1982-1987 Tech Bulletins
Contents
1. Official Recall Campaign 1980 SS440D SR540D 1981 SS440E SR540E SRX440E S82 008 The affected models listed below are equipped with a suction pipe cap on the top of the fuel tank This cap may have been overtightened at the factory causing possible cracking of the suction pipe neck on the fuel tank to occur Some fuel leakage may thus result when the tank is filled to capacity or the machine is tilted on its side YOU ARE HEREBY NOTIFIED THAT ALL MODELS LISTED BELOW MUST BE FITTED WITH A NEW SUCTION PIPE CAP AND UNDER GO A THOROUGH INSPECTION OF THE FUEL TANK WHICH MUST BE REPLACED AT THE SAME TIME IF ANY SIGNS OF CRACKING ARE FOUND THIS MODIFICATION MUST BE PERFORMED ON BOTH CUSTOMER AND DEALER OWNED MACHINES Owners of the affected models are being notified by mail that their machines require a modification They have been asked to return their machines to an authorized Yamaha dealership for this modification Affected Models and Serial Numbers Assemble the new suction pipe kit as illustrated Note ak 00008 000000 Slip the large hose clamp over the cap lip but do not tighten the clamp at this point see step 8 YAMAH MOTOR CANADA LTD MOTEUR DU CANADA LTEE S82 008 page 2 of 5 2 Drain the fuel from the gas tank Remove the seat from the cap machine and disconnect a the taillight cable tot p Cinna G a i 4 Remove the suction line chip _ suo2. The affected units are filled with coolant at the factory but levels must be checked during predelivery The correct topping up procedure is also outlined below In addition this bulletin gives the proper procedure for bleeding the cooling system This procedure is to be used any time the cooling system is drained AFFECTED UNITS All EX570L PROCEDURE OIL LEVEL SIGHT TUBE 1 Before filling the oil tank disconnect the sight tube from the T fitting 2 Fill the tube from a squirt can containing Yamalube 2 then reconnect the Sight tube and fill the oil tank MOTOR CANADA LTD MOTEUR DU CANADA LTEE YAMAH Bulletin S87 016 Page 2 of 3 COOLING SYSTEM FILLING le Check the coolant levels in the recovery tank and filler neck Add coolant as necessary to bring the levels to the FULL mark on the recovery tank and to the top of the filler neck Replace the recovery tank filler cap FILLER NECK With the track off the ground run the engine at 4000 rpm until the thermostat opens and the coolant freely circulates If the coolant level decreases in the filler neck with the engine running add coolant until the level is once again at the top of the filler neck and replace the cap WARNING To avoid being burned by hot coolant before removing the filler cap always be sure to carefully relieve any pressure build up if the engine has been running WARNING Avoid contact with the moving track Entanglement in the mach
3. ile Remove the primary sheave clutch the exhaust pipe the fuel tank and the engine before proceeding Note i Secure the shroud with a suitable piece of rope to protect against damage ii Drain the fuel tank and disconnect the fuel and oil lines iii Be sure to plug the fuel and oil lines iv Use the following special tools for clutch removal 90890 01878 Sheave puller 90890 01701 Sheave holder v Disconnect all electrical cables coming from the engine vi Disconnect both the throttle and starter cables at the carburetor side Zia Dismount the engine together with the carburetor and the air silencer Note Clean the engine area of the belly pan 3 Drill ten 10 4 1 mm holes 20 drill or 0 16 in in the steering bracket plate at the positions indicated by an open circle on the illustration on the next page Note i Before drilling punch ten 10 guide points and apply cutting oil 4 83 008 15 15 15 15 0 59 0 59 0 59 0 59 ii Take care not to damage the track while drilling iii See the illustra tion on the in struction sheet contained in the kit Spot welded Oo 4 1mm 0 16 in drilled hole for rivetting 4 Rivet the ten 10 positions illustrated using the washers and rivets contained in the kit Note i Use the six 6 washers supplied only at those posi tions indicated by a solid circle on the back side of t
4. 1 Trouble code 8423 2 Quantity l per unit 3 Part number 90891 50057 4 Description Deep Snow Kit 5 Labour time 0 5 hours per unit Note 1 Submit a separate warranty request for each unit modified Do not claim several modifications on the same request form 2 Submit a request only for those units you have actually modified ol val ea mal lt 2 rA da Q Lu Lu g 4 S Lu j l a 1984 PZ480H Z Engine Misfiring and Erratic Headlight Operation S February 29 1984 Engine misfiring and erratic headlight operation of the affected units may be caused by a shorting out of the handlebar wiring harness This may occur at two locations The first is where the harness passes tnrougn the cast handlebar and fairing mount the sharp edges of the mount may penetrate the insulation The second loca tion is where the voltage regulator wire passes between the left body panel and the footrest plate the wire may be pinched Procedures for repositioning the wires are provided below Perform these procedures on all affected units when they are brought in for service In addition follow the procedures below if an affected unit exhibits the symptoms described w Affected Units All PZ480H Procedures A Handlebar Wiring Harness 1 Remove tne handlebar pads and the fairing Handlebar i z iri h 2 Remove tne strap holding the Aaa Dicaceastas handlebar wiring h
5. Official Recall Campaign BR250F 1982 Steering and Slider Modifications September 15 1982 The affected model indicated below may have three possible defects involving the outer steering arms the sheet metal plate which positions the lower portion of the main steering shaft and the forward edge of the track slider frame 1 One defect involves insufficient reinforcement of the outer steering arms which control the movement of the skis Under severe riding conditions these arms may crack or break resulting in partial loss of steering control 2 Another possible defect involves inadequate penetration of the welds securing a sheet metal plate to the body of the snowmobile This plate which positions the lower portion of the main steering shaft may separate from the body under extreme conditions resulting in partial loss of steering control 3 Another defect involves the possibility of the forward edge of the track slider frame entering the openings of the track This may occur in instances of severe frontal impact on a track if the adjustment is too loose i e which is not adjusted to Yamaha s specifications resulting in rapid deceleration of the snowmobile YOU ARE HEREBY NOTIFIED THAT ALL UNITS LISTED BELOW MUST HAVE THE OUTER STEERING ARMS REPLACED ON BOTH SIDES THE SHEET METAL PLATE WHICH ANCHORS THE LOWER PORTION OF THE MAIN STEERING SHAFT MUST BE RIVETED TO THE BODY AND EXTENSION CAPS MUST BE FITT
6. 0 12 in iii Tightening torques are as follows Engine mount bolt 3 0 m kg 22 ft 1lb Engine mount nut 1 4 m kg 10 ft lb Primary sheave bolt first 10 0 m kg 72 5 f t 1b second 6 0 m kg 43 5 ft lb iv If you require further details see the BR250F Service Manual part number 8R4 28197 70 ee ee ee YAMAHA MOTOR CANADA LTD mem mmm ee ee ee ee 4 83 008 page 7 of 7 Parts Ordering All of the necessary parts for a complete modification are packaged as a complete kit Please order the quantity of modification kits you require from your Regional Parts Department MODEL QUANTITY DESCRIPTION PART NUMBER D N BR250F L kit unit BR250F Mod Kit 90891 50026 22 03 Warranty Coverage Parts Allowance The normal policy of dealer net 10 will apply Labour Allowance 40 00 per unit Claims should be submitted on a normal warranty claim form with mention of t chnical bulletin number 83 008 Claim only one unit on each warranty form Submit a claim only for those units you have actually modified m ee VV AMAHA MOTOR CANADA LTD mes mems ee ee es ee ee eee Z onl wal rea ond lt i Oo Wu e Wu g p Q W d d sa Model Year Serial Numbers SS440D 1980 8K4 000101 005650 SS440E 1981 8L8 010101 014252 SR540D 1980 8L0 009101 009553 SR540E 1981 8L9 016101 019113 SRX440E 1981 8M6 000101 001770 Procedure
7. This may cause the washer to catch in the front baffle plate when the hood is opened and closed When performing P D I and set up be sure to check the position of the hood stopper washer and reposition it as per illustration 1 if incorrectly installed Affected Units ALL SR540K s ALL XL540K s INCORRECT CORRECT Warranty Coverage To obtain warranty coverage please indicate the following information on your warranty request form TROUBLE CODE 7090 LABOUR CODE 5613 LABOUR HOURS 0 1 HRS NOTE 1 You may indicate up to ten serial numbers on a single request form provided the model name and trouble codes are the same for all units 2 Submit a warranty request only for those units you have modified YAMAHA MOTOR CANADA LTD MOTEUR DU CANADA LTEE d wal a a lt 2 A pa Q u Lu 4 L W j aul l a CF 300K ADDITIONAL IDLER WHEEL INSTALLATION 86 021 December 23 1985 It has been determined during our early product testing that under certain conditions slider wear on the CF300K may be excessive To eliminate this possibility YOU MUST install the additional idler wheels on this model at Palak If the unit has been retailed and is in use please contact your customer and arrange to have the unit brought in for this modification If the unit has been used check the sliders for wear and if the wear is beyond the limit also replace the slider
8. contained in the kit between the sliding sheave and each of the clutch weights as illustrated Note a After installing the spacers check the clearance between all weights and rollers by pushing the Sliding sheave toward the spider If there is no clearance remove the spacers b Do not forget to place washers on both sides of the weights Install the new primary spring colour code blue green contained in the kit Install the clutch cap and the six cap bolts Be sure to tighten the bolts evenly to specification Note Tightening torque 1 4 m kg 10 ft lb Reinstall the clutch on the machine and tighten the clutch bolt to specification Note Tightening torque A 12 0 m kg 85 ft lb B 6 0 m kg 43 ft lb Tighten the bolt to torque A first to seat the clutch on the taper then loosen the bolt and retorque to the final specification torque B Sheave distance 267 270 mm Sheave offset 10 5 11 5 mm Engagement RPM 3 000 3 400 Shift RPM 6 600 7 000 Bulletin S84 018 page 4 of 4 Final procedure 1 To indicate that the modification has been done put three centre punch marks on the primary sheave holding bolt as illustrated punch marks 2 Make sure that the sled does not creep forward when idling Parts ordering Please order the parts you require from your Regional Parts Department Clutch Mod Kit 90891 50051 1 78 Warranty coverage When completing your warranty request form ma
9. ie Loctite g 7 Nm 0 7 meg 5 1 ft tb j Hi 13 4 Nm 1 3 m kg 9 4 ft lb l Flywheel magneto 2 Flywheel pulley 3 Coil plate Parts Please order the number of spacers you require from your Regional Parts Department DESCRIPTION PART NUMBER QUANTITY DEALER NET 90891 50060 lpc unit Warranty To obtain warranty coverage for this modification please indicate the following information on your warranty request TROUBLE CODE S8515 PARTS as indicated above LABOUR 3 5 hr unit NOTE 1 You may indicate up to 10 serial numbers on a single request form provided the model name and trouble code are the same for all units 2 Submit a request only for those units you have actually modified ood al a wal aq Q pa O Lu y Lu O lt as S Lu ju a this bulletin ET340J EC340J PZ480H J EJ XL540J Shaft 5 Suspension Improvements August 14 1985 The suspension components to be discussed in this bulletin were originally designed for use on the 1984 Phazer model Those components were then improved for greater durability on the 1985 PZ s ET s EC s and XL s A design change on the 1986 Shaft 5 has led to further improvements and reliability Only the newly designed 1986 parts are now available This eliminates confusion for those placing orders and ensures full use of all improvements This bulletin will explain the differences among
10. the 84 85 and 86 Shaft 5 designs and give you the necessary information for ordering and installing the proper parts if replacement should be necessary AFFECTED UNITS 1985 1984 All ET340J s A11 PZ480H s All EC340J s All PZ480J s All PZ480EJ s All XL540J s LOCATION OF SHAFT 5 Shaft 5 is located near the front of the rear suspension system If you have a broken or damaged Shaft 5 replace it with the replacement kit discussed in FORWARD gt YAMAHA MOTOR CANADA LTD MOTEUR DU CANADA LTEE Bulletin S86 015 Page 2 of 4 1985 ET340J EC340J PZ480J EJ XL540J SHAFT 5 REPLACEMENT PROCEDURE Replace parts 1 2 3 4 and 5 on the affected units with the parts in the replacement kit Parts 6 7 and 8 on the affected unit must be reused with the replacement kit 8S AFFECTED UNIT BEFORE REPLACEMENT 85 AFFECTED UNIT AFTER REPLACEMENT NOTE When installing a new Shaft 5 assembly on an 85 use the new shaft to push out the old one This will eliminate the need to remove the entire suspension assembly 1985 PARTS ORDERING NOTE Do not order items 1 5 listed below hea PART NUMBER DESCRIPTION Shaft 5 These parts are superseded Collar by the replacement kit Collar Washer Bolts Collar 4 Reuse these parts Suspension Wheel 2 ea If lost or damaged you must Washer 2 ea reorder these parts Shaft 5 Shaft 5 replacement kit Collar This kit contains items 9 42 N
11. the shroud see illustration on following page Bulletin S84 023 page 4 of 5 Align foam 3 with cowl edge Air cowl foam rubber 3 c Fan Case Sealing 1 Remove the air shroud 2 Clean the areas of the fan case and crankcase where the fan case seals are to be affixed see illustration Fan case Fan case d foam rubber 1 Crankcase Fan case foam rubber 2 Crankcase e lt view A gt cannes Offixing area Bulletin 584 023 page 5 of 5 3 Remove the paper backing from the seals and apply them as shown Note The uppermost seal adheres to the side of the fan case and the lower seal adheres to the crankcase 4 Reinstall the air shroud 2 CARBURETOR SPRAYING Using a water displacing spray such as wo 40 or silicone spray with a long thin nozzle attachment heavily spray the two throttle shaft pivot areas of both carburetors It is essential that all water in these areas be removed to prevent possible throttle sticking After spraying apply a heavy coat of low temperature grease such as ESSO EP Arctic low temperature lithium base grease to all throttle shaft pivot areas Parts Ordering Please order all kits you require from your Regional Parts Department Description Part Number Quantity Dealer Net Deep Snow Kit 90891 50057 5 63 each Warranty Coverage To obtain warranty coverage for this modification indicate the following information on your warranty request form
12. 1W 000646 81W 000651 to 000948 NOTE Be sure to modify only those units listed Procedure 1 Remove choke cable 2 Remove the intake silencer box remove 3 bolts and loosen clamp on carburetor 3 Remove the carburetor NOTE It is not necessary to disconnect all the cables 3 Remove the V belt from the secondary clutch 4 Remove the spring pin shown in illustration 1 from the spring seat and secondary shaft using a pin punch Illustration 1 YAMAHA MOTOR CANADA LTD MOTEUR DU CANADA LTEE NOTE Bulletin S86 018 Page 2 of 3 Be sure to hold the spring seat as the secondary spring preload may cause it to jump out 5 Replace the old spring seat with a new spring seat identified by a blue paint mark TIPS FOR INSTALLING THE NEW SPRING SEAT g Position the secondary shaft so that the spring pin hole is at the top Engage one end of the secondary spring into the sliding sheave and the other into the spring seat Install the spring seat half way onto the secondary shaft by applying continuous force Insert an appropriate punch into the spring pin hole in the spring seat to prevent the spring seat from moving Rotate the sliding sheave 160 degrees approximately 1 2 turn counterclockwise as shown in illustration 2 to set spring preload Illustration 2 Align the spring pin holes in the seat and secondary shaft by sliding in and rotating the spring seat then insert a punch all the way through the se
13. ED TO BOTH LEADING EDGES OF THE TRACK SLIDER FRAME THESE MODIFICATIONS MUST BE PERFORMED ON ALL MACHINES DELIVERED FROM YAMAHA WHETHER NOW OWNED BY THE CUSTOMER OR THE DEALER Owners of the affected models are being notified by mail that their machines require modifications They have been asked to return their machines to an authorized Yamaha dealership or these modifications TC OU m m eV AMAHA MOTOR CANADA LTD me qam m ee es ee Se 83 008 page 2 of 7 Affected Units All 1982 BR250F model snowmobiles between the serial numbers of 8R4 010101 and 8R4 014711 Modification Procedures A EXTENSION CAP INSTALLATION SUSPENSION RUNNERS I Remove the long bolt from F bracket 1 located at the BOLT leading edge of the track Slider frame 2 Install extension caps to both the right and left leading edges of the track slider frame as illustrated LA we 20 Nm 2 0 m kg 14 ft lb Note i Be sure to position the extension caps OMET 1 SLIDING FRAME properly RS ii Cap 6 8R4 47321 00 T SS must be fitted to the left hand side and cap 7 8R4 47322 00 to the right hand side iii See the instruction sheet contained in the kit 3 Adjust the track alignment and SUSPENSION RUNNER tension as specified EXTENSION CAP Track tension 25 30 mm 1 0 1 2 in 10 kg ay Se Sia eee ee S83 008 page 3 of 7 B REPLACEMENT OF OUTER STEERING ARMS AND RIVETING OF STEERING SHAFT BRACKET PLATE
14. ON Please make the following correction to bulletin S84 018 page 3 of 4 procedure item 2 The primary spring contained in the kit is NOT colour coded Eliminate colour code blue green from item 2 ADDITIONAL INFORMATION Contents of clutch modification kit part no 90891 50051 primary spring part no 90501 45534 3 spacers YAMAH MOTOR CANADA LTD MOTEUR DU CANADA LTEE PZ480H Primary Clutch January 4 1984 _page 1 of 4 It has been determined that the PZ480H primary clutch may stick due to slight binding of the spider fingers to the plastic sliders and that the clutch weights may fall toward the engine side when the sled is lifted from the left side When this happens engagement amp shift RPM may become slightly elevated To avoid this the plastic sliders must be removed and filed and a new clutch modification kit must be installed These procedures must be performed during P D I of unsold units or periodic main tenance of units already retailed Affected Models All PZ480H s Procedure for removing and filing the plastic sliders 1 Remove the primary clutch from the machine using the special tool Note Primary sheave puller part no 90890 01898 Primary sheave holder part no 90890 01701 2 Remove the clutch cap by loosening the six bolts then remove the primary spring Caution The primary spring is held under pressure by the clutch cap Loosen the six bolts eve
15. anty period please indicate the following information on your warranty request TROUBLE CODE S8615 PARTS 90891 50061 00 dealer net 10 for handling will be credited to your parts account LABOUR 0 4 hours 1984 Should this replacement be necessary within the normal warranty period please indicate the following information on your warranty request TROUBLE CODE S8615 ae z PARTS 90387 160K7 00 dealer net 10 for handling will be 90891 50061 00 credited to your parts account LABOUR 1 5 hours NOTE You may indicate up to 10 serial numbers on a single request form provided the model name model year and trouble codes are the same for all units 2 Submit a warranty request only for those units whose Shaft 5 has actually been replaced z l l a l lt q O p Q Lid j Lu g Q Ww l m a ET340TRK SECONDARY CLUTCH SPRING SEAT REPLACEMENT November 13 1985 It has been determined that the units listed below have spring seats which do not meet Yamaha engineering standards YOU MUST replace the spring seat before delivering ANY OF THE AFFECTED UNITS to customers If a unit has already been released to a customer the spring seat must be replaced at the first service check CAUTION Customers must be advised that before shifting the snowmobile must be stopped and the engine at idle or damage to the transmission may occur Affected Units ET340TRK 81W 000623 8
16. arness to tne nandlebar and discard the strap 3 Pull the harness away from the nandlebar and inspect the wiring Repair any damage as required 4 Secure the wiring narness to tne speedometer cable using electrical tape Check to ensure that the harness is no longer touch ing any sharp edges if necessary use some emery paper to take off the sharp edges regulator lead 5 Reinstall the fairing and nandlebar pads YAMAH MOTOR CANADA LTD MOTEUR DU CANADA LTEE Bulletin S84 024 page 2 of 2 B Voltage Regulator Lead 1 Reposition the voltage regulator lead in front of the footrest plate Warranty Coverage To obtain warranty coverage for this modification indicate the following information on your warranty request form 1 Trouble code S8424 2 Labour time 0 6 hours per unit Note 1 Submit a separate warranty request for each unit modified Do not claim several modifications on the same request form 2 Submit a request only for those units you have actually modified La BULLETIN TECHNIQUE TECHNICAL BULLETIN 1984 VMX540H C D I MAGNETO STATOR PLATE September 19 1984 machined properly It has been determined that the water pump case cever has not been This results in uneven seating of the C D I magneto stator plate and may cause the plate to become cracked or damaged through engine vibration A spacer 90891 50060 which eliminates the uneven seating must be insta
17. at and shaft Rotate the secondary clutch 180 degrees so that the punch points up from the bottom and apply the parking brake 6 Insert the new spring pin contained in the kit through the spring seat to lock the seat onto the secondary shaft NOTE Wiggle the punch to align the holes in the seat and shaft 7 Reinstall the carburetor silencer box choke cable belt and guard Bulletin S86018 Page 3 of 3 PARTS ORDERING Please order the kits you require from your Regional Parts Department PART NUMBER DESCRIPTION QUANTITY REMARKS DLR NET 90891 50071 Spring kit seat 1 kit unit Includes 9 79 spring seat 1 pc ramp shoe 3 pcs spring pin 1 pc WARRANTY To obtain warranty coverage for this modification please indicate the following information on your warranty request form TROUBLE CODE 8618 PARTS 90891 50071 LABOUR 0 5 HRS NOTE 1 You may indicate up to 10 serial numbers on a single request form provided the model name and trouble codes are the same for all units 2 Submit a warranty request only for those units you have modified 3 You must enclose the defective spring seat with your warranty request form l zl ao val a lt rA p Q W Lu gt g n Q W W l i a SR540K XL540K HOOD STOPPER WASHER November 27 1985 It has been determined that the hood stopper washer has been installed incorrectly on some units
18. equest for each unit Do not list several units on one request form c Submit a request only for those units in which you have actually installed a front axle bearing retainer z l l a l lt o ra da S Lu l Ww g r L W j z l aa OFFICIAL RECALL CAMPAIGN P2480H 1984 SNOWMOBILE Throttle Shafts Sticking S84 023 January 26 1984 The affected units listed below may encounter icing of the carburetor throttle shafts under certain riding or weather conditions If this occurs the engine will not return to its normal idle speed and partial loss of machine control could result This problem may be encountered while the machine is being ridden or when first started after it has been sitting idle for a period of time IN ACCORDANCE WITH THE LEGISLATION SET OUT IN THE CANADIAN MOTOR VEHICLE SAFETY ACT YOU ARE HEREBY NOTIFIED THAT ALL UNITS LISTED BELOW MUST BE FITTED WITH A DEEP SNOW KIT AND THE THROTTLE SHAFTS MUST BE CLEANED AND LUBRICATED WITH A LOW TEMPERATURE GREASE THIS MODIFICATION MUST BE PERFORMED ON ALL CUSTOMER AND DEALER OWNED MACHINES AND ALL MACHINES SUBSEQUENTLY DELIVERED FROM YAMAHA Owners of the affected machines are being notified by mail that their machines require a safety related modification They have been asked to return their snowmobile to an authorized Yamaha snowmobile dealer for the modification and have been advised to avoid riding their snowmobiles un
19. he belly pan ii No washers are to be used at the remaining four 4 positions indica tec by an open circle 0 vama ua MAOTAR CANADA LTD men mm ee ee ee ee eee eee a S83 008 page 5 of 7 iii See the illustration on the instruction sheet contained in the kit 5 Remove the old outer steering arms 6 Install new outer steer ing arms as illustrated using the new washers nuts and cotter pins contained in the kit 30 Nm 3 0 m kg 22 ft Ib Note i Do not re use the old nuts washers and cotter pins ii The old outer steering arms a must be destroyed iii The new and old outer steering arms can be distinguished from one another by comparing them with the illustra tions shown opposite iv See the instruction sheet contained in the kit lt gt gt x gt O e D g gt 2 gt o gt rm o s A a ap A aaa ees 83 008 page 6 of 7 Te Adjust the ski centre to centre distance and toe out Centre to centre 750 mm 29 5 in Toe out 0a 6 mm 04 0 23 in ate Front p 1 Ski spindle center A C 0 6 mm 0 0 23 in A Dy B J j B Ski width mil 8 For reassembly reverse the above procedure Note i Bleed the air from the Autolube pump ii Be sure to adjust sheave centre to centre and offset as follows Centre to centre 266 2 0 mm 10 47 0 08 in offset 11 0 3 0 mm 0 43
20. he suc tion line to the pipe Be sure to secure the line in place with the clips removed earlier Rubber Cap Fuel Tank Reconnect the taillight cable and reinstall the E solani Aluminum Pipe Parts Ordering The following parts are required to perform this modification MODEL QUANTITY DESCRIPTION PART NUMBER SS440D SS440E SR540E 1 kit unit Suction Pipe Kit 90891 50012 SS440D SS440E 1 pc unit Fuel Tank 8K4 24111 00 SR540D SR540E SRX440E l pe unit 8M6 24111 00 Order the parts you require from your Regional Parts Department PLease Take Note It is estimated that only 5 of all affected units will require a new fuel tank Order these parts only if necessary However you must order one Suction Pipe Kit for every unit brought to your dealership for modification S82 008 page 5 of 5 Warranty Coverage Submit a claim for each unit modified Calculate parts and labour using the following table Job Suction Pipe Suction Pipe amp Fuel Tank Replace Description Replacement Fuel Tank Replacement ment after Suction only at same time Pipe has been replaced SS440D SS440E SR540D SR540E 8 00 unit 11 00 unit 3 00 unit sage 15 00 unit 18 00 unit 3 00 unit Submit a ckhaim onky gor those units you have actually modified BULLETIN TECHNIQUE TECHNICAL BULLETIN PZ480H Correction to clutch modification bulletin S84 018A January 11 1984 CORRECTI
21. in at the top of the filler neck and replace the cap and seat WARNING Avoid contact with the moving track Entanglement in the machinery of shop towels clothing or body parts could result in serious injury WARRANTY INFORMATION These procedures are part of normal predelivery service No special warranty allowances applies
22. inery of shop towels clothing or body parts could result in serious injury COOLING SYSTEM BLEEDING PROCEDURE its for any reason the cooling system is drained it is essential when refilling the system that all air be removed using the following method le Remove the seat and both filler caps and add coolant as necessary to bring the levels to the FULL mark on the recovery tank and to the top of the filler neck Replace the recovery tank cap HEAT EXCHANGER BLEED BOLT pen Bulletin S87 016 Page 3 of 3 COOLING SYSTEM BLEEDING PROCEDURE CONT D 2 Loosen do not remove the bleed bolt at the left side of the rear heat exchanger and allow coolant to run out until all air bubbles disappear from the coolant 3 Tighten the bleed bolt and replace the lost coolant CYLINDER HEAD BLEED BOLT O THERMOSTAT HOUSING 4 Loosen do not remove the bleed bolt on the cylinder head and once again allow coolant to run out until all air bubbles disappear 5 Tighten the bleed bolt and replace the lost coolant WARNING To avoid being burned by hot coolant before removing the filler cap always be sure to carefully relieve any pressure build up if the engine has been running 6 With the track off the ground run the engine at 4000 rpm until the thermostat opens and the coolant freely circulates If the coolant level decreases in the filler pipe with the engine running add coolant until the level is once aga
23. ke sure you clearly show Trouble code 8418 Parts 90891 50051 Labour code 7001 Time 0 6 hours Note a Submit a separate warranty request for each unit modified Do not claim several modifications on the same request form b Submit a request only for those units you have actually modified z al l a l lt Q w jem W E lt Q Lu l l a 1984 EC340H Excel IIT Front Axle Bearing Retainer October 26 1983 It has been determined that the front axle bearing retainer has not been installed on affected models This may cause damage to the bearing the speedometer gear or the front axle when the snowmobile is driven A front axle bearing retainer 8F3 47551 00 MUST be installed on all affected units mentioned below whether new or already sold Affected Unit Serial Range EC340H Excel III 8W8 14655l1 146750 Procedure l Inspect the right hand front axle area of the engine compartment to determine whether the bearing retainer has been installed or not NOTE a If three plates are located in this area there is no need to proceed b If one plate is missing from the right hand front axle proceed as follows Front Axle Speedometer missing Gear Housing Front Axle Bearing Retainer Inside Bearing Retainer YAMAH MOTOR CANADA LTD MOTEUR DU CANADA LTEE Bulletin S84 015 page 2 of 3 2 Remove the fancase cover by lo
24. lled on all 1984 VMX540H units whether new or already sold Please contact owners of delivered units so that this modification may be done Affected Units All 1984 VMX540H units Procedure First remove the engine from the chassis To save time you may choose to remove only those components which allow the right hand end of the motor to be tilted for access to the recoil starter and magneto Remove the four bolts holding the recoil starter Remove the three bolts holding the starter pulley Using the flywheel puller remove the flywheel magneto rotor and key Using a hand impact tool remove the magneto stator plate bolts and check the stator for any cracks or damage Install the spacer between the stator plate and the pump cover as shown below Stator plate AAAS 3 PAS Pump cover f Spacer 90891 50060 YAMAHA MOTOR CANADA LTD MOTEUR DU CANADA LT E Bulletin S85 015 Page 2 of 3 NOTE The spacer must be installed with the open ends positioned as shown below Spacer 90891 50060 Pump drive cover 7 Reassembly is the reverse of disassembly Remember to apply Loctite to the stator plate bolts NOTE Reset a Ignition Timing 1 6 6 05 mm 0 063 6 002 in b Sheave centre to centre 305 1 5 mm 12 01 0 06 in c Sheave offset 1 2 0 5 mm 0 433 0 02 ans Bulletin S85 015 Page 3 of 3 70 75 Nm i 17 0 7 5 m kg 50 6 54 2 ft ib paa ee
25. nly in stages to prevent the cap from being jammed to one side 3 Remove the three plastic sliders by carefully inserting a flat screwdriver under them and prying them up z l l a lt S lt Q W b LL g 4 ka Q m z l d a Note It is not necessary to remove the sliding sheave from the spider post YAMAH MOTOR CANADA LTD MOTEUR DU CANADA LTEE 4 5 6 8 9 Bulletin S84 018 page 2 of 4 Using a small half round file remove a small amount of material from both corners of each spider finger as illustrated Note Before filing place enough rags around the sliding sheave bushing to prevent filings from entering the sheave File around six corners Use compressed air to blow the metal filings and dirt out of the clutch Caution Wear eye protection whenever using compressed air to avoid injury Spray contact cleaner on both sides of the sliding sheave bushing and its contact area on the post to remove all dirt and grease Again use compressed air tc blow the metal filings and dirt out of the clutch Check the plastic sliders for burrs and file until smooth See illustration below File around corner Reinstall the sliders and check for smooth movement of the spider within the sliders PY 1 2 3 4 Bulletin S84 018 page 3 of 4 ocedure for installing spacers and primary spring from kit Install the three spacers
26. osening the three screws NOTE The two bottom screws must be loosened first to prevent the washer behind the fan case cover at the top screw from coming loose screw THREADED WASHER gt ai c T F ant Se Soy ia 7 SE N canoe TARTER ASSY SECTION A A y G 3 Remove the battery and the starter solenoid switch bracket 4 Elevate the right side of the machine by placing a suitable box under the right ski 5 Remove the speedometer gear housing 6 Install the front axle bearing retainer together with the speedometer gear housing NOTE a Make sure the speedometer drive coupler is properly installed in the speedometer gear housing b Tightening torque 2 3 kg m 16 ft lb 7 Install the starter solenoid switch bracket the battery and the fancase cover Parts Ordering Please order the number of front axle beraing retainers you require from your Regional Parts Department Description Part Part Number Quantity Dealer Net Front axle 8F3 Ee 00 l pc unit 1 46 bearing retainer Warranty IMPORTANT Parts Labour NOTE Bulletin S84 015 page 3 of 3 Warranty coverage will be given only when the entire procedure is performed Dealer net plus 10 will be credited 0 5 hours of labour will be credited a Bulletin number S8415 should be indicated in the trouble code area of the warranty request form b Submit a separate warranty r
27. s Affected Units All CF300K s ADDITIONAL WHEEL LOCATION APPLY LOCTITE TIGHTENING TORQUE 17 Nm 1 7 m kg 12 ft 1b YAMAH MOTOR CANADA LTD MOTEUR DU CANADA LTEE Bulletin S86 021 Page 2 of 2 PARTS ORDERING PART NUMBER DESCRIPTION QUANTITY DEALER NET 8K2 47320 00 Suspension Wheel Comp 93306 00416 Bearing 2 pcs unit CO ee eee ee ee 99009 42500 Circlip 2 pcs unit 90201 08681 Washer 2 pes unit 90109 08559 Bolt 2 pcs unit 2 pcs unit WARRANTY To obtain warranty coverage for this modification please indicate the following information on your warranty request form TROUBLE CODE 8621 PARTS As Listed LABOUR 0 2 Hrs Note 1 Submit a warranty request form only for those units you have modified 2 For units requiring slider replacement You must submit a separate request form for each unit including the the old parts The unit must have been registered No consideration will be given to requests received by Toronto Warranty Department after January 31 1986 BULLETIN TECHNIQUE TECHNICAL BULLETIN EX570L SPECIAL PREDELIVERY SERVICE PRECAUTIONS October 29 1986 When the oil tank is first filled on the affected units there may be a long delay before the oil level registers in the sight tube This is because of the viscosity of the oil and the fact that the sight tube is dry The simple procedure below eliminates this delay
28. til the modification has been carried out If you have not submitted a warranty registration card for any PZ480H units you have sold you should do so immediately Failure to comply could make you liable for any damages caused due to the above defect Affected Model and Serial Number Range Model Year Serial number range PZ480H 1984 8V0 019101 to 020107 YAMAH MOTOR CANADA LTD MOTEUR DU CANADA LTEE Bulletin S84 023 page 2 of 5 MODIFICATION PROCEDURE 1 INSTALLATION OF DEEP SNOW KIT Note Before installing the kit please read the instructions contained in the kit a Front Baffle Plate 1 Affix the warning label to the front baffle plate as shown Baffle plate Warning label 2 Install the baffle plate onto the front of the hood using the hood hinge securing screws see illustration Baffle plate Screw Caution This baffle plate must be removed when the_machine is operated at temperatures greater than 0 C Bulletin S84 023 page 3 of 5 b Air Shroud Sealing 1 Clean the areas of the air shroud where the three foam rubber seals are to be affixed see illustrations Air cowl foam rubber 2 j Align foam 2 with side and horizo edge of cowl Air cowl foam rubber 1 Align foam 1 with cowl edge Air cowl foam rubber 2 Remove the paper backing from the seals and apply them as indicated Note The right rear seal must be positioned so that 3 mm of seal material extends below
29. tin tine and the suction pipe cap from the gas tank and remove the fuel filter pipe assembly from the suction pipe cap chip m guel filter Note Do not lose the clips as they must be re Aad used during this procedure 5 Inspect the neck threaded area of the suction pipe cap for cracks If no cracks are found the fuel tank does not need replacing proceed to step 6 If cracks are found the fuel tank must be replaced before proceeding to step 6 example og Note cracking The instrument panel and suction pipe louvers on the SRX440E neck must be removed before this inspection can be done S82 008 6 Install the fuel filter f onto the new suction gt pipe assembled in step one 7 Clean the neck threaded area of the suction pipe cap and apply Three Bond 1215 to the threads as illustrated X Three Bond lotes 1215 A tube of Three Bond 1215 will be shipped to you automatically One tube of Three Bond iia a ti can be used for approxi ae EA mately 60 units 3 Three Bond 8 Install the suction e 1 seal completely pipe onto the gas tank A and tighten the large hose clamp as illustrated Note Make sure to leave 40 mm 1 57 in at the end of the clamp Do not leave more or less than is specified S82 008 Di Turn the aluminum pipe so that it faces left as shown in the illustration and then connect t
30. ut Cotter pin 6 7 8 a 90891 50061 00 NOTE Replace Shaft 5 only if failure occurs This is not a modification campaign Bulletin S86 015 Page 3 of 4 1984 PZ480H SHAFT 5 REPLACEMENT PROCEDURE NOTE Due to the design of Shaft 5 on 1984 Phazers it is necessary to remove the suspension assembly to make the replacement of Shaft 5 easier Replace parts 1 2 3 4 and 5 on the affected units with the parts in the replacement kit Order part 6 The Shaft 5 assembly design on 1984 Phazers does not include this collar over the centre of the shaft However this part is necessary with the new style shaft and must be ordered from your Regional Parts Department in addition to the replacement kit Parts 7 and 8 on the affected unit must be reused with the replacement kit 64 PHAZER BEFORE REPLACEMENT 84 PHAZER AFTER REPLACEMENT 1984 PHAZER PARTS ORDERING NOTE Do not order items 1 5 listed below iat 90387 160M7 00 eaa This part must be ordered Suspension Wheel 2 ea Reuse these parts If Washer 2 ea damaged you must reorder these parts Shaft 5 replacement kit 90891 50061 00 This kit contains items 9 42 NOTE Replace Shaft 5 only if failure occurs This is not a modification Campaign These parts are superseded by the replacement kit Bulletin S86 015 Page 4 of 4 WARRANTY 1985 Should this replacement be necessary within the normal warr
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