SNOWMOBILE OWNER’S MANUAL RS90K RS90MK RS90RK RSG90K YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.04-2.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM A ESU00286 1- MACHINE IDENTIFICATION Identification number records A. FRAME NUMBER: CZ-01E B B. ENGINE NUMBER (PRIMARY ID): CZ-01E C. KEY NUMBER: C CZ-01E Record the frame number, engine number (Primary ID), and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer. 1 The frame number is the seventeen-digit number stamped on the frame of the snowmobile. (See fig. È.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU00011 INTRODUCTION 2- Congratulations on your purchase of a Yamaha snowmobile. This model is the result of Yamaha’s vast experience in the production of fine sporting and touring snowmobiles. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this snowmobile.
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM WARNING @ PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE SNOWMOBILE. @ NOTE: @ ● ● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your snowmobile and this manual. If there is any question concerning this manual, please consult a Yamaha dealer.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU00003 CONTENTS YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTY .......................................1-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ...............................................1-4 LOCATION OF THE IMPORTANT LABELS .......................2-1 SAFETY INFORMATION ...................3-1 DESCRIPTION ...................................4-1 CONTROL FUNCTIONS ....................5-1 Main switch......................................
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM Operation on surfaces other than snow or ice ......................................7-6 Maximizing drive track life ...............7-7 Strap ................................................7-8 Driving .............................................7-9 Stopping the engine.......................7-10 Transporting ..................................7-11 PERIODIC MAINTENANCE ...............8-1 Periodic maintenance chart .............8-1 Tool kit ....................
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU00004 YAMAHA MOTOR CORPORATION, U.S.A.
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U8ES10.book Page 4 Monday, April 12, 2004 1:25 PM ESU04280 YAMAHA EXTENDED SERVICE (Y.E.S.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU04050 LOCATION OF THE IMPORTANT LABELS 2- Please read the following labels carefully before operating this snowmobile. NOTE: @ Maintain or replace safety and instruction labels, as necessary.
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U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM NOTE: @ The following suspension adjustment charts are included with the Owner’s Manual.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU00008 SAFETY INFORMATION 3- When you ride your snowmobile, you must know and use the following for your safety. Severe injury or death may result if you ignore any of the following. Before operating 1. Read the Owner’s Manual and all labels before operating this snowmobile. Become familiar with all of the operating controls and their function. Consult a Yamaha dealer about any control or function you do not understand. 2.
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM 7. Do not allow anyone to stand behind the snowmobile when starting, inspecting, or adjusting the snowmobile. A broken track, track fittings, or debris thrown by the track could be dangerous to the operator or bystanders. 8. Handle fuel with care; it is HIGHLY FLAMMABLE. ● Never add fuel when the engine is running or hot. Allow the engine to cool for several minutes after running. ● Use an approved fuel container.
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM 3. This snowmobile is not designed for use on surfaces other than snow or ice. Use on dirt, sand, grass, rocks, or bare pavement may cause loss of control and may damage the snowmobile. 4. Avoid operating on glare ice, or on snow which has a lot of dirt or sand mixed in. Operation under such conditions will damage or result in rapid wear of ski runners, drive track, slide runners, and drive sprockets. 5.
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U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU00013 5- CONTROL FUNCTIONS ESU00362 Main switch The main switch controls the following items. 1 “OFF” The ignition circuit is switched off. The key can be removed only in this position. 2 “ON” The ignition circuit is switched on. 3 “START” The starting circuit is switched on. The starter motor starts. CAUTION: @ Release the switch immediately after the engine starts.
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM ESU00201 Starter lever (choke) Use the starter lever (choke) when starting and warming up a cold engine. 1 2 3 4 Starter lever (choke) When starting a cold engine. Warming up When the engine is warm. NOTE: @ Refer the “Starting the engine” section for proper operation. @ ESU00022 Throttle lever Once the engine is running cleanly, squeezing a the throttle lever 1 will increase the engine speed and cause engagement of the drive system.
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM ESU04151 Throttle override system (T.O.R.S.) If the carburetor or throttle cable should malfunction during operation, the T.O.R.S. will operate when the throttle lever is released. The T.O.R.S. is designed to interrupt the ignition and keep the engine speed between 2,800 and 3,000 r/min if the carburetor fails to return to idle when the lever is released. WARNING @ ● ● A If the T.O.R.S.
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U8ES10.book Page 5 Monday, April 12, 2004 1:25 PM ESU03821 Fuel meter and grip/thumb warmer level indicator The fuel meter and grip/thumb warmer level indicator have eight segments 1 which show the amount of fuel remaining in the fuel tank, the grip warmer level, or the thumb warmer level. Fuel meter As the fuel level decreases in the fuel tank, the segments disappear until the level goes down to the last segment “E” (Empty).
U8ES10.book Page 6 Monday, April 12, 2004 1:25 PM ESU04260 Fuel level warning indicator The fuel level warning indicator indicates a malfunctioning sensor, disconnected coupler, broken lead, or short circuit when detected by the self-diagnosis device of the snowmobile. The fuel level warning indicator 1, warning light 2, and all segments of the fuel meter 3 warn the rider of the above problems by flashing continuously. When this occurs, have a Yamaha dealer inspect the snowmobile as soon as possible.
U8ES10.book Page 7 Monday, April 12, 2004 1:25 PM ESU04180 Coolant temperature warning indicator If the engine overheats, the coolant temperature warning indicator 1 and the warning light 2 come on. When this occurs, stop the engine immediately and allow the engine to cool down, and then check the coolant level in the coolant reservoir. (See page 6-4.) CAUTION: @ Do not operate the engine if it overheats.
U8ES10.book Page 8 Monday, April 12, 2004 1:25 PM ESU00031 Engine stop switch The engine stop switch 1 is used to stop the engine in an emergency. Simply push 2 the stop switch to stop the engine. To start the engine, pull 3 the stop switch and proceed with starting the engine. (See page 7-1 for more details.) During the first few rides, practice using the stop switch so that you can react quickly in an emergency. ESU00320 Brake lever The snowmobile is stopped by braking the entire drive system.
U8ES10.book Page 9 Monday, April 12, 2004 1:25 PM A ESU00035 Parking brake lever When parking the snowmobile or starting the engine, apply the parking brake by moving the brake lever 1 to the left. To release the parking brake, move the parking brake lever 1 to the right. B È To apply the parking brake É To release the parking brake WARNING @ ● ● Always set the parking brake before attempting to start the engine. Never run the snowmobile with the parking brake applied.
U8ES10.book Page 10 Monday, April 12, 2004 1:25 PM ESU00039 Headlight beam switch Push the headlight beam switch to change the headlight beam to high or low. 1 2 3 4 Headlight beam switch Push High beam Low beam ESU00481 Shroud latches To open the shroud, unhook the shroud latches, and then slowly raise the shroud forward until it stops. When closing the shroud, slowly lower it to its home position, and then hook the shroud latches.
U8ES10.book Page 11 Monday, April 12, 2004 1:25 PM ESU00053 V-belt holders Keep a spare V-belt for emergency use by placing it into the V-belt holders provided. CAUTION: @ Make sure that the V-belt is installed securely in the holders. @ ESU04080 Carburetor coolant shut-off lever For RS90M The carburetor coolant shut-off lever controls the flow of coolant through the carburetor.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU00072 PRE-OPERATION CHECKS 6- NOTE: @ Pre-operation checks should be made each time the snowmobile is used. @ WARNING @ The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair. @ ESU00075 Fuel Make sure that there is sufficient fuel in the fuel tank.
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM CAUTION: @ ● ● ● ● Oxygenated fuels (gasohol) containing a maximum 5% of ethanol can be used, although richer jetting may be required to prevent engine damage. Consult a Yamaha dealer. Gasohol containing methanol is not recommended. Make sure that snow or ice does not enter the fuel tank when refueling. Do not use alcohol deicers or water absorbing additives with oxygenated fuel. The fuel tank should be filled with straight gasoline as specified.
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM ESU03441 Engine oil level The engine oil level should be checked before each use. CAUTION: @ Do not run the engine with too much or not enough oil in the oil tank. Oil could flow into the air filter case and the engine could be damaged. @ Checking the engine oil level 1. Place the snowmobile on a level surface and apply the parking brake. 2. Start the engine, warm it up for 10–15 minutes, and then turn it off.
U8ES10.book Page 4 Monday, April 12, 2004 1:25 PM 6. Insert the oil level gauge/dipstick into the oil filler hole, and then tighten it securely. 7. Connect the oil level gauge coupler. ESU00086 Coolant Check the coolant level in the coolant reservoir when the engine is cold. If the coolant level is below the “COLD LEVEL” mark, add soft water until it reaches the “COLD LEVEL” mark. (See pages 8-13–8-14 for more details.
U8ES10.book Page 5 Monday, April 12, 2004 1:25 PM ESU00087 Throttle lever Check the throttle lever operation before starting the engine. The throttle lever must open smoothly and spring back to its home position when released. ESU00090 Throttle override system (T.O.R.S.) Check the T.O.R.S. for proper operation. WARNING @ When checking T.O.R.S.: ● Make sure that the parking brake is applied. ● Make sure that the throttle lever moves smoothly. ● Do not run the engine up to clutch engagement r/min.
U8ES10.book Page 6 Monday, April 12, 2004 1:25 PM ESU00091 Brake 1. Brake lever Test the brake at a low speed when starting out to make sure that it is working properly. If the brake does not provide proper braking performance, inspect the brake for wear or brake fluid leakage. (See pages 8-19–8-20 for more details.) WARNING @ ● ● A soft, spongy feeling in the brake lever indicates a failure in the brake system. Do not operate the snowmobile if you find any problems in the brake system.
U8ES10.book Page 7 Monday, April 12, 2004 1:25 PM ESU00093 Brake fluid leakage Apply the brake for a few minutes. Check to see if any brake fluid leaks out from the brake hose joints or the master cylinder. WARNING @ If brake fluid leakage is found, ask a Yamaha dealer for immediate repairs. @ CAUTION: @ Brake fluid may deteriorate painted surfaces or plastic parts. Never spill any brake fluid. If any is spilled, clean it up immediately. @ ESU00941 V-belt Open the shroud and remove the drive guard.
U8ES10.book Page 8 Monday, April 12, 2004 1:25 PM ESU00097 Drive track Check the drive track for deflection, wear, or damage. Adjust or replace if necessary. (See pages 8-29–8-31 for more details.) WARNING @ Do not operate the snowmobile if you find damage to the drive track, or if it has been maladjusted. Drive track damage or failure could result in loss of braking ability and snowmobile control, which could cause an accident. @ ESU00243 51-mm (2.
U8ES10.book Page 9 Monday, April 12, 2004 1:25 PM ESU00982 Slide runners Check the slide runners for wear and damage. If the slide runners reach the wear limit, they should be replaced. 1 Slide runners a Wear limit Wear limit height: For RS90/RS90M/RS90R 10.5 mm (0.41 in) For RSG90 10.0 mm (0.39 in) È RS90/RS90M/RS90R É RSG90 CAUTION: @ Ride on fresh snow frequently. Operating on ice or hard packed snow will rapidly wear the slide runners.
U8ES10.book Page 10 Monday, April 12, 2004 1:25 PM ESU00103 Steering system Check the handlebar for excessive free play: 1. Push the handlebar up and down and back and forth. 2. Turn the handlebar slightly to the right and left. If excessive free play is noticed, consult a Yamaha dealer. ESU00378 Lights Check the lights. Replace any burned out bulbs. CAUTION: @ Avoid using a scraper or hot water for cleaning the plastic lenses 1.
U8ES10.book Page 11 Monday, April 12, 2004 1:25 PM ESU00110 Fittings and fasteners Check the tightness of the fittings and fasteners. Tighten in proper sequence and torque if necessary. ESU00345 Tool kit and recommended equipment It is good practice to carry the tool kit, spare parts, and other necessary equipment with you while riding the snowmobile so that minor repairs can be done if necessary.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU00112 OPERATION 7- ESU00366 Starting the engine WARNING @ ● ● Be sure to check the “SAFETY INFORMATION” section carefully before starting the engine. Make sure that the parking brake is applied. @ NOTE: @ Make sure that the engine stop switch is in the on position. The starter motor cannot be operated when the engine stop switch is in the off position. @ 1. Fully open the starter lever (choke).
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM ESU00380 Break-in There is never a more important period in the life of your engine than the period between 0 and 500 km (300 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 500 km (300 mi). The various parts in the engine wear and polish themselves to the correct operating clearances.
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM totally familiar with the snowmobile’s handling and performance characteristics. Set the parking brake and follow the instructions on pages 7-1–7-2 to start the engine. Once the engine has warmed up, you are ready to begin riding your snowmobile. ESU01272 Riding your snowmobile Getting to know your snowmobile A snowmobile is a rider active vehicle, and your riding position and your balance are the two basic factors of maneuvering your snowmobile.
U8ES10.book Page 4 Monday, April 12, 2004 1:25 PM Turning Riding uphill For most snow surfaces, “body English” is the key to turning. As you approach a curve, slow down and begin to turn the handlebar in the desired direction. As you do so, put your weight on the running board to the inside of the turn and lean your upper body into the turn. This procedure should be practiced at low speeds many times, in a large flat area with no obstacles.
U8ES10.book Page 5 Monday, April 12, 2004 1:25 PM Riding downhill downhill leg on the seat and the foot of your uphill leg on the running board. This position will make it easier for you to shift your body weight as needed. Snow and ice are slippery, so be prepared for the possibility that your snowmobile could begin to slip sideways on the slope. If this happens, steer in the direction of the slide if there are no obstacles in your path.
U8ES10.book Page 6 Monday, April 12, 2004 1:25 PM Hard-packed snow WARNING It can be more difficult to negotiate on hard-packed snow as both the skis and drive track do not have as much traction as when the snowmobile is operated on fresh snow. Avoid rapid acceleration, turning, and braking. @ Drive track damage or failure could result in loss of braking ability and snowmobile control, which could cause an accident.
U8ES10.book Page 7 Monday, April 12, 2004 1:25 PM ESU00251 Maximizing drive track life Recommendations Track tension During initial break-in, the new drive track will tend to stretch quickly as the track settles. Be sure to correct the track tension and alignment frequently. (See pages 8-29–8-31 for adjustment procedures.) A loose track can slip (ratchet), derail or catch on suspension parts causing severe damage.
U8ES10.book Page 8 Monday, April 12, 2004 1:25 PM ESU00245 Strap For RS90M The strap 1 should be used only by experienced operators to assist them when traverse (side-hill) riding. WARNING @ Improper use of the strap on the handlebar can result in severe injury or death. ● Use the strap only as an operator grip point when needed to shift weight uphill to maintain balance during traverse (side-hill) riding. Only experienced operators should traverse slopes steep enough to require strap use.
U8ES10.book Page 9 Monday, April 12, 2004 1:25 PM ESU00347 Driving WARNING @ Be sure to read the “SAFETY INFORMATION” and “Riding your snowmobile” sections carefully before operating the snowmobile. @ NOTE: @ Make sure that the engine is warmed up enough before riding. @ For RS90/RS90M 1. Release the parking brake by moving the parking brake lever to the right. 2. Press the throttle lever slowly to move the snowmobile. 3. Turn the handlebar in the desired direction. 4.
U8ES10.book Page 10 Monday, April 12, 2004 1:25 PM CAUTION: @ Do not shift from “FWD” to “REV” or from “REV” to “FWD” while the snowmobile is moving. Otherwise, the drive system could be damaged. @ NOTE: @ The reverse buzzer beeps while the shift lever is in reverse. @ 2. Release the parking brake by moving the parking brake lever to the right. 3. Press the throttle lever slowly to move the snowmobile. 4. Turn the handlebar in the desired direction. 5. Squeeze the brake lever to stop the snowmobile. 6.
U8ES10.book Page 11 Monday, April 12, 2004 1:25 PM ESU00367 Transporting When transporting your snowmobile on a trailer or in a truck, observe the following recommendations to help protect it from damage: ● Make sure that the fuel level in the fuel tank is lower than the bottom of the carburetors. Otherwise, the vibration and bumps from the road surface could make it possible for fuel to flow through the carburetors into the cylinders.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU00139 PERIODIC MAINTENANCE 8- ESU00140 Periodic maintenance chart Regular maintenance is most important for best performance and safe operation. CD-01E Item Preoperation check (Daily) Remarks Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 3,200 km (2,000 mi) (160 hr) Spark plugs Check condition. Adjust gap and clean. Replace if necessary. ∗ Valve clearance Check clearance.
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM Item Preoperation check (Daily) Remarks Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 3,200 km (2,000 mi) (160 hr) Page Drive guard Check for cracks, bends or damage. ∗ Replace if necessary. ● 5-10, 6-7 V-belt Check for wear and damage. Replace if necessary. ● 6-7, 8-15–8-17 Drive track and idler wheels Check deflection, and for wear and damage. ∗ Adjust/replace if necessary. ● 6-8, 8-29–8-31 Check for wear and damage.
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM Item Preoperation check (Daily) Remarks Check engagement and shift speed. Adjust if necessary. Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 3,200 km (2,000 mi) (160 hr) Page ● Whenever operating elevation is changed. Inspect sheaves for wear/ damage. ∗ Primary and second- Inspect weights/rollers and bushings for wear-for primary. ary clutches Inspect ramp shoes/bushings for wear-for secondary. Replace if necessary.
U8ES10.book Page 4 Monday, April 12, 2004 1:25 PM ESU00376 Tool kit The owner’s tool kit has the tools which are sufficient for most periodic maintenance and minor repair. A torque wrench is also necessary to properly tighten nuts and bolts. 1 Tool kit CAUTION: @ Before starting the engine, make sure that the tool kit is firmly seated in the holder and is closed securely.
U8ES10.book Page 5 Monday, April 12, 2004 1:25 PM Spark plugs are produced in several different thread lengths. The thread length or reach is the distance from the spark plug gasket seat to the end of the threaded portion. If the reach is too long, overheating and engine damage may result. If the reach is too short, spark plug fouling and poor performance may result. Also, if the reach is too short, carbon will form on the exposed threads resulting in combustion chamber hot spots and thread damage.
U8ES10.book Page 6 Monday, April 12, 2004 1:25 PM ESU00370 Engine idle speed adjustment CAUTION: @ ● ● ● Be sure to have a Yamaha dealer make this adjustment. Make sure that the throttle lever moves smoothly. Make sure that the carburetor is synchronized first. @ 1. Start the engine and warm it up. NOTE: @ Refer to the “Starting the engine” section. @ 2. Turn the throttle stop screw 1 in or out to adjust the engine idle speed.
U8ES10.book Page 7 Monday, April 12, 2004 1:25 PM ESU04190 Carburetor adjustment CAUTION: @ ● ● Be sure to have a Yamaha dealer make this adjustment. Make sure that the air filter case is installed during running to prevent engine damage. @ Under some operating conditions the carburetor setting may have to be changed due to air temperature changes, elevation changes, use of alcohol oxygenated fuels, etc., and should be set by a Yamaha dealer.
U8ES10.book Page 8 Monday, April 12, 2004 1:25 PM Main jet replacement Replace the main jet according to the setting chart which is available at a Yamaha dealer. WARNING @ ● ● ● Never remove the drain plug or the float chamber while the engine is hot. Fuel will flow out from the float chamber which could ignite and cause injury. Place a rag under the carburetor before removing the drain plug or float chamber to catch any spilled fuel. Handle fuel with care: it is HIGHLY FLAMMABLE.
U8ES10.book Page 9 Monday, April 12, 2004 1:25 PM ESU00157 High altitude adjustments Operating at high altitude reduces the performance of a gasoline engine to about 3% for every 305 m (1,000 ft) of elevation. This is because there is less air as altitude increases. Less air means less oxygen available for combustion. Your snowmobile can be adjusted to overcome most of the problems found in high altitude riding. Carburetor adjustments are the most important.
U8ES10.book Page 10 Monday, April 12, 2004 1:25 PM ESU04200 Changing the engine oil It is recommended to have a Yamaha dealer change the engine oil. WARNING @ Engine oil is extremely hot immediately after the engine is turned off. Coming into contact with or getting any engine oil on your clothes could result in burns. @ CAUTION: @ ● ● ● Do not run the engine with too much or not enough oil in the oil tank. Oil could spray out or the engine could be damaged.
U8ES10.book Page 11 Monday, April 12, 2004 1:25 PM 7. Remove the oil filter cartridge 9 with an oil filter wrench. NOTE: @ An oil filter wrench is available at a Yamaha dealer. @ 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 9. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque. Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lb) 10.
U8ES10.book Page 12 Monday, April 12, 2004 1:25 PM 13. Add sufficient oil of the recommended type to raise it to the “F” level mark on the oil level gauge/dipstick. (See page 6-3 for the checking procedure.) CAUTION: @ ● ● When adding the engine oil, be careful not to fill above the “F” level mark on the oil level gauge/ dipstick. Make sure that no foreign material enters the engine oil tank. @ 14. Start the engine, and then let it idle for several minutes while checking it for oil leakage.
U8ES10.book Page 13 Monday, April 12, 2004 1:25 PM ESU00161 Cooling system Air bleeding the cooling system WARNING @ ● ● Do not remove the coolant reservoir cap when the engine is hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick rag or towel over the coolant reservoir cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
U8ES10.book Page 14 Monday, April 12, 2004 1:25 PM Coolant replenishment 1. Remove the coolant reservoir cap and pour the coolant to the “COLD LEVEL” mark. Recommended coolant: High quality ethylene glycol antifreeze containing corrosion inhibitors. Coolant and water mixed ratio: 60:40 Total amount: 4.7 L (4.14 Imp qt, 4.97 US qt) 1 “COLD LEVEL” mark 2 Coolant reservoir cap 2. Start the engine and add coolant until the coolant level does not go down, and then stop the engine. 3.
U8ES10.book Page 15 Monday, April 12, 2004 1:25 PM ESU00166 V-belt replacement WARNING @ When installing the new V-belt, make sure it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave assembly to 0.5 mm (0.02 in) below the edge a. If not, the V-belt clutch engagement speed will be changed. The snowmobile may move unexpectedly when the engine is started. Adjust the V-belt position by removing or adding a spacer 1 on each adjusting bolt. Have a Yamaha dealer make this adjustment.
U8ES10.book Page 16 Monday, April 12, 2004 1:25 PM 3. Pull 3 the V-belt up over the secondary fixed sheave. 4. Remove the V-belt from the secondary sheave assembly and primary sheave assembly. 5. Put the new V-belt back on the secondary sheave assembly only. Do not force the V-belt between the sheaves; the secondary sliding and fixed sheave must touch each other. Measure the V-belt position. Standard V-belt position a: From 1.5 mm (0.06 in) above the edge of the secondary sheave to 0.5 mm (0.
U8ES10.book Page 17 Monday, April 12, 2004 1:25 PM 8. Install the V-belt over the primary sheave assembly. 9. Rotate the secondary sliding sheave clockwise 6 and push 7 it so that it separates from the secondary fixed sheave. 10. Install the V-belt 8 between the secondary sliding and secondary fixed sheaves. 11. Install the drive guard. WARNING @ Never run the engine with the V-belt or drive guard removed.
U8ES10.book Page 18 Monday, April 12, 2004 1:25 PM A 3. Remove the dipstick and check that the oil is between the upper and lower levels. If not, add oil to the upper level. B 2 Upper level 3 Lower level Drive chain oil: GL-3 75W or 80W È For models without reverse transmissions (RS90/RS90M) É For models with reverse transmissions (RS90R/RSG90) CAUTION: @ Make sure that no foreign material enters the drive chain housing. @ 4.
U8ES10.book Page 19 Monday, April 12, 2004 1:25 PM ESU00174 Checking the brake pads Check the brake pads for wear. If the brake pads reach the wear limit, ask a Yamaha dealer to replace them. 1 Brake pad wear indicator Wear limit a: 1.5 mm (0.06 in) ESU00352 Checking the parking brake pads Check the parking brake pads for wear by measuring the thickness of the pads. If the parking brake pads reach the wear limit, ask a Yamaha dealer to replace them. Wear limit a: 1.2 mm (0.
U8ES10.book Page 20 Monday, April 12, 2004 1:25 PM ESU00180 Checking the brake fluid level Place the snowmobile on a level surface. Check that the brake fluid is above the lower level and replenish when necessary. 1 Lower level Specified brake fluid: DOT 4 WARNING @ Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. If the brake fluid level goes down, consult a Yamaha dealer.
U8ES10.book Page 21 Monday, April 12, 2004 1:25 PM ESU01911 Ski spring preload adjustment The spring preload can be adjusted by turning the spring preload adjuster 1. For RS90/RS90R/RSG90 CD-11E Spring seat length* Standard Increased ← → Decreased Preload Harder ← → a Length Maximum Minimum 172.0 mm 162.0 mm 155.5 mm (6.77 in) (6.38 in) (6.12 in) Softer ∗ The spring seat length changes approximately 1.5 mm (0.06 in) with each full turn of the adjuster.
U8ES10.book Page 22 Monday, April 12, 2004 1:25 PM WARNING @ This shock absorber contains highly pressurized nitrogen gas. It could explode by improper handling, causing injury or property damage. ● Do not tamper with or attempt to open the shock absorber. ● Do not subject the shock absorber to an open flame or other high heat source, which could cause it to explode. ● Do not deform or damage the shock absorber in any way. ● Do not dispose of a worn or damaged shock absorber by yourself.
U8ES10.book Page 23 Monday, April 12, 2004 1:25 PM The spring preload can be adjusted by turning the spring preload adjuster 3 on the front and rear shock absorbers. A For RS90/RS90R CD-17E Spring seat length* Standard Increased ← → Decreased Preload Harder ← → È a Length (front) Maximum Minimum 123.5 mm 113.5 mm 103.5 mm (4.86 in) (4.47 in) (4.07 in) Softer ∗ The spring seat length changes approximately 1.5 mm (0.06 in) with each full turn of the adjuster.
U8ES10.book Page 24 Monday, April 12, 2004 1:25 PM D For RS90/RS90M/RS90R CD-23E Spring adjuster position Preload S M H Soft Medium Hard Ë Standard (rear) E M For RSG90 CD-14E Spring adjuster position 1 Preload Soft Ì Standard (rear) 2 3 4 5 6 7 Hard 4 WARNING @ Be sure to have a Yamaha dealer make this adjustment. This shock absorber contains highly pressurized nitrogen gas. It could explode by improper handling, causing injury, or property damage.
U8ES10.book Page 25 Monday, April 12, 2004 1:25 PM ESU03890 Rear suspension damping force adjustment For RSG90 The damping force can be adjusted by turning the adjuster 1. CD-20E 16 clicks out Adjuster position Minimum 7 clicks out 1 click out Standard Maximum ∗ Turns out b Damping force Soft Turns in a Hard ∗ With the adjuster fully turned lightly in direction a CAUTION: @ ● ● ● Do not continue to turn the adjuster in direction a after it stops.
U8ES10.book Page 26 Monday, April 12, 2004 1:25 PM ESU01973 Rear suspension full rate adjustment For RSG90 The total suspension spring rate and damping characteristics can be adjusted by changing the installed position of the shock absorber. WARNING @ Be sure to have a Yamaha dealer make this adjustment. @ CD-07E Installation position Spring rate and damping Standard S M H Soft Medium Hard M NOTE: @ Be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile.
E_8es_Periodic.fm Page 27 Thursday, April 15, 2004 11:33 AM A ESU04220 Control rod adjustment The weight transfer can be adjusted by turning the control rod adjusting nut 1. 1. Loosen the locknut 2 while holding the control rod adjusting nut. 2. Turn the adjusting nut in direction a to increase weight transfer or direction b to decrease weight transfer. 3. Tighten the locknut while holding the adjusting nut in place. Locknut tightening torque: 25 Nm (2.5 m·kgf, 18.
U8ES10.book Page 28 Monday, April 12, 2004 1:25 PM ESU04271 Anti-bottoming stopper adjustment For RS90/RS90R The spring force can be adjusted by changing the installation location of the anti-bottoming stoppers. WARNING @ Be sure to have a Yamaha dealer make this adjustment. @ CD-24E Installation location Spring force Standard S M H Soft Medium Hard M NOTE: @ Be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile. @ 1.
E_8es_Periodic.fm Page 29 Tuesday, April 13, 2004 11:28 AM ESU03531 Drive track adjustment WARNING @ A broken track, track fittings or debris thrown by the drive track could be dangerous to an operator or bystanders. Observe the following precautions: ● Do not allow anyone to stand behind the snowmobile when the engine is running. ● When the rear of the snowmobile is raised to allow the drive track to spin, a suitable stand must be used to support the rear of the snowmobile.
U8ES10.book Page 30 Monday, April 12, 2004 1:25 PM Drive track adjustment WARNING @ ● ● ● Be sure to have a Yamaha dealer make this adjustment. Support the snowmobile securely on a suitable stand before working underneath the snowmobile. Operate the engine in a well-ventilated area. @ 1. Lift the rear of the snowmobile onto a suitable stand to raise the drive track off the ground. 2. Loosen the rear axle nut 1. 3. Start the engine and rotate the drive track one or two turns. Stop the engine. 4.
U8ES10.book Page 31 Monday, April 12, 2004 1:25 PM CAUTION: @ The right and left adjusters should be turned to an equal amount. @ 6. Recheck alignment and deflection. If necessary, repeat steps 3 to 5 until the proper adjustment is achieved. 7. Tighten the rear axle nut. Rear axle tightening torque: 75 Nm (7.5 m·kgf, 54.2 ft·lb) ESU00200 Ski alignment 1. Turn the handlebar so the skis face straight ahead. 2. Check the following for ski alignment: a. Skis are facing forward. b.
U8ES10.book Page 32 Monday, April 12, 2004 1:25 PM 2. Loosen the handlebar bolts. A 3. Move the handlebar up or down to adjust the handlebar height to the desired position.
U8ES10.book Page 33 Monday, April 12, 2004 1:25 PM CAUTION: @ Make sure that the projection on the handlebar is not installed into the area a shown. @ 4. Tighten the handlebar bolts and install the handlebar cover. Handlebar bolt tightening torque: 14.5 Nm (1.45 m·kgf, 10.5 ft·lb) CAUTION: @ Make sure that the small gap b side of the handlebar holders faces forward c.
U8ES10.book Page 34 Monday, April 12, 2004 1:25 PM ESU00371 Lubrication Lubricate the following points. Lubricant: Low-temperature grease 1 Throttle cable end 2 WARNING @ Apply a dab of grease onto the cable end only. Do not grease the throttle cable because it could become frozen, which could cause loss of control. @ 2 Front suspension 3 Rear suspension WARNING @ Be sure to have a Yamaha dealer lubricate the front and rear suspensions.
U8ES10.book Page 35 Monday, April 12, 2004 1:25 PM ESU00208 Headlight bulb replacement 1. Lift up the shroud. 2. Disconnect the headlight connector. 3. Remove the bulb holder cover. 4. Remove the bulb holder by depressing and turning it counterclockwise. 1 Bulb holder cover 5. Remove the bulb. WARNING @ Keep flammable products or your hands away from the hot bulb until it cools down. @ 6. Install the new bulb.
U8ES10.book Page 36 Monday, April 12, 2004 1:25 PM ESU00355 Battery This snowmobile is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the snowmobile is equipped with electrical accessories.
U8ES10.book Page 37 Monday, April 12, 2004 1:25 PM 1. Lift up the shroud. 2. Remove the right side cover 1. 3. Unhook the latch 2. 4. Loosen the clamp screws 3. 5. Slide the oil tank breather hose clamp 4 away from the air filter case, and then disconnect the oil tank breather hose 5. 6. Slide the crankcase breather hose clamp 6 up, and then disconnect the crankcase breather hose 7 from the engine. 7.
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U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM 3. Compression Insufficient ● Loose cylinder head nuts ... Tighten nuts properly. ● Worn or damaged gasket ... Replace gasket. ● Worn or damaged piston and cylinder ... Ask a Yamaha dealer to inspect. ESU04240 TROUBLESHOOTING 9- A. Engine turns over but does not start 1. Fuel system No fuel supplied to combustion chamber ● No fuel in tank ... Supply fuel. ● Clogged fuel line ... Clean fuel line. ● Clogged carburetor ... Clean carburetor.
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM 5. Connect the other end of the red (+) jumper cable to the positive (+) terminal of the booster battery. 6. Connect the black (-) jumper cable to the negative (-) terminal of the booster battery. 7. Pull the black (-) lead cover to expose the terminal through the slit in the cover, and then connect the black (-) jumper cable to the black terminal of the discharged battery. 2. Open the shroud. 3.
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM 4. Improper fuel flow ... See A.1 above. 5. Incorrect V-belt clutch settings for altitude or conditions ... Ask a Yamaha dealer to inspect. NOTE: @ Make sure that both the red (+) lead and the black (-) lead are seated securely in the lead holders. @ E. Engine constantly backfires or misfires 1. Faulty spark plugs ... Replace the spark plugs. 2. Clogged fuel system ... See A.1. above. 3. Malfunctioning T.O.R.S. system ... See A.2. above.
U8ES10.book Page 4 Monday, April 12, 2004 1:25 PM J. Engine does not upshift or downshift properly or engages harshly 1. Worn or damaged V-belt ... Replace the V-belt or ask a Yamaha dealer to inspect. 2. Incorrect V-belt clutch settings for altitude or conditions ... Ask a Yamaha dealer to inspect. 3. Worn or sticking primary sheave assembly ... Ask a Yamaha dealer to inspect. 4. Worn or sticking secondary sheave assembly ... Ask a Yamaha dealer to inspect. K.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM bustion chamber and crankshaft from corrosion. An alternate method is to remove the carburetor silencer and squirt oil into the carburetor throats while the engine is running. ESU03593 STORAGE 10- Long-term storage requires some preventive procedures to guard against deterioration. 1. Cleaning Thoroughly clean the snowmobile, inside and out, to remove the corrosive salts and acids that can accumulate.
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM Returning to service after storage When returning your snowmobile to service, install the V-belt and battery and adjust the drive track. Remove the spark plugs and clean or replace them if necessary. Perform all other pre-operation and seasonal maintenance checks listed in the periodic maintenance chart. CAUTION: @ ● ● ● Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM ESU00228 1- SPECIFICATIONS ESU00229 Dimensions CS-01E Overall length Overall width Overall height Dry weight Ski stance RS90/RS90M/RS90R/RSG90 2,755 mm (108.5 in): RS90/RS90R 3,185 mm (125.4 in): RS90M 3,000 mm (118.1 in): RSG90 1,225 mm ( 48.2 in): RS90/RS90R/ RSG90 1,165 mm ( 45.9 in): RS90M 1,215 mm ( 47.8 in) 243 kg ( 536 lb): RS90 259 kg ( 571 lb): RS90M 247 kg ( 545 lb): RS90R 256 kg ( 564 lb): RSG90 1,085 mm ( 42.
E_8es_Spec.fm Page 2 Tuesday, April 13, 2004 11:28 AM ESU00231 Chassis CS-03E RS90/RS90M/RS90R/RSG90 Drive track and suspension: Track Width Track deflection Length on ground Suspension type Drive sprocket Transmission: Type Sheave distance Sheave offset Engagement speed∗1 Shift speed∗1 Drive chain Reduction ratio Fuel tank: Tank capacity Oil quantity: With oil filter cartridge replacement Without oil filter cartridge replacement Total amount Molded rubber, fiber glass rod reinforced 381 mm (15.
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM RS90/RS90M/RS90R/RSG90 Brake: Type Operation Throttle: Operation Hydraulic disc type (ventilated disc) Handle lever, left hand operated Handle lever, right hand operated ESU00232 Electric CS-04E Ignition system Spark plug Battery Headlight Tail/brake light Meter light Indicator light Type Gap Capacity Maximum charge rate Bulb × Quantity Bulb × Quantity Bulb × Quantity Bulb × Quantity RS90/RS90M/RS90R/RSG90 TCI · R · CR8E (NGK) 0.7–0.8 mm (0.028–0.
1- 12-1 G W/B O/B B A Ch G/B R/B B B c O/B B R W/R W/G Lg L/W L/W Lg d L 2 L (20A) L (10A) B 3 W W W W W W 1 (BLACK) R (20A) R W/G W/R (15A) HI LO O/B Lg L/W L/W L/R f R/W R HEADLIGHT SUB-WIRE HARNESS 2 (BLACK) WIRE HARNESS Y/B G L/Y L/R Y W B L/Y G Y/B W Y L/R G B G G Lg Y G B A B B Br R L Y G e B Y B f Br/L Br Br/L Y G B B Y G B Dg B B R L/R X W V 6 (30A) B B R/W R B R/W Z [ Ch A Ch Ch Y (BLACK) Br Br/W Ch R/W Dg L/Y
Crankshaft position sensor AC magneto Rectifier/regulator Main switch Load control relay Main fuse Starter relay Starter motor Battery Engine stop switch Throttle switch Carburetor warmer relay Carburetor ground Carburetor warmer Grip warmer Thumb warmer CDI unit Ignition coil Spark plug Throttle position sensor Thermo unit Grip warmer adjustment switch Thumb warmer adjustment switch Frame ground DC back buzzer (RS90R/RSG90) Gear position switch (RS90R/RSG90) Q Brake light switch R Tail/brake light S Speed
SNOWMOBILE OWNER’S MANUAL RS90K RS90MK RS90RK RSG90K YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.04-2.
