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
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