Yamaha VK 540 LLL User Manual

SNOWMOBILE

OWNER’S MANUAL

VK540EG

LIT-12628-02-19

8AC-28199-18

ESU00286

MACHINE IDENTIFICATION

Identification numbers record

A. FRAME NUMBER:

861-002

B.ENGINE NUMBER (PRIMARY I.D.):

C.KEY NUMBER:

861-011

	Record your frame number, engine number (Primary I.D.)
	and key number in the spaces provided, to assist you in
	ordering spare parts from your Yamaha dealer.
860-002	1 The frame number is the seventeen-digit number

stamped on the frame of the machine. (See Fig. Å)

2 The engine number is stamped in the location as shown. (See Fig. ı)

3 Key number (See Fig. Ç)

Also, record and keep these I.D. numbers in a separate place in case your machine is stolen.

ESU00001

INTRODUCTION

Congratulations! Your choice of a Yamaha snowmobile assures you of the highest quality and dependability. Your Yamaha snowmobile is manufactured by a company wellknown for excellence in the field of snowmobiles. The most advanced production equipment and technology have made Yamaha one of the best machine manufacturers. We are confident that this snowmobile will meet the greatest expectations of our customers. This manual is designed to acquaint you with the operation of this snowmobile and minor maintenance required for satisfactory service.

Should major repairs ever be required, you are advised to consult a nearby Yamaha dealer who has the techniques, tools and parts to ensure your satisfaction. We hope that the information within this booklet will help you enjoy many hours of pleasure with your Yamaha snowmobile.

VK540EG

Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan

P/N LIT-12628-02-19


		WARNING
	PLEASE READ AND UNDERSTAND THIS MANUAL
	COMPLETELY BEFORE OPERATING THE MACHINE.

851-005	NOTE:

	•	Yamaha continually seeks advancements in product

		design and quality. Therefore, while this manual con-
		tains the most current product information available at
		the time of printing, there may be minor discrepancies
		between your machine and this manual. If there is any
		question concerning this manual, please consult your
	•	Yamaha dealer.
		This manual should be considered a permanent part of

this machine and should remain with this machine when resold.

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

The Safety Alert Symbol means ATTENTION! BECOME

ALERT! YOUR SAFETY IS INVOLVED!

WARNING

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

CAUTION:

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

NOTE:

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

ESU00003

YAMAHA MOTOR CORPORATION,
U.S.A. SNOWMOBILE LIMITED
WARRANTY .......................................	1-1
YAMAHA EXTENDED SERVICE
(Y.E.S.) ................................................	1-4
LOCATION OF THE IMPORTANT
LABELS ..............................................	2-1
SAFETY INFORMATION ....................	3-1
DESCRIPTION ....................................	4-1
CONTROL FUNCTIONS ....................	5-1
MAIN SWITCH ...................................	5-1
STARTER LEVER (CHOKE) .............	5-1
THROTTLE LEVER ...........................	5-2
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) ..........................................	5-2
ENGINE STOP SWITCH ...................	5-3
BRAKE LEVER ..................................	5-3
PARKING BRAKE BUTTON ..............	5-4
DRIVE SELECT LEVER
(SHIFT LEVER) .................................	5-4
HEADLIGHT BEAM SWITCH ............	5-5
HEADLIGHT ADJUSTING KNOB ......	5-5
GRIP AND THUMB WARMER
SWITCH .............................................	5-5
TRIP ODOMETER RESET KNOB .....	5-5
SHROUD LATCH ..............................	5-6
V-BELT GUARD ................................	5-6
ENGINE ROOM PLATES ..................	5-7
LUGGAGE BOX ................................	5-7
REAR CARRIER ................................	5-7
TOW HITCH ......................................	5-7
PRE-OPERATION CHECKS ..............	6-1
FUEL ..................................................	6-1
ENGINE OIL ......................................	6-2
THROTTLE LEVER ...........................	6-2
MANUAL STARTER ..........................	6-2

THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK .............................	6-3
BRAKE ...............................................	6-4
V-BELT ..............................................	6-4
DRIVE V-BELT GUARD ....................	6-5
DRIVE TRACK ...................................	6-5
SLIDE RUNNERS ..............................	6-5
SKI/SKI RUNNER ..............................	6-6
STEERING SYSTEM .........................	6-6
LIGHTS ..............................................	6-6
BATTERY ..........................................	6-6
FITTINGS/FASTENERS ....................	6-6
SERVICE TOOLS AND SPARE
PARTS ...............................................	6-7
OPERATION .......................................	7-1
STARTING THE ENGINE ..................	7-1
EMERGENCY ENGINE
STARTING .........................................	7-2
BREAK-IN ..........................................	7-2
RIDING YOUR SNOWMOBILE .........	7-3
GETTING TO KNOW YOUR
SNOWMOBILE ..................................	7-3
LEARNING TO RIDE YOUR
SNOWMOBILE ..................................	7-3
TO START OUT AND
ACCELERATE ...................................	7-4
BRAKING ...........................................	7-4
TURNING ..........................................	7-4
RIDING UPHILL .................................	7-5
RIDING DOWNHILL ..........................	7-6
CROSSING A SLOPE (SIDE HILL) ...	7-6
ICE OR ICY SURFACE .....................	7-7
HARD-PACKED SNOW ....................	7-7
OPERATION ON SURFACES
OTHER THAN SNOW OR ICE ..........	7-7
MAXIMIZING DRIVE TRACK LIFE ....	7-8
DRIVING ............................................	7-9
STOPPING THE ENGINE ...............	7-10
TRANSPORTING ............................	7-11

PERIODIC MAINTENANCE ...............	8-1
MAINTENANCE CHART ...................	8-1
TOOL KIT ..........................................	8-4
SPARK PLUG INSPECTION .............	8-4
ENGINE IDLE SPEED
ADJUSTMENT ...................................	8-5
THROTTLE CABLE
ADJUSTMENT ...................................	8-6
OIL PUMP CABLE ADJUSTMENT ....	8-6
CARBURETOR ADJUSTMENT ........	8-7
HIGH ALTITUDE ADJUSTMENTS ....	8-9
FAN BELT ........................................	8-10
DRIVE V-BELT REPLACEMENT ....	8-11
DRIVE CHAIN HOUSING ................	8-13
BRAKE/PARKING BRAKE ..............	8-14
SUSPENSION .................................	8-15
FULL RATE ADJUSTER .................	8-17
TRACK ADJUSTMENT ...................	8-18
SKI ALIGNMENT .............................	8-20
HANDLEBAR ADJUSTMENT ..........	8-21
LUBRICATION .................................	8-22
HEADLIGHT ....................................	8-23
BATTERY ........................................	8-24
FUSE REPLACEMENT ...................	8-25
TROUBLESHOOTING ........................	9-1
STORAGE ........................................	10-1
SPECIFICATIONS ............................	11-1
DIMENSIONS ..................................	11-1
ENGINE ...........................................	11-1
CHASSIS .........................................	11-1
ELECTRIC .......................................	11-2
WIRING DIAGRAM ...........................	12-1

ESU00004

YAMAHA MOTOR CORPORATION, U.S.A.

SNOWMOBILE LIMITED 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 authorized 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.

SPECIFIC EXCLUSIONS from this warranty shall 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 under this warranty shall be to:

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

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 remaining 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.

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.

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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, neglect, 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 maintenance 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.

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 information 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:

YAMAHA MOTOR CORPORATION,

U.S.A.

CUSTOMER RELATIONS

DEPARTMENT

P.O. Box 6555

Cypress, California 90630

1-2

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.

1-3

ESU00005

YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.).

•Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind.

•Y.E.S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, or 36 months beyond your warranty period.

•Y.E.S. is designed and administered by the same Yamaha people who handle your warranty — and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to “moving parts” or the “drive train” like many other plans. And Y.E.S. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted fac- tory-backed protection can be.

•You don’t have to pay anything for covered repairs.

There’s no deductible to pay, and repairs aren’t “pro-rated.” You don’t have any “outof pocket” expenses for covered repairs.

•In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire Y.E.S. plan period.

•Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.

•Y.E.S. coverage is transferable to a new owner if you sell or trade-in. That can make your Yamaha much more valuable!

This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service.

We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today!

A special note:

If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your engine number). We’ll be happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing P.O. Box 6555

Cypress, CA 90630

(714) 761-7631

1-4

ESU00007

LOCATION OF THE

IMPORTANT LABELS

Please read the following labels carefully before operating this machine.

NOTE:

Maintain or replace safety and instruction labels, as necessary.

WARNING

SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF THE FOLLOWING:

•Read the Owner’s Manual and all labels before operating this vehicle.

•Check throttle, brake, and steering for proper operation before starting engine.

•Set parking brake before attempting to start engine. Never run this vehicle with the parking brake applied.

•To stop engine in an emergency, push the engine stop switch down.

•Do not operate engine without drive belt or drive guard.

•Make sure the fuel tank cap is closed securely after refueling.

•Do not operate this vehicle on public roads. You could collide with another vehicle.

•Wear an approved helmet, eye protection, and adequate clothing for snowmobiling.

•Check lever position (Drive, Reverse, or Low) before moving.

D R L

DRIVE SELECT LEVER

•Read owner’s manual carefully before operating.

•Before moving the drive select lever, make sure that the vehicle is at a full stop and that the throttle lever is fully released.

•Low range must not be used for speeds exceeding 50 KM/H.

AVERTISSEMENT

AFIN D’ÉVITER TOUT RISQUE DE BLESSURE SÉRIEUSE OU MÊME MORTELLE, VEUILLEZ SUIVRE LES RECOMMANDATIONS SUIVANTES:

•Avant d’utiliser ce véhicule, lire le manuel du propriétaire et toutes les étiquettes.

•Avant de démarrer le moteur, vérifier l’opération du frein, de l’accélérateur et de la direction.

•Le frein de sécurité doit être appliqué lors du démarrage. Ne pas rouler avec le frein de sécurité actionné.

•En cas d’urgence, utiliser l’interrupteur d’arrêt du moteur.

•Ne pas laisser tourner le moteur sans la courroie ou sans son garde.

•S’assurer que le bouchon du réservoir soit bien refermé après le remplissage.

•Afin d’éviter tout risque de collision, ne pas rouler sur un chemin public.

•Toujours porter un casque approuvé et un habillement de motoneigiste. Prévoir une protection pour les yeux.

•Vérifier la position du levier (en marche, arrière ou bas) avant d’être en marche.

D R L

LEVIER DE SÉLECTION DE VITESSE

•Lire attentivement le manuel du propriétaire avant l’utilisation.

•S’assurer que le véhicule est complétement arrêtée et que le levier des gaz n’est pas actionné avant de déplacer le levier de sélection de vitesse.

•On ne peut utiliser la position “L” (pettie vitesse) pour des vitesses supérieures à 50 KM/H.

87R-77761-10

2WARNING

DO NOT OPERATE ENGINE WITHOUT

V-BELT OR DRIVE GUARD.

AVERTISSEMENT

NE PAS FAIRE FONCTIONNER LE

MOTEUR SANS COURROIE EN V

OU PROTECTEUR D'EMBRAYAGE.

8BD-7762-00

WARNING

This unit contains high pressure nitrogen gas. Mishandling can cause explosion.

•Read owner’s manual for instructions.

•Do not incinerate, puncture or open.

AVERTISSEMENT

Cette unité contient de l’azote à haute pression.

Une mauvaise manipulation peut entraîner d’explosion.

•Voir le manuel d’utilisateur pour les instructions.

•Ne pas brûler ni perforer ni ouvrir.

2-1

851-005

851-006

ESU00010

SAFETY INFORMATION

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 machine. 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 machine 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 machine after drinking alcohol or

taking drugs. Your ability to operate the machine is reduced by the influence of alcohol or drugs.

4.For safety and proper care of the machine, always perform the pre-operation checks on page 6-1 ~ 6-7 before starting the engine. Check the throttle, steering and brake operation every time before starting the engine. Be sure the throttle lever moves freely and it returns to the idle position when it is released.

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

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

3-1

851-003

851-001

7.Handle fuel with care; it is highly flammable.

•Never add fuel when the engine is running 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 vicinity of an open flame.

•Make sure the fuel tank cap is closed securely after refueling. Wipe up any spilled fuel immediately.

8.If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline into your eye(s), 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 snowmobile 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 machine in or out of the building. Open the outside doors; exhaust fumes are dangerous.

2.Be careful where you ride. There may be obstacles

851-002

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.

3-2

3.This machine 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 machine.

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 have other snowmobilers with you 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 hard-packed 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.

Maintenance and Storage

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

2.Never store the machine with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters, open flame, spark, clothes dryers, and the like. Allow the engine to cool before storing in any enclosure.

3.Always refer to “STORAGE” for important details if the machine is to be stored for an extended period.

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

3-3

ESU00012

DESCRIPTION

1 Windshield

2 Steering handlebar

3 Seat

4 Drive track

5 Slide rail suspension

6 Frame

7 Telescopic strut suspension

8 Steering ski

9 Headlight

0 Front baffle plate A Shroud

B Tail/brake light C Flap

D Tow hitch

E Luggage box

F Headlight adjusting knob G Engine stop switch

H Throttle lever

I Drive select lever (Shift lever) J Main switch

K Starter handle L Starter lever

M Grip warmer switch

N Headlight beam switch O Brake lever

P Parking brake button

4-1

ESU00013

CONTROL FUNCTIONS

ESU00018

MAIN SWITCH

The main switch controls the following items. 1 OFF:

Ignition circuit is switched off.

The key can be removed only in this position. 2 ON:

Ignition circuit is switched on. The engine can be started. 3 START:

Starting circuit is switched on.

The starter motor starts.

831-004

NOTE:

The lights will come on after the engine starts.

CAUTION:

Release the switch immediately after the engine starts.

ESU00020

STARTER LEVER (CHOKE)

Use this lever when starting and warming up a cold engine.

1 Starter lever (choke)

2 When starting a cold engine.

3 Warming up

815-001 4 When the engine is warm.

NOTE:

Refer to STARTING THE ENGINE for proper operation.

5-1

816-001

816-003

816-004

816-005

ESU00022

THROTTLE LEVER

Once the engine is running cleanly, squeezing 2 of the throttle lever 1 will increase the engine speed and cause engagement of the drive system. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle when the thumb is released

WARNING

Check throttle, brake, and steering for proper operation before starting engine.

ESU00025

THROTTLE OVERRIDE SYSTEM (T.O.R.S.)

If the carburetor or throttle cable should malfunction during operation, release the throttle lever. The T.O.R.S. is designed to interrupt the ignition and stop the engine if the carburetor fails to return to idle when the lever is released.

WARNING

If T.O.R.S. stops the engine, 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.

MODE	A	Idle	B		C
	A		B

		or		Run		Trouble
SWITCH		Starting
Throttle switch		OFF		ON		OFF

Carburetor switch		ON		OFF		OFF


Engine		RUN		RUN		STOP

Å Idle or starting ı Run

Ç Trouble

1 Carburetor switch

2 Throttle switch

3 Throttle cable

4 Throttle valve a “ON”

b “OFF”

5-2

831-008

818-002

ESU00031

ENGINE STOP SWITCH

The engine stop switch 1 is used to stall the engine in an emergency. Simply push 2 the engine stop switch, and the engine will stop. To start the engine, pull 3the engine stop switch and see page 7-1 for more details. During the first few rides, you should practice using the switch while driving so that you can react quickly in an emergency.

ESU00032

BRAKE LEVER

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

1 Brake lever

2 Brake lever end

3 Handlebar end

NOTE:

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

CAUTION:

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

5-3

818-001

817-003

ESU00034

PARKING BRAKE BUTTON

When parking the machine or starting the engine, apply the parking brake.

Squeeze the brake lever 1, then push down 3the parking brake button 2 while releasing the brake lever.

To release the parking brake, just squeeze the brake lever.

WARNING

•Always set the parking brake before attempting to start the engine.

•Never run the machine with the parking brake applied.

This may overheat the brake disc and reduce braking ability.

ESU00037

DRIVE SELECT LEVER (SHIFT LEVER)

The drive select lever is used to shift your machine into drive, low or reverse. After coming to a complete stop, squeeze the stopper underneath the lever and move the lever to the desired position.

1 Drive select lever (Shift lever)

2 Stopper

Lever position	Machine movement

3 D	Drive (forward)

4 R	Reverse

5 L	Low range (forward)

CAUTION:

Do not shift from “Forward” to “Reverse” or “Reverse” to “Forward” while the machine is moving. Otherwise the drive system could be damaged.

817-005

5-4

831-012

832-018

831-020

833-004

ESU00039

HEADLIGHT BEAM SWITCH

Push the switch to change the head light beam alternately to high or low.

1 Headlight beam switch

2 Push

3 High beam

4 Low beam

ESU00040

HEADLIGHT ADJUSTING KNOB

Use the knob to adjust the headlight vertical position.

1 Up

2 Down

ESU00042

GRIP AND THUMB WARMER SWITCH

This switch controls the electrically heated handlebar grips and throttle lever.

1 Grip and thumb warmer switch

2 ON

3 OFF

ESU00046

TRIP ODOMETER RESET KNOB

Use knob to reset the trip odometer.

1 Reset knob

2 Turn counterclockwise

5-5

ESU00048

SHROUD LATCH

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

845-014 1 Latch

2 Shroud

CAUTION:

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

WARNING

•Do not drive the machine with the shroud open or unlatched or with the shroud 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.

ESU00052

V-BELT GUARD

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

WARNING

• Be sure the V-belt guard is tightened securely

805-080

before operating the machine.

•Never run the engine without the V-belt or with the V-belt guard removed.

5-6

845-031

845-017

846-010

849-001

847-005

ESU00064

ENGINE ROOM PLATES

Open the plates to cool down the engine.

CAUTION:

•Close the plate when the machine is operated in deep snow.

•Remove the belly pan plates 1 when the ambient temperature is 5°C (41.5°F) or higher.

ESU00069

LUGGAGE BOX

Luggage box is located under the seat. The seat can be opened left side by unhooking the latches on the right side seat. To close the seat, slowly turn the seat right side. When it fits back to the home position, hook the latches.

ESU00070

REAR CARRIER

Maximum load limit: 20 kg (44 lb)

ESU00071

TOW HITCH

Use the tow point within the specified weight limits.

1 Tow point