Yamaha VK 540 LLL Manual

SNOWMOBILE

OWNER’S MANUAL

VK540EK

LIT-12628-02-34

8AC-28199-1B

A

B

C

ESU02860

MACHINE IDENTIFICATION

Identification number records

A.FRAME NUMBER:

B.ENGINE NUMBER (PRIMARY ID):

C.KEY NUMBER:

Record the frame number, engine number (Primary ID), and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer.

1 The frame number is the seventeen-digit number stamped on the frame of the snowmobile. (See fig. È.)

2 The engine number is stamped in the location as shown. (See fig. É.)

3 Key number (See fig. Ê.)

Also, record and keep the ID numbers in a separate place in case the snowmobile is stolen.

ESU00011

INTRODUCTION

Congratulations on your purchase of a Yamaha snowmobile. This model is the result of Yamaha’s vast experience in the production of fine sporting and touring snowmobiles. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

This manual will give you an understanding of the operation, inspection, and basic maintenance of this snowmobile. If you have any questions concerning the operation or maintenance of your snowmobile, please consult a Yamaha dealer.

To maintain the high quality and performance of this snowmobile, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.

VK540EK

OWNER’S MANUAL

©2004 by Yamaha Motor Corporation, U.S.A. 1st Edition, March 2004

All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan

P/N LIT-12628-02-34

WARNING

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

NOTE:

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

●This manual should be considered a permanent part of this snowmobile and should remain with the snowmobile 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 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 to make procedures easier or clearer.

ESU00030

CONTENTS

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 .............................	5-4
Headlight beam switch ....................	5-5
Headlight adjusting knob .................	5-5
Grip and thumb warmer switch........	5-5
Tripmeter reset knob .......................	5-5
Shroud latches.................................	5-6
Drive guard ......................................	5-6
Engine compartment plates.............	5-7
Luggage box....................................	5-7
Rear carrier......................................	5-7
Tow hitch .........................................	5-8
PRE-OPERATION CHECKS..............	6-1
Fuel..................................................	6-1
Engine oil.........................................	6-2
Throttle lever....................................	6-2
Recoil starter ...................................	6-2

Throttle override system
(T.O.R.S.) ........................................	6-3
Brake ...............................................	6-4
V-belt ...............................................	6-4
Drive guard ......................................	6-5
Drive track .......................................	6-5
Slide runners ...................................	6-5
Skis and ski runners ........................	6-6
Steering system...............................	6-6
Lights ...............................................	6-6
Battery .............................................	6-6
Fittings and fasteners ......................	6-6
Tool kit and recommended
equipment........................................	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..............	7-3
Braking ............................................	7-3
Turning ............................................	7-4
Riding uphill .....................................	7-4
Riding downhill ................................	7-5
Traversing a slope ...........................	7-5
Ice or icy surface .............................	7-5
Hard-packed snow ..........................	7-6
Operation on surfaces other than
snow or ice ......................................	7-6
Maximizing drive track life ...............	7-7
Driving .............................................	7-8
Stopping the engine ........................	7-9
Transporting ..................................	7-10
PERIODIC MAINTENANCE ...............	8-1
Periodic 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
Checking the fan belt deflection ....	8-10
V-belt replacement ........................	8-11
Checking the drive chain housing
oil level and the drive chain
tension ...........................................	8-13
Checking the brake pads...............	8-14
Suspension....................................	8-14
Drive track adjustment...................	8-18
Ski alignment .................................	8-20
Handlebar adjustment ...................	8-21
Lubrication .....................................	8-22
Headlight bulb replacement...........	8-23
Headlight beam adjustment...........	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..........................................	11-2
Electric...........................................	11-3
WIRING DIAGRAM .........................	12-1

ESU00040

YAMAHA MOTOR CORPORATION, U.S.A. SNOWMO-

BILE LIMITED WARRANTY

1-1

1-2

1-3

ESU04280

YAMAHA EXTENDED SERVICE (Y.E.S.)

1-4

ESU00070

LOCATION OF THE IMPORTANT

LABELS

Please read the following labels carefully before operating this snowmobile.

NOTE:

Maintain or replace safety and instruction labels, as necessary.

1

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

2			3

2-1

ESU00101

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 snowmobile. Become familiar with all of the operating controls and their function. Consult a Yamaha dealer about any control or function you do not understand.

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

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

4.For safety and proper care of the snowmobile, always perform the pre-operation checks on pages 6-1–6-7 before starting the engine. Check the throttle, brake, and steering for proper operation every time before starting the engine. Make sure that the throttle lever moves freely and it returns to the home position when it is released.

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

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

3-1

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 that 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 eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash your skin with soap and water, and change your clothes.

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

Operation

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

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

3-2

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

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

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

6.Many surfaces such as ice and 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 snowmobile not approved by Yamaha, or the removal of original equipment may render your snowmobile unsafe for use that may cause severe personal injury. Modifications may also make the snowmobile illegal to use.

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

3.Always refer to the “STORAGE” section if the snowmobile is to be stored for an extended period.

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

3-3

ESU00120

DESCRIPTION

1Windshield

2Steering handlebar

3Seat

4Drive track

5Slide rail suspension

6Frame

7Telescopic strut suspension

8Skis

9Headlight

0 Engine compartment plate

AShroud

BTail/brake light

CSnow flap

DTow hitch

EStorage compartment

FHeadlight adjusting knob

GEngine stop switch

HThrottle lever

IDrive select lever

JMain switch

KStarter handle

LStarter lever

MGrip and thumb warmer switch

NHeadlight beam switch

OBrake lever

PParking brake button

4-1

ESU00130

CONTROL FUNCTIONS

ESU00180

Main switch

The main switch controls the following items.

1 “OFF”

The ignition circuit is switched off.

The key can be removed only in this position.

2 “ON”

The ignition circuit is switched on. The engine can be started.

NOTE:

The headlight, meter lights, and taillight will come on after the engine starts.

3 “START”

The starting circuit is switched on. The starter motor starts.

CAUTION:

@

Release the switch immediately after the engine starts.

ESU00201

Starter lever (choke)

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

1Starter lever (choke)

2When starting a cold engine.

3Warming up

4When the engine is warm.

NOTE:

Refer the “Starting the engine” section for proper operation.

5-1

A

B

C

ESU00220

Throttle lever

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

WARNING

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

ESU00252

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

If the carburetor or throttle cable should malfunction during operation, the T.O.R.S. will operate when the throttle lever is released.

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 the T.O.R.S. is activated, make sure that the cause of the malfunction has been corrected and that the engine can be operated without a problem before restarting the engine.

	A	Idling/	B		C
			Running		Trouble
	starting
Throttle switch		Off		On		Off
Carburetor switch		On		Off		Off
Engine		Run		Run		Stop

È Idling/starting

É Running

Ê Trouble

1Carburetor switch

2Throttle switch

3Throttle cable

4Throttle valve a On

b Off

5-2

ESU00310

Engine stop switch

The engine stop switch 1 is used to stop the engine in an emergency. Simply push 2 the stop switch to stop the engine. To start the engine, pull 3 the stop switch and proceed with starting the engine. (See page 7-1 for more details.)

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

ESU00320

Brake lever

The snowmobile is stopped by braking the entire drive system.

Squeeze the brake lever towards the handlebar grip to stop the snowmobile.

1Brake lever

2Brake lever end

3Handlebar end

NOTE:

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

CAUTION:

@

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

5-3

ESU00341

Parking brake button

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

Squeeze the brake lever 1, push and hold the parking brake button 2 down 3, and then release the brake lever.

To release the parking brake, squeeze the brake lever.

WARNING

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

●Never run the snowmobile with the parking brake applied. This may overheat the brake disc and reduce braking ability.

ESU03371

Drive select lever

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

1Drive select lever

2Stopper

Lever position	Snowmobile movement
3 D	Drive (forward)
4 R	Reverse
5 L	Low (forward)

CAUTION:

@

Do not shift from forward to reverse or from reverse to forward while the snowmobile is moving. Otherwise, the drive system could be damaged.

5-4

ESU00390

Headlight beam switch

Push the headlight beam switch to change the headlight beam to high or low.

1Headlight beam switch

2Push

3High beam

4Low beam

ESU00401

Headlight adjusting knob

Use the headlight adjusting knob to adjust the headlight vertically.

Headlight beam moves:

1Up

2Down

ESU00421

Grip and thumb warmer switch

The grip and thumb warmer switch controls the electrically heated handlebar grips and throttle lever.

1Grip and thumb warmer switch

2ON

3OFF

ESU00461

Tripmeter reset knob

Use the tripmeter reset knob to reset the tripmeter.

1Tripmeter reset knob

2Turn counterclockwise

5-5

ESU00481

Shroud latches

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

1Shroud latch

2Shroud

CAUTION:

@

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

WARNING

●Do not drive the snowmobile with the shroud open, unlatched, or removed.

●Keep your body and clothing away from rotating parts when servicing with the shroud open.

●Do not touch the hot muffler and engine during or immediately after operation.

ESU00521

Drive guard

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

WARNING

●Make sure that the drive guard is tightened securely before operating the snowmobile.

●Never run the engine with the V-belt or drive guard removed.

5-6

ESU00641

Engine compartment plates

This snowmobile is equipped with an engine compartment plate 1 in the shroud that can be opened and engine compartment plates 2 in the belly pan that can be removed to cool down the engine.

CAUTION:

@

●Make sure that the engine compartment plate in the shroud is closed and the engine compartment plates in the belly pan are installed when operating the snowmobile in deep snow.

●Open the engine compartment plate in the shroud and remove the engine compartment plates in the belly pan when the ambient temperature is above 5 °C (41.5 °F).

ESU00691

Storage compartment

The storage compartment is located under the seat. To open the seat, unhook the latches, and then lift the right side of the seat up. To close the seat, slowly lower it to its original position, and then hook the latches.

ESU00701

Rear carrier

Maximum load limit: 20 kg (44 lb)

5-7