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 Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snowmobile.

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

NOTE: A NOTE provides key information that can make procedures easier or clearer.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g.,

•Bearings

Pitting/damage → Replace.

EXPLODED DIAGRAM

Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.

1	2
GEN		INSP
INFO		ADJ
3	4
CHAS		POWR
		TR
5	6
ENG		COOL
7	8
CARB		ELEC –	+
9
SPEC
0	A	B
		T
		.
		R
		.
C	D	E
F	G	H
	LT	5
I	J	K
E	G	M
L	M	N
B	LS	M
O
New

ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content.

1General information

2Periodic inspection and adjustment

3Chassis

4Power train

5Engine

6Cooling system

7Carburetion

8Electrical

9Specifications

Illustrated symbols 0 to F are used to identify the specifications which appear.

0 Filling fluid

ALubricant

BTightening

CWear limit, clearance

DEngine speed

ESpecial tool

FΩ, V, A

Illustrated symbols G to O in the exploded diagram indicate grade of lubricant and location of lubrication point.

GApply locking agent (LOCTITE®)

HApply Yamabond No.5®

IApply engine oil

JApply gear oil

KApply molybdenum disulfide oil

LApply wheel bearing grease

MApply low-temperature lithium-soap base grease

NApply molybdenum disulfide grease

OUse new one

INDEX

GENERAL INFORMATION	GEN	1
	INFO

PERIODIC INSPECTION AND ADJUSTMENT

INSPADJ

2

CHASSIS

POWER TRAIN

ENGINE

COOLING SYSTEM

CARBURETION

ELECTRICAL

CHAS 3

POWR 4 TR

ENG 5

COOL 6

CARB 7

–+

ELEC 8

SPECIFICATIONS

SPEC 9

GENERAL INFORMATION
SPECIAL TOOLS .................................................	1
FOR ELECTRICAL SERVICE ........................	1
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION...................................................	2
PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM..................	2
GENERAL MAINTENANCE AND
LUBRICATION CHART........................................	3
POWER TRAIN.....................................................	5
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
POWER TRAIN
SHIFT LEVER.....................................................	19
INSTALLATION ............................................	21
DRIVE CHAIN HOUSING ...................................	22
REMOVAL ....................................................	25
INSPECTION ................................................	25
INSTALLATION ............................................	27
SECONDARY SHAFT ........................................	29
SECONDARY SHAFT AND DRIVE CHAIN
HOUSING INSTALLATION...........................	29
BRAKE ...............................................................	31
BRAKE PAD REPLACEMENT .....................	32
BRAKE CALIPER DISASSEMBLY ...............	36
BRAKE CALIPER INSTALLATION...............	36
FRONT AXLE AND TRACK...............................	37
INSTALLATION ............................................	37

ENGINE
CAMSHAFTS.....................................................	38
INSTALLATION............................................	38
CARBURETION
CARBURETORS ...............................................	43
THROTTLE POSITION SENSOR (T.P.S.)
INSPECTION AND ADJUSTMENT .............	44
ELECTRICAL
SIGNAL SYSTEM ..............................................	46
CIRCUIT DIAGRAM.....................................	46
TROUBLESHOOTING .................................	48
GEAR POSITION SWITCH..........................	49
GEAR POSITION SWITCH RELAY.............	49
SPECIFICATIONS
GENERAL SPECIFICATIONS...........................	50
MAINTENANCE SPECIFICATIONS..................	52
ENGINE .......................................................	52
POWER TRAIN............................................	57
CHASSIS .....................................................	60
ELECTRICAL ...............................................	61
HIGH ALTITUDE SETTINGS.......................	64
TIGHTENING TORQUE.....................................	66
ENGINE .......................................................	66
POWER TRAIN............................................	68
CHASSIS .....................................................	70
GENERAL TORQUE SPECIFICATIONS ..........	71
DEFINITION OF UNITS .....................................	71
CABLE ROUTING .............................................	72

GEN

SPECIAL TOOLS INFO

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.

1

1

INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION

This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

			Initial	Every
		Pre-opera-	1 month or	Seasonally
Item	Remarks	tion check	800 km	or 4,000 km
		(Daily)	(500 mi)	(2,500 mi)
			(40 hr)	(200 hr)
	Check condition.
Spark plugs	Adjust gap and clean.
	Replace if necessary.
Valve clearance	Check clearance.	Every 40,000 km (25,000 mi)
	Adjust clearance when engine is cold.
Crankcase breather system	Check breather hose for cracks or damage.
	Replace if necessary.
Fuel filter	Check condition.
	Replace if necessary.
Fuel line	Check fuel hose for cracks or damage.
	Replace if necessary.
Idle speed	Check and adjust engine idle speed.
	Adjust synchronization of carburetors.
Carburetors
	Adjust the jets.	Whenever operating condition (elevation/
		temperature) is changed.
Exhaust system	Check for leakage.
	Tighten or replace gasket if necessary.

2

GENERAL MAINTENANCE AND LUBRICATION CHART					INSP
					ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
					Initial			Every
		Pre-opera-	1 month or				Seasonally
Item	Remarks	tion check			800 km		or 4,000 km
		(Daily)		(500 mi)				(2,500 mi)
					(40 hr)			(200 hr)
Engine oil	Check oil level.
	Replace.
							Every
Engine oil filter cartridge	Replace.						20,000 km
							(12,000 mi)
Fuel	Check fuel level.
Engine coolant	Check coolant level.
	Air bleed the cooling system if necessary.
Louvers	Check condition.
	Remove snow if necessary.
Throttle lever (carburetor	Check throttle lever operation.
side)
Throttle lever (handlebar	Check operation.
side)	Repair if necessary.
Throttle override system	Check operation.
(T.O.R.S.)	Repair if necessary.
Engine stop switch	Check operation.
	Repair if necessary.
Drive guard	Check for cracks, bends or damage.
	Replace if necessary.
V-belt	Check for wear and damage.
	Replace if necessary.
Drive track and idler wheels	Check deflection, and for wear and damage.
	Adjust/replace if necessary.
Slide runners	Check for wear and damage.
	Replace if necessary.
	Check operation and fluid leakage.
Brake and parking brake	Adjust free play and/or replace pads if necessary.
	Replace brake fluid.	See NOTE on page 4.
	Check for slight free play.						Every
Disc brake installation							1,600 km
	Lubricate shaft with specified grease as required.
							(1,000 mi)
Drive chain oil	Check oil level.
	Replace.
Drive chain	Check deflection.	Initial at 500 km (300 mi) and every 800 km
	Adjust if necessary.	(500 mi) thereafter.
Skis and ski runners	Check for wear and damage.
	Replace if necessary.
Steering system	Check operation.
	Adjust toe-out if necessary.
Strap	Check for damage.
	Replace if necessary.
Lights	Check operation.
	Replace bulbs if necessary.
Battery	Check condition.
	Charge if necessary.
	Check engagement and shift speed.
	Adjust if necessary.	Whenever operating elevation is changed.
Primary and secondary	Inspect sheaves for wear/damage.
	Inspect weights/rollers and bushings for wear-for pri-
clutches	mary.
	Inspect ramp shoes/bushings for wear-for secondary.
	Replace if necessary.
	Lubricate with specified grease.

3

2

GENERAL MAINTENANCE AND LUBRICATION CHART					INSP
					ADJ
					Initial			Every
		Pre-opera-	1 month or				Seasonally
Item	Remarks	tion check			800 km		or 4,000 km
		(Daily)		(500 mi)				(2,500 mi)
					(40 hr)			(200 hr)
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	Lubricate with specified grease.
	Check cable damage.
lever end/throttle cable end
	Replace if necessary.
Shroud latches	Make sure that the shroud latches are hooked.

Fittings and fasteners

Check tightness.

Repair if necessary.

Tool kit and recommended

Check for proper placement.

equipment

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

DRIVE V-BELT

POWER TRAIN

DRIVE V-BELT

WARNING

INSP ADJ

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

DRIVE V-BELT ADJ

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	Remove a spacer
edge
From 1.5 mm (0.06 in)
above the edge to	Not necessary
–0.5 mm (–0.02 in)	(It is correct.)
below the edge
More than –0.5 mm
(–0.02 in) below the	Add spacer
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

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 thin-

ner or solvent to remove the oil or grease. Check the primary and secondary sheaves.

6

DRIVE V-BELT/BRAKE PAD INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

INSP ADJ

6.Measure:

•Drive V-belt circumference a Out of specification → Replace.

V-belt circumference:

1,132 ~ 1,138 mm (44.6 ~ 44.8 in)

1

aa

1 1

2

2

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:

4.7mm (0.19 in)

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 2.

d.Place the other ends of the hoses in a container.

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.

7

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ DRIVE CHAIN

INSP ADJ

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

DRIVE CHAIN ADJ

1

2

b a

Checking steps:

•Remove the rubber cap 1.

•Check the oil level through the check window 2 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.

Recommended oil: Gear oil “GL-3” 75W or 80W

CAUTION:

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

3

• Reinstall the dipstick 3.

NOTE:

Align the notch c of the dipstick handle with the projection d of the drive chain housing.

• Install the rubber cap.

9

INSP

DRIVE CHAIN ADJ

1

Oil replacement

Oil replacement steps:

•Place the oil pan under the drain hole.

•Remove the oil drain bolt (along with the gasket) 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 finger tight, and then loosen it 1/4 turn.

•Hold the adjusting bolt 2 in place while tightening the chain adjusting locknut 1.

Drive chain adjusting locknut: 25 Nm (2.5 m · kg, 18 ft · lb)

T .

R .

10

CLUTCH

TUNING

INSP ADJ

	CLUTCH					L		Blue		P	Pink
	High altitude
						W		White		Y	Yellow
	Specifications
	È Elevation	~ 800 m	600 ~ 1,400 m	1,200 ~ 2,000 m		1,800 ~ 2,600 m				2,400 ~ 3,000 m
		(~ 2,500 ft)	(2,000 ~ 4,500 ft)	(4,000 ~ 6,500 ft)	(6,000 ~ 8,500 ft)					(8,000 ~ 10,000 ft)
	É Engine idle speed	1,400 ± 100 r/min	←	←				←			←
	Ê Engagement r/min	Approx. 2,400 r/min	←	Approx. 2,500 r/min				←	Approx. 2,600 r/min
	Ë Shift r/min	Approx. 8,500 r/min	←	←				←			←
	Ì Main jet
	Í Pilot jet	, Refer to “HIGH ALTITUDE SETTINGS” in “MAINTENANCE SPECIFICATIONS”.
	Î Pilot screw
	Ï Secondary reduc-
	tion ratio (number	20/39 (68 L)	←	19/39 (68 L)				←			←
	of links)
	Ð Primary sheave	90501-550A2	←	←				←	90501-580A1
	spring
	Ñ Color	W-L-W	←	←				←	L-Y-L
	Ò Free length	82.3 mm (3.24 in)	←	←				←	81.4 mm (3.20 in)
	Ó Preload	196 N (20 kg, 44 lb)	←	←				←			←
		22.1 N/mm							24.5 N/mm
	Ô Spring rate	(2.25 kg/mm,	←	←				←	(2.5 kg/mm,
		126 lb/in)							140 lb/in)
	Õ Wire diameter	5.5 mm (0.217 in)	←	←				←	5.8 mm (0.228 in)
	Ö Outside diameter	59.5 mm (2.34 in)	←	←				←			←
	× Weight (ID)	8FN-17605-00	←	←				←			←
		(8FN00)
		Steel 17.2 (OUT)	Steel 17.2 with hole	Steel 13.3 with hole	Aluminum 13.3 with				None (OUT)
			(OUT)	(OUT)	hole (OUT)
	Ø Weight rivet
		Steel 17.2 with hole	Steel 17.2 with hole	Steel 13.3 with hole	Aluminum 13.3 with				None (IN)
		(IN)	(IN)	(IN)	hole (IN)
	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	90508-60012	←	←				←			←
	spring
	Þ Color	P	←	←				←			←
	ß Free length	75 mm (2.95 in)	←	←				←			←
	À Preload rate	60° (3-3)	←	←				←			←
		1,211 kg · mm/rad
	Á Wire diameter	6.0 mm (0.236 in)	←	←				←			←
	+ Outside diameter	69.5 mm (2.74 in)	←	←				←			←
	, Sec. torque cam	39°	←	←				←			←
	angle
	- Sec. clutch shim	1.0 mm (0.04 in)	←	←				←			←

11

INSP

CLUTCH/GEAR SELECTION ADJ

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

GEAR SELECTION

1 Chain and sprocket part number

INSP ADJ

È Parts name

É Teeth & links

Ê Parts no.

Ë Standard

19 teeth

8FA-17682-90

20 teeth

8FA-17682-00

Ì Drive sprocket

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

Í Driven sprocket

39 teeth

8FB-47587-90

√

40 teeth

8FB-47587-00

Î Chain

68 links

94890-09068

√

70 links

94890-09070

2 Gear ratio

È Drive gear

19 teeth

20 teeth

21 teeth

22 teeth

23 teeth

24 teeth

É Driven gear

38 teeth

1.90

1.81

1.73

1.65

1.58

68 links

68 links

68 links

70 links

70 links

39 teeth

2.05

1.95

1.86

1.77

1.70

1.63

68 links

68 links

68 links

70 links

70 links

70 links

40 teeth

2.11

2.00

1.91

1.82

1.74

1.67

68 links

68 links

70 links

70 links

70 links

70 links

3 Secondary sheave spring

É Spring rate

Ê Preload

Ì Wire gauge

Î Free length

Ï Outside

È Part No.

N · mm/rad

N/mm (kg/mm)

Ë Color

Í No. of coils

diameter

Ð Standard

(kg · mm/rad)

(lb/in)

mm (in)

mm (in)

mm (in)

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)

13

			GEAR SELECTION			INSP
						ADJ
4 Secondary spring twist angle
È Seat		0	3	6			9
É Sheave
1		10°	40°	70°			100°
2		20°	50°	80°			110°
3		30°	60°	90°			120°

5 Torque cam (secondary spring seat)

É Effects				Ê Part no.	Ë Cam angle	Ì Identification mark	Í Standard
Î Quicker upshifting dur-				8FA-17604-00	51-43°	8BVFA
ing acceleration
				8BV-17604-71	47°	8BV71
				8BV-17604-51	45°	8BV51
				8BV-17604-31	43°	8BV31
Ï Quicker backshifting				8BV-17604-11	41°	8BV11
under load				8BV-17604-91	39°	8BV91	√

14

GEAR SELECTION

6 Primary spring

INSP ADJ

Ë Parts No.	Ì Spring rate	Í Preload	Î Color	Ï Wire gauge	Ð Outside	Ñ No. of coils	Ò Free length	Ó Standard
	N/mm	N (kg)		mm (in)	diameter		mm (in)
	(kg/mm)				mm (in)
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)

15

7 Clutch weight

	É Weight g (oz)
È Parts No.	without bush
	and rivets
8BU-17605-20	45.41 (1.603)
8CH-17605-10	35.32 (1.246)
8DG-17605-00	34.26 (1.208)
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)
8FN-17605-00	75.28 (2.657)

INSP

GEAR SELECTION ADJ

Ê Shape & ID mark	Ë Standard
8BU 10

8DN 10
8ES 00
00	8FA
00	8FN

√

16

GEAR SELECTION

8 Weight rivets

INSP ADJ

È Parts No.

É Material

Ê Length

Ë Weight

Ì Standard

Í Effects

mm (in)

g (oz)

90261-06033

Steel

17.2 (0.677)

4.5 (0.159)

√ (OUT)

Î Increased force

90261-06034

Steel

13.9 (0.547)

3.6 (0.127)

90269-06006

Steel

17.2 (0.677)

3.6 (0.127)

√ (IN)

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)

Ï Decreased force

90266-06001

Aluminum

13.3 (0.524)

0.85 (0.030)

90386-09001

(14.6 mm)

8FG-17624-10

15.0 (0.59)

VESPEL

Ï Grooved

TP-8549

90386-09001

(14.6 mm)

8FG-17624-20

15.6 (0.61)

VESPEL

Ð No Mark

TP-8549

√

90386-09001

(14.6 mm)

8FG-17624-30

16.0 (0.63)

VESPEL

Ñ Grooved & Grooved

TP-8549

90386-09001

(14.6 mm)

8FG-17624-40

16.5 (0.65)

VESPEL

Ò Machined

9 Rollers

TP-8549

90386-09001

(14.6 mm)

17

I.D. 9 mm (0.354 in)

È Roller with bush-

É Outside

Ê Bushing type

Ë Identification mark

ing part number

diameter

(P/N)

(Width)

Ì Standard

Í Effects

mm (in)

8FG-17624-00

14.5 (0.57)

VESPEL

Î Grooved & Machined

Ó Increased force

TP-8549

Ô Decreased force

HIGH ALTITUDE TUNING

HIGH ALTITUDE TUNING

INSP ADJ

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

Adjust the size of the main jet

Not OK

(performance & plug color)

Re-test

OK

OK

Not OK

Test the low speed setting

OK

Adjust the engine

Check to see if the gearing is too high

idle speed by

or low

Not OK

turning the stop

screw of carbure-

tor.

OK

Try high altitude settings

OK

Not OK

Adjust the engine idle speed by turning the stop screw of carburetor.

Decide if the problem is with the pilot jet and adjust accordingly

	Not OK			OK

Check the engagement speed and shift performance

	Not OK				OK

Adjust the primary clutch as required

Not OK		Not OK

Adjust the secondary clutch as required

High altitude tuning OK

OK

OK

18

POWR

SHIFT LEVER TR

POWER TRAIN

SHIFT LEVER

	È: 10 Nm (1.0 m • kg, 7.2 ft • lb)
É	É: 23 Nm (2.3 m • kg, 17 ft • lb)
	2
	É
	È
4	3
	É
1

Order	Job name/Part name	Q’ty	Remarks
	Shift lever assembly removal		Remove the parts in the order listed below.
	Right side cover
1	Shift knob	1
2	Bracket	1
3	Shift rod	1	Disconnect.
4	Shift lever assembly	1
			For installation, reverse the removal proce-
			dure.

4

19

		SHIFT LEVER			POWR
					TR
				È: 23 Nm (2.3 m • kg, 17 ft • lb)
	7	0		É: 59 Nm (5.9 m • kg, 43 ft • lb)
				È
	LS
		È
	New
	8
		4
		New
	LS
	6	9
		2
			3
New	5			1	É
	4

Order	Job name/Part name	Q’ty	Remarks
	Shift lever disassembly		Remove the parts in the order listed below.
1	Shift lever stay	1
2	Circlip	1
3	Bearing	1
4	Circlip	2
5	Collar	1
6	Shift lever pin	1
7	Shift lever	1
8	Shift lever guide	1
9	Spring	1
0	Shift lever stopper	1
			For assembly, reverse the disassembly pro-
			cedure.

20

			SHIFT LEVER
			INSTALLATION
		1	1. Install:
	3		• Shift lever 1
			• Shift lever stopper 2
			• Shift guide 3
	2		• Shift lever pin 4
	4		• Spring

POWR

TR

6 4

1

2 53

Installation steps:

•Install the shift lever 1 onto the shift lever stopper 2.

•Install the shift lever guide 3 and spring 5 onto 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.

21

DRIVE CHAIN HOUSING

DRIVE CHAIN HOUSING

POWR

TR

È: 6 Nm (0.6 m • kg, 4.3 ft • lb)						Ì: 18 Nm (1.8 m • kg, 13 ft • lb)					Ï: 43 Nm (4.3 m • kg, 31 ft • lb)
É: 10 Nm (1.0 m • kg, 7.2 ft • lb)						Í: 20 Nm (2.0 m • kg, 14 ft • lb)					Ð:	55 Nm (5.5 m • kg, 40 ft • lb)
Ê: 14 Nm (1.4 m • kg, 10 ft • lb)						Î:	24 Nm (2.4 m • kg, 17 ft • lb)
Ë: 16 Nm (1.6 m • kg, 11 ft • lb)								New		New		7
			Í	Ì				9			37	LTLT	New
								G
		New 11						10		32		Ê
										27 28
			É
	New	6						12		New	New		New
										38
		5
4
			É							39			Ë
			Î						30				New
New								29
				(3)
		È						19		É
					(2)		17
									New
	3	LT	É			16		Ì			33	44
		13				Ï
2													8
			15
1						LT

14	G			43 LT
				É		41 40
			31
		23	34
	22			36
G
				19 35
Ð						25
	20		16	18	26	24
	21			New
	LT		42
	New

(2)

Ï

New

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order	Job name/Part name	Q’ty	Remarks
	Drive chain housing removal		Remove the parts in the order listed below.
	Right side cover/shift lever/parking brake/		Refer to “SHIFT LEVER” and “BRAKE”.
	brake caliper
1	Shim	—	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.
9	Spring	1
10	Ball	1
11	Gear position switch	1
12	Drive chain housing cover	1
13	Shift drum	1

22

DRIVE CHAIN HOUSING

POWR

TR

È: 6 Nm (0.6 m • kg, 4.3 ft • lb)

Ì: 18 Nm (1.8 m • kg, 13 ft • lb)

Ï: 43 Nm (4.3 m • kg, 31 ft • lb)

É: 10 Nm (1.0 m • kg, 7.2 ft • lb)

Í: 20 Nm (2.0 m • kg, 14 ft • lb)

Ð:

55 Nm (5.5 m • kg, 40 ft • lb)

Ê: 14 Nm (1.4 m • kg, 10 ft • lb)

Î:

24 Nm (2.4 m • kg, 17 ft • lb)

Ë: 16 Nm (1.6 m • kg, 11 ft • lb)

New

New

7

Í

Ì

9

37

LTLT

New

G

New 11

10

32

Ê

27 28

É

New

6

12

New

New

New

38

5

4

É

39

Ë

Î

30

New

New

29

(3)

È

19

É

(2)

17

New

3

LT

É

16

Ì

33

44

13

Ï

2

8

15

1

LT

14	G			43 LT
				É		41 40
			31
		23	34
	22			36
G
				19 35
Ð						25
	20		16	18	26	24
	21			New
	LT		42
	New

(2)

Ï

New

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order	Job name/Part name	Q’ty	Remarks
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

23

DRIVE CHAIN HOUSING

POWR

TR

È: 6 Nm (0.6 m • kg, 4.3 ft • lb)

Ì: 18 Nm (1.8 m • kg, 13 ft • lb)

Ï: 43 Nm (4.3 m • kg, 31 ft • lb)

É: 10 Nm (1.0 m • kg, 7.2 ft • lb)

Í: 20 Nm (2.0 m • kg, 14 ft • lb)

Ð:

55 Nm (5.5 m • kg, 40 ft • lb)

Ê: 14 Nm (1.4 m • kg, 10 ft • lb)

Î:

24 Nm (2.4 m • kg, 17 ft • lb)

Ë: 16 Nm (1.6 m • kg, 11 ft • lb)

New

New

7

Í

Ì

9

37

LTLT

New

G

New 11

10

32

Ê

27 28

É

New

6

12

New

New

New

38

5

4

É

39

Ë

Î

30

New

New

29

(3)

È

19

É

(2)

17

New

3

LT

É

16

Ì

33

44

13

Ï

2

8

15

1

LT

14	G			43 LT
				É		41 40
			31
		23	34
	22			36
G
				19 35
Ð						25
	20		16	18	26	24
	21			New
	LT		42
	New

(2)

Ï

New

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order	Job name/Part name	Q’ty	Remarks
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
			For installation, reverse the removal proce-
			dure.

24