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SUPPLEMENTARY SERVICE MANUAL

1. 80 Right handlebar switch 2 Handlebar holder 3 Throttle cable Pass all of the leads and cables through the guide except the parking brake cable Do not pass the brake hose through the guide 5 Fasten the wire harness with the plastic band 6 Parking brake cable 7 Left handlebar switch Starter cable Pass the starter cable over the left handle leads 9 Speed sensor coupler Lead cover Route the fuel tank breather hose along the frame cross member 2 Radiator fan motor coupler 3 Fuel sender coupler There should be no slack in the radiator fan motor lead Fasten the relay lead speed sensor lead and radiator fan motor lead with the plastic band Fasten the compression spring section of the fuel tank breather hose with the holder 2 Route the float chamber air vent hoses behind the battery bracket Face the ends of the clamp upward Install the fuel tank breather hose onto the breather pipe making sure that it contacts the running board support Back buzzer relay Passenger grip warmer relay Radiator fan motor relay 3 To the speed sensor To the oil tank Negative battery lead 08 To the par
2. Chain drive right 24 500 24 521 mm 0 9646 0 9654 in 24 459 24 472 0 9630 0 9635 in 0 028 0 062 mm 0 0011 0 0024 33 75 33 85 mm 1 3287 1 3327 in 33 65 mm 1 3248 in 24 95 25 05 mm 0 9823 0 9862 in 24 85 mm 0 9783 in 33 75 33 85 mm 1 3287 1 3327 in 33 65 mm 1 3248 in 24 95 25 05 mm 0 9823 0 9862 in 24 85 mm 0 9783 in 0 03 mm 0 0012 in Timing chain Model Number of links Tensioning system 98XTRH2005 140 Automatic 52 MAINTENANCE SPECIFICATIONS SPEC ye Model Valves valve seats valve guides Valve clearance cold Intake 0 15 0 22 mm 0 0059 0 0087 Exhaust 0 21 0 25 mm 0 0083 0 0098 in Valve dimensions Valve head diameter A Intake 29 9 30 1 mm 1 1771 1 1850 in Exhaust 25 9 26 1 mm 1 0197 1 0276 in Valve face width B Intake 1 90 2 62 mm 0 0748 0 1031 in Exhaust 1 90 2 62 mm 0 0748 0 1031 in Valve seat width C Intake 0 9 1 1 mm 0 035 0 043 in Exhaust 0 9 1 1 mm 0 035 0 043 in Valve margin thickness D Intake 0 8 1 2 mm 0 0315 0 0472 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake 4 975 4 990 mm 0 1959 0 1965 in lt Limit gt 4 945 mm 0 1947 in Exhaust 4 965 4 980 mm 0 1955 0 1961 in lt Limit gt 4 935 mm 0 1943 in Valve guide inside diame
3. 88 To the starter motor Starter motor positive lead Negative battery lead 2 Positive battery lead 5 Ignitor unit Ignitor unit bracket C Air filter case latch Battery band 9 Battery cover To the carburetor Wire harness 2 Battery bracket 89 CABLE ROUTING SPEC CABLE ROUTING SPEC ue 90 Forward 2 Wire harness Battery bracket 2 To the air filter case 5 magneto lead Route the crankcase breather hose inside of the wire harness and then over the starter motor positive lead and under the bat tery bracket Crankcase breather hose Face the paint mark towards vehicle outside 91 CABLE ROUTING SPEC CABLE ROUTING SPEC ue 92 Fasten the passenger grip warmer lead with the plastic band making sure that the end of the band is on top of the pipe and facing rearward The plastic band should not be visible when the passenger seat is installed Route the passenger grip warmer lead along the groove in the storage compartment Route the passenger grip warmer lead along the groove in the storage compartment m
4. COOLING SYSTEM 6 v CARBURETION EN 7 ELECTRICAL up SPECIFICATIONS GENERAL INFORMATION SPECIAL TOOLS 1 FOR ELECTRICAL SERVICE 1 PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION 2 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 2 GENERAL MAINTENANCE AND LUBRICATION 3 POWER TRAIN 5 DRIVE V BELT een 5 BRAKE PAD INSPECTION 7 AIR BLEEDING HYDRAULIC BRAKE 7 DRIVE CHAIN o ee 8 TUNING ernste 11 11 GEAR SELECTION 12 HIGH ALTITUDE TUNING 18 POWER SHIFT LEVER naan 19 INSTALLATION ees 21 DRIVE CHAIN HOUSING e 22 REMOVAL LAE 25 INSPECTION 25 INSTALLATION etn 27 SECONDARY SHAFT ansssawass 29 SECONDARY SHAFT AND DRIVE CHAIN HOUSING 29 BRAKE nu kaan dt ed 31 BRAKE PAD REPLACEMENT 32 BRAKE CALIPER DISASSEMBLY 36 BRAKE CALIPER INSTALLATION 36 FRONT AXLE AND TRACK 37 INSTALLATION ener 37 ENGINE 22 2 1 4 74 4 4 4 1 38 INSTALLATION iri
5. Apply bond TB1541 1 onto the mating surfaces of the cylinder head cover and cylinder head cover gasket e Apply Sealant Quick Gasket or Yamaha bond No 1215 2 onto the mating surfaces of the cylin der head cover gasket and cylinder head Tighten the cylinder head cover bolts stages and in a crisscross pattern CARBURETORS CARB CARBURETION CARBURETORS 2 pu 2 pu 3 EE Go 1 qc Bd Q gt E tr For installation reverse the removal proce Job name Part name Carburetor separation Sub wire harness 3 Carburetor heating hose Fuel delivery hose Float chamber air vent hose Vacuum hose Spring Starter plunger link Connecting bolt Throttle position sensor Carburetor O O O 43 CARBURETORS CARB D THROTTLE POSITION SENSOR T P S INSPECTION AND ADJUSTMENT NOTE lt _ ns Before adjusting the throttle position sensor prop erly adjust the idle speed 1 Inspect Throttle position sensor Inspection steps e Disconnect the throttle position sensor coupler Connect the pocket tester 2 x 1k to the throt tle position sensor coupler Positive tester probe Blue 1 Negative tester probe 5 Black 2 Check the throttle position sensor resistance Throttle position sensor resistance Ry 4 6 KQ at 20 C 68 F Blue Black
6. White Black W G White Green W R White Red White Y ellow YIB Yellow Black Yellow Blue Yellow Red YAMAHA YAMAHA MOTOR CO LTD DARK GREEN CE de m GR BH BLACK l L gt o Sw O B 0 B n i i i i i i i i i i i i i i i DIA Y ISA XXX CO Lg D E n gt g E g m 12 B Y WIG R W B W Br B L Bun gt lt SUB WIRE HARNESS 3 N N ke WIRE HARNESS A R RM Br Br R AC UR 0 G B TAILIBRAKE LIGHT SUB WIRE HARNESS 1 EE A ele WIRE HARNESS 15A
7. 5 Throttle valve Th V Valve seat size V S Starter jet G S Float height F H Fuel level below the line on the float cham ber Throttle cable free play Engine idle speed CVK40 3 KEIHIN 8ES1 02 148 70 N425 BSJOO W9554 26538 6 45 120 0 9 0 8 0 8 0 8 0 8 0 8 1020 B70 80 6 10 1 9 70 16 0 630 0 2 2 2 mm 0 008 0 087 in 2 0 3 0 mm 0 08 0 12 in 1 300 1 500 r min Fuel pump Type Diaphragm Manufacturer 8FA MIKUNI Oil filter Oil filter type Cartridge paper Bypass valve opening pressure 78 118 kPa 0 78 1 18 kg cm 11 1 16 8 psi Oil pump Oil pump type Trochoidal Inner rotor to outer rotor tip clearance Outer rotor to oil pump housing clearance Relief valve operating pressure Oil pressure hot 0 09 0 15 mm 0 004 0 006 in 0 03 0 08 mm 0 001 0 003 in 440 560 kPa 4 4 5 6 kg cm 62 6 79 6 psi 45 kPa 0 45 kg cm 6 40 psi at 1 400 r min Cooling system Filler cap opening pressure Thermostat opening temperature Valve lift Water pump type Reduction ratio Coolant type Coolant mixing ratio coolant water Capacity Max impeller shaft tilt Limit 93 3 122 7 kPa 0 93 1 23 kg cm 13 2 17 5 psi 80 84 C 176 183 F 7 0 mm 0 28 at 95 203 F Single suction centrifugal pump Impeller type 22 28 0 786 High quality silicate free ethylene glycol antifreeze co
8. BLACK HEADLIGHT SUB WIRE HARNESS 2 R 15A G ve ve a un wy Jur BLACK WIRE HARNESS WIRING DIAGRAM VK10W 2007 scs oroo1 00 GA aaa 20 ch B Y G B HEADLIGHT SUB WIRE HARNESS 1 GA G B a BN WIRE HARNESS
9. Steering column bearing Lubricate with specified grease Ski and front suspension Lubricate with specified grease Suspension component Lubricate with specified grease Lubricate with specified grease Check cable damage Replace if necessary Shroud latches Make sure that the shroud latches are hooked Check tightness Repair if necessary Parking brake cable end and lever end throttle cable end Fittings and fasteners Tool kit and recommended equipment NOTE Brake system After disassembling the master cylinder or caliper cylinder always change the brake fluid Regularly check the brake fluid level and add fluid if necessary Replace the oil seals of the master cylinder and caliper cylinder every two years Replace the brake hose every four years or if cracked or damaged Check for proper placement wma NC INSP DRIVE V BELT POWER TRAIN DRIVE V BELT WARNING When installing the new V belt make sure that it is positioned from 1 5 mm 0 06 in above the edge of the secondary sheave to 0 5 mm 70 02 in below the edge If the V belt is not positioned correctly the clutch engagement speed will be changed The machine may move unexpectedly when the engine is started Adjust the V belt position by removing or add ing a spacer 1 on each adjusting bolt CAUTION As the V belt wears adjustment may be neces sary
10. YAMAHA FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the VK10W For complete information on service procedures it is necessary to use this Supple mentary Service Manual together with following manual RS90K RS90RK RSG90K RS90MK RST90K RST90TFK SERVICE MANUAL 8FJ 28197 10 981096 LIT 12618 02 38 VK10L SUPPLEMENTARY SERVICE MANUAL 8FN 28197 10 LIT 12618 02 42 VK10W SUPPLEMENTARY SERVICE MANUAL 2006 by Yamaha Motor Corporation U S A 1st Edition July 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 12618 02 57 This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics It is not possible to put an entire mechanic s education into one manual so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understanding of the mechanical concepts and procedures inherent snowmobile repair Without such knowledge attempted repairs or service to this model may render it unfit and or unsafe to use This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions Proper service with the correct tools is necessary to ensure that the vehicle wil
11. Approx 8 500 r min lt lt lt lt Pilot jet Pilot screw Refer to HIGH ALTITUDE SETTINGS in MAINTENANCE SPECIFICATIONS Secondary reduc tion ratio number of links 20 39 68 1 19 39 68 L Primary sheave spring 90501 550A2 90501 580A1 Color W L W L Y L Free length 82 3 mm 3 24 in 81 4 mm 3 20 in Preload 196 N 20 kg 44 Ib Spring rate 22 1 N mm 2 25 kg mm 126 Ib in 24 5 N mm 2 5 kg mm 140 Ib in Wire diameter 5 5 mm 0 217 in 5 8 mm 0 228 in Outside diameter 59 5 mm 2 34 in lt lt lt lt Weight ID 8FN 17605 00 8FNOO lt lt Weight rivet Steel 17 2 OUT Steel 17 2 with hole OUT Steel 13 3 with hole OUT Aluminum 13 3 with hole OUT None OUT Steel 17 2 with hole IN Steel 17 2 with hole IN Steel 13 3 with hole IN Aluminum 13 3 with hole IN None IN Weight bushing VESPEL TP 8549 Roller outer dia 15 6 mm 0 61 in Roller bushing VESPEL TP 8549 Pri clutch shim None Secondary sheave spring 90508 60012 Color P Free length 75 mm 2 95 in Preload rate 602 3 3
12. 38 CARBURETORS cette ttn 43 THROTTLE POSITION SENSOR T P S INSPECTION AND ADJUSTMENT 44 ELECTRICAL SIGNAL SYSTEM 46 CIRCUIT DIAGRAM 46 TROUBLESHOOTING 48 GEAR POSITION SWITCH 49 GEAR POSITION SWITCH RELAY 49 SPECIFICATIONS GENERAL SPECIFICATIONS 50 MAINTENANCE SPECIFICATIONG 52 ENGINE ann 52 POWER TRAIN mm 57 CHASSIS mtd dina 60 ENEE 61 HIGH ALTITUDE SETTINGS 64 TIGHTENING 66 ENGINE eebe 66 POWER TRAIN iia 68 ER 70 GENERAL TORQUE SPECIFICATIONS 71 DEFINITION OF UNITS 71 CABLE ROUTING 72 SPECIAL TOOLS a GENERAL INFORMATION SPECIAL TOOLS Some special tools are necessary for a completely accurate tune up and assembly Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques NOTE Be sure to use the correct part number when ordering the tool since the part number may differ according to country e For USA and Canada use par
13. 0 63 VESPEL J Grooved 4 Grooved i 1 90386 09001 14 6 mm 8FG 17624 40 16 5 0 65 VESPEL Machined TP 8549 90386 09001 14 6 17 lt Decreased force HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions carefully tune the snowmobile as outlined below INSP HIGH ALTITUDE TUNING ADJ Check STD settings Carburetors Spark plugs Adjust the main jet size according to the chart Testthe mainjet Not OK Adjust the size of the main jet performance 8 plug color OK Re test Not Test the low speed setting E Adjust the engine Check to see if the gearing is too high idle speed by or low Not OK turning the stop screw of carbure tor OK Y Try high altitude settings Adjust the engine idle speed by turning the stop screw of carburetor OK Not OK Decide if the problem is with the pilot Check the engagement speed and jet and adjust accordingly shift performance High altitude Not OK OK B OK tuning OK A Adjust the primary clutch as OK required Not OK Not OK Adjust the secondary clutch as OK required 18 POWR SHIFT LEVER H POWER TRAIN SHIFT LEVER 10 Nm
14. 10 3 27 10 10 10 7 6 7 25 7 23 45 23 20 1 2 3 5 1 0 13 1 2 1 2 1 2 1 0 0 6 1 0 1 0 0 3 2 7 1 0 1 0 1 0 0 7 0 6 0 7 2 5 0 7 2 3 4 5 2 3 2 0 8 7 NOTE 3 25 7 2 94 8 7 8 7 8 7 7 2 4 3 79 7 2 2 2 20 7 2 7 2 7 2 5 1 43 5 1 18 5 1 17 32 17 14 Apply LOCTITE Apply the engine oil Apply LOCTITES Apply LOCTITES Apply LOCTITES Apply LOCTITES Apply LOCTITE 1 Tighten the cylinder head bolts to 25 Nm 2 5 kg 18 ft Ib in the proper tightening sequence loosen retighten the cylinder head bolts to 25 Nm 2 5 m kg 18 ft Ib the proper tightening sequence and then tighten the cylinder head bolts further to reach the specified angle 180 in the proper tightening sequence 2 Tighten the crankcase bolts to 15 Nm 1 5 kg 11 ft Ib in the proper tightening sequence loosen and retighten the crankcase bolts to 15 Nm 1 5 m kg 11 ft Ib in the proper tightening sequence and then tighten the crankcase bolts further to reach the specified angle 65 70 in the proper tightening sequence 3 Tighten the connecting rod nuts to 20 Nm 2 0 kg 14 ft Ib and then tighten the connecting rod nuts further to reach the specified angle 120 67 TIGHTENING TORQUE SPEC ye POWER TRAIN Tightening t Parts to be tightened AS Remarks Nm m kg ft Ib Primary sheave See NOTE Spider and sliding sheave 20 145 Lef
15. F Headlight relay gear position switch relay Model Manufacturer Coil resistance 5DM OMRON 94 5 115 5 Q at 20 C 68 F Grip warmer Heater resistance 1 53 1 87 Q at 20 C 68 F 1 53 1 87 Q at 20 C 68 F Thumb warmer Heater resistance 37 0 45 2 Q at 20 C 68 F Passenger grip warmer Heater resistance high Heater resistance low 8 82 10 78 Green Black 14 67 17 93 Q Yellow Black Circuit breaker Type Amperage for individual circuit Main fuse Headlight fuse Signal fuse Ignition fuse Carburetor heater fuse DC terminal fuse Radiator fan fuse Reserve fuse Reserve fuse Reserve fuse Reserve fuse Reserve fuse Fuse 30 A x 1 20 1 10 Ax 1 15 20 A x 1 3Ax1 15 30 A x 1 20Ax1 15Ax1 10Ax1 1 Coolant temperature sensor Model Manufacturer Resistance Indicator light 8CC MITSUBISHI 5 21 6 37 at 0 C 32 F 0 290 0 354 at 80 C 176 F 0 170 0 208 at 100 212 95 116 C 203 241 F 90 110 C 194 230 F Radiator fan ON OFF 86 105 C 187 221 F 79 97 C 174 207 F 62 MAINTENANCE SPECIFICATIONS SPEC ye Model Speed sensor Model Manufacture 8EK NIPPON SEIKI Carburetor heater Model Manufacture Wattage Resistance 5FU NIPPON THERMOSTAT 30 W 6 10 Q at 20 C 68 F 63 MAINTENANCE SPECIFICATIONS
16. Fasten the ignition coil lead to the frame cross member with the plastic band making sure to fas ten the lead under the fuel hoses and to face the end of the band rearward 49 Fasten the fuel hoses with the holders Fasten the coolant hoses with plastic band making sure that the end of the band is to the rear of the hose facing downward 42 Fasten the coolant hose and throttle position sensor coupler with the plastic band making sure that the end of the band is to the rear of the hose facing downward 43 Slide the boot completely over the throttle position sensor cou pler and then fasten the coupler to the coolant hose with the plas tic band Air duct 45 When installing the air duct make sure that it contacts the bulkhead 46 Install the ground lead terminal and the rectifier regulator using the same bolt Rectifier regulator 48 Insert the front section of the cover into the frame 9 Fasten the wire harness at the white tape with the plastic band 69 To the headlight and meter assembly 6 Install the starter motor lead ter minal so that the bent section of the terminal is facing upward Up 63 Front 64 Load control relay 65 Headlight relay 69 Fasten the gear position switch lead at the positioning tape with the plastic locking tie 6 Carburetor heater relay 68 Back buzzer 69 When installing the back buzzer make sure that it contacts the rivet 69 To the tail brake light Nut Bo
17. Length on ground Track deflection mm 100 N 10 kg 22 Ib Internal drive type 500 mm 19 69 in 1 204 mm 47 40 in 35 45 mm 1 38 1 78 in Brake Brake type Operation method Caliper type disc brake Handlebar left hand operated Electrical Ignition system Generator system Transistorized coil ignition A C magneto Headlight bulb type Halogen bulb Bulb wattage x Quantity Headlight Tail Brake light Meter light High beam indicator light Information indicator light Low coolant temperature light 12 V 60 W 55 W x2 12 5 W 21 W 14 5OMA x 6 14 V 80 mA 14 V 80 mA 14 V 80 mA 51 MAINTENANCE SPECIFICATIONS SPEC ye MAINTENANCE SPECIFICATIONS ENGINE Model VK10W Cylinder head Volume with spark plug lt Warpage limits 22 82 23 62 cm 1 39 1 44 cu in 0 10 mm 0 0039 in Lines indicate straight edge measurement Cylinder Material Bore size Taper limits Out of round Aluminum alloy with dispersion coating 79 000 79 010 mm 3 1102 3 1106 0 050 mm 0 0020 in 0 050 mm 0 0020 in Camshaft Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft journal to camshaft cap clear ance Camshaft dimensions Intake Limit pr lt Limit gt Exhaust A lt Limit gt B lt Limit gt Camshaft runout
18. Out of specification gt Replace the throttle posi tion sensor Connect the pocket tester Q x 1k to the throt tle position sensor coupler Positive tester probe gt Yellow 3 Negative tester probe gt Black 2 While slowly pushing the throttle check the throttle position sensor resistance Throttle position sensor resistance Ro 0 4 kQ at 20 C 68 F Yellow Black Out of specification gt Replace the throttle posi tion sensor 44 45 CARBURETORS CARB D 2 Adjust Throttle position sensor angle Adjustment steps e Disconnect the throttle position sensor coupler Connect the test coupler to the throttle position sensor Connect three dry cells 1 5 V x 3 pcs in series to the test coupler Dry cells negative end gt Dry cells positive end gt 2 Connect the digital multi meter to the test cou pler Digital multi meter negative lead gt Digital multi meter positive lead 3 Measure the voltage 4 NOTE n When measuring the voltage be sure that the test coupler is connected to the throttle position sensor e Calculate the specified voltage Specified voltage Voltage x 0 136 Loosen the throttle position sensor bolt 4 e Connect the digital multi meter to the test cou pler Digital multi meter negative lead gt Digital multi meter positive lead 3 e Adjust the throttle position sensor position to o
19. SPEC ye HIGH ALTITUDE SETTINGS Temperature Altitude Idling speed r min 0 200 m 0 700 ft 200 1 500 m 700 5 000 ft 1 500 3 000 m 5 000 10 000 ft Production spec MJ 1 2 3 148 PJ 45 64 1 400 1 400 1 400 MAINTENANCE SPECIFICATIONS SPEC ye 65 TIGHTENING TORQUE SPEC ye Tightening torque Nm m kg ft Ib Spark plug 13 1 3 9 4 Cylinder head bolt M10 x 1 25 See NOTE Cylinder head bolt 12 1 2 8 7 Camshaft cap and cylinder head 10 1 0 7 2 Apply the engine Cylinder head cover 12 1 2 8 7 and camshaft sprocket 24 2 4 17 Timing chain tensioner 10 1 0 7 2 Timing chain tensioner cap 7 0 7 5 1 Timing chain guide exhaust and intake 10 1 0 7 2 Apply LOCTITE Cylinder head water jacket 10 1 0 7 2 Thermostat housing cover 10 1 0 7 2 Coolant temperature sensor 23 2 3 17 Hose band 2 0 2 1 4 Water pump 12 1 2 8 7 Coolant reservoir 10 1 0 7 2 Coolant hose joint 10 1 0 7 2 Carburetor coolant shut off assembly 5 0 5 3 6 Oil cooler 10 1 0 7 2 Apply LOCTITES Engine mounting adjust bolt 9 0 9 6 5 Engine mounting nut 65 6 5 47 Engine mounting bracket 25 2 5 18 Oil pan 10 1 0 7 2 Oil pan drain bolt 10 1 0 7 2 Oil filter cartridge 17 1 7 12 Oil pump 12 1 2 8 7 Oil pump drive chain guide 10 1 0 7 2 Oil pump housing cover 3 0 3 2 2 Oil pump driven gear 15 1 5 11 Oil tank drain bolt 16 1 6 11 Oil tank and frame b
20. To ensure proper clutch performance the V belt position should be adjusted by adding a spacer on each adjusting bolt when the V belt position reaches 1 5 mm 0 06 in below the edge New belt width 34 1 mm 1 34 in Belt wear limit width 32 1 mm 1 26 in 1 Measure V belt position 8 NOTE Install the new V belt onto the secondary sheave only Do not force the V belt between the sheaves the sliding and fixed sheaves must touch each other Standard V belt height 0 5 1 5 mm 0 02 0 06 in DRIVE V BELT INSP Q 2 Adjust the position of the V belt by removing or adding a spacer 1 on each adjusting bolt 2 V belt position Adjustment More than 1 5 mm 0 06 in above the Remove a spacer edge From 1 5 mm 0 06 in above the edge to Not necessary 0 5 mm 0 02 in It is correct below the edge More than 0 5 mm 0 02 in below the Add spacer edge Part number Thickness 90201 061H1 0 5 mm 0 02 in 90201 06037 1 0 mm 0 04 in 3 Tighten Adjusting bolt Adjusting bolt 22 10 Nm 1 0 kg 7 2 ft Ib 4 Inspect Drive V belt Cracks damage wear Replace Oil or grease on the V belt 5 Check the pri mary and secondary sheaves 5 Inspect Primary sheave Secondary sheave Oil or grease on the primary and secondary sheaves Use a rag soaked in lacquer thin ner or solvent to remove the oil or grease Check t
21. Washer Counter gear Low pinion gear Spring Collar Driven gear Journal Washer Chain tensioner Washer Collar Collar Washer Reverse drive gear oo oo sch bk bk NAA N 9 sch 23 POWR DRIVE CHAIN HOUSING pi 18 Nm 1 8 m kg 13 ft Ib 20 Nm 2 0 kg 14 ft Ib 43 Nm 4 3 m kg 31 ft Ib 55 Nm 5 5 kg 40 ft Ib 24 Nm 2 4 m kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 14 Nm 1 4 m kg 10 ft Ib 16 Nm 1 6 kg 11 ft Ib EL 6 0 6 m kg 4 3 ft Ib E F 7 ESSO beacon 325 grease or Aeroshell grease 7A Order Job name Part name Q ty Remarks 30 Washer 1 31 Low drive gear 1 32 Drive sprocket 1 33 Drive chain 1 34 Driven sprocket 1 35 Low wheel gear 1 36 Washer 1 37 Collar 1 38 Plate 1 39 Shaft 1 40 Plate 1 41 Shaft 1 42 Rubber seal 1 43 Washer 1 44 Drive chain housing 1 For installation reverse the removal proce dure 24 POWR DRIVE CHAIN HOUSING TR 25 REMOVAL 1 Remove Driven gear 1 NOTE While holding the front axle assembly with spanner wrench 2 loosen the reverse driven gear bolt INSPECTION 1 Inspect e Drive chain housing e Drive chain housing cover Cracks damage Replace e Shift fork Pitting wear damage gt Replace Oil seals drive chain housing and
22. 0 6 m kg 4 3 ft Ib B 10 Nm 1 0 m kg 7 2 ft lb F 20 Nm 2 0 kg 14 ft Ib C 14 Nm 1 4 m kg 10 ft Ib D 16 Nm 1 6 m kg 11 ft Ib Job name Part name E 18 Nm 1 8 m kg 13 ft Ib POWR TR 43 Nm 4 3 kg 31 ft Ib 55 5 5 kg 40 ft Ib de 32 2 37 EB 1 ESSO beacon 325 grease or Aeroshell grease 7A Remarks JO Od ON Drive chain housing removal Right side cover shift lever parking brake brake caliper Shim Washer Collar Brake disc Straight key Collar Shift rod Chain tension adjusting bolt Spring Ball Gear position switch Drive chain housing cover Shift drum a a a a a 22 Remove the parts the order listed below Refer to SHIFT LEVER and BRAKE t 0 5 t 1 0 Loosen DRIVE CHAIN HOUSING Hie e 18 Nm 1 8 m kg 13 ft Ib 20 Nm 2 0 kg 14 ft Ib 43 Nm 4 3 m kg 31 ft Ib 55 Nm 5 5 kg 40 Ib 24 Nm 2 4 m kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 14 Nm 1 4 m kg 10 ft Ib 16 Nm 1 6 kg 11 ft Ib EL 6 0 6 m kg 4 3 ft Ib E F 7 ESSO beacon 325 grease or Aeroshell grease 7A Job name Part name Shift fork guide bar Shift fork
23. 0 9641 in 24 457 mm 0 9629 in 24 500 24 518 mm 0 9646 0 9653 in 24 548 mm 0 9665 in 24 500 24 518 mm 0 9646 0 9653 in 24 548 mm 0 9665 in Piston Piston size D D Measuring point H A Da a Piston to cylinder clearance lt Limit gt Piston pin bore off set Off set direction Piston pin bore inside diameter lt Limit gt 78 935 78 950 mm 3 1077 3 1083 in 5 0 mm 0 20 in 0 050 0 075 mm 0 0020 0 0030 in 0 120 mm 0 0047 in 0 5 mm 0 0197 in Exhaust side 19 004 19 015 mm 0 7482 0 7486 in 19 045 mm 0 7498 in Piston pin Piston pin outside diameter lt Limit gt Piston pin length Piston pin to piston pin bore clearance lt Limit gt 18 991 19 000 mm 0 7477 0 7480 in 18 971 mm 0 7469 in 52 9 53 0 mm 2 083 2 087 in 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm 0 0029 in 54 MAINTENANCE SPECIFICATIONS SPEC ye Piston ring Sectional sketch Top ring Ring type Dimensions B x T 2nd ring Ring type Dimensions B x T Oil ring Dimensions B x T End gap installed Top ring 2nd ring Oil ring Side clearance installed Top ring 2nd ring Oil ring Plating coating Top ring 2nd ring Barrel 1 00 x 2 80 mm 0 039 x 0 110 in Taper 1 00 x 2 90 mm 0 039 x 0 114 in 2 00 x 2 50 mm 0 079 x 0 098 in 0 35 0 45 mm 0 014 0 018 in 0 75 0 85 mm 0 030 0 033 in 0 20 0
24. 00 59 5 2 34 4 89 83 4 3 28 90501 550A3 22 1 2 25 59 5 2 34 4 56 82 3 3 24 59 5 2 34 4 91 88 4 3 48 Free length mm in Standard Blue Blue Blue 5 5 0 217 White Blue White 5 5 0 217 Blue Pink Blue 5 5 0 217 Blue Silver Blue 5 5 0 217 Blue Green Blue 5 5 0 217 Yellow Blue Yellow 5 8 0 228 Yellow Pink Yellow 5 8 0 228 Green Pink Green 5 8 0 228 Yellow Silver Yellow 5 8 0 228 Green Silver Green 5 8 0 228 90501 551L3 19 6 2 00 90501 551L9 19 6 2 00 59 5 2 34 4 91 90 9 3 58 90501 552L5 19 6 2 00 90501 580A1 24 5 2 50 90501 581L5 24 5 2 50 90501 58116 27 0 2 75 90501 58211 24 5 2 50 90501 582L2 27 0 2 75 59 5 2 34 4 91 93 4 3 68 59 5 2 34 4 91 81 4 3 20 59 5 2 34 4 92 85 4 3 36 59 5 2 34 4 66 84 3 3 32 59 5 2 34 4 92 87 4 3 44 59 5 2 34 4 66 86 1 3 39 90501 58216 22 1 2 25 White Green White 5 8 0 228 59 5 2 34 5 25 91 2 3 59 90501 58217 24 5 2 50 Yellow Green Yellow 5 8 0 228 59 5 2 34 4 92 89 4 3 52 90501 583L0 19 6 2 00 Blue White Blue 5 8 0 228 59 5 2 34 5 65 95 9 3 78 90501 58311 22 1 2 25 White White White 5 8 0 228 59 5 2 34 5 25 93 4 3 68 9
25. 1 0 m kg 7 2 ft Ib 23 2 3 kg 17 ft Ib Order Job name Part name Q ty Remarks Shift lever assembly removal Remove the parts in the order listed below Right side cover 1 Shift knob 1 2 Bracket 1 3 Shift rod 1 Disconnect 4 Shift lever assembly 1 For installation reverse the removal proce dure POWR SHIFT LEVER on A 23 Nm 2 3 m kg 17 ft Ib B 59 Nm 5 9 kg 43 ft Ib Job name Part name Remarks Shift lever disassembly Remove the parts in the order listed below Shift lever stay Circlip Bearing Circlip Collar Shift lever pin Shift lever Shift lever guide Spring Shift lever stopper Go A 2 sch sch sch N ech nr For assembly reverse the disassembly cedure 20 21 POWR SHIFT LEVER M INSTALLATION 1 Install e Shift lever 1 Shift lever stopper 2 Shift guide e Shift lever 4 Spring Installation steps e Install the shift lever 1 onto the shift lever stop per Q Install the shift lever guide 3 and spring onto the shift lever position the shift lever and shift lever guide as shown and then install the shift lever pin 2 sure that the end of the spring is installed between the washer 6 and the shift ever guide 3 DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING A 6 Nm
26. 60 mm 0 008 0 024 in 0 030 0 070 mm 0 0012 0 0028 in 0 020 0 060 mm 0 0008 0 0024 in 0 060 0 150 mm 0 0024 0 0059 in Chrome plated parkerizing Parkerizing Connecting rod Small end diameter Big end diameter Crankshaft pin to big end bearing clearance Bearing color code 19 005 19 018 mm 0 7482 0 7487 in 41 000 41 018 mm 1 6142 1 6149 in 0 033 0 050 mm 0 0013 0 0020 in 0 White White 1 Blue Blue 2 Black Black 3 Brown Brown 4 Green Green 5 Yellow Yellow Crank pin Crank pin outside diameter 37 976 38 000 mm 1 4951 1 4961 in Crankshaft Measuring point 1 Measuring point 2 Width A Width B Crankshaft runout C Big end side clearance D Crankshaft journal to crankshaft journal bearing clearance Bearing color code 62 0 mm 2 44 in 100 0 mm 3 94 in 62 25 62 65 mm 2 451 2 467 in 234 65 235 65 mm 9 24 9 28 in 0 03 mm 0 0012 in 0 160 0 262 mm 0 0063 0 0103 in 0 027 0 045 mm 0 0011 0 0018 in 2 Black 3 Brown 4 Green 5 Yellow 6 Pink 7 Red 8 White 55 MAINTENANCE SPECIFICATIONS SPEC ye VK10W Model Carburetor Type Quantity Manufacturer mark Main jet M J Main air jet M A J Jet needle J N Needle jet N J Pilot jet P J Pilot air jet P A J Pilot outlet P O Bypass 1 DPI 2 4
27. A 58 MAINTENANCE SPECIFICATIONS SPEC ye Model VK10W Shock absorber Damping force Front Extension 540 N 0 3 m s 55 1 kg 0 3 m s 121 4 Ib 0 3 m s Compression 1 130 N 0 3 m s 115 2 kg 0 3 m s 254 0 Ib 0 3 m s Rear Extension 2 530 N 0 3 m s 258 0 kg 0 3 m s 568 7 Ib 0 3 m s Compression 690 N 0 3 m s 70 4 kg 0 3 m s 155 1 Ib 0 3 m s Slide runner Thickness 17 8 mm 0 70 in Wear limit 10 mm 0 39 in Track sprocket wheel Material Ultra high molecular weight polyethylene Number of teeth 8 Rear guide wheel Material High molecular weight polyethylene with rubber Outside diameter 178 mm 7 01 Recommended brake fluid Pad thickness Pad wear limit Parking brake pad clearance Parking brake cable distance Disc outside diameter Disc minimum thickness DOT4 10 2 mm 0 40 in 4 7 mm 0 19 in 1 5 2 0 mm 0 059 0 079 in 43 5 46 5 mm 1 713 1 831 in 200 mm 7 87 in 3 5 mm 0 14 in 59 MAINTENANCE SPECIFICATIONS SPEC ye CHASSIS VK10W Frame Frame material Seat height Luggage box location Monocoque Aluminum amp Steel 716 mm 28 2 in Under seat Steering Lock to lock angle Ski alignment Toe out size Caster angle Ski stance center to center 29 7 ski 34 4 L ski 34 4 ski 29 77 L ski Toe out 0 15 mm 0 0 59 in 23 1 020 40 2 Ski Ski material Length Width Ski runner m
28. Withstand voltage Short circuit type FH001 SHINDENGEN 14 1 14 9 V 35A 40 V Battery Specific gravity Manufacturer Type Ten hour rate amperage 1 32 YUASA YTX20L BS 12V 18Ah 18A Electric starter system Type Constant mesh type Starter motor Model Manufacturer Output Armature coil resistance Continuity check Insulation check Brush Overall length Wear limit Spring pressure Commutator diameter Wear limit Mica undercut 8ES1 MORIC 12 V 0 95 kW 0 008 0 010 Q at 20 C 68 F More than 100 kQ at 20 C 68 F 9 8 mm 0 39 5 0 mm 0 20 in 7 36 11 04 750 1 126 0 26 5 39 7 02 28 5 mm 1 12 in 27 5 mm 1 08 in 1 5 mm 0 059 in Starter relay Model Manufacturer Amperage rating Coil resistance MS5F 421 JIDECO 180 A 4 18 4 62 Q at 20 68 61 MAINTENANCE SPECIFICATIONS SPEC ye Model T P S throttle position sensor Manufacturer Resistance KEIHIN 4 6 KQ at 20 C 68 F Blue Black 0 4 at 20 C 68 F Yellow Black Oil level switch Model Manufacturer 8FA ASTI Fuel sender Model Manufacturer Sender resistance Full Empty 8FN NIPPON SEIKI 10 120 at 20 C 68 F 179 185 Q at 20 C 68 F Starting circuit cut off relay passenger grip warmer relay radiator fan motor relay Model Manufacturer Coil resistance 8DM MATSUSHITA 75 7 92 5 Q at 20 C 68
29. cover Wear damage gt Replace e Bearings drive chain housing and cover Pitting damage gt Replace Replacement steps e Remove the circlip drive chain housing and cover Remove the bearing s using a general bearing puller Install the new bearing s NOTE oes Use a socket 1 that is the same size as the outside diameter of the bearing race CAUTION Do not strike the inner race 2 or ball bearings Contact only the outer race 2 Install a new circlip drive chain housing and cover CAUTION Always use new circlips DRIVE CHAIN HOUSING 2 Inspect Drive sprocket Driven sprocket Driven gear Reverse drive gear Counter gear Low pinion gear Low wheel gear Low drive gear Journal Chain tensioner Pitting wear damage gt Replace Drive chain Wear damage gt Replace Shift gt Clean or replace Shift lever assembly Bearing chain tensioner Pitting damage gt Replace the bearing and the inner race holder as a set 3 Measure e 14 link section 2 of the drive chain Using a spring scale pull on the drive chain with 36 kg 80 Ib of force Out of specification gt Replace the drive chain Maximum 14 link drive chain section length 133 35 mm 5 25 in Limit 137 35 mm 5 41 in NOTE dd Measure the length between drive chain 1 and 5 as shown e Perform this measurement at two or three differ ent places If replacement is neces
30. the surfaces are fairly smooth or better snow conditions exist decrease the ratio Gear ratio chart The drive and driven gears and the chains shown in the gear ratio chart are available as options The figures containing a decimal point represent the drive driven gear ratios while the bottom numbers designate the number of links in the chain GEAR SELECTION Chain and sprocket part number Parts name Teeth 4 links Parts no D Standard 19 teeth 8FA 17682 90 20 teeth 8FA 17682 00 21 teeth 8FA 17682 10 Drive sprocket 22 teeth 8FA 17682 20 23 teeth 8FA 17682 30 24 teeth 8FA 17682 40 38 teeth 8FB 47587 80 LE Driven sprocket 39 teeth 8FB 47587 90 40 teeth 8FB 47587 00 68 links 94890 09068 IG Chain 70 links 94890 09070 2 Gear ratio Drive gear 19 teeth 20 teeth 21 teeth 22 teeth 23 teeth 24 teeth Driven gear 1 90 1 81 1 73 1 65 1 58 68 links 68links 68links 70links 70 links 39 teeth 2 05 1 95 1 86 1 77 1 70 1 63 68 links 68 links 68 links 70 links 70 links 70 links 40 teeth 2 11 2 00 1 91 1 82 1 74 1 67 68 links 68 links 70 links 70 links 70 links 70 links 3 Secondary sheave spring B Spring rate Preload Wire gauge Free lenath H Outside Part mm rad N mm kg mm in in 9 No of coils mim in diameter Standard kg mm rad Ib in mm in 90508 500B1 6003
31. 0501 58314 22 1 2 25 White Silver White 5 8 0 228 90501 583L5 22 1 2 25 White Pink White 5 8 0 228 90501 600A1 29 4 3 00 Pink Blue Pink 6 0 0 236 90501 601L7 29 4 3 00 Pink Pink Pink 6 0 0 236 90501 601L8 31 9 3 25 Orange Pink Orange 6 0 0 236 90501 602L3 29 4 3 00 Pink Silver Pink 6 0 0 236 90501 602L8 27 0 2 75 90501 602L9 29 4 3 00 90501 603L2 24 5 2 50 90501 603L3 27 0 2 75 90501 624L8 31 9 3 25 59 5 2 34 5 25 89 0 3 50 59 5 2 34 5 25 86 7 3 41 59 5 2 34 4 81 80 1 3 15 59 5 2 34 4 82 83 4 3 28 59 5 2 34 4 60 82 6 3 25 59 5 2 34 59 5 2 34 59 5 2 34 59 5 2 34 59 5 2 34 59 5 2 34 4 82 85 1 3 35 5 08 87 9 3 46 4 82 86 7 3 41 5 39 91 4 3 60 5 08 89 8 3 54 5 00 84 2 3 31 Green Green Green 0 236 6 0 Pink Green Pink 6 0 0 236 Yellow White Y ellow 6 0 0 236 6 0 6 2 0 236 0 244 Green White Green Orange Silver Orange 15 Clutch weight Parts No Weight g oz without bush and rivets GEAR SELECTION Shape amp ID mark Q D Standard 8BU 17605 20 45 41 1 603 8CH 17605 10 35 32 1 246 8DG 17605 00 34 26 1 208 8DJ 17605 00 37 77 1 332 8DN 17605 10 39 76 1 402 8ES 17605 00 54 63 1 928 8FA 17605 10 63 81 2 251 8FN 17
32. 1 211 kg mm rad Wire diameter 6 0 mm 0 236 in Outside diameter 69 5 mm 2 74 in Sec torque cam angle 39 Sec clutch shim 1 0 mm 0 04 in 11 CLUTCH GEAR SELECTION 12 The clutch may require tuning depending upon where the machine will be operated and the desired handling characteristics The clutch can be tuned by changing the engagement and shifting speeds Clutch engagement speed is defined as the engine speed at which the machine first begins to move from a complete stop Clutch shifting speed is defined as the engine speed reached when the machine has travelled 800 m 2 500 ft after being started at full throttle from a dead stop Normally when a machine reaches shifting speed the vehicle speed increases but the engine speed remains nearly constant Under unfavorable condi tions wet snow icy snow hills or rough terrain however engine speed may decrease after the shifting speed has been reached Engine speed Good condition Clutch shifting speed Clutch engagement speed Starting position Distance travelled 800 m 2 500 ft TY Im jo O 0 GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions If there are many rough surfaces or unfavorable snow conditions the drive driven gear ratio should be increased If
33. 6006 Steel 17 2 mm 0 677 in 3 3 Nothing Secondary sheave spring Part number Color code Outside diameter Wire diameter 90508 60012 Pink 69 5 mm 2 736 in 6 0 mm 0 236 in 57 MAINTENANCE SPECIFICATIONS SPEC ye Model Hole position Sheave side spring side twist angle Clo Spring rate Number of coils Free length Torque cam angle 12 3 N mm 1 25 kg mm 70 23 Ib in 5 53 75 mm 2 95 in 399 Drive chain Type Number of links Secondary reduction ratio Maximum 14 link drive chain section length lt Limit gt Borg Warner Automotive 23RH303 68ASM 68L 1 95 39 20 133 35 mm 5 25 in 137 35 mm 5 41 in Track Part number Width Length Pitch Number of links Thickness A Height B mz Track deflection at 100 N 10 kg 22 Ib 8FN 47110 00 500 mm 19 69 in 3 969 mm 156 24 in 64 mm 2 52 in 42 5 1 mm 0 20 in 31 8 mm 1 25 in 35 45 mm 1 38 1 77 in Slide rail suspension rear suspension Front travel Rear travel Suspension spring rate Front Rear Suspension wire diameter Front Rear 212 mm 8 3 in 262 mm 10 31 in 12 7 N mm 1 29 kg mm 72 5 Ib in 68 6 Nimm 7 00 kg mm 391 7 Ib in 6 8 mm 0 268 in 13 3 mm 0 524 in Suspension setting position Hook setting length Standard Maximum Minimum Full rate adjusting position 14 5 15 5 mm 0 571 0 610 in 35 mm 1 37 in 10 mm 0 40 in
34. 605 00 75 28 2 657 16 Weight rivets Parts Material C Length mm in GEAR SELECTION Weight 9 2 Standard INSP lt F Effects 90261 06033 Steel 17 2 0 677 0 159 Increased force 90261 06034 Steel 13 9 0 547 90269 06006 Steel 17 2 0 677 0 127 90261 06019 Steel 13 3 0 524 4 5 3 6 0 127 3 6 3 1 0 109 90261 06015 Steel 2 44 0 086 90266 06002 Steel 13 3 0 524 2 44 0 086 90261 06028 Aluminum 10 3 0 406 90266 06001 9 Rollers Aluminum 10 3 0 406 13 3 0 524 0 85 0 030 0 85 0 030 Decreased force 9 mm 0 354 in B Outside VOS A D Roller with bush diameter C Bushing type Identification mark El Standard El Effects ing part number P N Width mm in 8FG 17624 00 14 5 0 57 VESPEL G Grooved amp Machined TP 8549 L Increased force 90386 09001 14 6 mm 8FG 17624 10 15 0 0 59 VESPEL H Grooved i 90386 09001 14 6 8FG 17624 20 15 6 0 61 VESPEL 1 No Mark TP 8549 LJ 90386 09001 14 6 8 17624 30 16 0
35. 613 6 2 0 63 35 28 5 0 0 196 5 19 69 5 2 736 90508 536A9 7147 729 7 3 0 74 41 44 Red 5 3 0 209 5 53 69 5 2 736 90508 556 2 8314 848 8 5 0 87 48 72 Green 5 5 0 217 5 53 69 5 2 736 90508 556 7 9460 965 10 2 1 04 58 24 Silver 5 5 0 217 4 86 69 5 2 736 90508 60012 11876 1211 12 3 1 26 70 56 6 0 0 236 5 53 69 5 2 736 90508 60007 12654 1290 13 5 1 37 76 72 White 6 0 0 236 5 19 69 5 2 736 13 2 Secondary spring twist angle Seat GEAR SELECTION Q Torque cam secondary spring seat Effects Part no D Cam angle Identification mark Identification mark Standard Quicker upshifting dur 8 17604 00 51 43 8BVFA ing acceleration 8BV 17604 71 47 8BV71 45 8BV51 8BV 17604 51 8BV 17604 31 435 8BV31 Quicker backshifting 8BV 17604 11 41 8BV11 under load 8BV 17604 91 39 14 8 91 INSP o GEAR SELECTION ADJ Primary spring Spring identification color code Spring rate color C Preload color Spring rate 1 Outside Parts No N mm Freload Color js in diameter No of coils mm in kg mm 90501 550 2 19 6 2
36. Check and adjust engine idle speed o Adjust synchronization of carburetors e Carburetors Adjust the jets Whenever operating condition elevation temperature is changed Crankcase breather system Fuel filter Fuel line Check for leakage Exhaust system Tighten or replace gasket if necessary GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART Remarks Pre opera tion check Daily INSP ADJ Initial 1 month or 800 km 500 mi 40 hr Q Seasonally or 4 000 km 2 500 mi 200 hr Engine oil Check oil level Replace Engine oil filter cartridge Replace Every 20 000 km 12 000 mi Fuel Check fuel level Engine coolant Check coolant level Air bleed the cooling system if necessary Louvers Check condition Remove snow if necessary Throttle lever carburetor side Check throttle lever operation Throttle lever handlebar side Check operation Repair if necessary Throttle override system T O R S Check operation Repair if necessary Engine stop switch Check operation Repair if necessary Drive guard Check for cracks bends or damage Replace if necessary V belt Check for wear and damage Replace if necessary Drive track and idler wheels Check deflection and for wear and damage Adjust replace if necessary Slide
37. Electric starter Lubrication system Dry sump Engine oil Type Oil capacity Periodic oil change With oil filter replacement Total amount SE SF SG or higher SAE OW 30 2 8 L 2 5 Imp qt 3 0 US qt 3 0 L 2 6 Imp qt 3 2 US qt 3 7 L 3 3 Imp qt 3 9 US qt Cil filter filter type Cartridge paper Drive chain housing oil Type Capacity Gear oil GL 3 75W or 80W 0 35 L 0 31 Imp qt 0 37 US qt Coolant Filler cap opening pressure Capacity 93 3 122 7 kPa 0 93 1 23 13 2 17 5 psi 4 7 L 4 14 Imp qt 4 97 US qt Fuel Type Tank capacity Regular unleaded gasoline Pump Octane 5 86 or higher For USA Canada Research Octane 91 or higher For Europe 42 L 9 24 Imp gal 11 10 US gal Carburetors Type Quantity Manufacture CVK40 3 KEIHIN 50 GENERAL SPECIFICATIONS Spark plug Type Manufacture Gap NGK R CR8E NGK 0 7 0 8 mm 0 028 0 031 in Transmission Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio Reverse system V Belt 3 8 1 1 Automatic centrifugal engagement Chain 1 95 39 20 Yes Chassis Frame type Caster Ski stance center to center Monocoque 23 0 1 020 mm 40 2 in Suspension Front suspension type Rear suspension type Double wishbone Slide rail suspension Track Track type Track width
38. SO beacon 325 grease or Aeroshell grease For the shaft drive chain housing installation refer to SECONDARY SHAFT POWR DRIVE CHAIN HOUSING bal 28 L O 1 mm 0 0 039 3 Install e Shift rod lock washer 1 NOTE Bend a lock washer tab along a flat side of the bolt 4 Adjust e Shift rod length Adjustment steps e Adjust the shift rod length Shift rod length 236 mm 9 29 in Check that the shift lever pin moves smoothly when the shift lever is pulled out 21 mm 0 83 in to the position b shown Also check that the shift lever pin returns to its original position by the force of the spring when the shift lever is released If the pin moves to a dif ferent position adjust the shift rod length 5 Fill Drive chain housing Refer to DRIVE CHAIN in CHAPTER 2 6 Adjust e Drive chain slack Refer to DRIVE CHAIN in CHAPTER 2 POWR SECONDARY SHAFT SECONDARY SHAFT SECONDARY SHAFT AND DRIVE CHAIN HOUSING INSTALLATION 1 Install Secondary shaft Drive chain housing Installation steps Install the secondary shaft Tighten the bolt NG Secondary shaft bolt A 30 Nm 3 0 kg 22 ft Ib Install the drive chain housing 1 Tighten the bolts and nut 2 Drive c
39. TE For track with a direction of rotation mark 8 Install the track with the mark pointing in the direc tion of track rotation 3 Install Bearing holder 1 NOTE o Align the punch mark on the bearing holder 1 with the rivet 37 ENG ENGINE CAMSHAFTS INSTALLATION 1 Install Exhaust camshaft sprocket 1 e Intake camshaft sprocket with the special tool CO Rotor holding tool 90890 01235 YU 01235 Camshaft sprocket bolts NG Camshaft sprocket bolt A 24 Nm 2 4 kg 17 ft Ib NOTE KZ Make sure that the holes in the cylinder 3 and marks on the camshaft sprockets in the position shown in the illustration Exhaust side gt Intake side Cylinder 3 cam 38 39 ENG 2 Install e Exhaust camshaft e Intake camshaft with the camshaft sprockets Installation steps Turn the crankshaft clockwise e When piston 3 is at TDC on the compression stroke align the mark on the A C mag neto rotor with the stationary pointer the A C magneto cover Install the timing chain onto both camshaft sprockets and then install the camshafts NOTE o e Install the camshafts with the hole in the cylin der 3 cam facing up Wh
40. TION SWITCH RELAY 1 Inspect Gear position switch relay Inspection steps Disconnect the gear position switch relay from the coupler Connect the pocket tester 2 x 1 and battery 12 V to the gear position switch relay terminals as shown Positive battery terminal gt Blue Red 1 Negative battery terminal gt Black Red Positive tester probe gt Pink 3 Negative tester probe gt Black 4 f gear position switch relay does not have conti nuity between the pink and black terminals replace it GENERAL SPECIFICATIONS SPEC ye SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number 8GS1 USA Canada 8652 Europe Dimensions Overall length Overall width Overall height 3 270 mm 128 7 in 1 200 mm 47 2 in 1 380 mm 54 3 in Weight Dry weight 360 kg 794 Ib Minimum turning radius Clockwise Counterclockwise 4 7 m 15 4 ft 4 7 m 15 4 ft Engine Engine type Cylinder type Displacement Bore x stroke Compression ratio Maximum hose power r min Maximum torque r min Vacuum pressure at engine idling speed Standard compression pressure at sea level Starting system Liquid cooled 4 stroke DOHC Backward inclined parallel 3 cylinder 973 cm 59 37 cu in 79 0 x 66 2 mm 3 11 x 2 61 in 11 3 1 84 7 kw 115 2 PS 8 500 r min 101 6 Nm 10 4 kgf 7 000 r min 24 0 kPa 0 24 kg cm 3 41 psi 1 450 kPa 14 5 kg cm 206 psi at 400 r min
41. To the tail brake light Route the wire harness to the front of the frame cross member bolts making sure that the har ness is not on the bolts Fasten the wire harness with the holder Secure the frame cross member and the holder to the frame with the nut and bolt Gear position switch lead Fuse box Wire harness 2 Conduction assembly 3 Brake hose Parking brake cable Coolant reservoir Route the parking brake cable so that it is not caught on the check valve hose clamp Fasten the positive battery lead terminal and negative battery lead terminal with the holder 85 CABLE ROUTING SPEC CABLE ROUTING SPEC ue 86 Fuel pumps Face the ends of each clamp outward Fuel hoses 2 Coolant reservoir 5 Fasten the fuel tank breather hose speed sensor lead and relay leads with the holder Secure the frame cross member and the holder to the frame with the nut and bolt Speed sensor lead holder 7 Rivet quantity 4 Align the punch mark on the bearing holder with the rivet Bearing holder Speed sensor Front axle Primary sheave 3 Water pump inlet hose More than 5 mm 0 2 in 9 Water pump 87 CABLE ROUTING SPEC CABLE ROUTING SPEC ue
42. aking sure that there is not excessive slack in the lead 9 Be sure to install the passenger grip warmer switch with the HI side up Position the coupler on the inside of the storage compartment 5 Fasten the tail brake light sub wire harness with the plastic band quantity 7 Pass the passenger grip warmer lead through the hole in the frame routing it towards the inside of the snowmobile and then pass the lead through the hole in the storage compartment before connecting it Connect the tail brake light sub wire harness coupler on the out side of the storage compartment Tail brake light sub wire harness 9 Route the handlebar switch lead on top of the sponge cushion that is affixed to the frame Position the tail brake light sub wire harness coupler in the loca tion shown in the illustration 93 CABLE ROUTING SPEC WIRING DIAGRAM VK10W 2007 8GS 0F001 00 Pickup coil A C magneto Rectifier regulator Main switch Load control relay Main fuse Starter relay Starter motor Battery Engine stop switch Throttle switch Carburetor heater relay Carburetor ground Carburetor heater Radiator fan motor relay Radiator fan motor Grip warmer Thumb warmer Ignitor unit Ignition coil Spark plug Throttle position sensor Coolant temperature sensor Grip warmer adjustment switch Thumb warmer adjustment switch Frame ground Passenger grip warmer relay Passenger grip warmer switch Pas
43. aliper bleed screws and push the pistons into the caliper with your finger Tighten the caliper bleed screws 2 Bleed screw A 6 Nm 0 6 kg 4 3 ft Ib Install the brake pads and pad spring 3 Check Brake fluid level 4 Check Brake lever operation A soft or spongy feeling gt Bleed brake sys tem Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 2 Q Job name Part name A 10 Nm 1 0 m kg 7 2 ft Ib 16 Nm 1 6 kg 118 Ib C Nm 3 0 kg 22 ft Ib 0 48 Nm 4 8 m kg 35 ft Ib Remarks Brake caliper and parking brake removal Brake fluid Brake hose Brake caliper assembly Parking brake cable Spring Parking brake assembly Collar Remove the parts in the order listed below Drain For installation reverse the removal proce dure 34 POWR A 6 Nm 0 6 kg 4 3 ft Ib B 18 Nm 1 8 m kg 13 ft Ib Job name Part name NG New Remarks Brake caliper disassembly Cap bolt Retaining pin Pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw Remove the parts in the order listed below For assembly reverse the disassembly pro cedure 35 36 POWR BRAKE pal BRAKE CALIPER DISASSEMBLY NOTE az Before disassembling a caliper drain brake fluid from brake hose master cylinder brake cal
44. ar position switch 63 Brake light switch Tail brake light amp Speed sensor Fuel sender Oil level switch Multi function meter Warning light Low coolant temperature indicator light 49 Signal fuse Ignition fuse 47 SIGNAL SYSTEM ELEC SIGNAL system ELE BACK BUZZER DOES NOT SOUND TROUBLESHOOTING Check the signal fuse OK FAULTY Replace the signal fuse Check the battery OK OUT OF SPECIFICATION Replace and or charge the battery Check the stator coil OK OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch OK FAULTY Replace the main switch Check the gear position switch OK FAULTY Replace the gear position switch Check the gear position switch relay OK FAULTY Replace the gear position switch relay Check the load control relay OK FAULTY Replace the load control relay Check the DC back buzzer OK DOES NOT SOUND Replace the DC back buzzer Check the signal system s wiring OK FAULTY Properly connect or repair the signal system s wir ing Correct the connection and or replace the rectifier regulator and or ignitor unit 48 49 SIGNAL SYSTEM ELEC GEAR POSITION SWITCH 1 Check Gear position switch 1 continuity Faulty gt Replace Shift lever position Continuity DRIVE D or LOW L Yes REVERSE No GEAR POSI
45. aterial Ski cover Ski runner wear limit Plastic ski wear limit Plastic 1 073 mm 42 24 in 180 mm 7 09 in Steel No 8 mm 0 31 in 25 mm 0 98 in Ski suspension front suspension Type Travel Spring type Spring rate Wire diameter Independent wishbone 175 0 mm 6 89 in Coil spring 42 2 N mm 4 30 kg mm 24 0 Ib in 10 0 mm 0 394 in Shock absorber Damping force Extension Compression 1 010 N 0 3 m s 103 0 kg 0 3 m s 227 0 Ib 0 3 m s 460 N 0 3 m s 46 9 kg 0 3 m s 103 4 Ib 0 3 m s 60 MAINTENANCE SPECIFICATIONS SPEC ye ELECTRICAL Voltage 12V Ignition system Ignition timing B T D C Advanced type 5 at 1 400 r min Digital type Ignition coil Model Manufacturer Ignition spark gap Primary coil resistance Secondary coil resistance F6T558 MITSUBISHI 6 0 mm 0 24 in 1 19 1 61 Q at 20 C 68 F 8 5 11 5 at 20 C 68 F Charging system Type Nominal output A C magneto 14 V less than 35 A at 5 000 r min DC C D l Magneto model Manufacturer Standard Pickup coil resistance color code Stator coil resistance color code Ignitor unit model Manufacturer F074T38571 MITSUBISHI 14 V 30 A 420 W at 5 000 r min 189 231 at 20 C 68 F Gray Black 0 22 0 26 at 20 68 F White White J4T16271 MITSUBISHI Rectifier regulator Type Model Manufacturer No load regulated voltage DC Capacity DC
46. bly and disassembly operations In this revised format the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol e g Bearings Pitting damage gt Replace EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct dis assembly and assembly procedures INSP nro see ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter s number and content D General information Periodic inspection and adjustment Chassis Power train 5 Engine 8 Cooling system 7 Carburetion Electrical 9 Specifications Illustrated symbols 9 to 46 are used to identify the specifications which appear Filling fluid Lubricant 2 Tightening Wear limit clearance Engine speed Special tool Q V A Illustrated symbols to the exploded diagram indicate grade of lubricant and location of lubrica tion point Apply locking agent LOCTITE Apply Yamabond No 5 Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply low temperature lithium soap base grease Apply molybdenum disulfide grease Use new one INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS 00 POWER TRAIN 4
47. btain the specified voltage 8 Tighten the throttle position sensor bolt 4 e Disconnect the test coupler and connect the throttle position sensor coupler SIGNAL SYSTEM ELEC ELECTRICAL oova towa oova EE rm AD PI A GAW 8 A 8 9 towa oova J Jett bert CN vor 9 9 wo Ts 1 Two E So aa na 51 wg an ESSINYYH EE EE GE 583 2 SSINYYH 1 SS3NHYH au mens ssanuvHaum au mans _ SSINYVH gen 1HOllavaH ola un aro towa LINYYII WALSAS 5 46 SIGNAL SYSTEM CIRCUIT DIAGRAM magneto Rectifier regulator Main switch 5 Load control relay Main fuse Battery Ignitor unit 03 Coolant temperature sensor 9 Frame ground DC back buzzer Gear position switch relay 6 Ge
48. en installing the timing chain start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side e Make sure the marks and on the timing chain sprockets are parallel with the edge of the cylinder head d Exhaust side gt Intake side Cylinder 3 3 Install Dowel pins e Intake camshaft caps Exhaust camshaft caps NOTE 4 mark refers to the intake camshaft caps and the E mark refers to the exhaust camshaft Z Ge Fu UN e Install the camshaft caps with the arrow mark 8 pointing towards the right side of the engine Make sure the punch marks in the camshaft are aligned with the arrow mark on the cam shaft caps 4 Install Camshaft cap bolts Camshaft cap bolt A 10 Nm 1 0 m kg 7 2 ft Ib NOTE Tighten the camshaft cap bolts stages and crisscross pattern working from the inner caps out CAUTION e Lubricate the camshaft cap bolts with the engine oil e The camshaft cap bolts must be tightened evenly or damage to the cylinder head cam shaft caps and camshafts will result e Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing 40 ENG 5 Install Timing chain tensioner CO Installation steps e While lightly pressin
49. g the timing chain tensioner rod by hand turn the tensioner rod fully clock wise with a thin screwdriver 1 NOTE Make sure that the tensioner rod has been fully set clockwise e With the timing chain tensioner rod turned all the way into the timing chain tensioner housing with the thin screwdriver still installed install the gasket and the timing chain tensioner 2 onto the cylinder block WARNING Always use new gasket Tighten the timing chain tensioner bolts 3 to the specified torque Timing chain tensioner bolt 10 Nm 1 0 m kg 7 2 ft Ib Remove the screwdriver make sure the timing chain tensioner rod releases and then tighten the cap bolt to the specified torque Cap bolt Nm 0 7 kg 5 1 ft Ib 6 Turn e Crankshaft several turns clockwise 7 Inspect mark Make sure the I mark on the mag neto rotor is aligned with the stationary pointer on the A C magneto cover e Camshaft punch marks Make sure the punch marks in the cylinder 3 cam are aligned with the arrow marks on the camshaft caps Out of alignment gt Adjust Refer to the installation steps above 41 42 ENG 8 Measure e Valve clearance Out of specification Adjust 9 Install e Cylinder head cover gasket e Cylinder head cover Cylinder head cover bolt 12 Nm 1 2 m kg 8 7 ft Ib NOTE
50. hain housing bolt and nut 43 Nm 4 3 m kg 31 ft Ib e Install the drive chain drive sprocket and reverse drive gear Install the drive chain housing cover 3 Properly install the rubber seal onto the drive chain housing making sure that these are no gaps Tighten the bolts 2 Drive chain housing cover bolt 10 Nm 1 0 m kg 7 2 ft Ib Install the collar Tighten the collar set screw 7 Collar set screw 6 Nm 0 6 m kg 4 3 ft Ib LOCTITE Install the brake disc Adjust the brake disc clearance e Adjust the drive chain slack 29 30 POWR SECONDARY SHAFT 2 Measure Brake disc clearance 8 Out of the specification gt Adjust Brake disc clearance 0 2 0 7 mm 0 008 0 028 in 3 Adjust Brake disc clearance Adjustment steps Remove the circlip 8 Adjust the brake disc clearance by adding or removing shim s 9 Shim size Part number Thickness 90201 252F1 0 5 mm 0 02 in nstall the new circlip Order Job name Part name 6 Nm 0 6 kg 4 3 ft Ib 18 Nm 1 8 kg 13 ft Ib 48 Nm 4 8 m kg 35 ft Ib Remarks ON Brake pad removal Right side cover Cap bolt Retaining pin Pad spring Brake pad Brake caliper assembly NV n 31 Remove the parts in the order li
51. he primary and secondary sheaves DRIVE V BELT BRAKE PAD INSPECTION INSP AIR BLEEDING HYDRAULIC BRAKE SYSTEM ADJ Q 6 Measure Drive V belt circumference 2 Out of specification gt Replace V belt circumference 1 132 1 138 mm 44 6 44 8 in BRAKE PAD INSPECTION 1 Apply the brake lever 2 Inspect e Brake pad wear Wear indicator 1 nearly contacts the brake disc gt Replace as a set Wear limit 4 7 mm 0 19 in AIR BLEEDING HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system the following cases e The system has been disassembled e A brake hose is loosened or removed e The brake fluid has been very low e Brake operation is faulty If the brake system is not properly bled a loss of braking performance may occur 1 Bleed Brake system Air bleeding steps a Fill the brake master cylinder reservoir with the proper brake fluid b Install the diaphragm Be careful not to spill any fluid or allow the brake master cylinder reservoir to overflow Connect clear plastic hoses 1 tightly to the brake caliper bleed screws 2 d Place the other ends of the hoses in a con tainer e Slowly apply the brake lever several times f Pull the lever in then hold the lever in position g Loosen the bleed screws and allow the brake lever to travel towards its limit h Tigh
52. ign the notch of the dipstick handle with the projection of the drive chain housing Install the rubber cap 10 DRIVE CHAIN ADJ Oil replacement Oil replacement steps e Place the oil pan under the drain hole Remove the oil drain bolt along with the gas ket and drain the oil CAUTION Be sure to remove any oil from the heat protec tor e Install the new gasket and oil drain bolt 1 N Oil drain bolt A 16 Nm 1 6 m kg 11 ft Ib Recommended oil Gear oil GL 3 75W or 80W Oil capacity 0 35 L 0 31 Imp at 0 37 US qt Chain slack adjustment 1 Adjust Drive chain slack Adjustment steps e Loosen the locknut 1 Turn the adjusting bolt 2 clockwise until it is fin ger tight and then loosen it 1 4 turn Hold the adjusting bolt in place while tighten ing the chain adjusting locknut 1 Drive chain adjusting locknut 25 Nm 2 5 kg 18 ft Ib TUNING CLUTCH High altitude Specifications Elevation 800 m 2 500 ft 600 1 400 m 2 000 4 500 ft CLUTCH INSP ADJ Q 1 200 2 000 m 4 000 6 500 ft 1 800 2 600 m 6 000 8 500 ft 2 400 3 000 m 8 000 10 000 ft Engine idle speed 1 400 100 r min lt lt lt lt Engagement r min Approx 2 400 r min 2 500 lt 2 600 Shift r min
53. iper and brake reservoir of their brake fluid 1 Remove e Pistons Piston seals 1 Removal steps Using a wood of piece 2 lock the right piston e Blow compressed air into the hose joint opening to force out the left piston from the caliper body Remove the piston seals and reinstall the pis ton Repeat the previous steps to force out the right piston from the caliper body A WARNING Never try to pry out the pistons e Do not loosen the retaining pins 3 BRAKE CALIPER INSTALLATION 1 Install Brake 1 CAUTION When installing the brake hose 1 onto the brake caliper 2 make sure that the brake pipe touches the projection 2 on the brake caliper N Union bolt brake hose A 30 Nm 3 0 kg 22 ft Ib AND kon KEEN KEE 103 5 mm AXLE AND TRACK E cce INSTALLATION j E 5 1 Install R Sprocket wheels Guide wheels AF a NOTE d 3 5 Somm 925 mm When pressing the sprocket wheels onto the front gt 2 5 42mm 58 5 mm 58 5 mm 1 28 in 1 65 in 2 30 in 2 30 in 1 54 in 8 64 in Az 125 mm 182mm axle align the lugs on each sprocket wheel 4 92 in 7 17 in m e Position each sprocket wheel the axle as shown in the illustration 2 Place the track in the chassis NO
54. king brake To the brake caliper Brake hose Fasten the wire harness with the plastic band Fasten the coolant hose with the clamp Fuel hoses 62 Fasten the wire harness and the fuel tank breather hose next to the rubber damper on the frame cross member with the holder making sure that the ends of the holder are facing up amp Fasten the fuel tank breather hose with the holder Fasten the wire harness with the plastic band 81 CABLE ROUTING SPEC CABLE ROUTING 82 Pass the wire harness brake hose and parking brake cable through the guide Do not pass the throttle cable and starter cable through the guide amp Place the end of the plastic band between the frame cross mem ber and the fuel tank 83 CABLE ROUTING SPEC CABLE ROUTING SPEC 84 Headlight sub wire harness Oil tank outlet hose 3 Starter motor positive lead Pass the starter motor positive lead behind the engine 5 Gear position switch lead
55. l operate as designed If there is any question about a service procedure it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all models manufactured by Yamaha Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will where applicable appear in future editions of this manual HOW TO USE THIS MANUAL Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED FOOT OUER 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 that can make procedures easier or clearer MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The informa tion has been compiled to provide the mechanic with an easy to read handy reference that contains comprehensive explanations of all inspection repair assem
56. lt 63 Pass the negative battery leads under the starter relay 75 CABLE ROUTING SPEC CABLE ROUTING SPEC u o O fem D 572218 22 gt 2222227222222 T 1 76 Pass the carburetor heater lead under the positive starter motor lead 65 Be sure to install the positive bat tery lead terminal so that it is fac ing rearward 77 CABLE ROUTING SPEC CABLE ROUTING SPEC 78 Headlight sub wire harness Fasten the headlight sub wire harness at the white tape with the holder on the shroud 3 Fasten the headlight sub wire harness with the holder Shroud stopper 5 Pass the headlight sub wire har ness inside of the shroud stop per Fasten the headlight sub wire harness and lead at the tape with the plastic band After connect ing the coupler install the rubber cover securely 7 Install the meter assembly cou pler rubber cover until it contacts the meter assembly 79 CABLE ROUTING SPEC CABLE ROUTING
57. m and steering knuckle 40 4 0 29 Lower arm and frame 37 3 7 27 Lower arm and steering knuckle 65 6 5 47 Front bumper 27 2 7 19 Rider seat 10 1 0 7 2 Rear carrier and frame 48 4 8 35 Rear carrier and tail brake light bracket 23 2 3 17 Tail brake light bracket and frame front 18 1 8 13 Tail brake light bracket and frame rear 30 3 0 22 Rear carrier seat 7 0 7 5 1 Tail brake light cover 7 0 7 5 1 Passenger assist grip 48 4 8 35 Passenger assist grip bracket 21 2 1 15 Tail brake light assembly 7 0 7 5 1 Battery bracket 18 1 8 13 Main switch 2 0 2 1 4 Shroud 13 1 3 9 4 70 GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I S O pitch threads Torque specifi cations for special components or assemblies are included in the applicable sections of this book To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Components should be at room temperature e LO A Distance across flats Outside thread diameter DEFINITION OF UNITS Read General torque specifications Nm m kg ft Ib 6 0 6 4 3 15 15 11 30 3 0 22 55 5 5 40 85 8 5 61 Definition 13 0 Measurement 94 Millimete
58. ng hook 28 2 8 20 Apply grease Rear axle 80 8 0 58 Set bolt front axle 9 0 9 6 5 Apply LOCTITE Speed sensor 20 2 0 14 Bearing holder 20 2 0 14 Gear unit speed sensor 40 4 0 29 ESSO beacon 325 grease or Aeroshell grease 7A NOTE Tightening steps 1 Tighten the bolt to a torque at 120 Nm 12 0 kg 85 ft Ib 2 Loosen the bolt completely 3 Retighten the bolt to a torque of 60 Nm 6 0 kg 43 ft Ib 69 TIGHTENING TORQUE SPEC ye Tightening torque Parts to be tightened E Remarks Nm m kg ft Ib Handlebar holder 15 1 5 11 CHASSIS Steering column 1 front 23 2 3 17 Steering column 1 rear upper 23 2 3 17 Steering column 1 rear lower 35 3 5 25 Steering column 2 upper 23 2 3 17 Steering column 2 lower 23 2 3 17 Steering column 2 and steering shaft 35 3 5 25 Steering shaft end locknut 25 2 5 18 Apply LOCTITES Steering shaft and steering column 1 35 3 5 25 Steering column 1 and relay rod 35 3 5 25 Relay rod and idler arm 30 3 0 22 Relay arm and idler arm 35 3 5 25 Idler arm and tie rod 30 3 0 22 Tie rod and steering arm 35 3 5 25 Relay arm 53 5 3 38 Tie rod end locknut 25 25 18 Apply LOCTITES Ski 48 4 8 35 Ski runner 19 1 9 14 Ski and ski handle M8 x 55 11 1 1 8 Ski and ski handle M8 x 100 17 1 7 12 Shock absorber upper 45 45 33 Shock absorber lower 45 4 5 33 Steering arm and ski column 35 3 5 25 Upper arm and frame 37 3 7 27 Upper ar
59. nion bolt brake master cylinder side 3 0 22 Parking brake cable and parking brake lever 1 0 7 2 Parking brake cable locknut 0 6 4 3 Brake master cylinder 1 0 7 2 Brake master cylinder holder and parking brake 2 3 17 lever Slide rail suspension mounting bolt M10 7 2 52 Apply LOCTITE Stopper band 0 4 2 9 Hook and front pivot arm 1 6 11 Front suspension bracket and sliding frame 7 2 52 LOCTITE Bracket bolt rear 3 0 22 Apply LOCTITE9 68 TIGHTENING TORQUE SPEC Parts to be tightened tordue Remarks Nm m kg ft Ib Shaft and sliding frame 72 7 2 52 Apply LOCTITE Shock absorber and front pivot arm 49 4 9 35 Shock absorber and front suspension bracket 49 4 9 35 Front pivot arm and sliding frame 72 7 2 52 LOCTITE Suspension wheel front center and rear 72 7 2 52 Apply LOCTITE Wheel bracket and sliding frame 24 2 4 17 Shock absorber and rear suspension bracket 49 4 9 35 Rear pivot arm and pull rod 49 4 9 35 LOCTITE Rear suspension bracket and pull rod 49 4 9 35 Apply LOCTITE Shock absorber and rear pivot arm 49 4 9 35 Rear pivot arm and rear pivot arm bracket 24 2 4 17 Control rod and sliding frame 72 7 2 52 Apply LOCTITE Control rod bolt 32 3 2 23 Rear pivot arm bracket 72 7 2 52 Apply LOCTITE Wheel bracket shaft and sliding frame 80 8 0 58 Pivot bracket and sliding bracket 69 6 9 50 Pivot bracket and rear sliding frame 34 3 4 24 Pivot bracket and spri
60. ntain ing corrosion inhibitors 3 2 6096 4096 4 7 L 4 14 Imp qt 4 97 US qt 0 15 mm 0 0059 in 0 072 mm 0 0028 in 56 MAINTENANCE SPECIFICATIONS SPEC ye POWER TRAIN Transmission Type Range of ratio Engagement speed r min Shift r min Sheave distance Sheave offset Secondary sheave free play clearance Secondary sheave clearance V belt height standard V belt automatic 3 8 1 0 1 2 200 2 600 r min 8 250 8 750 r min 267 270 mm 10 51 10 63 in 13 5 16 5 mm 0 53 0 65 in 1 0 2 0 mm 0 04 0 08 in 35 0 35 8 mm 1 38 1 41 in 0 5 1 5 mm 0 02 0 06 in V belt Part number Manufacturer Circumference Width A Wear limit B 8GS 17641 00 MITSUBOSHI 1 132 1 138 mm 44 6 44 8 in 34 1 mm 1 34 in 32 1 mm 1 26 in Primary sheave spring Part number Color code Diameter Wire diameter Preload Spring rate Number of coils Free length Set length 90501 550A3 White Blue White 59 5 mm 2 34 in 5 5 mm 0 217 in 196 N 20 0 kg 44 1 Ib 22 1 N mm 2 25 kg mm 126 bim 4 56 82 3 mm 3 24 in 73 4 mm 2 89 in Primary sheave weight arm Part number with bush Weight without bush and rivets 8FN 17605 00 75 28 g 2 657 Rivet Outer Part number Material Size Quantity Hole quantity Inner Part number Material Size Quantity Hole quantity None outer and inner 90261 06033 Steel 17 2 mm 0 677 in 3 3 90269 0
61. olt 10 1 0 7 2 Oil tank and frame nut 19 1 9 14 Oil gallery bolt 20 2 0 14 Oil cooler outlet pipe 10 1 0 7 2 Check valve 10 1 0 7 2 Exhaust pipe joint 25 2 5 18 Muffler band 20 2 0 14 Exhaust pipe 25 2 5 18 Exhaust pipe joint band 9 0 9 6 5 Muffler 16 1 6 11 Muffler cover 11 1 1 8 Muffler cover plate 11 1 1 8 Exhaust pipe joint cover 7 0 7 5 1 Crankcase M9 x 1 25 See NOTE Apply the engine oil Crankcase M8 x 1 25 24 2 4 17 Apply the engine Crankcase M6 x 1 0 12 1 2 8 7 Apply the engine TIGHTENING TORQUE ENGINE Parts to be tightened Remarks 66 Parts to be tightened TIGHTENING TORQUE SPEC Tightening torque Nm m kg ft Ib Remarks Primary sheave drive shaft assembly bolt Connecting rod and cap Balancer Balancer shaft bearing retainer A C magneto rotor A C magneto rotor cover bolt M6 x 1 0 x 11 A C magneto rotor cover bolt M6 x 1 0 x 1 Starter clutch Stator coil Pickup coil A C magneto lead holder Carburetor joint Air filter case joint clamp screw Starter motor Fuel pump Fuel pump stay Fuel tank Starter motor lead Throttle cable locknut Rectifier regulator Ground earth lead engine mounting bracket Ground earth lead Ignitor unit Frame cross member front Frame cross member side front Frame cross member side rear Frame cross member under side rear NOTE 12 Se 35 10 12 12 12 10 6 10
62. r Centimeter 10 meter 1072 meter Length Length Kilogram 103 gram Weight Newton 1 kg x m sec Force Newton meter Meter kilogram Nxm m x kg Torque Torque Pascal Newtons per millimeter 2 Nimm Pressure Spring rate Liter Cubic centimeter Volume or capacity Rotations per minute 71 Engine speed CABLE ROUTING SPEC u o O fem D 572218 22 gt 2222227222222 T 1 72 CABLE ROUTING Positive battery lead 2 Negative battery lead Pass the wire harness two leads through the hole in the cover Wire harness 5 magneto lead 6 Negative battery lead coupler C Positive starter motor lead Fasten the A C magneto lead and wire harness with the plastic band Negative battery lead terminal Positive battery lead terminal Oil level switch lead coupler Oil level gauge dipstick Route the oil level switch lead behind the battery bracket Carburetor heater coupler Fasten the positive starter motor lead and oil tank inlet hose with the plastic band Face the end of the plastic band towards the bat
63. runners Check for wear and damage Replace if necessary Brake and parking brake Check operation and fluid leakage Adjust free play and or replace pads if necessary Replace brake fluid See NOTE on page 4 Disc brake installation Check for slight free play Lubricate shaft with specified grease as required Every 1 600 km 1 000 mi Drive chain oil Check oil level Replace Drive chain Check deflection Adjust if necessary Initial at 500 km 300 mi and every 800 km 500 mi thereafter Skis and ski runners Check for wear and damage Replace if necessary Steering system Check operation Adjust toe out if necessary Strap Check for damage Replace if necessary Lights Check operation Replace bulbs if necessary Battery Check condition Charge if necessary Primary and secondary clutches Check engagement and shift speed Adjust if necessary Whenever oper ating elevation is changed Inspect sheaves for wear damage Inspect weights rollers and bushings for wear for pri mary Inspect ramp shoes bushings for wear for secondary Replace if necessary Lubricate with specified grease INSP GENERAL MAINTENANCE AND LUBRICATION CHART ADJ Q Initial Pre opera 1 month or Seasonally Remarks tion check 800 km or 4 000 km Daily 500 2 500 mi 40 hr 200 hr
64. sary always replace the chain and the sprockets as a set 4 Inspect e Drive chain f 2 Stiffness gt Clean and lubricate or replace e Drive chain plates 1 AN Damage wear Replace the drive chain NG ooo Cracks gt Replace the drive chain 26 DRIVE CHAIN HOUSING 27 5 Measure e Brake disc thickness Measure the brake disc thickness 1 3 mm 0 04 0 12 in from the edge of the brake disc Out of specification gt Replace Minimum thickness 3 5 mm 0 14 in INSTALLATION 1 Install e Shift drum NOTE Make sure that the projection 1 on the shift fork is properly seated in the shift drum groove 2 2 During installation pay attention to the follow ing Properly install the rubber seal onto the drive chain housing making sure that there are no gaps Make sure that the bearing seals face towards the drive chain as shown Install the washer as shown Be sure to install the spacers in their original posi tions otherwise the brake disc and shaft will stick 0 2 0 7 mm 0 008 0 028 in Make sure that the bearing does not protrude past the end of the counter gear 1 8 0 5 mm 0 071 0 020 6 0 5 mm 0 236 0 020 Stamp side 1 8 0 5 mm 0 071 0 020 5 0 5 mm 0 197 0 020 in ES
65. senger grip warmer DC back buzzer Gear position switch relay Gear position switch Brake light switch Tail brake light Speed sensor Fuel sender Oil level switch Meter assembly Multi function meter Warning light Low coolant temperature indicator light Meter light High beam indicator light Auxiliary DC jack fuse Headlight fuse Signal fuse Cooling fan motor fuse Carburetor heater fuse Ignition fuse Auxiliary DC jack Headlight beam switch Headlight relay Headlight 6 6 amp 6 GG 6 9G 6 GGG GGG 6 COLOR CODE Black Brown Dg Dark green MARAHANG Green Gray Lea Blue Lg Light green p Orange Pr Pink Wins White Vinkul Yellow Black Blue B G Black Green BW Black White Black Yellow Br B Brown Black Br G Brown Green Br L Brown Blue Br R Brown Red DAN Brown White Br Y Brown Yellow G B Green Black G R Green Red G N Green White G Y Green Yellow L G Blue Green L R Blue Red L Y auus Blue Yellow Lol Light green Blue Lg W Light green White O B Orange Black O R Orange Red R B Red Black R L Red Blue R W Red White R Y Red Yellow
66. sted below For installation reverse the removal proce dure 32 CAUTION Disc brake components rarely require disas sembly DO NOT e Do not disassemble components unless absolutely necessary Do not use solvents on internal brake compo nents Do not use contaminated brake fluid for cleaning Use only clean brake fluid Do not allow brake fluid to contact the eyes otherwise eye injury may occur Do not allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur Do not disconnect any hydraulic connection otherwise the entire system must be disas sembled drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE n It is not necessary to disassemble the brake caliper and brake hose in order to replace the brake pads 1 Remove e Brake pads NOTE Do not depress the brake lever when the caliper or disc is off the machine otherwise the brake pads will be forced shut Install a new brake pad spring and shims when the brake pads are replaced Replace the pads as a set if either one is found to be worn to the wear limit Wear limit 4 7 mm 0 19 in 33 POWR ener TA 2 Install Brake pads e Pad spring Installation steps Connect a suitable hoses 1 tightly to the cali per bleed screws 2 Put the other end of this hose into an open container Loosen the c
67. t hand thread Apply LOCTITES Primary sheave cap and sliding sheave 1 4 10 Roller and weight primary 0 6 4 3 Set bolt primary sheave collar 0 4 2 9 Apply LOCTITES Secondary sheave 6 4 46 Stopper secondary sheave 0 7 5 1 Spring seat secondary sheave 2 3 17 Secondary sheave adjusting bolt 1 0 7 2 Secondary shaft bolt 3 0 22 Drive chain adjusting locknut 2 5 18 Drive chain housing and frame 4 3 31 Drive chain housing cover chain housing and 4 3 31 frame Shift cam bolt 1 8 13 Gear position switch 2 0 14 Drive chain housing oil drain bolt 1 6 12 Drive chain housing cover M8 2 4 17 Drive chain housing cover M6 1 0 7 2 Set bolt secondary shaft 06 4 3 Apply LOCTITE Shift lever assembly 2 3 17 Shift lever stay and shift lever stopper 2 3 17 Shift lever stay and shift lever guide 5 9 43 Shift lever assembly and lever rod 1 0 7 2 Lever and drive chain housing 1 4 10 Apply LOCTITES Low wheel gear 1 0 7 2 Apply LOCTITE Low pinion gear 1 0 7 2 Apply LOCTITE9 Reverse drive gear shaft 1 0 7 2 Apply LOCTITES Driven gear 5 5 40 Apply LOCTITE Counter gear 1 0 7 2 Apply LOCTITES Driven sprocket and low drive gear 1 8 13 Apply LOCTITE Drive chain housing and brake caliper 4 8 35 Brake caliper bleed screw 0 6 4 3 Brake caliper retaining pin 1 8 13 Brake hose union bolt caliper side 3 0 22 Parking brake assembly and drive chain housing 1 0 7 2 Lever and parking brake assembly 1 6 11 Brake hose u
68. t number starting with YB YM YU or YS ACC For others use part number starting with 90890 FOR ELECTRICAL SERVICE Pocket tester P N YU 03112 C 90890 03112 This instrument is necessary for checking the electrical components INTRODUCTION PERIODIC MAINTENANCE CHART FOR INSP THE EMISSION CONTROL SYSTEM ADJ Q PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments These preventive maintenance procedures if followed will ensure more reliable machine operation and a longer ser vice life In addition the need for costly overhaul work will be greatly reduced This information applies to machines already in service as well as new machines that are being prepared for sale All service technicians should be familiar with this entire chapter PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM Initial Pre opera 1 month or Seasonally Remarks tion check 800 km or 4 000 km Daily 500 2 500 mi 40 hr 200 hr Check condition Spark plugs Adjust gap and clean Replace if necessary Valve clearance Geneck clearance Every 40 000 km 25 000 mi Adjust clearance when engine is cold Check breather hose for cracks or damage Replace if necessary Check condition Replace if necessary Check fuel hose for cracks or damage Replace if necessary Idle speed
69. ten the bleed screws when the brake lever limit has been reached then release the lever AIR BLEEDING HYDRAULIC BRAKE SYSTEM INSP go DRIVE CHAIN ADJ Q i Repeat steps e to h until all of the air bubbles have disappeared from the fluid j Tighten the bleed screws Ng Bleed screw A 6 Nm 0 6 kg 4 3 ft Ib NOTE _ If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bub bles the system have disappeared Add brake fluid to the proper level WARNING After bleeding the brake system check the brake operation DRIVE CHAIN Oil level inspection A WARNING The engine and muffler will be very hot after the engine has run Avoid touching a hot engine and muffler while they are still hot with any part of your body or clothing during inspection or repair 1 Place the machine on a level surface 2 Check e Oil level DRIVE CHAIN ADJ Checking steps e Remove the rubber D e Check the oil level through the check window located on the drive chain housing e f the oil is below the minimum level mark 2 remove the dipstick and add sufficient oil to the maximum level mark Recommended oil Gear oil GL 3 75W or 80W CAUTION Make sure that no foreign material enters the drive chain housing Reinstall the dipstick 3 NOTE n Al
70. ter Intake 5 000 5 012 mm 0 1969 0 1973 in lt Limit gt 5 05 mm 0 199 in Exhaust 5 000 5 012 mm 0 1969 0 1973 in lt Limit gt 5 05 mm 0 199 in Valve stem to valve guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in lt Limit gt 0 08 mm 0 0031 in Exhaust 0 020 0 047 mm 0 0008 0 0019 in lt Limit gt 0 10 mm 0 0039 Valve stem runout limit 0 01 mm 0 0004 in Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 lt Limit gt 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in lt Limit gt 1 6 mm 0 0630 in 53 MAINTENANCE SPECIFICATIONS SPEC ye Valve spring Free length Intake lt Limit gt Exhaust lt Limit gt Installed length valve closed Intake Exhaust Compressed spring force installed Intake Exhaust Spring tilt Intake Exhaust Winding direction top view Intake Exhaust 39 73 mm 1 56 in 37 74 mm 1 48 in 39 73 mm 1 56 in 37 74 mm 1 48 in 33 0 mm 1 30 in 33 0 mm 1 30 in 136 158 N 13 9 16 1 kg 30 6 35 5 lb 136 158 13 9 16 1 kg 30 6 35 5 Ib 2 5 1 7 mm 0 07 in 2 5 1 7 mm 0 07 in Clockwise Clockwise Valve lifter Valve lifter outside diameter Intake lt Limit gt Exhaust lt Limit gt Valve lifter hole inside diameter Intake lt Limit gt Exhaust lt Limit gt 24 482 24 488 mm 0 9639 0 9641 in 24 457 mm 0 9629 in 24 482 24 488 mm 0 9639
71. tery bracket Pass the carburetor heater lead over the oil cooler outlet hose 7 Fasten the wire harness coolant hose with the plastic band making sure that the wire harness is not routed under the hose Starter motor Coolant temperature sensor cou pler 45 5 mm 1 77 0 20 in To the brake caliper Pass the coolant temperature sensor lead over the coolant hose 3 Less than 145 mm 5 71 in Fasten the ignition coil lead and wire harness to the frame cross member with the plastic band making sure to face the end of the band rearward Place the main switch lead cou pler underneath the fuel tank cover 08 Main switch Handlebar switch lead couplers Tail brake light sub wire harness coupler 09 Throttle cable 69 To the tail brake light Thumb warmer switch lead cou plers 62 Grip warmer connectors 63 Headlight beam switch coupler Grip warmer adjustment switch lead coupler Brake light switch coupler 73 CABLE ROUTING SPEC CABLE ROUTING SPEC u o O fem D 572218 22 gt 2222227222222 T 1 74 56 Starter cable Brake hose G Fuel sender lead coupler

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