YAMAHA VK10W SERVICE MANUAL
SUPPLEMENTARY SERVICE MANUAL
VK10W
LIT-12618-02-57 8GS-28197-10
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new data for
the VK10W. For complete information, on service procedures, it is necessary to use this Supplementary Service Manual together with following manual:
RS90K, RS90RK, RSG90K, RS90MK, RST90K, RST90TFK SERVICE MANUAL:
8FJ-28197-10 (981096) (LIT-12618-02-38)
VK10L SUPPLEMENTARY SERVICE MANUAL:
8FN-28197-10 (LIT-12618-02-42)
VK10W
SUPPLEMENTARY SERVICE MANUAL
©2006 by Yamaha Motor
Corporation, U.S.A.
1st Edition, July 2006
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N.LIT-12618-02-57
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha
snowmobiles have a basic understanding of the mechanical concepts and procedures inherent in
snowmobile repair. Without such knowledge, attempted repairs or service to this model may render
it unfit and/or unsafe to use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by
Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to
all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
HOW TO USE THIS MANUAL
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
CAUTION:
NOTE:
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all inspection, repair, assembly, and disassembly operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required to correct the problem will follow the symbol, e.g.,
•Bearings
Pitting/damage → Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.
Failure to follow WARNING instructions could result in severe injury or death
the snowmobile operator, a bystander, or a person inspecting or repairing the
snowmobile.
A CAUTION indicates special precautions that must be taken to avoid damage
to the snowmobile.
A NOTE provides key information that can make procedures easier or clearer.
to
1 2
GEN
INFO
34
INSP
ADJ
POWR
CHAS
TR
56
ENG
78
COOL
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 9 are designed as thumb
tabs to indicate the chapter’s number and content.
1 General information
2 Periodic inspection and adjustment
3 Chassis
4 Power train
5 Engine
6 Cooling system
7 Carburetion
8 Electrical
9 Specifications
CARB
9
ELEC
–+
SPEC
0
CDE
FGH
IJK
E
LMN
B
AB
T
.
R
.
LT
G
LS
5
M
M
Illustrated symbols 0 to F are used to identify the
specifications which appear.
0
Filling fluid
A Lubricant
B Tightening
C Wear limit, clearance
D Engine speed
E Special tool
FΩ, V, A
Illustrated symbols G to O in the exploded diagram
indicate grade of lubricant and location of lubrication point.
G Apply locking agent (LOCTITE
H Apply Yamabond No.5
I Apply engine oil
J Apply gear oil
K Apply molybdenum disulfide oil
L Apply wheel bearing grease
M Apply low-temperature lithium-soap base grease
N Apply molybdenum disulfide grease
O Use new one
®
®
)
O
New
INDEX
GENERAL INFORMATION
PERIODIC INSPECTION AND
ADJUSTMENT
CHASSIS
POWER TRAIN
ENGINE
GEN
INFO
INSP
ADJ
CHAS
POWR
TR
ENG
1
2
3
4
5
COOLING SYSTEM
CARBURETION
ELECTRICAL
SPECIFICATIONS
COOL
CARB
– +
ELEC
SPEC
6
7
8
9
GENERAL INFORMATION
ENGINE
SPECIAL TOOLS
FOR ELECTRICAL SERVICE ........................1
.................................................1
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION
PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM
GENERAL MAINTENANCE AND
LUBRICATION CHART
POWER TRAIN
DRIVE V-BELT ...............................................5
BRAKE PAD INSPECTION ............................7
AIR BLEEDING (HYDRAULIC BRAKE
SYSTEM) ........................................................7
DRIVE CHAIN.................................................8
TUNING
..............................................................11
CLUTCH .......................................................11
GEAR SELECTION ......................................12
HIGH ALTITUDE TUNING............................18
...................................................2
..................2
........................................3
.....................................................5
POWER TRAIN
SHIFT LEVER
INSTALLATION ............................................21
DRIVE CHAIN HOUSING
REMOVAL ....................................................25
INSPECTION ................................................25
INSTALLATION ............................................27
.....................................................19
...................................22
CAMSHAFTS
INSTALLATION............................................ 38
..................................................... 38
CARBURETION
CARBURETORS
THROTTLE POSITION SENSOR (T.P.S.)
INSPECTION AND ADJUSTMENT ............. 44
............................................... 43
ELECTRICAL
SIGNAL SYSTEM
CIRCUIT DIAGRAM..................................... 46
TROUBLESHOOTING ................................. 48
GEAR POSITION SWITCH.......................... 49
GEAR POSITION SWITCH RELAY ............. 49
.............................................. 46
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE ....................................................... 52
POWER TRAIN............................................ 57
CHASSIS ..................................................... 60
ELECTRICAL ............................................... 61
HIGH ALTITUDE SETTINGS....................... 64
TIGHTENING TORQUE
ENGINE ....................................................... 66
POWER TRAIN............................................ 68
CHASSIS ..................................................... 70
GENERAL TORQUE SPECIFICATIONS
........................... 50
.................. 52
..................................... 66
.......... 71
SECONDARY SHAFT
SECONDARY SHAFT AND DRIVE CHAIN
HOUSING INSTALLATION...........................29
BRAKE
FRONT AXLE AND TRACK
...............................................................31
BRAKE PAD REPLACEMENT .....................32
BRAKE CALIPER DISASSEMBLY ...............36
BRAKE CALIPER INSTALLATION...............36
INSTALLATION ............................................37
........................................29
...............................37
DEFINITION OF UNITS
CABLE ROUTING
............................................. 72
..................................... 71
GEN
SPECIAL TOOLS
GENERAL INFORMATION
SPECIAL TOOLS
Some special tools are necessary for a completely accurate tune-up and
assembly. Using the correct special tool will help prevent damage that can
be caused by the use of improper tools or improvised techniques.
NOTE:
• Be sure to use the correct part number when ordering the tool, since the
part number may differ according to country.
• For USA and Canada, use part number starting with “YB-”, “YM-”, “YU-”
or “YS-”, “ACC-”.
• For others, use part number starting with “90890-”.
FOR ELECTRICAL SERVICE
• Pocket tester
P/N: YU-03112-C
90890-03112
This instrument is necessary for checking the electrical components.
INFO
1
1
INSP
ADJ
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These
preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to
machines already in service as well as new machines that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
Item Remarks
Spark plugs
Valve clearance
Crankcase breather system
Fuel filter
Fuel line
Idle speed Check and adjust engine idle speed.
Carburetors
Exhaust system
Check condition.
Adjust gap and clean.
Replace if necessary.
Check clearance.
Adjust clearance 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.
Adjust synchronization of carburetors.
Adjust the jets.
Check for leakage.
Tighten or replace gasket if necessary.
Initial
Pre-opera-
tion check
(Daily)
Every 40,000 km (25,000 mi)
Whenever operating condition (elevation/
temperature) is changed.
1 month or
800 km
(500 mi)
(40 hr)
Every
Seasonally
or 4,000 km
(2,500 mi)
(200 hr)
2
INSP
ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
GENERAL MAINTENANCE AND LUBRICATION CHART
Item Remarks
Engine oil
Engine oil filter cartridge Replace.
Fuel Check fuel level.
Engine coolant
Louvers
Throttle lever (carburetor
side)
Throttle lever (handlebar
side)
Throttle override system
(T.O.R.S.)
Engine stop switch
Drive guard
V-belt
Drive track and idler wheels
Slide runners
Brake and parking brake
Disc brake installation
Drive chain oil
Drive chain
Skis and ski runners
Steering system
Strap
Lights
Battery
Primary and secondary
clutches
Check oil level.
Replace.
Check coolant level.
Air bleed the cooling system if necessary.
Check condition.
Remove snow if necessary.
Check throttle lever operation.
Check operation.
Repair if necessary.
Check operation.
Repair if necessary.
Check operation.
Repair if necessary.
Check for cracks, bends or damage.
Replace if necessary.
Check for wear and damage.
Replace if necessary.
Check deflection, and for wear and damage.
Adjust/replace if necessary.
Check for wear and damage.
Replace if necessary.
Check operation and fluid leakage.
Adjust free play and/or replace pads if necessary.
Replace brake fluid. See NOTE on page 4.
Check for slight free play.
Lubricate shaft with specified grease as required.
Check oil level.
Replace.
Check deflection.
Adjust if necessary.
Check for wear and damage.
Replace if necessary.
Check operation.
Adjust toe-out if necessary.
Check for damage.
Replace if necessary.
Check operation.
Replace bulbs if necessary.
Check condition.
Charge if necessary.
Check engagement and shift speed.
Adjust if necessary.
Inspect sheaves for wear/damage.
Inspect weights/rollers and bushings for wear-for primary.
Inspect ramp shoes/bushings for wear-for secondary.
Replace if necessary.
Lubricate with specified grease.
Initial
Pre-opera-
tion check
(Daily)
1 month or
800 km
(500 mi)
(40 hr)
Initial at 500 km (300 mi) and every 800 km
(500 mi) thereafter.
Whenever operating elevation is changed.
Every
Seasonally
or 4,000 km
(2,500 mi)
(200 hr)
Every
20,000 km
(12,000 mi)
Every
1,600 km
(1,000 mi)
2
3
INSP
ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
Every
Seasonally
or 4,000 km
(2,500 mi)
(200 hr)
Item Remarks
Steering column bearing Lubricate with specified grease.
Ski and front suspension Lubricate with specified grease.
Suspension component Lubricate with specified grease.
Parking brake cable end and
lever end/throttle cable end
Shroud latches Make sure that the shroud latches are hooked.
Fittings and fasteners
Tool kit and recommended
equipment
Lubricate with specified grease.
Check cable damage.
Replace if necessary.
Check tightness.
Repair if necessary.
Check for proper placement.
Pre-opera-
tion check
(Daily)
Initial
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.
4
INSP
ADJ
DRIVE V-BELT
POWER TRAIN
DRIVE V-BELT
WARNING
When installing the new V-belt, make sure that
it is positioned from 1.5 mm (0.06 in) above
the edge of the secondary sheave to –0.5 mm
(–0.02 in) below the edge a.
If the V-belt is not positioned correctly, the
clutch engagement speed will be changed. The
machine may move unexpectedly when the
engine is started.
Adjust the V-belt position by removing or adding a spacer 1 on each adjusting bolt 2.
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.
New belt width:
34.1 mm (1.34 in)
Belt wear limit width:
32.1 mm (1.26 in)
1. Measure:
• V-belt position a
NOTE:
Install the new V-belt onto the secondary sheave
only. Do not force the V-belt between the sheaves;
the sliding and fixed sheaves must touch each
other.
Standard V-belt height:
–0.5 ~ 1.5 mm (–0.02 ~ 0.06 in)
5
INSP
ADJ
DRIVE V-BELT
2. Adjust the position of the V-belt by removing or
adding a spacer 1 on each adjusting bolt 2.
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
Part number Thickness
90201-061H1 0.5 mm (0.02 in)
90201-06037 1.0 mm (0.04 in)
3. Tighten:
• Adjusting bolt 2
Remove a spacer
Not necessary
(It is correct.)
Add spacer
Adjusting bolt:
10 Nm (1.0 m · kg, 7.2 ft · lb)
T
.
R
.
4. Inspect:
• Drive V-belt
Cracks/damage/wear → Replace.
Oil or grease on the V-belt → Check the primary and secondary sheaves.
5. Inspect:
• Primary sheave
• Secondary sheave
Oil or grease on the primary and secondary
sheaves → Use a rag soaked in lacquer thinner or solvent to remove the oil or grease.
Check the primary and secondary sheaves.
6
INSP
ADJ
DRIVE V-BELT/BRAKE PAD INSPECTION/
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
6. Measure:
• Drive V-belt circumference a
Out of specification → Replace.
V-belt circumference:
1,132 ~ 1,138 mm (44.6 ~ 44.8 in)
BRAKE PAD INSPECTION
1. Apply the brake lever.
2. Inspect:
• Brake pad wear a
Wear indicator 1 nearly contacts the brake
disc → Replace as a set.
Wear limit:
4.7 mm (0.19 in)
a
1
a
1
2
1
2
AIR BLEEDING (HYDRAULIC BRAKE
SYSTEM)
WARNING
Bleed the brake system in the following cases:
• The system has been disassembled.
• A brake hose is loosened or removed.
• The brake fluid has been very low.
• Brake operation is faulty.
If the brake system is not properly bled a loss of
braking performance may occur.
1. Bleed:
• Brake system
Air bleeding steps:
a. Fill the brake master cylinder reservoir with the
proper brake fluid.
b. Install the diaphragm. Be careful not to spill any
fluid or allow the brake master cylinder reservoir
to overflow.
c. Connect clear plastic hoses 1 tightly to the
brake caliper bleed screws
d. Place the other ends of the hoses in a con-
tainer.
e. Slowly apply the brake lever several times.
f. Pull the lever in, then hold the lever in position.
g. Loosen the bleed screws and allow the brake
lever to travel towards its limit.
h. Tighten the bleed screws when the brake lever
limit has been reached, then release the lever.
2.
7
INSP
ADJ
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/
DRIVE CHAIN
i. Repeat steps (e) to (h) until all of the air bubbles
have disappeared from the fluid.
j. Tighten the bleed screws.
Bleed screw:
6 Nm (0.6 m · kg, 4.3 ft · lb)
T
.
R
.
NOTE:
If bleeding is difficult, it may be necessary to let the
brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.
k. Add brake fluid to the proper level.
WARNING
After bleeding the brake system, check the
brake operation.
DRIVE CHAIN
Oil level inspection
WARNING
The engine and muffler will be very hot after the
engine has run. Avoid touching a hot engine
and muffler while they are still hot with any part
of your body or clothing during inspection or
repair.
1. Place the machine on a level surface.
2. Check:
• Oil level
8
INSP
ADJ
DRIVE CHAIN
Checking steps:
• Remove the rubber cap 1.
• Check the oil level through the check window
located on the drive chain housing.
• If the oil is below the minimum level mark a,
remove the dipstick 3 and add sufficient oil to
the maximum level mark b.
2
2
1
3
Recommended oil:
Gear oil “GL-3”
75W or 80W
CAUTION:
Make sure that no foreign material enters the
drive chain housing.
b
a
• Reinstall the dipstick 3.
NOTE:
Align the notch
projection d of the drive chain housing.
• Install the rubber cap.
9
c of the dipstick handle with the
INSP
ADJ
1
DRIVE CHAIN
Oil replacement
Oil replacement steps:
• Place the oil pan under the drain hole.
• Remove the oil drain bolt (along with the gas-
ket) 1 and drain the oil.
CAUTION:
Be sure to remove any oil from the heat protector.
• Install the new gasket and oil drain bolt 1.
Oil drain bolt:
16 Nm (1.6 m · kg, 11 ft · lb)
T
.
R
.
Recommended oil:
Gear oil “GL-3”
75W or 80W
Oil capacity:
0.35 L (0.31 Imp qt, 0.37 US qt)
Chain slack adjustment
1. Adjust:
• Drive chain slack
Adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting bolt
2 clockwise until it is fin-
ger tight, and then loosen it 1/4 turn.
• Hold the adjusting bolt 2 in place while tighten-
ing the chain adjusting locknut 1.
Drive chain adjusting locknut:
25 Nm (2.5 m · kg, 18 ft · lb)
T
.
R
.
10
INSP
ADJ
TUNING
CLUTCH
High altitude
Specifications
CLUTCH
LBlue PPink
W White Y Yellow
È
Elevation
É
Engine idle speed 1,400 ± 100 r/min
Ê
Engagement r/min Approx. 2,400 r/min
Ë
Shift r/min Approx. 8,500 r/min
Ì
Main jet
Í
Pilot jet
Î
Pilot screw
Ï
Secondary reduction ratio (number
of links)
Ð
Primary sheave
spring
Ñ
Color W-L-W
Ò
Free length 82.3 mm (3.24 in)
Ó
Preload 196 N (20 kg, 44 lb)
Ô
Spring rate
Õ
Wire diameter 5.5 mm (0.217 in)
Ö
Outside diameter 59.5 mm (2.34 in)
×
Weight (ID)
Ø
Weight rivet
Ù
Weight bushing VESPEL TP-8549
Ú
Roller outer dia. 15.6 mm (0.61 in)
Û
Roller bushing VESPEL TP-8549
Ü
Pri. clutch shim None
Ý
Secondary sheave
spring
Þ
Color P
ß
Free length 75 mm (2.95 in)
À
Preload rate
Á
Wire diameter 6.0 mm (0.236 in)
+
Outside diameter 69.5 mm (2.74 in)
,
Sec. torque cam
angle
-
Sec. clutch shim 1.0 mm (0.04 in)
~ 800 m
(~ 2,500 ft)
,
Refer to “HIGH ALTITUDE SETTINGS” in “MAINTENANCE SPECIFICATIONS”.
20/39 (68 L)
90501-550A2
22.1 N/mm
(2.25 kg/mm,
126 lb/in)
8FN-17605-00
(8FN00)
Steel 17.2 (OUT)
Steel 17.2 with hole
(IN)
90508-60012
60° (3-3)
1,211 kg · mm/rad
39°
600 ~ 1,400 m
(2,000 ~ 4,500 ft)
←←←←
←
←←←←
←
←←←
←←←
←←←
←←←←
←←←
←←←
←←←←
←←←←
Steel 17.2 with hole
(OUT)
Steel 17.2 with hole
(IN)
←←←←
←←←←
←←←←
←←←←
←←←←
←←←←
←←←←
←←←←
←←←←
←←←←
←←←←
←←←←
1,200 ~ 2,000 m
(4,000 ~ 6,500 ft)
Approx. 2,500 r/min
19/39 (68 L)
Steel 13.3 with hole
(OUT)
Steel 13.3 with hole
(IN)
1,800 ~ 2,600 m
(6,000 ~ 8,500 ft)
←
←←
Aluminum 13.3 with
hole (OUT)
Aluminum 13.3 with
hole (IN)
2,400 ~ 3,000 m
(8,000 ~ 10,000 ft)
Approx. 2,600 r/min
90501-580A1
L-Y-L
81.4 mm (3.20 in)
24.5 N/mm
(2.5 kg/mm,
140 lb/in)
5.8 mm (0.228 in)
None (OUT)
None (IN)
11
INSP
ADJ
CLUTCH/GEAR SELECTION
The clutch may require tuning depending upon
where the machine will be operated and the desired
handling characteristics. The clutch can be tuned
by changing the engagement and shifting speeds.
Clutch engagement speed is defined as the engine
speed at which the machine first begins to move
from a complete stop.
Clutch shifting speed is defined as the engine
speed reached when the machine has travelled
800 m (2,500 ft) after being started at full-throttle
from a dead stop.
Normally, when a machine reaches shifting speed,
the vehicle speed increases but the engine speed
remains nearly constant. Under unfavorable conditions (wet snow, icy snow, hills, or rough terrain),
however, engine speed may decrease after the
shifting speed has been reached.
È Engine speed
É Good condition
Ê Clutch shifting speed
Ë Clutch engagement speed
Ì Starting position
Í Distance travelled 800 m (2,500 ft)
GEAR SELECTION
The reduction ratio of the driven gear to the drive
gear must be set according to the snow conditions.
If there are many rough surfaces or unfavorable
snow conditions, the drive/driven gear ratio should
be increased. If the surfaces are fairly smooth or
better snow conditions exist, decrease the ratio.
Gear ratio chart
The drive and driven gears and the chains shown in
the gear ratio chart are available as options. The
figures containing a decimal point represent the
drive/driven gear ratios, while the bottom numbers
designate the number of links in the chain.
12
INSP
ADJ
Chain and sprocket part number
1
GEAR SELECTION
Parts name
È
Drive sprocket
Ì
Driven sprocket
Í
Chain
Î
Gear ratio
2
Driven gear
É
È
38 teeth
39 teeth
40 teeth
É
Drive gear
Teeth & links
Parts no.
Ê
Standard
Ë
19 teeth 8FA-17682-90
20 teeth 8FA-17682-00
21 teeth 8FA-17682-10
22 teeth 8FA-17682-20
23 teeth 8FA-17682-30
24 teeth 8FA-17682-40
38 teeth 8FB-47587-80
39 teeth 8FB-47587-90
√
40 teeth 8FB-47587-00
68 links 94890-09068
√
70 links 94890-09070
19 teeth 20 teeth 21 teeth 22 teeth 23 teeth 24 teeth
2.05
68 links
2.11
68 links
1.90
68 links
1.95
68 links
2.00
68 links
1.81
68 links
1.86
68 links
1.91
70 links
1.73
68 links
1.77
70 links
1.82
70 links
1.65
70 links
1.70
70 links
1.74
70 links
1.58
70 links
1.63
70 links
1.67
70 links
Secondary sheave spring
3
É
È
Part No.
90508-500B1 6003 (613) 6.2 (0.63), 35.28 Brown 5.0 (0.196) 5.19 75 (2.95) 69.5 (2.736)
90508-536A9 7147 (729) 7.3 (0.74), 41.44 Red 5.3 (0.209) 5.53 75 (2.95) 69.5 (2.736)
90508-556A2 8314 (848) 8.5 (0.87), 48.72 Green 5.5 (0.217) 5.53 75 (2.95) 69.5 (2.736)
90508-556A7 9460 (965) 10.2 (1.04), 58.24 Silver 5.5 (0.217) 4.86 75 (2.95) 69.5 (2.736)
90508-60012 11876 (1211) 12.3 (1.26), 70.56 Pink 6.0 (0.236) 5.53 75 (2.95) 69.5 (2.736)
90508-60007 12654 (1290) 13.5 (1.37) 76.72 White 6.0 (0.236) 5.19 75 (2.95) 69.5 (2.736)
Spring rate
N · mm/rad
(kg · mm/rad)
Ê
Preload
N/mm (kg/mm)
(lb/in)
Ë
Color
Ì
Wire gauge
mm (in)
Í
No. of coils
Î
Free length
mm (in)
Ï
Outside
diameter
mm (in)
Ð
Standard
√
13
INSP
ADJ
Secondary spring twist angle
4
Seat
È
Sheave
É
110° 40° 70° 100°
220° 50° 80° 110°
330° 60° 90° 120°
Torque cam (secondary spring seat)
5
GEAR SELECTION
0369
Effects
É
Quicker upshifting dur-
Î
ing acceleration
Quicker backshifting
Ï
under load
Part no.
Ê
8FA-17604-00 51-43° 8BVFA
8BV-17604-71 47° 8BV71
8BV-17604-51 45° 8BV51
8BV-17604-31 43° 8BV31
8BV-17604-11 41° 8BV11
8BV-17604-91 39° 8BV91
Cam angle
Ë
Identification mark
Ì
Standard
Í
√
14
INSP
ADJ
Primary spring
6
GEAR SELECTION
Ì
Ë
Parts No.
90501-550A2 19.6 (2.00) 196 (20) Blue-Blue-Blue 5.5 (0.217) 59.5 (2.34) 4.89 83.4 (3.28)
90501-550A3 22.1 (2.25) 196 (20) White-Blue-White 5.5 (0.217) 59.5 (2.34) 4.56 82.3 (3.24)
90501-551L3 19.6 (2.00) 294 (30) Blue-Pink-Blue 5.5 (0.217) 59.5 (2.34) 4.91 88.4 (3.48)
90501-551L9 19.6 (2.00) 343 (35) Blue-Silver-Blue 5.5 (0.217) 59.5 (2.34) 4.91 90.9 (3.58)
90501-552L5 19.6 (2.00) 392 (40) Blue-Green-Blue 5.5 (0.217) 59.5 (2.34) 4.91 93.4 (3.68)
90501-580A1 24.5 (2.50) 196 (20) Yellow-Blue-Yellow 5.8 (0.228) 59.5 (2.34) 4.91 81.4 (3.20)
90501-581L5 24.5 (2.50) 294 (30) Yellow-Pink-Yellow 5.8 (0.228) 59.5 (2.34) 4.92 85.4 (3.36)
90501-581L6 27.0 (2.75) 294 (30) Green-Pink-Green 5.8 (0.228) 59.5 (2.34) 4.66 84.3 (3.32)
90501-582L1 24.5 (2.50) 343 (35) Yellow-Silver-Yellow 5.8 (0.228) 59.5 (2.34) 4.92 87.4 (3.44)
90501-582L2 27.0 (2.75) 343 (35) Green-Silver-Green 5.8 (0.228) 59.5 (2.34) 4.66 86.1 (3.39)
90501-582L6 22.1 (2.25) 392 (40) White-Green-White 5.8 (0.228) 59.5 (2.34) 5.25 91.2 (3.59)
90501-582L7 24.5 (2.50) 392 (40) Yellow-Green-Yellow 5.8 (0.228) 59.5 (2.34) 4.92 89.4 (3.52)
90501-583L0 19.6 (2.00) 441 (45) Blue-White-Blue 5.8 (0.228) 59.5 (2.34) 5.65 95.9 (3.78)
90501-583L1 22.1 (2.25) 441 (45) White-White-White 5.8 (0.228) 59.5 (2.34) 5.25 93.4 (3.68)
90501-583L4 22.1 (2.25) 343 (35) White-Silver-White 5.8 (0.228) 59.5 (2.34) 5.25 89.0 (3.50)
90501-583L5 22.1 (2.25) 294 (30) White-Pink-White 5.8 (0.228) 59.5 (2.34) 5.25 86.7 (3.41)
90501-600A1 29.4 (3.00) 196 (20) Pink-Blue-Pink 6.0 (0.236) 59.5 (2.34) 4.81 80.1 (3.15)
90501-601L7 29.4 (3.00) 294 (30) Pink-Pink-Pink 6.0 (0.236) 59.5 (2.34) 4.82 83.4 (3.28)
90501-601L8 31.9 (3.25) 294 (30) Orange-Pink-Orange 6.0 (0.236) 59.5 (2.34) 4.60 82.6 (3.25)
90501-602L3 29.4 (3.00) 343 (35) Pink-Silver-Pink 6.0 (0.236) 59.5 (2.34) 4.82 85.1 (3.35)
90501-602L8 27.0 (2.75) 392 (40) Green-Green-Green 6.0 (0.236) 59.5 (2.34) 5.08 87.9 (3.46)
90501-602L9 29.4 (3.00) 392 (40) Pink-Green-Pink 6.0 (0.236) 59.5 (2.34) 4.82 86.7 (3.41)
90501-603L2 24.5 (2.50) 441 (45) Yellow-White-Yellow 6.0 (0.236) 59.5 (2.34) 5.39 91.4 (3.60)
90501-603L3 27.0 (2.75) 441 (45) Green-White-Green 6.0 (0.236) 59.5 (2.34) 5.08 89.8 (3.54)
90501-624L8 31.9 (3.25) 343 (35) Orange-Silver-Orange 6.2 (0.244) 59.5 (2.34) 5.00 84.2 (3.31)
Spring rate
N/mm
(kg/mm)
Í
Preload
N (kg)
Î
Color
Ï
Wire gauge
mm (in)
Ð
Outside
diameter
mm (in)
Ñ
No. of coils
Ò
Free length
mm (in)
Ó
Standard
√
15
INSP
ADJ
Clutch weight
7
Weight g (oz)
É
Parts No.
È
8BU-17605-20 45.41 (1.603)
8CH-17605-10 35.32 (1.246)
8DG-17605-00 34.26 (1.208)
without bush
and rivets
GEAR SELECTION
Shape & ID mark
Ê
8BU
10
Standard
Ë
8DJ-17605-00 37.77 (1.332)
8DN-17605-10 39.76 (1.402)
8ES-17605-00 54.63 (1.928)
8FA-17605-10 63.81 (2.251)
00
00
10
8DN
8ES
00
8FA
8FN
8FN-17605-00 75.28 (2.657)
16
√
INSP
ADJ
Weight rivets
8
GEAR SELECTION
Ê
È
Parts No.
90261-06033 Steel 17.2 (0.677) 4.5 (0.159)
90261-06034 Steel 13.9 (0.547) 3.6 (0.127)
90269-06006 Steel 17.2 (0.677) 3.6 (0.127)
90261-06019 Steel 13.3 (0.524) 3.1 (0.109)
90261-06015 Steel 10.3 (0.406) 2.44 (0.086)
90266-06002 Steel 13.3 (0.524) 2.44 (0.086)
90261-06028 Aluminum 10.3 (0.406) 0.85 (0.030)
90266-06001 Aluminum 13.3 (0.524) 0.85 (0.030)
Rollers
9
I.D. 9 mm (0.354 in)
È
Roller with bushing part number
8FG-17624-00 14.5 (0.57) VESPEL
8FG-17624-10 15.0 (0.59) VESPEL
É
Material
É
diameter
Outside
mm (in)
Length
mm (in)
Ê
Bushing type
(P/N)
TP-8549
90386-09001
TP-8549
Ë
Ë
Î
Weight
g (oz)
√
(OUT)
√
(IN)
Identification mark
(Width)
Grooved & Machined
(14.6 mm)
Ï
Grooved
Ì
Standard
Ì
Standard
Í
Effects
Î
Increased force
Ï
Decreased force
Í
Effects
Ó
Increased force
90386-09001
8FG-17624-20 15.6 (0.61) VESPEL
TP-8549
90386-09001
8FG-17624-30 16.0 (0.63) VESPEL
TP-8549
90386-09001
8FG-17624-40 16.5 (0.65) VESPEL
TP-8549
90386-09001
(14.6 mm)
Ð
No Mark
(14.6 mm)
Ñ
Grooved & Grooved
(14.6 mm)
Ò
Machined
(14.6 mm)
√
Ô
Decreased force
17
INSP
ADJ
HIGH ALTITUDE TUNING
HIGH ALTITUDE TUNING
To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below.
Check STD settings
• Carburetors
• Spark plugs
Adjust the main jet size according to the
chart
Test the main jet
(performance & plug color)
OK
Test the low speed setting
OK
Not OK
Try high altitude settings
OK
Not OK
Not OK
Adjust the engine
idle speed by
turning the stop
screw of carburetor.
Adjust the engine idle speed
by turning the stop screw of
carburetor.
Adjust the size of the main jet
Re-test
OK
Check to see if the gearing is too high
or low
Not OK
OK
Decide if the problem is with the pilot
jet and adjust accordingly
Not OK
OK
Not OK
Check the engagement speed and
shift performance
Not OK
Adjust the primary clutch as
required
Not OK
Adjust the secondary clutch as
required
18
OK
High altitude
tuning OK
OK
OK
SHIFT LEVER
SHIFT LEVER
POWER TRAIN
POWR
TR
É
4
10 Nm (1.0 m
È:
23 Nm (2.3 m
É:
2
É
È
• kg, 7.2 ft • lb)
• kg, 17 ft • lb)
3
4
É
1
Order Job name/Part name
Shift lever assembly removal
Right side cover
1 Shift knob 1
2 Bracket 1
3 Shift rod 1 Disconnect.
4 Shift lever assembly 1
Q’ty Remarks
Remove the parts in the order listed below.
For installation, reverse the removal procedure.
19
SHIFT LEVER
POWR
TR
LS
8
LS
New
7
4
0
È
New
23 Nm (2.3 m
È:
59 Nm (5.9 m
É:
È
• kg, 17 ft • lb)
• kg, 43 ft • lb)
6
New
5
4
Order Job name/Part name
Shift lever disassembly
1
2
3
4
5
6
7
8
9
0
Shift lever stay 1
Circlip 1
Bearing 1
Circlip 2
Collar 1
Shift lever pin 1
Shift lever 1
Shift lever guide 1
Spring 1
Shift lever stopper 1
9
2
Q’ty Remarks
Remove the parts in the order listed below.
For assembly, reverse the disassembly procedure.
3
1
É
20
2
3
2
6
5
4
1
4
3
1
POWR
SHIFT LEVER
INSTALLATION
1. Install:
• Shift lever
• Shift lever stopper
• Shift guide
• Shift lever pin
• Spring
Installation steps:
• Install the shift lever 1 onto the shift lever stop-
per 2.
• Install the shift lever guide 3 and spring
the shift lever, position the shift lever and shift
lever guide as shown, and then install the shift
lever pin 4.
NOTE:
Make sure that the end of the spring 5 is installed
between the washer 6 and the shift lever guide 3.
1
2
3
4
TR
5 onto
21
DRIVE CHAIN HOUSING
DRIVE CHAIN HOUSING
POWR
TR
6 Nm (0.6 m
È:
10 Nm (1.0 m
É:
14 Nm (1.4 m
Ê:
16 Nm (1.6 m
Ë:
4
New
2
1
New
3
14
5
G
Ð
• kg, 4.3 ft • lb)
• kg, 7.2 ft • lb)
• kg, 10 ft • lb)
• kg, 11 ft • lb)
New
11
É
6
É
È
LT
13
LT
New
Í
É
Î
15
20
G
Ì
(3)
(2)
21
Ì:
Í:
Î:
16
Ï
LT
22
18 Nm (1.8 m
20 Nm (2.0 m
24 Nm (2.4 m
New
9
G
10
12
29
19
17
Ì
31
34
23
16
42
• kg, 13 ft • lb)
• kg, 14 ft • lb)
• kg, 17 ft • lb)
New
27
New
38
39
30
É
New
LT
43
É
36
35
19
18
New
28
26
32
41
New
33
40
24
Ï:
Ð:
37
25
43 Nm (4.3 m
55 Nm (5.5 m
• kg, 31 ft • lb)
• kg, 40 ft • lb)
7
LT
LT
New
Ê
New
Ë
New
44
8
(2)
Ï
New
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
Order Job name/Part name
Drive chain housing removal
Right side cover/shift lever/parking brake/
brake caliper
1Shim — t = 0.5
2 Washer 1 t = 1.0
3 Collar 1
4 Brake disc 1
5 Straight key 1
6 Collar 1
7 Shift rod 1
8 Chain tension adjusting bolt 1 Loosen.
9Spring 1
10 Ball 1
11 Gear position switch 1
12 Drive chain housing cover 1
13 Shift drum 1
Q’ty Remarks
Remove the parts in the order listed below.
Refer to “SHIFT LEVER” and “BRAKE”.
22
DRIVE CHAIN HOUSING
POWR
TR
6 Nm (0.6 m
È:
10 Nm (1.0 m
É:
14 Nm (1.4 m
Ê:
16 Nm (1.6 m
Ë:
4
New
2
1
New
3
14
5
G
Ð
• kg, 4.3 ft • lb)
• kg, 7.2 ft • lb)
• kg, 10 ft • lb)
• kg, 11 ft • lb)
New
11
É
6
É
È
LT
13
LT
New
Í
É
Î
15
20
Ì
(3)
G
(2)
21
Ì:
Í:
Î:
16
Ï
LT
22
18 Nm (1.8 m
20 Nm (2.0 m
24 Nm (2.4 m
New
9
G
10
12
29
19
17
Ì
31
34
23
16
42
• kg, 13 ft • lb)
• kg, 14 ft • lb)
• kg, 17 ft • lb)
New
27
New
38
39
30
É
New
LT
43
É
36
35
19
18
New
28
26
32
41
New
33
40
24
Ï:
Ð:
37
25
43 Nm (4.3 m
55 Nm (5.5 m
• kg, 31 ft • lb)
• kg, 40 ft • lb)
7
LT
LT
New
Ê
New
Ë
New
44
8
(2)
Ï
New
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
Order Job name/Part name
14 Shift fork guide bar 1
15 Shift fork 1
16 Washer 2
17 Counter gear 1
18 Low pinion gear 1
19 Spring 2
20 Collar 1
21 Driven gear 1
22 Journal 1
23 Washer 1
24 Chain tensioner 1
25 Washer 1
26 Collar 1
27 Collar 1
28 Washer 1
29 Reverse drive gear 1
Q’ty Remarks
23
DRIVE CHAIN HOUSING
POWR
TR
6 Nm (0.6 m
È:
10 Nm (1.0 m
É:
14 Nm (1.4 m
Ê:
16 Nm (1.6 m
Ë:
4
New
2
1
New
3
14
5
G
Ð
• kg, 4.3 ft • lb)
• kg, 7.2 ft • lb)
• kg, 10 ft • lb)
• kg, 11 ft • lb)
New
11
É
6
É
È
LT
13
LT
New
Í
É
Î
15
20
Ì
(3)
G
(2)
21
Ì:
Í:
Î:
16
Ï
LT
22
18 Nm (1.8 m
20 Nm (2.0 m
24 Nm (2.4 m
New
9
G
10
12
29
19
17
Ì
31
34
23
16
42
• kg, 13 ft • lb)
• kg, 14 ft • lb)
• kg, 17 ft • lb)
New
27
New
38
39
30
É
New
LT
43
É
36
35
19
18
New
28
26
32
41
New
33
40
24
Ï:
Ð:
37
25
43 Nm (4.3 m
55 Nm (5.5 m
• kg, 31 ft • lb)
• kg, 40 ft • lb)
7
LT
LT
New
Ê
New
Ë
New
44
8
(2)
Ï
New
: 1 ESSO beacon 325 grease
or Aeroshell grease #7A
Order Job name/Part name
30 Washer 1
31 Low drive gear 1
32 Drive sprocket 1
33 Drive chain 1
34 Driven sprocket 1
35 Low wheel gear 1
36 Washer 1
37 Collar 1
38 Plate 1
39 Shaft 1
40 Plate 1
41 Shaft 1
42 Rubber seal 1
43 Washer 1
44 Drive chain housing 1
Q’ty Remarks
For installation, reverse the removal procedure.
24
Loading...