3. CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTifiCATION ..................................... 1-'
FRAME SERIAL NUMBER .................................... '-1
ENGINE SERIAL NUMBER .................................... 1-1
DSTORAGE .................................................... 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
4. 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.
5. STORAGE/PRE-SEASON PREPARATION I~l:~IĀ
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.
ā¢ Completely drain the fuel tank, and disconnect
the fuel line from the carburetor.
ā¢ 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.
ā¢ Disassemble the suspension, clean and grease
all parts, and reassemble the suspension.
ā¢ Lightly coat all shafts and axles with grease.
ā¢ Oil all fittings and cable controls with a lightly
oiled cloth.
ā¢ Loosen the track.
ā¢ Block the chassis so that the track is off the
floor.
ā¢ 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
6. '-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.
7. 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-"
8. 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.
9. 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
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
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:
ā¢ Operation of starter jet 0 0
ā¢ Mixing adjuster (pilot screw) 0 0
ā¢ 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
16. 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 mi)
BODY:
Tightness of bolts and nuts 0 0
Bends and cracks 0 0
Welded/riveted, joints 0 0
Ski adjustment 0 0
Ski runner wear 0 0
Breaks in fuel tank 0 0
Cleaning of fuel tank 0
Fuel filter 0
Loose connection and breaks in fuel pipe 0 0
Breaks in oil tank 0 0
Oil filter 0
ELECTRICAL:
Wear, breakage of wire covering 0 . 0
Breaks in high-tension cord 0 0
Voltage regulator working voltage 0
Operation of engine stop switch 0 0
Operation of throttle override system 0 0
Headlight 0 0
Taillight 0 0
Brake light 0 0
** Retighten every 10 hours from the first use.
2-2
17. Ir8fIQILUBRICATION INTERVALS
LUBRICATION INTERVALS
Every
Check point 20 hrs. or 40 hrs. or 80 hrs. or When
400 km 800 km 1,600 km necessary
(250 mi) (500 mi) (1,000 mi)
ENGINE:
Starter case
Oil pump control box 0
Pump drive cover 0
Oil in the oil tank 0
DRIVE:
Primary sheave weight
0and roller pins
Secondary shaft and
0sliding sheave
Front axle housing 0
Shaft 1 and shaft 2
0(Slide rail)
Drive chain oil Initial
0replacement 0
BODY:
Steering column lower
0bearing
Steering column upper
0bearing
Steering links 0
Ski column 0
Ski wear plate 0
Ski retaining pin 0
Brake wire and stopper
0and brake lever
2-3
Seasonally
Oil/Grease
Brand name
0
0 Aeroshell grease #7A or
Esso Beacon 325 grease
0
YAMALUBE 2-cycle oil
0 Molybdenum disulfide
snowmobile grease
0 Molybdenum disulfide
snowmobile grease
0
0
Light all-purpose grease
0 Gear oil API GL-3
SAE #75 or #80
0 Light all-purpose grease
0 Motor oil
0
Light all-purpose grease
0
0
Light all-purpose grease
0
0 Esso Beacon 325 grease
18. IlANOSJP I~ ISHROUD OPENING/SHROUD/SEAT ~
-----------------------------------------------------SHROUD COVERS AND SEAT
SHROUD OPENING
When the engine requires a check or service, the
shroud can be opened forward.
1. Unhook:
- Shroud latches CD
Right and left of the shroud.
2. Should be slowly raised until shroud stops.
SHROUD
Removal
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Disconnect:
- Headlight lead CD
- Meter light leads Ā®
-Speedometer cable Ā®
3. Unhook:
-Stop wire CD
4. Remove:
-Shroud Ā®
Installation
Reverse the removal procedure.
Note the following points.
1. Install:
-Shroud
SEAT
Removal
Nuts (Shroud hinger):
5 Nm (0.5 mĀ· kg, 3.6 ftĀ·lb)
1. Unhook:
- Seat latches CD
2-4
19. Ir&rIfitIHANDLEBAR COVER
2-5
2. Remove:
-Seat hinge pins CD
3. Remove:
-Seat CD
Installation
Reverse the removal procedure.
1. Install:
-Seat
HANDLEBAR COVER
Removal
1. Remove:
- Handlebar covers (Front CD and rear CV )
Installation
1. Install:
- Handlebar covers (Front and rear)
20. WIND SHIELD, SPEEDOMETER AND HEADLIGHT
WIND SHIELD, SPEEDOMETER AND HEAD-
LIGHT
Removal
1. Remove:
.Windshield CD
2. Open the shroud.
3. Disconnect:
ā¢ Speedometer cable CD
ā¢ Meter light leads CV
4. Remove:
ā¢ Front cowl CD
ā¢ Headlight adjuster handle CV
ā¢ Meter panel @
5. Disconnect:
ā¢ Headlight lead CD
2-6
21. Ir8flĀ§ll_co_V_ER_S______________________
2-7
6. Remove:
ā¢ Headlight CD
Installation
Reverse the removal procedure.
Note the following points.
1. Install:
-Headlight
ā¢ Front cowl
Nuts (Front cowl):
5 Nm (0.5 m' kg, 3.6 ftĀ·lb)
2. Install:
ā¢ Meter panel
Nuts:
2 Nm (0.2 m' kg, 1.4 ftĀ·lb)
fo-iiiiiOIIo.... Screw:
2 Nm (0.2 mĀ·kg, 1.4 ftĀ·lb)
3. Install:
et Windshield
I~ Screw:
2 Nm (0.2 mĀ·kg, 1.4 ftĀ·tb)
COVERS
Removal
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
ā¢ Side covers (Left CD and right CV )
22. COVERS
3. Remove:
ā¢ Main switch holding nut CD
."STARTER" lever holding nut CID
ā¢ Tether switch holding nut @
4. Remove:
ā¢ Handlebar cover (Lower) CD
5. Remove:
ā¢ Drive select lever boots CD
6. Open the seat.
7. Remove:
ā¢ Fuel level indicator hose CD
.Oillevel indicator hose CID
ā¢ Center cover @
2-8
23. 2-9
llEVEl INSPECTION
Installation
Reverse the removal procedure.
Note the following points.
1. Install:
ā¢ Center cover
.Oillevei indicator hose CD
ā¢ Fuel level indicator hose CV
NOTE:_____________....
When installing the oil and fuel level indicator
hoses, be sure to secure the hoses using the
white guide plates in proper positions.
ENGINE
ENGINE Oil lEVEL INSPECTION
1. Place the machine on a level place.
2. Inspect:
"Engine oil level
Oil level low -? Add sufficient oil.
CD "F" (Full) level mark
CV "E" (Empty) level mark
3. Open the shroud.
Refer to the "SHROUD OPENING" section.
4. Add the engine oil until the oil level reaches
"F" level mark.
~ Recommended oil:
ā¢U YAMAlUBE "2" or equivalent
CD Oil tank cap
Always use the same type of engine oil; mixing
oils may result in a hurmful chemical reaction
and lead to poor performance.
24. FUEL LINE INSPECTION/ENGINE 01 L LINE INSPECTIONI
ENGINE IDLE SPEED ADJUSTMENT
FUEL LINE INSPECTION
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Inspect:
~ Fuel hose
Crack/Damage -+ Replace.
ENGINE OIL LINE INSPECTION
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. inspect:
@ Engine oil hose
Crack/Damage -+ Replace.
ENGINE iDLE SPEED ADJUSTMENT
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Adjust:
@Pilot screw CD
Pilot screw adjustment steps:
@Turn in the both pilot screw until they are
lightly seated.
Ii Turn out the both piiot screw to specifica-
tion.
Pilot Screw:
1-1/4 turns out
3. Start the engine and let it warm up.
4. Adjust:
ā¢ Engine idle speed
Adjustment steps:
ā¢ Turn the throttle stop screw CD in or out
until the specified engine speed is obtained.
2-10
25. IlANDS.JP IMlĀ·1~ THROTTLE CABLE FREE PLAY ADJUSTMENT
--------------------------------------------------
2-11
Turn in Idle speed becomes higher.
Turn out Idle speed becomes lower.
Engine Idle Speed:
C1 1,100 '" 1,200 r/min
NOTE:
After adjusting the engine idle speed, the
throttle cable free play should be adjusted.
THROTTLE CABLE FREE PLAY ADJUST-
MENT
NOTE:_________________
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
1. Measure:
ā¢ Throttle cable free play Ā®
Out of specification ~ Adjust.
Throttle Cable Free Play:
1.0 '" 2.0 mm (0.04 '" 0.08 in)
2. Open the shroud.
Refer to the "SHROUq OPENING" section.
3. Adjust:
ā¢ Throttle cable free play
Free play adjustment steps:
ā¢ Open the shroud.
Refer to the "SHROUD OPENING" section.
ā¢ Loosen the locknut CD .
ā¢ Turn the adjuster CV in or out until the
specified free play is obtained.
Turn in Free play is increased.
Turn out Free play is decreased.
ā¢ Tighten the locknut.
4. Close the shroud.
26. STARTER CABLE ADJUSTMENT/
OIL PUMP CABLE FREE PLAY ADJUSTMENT
~H---+Ā®
STARTER CABLE ADJUSTMENT
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
ā¢ Rubber cap CD
3. Pull the outer tube of starter cable upward.
4. Measure:
ā¢ Starter cable free play Ā®
Out of specification -+ Adjust.
FreePlayĀ®:
0.5'" 1.5 mm (0.02'" 0.06 in)
5. Adjust:
ā¢ Starter cable free play
Free play adjustment steps:
ā¢ Loosen the locknut CD .
ā¢ Turn the adjuster <ID in or out until the
specified free play is obtained.
Turn in Free play is increased.
Turn out Free play is decreased.
.Tighten the locknut and install the rubber
cap.
6. Close the shroud.
OIL PUMP CABLE FREE PLAY ADJUST-
MENT
NOTE:___________________________
Before adjusting the oil pump cable free play,
the throttle cable free play should be adjusted.
1. Open the shroud.
Refer to the "SHROUD OPENING"
section.
2-12
27. I IANDSJPlel_~~~~~~~~__ _~ _OIL PUMP STROKE ADJUSTMENT
11'
2-13
2_ Pull:
.Oil pump outer cable
3. Measure:
ā¢ Oil pump cable free play Ā®
Out of specification -+ Adjust.
Free Play:
24 - 26 mm (0.94 - 1.02 in)
4. Adjust:
ā¢ Oil pump cable free play
Free play adjustment steps:
ā¢ Loosen the locknut CD .
ā¢ Turn the adjuster Ā® in or out until the
specified free play is obtained.
Turn in Free play is increased.
Turn out Free play is decreased.
ā¢ Tighten the locknut and install the rubber
cap.
5. Close the shroud.
OIL PUMP STROKE ADJUSTMENT
1. Open the shroud.
2. Remove:
ā¢ Drive V-belt guard CD
3. Loosen:
ā¢ Locknut CD (Oil pump cable)
.Adjuster Ā® (Oil pump cable)
4. Remove:
.Oil pump cable Ā®
28. OIL PUMP STROKE ADJUSTMENT
5. Disconnect:
ā¢ Oil hoses CD
.Oil delivery hoses Ā®
NOTE:_________- - -
Plug the oil hoses and oil delivery hoses so that
oil does not run out.
6. Remove:
.Oil pump assembly CD
7. Remove:
.Oil pump driven gear housing CD
Place a rug under the oil pump assembly.
8. Disconnect:
.Oil hoses Ā®
9. Remove:
ā¢ Oil pump cover CD
10. Wipe off the grease from the plunger top.
2-14
29. IlANOSJP IMlĀ·Ā·1~ OIL PUMP STROKE ADJUSTMENT
.Ā®~Ā®
@
2-15
---------------------------------------------------------
11. Measure:
-Minimum pump stroke Ā®
Out of specification ~ Adjust.
Minimum Pump Stroke:
0.20'" 0.25 mm (O.OOS'" 0.010 in)
Minimum pump stroke measurement steps:
- Turn the pump worm gear CD with your
fingers, until the plunger top Ā® is at its
maximum distance from the pump body
mating surface @ of the pump cover.
- Using a Feeler Gauge, measure the minimum
pump stroke Ā® between the adjusting plate
@ and the raised boss <ID on the adjusting
pulley.
-If minimum pump stroke is not within the
specjfied limits, perform the adjustment
steps.
12. Measure:
- Maximum pump stroke@
Out of specification ~ Adjust.
Maximum Pump Stroke:
1.65'" 1.S7 mm (0.065'" 0.074 in)
Maximum pump stroke measurement steps:
- Pull the oil pump cable CD out of its sheather
as far as it will go. The cable must be held in
this taut position when measuring the
maximum pump stroke.
NOTE: _________________________
It may be helpful to securely warp duct tape
Ā® around the cable where it enters the
sheath.
- Turn the pump worm gear @ with your
fingers, until the plunger top @ is at its
maximum distance from the pump body <ID.
- Using a Feeler Gauge, measure the maxi-
mum pump stroke @ .
-If maximum pump stroke is not within the
specified limits, perform the adjustment
steps.
30. 01 L PUMP STROKE ADJUSTM ENT
13. Adjust:
.Oil pump stroke
Adjustment steps:
ā¢ Remove the locknut CD , spring washer Ā®
and adjusting plate @ .
ā¢ Adjust the pump stroke by adding or remov-
ing a shim.
(4)'Shims
Add shim Pump stroke is increased.
Remove shim Pump stroke is decreased.
ā¢ Reinstall the adjusting plate, spring washer
and locknut.
IĀ® Locknut:
7 Nm (0.7 mĀ·kg, 5.1 ft'lb)
ā¢ Recheck the minimum and maximum pump
stroke.
If out of specification limits, perform the
above steps again.
14. Apply:
ā¢ Lithium soap base grease
To out side of pump pulley.
15. Install:
ā¢ Oil pump cover CD
NOTE:____________
Apply the Yamabond No. 5Ā® (ACC-ll001-31-
00) to the mating surface of the oil pump cover.
2-16
31. ,
2-17
6 pump driven gear
i:
pump
. !I1stai!:
@
III
@ hoses
pump, oil hose and oH
bleed.
to
section.
23. Adjust:
IL
'" Oil pump cable free
Free Play:
CD
AIR B
24 ~ 26 mm (0.94 - 1.02 in)
Refer to the "OIL PUMP CABLE. FREE
PLAY ADJUSTMENT" section.
24. Close the shroud.
32. OIL PUMP AIR BLEEDING
OIL PUMP AIR BLEEDING
The oil pump and delivery line must be bled on
the following occasions:
.Any portion of the oil system has beendis-
connected.
ā¢ The machine has been turned on its side.
ā¢ Whenever the oil tank has been run empty.
ā¢ During predelivery.
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Disconnect:
.Oil delivery hoses CD
3. Fill:
.Oil tank CD
~ Recommended Oil:
'u Yamalube "2" or equivalent
4. Place a rug under the oil pump assembly.
5. Put Yamalube "2" or equivalent into the oil
delivery hoses for complete air bleeding.
Then, connect them with the oil pump.
6. Remove:
ā¢ Bleed screw CD
7. Inspect:
ā¢ Gasket (B leed screw)
Damage ~ Replace.
2-18
33. 2-19
OIL FILTER INSPECTION
8. Keep the oil running out until air bubbles
disappear.
9. Install:
ā¢ Gasket (Bleed screw)
ā¢ Bleed screw
10. Close the shroud.
OIL FILTER INSPECTION
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
ā¢ Drive V-belt guard CD
3. Remove:
ā¢ Oil filter CD
NOTE:____________
Plug the oil hoses so that the oil will not run
out of the oil tank and oil pump.
4. Inspect:
ā¢ Oil filter CD
Contamination ~ Replace.
Recommended Replacement Interval:
Every season
5. Install:
.Oil filter
6. Install:
ā¢ Drive V-belt guard
7. Close the shroud.
34. FUEL FILTER INSPECTION/FUEL PUMP OPERATION CHECK
FUEL FILTER INSPECTION
1. Remove the center cover.
Refer to the "COVE RS" section.
2. Remove:
-Springs CD
3. Remove:
-Cap CD
- Fuel filter CV
4. Inspect:
- Fuel filter CD
Contamination -+- Replace.
Recommended Replacement Interval:
Every season .
5. Install:
- Fuel filter
-Cap
-Springs
- Center cover
FUEL PUMP OPERATION CHECK
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
-Oil tank CD
2Ā·20
35. I IANDSJPlel_~~~~~~~~__ _~ _ FUEL PUMP OPERATION CHECK
2-21
3. Disconnect:
ā¢ Fuel hoses CD
ā¢ PuIser hose CV
4. Remove:
ā¢ Fuel pump CD
5. Inspection:
ā¢ Fuel hoses CD
ā¢ Pulser hose CV
Clog/Damage -+ Replace.
6. Check:
ā¢ Fuel pump operation
Fuel pump operation checking steps:
ā¢ Connect a hand-operated vacuum pump
(such as Mighty - VacĀ®) to the pulser hose
CD.
ā¢ When operating a hand-operated vacuum
pump, fuel flows out of the fuel hose CV
and@.
ā¢ If fuel does not flow out, replace the fuel
pump.
36. 1lANOSJP 1"'1COOLING FAN BELT INSPECTION _ _~ _
-------------------------------------------------
7. Install:
ā¢ Fuel pump
8. Connect:
ā¢ Fuel hoses
ā¢ Pulser hose
9. Install:
.Oil tank
10. Close the shroud.
COOLING FAN BELT INSPECTION
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
ā¢ Seal rubber stay (Air duct) CD
ā¢ Recoil starter assembly CID
ā¢ Cooling fan cover Ā®
3. Remove:
ā¢ Starter pu lIey CD
NOTE:___________________________
Attach the Universal Rotor Holder (YU-01235)
CID to hold the starter pulley.
ā¢ Fan belt drive pulley Ā®
ā¢ Fan belt @
4. Remove:
ā¢ Fan belt driven pulley CD
5. Inspect:
ā¢ Fan belt
Wear/Crank/Damage -+- Replace.
2-22
37. 2-23
COOLING FAN BELT TENSION ADJUSTMENT
6. Install:
ā¢ Fan belt driven pulley
Nut (Driven Pulley):
43 Nm (4.3 m- kg, 31 ftĀ·lb)
7. Install:
ā¢ Fan belt
ā¢ Fan belt drive pulley
ā¢ Starter pulIey
ā¢ Cooling fan cover
ā¢ Recoil starter assembly
ā¢ Seal rubber stay (Air duct)
8. Close the shroud.
COOLING FAN BELT TENSION ADJUST-
MENT
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
ā¢ Seal rubber stay (Air duct) CD
ā¢ Cooling fan cover CV
3. Measure:
ā¢ Fan belt deflection Ā®
Pushed at belt center by a force of 4 - 6
kg(8.8-13.2Ib).
Out of specification -+- Adjust.
Fan Belt Deflection Ā®:
8 mm (0.31 in)!
4 - 6 kg (8.8 - 13.2Ib)
4. Adjust:
ā¢ Fan belt deflection
Fan belt deflection adjustment steps:
ā¢ Remove the recoil starter assembly and
drive pulley.
Refer to the "COOLING FAN BELT INS-
PECTION" section.
38. 2
COOLING FAN BELT TENSION ADJUSTMENT I~gr I~I
ā¢ Remove the pulley (Outer half) and shim(s).
ā¢ There are usually two shims, one of 0.5 mm
(0.02 in) thickness CD and the other of
1.0 mm (0.04 in) thickness CV , between
the pulley halves. Check the number of the
shims and their thicknesses.
ā¢ Select the suitable shim(s) using the follow-
ing chart.
NOTE:
Install the removed shim(s) on the outside
of the pulley. Do not dispose of the removed
shim(s).
Shim requirement!
Place one 1.0 mm (0.04 in) shim
between the pulley halves.
~
After securing the driven pulley nut,
I~check the belt tension.
~
ā¢18 mm (0.31 in)
I
8 mm (0.31 in)
or more
~
Proper belt tension
is attained.
"Iq ,.
Change the "Shim requirement" to (1) and
then (2), and repeat the same procedure.
(1) Place one 0.5 mm (0.02 in) shim
between the pulley halves.
(2) Remove both shims between the pulley
halves.
5. Install:
ā¢ Fan belt driven pulley
Refer to the "COOLING FAN BELT
INSPECTION" section.
6. Close the shroud.
2-24
39. IlANOSJP I~ I~ DRIVE V-BELT INSPECTION
2-25
---------------------------------------------------------POWER TRAIN
DRIVE V-BELT INSPECTION
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
ā¢ Drive V-belt guard CD
ā¢ Drive V-belt CID
Drive V-belt removal steps:
ā¢ Turn the secondary sliding sheave <V clock-
wise and push it towards the engine.
ā¢ While holding the secondary sliding sheave
in this compressed position, remove the
drive V-belt CID from the secondary sheave.
ā¢ Then, remove the drive V-belt from the
primary sheave.
3. Inspect:
ā¢ Drive V-belt
Crack/Wear/Damage -7 Replace.
Oil or grease adhered to the V-belt -7 Check
the primary and secondary sheaves.
4. Inspect:
ā¢ Primary sheave
ā¢ Secondary sheave
Oil or grease adhered to the primary and
secondary sheaves -7 Remove the oil or
grease using a rug soaked in lacquer thinner
or solvent.
40. Thank you very much
for your reading.
Please Click Here
Then Get More
Information.
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ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols Q) to Ā® are designed as
'thumb tabs to indicate the chapter's number and
content.
Q)General information
Ā®Periodic inspection and adjustment
@Engine
@Cooling system
CIDCarburetion
CIDPower train
(j)Chassis
Ā®Electrical
Ā®Appendices
Illustrated symbols QW to @ are used to iden-
tify the specifications appearing.
QWFilling fluid
@Lubricant
@Tightening
@Wear limit, clearance
@ Engine speed
@n,V,A
Illustrated symbols @ to @ in the exploded
diagram indicate grade of lubricant and location
of lubrication point.
@Apply locking agent (LOCTITE@)
@Apply engine oil
@ Apply gear oil
@Apply molybdenum disulfide oil
Ā®Apply wheel bearing grease
Ā®Apply low-temperature lithium-soap base grease
@Apply molybdenum disulfide grease](https://image.slidesharecdn.com/2003yamahavikingvk540seriessnowmobileservicerepairmanual-171227141205/85/2003-yamaha-viking-vk-540-series-snowmobile-service-repair-manual-1-320.jpg)
