Yamaha VK 540 LLL User Manual

OWNER’S MANUAL

SNOWMOBILE

LIT-12628-02-34

VK540EK

8AC-28199-1B

A

ESU02860

MACHINE IDENTIFICATION

Identification number records

A. FRAME NUMBER:

CZ-01E

B

B. ENGINE NUMBER (PRIMARY ID):

CZ-01E

C. KEY NUMBER:

CZ-01E

C

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

YAMAHA EXTENDED SERVICE
(Y.E.S.)

LOCATION OF THE IMPORTANT
LABELS

SAFETY INFORMATION

DESCRIPTION

CONTROL FUNCTIONS

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

.......................................1-1

...............................................1-4

..............................................2-1

...................3-1

...................................4-1

....................5-1

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

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

......................................7-1

PRE-OPERATION CHECKS

Fuel..................................................6-1

Engine oil.........................................6-2

Throttle lever....................................6-2

Recoil starter ...................................6-2

..............6-1

PERIODIC MAINTENANCE

Periodic maintenance chart .............8-1

Tool kit.............................................8-4

Spark plug inspection ......................8-4

Engine idle speed adjustment .........8-5

...............8-1

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

1-

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

BILE LIMITED WARRANTY

CW-01E

1-1

CW-02E

1-2

CW-03E

1-3

ESU04280

CW-06E

YAMAHA EXTENDED SERVICE (Y.E.S.)

1-4

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.

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.

ESU00070

2-

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.

@

D LR

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.

D LR

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

3-

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 oper-
ating 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 snow-
mobile is to be stored for an extended period.

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

3-3

ESU00120

4-

DESCRIPTION

Windshield

1

Steering handlebar

2

Seat

3

Drive track

4

Slide rail suspension

5

Frame

6

Telescopic strut suspension

7

Skis

8

Headlight

9

Engine compartment plate

0

Shroud

A

Tail/brake light

B

Snow flap

C

Tow h i t c h

D

Storage compartment

E

Headlight adjusting knob

F

Engine stop switch

G

Throttle lever

H

Drive select lever

I

Main switch

J

Starter handle

K

Starter lever

L

Grip and thumb warmer switch

M

Headlight beam switch

N

Brake lever

O

Parking brake button

P

4-1

ESU00130

5-

CONTROL FUNCTIONS

ESU00180

Main switch

The main switch controls the following items.

“OFF”

1

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

“ON”

2

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.

@

“START”

3

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.

Starter lever (choke)

1

When starting a cold engine.

2

Warming up

3

When the engine is warm.

4

NOTE:

@

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

@

5-1

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

A

B

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.

@

CA-04E

Mode

Item

A

Idling/

starting

B C

Running Trouble

Throttle switch Off On Off
Carburetor switch On Off Off
Engine Run Run Stop

Idling/starting

C

È

Running

É

Tr o u b l e

Ê

Carburetor switch

1

Throttle switch

2

Throttle cable

3

Throttle valve

4

On

a

Off

b

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.

Brake lever

1

Brake lever end

2

Handlebar end

3

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.

Drive select lever

1

Stopper

2

CA-18E

Lever position Snowmobile movement

D Drive (forward)

3

R Reverse

4

L Low (forward)

5

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.

Headlight beam switch

1

Push

2

High beam

3

Low beam

4

ESU00401

Headlight adjusting knob

Use the headlight adjusting knob to adjust the headlight
vertically.
Headlight beam moves:

Up

1

Down

2

ESU00421

Grip and thumb warmer switch

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

Grip and thumb warmer switch

1

ON

2

OFF

3

ESU00461

Tripmeter reset knob

Use the tripmeter reset knob to reset the tripmeter.

Tripmeter reset knob

1

Turn counterclockwise

2

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.

Shroud latch

1

Shroud

2

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

ESU00712

Tow h i tch

Use the tow hitch within the specified weight limits.

To w h i tc h

1

Tow weight limit:

120 kg (265 lb)

Vertical weight limit:

15 kg (33.1 lb)

CAUTION

@

:

Avoid towing for long periods under 10 km/h
(6.2 mph) to prevent early wear of the V-belt.

@

5-8

ESU00720

R+M

2

6-

PRE-OPERATION CHECKS

NOTE:

@

Pre-operation checks should be made each time the
snowmobile is used.

@

WARNING

@

The engine and muffler will be very hot after the
engine has been run.
Avoid touching the engine and muffler while they are
still hot with any part of your body or clothing during
inspection or repair.

@

ESU00741

Fuel

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

Recommended fuel:

Unleaded gasoline

Pump octane ; 88 or higher

Fuel tank capacity:

31.0 L (6.8 Imp gal, 8.2 US gal)

WARNING

@

●

Fuel is HIGHLY FLAMMABLE and poisonous.
Check the “SAFETY INFORMATION” section
carefully before refueling. (See page 3-2.)

●

Do not fill the fuel tank all the way to the top. Fuel
could overflow if the snowmobile is tilted on its
side or if the ambient temperature rises, causing
the fuel to warm up and expand.

●

Make sure that the fuel tank cap is closed
securely after refueling. Leaking fuel can catch
fire.

@

6-1

CAUTION

@

●

Oxygenated fuels (gasohol) containing a maxi-

:

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

●

Make sure that snow or ice do not enter the fuel
tank when refueling.

●

Do not use alcohol deicers or water absorbing
additives with oxygenated fuel.

●

The fuel tank should be filled with straight gaso­line as specified.

@

ESU00842

Engine oil

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

Lower level

1

Upper level

2

Oil tank capacity:

2.5 L (2.2 Imp qt, 2.6 US qt)

Recommended oil:

YAMALUBE 2-cycle oil

ESU00870

Throttle lever

Check the throttle lever operation before starting the
engine.
The throttle lever must open smoothly and spring back to
its home position when released.

ESU00880

Recoil starter

Check the recoil starter for proper operation and the
recoil starter rope for damage.

6-2

ESU00890

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

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

WARNING

@

When checking T.O.R.S.:

●

Make sure that the parking brake is applied.

●

Make sure that the throttle lever moves smoothly.

●

Do not run the engine up to clutch engagement
r/min. Otherwise, the snowmobile could start
moving forward unexpectedly, which could cause
an accident.

@

1. Start the engine.

NOTE:

@

Refer to the “Starting the engine” section.

@

2. Hold the pivot point of the throttle lever away from the
throttle switch by putting your thumb (above) and
forefinger (below) between the throttle lever pivot
and the engine stop switch housing 2.
While holding the pivot point as described above,
press the throttle lever 3 gradually.
The T.O.R.S. will operate and the engine should stop
immediately.

1

WARNING

@

If the engine does not stop, stop the engine by turn­ing the main switch to the “OFF” position and con­sult a Yamaha dealer.

@

6-3

ESU00921

Brake

Test the brake at a low speed when starting out to make
sure that it is working properly. If the brake does not pro­vide proper braking performance, inspect the brake for
wear. (See page 8-14 for more details.)

WARNING

@

Do not operate the snowmobile if you find any prob­lems in the brake system. You could lose braking
ability, which could lead to an accident. Ask a
Yamaha dealer to inspect and repair the brake sys­tem.

@

CAUTION

@

:

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

@

ESU00941

V-bel t

Open the shroud and remove the drive guard.
Check the V-belt for wear and damage. Replace if neces­sary.

Wear limit a:

31.4 mm (1.24 in)

WARNING

@

●

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

●

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

@

6-4

ESU03990

Drive guard

Check the drive guard mounts for damage. Make sure
that the wing bolt is tightened securely and the drive
guard is firmly in place.

ESU00970

Drive track

Check the drive track for deflection, wear, or damage.
Adjust or replace if necessary. (See pages 8-18–8-20 for
more details.)

WARNING

@

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

@

ESU00980

Slide runners

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

Slide runners

1

Wear limit

a

Wear limit height:

10 mm (0.39 in)

CAUTION

@

:

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

@

6-5

ESU01020

Skis and ski runners

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

Ski runner wear limit a:

8 mm (0.31 in)

Ski wear limit b:

25 mm (0.98 in)

CAUTION

@

:

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

@

ESU01030

Steering system

Check the handlebar for excessive free play:

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

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

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

ESU01041

Lights

Check the lights.
Replace any burned out bulbs.

ESU03020

Battery

Check the fluid level and fill if necessary.
Use only distilled water if refilling is necessary. (See
page 8-24 for more details.)

ESU01100

Fittings and fasteners

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

6-6

ESU01111

Tool kit and recommended equipment

It is good practice to carry the tool kit, spare parts, and
other necessary equipment with you while riding the
snowmobile so that minor repairs can be done if neces­sary. The following should be carried at all times:

Tool kit

●

Flashlight

●

Roll of plastic tape

●

Steel wire

●

Tow rope

●

Emergency starter rope

●

V-belt

●

Light bulbs

●

Spark plugs

●

When you start out for a long distance trip, extra fuel and
oil should be carried as well.

6-7

ESU01120

7-

OPERATION

ESU01140

Starting the engine

WARNING

@

●

Be sure to check the “SAFETY INFORMATION”
section carefully before starting the engine.

●

Make sure that the parking brake is applied.

@

NOTE:

@

Make sure that the engine stop switch is in the on posi­tion.

@

1. Fully open the starter lever (choke).

Starter lever (choke)

1

Fully open (cold engine starting)

2

Half-open (warm engine up)

3

Closed (warm engine starting)

4

NOTE:

@

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

@

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

“START”

1

CAUTION

@

●

Release the switch immediately after the engine

:

starts.

●

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

@

7-1

ESU01202

Emergency engine starting

1. Proceed with item 1. in “Starting the engine”.

2. Turn the main switch to the “ON” position.

“ON”

1

3. Pull slowly on the recoil starter until it is engaged,
then pull it briskly. After the engine starts, put the
starter lever (choke) in the half-open position. Warm
up the engine until it does not run roughly or begin to
stall when the starter lever (choke) is returned to the
closed position.

ESU01260

Break-in

There is never a more important period in the life of your
snowmobile than the break-in period. For the first 10
hours, approximately 200 km (125 mi), do not put an
excessive load on the engine. Avoid prolonged full throt­tle operation.
Also avoid lugging the engine, such as laborious opera­tion in wet snow. If any abnormal condition is noticed,
such as excessive vibration or noise, consult a Yamaha
dealer.

NOTE:

@

To ensure proper engine break-in, use a 50:1 gasoline/oil
mixture when filling the fuel tank of a new snowmobile for
the first time.
For example:
10 L of gasoline per 0.2 L of oil (1 gal of gasoline per

2.6 oz of oil) equals a 50:1 mixing ratio.
(See pages 6-1–6-2 for the recommended gasoline and
oil.)

@

7-2

ESU02733

Riding your snowmobile

Getting to know your snowmobile

A snowmobile is a rider active vehicle, and
your riding position and your balance are
the two basic factors of maneuvering your
snowmobile.
Riding your snowmobile requires skills
acquired through practice over a period of
time. Take the time to learn the basic tech­niques well before attempting more difficult
maneuvers.
Riding your new snowmobile can be a very
enjoyable activity, providing you with hours
of pleasure. However, it is essential to
familiarize yourself with the operation of
the snowmobile to achieve the skill neces­sary to enjoy riding safely. Before operating
the snowmobile, read this Owner’s Manual
completely and understand the operation
of the controls.
Pay particular attention to the safety infor­mation on pages 3-1–3-3. Please read all
warning and caution labels on your snow­mobile. Also, read the Snowmobiler’s
Safety Handbook that is supplied with your
snowmobile.

Learning to ride your snowmobile

Before you ride, always perform the pre­operation checks listed on pages 8-1–8-3.
The short time spent checking the condi­tion of the snowmobile will be rewarded
with added safety and a more reliable
snowmobile. Always wear the proper cloth­ing for both warmth and to help protect you
from injury if an accident occurs.
Become familiar with operating your snow­mobile at low speeds, even if you are an
experienced rider. Do not attempt to oper­ate at maximum performance until you are

totally familiar with the snowmobile’s han-
dling and performance characteristics.
The beginning operator should select a
large flat area to become familiar with the
snowmobile. Make sure that this area is
free of obstacles and other traffic. You
should practice control of the throttle and
brake, and master turning techniques in
this area before trying more difficult terrain.

Set the parking brake and follow the
instructions on page 7-1 to start the
engine. Once the engine has warmed up,
you are ready to begin riding your snow­mobile.

To start out and accelerate

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

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

WARNING

@

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

@

Braking

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

WARNING

@

●

Many surfaces such as ice and hard­packed snow require much longer
stopping distances. Be alert, plan
ahead, and begin decelerating early.

7-3

●

Improper use of the brake can cause
the drive track to lose traction,
reduce control, and increase the
possibility of an accident.

@

Tu rn in g

For most snow surfaces, “body English” is
the key to turning.
As you approach a curve, slow down and
begin to turn the handlebar in the desired
direction. As you do so, put your weight on
the running board to the inside of the turn
and lean your upper body into the turn.
This procedure should be practiced at low
speeds many times, in a large flat area
with no obstacles. Once you have learned
this technique, you should be able to per­form it at higher speeds or in tighter
curves. Lean more as the turn gets
sharper or is made at higher speeds.
Improper riding techniques such as abrupt
throttle changes, excessive braking, incor­rect body movements, or too much speed
for the sharpness of the turn may cause
the snowmobile to tip.
If your snowmobile begins to tip while turn­ing, lean more into the turn to regain bal­ance. If necessary, gradually let off on the
throttle or steer to the outside of the turn.

Remember:

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

Riding uphill

You should practice first on gentle slopes.
Try more difficult climbs only after you have
developed your skill. As you approach a
hill, accelerate before you start the climb,
and then reduce the throttle to prevent
track slippage. It is also important to keep
your weight on the uphill side at all times.
On climbs straight up the hill, this can be
accomplished by leaning forward and, on
steeper inclines, standing on the running
boards and leaning forward over the han­dlebar. (Also see “Traversing a slope.”)
Slow down as you reach the crest of the
hill, and be prepared to react to obstacles,
sharp drops, or other vehicles or people
which may be on the other side. If you are
unable to continue up a hill, do not spin the
track. Stop the engine and set the parking
brake. Then pull the rear of the snowmo­bile around to point the snowmobile back
down the hill. When the snowmobile is
pointed downhill, mount your snowmobile
from the uphill side. Restart the engine,
release the parking brake, and descend
the hill.

WARNING

@

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

@

7-4

Riding downhill

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

WARNING

@

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

@

Traversing a slope

downhill leg on the seat and the foot of
your uphill leg on the running board. This
position will make it easier for you to shift
your body weight as needed.
Snow and ice are slippery, so be prepared
for the possibility that your snowmobile
could begin to slip sideways on the slope. If
this happens, steer in the direction of the
slide if there are no obstacles in your path.
As you regain proper balance, gradually
steer again in the direction you wish to
travel.
If your snowmobile starts to tip, steer down
the hill to regain balance.

WARNING

@

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

@

Ice or icy surface

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

WARNING

@

Traversing slopes is not recommended
for a novice snowmobiler.

@

Traversing a slope requires you to properly
position your weight to maintain proper bal­ance. As you travel across the slope, lean
your body to position your weight towards
the uphill side. A recommended riding
position is to kneel with the knee of your

WARNING

@

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

@

7-5

Hard-packed snow

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

Operation on surfaces other than snow or ice

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

1. Dirt

2. Sand

3. Rocks

4. Grass

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

1. Glare ice surfaces

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

WARNING

@

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

●

Always check the drive track for
damage or maladjustment before
operating the snowmobile.

●

Do not operate the snowmobile if
you find damage to the drive track.

@

CAUTION

@

:

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

@

7-6

ESU02510

Maximizing drive track life

Recommendations

Track tension

During initial break-in, the new drive track will tend to
stretch quickly as the track settles. Be sure to correct the
track tension and alignment frequently. (See pages
8-18–8-20 for adjustment procedures.) A loose track can
slip (ratchet), derail or catch on suspension parts caus­ing severe damage. Do not overtighten the drive track,
otherwise it may increase the friction between the track
and the slide runners, resulting in the rapid wear of both
components. Also, this may put an excessive load on the
suspension components, resulting in component failure.

Marginal snow

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

Off-trail riding

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

Studded track

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

Yamaha does not recommend track studding.

7-7

ESU03381

Driving

WARNING

@

Be sure to read the “SAFETY INFORMATION” and
“Riding your snowmobile” sections carefully before

operating the snowmobile.

@

NOTE:

@

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

@

1. Select the desired operating position by moving the
drive select lever.

“D” Drive (forward)

1

“R” Reverse

2

“L” Low (forward)

3

WARNING

@

●

Make sure that the throttle lever is fully released
and the snowmobile is at a full stop before shift­ing.

●

Be sure to move the drive select lever to forward
or reverse until it stops completely while the
engine is idling.

●

Low must not be used for speeds exceeding 50
km/h (30 mph).

●

Make sure that the area behind the snowmobile is
clear before reversing. Watch behind.

●

Reduce speed and avoid sharp turning when
operating the snowmobile in reverse.

@

NOTE:

@

The reverse buzzer beeps while the drive select lever is
in reverse.

@

2. Release the parking brake by squeezing the brake
lever.

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

4. Turn the handlebar in the desired direction.

5. Squeeze the brake lever to stop the snowmobile.

7-8

6. Apply the parking brake — squeeze the brake lever,
push and hold the parking brake button down, and
then release the brake lever.

ESU01360

Stopping the engine

Turn the main switch to the “OFF” position to stop the
engine.

“OFF”

1

WARNING

@

●

Push down the engine stop switch to stop the
engine in an emergency.

●

Make sure that the key is removed from the main
switch whenever the operator leaves the snow­mobile, to prevent accidental starting.

@

7-9

ESU01380

Transporting

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

Make sure that the fuel level in the fuel tank is lower

●

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

●

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

●

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

7-10

ESU01390

8-

PERIODIC MAINTENANCE

ESU02621

Periodic maintenance chart

Regular maintenance is most important for best performance and safe operation.

CD-01E

Pre-

Item Remarks

operation

check

(Daily)

Check condition.

Spark plugs

Adjust gap and clean.
Replace if necessary.

Engine oil

Check oil level.

Air bleed the oil pump if

∗

●

necessary.

Oil filter

∗

Fuel Check fuel level.

Fuel filter

∗

Check condition.
Replace if necessary.

●

Check condition.
Replace if necessary.

Check fuel hose for cracks or

Fuel line

∗

damage.
Replace if necessary.

Check oil hose for cracks or

Oil line

∗

damage.
Replace if necessary.

Carburetor

Check throttle lever operation.

Adjust the jets.

∗

●

Whenever operating condition
(elevation/temperature) is changed.

Check wear and damage.

Fan belt

∗

Replace if necessary.

Adjust fan belt if necessary.

Check operation and rope

Recoil starter

Engine stop switch

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

Throttle lever

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

∗

Apply “initial 1 month or 400 km (250 mi, 20 hr)”.

∗∗

damage.

Replace if necessary.

∗

Check operation.

Repair if necessary.

∗

Check operation.

Repair if necessary.

∗

Check operation.

Repair if necessary.

∗

●

●

●

●

Initial

1 month

or

800 km

(500 mi)

(40 hr)

Every

Seasonally

or

3,200 km

(2,000 mi)

(160 hr)

●

●

●

●

●

●

●

●

Page

8-4–8-5

6-2

6-1–6-2

5-2, 6-2,

8-6

8-10

6-2

5-3

5-2, 6-3

5-2, 6-2

8-1

Pre-

Item Remarks

operation

check

(Daily)

Check for leakage.

Exhaust system

∗

Tighten or replace gasket if
necessary.

Decarbonization More frequently if necessary.

∗

Check for cracks, bends or

Drive guard

V-belt

Drive track and idler
wheels

Slide runners

Brake and parking
brake

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.

Adjust free play and/or

∗

●

●

●

●

●

replace pads if necessary.

Drive chain oil

Drive chain

Skis and ski runners

Steering system

Lights

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 operation.
Replace bulbs if necessary.

●

●

●

Check fluid level.

Battery

Add only distilled water if nec­essary.

Check specific gravity and

∗

●

breather hose operation.
Charge/correct if necessary.

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

∗

Apply “initial 1 month or 400 km (250 mi, 20 hr)”.

∗∗

Initial

1 month

or

800 km

(500 mi)

(40 hr)

Every

Seasonally

or

3,200 km

(2,000 mi)

(160 hr)

●

●

●

●

●

∗∗ ●●

●●

●

●

●

Page

5-6, 6-5

6-4,

8-11–8-12

6-6,

8-18–8-20

6-5

5-3

–

5-4,

6-4, 8-14

8-13

8-13

6-6

6-6

6-6, 8-23

6-6, 8-24

8-2

Pre-

Item Remarks

operation

check

(Daily)

Check engagement and shift
speed.
Adjust if necessary.

Whenever operating elevation is changed.

Inspect sheaves for wear/
damage.

Primary and second-

∗

ary clutches

Inspect weights/rollers and
bushings for wear-for primary.
Inspect ramp shoes/bushings
for wear-for secondary.
Replace if necessary.

Lubricate with specified
grease.

Steering column

∗

bearing

Ski and front

∗

suspension

Suspension

∗

component

Brake cable end and

∗

lever end/throttle
cable end

Shroud latches

Fittings and fasteners

Tool kit and recom­mended equipment

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

∗

Apply “initial 1 month or 400 km (250 mi, 20 hr)”.

∗∗

Lubricate with specified
grease.

Lubricate with specified
grease.

Lubricate with specified
grease.

Lubricate with specified
grease.

Check cable damage.
Replace if necessary.

Make sure that the shroud
latches are hooked.

Check tightness.

Repair if necessary.

∗

Check for proper placement.

●

●

●

Initial

1 month

or

800 km

(500 mi)

(40 hr)

Every

Seasonally

or

3,200 km

(2,000 mi)

(160 hr)

●

●

●

●

●

●

●

●

Page

8-22

8-22

8-22

5-6

6-6

6-7

8-3

ESU01430

Tool kit

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

Tool kit

1

CAUTION

@

:

Before starting the engine, make sure that the tool
kit is firmly seated in the holder and is secured with
the holding band.

@

NOTE:

@

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

@

ESU01441

Spark plug inspection

The spark plug is an important engine component and is
easy to inspect. The condition of the spark plug can indi­cate the condition of the engine. Check the coloration on
the white porcelain insulator around the center electrode.
The ideal coloration at this point is a medium to a light
tan color for a snowmobile that is being ridden normally.
If a spark plug shows a distinctly different color, there
could be something wrong with the engine. For example,
a very white center electrode porcelain color could indi­cate an intake track air leak or carburetion problem for
that cylinder. Do not attempt to diagnose such problems
yourself. Instead, take the snowmobile to a Yamaha
dealer for inspection and possible repairs. You should
periodically remove and inspect the spark plug because
heat and deposits will cause a spark plug to slowly break
down and erode. Consult a Yamaha dealer before chang­ing to a different type of spark plug.

Specified spark plug:

BR9ES (NGK)

8-4

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

Spark plug reach a:

19.0 mm (0.75 in)

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

Spark plug gap b:

0.7–0.8 mm (0.028–0.031 in)

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

Spark plug tightening torque:

20 Nm (2.0 m·kgf, 14 ft·lb)

ESU01461

Engine idle speed adjustment

CAUTION

@

●

Be sure to have a Yamaha dealer make this
adjustment.

●

Make sure that the throttle lever moves smoothly.

@

1. Start the engine.

NOTE:

@

Refer to the “Starting the engine” section.

@

2. Turn the throttle stop screw 1 in or out to adjust the
engine idle speed.

Standard engine idle speed:

1,200 ± 100 r/min

:

8-5

ESU01471

Throttle cable adjustment

CAUTION

@

:

Be sure to adjust the engine idle speed first.

@

1. Loosen the locknut.

2. Turn the adjuster in or out until the proper throttle
lever free play is achieved.

Throttle lever free play a:

1.0–2.0 mm (0.04–0.08 in)

Locknut

1

Adjuster

2

3. Tighten the locknut.

ESU01491

Oil pump cable adjustment

CAUTION

@

Be sure to adjust the throttle cable first.

@

1. Loosen the locknut.

2. Pull the oil pump outer cable and adjust the free play
between the adjuster and outer cable by turning the
adjuster in or out.

:

Pump cable free play a:

25 ± 1 mm (0.98 ± 0.04 in)

Locknut

1

Adjuster

2

3. Tighten the locknut.

8-6

ESU01523

Carburetor adjustment

CAUTION

@

●

Be sure to have a Yamaha dealer make this

:

adjustment.

●

Make sure that the carburetor silencer is installed
before running to prevent engine damage.

@

Under some operating conditions, the carburetor setting
may have to be changed due to air temperature changes,
elevation changes, use of alcohol-oxygenated fuels, etc.,
and should be set by a Yamaha dealer.

CAUTION

@

:

The drive chain gears and V-belt clutch should be
adjusted when operating over a high altitude of
900 m (3,000 ft). Consult a Yamaha dealer.

@

Pilot screw adjustment

Turn the pilot screw in or out to adjust low speed tuning.

Standard pilot screw position:

1 1/4 turns out from the seated position.

CD-02E

Pilot screw Mixture Condition

Turn in Lean

Turn out Rich

Warm weather

High altitude

Cold weather

Low altitude

8-7

Main jet replacement

Replace the main jet according to the setting chart which
is available at a Yamaha dealer.

WARNING

@

●

Never remove the drain plug or the float chamber
while the engine is hot.
Fuel will flow out from the float chamber which
could ignite and cause injury.

●

Place a rag under the carburetor before removing
the drain plug or float chamber to catch any
spilled fuel.

●

Handle fuel with care: it is HIGHLY FLAMMABLE.

@

Standard main jet:

#141.3

CD-04E

Main jet Mixture Condition

Small No. Lean

Large No. Rich

Warm weather

High altitude

Cold weather

Low altitude

1. Loosen the carburetor clamps and turn over the car­buretor.

2. Pinch the fuel hose to prevent fuel flowing.

3. Remove the drain plug and install the proper main jet.

4. Assemble by reversing the removal steps.

WARNING

@

Make sure that the throttle outer cable is firmly
seated in the holder and throttle operates smoothly
after assembling the carburetor.

@

8-8

ESU01570

High altitude adjustments

Operating at high altitude reduces the performance of a
gasoline engine to about 3% for every 305 m (1,000 ft) of
elevation. This is because there is less air as altitude
increases. Less air means less oxygen available for com­bustion.
Your snowmobile can be adjusted to overcome most of
the problems found in high altitude riding. Carburetor
adjustments are the most important. Less air at high alti­tude makes the air/fuel ratio too rich, which can cause
poor performance. Common problems are hard starting,
bogging, and plug fouling. Follow the Main Jet Setting
chart which is available at a Yamaha dealer carefully.
Proper carburetion adjustments will correct the air/fuel
ratio.

Remember:

less horsepower available, even with proper carburetion.
Expect acceleration and top speed to be reduced at
higher altitudes.
To overcome operating with less power at high altitudes,
your snowmobile may also require different settings for
the drive chain gears and V-belt clutch to avoid poor per­formance and rapid wear. If you plan to operate your
snowmobile at an altitude different from the area where
you bought it, be sure to consult a Yamaha dealer. They
can tell you if there are any changes necessary for the
altitude where you plan to ride.

less air at higher altitude means there is

CAUTION

@

:

The drive chain gears and V-belt clutch should be
adjusted when operating over a high altitude of
900 m (3,000 ft). Consult a Yamaha dealer.

@

8-9

ESU01621

Checking the fan belt deflection

1. Remove the fan cover.

2. Measure the fan belt deflection by applying 50 N
(5 kg, 11 lb) of force at the center of belt.

Deflection

1

50 N (5 kg, 11 lb)

2

Standard belt deflection:

8 mm (0.31 in) / 50 N (5 kg, 11 lb)

If the deflection exceeds the specification, consult a
Yamaha dealer.

8-10

ESU01645

V-belt replacement

WARNING

@

●

When replacing the V-belt, make sure that the two
spacers 1 are installed between the secondary
fixed sheave and the secondary sliding sheave.
If the spacers are not positioned correctly, the V­belt clutch engagement speed will be changed
and the snowmobile may move unexpectedly
when the engine is started.

●

Have a Yamaha dealer replace the V-belt and
adjust the gap between the secondary fixed
sheave and the secondary sliding sheave.
Serious injury can occur from the sudden release
of spring tension during sheave disassembly.

@

Belt
width

Spacer
position

CAUTION

@

:

To ensure proper clutch performance as the V-belt
wears, it is necessary to adjust the gap between the
secondary fixed sheave and secondary sliding
sheave by changing the positions of the spacers.
Have a Yamaha dealer make this adjustment.

@

CD-21E

34.4 mm (1.35 in) 33.4 mm (1.31 in) 32.4 mm (1.28 in)

2 spacers between

the sheaves

CD-05E

1 spacer between

the sheaves

No spacer between

the sheaves

New belt width 34.4 mm (1.35 in)

Belt wear limit width 31.4 mm (1.24 in)

8-11

NOTE:

@

Apply the parking brake before replacing the V-belt.

@

1. Remove the drive guard.

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

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

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

5. Install the new V-belt over the primary sheave assem­bly.

6. Rotate the secondary sliding sheave clockwise
and push 5 it so that it separates from the secondary
fixed sheave.

7. Install the V-belt 6 between the secondary sliding
and secondary fixed sheaves.

8. Install the drive guard.

1

4

WARNING

@

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

@

8-12

ESU01674

Checking the drive chain housing oil level and
the drive chain tension

Oil level check

1. Check the oil level by removing the oil level check
bolt1 and filler cap 2. The oil level is correct if a
small amount of oil flows out of the oil level check
hole.

2. If no oil flows out of the oil level check hole, add drive
chain oil until it begins to flow out of the hole.

Drive chain oil: GL-3

75W or 80W

CAUTION

@

:

Make sure no foreign material enters the drive chain
housing.

@

3. Check the filler cap O-ring and the oil level check bolt
gasket.
Replace if damaged.

4. Install the oil level check bolt and filler cap.

Chain tension adjustment

1. Remove the check hole cap and measure the chain
deflection by pushing the chain with your finger.

Check hole cap

1

Standard drive chain deflection a:

8–15 mm (0.3–0.6 in)

If the deflection is not within the specified range, adjust
the chain tension.

2. Loosen the locknut.

3. Turn the adjusting bolt in or out until proper chain
deflection is achieved.

Locknut

2

Adjusting bolt

3

4. Tighten the locknut.

5. Install the check hole cap.

8-13

ESU01762

Checking the brake pads

Check the brake pads for wear by measuring the thick­ness of each pad.
If the brake pads reach the wear limit, have a Yamaha
dealer replace them.

Wear limit a: 9.5 mm (0.37 in)

Adjustment

This snowmobile has a self-adjusting brake caliper. No
adjustment is necessary under normal conditions. If free
play at the brake lever seems excessive or insufficient,
inspection of the brake system is necessary.

WARNING

@

Be sure to have a Yamaha dealer inspect the brake
system.

@

ESU01882

Suspension

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

WARNING

@

Be sure to have a Yamaha dealer make this adjust­ment.

@

8-14

Spring preload adjustment

The spring preload can be adjusted by turning the
adjuster 1.

A

CD-13E

Spring adjuster position 12345

Preload Soft Hard

Standard (front) 3

È

B

CD-14E

Spring adjuster position 1234567

Preload Soft Hard

Standard (rear) 4

É

WARNING

@

This shock absorber contains highly pressurized
nitrogen gas.
It could explode by improper handling, causing
injury or property damage.

●

Do not tamper with or attempt to open the shock
absorber.

●

Do not subject the shock absorber to an open
flame or other high heat sources, which could
cause it to explode.

●

Do not deform or damage the shock absorber in
any way.

●

Do not dispose of a worn or damaged shock
absorber by yourself. Take the unit to a Yamaha
dealer.

@

8-15

Extension spring preload adjustment

Adjust the extension spring preload by turning the
adjuster 1.

CD-22E

Adjuster Turn in Turn out

Preload Hard Soft

Snow condition Icy Soft

Standard length 16 mm (0.63 in)

a

CAUTION

@

:

Be sure the left and right extension spring preloads
are the same. Uneven settings can cause loss of sta­bility.

@

8-16

ESU01973

Rear suspension full rate adjustment

The total suspension spring rate and damping character­istics can be adjusted by changing the installed position
of the shock absorber.

WARNING

@

Be sure to have a Yamaha dealer make this adjust­ment.

@

CD-07E

Installation position S M H

Spring rate and
damping

Soft Medium Hard

Standard S

NOTE:

@

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

@

1. Loosen the full rate adjusting nut 1 1/2 or 3/4 turn,
while holding the adjusting bolt 2 securely with a
wrench so it does not move.

CAUTION

@

:

Never allow the adjusting bolt 2 to move while loos­ening the nut.

@

2. Turn the adjusting bolt 2 to the desired position.

CAUTION

@

:

Make sure that the adjusting bolt ends are set at the
same position on each side.

@

3. While holding the adjusting bolt securely, tighten the
full rate adjusting nut 1.

Full rate adjusting nut tightening torque:

49 Nm (4.9 m·kgf, 35.4 ft·lb)

CAUTION

@

:

Never allow the adjusting bolt to move while tighten­ing the nut.

@

8-17

ESU03530

Drive track adjustment

WARNING

@

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

●

Do not allow anyone to stand behind the snow­mobile when the engine is running.

●

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

●

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

@

Drive track deflection measurement

1. Lay the snowmobile on its side.

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

NOTE:

@

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

@

Deflection

1

100 N (10 kg, 22 lb)

2

Standard drive track deflection:

35–45 mm (1.38–1.77 in) / 100 N (10 kg, 22 lb)

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

8-18

Drive track adjustment

WARNING

@

●

Be sure to have a Yamaha dealer make this
adjustment.

●

Support the snowmobile securely on a suitable
stand before working underneath the snowmo­bile.

●

Operate the engine in a well-ventilated area.

@

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

2. Loosen the rear axle nut 1.

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

4. Check the drive track alignment with the slide runners

. If the alignment is incorrect, align the drive track

2

by turning the left and right adjusters.

CD-08E

Drive track

alignment

Left adjuster Turn out Turn in

3

Right adjuster Turn in Turn out

4

Slide runners

7

Drive track

8

Slide metal

9

Gap

a

Forward

b

Shifted to right6 Shifted to left

5

5. Adjust the drive track deflection to specification.

CD-09E

Drive track

deflection

Left adjuster Turn in Turn out

3

Right adjuster Turn in Turn out

4

CAUTION

@

:

More than

specified

Less than

specified

The right and left adjusters should be turned to an
equal amount.

@

8-19

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

7. Tighten the rear axle nut.

Rear axle tightening torque:

80 Nm (8.0 m·kgf, 58 ft·lb)

ESU02000

Ski alignment

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

2. Check the following for ski alignment:
a. Skis are facing forward.
b. Ski toe-out (1 – 2) is within specification.

Ski toe-out (1 – 2): 0–15 mm (0–0.6 in)

3. If the alignment is not correct, consult a Yamaha
dealer.

8-20

ESU02011

Handlebar adjustment

1. Remove the handlebar cover 1.

2. Loosen the handlebar bolts. Move the handlebar up
or down to adjust the handlebar height to the desired
position.

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

Handlebar bolt tightening torque:

15 Nm (1.5 m·kgf, 11 ft·lb)

CAUTION

@

:

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

@

8-21

ESU02042

Lubrication

Lubricate the following points.

Lubricant:Low-temperature grease

Brake/throttle cable ends

1

WARNING

@

Apply a dab of grease onto the cable ends only. Do
not grease the brake and throttle cables themselves
because they could become frozen, which could
cause loss of control.

@

Front suspension

2

Rear suspension

3

8-22

ESU02112

Headlight bulb replacement

1. Lift up the shroud.

2. Disconnect the lead coupler.

3. Remove the socket cover and bulb set spring.

Socket cover

1

4. Remove the bulb.

WARNING

@

Keep flammable products or your hands away from
the hot bulb until it cools down.

@

5. Install the new bulb.

Bulb type: 12 V, 60/55 W

CAUTION

@

:

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

@

6. Set the spring and install the socket cover, and then
connect the lead coupler.

ESU04000

Headlight beam adjustment

1. Turn the headlight beam adjuster 1 in or out to
adjust the headlight beam.

8-23

ESU02130

Battery

Replenishing the battery fluid

1. Check the fluid level. The level should be between the
upper and lower level marks.

“UPPER LEVEL”

a

“LOWER LEVEL”

b

2. Add only distilled water if necessary.

CAUTION

@

:

Normal tap water contains minerals which are harm­ful to a battery; therefore refill only with distilled
water.

@

WARNING

@

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

●

EXTERNAL: Flush with water.

●

INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg,
or vegetable oil. Call physician immediately.

●

EYES: Flush with water for 15 minutes and get
prompt medical attention.

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

@

8-24

ESU03071

Fuse replacement

WARNING

@

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

@

CAUTION

@

:

Make sure that the main switch is turned off to pre­vent accidental short circuiting.

@

1. Lift up the shroud.

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

NOTE:

@

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

@

Fuse type: 10 A

8-25

ESU02773

9-

TROUBLESHOOTING

A. Engine turns over but does not start

1. Fuel system
No fuel supplied to combustion cham­ber
No fuel in tank ... Supply fuel.

●

Clogged fuel line ... Clean fuel line.

●

Clogged carburetor ... Clean carbure-

●

tor.
Fuel supplied to combustion chamber
Flooded engine (too much choke) ...

●

Crank engine with throttle open or wipe
the spark plugs dry.

2. Electrical system
Poor or no spark
Spark plugs are dirty with carbon or are

●

wet ... Remove carbon or wipe the
spark plugs dry; replace if necessary.
Faulty ignition system ... Ask a Yamaha

●

dealer to inspect.
T.O.R.S. system malfunction ... Discon-

●

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

3. Compression
Insufficient
Loose cylinder head nuts ... Tighten

●

nuts properly.
Worn or damaged gasket ... Replace

●

gasket.
Worn or damaged piston and cylinder

●

... Ask a Yamaha dealer to inspect.

B. Engine does not turn over with the

recoil starter

1. Seized engine ... Seizure is caused by
poor lubrication, inadequate fuel, or an
air leak—Ask a Yamaha dealer to
inspect.

2. “Hydrolock” occurs when fuel has filled
the crankcase when the vehicle has

been transported. ... Remove the spark

plugs and turn the engine over several
times with the ignition off to expel
excess fuel. Ask a Yamaha dealer to
inspect.

C. Electric starter does not operate or

operates slowly

1. Faulty wire connections ... Check con­nections or ask a Yamaha dealer to
inspect.

2. Discharged battery... Check battery
fluid and charge battery.

3. Engine trouble ... Check B above.

WARNING

@

●

Before bypassing the T.O.R.S., make
sure that the throttle returns prop­erly to the fully-closed position.

●

The T.O.R.S. is an important safety
device; in the case of a malfunction,
take the snowmobile to a Yamaha
dealer immediately for repair.

@

D. Engine power is low

1. Faulty spark plugs ... Clean or replace
the spark plugs.

2. Incorrect jetting for altitude or tempera­ture ... Carburetor. Ask a Yamaha
dealer to inspect.

3. Improper fuel flow ... See A.1. above.

4. Incorrect V-belt clutch settings for alti­tude or conditions ... Ask a Yamaha
dealer to inspect.

9-1

E. Engine constantly backfires or mis-

fires

1. Faulty spark plugs ... Replace the
spark plugs.

2. Clogged fuel system ... See A.1. above.

3. Malfunctioning T.O.R.S. system ... See
A.2. above.

F. Snowmobile does not move

1. Malfunctioning V-belt clutch ... Ask a
Yamaha dealer to inspect.

2. Drive track does not move ... Foreign
object is caught in the drive track, or
slide runners have melted to the slide
metal due to lack of lubrication.

3. Tight, loose, or broken drive chain ...
Ask a Yamaha dealer to inspect.

G. V-belt twists

1. Improper V-belt ... Replace with the
correct V-belt.

2. Incorrect V-belt clutch offset ... Ask a
Yamaha dealer to inspect.

3. Loose or broken engine mount ... Ask a
Yamaha dealer to inspect.

3. Worn or sticking primary sheave
assembly ... Ask a Yamaha dealer to
inspect.

4. Worn or sticking secondary sheave
assembly ... Ask a Yamaha dealer to
inspect.

J. Noise or excessive vibration in drive

chain and sprockets

1. Broken V-belt clutch components ...
Ask a Yamaha dealer to inspect.

2. Worn or damaged bearings ... Ask a
Yamaha dealer to inspect.

3. Worn or damaged V-belt with flat spots
... Replace.

4. Worn or damaged idler wheels or
shafts ... Ask a Yamaha dealer to
inspect.

5. Worn or damaged drive track ... Ask a
Yamaha dealer to inspect.

H. V-belt slips or burns

1. Oily or dirty V-belt or primary and sec­ondary sheave assembly surfaces ...
Clean.

2. Problem with the driveline ... See G
above.

I. Engine does not upshift or down-

shift properly or engages harshly

1. Worn or damaged V-belt ... Replace the
V-belt or ask a Yamaha dealer to
inspect.

2. Incorrect V-belt clutch settings for alti­tude or conditions ... Ask a Yamaha
dealer to inspect.

9-2

ESU02523

10-

STORAGE

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

lent fogging oil, to protect both the com­bustion chamber and crankshaft from
corrosion. An alternate method is to
remove the carburetor silencer and squirt
oil into the carburetor throats while the
engine is running.

1. Cleaning

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

2. Lubrication

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

3. Fuel system preparation

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

4. Engine

Proper storage of the engine is essential to
prevent costly rust and corrosion damage
to internal engine components. This is
more important in areas where oxygenated
fuel (gasohol) is used, because the alcohol
content in the fuel increases the chance for
water to enter the engine. Use Yamaha
Stor-Rite Engine Fogging Oil, or an equiva-

CAUTION

@

:

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

@

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

6. Battery
Remove the battery from the snowmobile
and check the fluid level. Add only distilled
water if necessary. (See the “Battery—
Replenishing the battery fluid” section on
page 8-24 for instructions.) After checking
the fluid level, fully charge the battery.
Store it in a cool, dry place that is above
0 °C (32 °F), but less than 30 °C (90 °F).
Check the condition of the battery with a
hydrometer once a month, and charge it as
necessary.

10-1

WARNING

@

●

Never smoke around the battery
while it is being charged. Sparks
may ignite the hydrogen gas created
by the battery.

●

Never connect to or disconnect the
battery from the snowmobile while it
is being charged. Sparks may ignite
the hydrogen gas created by the bat­tery.

●

Make sure that the battery terminals
are tight and that the battery vent
tube is properly routed and is
securely attached to the battery.

@

CAUTION

@

:

Do not charge the battery quickly.
Charge the battery for 10 hours at

1.6 amperes.

@

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

Returning to service after storage

When returning your snowmobile to ser­vice, reinstall the V-belt and adjust the
drive track. Before installing the battery,
have a Yamaha dealer inspect and fully
charge it. Install the battery, and make sure
that the battery vent tube is properly
installed and that there are no kinks in it.
Remove the spark plugs and clean or
replace them if necessary. Perform all
other pre-operation and seasonal mainte­nance checks listed in the periodic mainte­nance chart.
For peak performance, it is recommended
that you have your snowmobile checked
and tuned by a Yamaha dealer. They have
the experience and training to help you get
the maximum performance and use of your
Yamaha snowmobile.

8. V-belt
Remove the V-belt and store separately.

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

10-2

ESU02280

R + M

2

11-

SPECIFICATIONS

ESU02290

Dimensions

CS-01E

VK540E
Overall length 3,125 mm (123.0 in)
Overall width 1,140 mm ( 44.9 in)
Overall height 1,350 mm ( 53.1 in)
Dry weight 289 kg ( 637 lb)
Ski tread 960 mm ( 37.8 in)

ESU02300

Engine

CS-02E

VK540E
Type Axial fan cooled 2-stroke, 7-port
Cylinder arrangement Parallel 2-cylinder
Displacement 535 cm
Bore × Stroke 73.0 × 64.0 mm (2.87 × 2.52 in)
Idle speed 1,200 ± 100 r/min
Engine oil type YAMALUBE 2-cycle oil
Carburetor type MIKUNI, B38-34 × 1
Fuel Unleaded gasoline

3

Pump octane ; 88 or higher

Starting system Electric starter and manual with recoil

starter

11-1

ESU02310

Chassis

CS-03E

VK540E
Drive track and suspension:

Track Molded rubber, fiber glass rod reinforced
Width 500 mm (19.7 in)
Track deflection 35–45 mm (1.38–1.77 in)/

100 N (10 kg, 22 lb)
Length on ground 1,204 mm (47.4 in)
Suspension type Slide Rail Suspension
Drive sprocket Triple polyethylene, 9 teeth

Transmission:

Type Automatic centrifugal engagement, infinite-

ly variable 3.8:1–0.95:1
Sheave distance Approx. 268.5 mm (10.57 in)
Sheave offset Approx. 16 mm (0.63 in)
Engagement speed
Shift speed

∗

∗

Drive chain Triple roller chain enclosed in oil bath
Reduction ratio 39/17 (2.29),

Fuel tank:

Tank capacity 31.0 L (6.8 lmp gal, 8.2 US gal)

Oil tank:

Tank capacity 2.5 L (2.2 lmp qt, 2.6 US qt)

Brake:

Type Caliper type, self-adjusting mechanical disc
Operation Handle lever, left hand operated

Throttle:

Operation Handle lever, right hand operated

Subject to change according to elevation settings.

∗

Approx. 2,600 r/min

Approx. 6,700 r/min

Low: (28/22 × 28/22) × (39/17) = (3.72)

11-2

ESU02320

Electric

CS-04E

VK540E
Ignition system CDI
Spark plug Type BR9ES (NGK)

Gap 0.7–0.8 mm (0.028–0.031 in)

Battery Capacity YB16AL-A2/12 V 16 A·h

Maximum charge rate 1.6 Amperes/hr for 10 hrs
Headlight Bulb × Quantity 12 V, 60/55 W × 1
Tail/brake light Bulb × Quantity 12 V, 8/23 W × 1
Meter light Bulb × Quantity 12 V, 3.4 W× 1

11-3

BGY

PL

HARNESS

SUB-WIRE

B

O

O

Y/B

Y/R

RW/R

BrB/Y

B

Y/B

B/YB/W

W/R

Ch

Y/B

W/R

LB

W

Y/B

YB

W

W/R

Ch

A

B/Y

B/W

W/R

RR

B/W

L

Y/B

B/W

W/R

R

Br

1

WB

7

RR

3

Y/B

Y/R

ON

OFF

B

B/W

R

R/W

Br

B

B/WR/W

Br

ON

OFF

START

R

(10A)

RW

2

R

W

W

R

HEADLIGHT

A

LP

G

Y

B

WIRE HARNESS

(BLACK) (BLACK)

Y/BY/R

C

Br

R

R/W

B

B/W

R

B

Y/RB/Y

D

ON

OFF

0

Y/R

F98

B/YB/W

ON

OFF

OFF

RUN

B/YB/W

B

B

R/W

R/W

L/W

R/W

R

R

R

5

B

B

R

R

4

B

B

E

Ch

B

Ch

B

B

W

Y/R

B

Ch

B/WB/Y

R

6

B

BL

G

LLL

A

L

L

B

L

B

G/Y

ON

OFF

NM

L Br

HI

LO

Y

L

G

G

L

Y

P
PPPL

A

H

L

P

L

P

B

L G/Y

L

L

B

A A

G

G/Y

Br

G/Y

B

I

P

B

P

B

L G/Y B

L G/Y B

B

G/Y

J

B

G/Y

BB

O

G

GYGYGY

K

B

B

Y

BY

G

A

ESU02330

WIRING DIAGRAM

1-

12-1

COLOR CODE

B ................... Black

Br.................. Brown

Ch................. Chocolate

G................... Green

L ................... Blue

O................... Orange

P ................... Pink

R................... Red

W .................. White

Y ................... Yellow

B/W............... Black/White

B/Y................ Black/Yellow

G/Y ............... Green/Yellow

L/W ............... Blue/White

R/W .............. Red/White

W/R .............. White/Red

Y/B................ Yellow/Black

Y/R ............... Yellow/Red

CDI magneto2Rectifier3Fuse4Battery5Starter relay6Starter motor7Main switch8Engine stop switch9Throttle switch0Carburetor switchACDI unitBIgnition coilCGrip and thumb warmer switchDGrip warmer (left)EGrip warmer (right)FThumb warmerGSpeedometerHBack buzzerIGear position switchJTail/brake lightKHeadlightLVoltage regulatorMHeadlight beam switchNBrake light switchOFrame ground

1

12-2

YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER

PRINTED IN JAPAN

2004.04-0.3×1 CR

(E)