide runners.

ESU12190

Lubrication

Lubricate the following points with the specified grease.

EWS00510

WARNING

● Apply a dab of grease onto the cable end

only. Do not grease the throttle cable because it could become frozen, which could cause loss of control.

● Be sure to have a Yamaha dealer lubri-

cate the front and rear suspensions.

Lubricant:

Low-temperature grease

1. Slide runner

2. Wear limit height

Slide runner wear limit height:

10.5 mm (0.41 in)

1. Throttle cable end

Page 69

Periodic maintenance

1. Lubrication point

ESU12210

Replacing a headlight bulb

EWS00530

WARNING

Keep flammable products and your hands away from the hot bulb until it has cooled down.

1. Open the shroud.

2. Disconnect the headlight coupler.

3. Remove the bulb holder cover.

1. Bulb holder cover

4. Unhook the bulb holder by pushing it in, then upward.

1. Bulb holder

5. Remove the bulb.

6. Install the new bulb, and then hook the bulb holder onto the headlight unit.

Bulb type:

Halogen bulb

ECS00620

CAUTION:

Keep oil and your hands away from the glass part of the bulb or its life and illumination will be affected. If the glass is oil stained, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

Page 70

Periodic maintenance

1. Do not touch the glass part of the bulb.

7. Install the bulb holder cover, and then connect the headlight coupler.

8. Close the shroud.

ESU12260

Adjusting the headlight beam

1. Open the shroud.

2. Insert a Phillips screwdriver into the hole under the shroud to access the headlight beam adjusting screw.

1. Headlight beam adjusting screw

3. Turn the headlight beam adjusting screw to adjust the headlight beam. To lower the headlight beam, turn the headlight beam adjusting screw in direction (a). To raise the headlight beam, turn the headlight beam adjusting screw in direction (b).

1. Phillips screwdriver

4. Close the shroud.

ESU12290

Fittings and fasteners

Check the tightness of the fittings and fasteners. Tighten in proper sequence and torque if necessary.

ESU12300

Battery

This snowmobile is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water.

To charge the battery

Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the snowmobile is equipped with electrical accessories.

EWS00540

WARNING

Battery electrolyte is poisonous and dangerous. It contains sulfuric acid and can cause severe burns. Avoid contact with skin, eyes, or clothing. ANTIDOTE:

● EXTERNAL: Flush with water.

● INTERNAL: Drink large quantities of wa-

ter or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

Page 71

● EYES: Flush with water for 15 minutes

and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF THE REACH OF CHILDREN.

ESU12311

Replacing a fuse

EWS00550

WARNING

Be sure to use the specified fuse. A wrong fuse could cause electrical system damage or A FIRE HAZARD.

ECS00631

CAUTION:

Be sure to turn the main switch to the off position and disconnect the negative battery lead to prevent accidental short-circuiting.

1. Open the shroud.

2. Remove the right side cover.

Periodic maintenance

1. Fastener

4. Loosen the joint clamp screws.

1. Joint clamp screw

5. Slide the oil tank breather hose clamp away from the air filter case, and then disconnect the oil tank breather hose.

1. Right side cover

3. Unhook the air filter case cover fastener.

1. Oil tank breather hose clamp

2. Oil tank breather hose

6. Slide the crankcase breather hose clamp (crankcase side) up, and then disconnect the crankcase breather hose from the engine.

Page 72

Periodic maintenance

1. Crankcase breather hose clamp (crankcase side)

2. Crankcase breather hose

7. Lift up the air filter case, slide the crankcase breather hose clamp (air filter case side) down, disconnect the crankcase breather hose from the air filter case, and then remove the air filter case.

1. Crankcase breather hose clamp (air filter case side)

8. Disconnect the negative battery lead.

9. Replace the blown fuse with one of the proper amperage.

1. Main fuse

2. Spare main fuse

1. “HEAD” (headlight) fuse

2. “SIG” (signal) fuse

3. “DC TERM” (auxiliary DC jack) fuse

4. “C/W” (carburetor warmer) fuse

5. “IGN” (ignition) fuse

6. Spare fuse

Page 73

Specified fuses:

Main fuse:

30.0 A

Spare main fuse:

30.0 A

“HEAD” (headlight) fuse:

20.0 A

“SIG” (signal) fuse:

10.0 A

“DC TERM” (auxiliary DC jack) fuse:

3.0 A

“C/W” (carburetor warmer) fuse:

20.0 A

“IGN” (ignition) fuse:

15.0 A

Spare fuses:

20.0 A, 15.0 A, 10.0 A, 3.0 A

10. Connect the negative battery lead.

11. Install the air filter case by reversing the removal steps.

ECS00640

CAUTION:

Be sure to connect the breather hoses securely when installing the air filter case.

Periodic maintenance

NOTE:

When installing the air filter case, connect the crankcase breather hose to the air filter case first, and then connect it to the engine.

12. Install the right side cover and close the shroud.

NOTE:

If the fuse immediately blows again, ask a Yamaha dealer to inspect the snowmobile.

Page 74

Troubleshooting

ESU12372

Engine turns over but does not start

1. Fuel system

No fuel supplied to combustion chamber

• No fuel in tank: Supply fuel.

• Clogged fuel line: Clean fuel line.

• Clogged carburetor: Clean carburetor.

Fuel supplied to combustion chamber

• Flooded engine (too much choke): Crank engine with throttle open or wipe the spark plugs dry.

2. Electrical system Poor spark or no spark

• Spark plugs are dirty with carbon or are

wet: Remove carbon or wipe the spark plugs dry. Replace if necessary.

• Faulty ignition system: Ask a Yamaha

dealer to inspect.

• T.O.R.S. malfunction: Disconnect the

throttle switch connectors and connect the wire harness connectors together to bypass the T.O.R.S.

EWS00560

WARNING

● Before bypassing the T.O.R.S., make

sure that the throttle returns properly to the fully closed position.

● The T.O.R.S. is an important safety de-

vice; in the case of a malfunction, take the snowmobile to a Yamaha dealer immediately for repair.

3. Compression Insufficient

• Loose cylinder head nuts: Tighten nuts

properly.

• Worn or damaged gasket: Replace gas-

ket.

• Worn or damaged piston and cylinder:

Ask a Yamaha dealer to inspect.

Discharged battery

If the battery is discharged, the engine can be started using a fully-charged 12-volt battery and jumper cables. Two connecting leads have been provided for jump-starting the snowmobile. Due to the rubber engine mounting, the snowmobile frame is not a suitable grounding point for jump-starting the engine.

EWS00570

WARNING

● Connect the jumper cables only to the

connecting lead terminals. Do not connect them to the frame or any wire or other lead.

● When connecting the jumper cables, do

not contact the jumper cables or connecting lead terminals to each other or to the frame or any metal part of the snowmobile. This can cause electrical system damage or A FIRE HAZARD.

● Be sure to pull the lead covers back over

the terminals completely. If the terminals are exposed, they could come into contact with the frame or a metal part of the snowmobile and this can cause electrical system damage or A FIRE HAZARD.

ECS00650

CAUTION:

Use the connecting leads to jump-start the snowmobile only. Do not use the connecting leads for any other purpose.

Page 75

To start the engine using the booster battery

1. Apply the parking brake and turn the main switch to the off position.

2. Open the shroud.

3. Remove the red (+) connecting lead from the lead holder and move it away from the black (–) connecting lead.

ECS00660

CAUTION:

Be sure to connect the red (+) jumper cable to the red (+) connecting lead and the black (–) jumper cable to the black (–) connecting lead. Do not reverse the connections.

Troubleshooting

5. Connect the other end of the red (+) jumper cable to the positive (+) terminal of the booster battery.

6. Connect the black (–) jumper cable to the negative (–) terminal of the booster battery.

7. Pull the black (–) connecting lead cover to expose the terminal through the slit in the cover, and then connect the black (–) jumper cable to the black (–) connecting lead.

4. Pull the red (+) connecting lead cover to expose the terminal through the slit in the cover, and then connect the red (+) jumper cable to the red (+) connecting lead.

Page 76

Troubleshooting

8. Start the engine.

9. Disconnect the black (–) jumper cable from the black (–) connecting lead, and then pull the cover completely over the lead terminal.

10. Disconnect the black (–) jumper cable from the negative (–) terminal of the battery used to jump start the engine.

11. Disconnect the red (+) jumper cable from the positive (+) terminal of the battery used to jump start the engine.

12. Disconnect the red (+) jumper cable from the red (+) connecting lead, and then pull the cover completely over the lead terminal.

13. Install the red (+) connecting lead into the lead holder.

14. Close the shroud.

NOTE:

Make sure that both the red (+) connecting lead and the black (–) connecting lead are seated securely in the lead holders.

Electric starter does not operate or operates slowly

● Engine stop switch is pushed in: Pull it out.

● Faulty wire connections: Check connec-

tions or ask a Yamaha dealer to inspect.

● Discharged battery: Charge battery or see

“Starting the engine with a discharged battery” above.

● Seized engine: Seizure is caused by poor

lubrication, inadequate fuel, or an air leak. Ask a Yamaha dealer to inspect.

● “Hydrostatic lock” occurs when fuel has

filled the cylinders when the vehicle has been transported: Remove the spark plugs and turn the engine over several times with the ignition off to expel excess fuel. Ask a Yamaha dealer to inspect.

Engine power is low

● Low coolant temperature indicator light is

flashing: Warm the engine up.

● Faulty spark plugs: Clean or replace the

spark plugs.

● Incorrect carburetor jetting for altitude or

temperature: Ask a Yamaha dealer to inspect.

● Improper fuel flow: See “Engine turns over

but does not start–Fuel system” above.

● Incorrect V-belt clutch settings for altitude

or conditions: Ask a Yamaha dealer to inspect.

Engine constantly backfires or misfires

● Faulty spark plugs: Replace the spark

plugs.

● Clogged fuel system: See “Engine turns

over but does not start–Fuel system” above.

Page 77

Troubleshooting

● Malfunctioning T.O.R.S.: See “Engine turns

over but does not start–Electrical system” above.

Engine overheats

● Insufficient coolant: Add coolant.

● Air in cooling system: Bleed the cooling sys-

tem or ask a Yamaha dealer to inspect.

● Leaking coolant: Ask a Yamaha dealer to

inspect.

Snowmobile does not move

● Malfunctioning V-belt clutch: Ask a Yamaha

dealer to inspect.

● Drive track does not move: Foreign object is

caught in the drive track, or slide runners have melted to the slide metal due to lack of lubrication.

● Tight, loose, or broken drive chain: Ask a

Yamaha dealer to inspect.

V-belt twists

● Improper V-belt: Replace with the correct V-

belt.

● Incorrect V-belt clutch offset: Ask a Yamaha

dealer to inspect.

● Loose or broken engine mount(s): Ask a

Yamaha dealer to inspect.

V-belt slips or becomes extremely hot

● Oily or dirty V-belt or primary and second-

ary sheave assembly surfaces: Clean.

● Problem with the driveline: See “V-belt

twists” above.

Engine does not upshift or downshift properly or engages harshly

● Worn or damaged V-belt: Replace the V-

belt or ask a Yamaha dealer to inspect.

● Incorrect V-belt clutch settings for altitude

or conditions: Ask a Yamaha dealer to inspect.

● Worn or sticking primary sheave assembly:

Ask a Yamaha dealer to inspect.

● Worn or sticking secondary sheave assem-

bly: Ask a Yamaha dealer to inspect.

Noise or excessive vibration in drive chain and sprockets

● Broken V-belt clutch components: Ask a

Yamaha dealer to inspect.

● Worn or damaged bearings: Ask a Yamaha

dealer to inspect.

● Worn or damaged V-belt with flat spots: Re-

place.

● Worn or damaged idler wheels or shafts:

Ask a Yamaha dealer to inspect.

● Worn or damaged drive track: Ask a

Yamaha dealer to inspect.

Page 78

Storage

ESU12410

Long-term storage requires some preventive procedures to guard against deterioration.

Cleaning

Thoroughly clean the snowmobile, inside and out, to remove the corrosive salts and acids that can accumulate. Use Yamaha Mud, Grease, and Engine Cleaner, or an equivalent product, to loosen mud, grease, and grime. Wash with mild soap, then rinse and dry completely.

Lubrication

Lubricate moving parts, suspension linkage, and pivot points. Use the grease or lubricant specified in the MAINTENANCE section, or Yamaha Lube-Zall general-purpose lubricant. Proper lubrication fights corrosion while it reduces friction.

Fuel system

Add Yamaha Fuel Stabilizer and Conditioner, or an equivalent stabilizer, to the fuel tank to help prevent fuel oxidation and gum and varnish deposits, and to inhibit corrosion in the fuel system and carburetor. In areas where oxygenated fuel (gasohol) is used, completely drain the fuel system. Consult a Yamaha dealer if further information is needed.

Engine

Proper storage of the engine is essential to prevent costly rust and corrosion damage to internal engine components. This is more important in areas where oxygenated fuel (gasohol) is used, because the alcohol content in the fuel increases the chance for water to enter the engine. Use Yamaha Stor-Rite Engine Fogging Oil, or an equivalent fogging oil, to protect both the combustion chamber and crankshaft from corrosion. An alternate method is to remove the air filter case and squirt oil into the carburetor throats while the engine is running.

ECS00680

CAUTION:

Do not attempt to store the snowmobile by simply starting the engine occasionally during the storage period. This can cause more harm than good! Moisture and acids form during combustion which can actually increase the chance for corrosion damage during the storage period.

Surface protection

Apply a coat of wax to painted surfaces. Apply suitable protectants to the exterior of the engine, drive track, and to other metal, plastic, and rubber parts.

Battery

EWS00610

WARNING

● Never smoke around the battery while it

is being charged. Sparks may ignite the hydrogen gas created by the battery.

● Disconnect the negative lead first, then

the positive lead from the battery.

● Connect the positive lead first, then the

negative lead to the battery when installing the battery.

● Never connect the battery to or discon-

nect it from the snowmobile while it is being charged. Sparks may ignite the hydrogen gas created by the battery.

● Make sure that the battery terminals are

tight.

Remove the battery from the snowmobile. Store it in a cool, dry place that is above 0 °C (32 °F), but less than 30 °C (90 °F). Check the condition of the battery once a month, and charge it as necessary.

ECS00690

CAUTION:

● Always keep the battery charged. Stor-

ing a discharged battery can cause permanent battery damage.

Page 79

● To charge a sealed-type (MF) battery, a

special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery.

● Do not charge the battery quickly.

Charge the battery for 10 hours at 1.8 amperes.

Drive track

Loosen the drive track and block up the chassis so that the track is suspended above the ground.

V-belt

Remove the V-belt and store separately.

Storage

Store the snowmobile in a dry, well-ventilated place out of direct sunlight. Put a fabric cover over the snowmobile, preferably one that is designed for it. Do not use a plastic or vinyl cover—condensation could be trapped underneath which could increase the chances of rusting.

Returning to service after storage

When returning your snowmobile to service, install the V-belt and battery and adjust the drive track. Remove the spark plugs and clean or replace them if necessary. Perform all other pre-operation and seasonal maintenance checks listed in the periodic maintenance chart.

Storage

NOTE:

Before installing the battery, have a Yamaha dealer inspect and fully charge it.

For peak performance, it is recommended that you have your snowmobile checked and tuned by a Yamaha dealer. The dealer has the experience and training to help you get the maximum performance and use out of your Yamaha snowmobile.

Page 80

Specifications

ESU12462

Dimensions:

Overall length:

3135 mm (123.4 in)

Overall width:

1225 mm (48.2 in)

Overall height:

1330 mm (52.4 in)

Dry weight:

RST90 284.0 kg (626 lb) RST90GT 285.0 kg (628 lb)

Ski stance:

1086 mm (42.8 in)

Engine:

Type:

Liquid cooled 4-stroke, 12 valves

Cylinder arrangement:

Backward-inclined parallel 3-cylinder

Displacement:

973.0 cm³

Bore × stroke:

79.0 × 66.2 mm (3.11 × 2.61 in)

Idling speed:

1300–1500 r/min

Engine oil:

Recommended grade:

API service SG type or higher, JASO standard MA

Type:

SAE 0W-30

Carburetor:

Manufacturer:

KEIHIN

Model × quantity:

CVK40 × 3

Fuel:

Type:

REGULAR UNLEADED GASOLINE ONLY

Minimum pump octane (R+M)/2:

Starting system:

Electric starter

Chassis:

Drive track:

Material:

Molded rubber, fiberglass-rod reinforced

Type:

Internal drive type

Width:

381 mm (15.0 in)

Deflection:

30.0–35.0 mm (1.18–1.38 in)

Length on ground:

985 mm (38.8 in)

Rear suspension:

Type:

Slide rail suspension

Track sprocket wheel:

Material:

Polyethylene

Number of teeth:

Transmission:

Clutch type:

Automatic centrifugal engagement

Ratio range:

3.80–1.00 :1

Sheave distance:

267.0–270.0 mm (10.51–10.63 in)

Sheave offset:

13.5–16.5 mm (0.53–0.65 in) Engagement speed (Subject to change according to elevation settings.):

3000–3400 r/min Shift speed [Subject to change according to elevation settings. Usually achieved after approximately 800m (0.5 mi) traveled.]:

8250–8750 r/min Drive chain type:

Silent chain enclosed in oil bath Reverse system:

Yes Secondary reduction ratio:

39/22 (1.77) Secondary reduction ratio [R]:

2.27

Fuel tank capacity:

39.3 L (10.38 US gal) (8.65 Imp.gal)

Engine oil quantity:

With oil filter cartridge replacement:

3.0 L (3.17 US qt) (2.64 Imp.qt)

Without oil filter cartridge replacement:

2.8 L (2.96 US qt) (2.46 Imp.qt)

Total amount:

3.7 L (3.91 US qt) (3.26 Imp.qt)

Brake:

Type:

Hydraulic disc type (ventilated disc)

Page 81

Operation:

Handle lever, left-hand operated

Throttle:

Operation:

Handle lever, right-hand operated

Electrical system:

Ignition system:

T.C.I.

Spark plug:

Manufacturer:

NGK

Model:

CR8E

Gap:

0.7–0.8 mm (0.028–0.031 in)

Battery:

Model:

YTX20L-BS

Voltage, capacity:

12 V, 18.0 Ah

Ten-hour rate amperage:

1.8 A

Bulb voltage, wattage × quantity:

Headlight:

12 V, 60/55 W × 2

Headlight bulb type:

Halogen bulb

Tail/brake light:

12 V, 5/21 W × 2

Meter lighting:

14 V, 50 mA × 6

High beam indicator light:

14 V, 80 mA × 1

Warning light:

14 V, 80 mA × 1

Low coolant temperature indicator light:

14 V, 80 mA × 1

Specifications

Page 82

Consumer information

ESU12480

Identification number records

Record the frame serial number, engine serial number (Primary ID), and key identification number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer. Also, record and keep the ID numbers in a separate place in case the snowmobile is stolen.

Frame serial number

The frame serial number is the seventeendigit number stamped on the frame of the snowmobile.

1. Engine serial number

Key identification number

The key identification number is stamped in the location as shown.

1. Frame serial number

Engine serial number (Primary ID)

The engine serial number is stamped in the location as shown.

1. Key identification number

Page 83

Consumer information

ESU12500

YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMIT-

ED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha snowmobiles purchased from an authorized Yamaha snowmobile dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.

WARRANTY PERIOD:

1. All Yamaha snowmobiles shall be warranted for a term of one (1) year from the date of purchase, plus a special early-season extension (if applicable).

2. All Yamaha snowmobile clutch components are warranted against abnormal wear for one (1) year from the date of purchase, plus a special early-season extension (if applicable).

DURING THE PERIOD OF WARRANTY any au-

thorized Yamaha snowmobile dealer will, free of charge, repair or replace, at Yamaha’s option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the snowmobile’s warranty period. All parts replaced under warranty become the property of Yamaha Motor Corporation, U.S.A.

GENERAL EXCLUSIONS from this warranty shall

include any failures to the machine caused by:

1. Competition, racing, or non-Yamaha authorized rental use.

2. Operation on surfaces other than snow or ice.

3. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts.

4. Abnormal strain, neglect, or abuse.

5. Lack of proper maintenance.

6. Accident or collision damage.

7. Modification to original parts.

2. Give notice to an authorized Yamaha snowmobile dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory.

WARRANTY TRANSFER: To transfer any remain-

ing warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha snowmobile dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after ownership transfer. An inspection and registration fee will be charged for this service.

EMISSION CONTROL SYSTEM WARRANTY

Yamaha Motor Corporation, USA also warrants to the ultimate purchaser and each subsequent purchaser of each 2006 and later model Yamaha snowmobile covered by this warranty that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

All Models

Thirty (30) months from the original purchase date

SPECIFIC EXCLUSIONS

include parts replaced due to normal wear or routine maintenance including oil, spark plugs, clutch drive belts, slide runners, and track.

THE CUSTOMER’S RESPONSIBILITY

warranty shall be to:

1. Operate and maintain the snowmobile as specified in the appropriate Owner’s Manual.

from this warranty shall

under this

Page 84

Consumer information

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

SPECIAL EARLY-SEASON WARRANTY EXTENSION

A special warranty extension is available for all new Yamaha snowmobiles purchased between June 1 and December 1.

All new Yamaha snowmobiles purchased between June 1 and December 1 will have the warranty extended to November 30 of the following year.

YAMAHA MOTOR CORPORATION, U.S.A.

Post Office Box 6555

Cypress, California 90630

WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty

period?

A. The customer’s responsibility includes all costs of

normal maintenance services, non-warranty repairs, accident and collision damages, as well as oil, spark plugs, clutch drive belts, and slide runners.

Q. What are some examples of “abnormal” strain, ne-

glect, or abuse?

A. These terms are general and overlap each other in

areas. Specific examples include: Running the machine out of oil, hitting an object submerged under snow, operation on surfaces other than snow or ice, operating the machine with a broken or damaged part which causes another part to fail, and so on. If you have any specific questions on operation or maintenance, please contact your dealer for advice.

Q. May I perform any or all of the recommended main-

tenance shown in the Owner’s Manual instead of having the dealer do them?

A. Yes, if you are a qualified snowmobile mechanic and

follow the procedures specified in the Owner’s and Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha snowmobile dealer.

Q. Under what conditions is the clutch not covered by

warranty?

A. Clutches as well as clutch components wear with

use. Normal wear is not covered under warranty such service is the customer’s responsibility. Abnormal wear is, however, covered for one (1) year from the date of purchase. Your Yamaha snowmobile dealer possesses criteria as to what constitutes abnormal wear.

Q. Will the warranty be void or canceled if I do not

operate or maintain my new Yamaha exactly as specified in the Owner’s Manual?

A. No. The warranty on a new Yamaha cannot be

“voided” or “canceled.” However, if a particular failure is caused by operation or maintenance other than as shown in the Owner’s Manual, that failure may not be covered under warranty.

Page 85

Consumer information

Q. What responsibility does my dealer have under this

warranty?

A. Each Yamaha snowmobile dealer is expected to:

1. Completely set up every new machine before sale.

2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date.

3. In addition, each Yamaha snowmobile dealer is held responsible for his setup, service and warranty repair work.

Q. Whom should I contact if I have further questions

about this warranty?

A. Your Yamaha snowmobile dealer has the informa-

tion and experience necessary to answer almost any questions about this warranty. If the dealer is not able to do so, he is expected to contact Yamaha Motor Corporation, U.S.A., for clarification or assistance.

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha snowmobile dealer within the continental United States. Be sure to bring your warranty identification card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

When contacting Yamaha Motor Corporation, U.S.A. be sure to include the model, serial number, names, dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new snowmobile, please advise us of your new address by sending a postcard listing your snowmobile model name, engine serial number, dealer number (or dealer’s name) as it is shown on your warranty registration identification, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A.

WARRANTY DEPARTMENT

P.O. Box 6555

Cypress, California 90630

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

YAMAHA MOTOR CORPORATION, U.S.A.

CUSTOMER RELATIONS

DEPARTMENT

P.O. Box 6555

Cypress, California 90630

Page 86

Consumer information

ESU12510

YAMAHA EXTENDED SERVICE (Y.E.S.)

Page 87

Index

Air filter, checking..................................... 44

Auxiliary DC jack...................................... 16

Backrest ................................................... 20

Battery...................................................... 64

Brake and parking brake .......................... 55

Brake lever............................................... 17

Break-in.................................................... 31

Carburetors .............................................. 45

Control rods, adjusting............................. 26

Coolant temperature warning indicator .... 15

Cooling system......................................... 50

Drive chain housing.................................. 54

Drive guard............................................... 19

Drive track and slide runners ................... 59

Drive track life, maximizing ...................... 34

Driving...................................................... 35

Engine idling speed, adjusting ................. 43

Engine oil and oil filter cartridge............... 46

Engine overheating prevention system .... 10

Engine stop switch ................................... 15

Fittings and fasteners............................... 64

Footrests .................................................. 20

Fuel .......................................................... 23

Fuel level warning indicator...................... 14

Fuel meter and grip/

thumb warmer level indicator................ 13

Fuse, replacing......................................... 65

General maintenance and

lubrication chart ....................................40

Grip/thumb warmer adjustment switch..... 16

Headlight beam, adjusting........................ 64

Headlight beam switch............................. 16

Headlight bulb, replacing.......................... 63

High beam indicator light.......................... 12

High-altitude settings................................ 45

Identification numbers .............................. 76

Label locations ...........................................4

Low coolant temperature indicator light ... 12

Lubrication................................................ 62

Main switch ................................................ 9

Oil level warning indicator ........................14

Parking brake lever .................................. 17

Part locations ............................................. 7

Passenger grip warmer switch ................. 19

Periodic maintenance chart

for the emission control system ............ 38

Pre-operation check list............................ 28

Rear storage area and rear carrier........... 20

Rear suspension spring preload,

adjusting ...............................................25

Riding your snowmobile ...........................31

Safety information ...................................... 1

Self-diagnosis device ............................... 15

Shift lever ................................................. 18

Shroud latches ......................................... 18

Ski damping force,

adjusting(RST90GT)............................. 24

Ski spring preload, adjusting .................... 24

Skis and ski runners................................. 57

Spark plugs, checking .............................. 42

Specifications...........................................74

Speedometer unit..................................... 11

Starter (choke) lever................................... 9

Starting the engine................................... 30

Steering system .......................................58

Stopping the engine ................................. 36

Storage..................................................... 72

Storage areas........................................... 20

Storage compartment............................... 20

Suspension ..............................................23

Throttle cable free play, adjusting ............ 43

Throttle lever .............................................. 9

Throttle override system (T.O.R.S.) ......... 10

Throttle override system (T.O.R.S.),

checking................................................ 44

Page 88

Index

Tool kit...................................................... 42

Transporting............................................. 36

Troubleshooting ....................................... 68

Valve clearance........................................ 46

V-belt........................................................ 51

V-belt holders........................................... 19

Page 89

Page 90

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2007.04-0.3×1 CR

PRINTED ON RECYCLED PAPER

Yamaha RST90X, RST90GTX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Important manual information

Contents

Safety information

Location of the important labels

Description

Main switch

Starter (choke) lever

Control functions

Throttle lever

Speedometer unit

High beam indicator light “”

Fuel level warning indicator “”

Oil level warning indicator “”

Self-diagnosis device

Engine stop switch “”

Auxiliary DC jack

Brake lever

Parking brake lever

Shift lever

Shroud latches

Drive guard

V-belt holders

Passenger grip warmer switch

Footrests

Storage areas

Backrest

Fuel

Suspension

Pre-operation checks

Pre-operation check list

Operation

Starting the engine

Break-in

Riding your snowmobile

Maximizing drive track life

Driving

Stopping the engine

Transporting

Periodic maintenance

Periodic maintenance chart for the emission control system

General maintenance and lubrication chart

Tool kit

Checking the spark plugs

Checking the air filter

Carburetors

High-altitude settings

Valve clearance

Engine oil and oil filter cartridge

Cooling system

V-belt

Drive chain housing

Brake and parking brake

Skis and ski runners

Steering system

Drive track and slide runners

Lubrication

Replacing a headlight bulb

Adjusting the headlight beam

Fittings and fasteners

Battery

Replacing a fuse

Troubleshooting

Storage

Specifications

Consumer information

Identification number records

YAMAHA EXTENDED SERVICE (Y.E.S.)

Index