service repair manual

1. INDEX
GENERAL INFORMATION
PERIODIC INSPECTIONS
AND ADJUSTMENTS
ENGINE OVERHAUL
CARBURETION
POWER TRAIN
CHASSIS
ELECTRICAL
APPENDICES
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2. CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTifiCATION ..................................... 1-'
FRAME SERIAL NUMBER .................................... '-1
ENGINE SERIAL NUMBER .................................... 1-1
D
STORAGE .................................................... 1-2
PRE-SEASON PREPARATION .................................... '-2
IMPORTANT INfORMATION..................................... 1-3
NO FLAME SOURCES ........................................ 1-3
WASHING AND CLEANING ................................... 1-3
RIGHT TOOLS .............................................. '-3
MAKING IT NEAT........................................... 1-3
TIGHTENING TORQUE ...................................... 1-3
ALL REPLACEMENT PARTS .................................. 1-4
GASKETS, Of L SEALS, AND O-RINGS .......................... 1-4
LOCK WASHERS/PLATES AND COTTER PINS.................... 1-4
BEARINGS AND OIL SEALS .................................. 1-4
Cl RCLIPS .................................................. 1-5
SPECIAL TOOLS ............................................... 1-5
FOR TUNE UP .............................................. 1-5
FOR ENGINE SERVICE ...................................... 1-6
FOR POWE R TRAI N SERVICE ................................. 1-6
FOR ELECTRICAL SERVICE .................................. 1-7
SPECIAL TOOLS CROSS REFERENCE LIST......................... 1-9

3. IM'j:~I~IMACHINE IDENTIFICATION
1-1
GENERAL
INFORMATION
MACHINE IDENTI FICATION
FRAME SERIAL NUMBER
The frame serial number ill is located on the
right-hand side of the frame (just below the
front of the seat).
ENGINE SERIAL NUMBER
The engine serial number ill, is located on thp
right-hand side of the crankcase.
NOTE: __________________________
The first three digits of these numbers are for
model identifications; the remaining digits are
the unit production number.
Starting Serial Number:
For (OK, N, NL, S, SF):
83R-000101
For (CON):
84R-000101
NOTE: _________________________
Designs and specifications are subject to change
without notice.

4. STORAGE/PRE-SEASON PREPARATION I~l:~I­
STORAGE
If a snowmobile will not be used for several
months, it should be stored in a proper place so
that both the engine and the track are not
damaged.
• Completely drain the fuel tank, and disconnect
the fuel line from the carburetor.
• With the engine running at idle, squirt oil into
the carburetor until the engine dies. This will
distribute oil evenly throughout the engine,
and protect it against rust.
• Disassemble the suspension, clean and grease
all parts, and reassemble the suspension.
• Lightly coat all shafts and axles with grease.
• Oil all fittings and cable controls with a lightly
oiled cloth.
• Loosen the track.
• Block the chassis so that the track is off the
floor.
• Protect the snowmobile with a covering.
PRE-SEASON PREPARATION
Perform the predelivery service as described in
the predelivery check list before operating any
snowmobile that has been stored for several
months. (Refer to CHAPTER 2. "PERIODIC
MAINTENANCE TABLE", page 2-1.)
1-2

5. '-3
IMPORTANT INFORMATION
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassembly.
While cleaning, take care to protect the
electrical parts, such as relays, switches,
motor, resistors, controllers, etc., from
high pressure water splashes.
2. Use proper tools and cleaning equipment.
Refer to "SPECIAL TOOLS".
3. When disassembling the machine, keep
mated parts together. This includes gears,
cylinders, pistons, and other mated parts
that have been "mated" through normal
wear. Mated parts must be reused as an
assembly or replaced.
4. During the machines disassembly, clean all
parts and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are
correctly reinstalled.
5. Keep away from fire.
6. Be sure to keep to tightening torque specifi-
cations. When tightening bolts, nuts, and
screws, start with a larger-diameter one and
from an inner-positioned one to an outer-
positioned one in a criss-cross pattern.

6. IMPORTANT INFORMATION I~1f=~1-
ALL REPLACEMENT PARTS
300-000
300-002
300-003
1. We recommend to use Yamaha genuine parts
for all replacements. Use oil and/or grease
recommended by Yamaha for assembly and
adjustment.
GASKETS, OIL SEALS, AND O-RINGS
1. All gaskets, seals, and O-rings should be re-
placed when an engine is overhauled. All
gasket surfaces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates CD and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been pro-
perly tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) CD and oil seal(s) CV
with their manufacturer's marks or numbers
facing outward. (In other words, the
stamped letters must be on the side exposed
to view.) When installing oil seal(s), apply a
light coating of light-weight lithium base
grease to the seallip(s). Oil the bearings libe-
rally when installing.
Do not use compressed air to spin the bearings
dry. This causes damage to the bearing surfaces.
1-"

7. I~~~I.I si SPECIAL TOOLS
300-001
1-5
ClRCLIPS
1. All circlips should be inspected carefully be-
fore reassembly. Always replace piston pin
clips after one -use. R.eplace distorted cir-
clips. When installing a circlip <D , make sure
that the sharp edged corner <ID is positioned
opposite to the thrust @ it receives. See the
sectional view.
@Shaft
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or impro-
vised techniques.
FOR TUNE UP
1. Sheave Gauge
PIN YS-91047
This gauge is used for sheave distance and offset
adjustment.
2. Dial Gauge
PIN YU-03097
This gauge is used for ignition timing adjust-
ment.
3. Dial Gauge Stand Set
PIN YU-01256
These tools are uSed for ignition timing adjust-
ment.

8. SPECIAL TOOLS IMIf=~I-
FOR ENGINE SERVICE
1. Universal Rotor Holder
PIN YU-01235
This tool is used to hold starter pulley and COl
magneto.
2. Piston Pin Puller
PIN YU-01304
This tool is used to remove piston pin.
3. Rotor Puller
PIN YU-33270
This tool is used to remove COl magneto.
FOR POWER TRAIN SERVICE
1. Primary Sheave Holder
PIN YS-01880
This tool is used to hold primary sheave.
2. Primary Sheave Puller
PIN YS-01882-A
This tool is used for removing primary sheave.
1-6

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10. SPECIAL TOOLS
1-7
3. Sheave Compressor
PIN YS-28891
This tool is used for disassembling and assembl-
ing sheave.
4. Clutch Spider Separator
PIN YS-28890-A
These tools are used for disassembling and
assembling primary sheave.
5. Clutch Separator Adapter
PIN Y5-34480
This tool is used for disassembling and assembl-
ing primary sheave.
6. Track Clip Installer
PIN Y5-91045
This tool is used for installing the track clip.
FOR ELECTRICAL SERVICE
1. Pocket Tester
PIN Y U-03112
This instrument is necessary for checking the
electrical components.

11. SPECIAL TOOLS
2. Electro Tester
PIN Y U-33260
This instrument is invaluable for checking the
electrical system.
1-8

12. SPECIAL TOOLS CROSS REFERENCE LIST
SPECIAL TOOLS CROSS REFERENCE LIST
SPECIAL TOOL NAME PART NUMBER PART NUMBER
FOR TUNE UP
1. Sheave Gauge YS-91 047 -
2. Dial Gauge YU-03097 90890-03097
3. Dial Gauge Stand Set YU-01256 90890-01256
FOR ENGINE SERVICE
1. Universal Rotor Holder YU-01235 90890-01235
2. Piston Pin Puller YU-01304 90890-01304
3. Rotor Puller YU-33270 -
FOR POWER TRAIN SERVICE
1. Primary Sheave Holder YS-01880 90890-01701
2. Primary Sheave Puller YS-01882-A 90890-01898
3. Sheave Compressor YS-28891 90890-01712
4. Clutch Spider Separator YS-28890-A 90890-01711
5. Clutch Separator Adapter YS-34480 -
6. Track Clip Installer YS-91 045 TLS90-91 045
FOR ELECTRICAL SERVICE
1. Pocket Tester YU-03112 90890-03112
2. Electra Tester YU-33260 90890-03021
1-9

13. CHAPTER 2.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-1
PERIODIC MAINTENANCE TABLE ............................... 2-1
LUBRICATION INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-3
SHROUD COVERS AND SEAT ........... , ....................... 2-4
SHROUD OPENING .. " ...... " .. " ., .. " ................... 2-4
SHROUD ................................................. 2-4
SEAT ........ , .. " ............... , ....................... 2-4
HANDLEBAR COVER ....................................... 2-5
WIND SHIELD SPEEDOMETER AND HEADLIGHT ............... 2-6
COVERS.................................................. 2-7
ENGINE .................... ; .............................. " 2-9
ENGINE OIL LEVEL INSPECTION............................. 2-9
FUEL LINE INSPECTION .................................... 2-10
ENGINE OIL LINE INSPECTION .............................. 2-10
ENGINE IDLE SPEED ADJUSTMENT ........ , ................. 2-10
THROTTLE CABLE FREE PLAY ADJUSTMENT ... , ............. 2-11
STARTER CABLE ADJUSTMENT ... , ......................... 2-12
OIL PUMP CABLE FREE PLAY ADJUSTMENT................... 2-12
OIL PUMP STROKE ADJUSTMENT ............................ 2-13
OIL PUMP AIR BLEEDING ................................... 2-18
OIL FILTER INSPECTION ................................... 2-19
FUEL FILTER INSPECTION.................................. 2-20
FUEL PUMP OPERATION CHECK ............................. 2-20
COOLING FAN BELT INSPECTION ............................ 2-22
COOLING FAN BELT TENSION ADJUSTMENT .................. 2-23
POWER TRAIN ........... ',' .................................. 2-25
DRIVE V-BELTINSPECTION ..................... , ........... 2-25
SHEAVE DISTANCE AND OFFSET ADJUSTMENT ............... 2-27
DRIVE CHAIN HOUSING OIL LEVEL INSPECTION..... , ......... 2-30
DRIVE CHAIN HOUSING OIL REPLACEMENT ...... , ... , ....... 2-31
DRIVE CHAIN SLACK ADJUSTMENT................ , ......... 2-32
BRAKE PAD INSPECTION ................................... 2-34
BRAKE ADJUSTMENT ...................................... 2-34
TRACK TENSION ADJUSTMENT.............................. 2-36
HINGED EXTENSION ADJUSTMENT .......................... 2-38
....

14. CHASSIS..................................................... 2-39
SKI ADJUSTMENT ......................................... 2-39
BRAKE CABLE END LUBRICATION ........................... 2-40
SLlDER RUNNER INSPECTION ............................... 2-41
ELECTRICAL................................................. 2-41
SPARK PLUG INSPECTION .............. , . '" .............. , 2-41
IGNITION TIMING ADJUSTMENT......................... , ... 2-42
HEADLIGHT BULB REPLACEMENT ........................... 2-44
HEADLIGHT BEAM ADJUSTMENT ............................ 2-45
TAIL/BRAKE LIGHT REPLACEMENT.......................... 2-46
METER LIGHT REPLACEMENT............................... 2-46
TUNING . .................................................... 2-47
CARBURETOR TUNING ..................................... 2-47
CLUTCH TUNING .................. , ....................... 2-55
SLIDE RAIL SUSPENSION TUNING ... , ....................... 2-57
HIGH ALTITUDE TUNING ........... , ....................... 2-59

15. INTRODUCTION/PERIODIC MAINTENANCE TABLE
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to vehicles already in service as well as new vehicles that are being prepared for sale. All service
technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE
Every
Check point 20 hrs. or 40 hrs. or 80 hrs. or When
Seasonally
400 km 800 km 1,600 km necessary
(250 mi) (500 mi) (1,000 mU
ENGINE:
Tightness of bolts and nuts 0 0
Bends, cracks and wear 0 0
Abnormal noise 0 0
Loose connection and breaks of fuel and pulse pipes 0 0
Loose connection and breaks of oil pipes 0 0
Loose connection and breaks of oil delivery pipe 0 0
Manual rope starter system 0 0
CARBURETOR:
• Operation of starter jet 0 0
• Mixing adjuster (pilot screw) 0 0
• Idling speed adjustment 0 0
Operation and adjustment of oil pump 0 0
Ignition timing 0
Engine compression 0 0
Cylinder head/exhaust pipe decarbonization 0
Fan belt tension, damage 0 0
Spark plug condition, gap and cleaning 0 0
Tightening of the cylinder head** 0
DRIVE:
Tightness of bolts and nuts 0 0
Wear on slide runners 0 0
Primary drive system 0 0
V-belt 0 0
Secondary drive system 0 0
Sheave distance 0 0
Sheave offset 0 0
Brake pad wear 0 0
Brake operation and adjustment 0 0
Guide wheel rubber 0 0
Wear of drive track wheel sprocket 0 0
Drive track adjustment 0 0
Breaks in drive track 0 0
Bends in front and rear axles 0 0
Checking of lock washers 0 0
Drive chain adjustment 0 0
Drive chain oil level 0 0
2-1