SERVICE MANUAL
ESS00002 ESS00004 NOTICE HOW TO USE THIS MANUAL 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 in snowmobile repair.
ESS00006 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspection and adjustment 3 Chassis 4 Power train 5 Engine overhaul 6 Carburetion 7 Electrical 8 Specifications Illustrated symbols 9 to 15 are used to identify the specifications which appear.
INDEX GENERAL INFORMATION GEN INFO 1 PERIODIC INSPECTIONS AND ADJUSTMENTS INSP ADJ 2 CHASSIS CHAS 3 POWR TR 4 ENG 5 CARB 6 ELEC 7 SPEC 8 POWER TRAIN ENGINE CARBURETION ELECTRICAL SPECIFICATIONS
CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION . . . . . . . . . . . 1-1 FRAME SERIAL NUMBER . . . . . . . . . . 1-1 ENGINE SERIAL NUMBER . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . 1-2 ALL REPLACEMENT PARTS . . . . . . . . 1-3 GASKETS, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION . . . . . . . . . . . . . . . . 3-8 HANDLING NOTES . . . . . . . . . . . . . . . . 3-9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 3-9 INSTALLATION . . . . . . . . . . . . . . . . . . 3-10 CYLINDER HEAD AND CYLINDER . . . . . 5-5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 5-6 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 5-6 INSTALLATION . . . . . . . . . . . . . . . . . . . 5-11 CHAPTER 4. POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT . . . . . . . . . . .
STARTER MOTOR . . . . . . . . . . . . . . . 7-21 CHAPTER 7. ELECTRICAL SWITCH INSPECTION . . . . . . . . . . . . . . . . 7-1 SWITCH INSPECTION . . . . . . . . . . . . . 7-1 INSPECTING A SWITCH SHOWN IN THE MANUAL . . . . . . . . . . . . . . . . . . . . . 7-1 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . 7-2 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . 7-2 TROUBLESHOOTING . . . . . . . . . . . . . . 7-3 SPARK PLUG CAP . . . . . . . . . . . . . . . . 7-4 IGNITION COIL . . . . . . . . . . . . . . .
MACHINE IDENTIFICATION GEN INFO ESS00011 GENERAL INFORMATION ESS00012 MACHINE IDENTIFICATION ESS00013 FRAME SERIAL NUMBER The frame serial number 1 is located on the right hand side of the frame (just below the front of the seat). ESS00014 ENGINE SERIAL NUMBER The engine serial number 2 is located on the left hand side of the crankcase. NOTE: Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION GEN INFO ESS00015 IMPORTANT INFORMATION ESS00016 PREPARATION FOR REMOVAL AND DISASSEMBLY 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.
IMPORTANT INFORMATION GEN INFO ESS00017 ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments. ESS00018 GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced 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.
IMPORTANT INFORMATION GEN INFO ESS00021 CIRCLIPS All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing a circlip 1 , make sure that the sharp edged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view. 4 Shaft ESS00022 LOCTITE After installing fasteners that have LOCTITE applied, wait 24 hours before using the machine. This will give the LOCTITE time to dry properly.
SPECIAL TOOLS GEN INFO ESS00023 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.
SPECIAL TOOLS GEN INFO Rotor holding puller P/N: YU-33270 (for U.S.A./Canada) 90890-01362 (for Europe) This tool is used to remove the magneto rotor. Rotor holding tool P/N: YU-01235 (for U.S.A./Canada) 90890-01235 (for Europe) This tool is used to remove the starter pulley. ESS00026 FOR POWER TRAIN SERVICE Primary sheave holder P/N: YS-01880 (for U.S.A./Canada) 90890-01701 (for Europe) This tool is used to hold the primary sheave.
SPECIAL TOOLS GEN INFO Clutch separator adapter P/N: YS-34480 (for U.S.A./Canada) 90890-01740 (for Europe) This tool is used when disassembling and assembling the primary sheave. YXR clutch bushing jig kit P/N: YS-39752 This tool is used for removal and installation of primary clutch weight and roller bushings. Track clip installer P/N: YS-91045-A (for U.S.A./Canada) 90890-01721 (for Europe) This tool is used for installing the track clip.
SPECIAL TOOLS GEN INFO Electro tester P/N: YU-33260-A (for U.S.A./Canada) 90890-03021 (for Europe) This instrument is invaluable for checking the electrical system.
INTRODUCTION/PERIODIC MAINTENANCE TABLE INSP ADJ ESS00029 PERIODIC INSPECTIONS AND ADJUSTMENTS ESS00030 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 service life. In addition, the need for costly overhaul work will be greatly reduced.
INSP ADJ INTRODUCTION/PERIODIC MAINTENANCE TABLE Item Drive track / Idler wheels Slide runners Brake / Parking brake Drive chain oil Drive chain Ski / Ski runner Steering system Lights Battery Preoperation check (Daily) Remarks Check deflection, wear and damage. Adjust / replace if necessary. Check wear and damage. Secondary sheave Every Seasonally or 3,200 km (2,000 mi) (160 hr) Replace if necessary. Check operation. Adjust free play and / or replace pads if necessary.
SPARK PLUGS INSP ADJ ESS00032 ENGINE ESS00033 SPARK PLUGS 1. Remove: S Spark plug caps S Spark plugs 2. Inspect: S Electrodes 1 Damage/wear Replace the spark plug. S Insulator color 2 3. Measure: S Spark plug gap a Out of specification Regap. Use a wire thickness gauge. Spark plug gap a : 0.7 0.8 mm (0.028 0.032 in) If necessary, clean the spark plugs with a spark plug cleaner. Standard spark plug: BR9ES (NGK) Before installing a spark plug, clean the gasket surface and spark plug surface. 4.
OIL PUMP INSP ADJ ESS00034 OIL PUMP ESS00035 Air bleeding CAUTION: The oil pump and oil delivery line must be bled in the following cases: S Any portion of the oil system has been disconnected. S The machine has been turned on its side. S The oil tank has been run empty. S As part of the pre-delivery service. 1. Fill: S Oil tank 1 Recommended oil: YAMALUBE 2-cycle oil Oil tank capacity: 2.5 L (2.2 Imp qt, 2.6 US qt) 2. Remove: S Drive V-belt guard S Carburetors Refer to “CARBURETORS” in CHAPTER 6. 3.
OIL PUMP INSP ADJ 10. Remove: S Bleed bolt 1 S Gasket (bleed bolt) 11. Drain the oil until no more air bubbles appear from the bleed hole. 12. Inspect: S Gasket 1 (bleed bolt) Damage/wear Replace. 13. Install: S Gasket 1 (bleed bolt) S Bleed bolt 2 14. Install: S Carburetors Refer to “CARBURETORS” in CHAPTER 6. ESS00036 Cable adjustment NOTE: Before adjusting the oil pump cable, the throttle cable distance should be adjusted. Adjustment steps: S Pull back the adjuster cover. S Loosen the locknut 1 .
OIL FILTER INSPECTION/ENGINE OIL LINE INSPECTION INSP ADJ OIL FILTER INSPECTION 1. Remove: S Oil tank 1 2. Remove: S Oil filter 1 NOTE: Plug the oil hoses so that the oil will not run out of the oil tank and oil pump. 3. Inspect: S Oil filter 1 Contamination Replace. Recommended replacement interval: Every season ENGINE OIL LINE INSPECTION 1. Inspect: S Oil hoses 1 S Oil delivery hoses 2 Cracks/Damage Replace.
FUEL LINE INSPECTION/FUEL FILTER INSPECTION INSP ADJ ESS00037 FUEL LINE INSPECTION 1. Inspect: S Fuel hose 1 S Fuel delivery hoses 2 S Vacuum hose 3 Cracks/damage Replace. FUEL FILTER INSPECTION 1. Remove: S Side cover (left 1 and right 2 ) S Plate 3 2. Remove: S Main switch holding nut 1 S “STARTER” lever holding nut 2 S Grip warmer switch holding nut 3 3. Remove: S Handlebar cover (lower) 1 4.
FUEL FILTER INSPECTION INSP ADJ 5. Remove: S Seat 1 6. Remove: S Fuel lever indicator hose 1 S Oil level indicator hose 2 S Center cover 3 7. Remove: S Spring bands 1 S Cap 2 S Fuel filter 3 8. Inspect: S Fuel filter 1 Contamination Replace.
COOLING FAN BELT TENSION ADJUSTMENT INSP ADJ COOLING FAN BELT TENSION ADJUSTMENT 1. Adjust: S Fan belt deflection a Pushed at belt center by hand. Out of specification Adjust. Fan belt deflection a : 8 mm (0.31 in)/ 4 6 kg (8.8 13.2 lb) 2. Adjust: S Fan belt deflection. Adjustment steps: S Remove the recoil starter assembly, drive pulley and fan belt. S Remove the driven pulley (outer half) 1 and shim(s) 2 . S Adjust the drive belt tension by adding or removing a shim(s) 2 .
ENGINE IDLE SPEED ADJUSTMENT/ THROTTLE CABLE FREEPLAY ADJUSTMENT INSP ADJ ESS00044 ENGINE IDLE SPEED ADJUSTMENT 1. Adjust: S Engine idle speed Adjustment steps: S Start the engine and let it warm up. S Turn the throttle stop screw 1 in or out until the specified engine idle speed is obtained. Turning in Idle speed is increased. Turning out Idle speed is decreased. Engine idle speed: 1,200 ± 100 r/min NOTE: After adjusting the engine idle speed, the throttle cable freeplay should be adjusted.
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK INSP ADJ ESS00048 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK WARNING When checking T.O.R.S.: S Be sure the parking brake is applied. S Be sure the throttle lever moves smoothly. S Do not run the engine up to the clutch engagement speed. Otherwise, the machine could start moving forward unexpectedly, which could cause an accident. 1. Start the engine. 2.
STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT/ EXHAUST SYSTEM INSPECTION INSP ADJ ESS00050 STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT 1. Pull back the starter cable outer tube 1 . 2. Measure: S Starter cable freeplay a Out of specification Adjust. Starter cable freeplay a : 0.5 1.5 mm (0.02 0.06 in) 3. Adjust: S Starter cable freeplay Adjustment steps: S Pull back the adjuster cover 1 . S Loosen the locknut 2 . S Turn the adjuster 3 in or out until the specified freeplay is obtained.
DRIVE V-BELT INSP ADJ ESS00054 POWER TRAIN ESS00055 ,,,, ,,, ,,,, ,,,, ,,,, ,,,, ,,,,,,, ,,,,,,,, ,,,, DRIVE V-BELT 1. Remove: S Drive V-belt guard 1 ,,, ,,, ,,, ,,, ,,, ,,, WARNING S Be sure there are shims (2 pcs) 1 between secondary fixed and sliding sheaves when installing the NEW belt. S If there is no gap, the clutch engagement speed will be reduced. The machine may move unexpectedly when the engine is started. S The spacer of the secondary sheave should be adjusted.
DRIVE V-BELT INSP ADJ V-belt width 1 Number of spacers A 35 mm (1.38 in) or more 2 spacers B 34 mm (1.34 in) 1 spacer C 33 mm (1.30 in) No spacer 32 mm (1.26 in) or less Replace the V-belt 3. Remove: S Drive V-belt 1 Removal steps: S Rotate the secondary sliding sheave clockwise 2 and push it 3 so that it separates from the fixed sheave. S Pull 4 the belt up over the secondary fixed sheave. S Remove the belt from the secondary sheave and primary sheave. 4.
DRIVE V-BELT INSP ADJ 5. Inspect: S Primary sheave S Secondary sheave Oil or grease adhered to the primary and secondary sheaves Remove the oil or grease using a rag soaked in lacquer thinner or solvent. Check the primary and secondary sheaves. 6. Measure: S Drive V-belt length a Out of specification Replace. Drive V-belt length a : 1,118 1,128 mm (44.0 44.
SHEAVE DISTANCE AND OFFSET ADJUSTMENT INSP ADJ ESS00055 SHEAVE DISTANCE AND OFFSET ADJUSTMENT 1. Measure: S Sheave distance a Use the sheave gauge. Out of specification Adjust. ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, Sheave distance a : 267 270 mm (10.5 10.6 in) Sheave gauge: 90890-01702, YS-91047-3 2.
SHEAVE DISTANCE AND OFFSET ADJUSTMENT INSP ADJ Shim size Part Number Thickness 90201-252F1 0.5 mm (0.02 in) 90201-25527 1.0 mm (0.04 in) 90201-25526 2.0 mm (0.08 in) S Install the secondary sheave and bolt (secondary sheave). Bolt (secondary sheave): 60 Nm (6.0 mSkg, 43 ftSlb) S Recheck the sheave offset. If out of specification, repeat the above steps. NOTE: When adjusting the sheave offset, the secondary sheave free play (clearance) should be adjusted. 5.
ENGAGEMENT SPEED CHECK/ADJUSTING THE BRAKE INSP ADJ ESS00057 ENGAGEMENT SPEED CHECK 1. Place the machine on a level surface of hardpacked snow. 2. Check: S Clutch engagement speed Checking steps: S Start the engine, and open the throttle lever gradually. S Check the engine speed when the machine starts moving forward. Out of specification Adjust the primary sheave.
BRAKE PAD INSPECTION/DRIVE CHAIN INSP ADJ ESS00062 BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Inspect: S Brake pad thickness a Out of specification Replace brake pad as a set. Wear limit a : 10 mm (0.39 in) ESS00065 DRIVE CHAIN ESS00066 Oil level inspection 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.
DRIVE CHAIN INSP ADJ ESS00067 Oil replacement Oil replacement steps: S Place the oil pan under the drain hole 1 . S Remove the oil drain bolt 2 and drain the oil. CAUTION: Be sure to remove any oil from the heat protector. S Install the oil drain bolt 2 . Oil drain bolt: 10 Nm (1.0 mSkg, 7.2 ftSlb) Recommended oil: Gear oil API GL-3 SAE #75 or #80 Oil capacity: 0.35 L (12.3 Imp oz, 11.8 US oz) ESS00068 Chain slack adjustment 1. Adjust: S Drive chain slack Adjustment steps: S Loosen the locknut 1 .
TRACK TENSION ADJUSTMENT INSP ADJ ESS00069 TRACK TENSION ADJUSTMENT WARNING A broken track or track fittings, and debris thrown by the track could be dangerous to an operator or bystanders. Observe the following precautions. S Do not allow anyone to stand behind the machine when the engine is running. S When the rear of the machine is raised to allow the track to spin, a suitable stand must be used to support the rear of the machine.
TRACK TENSION ADJUSTMENT/ SLIDE RUNNER INSPECTION INSP ADJ a. Start the engine and rotate the track once or twice. Stop the engine. b. Check the track alignment with the slide runner 3 . If the alignment is incorrect, turn the left and right adjusters to adjust. Track alignment 6 Shifted to right 7 Shifted to left 4 Left adjuster Turn out Turn in 5 Right adjuster Turn in 8 Slide runner 9 Track 10 Track metal 11 Gap Turn out 12 Forward c.
SKI/SKI RUNNER/STEERING SYSTEM INSP ADJ ESS00071 CHASSIS ESS00072 SKI/SKI RUNNER 1. Check: S Ski S Ski runner Wear/Damage Replace. Ski runner wear limit 1 : 4.5 mm (0.18 in) ESS00073 STEERING SYSTEM ESS00074 Freeplay check 1. Check: S Steering system freeplay Move the handlebar up and down and back and forth. Turn the handlebar slightly to the right and left. Excessive freeplay Check that the handlebar, tie rod ends and relay rod ends are installed securely in position.
STEERING SYSTEM INSP ADJ ESS00075 Toe-out adjustment 1. Place the machine on a level surface. 2. Check: S Ski toe-out Point the skis forward. Out of specification Adjust. Ski toe-out ( a – c ): 0 15 mm (0 0.59 in) Ski stance b (center to center): 960 mm (37.8 in) 3. Adjust: S Ski toe-out Adjustment steps: S Loosen the locknuts (tie-rod) 1 . S Turn the tie-rod 2 in or out until the specified toe-out is obtained. S Tighten the locknuts (tie-rod) 1 . A Locknut (rod end): 25 Nm (2.
LUBRICATION INSP ADJ ESS00076 LUBRICATION ESS00077 Brake lever, throttle lever and throttle cable end 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cable and brake cable. Recommended lubricant: Esso Beacon 325 Grease WARNING Apply a dab of grease onto only the end of the cable. Do not grease the throttle cables. They could freeze and cause a loss of control.
LUBRICATION INSP ADJ ESS00078 A Front and rear suspension 1. Use a grease gun to inject grease into the nipples 1 and ball joints 2 .
HEADLIGHT BEAM ADJUSTMENT INSP ADJ ESS00079 ELECTRICAL ESS00080 HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Measure the distance from the floor to the center of the headlight and place a mark on the wall equal to distance H from the floor. 3. Place the machine from the wall at a distance D indicated by the chart below. 4. With a person sitting on the machine, apply the parking brake, start the engine and let it idle. 5.
BATTERY INSPECTION INSP ADJ ESS00081 BATTERY INSPECTION WARNING Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: S Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. S Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): S SKIN – Flush with water. S EYES – Flush with water for 15 minutes and get immediate medical attention.
BATTERY INSPECTION INSP ADJ 3. Check: S Specific gravity Less than 1.280 Recharge battery. Charging current: 1.4 amps/10 hrs Specific gravity: 1.280 at 20_C (68_F) Replace the battery if: S Battery voltage will not rise to a specific value or if bubbles fail to rise even after many hours of charging. S Sulfation of one or more cells occurs, as indicated by the plates turning white, or if an accumulation of material exists in the bottom of the cell.
FUSE INSPECTION INSP ADJ FUSE INSPECTION 1. Remove: S Fuse 1 S Spare fuse 2 2. Inspect: S Fuse Inspection: S Connect a pocket tester to the fuse and check it for continuity. NOTE: Set the tester selector to “Ω 1” position. Pocket tester: 90890-03112, YU-03112 S If the tester indicates ∞ the fuse is blown. It must be replaced. 3. Replace: S Blown fuse Replacement steps: S Turn off the ignition and the circuit. S Install a new fuse of proper amperage.
INSP ADJ CARBURETOR TUNING ESS00083 TUNING ESS00084 CARBURETOR TUNING The carburetors are set at the factory to run at temperatures of 0_C –20_C (32_F –4_F) at sea level. If the machine is to be operated under conditions other than those specified above, the carburetors must be properly adjusted. Special care should be taken in carburetor setting so that the pistons will not be damaged or will not seize. CAUTION: Engine oil is mixed with fuel just before the fuel enters the carburetors.
CARBURETOR TUNING INSP ADJ ESS00066 Mid-range and high speed tuning Adjustments are normally not required, but may sometimes be necessary, depending on temperatures, altitude or both. Mid-range speed and high speed tuning (from 1/4 to full-throttle) can be done by adjusting the main jet. CAUTION: Never run the engine without the air intake silencer installed. Severe engine damage may result. 1.
CARBURETOR TUNING INSP ADJ ESS00088 Guide for carburetion 2E301 1. Fuel flow chart: A guide to the fuel flow rate according to the throttle opening. CAUTION: If the air intake silencer and air chamber are removed from the carburetors, the change in pressure in the intake will create a lean mixture that could result in severe engine damage. Removal of the air intake silencer and the air chamber do not improve performance characteristics.
CARBURETOR TUNING INSP ADJ ESS00089 Low speed tuning The carburetors are built so that low speed tuning can be done by adjusting the pilot screw 1 and throttle stop screw 2 . CAUTION: Never run the engine without the air intake silencer installed. Severe engine damage may result. 1. Tighten the pilot screw until it is lightly seated and then back it out the specified number of turns. Pilot screw 1 : 1-1/4 turns out Pilot screw effects: Turn in STD setting Leaner Mixture Turn out Richer Mixture 2.
CARBURETOR TUNING INSP ADJ ESS00090 Main jet selection chart Main jet selection chart Spark plug color Diagnosis Remedy Light tan or gray Carburetors are tuned properly. Dry black or fluffy deposits Mixture is too rich. Replace the main jet with the next smaller size. White or light gray Mixture is too lean. Replace the main jet with the next larger size. White or gray insulator with small black or grayish brown spots and electrodes having a bluish-burnt appearance Mixture is too lean.
CARBURETOR TUNING INSP ADJ ESS00091 Troubleshooting Trouble Hard starting Diagnosis Adjustment Insufficient fuel Add gasoline. Excessive use of the starter or choke Return the starter lever to its seated position so that the starter valve is fully closed. Fuel passage is clogged or frozen S Check and, if necessary, clean the fuel tank air vent, the fuel filter and all of the fuel passages. S Check and, if necessary, clean the carburetor air vents, fuel passages and the float valve.
CARBURETOR TUNING Trouble Poor performance at high speeds: S Power loss S Poor acceleration Diagnosis INSP ADJ Adjustment Starter valve is left open Return the starter lever to its seated position so that the starter valve is fully closed. Clogged air vent Remove and clean the air vent. Clogged or loose main air jet S Remove the main jet, clean it with compressed air, and then install it. S Make sure that the main jet is fully tightened. Clogged fuel line Clean or replace the fuel line.
CLUTCH INSP ADJ ESS00092 CLUTCH ESS00093 High altitude Specifications S Silver Y Yellow L Blue W White Model: VK540E A ELEVATION B Idle speed C Clutch engarement D Shift speed E Gearing F Primary spring G Color H Length I Preload rate J Wire diameter K Outside diameter L Weight (ID) M Weight rivet N Weight bushing O Roller outer dia. P Roller bushing Q Pri. clutch shim R Secondary spring S Color T Length U Preload rate V Wire diameter W Outside diameter X Sec. torque cam Y Sec.
CLUTCH/GEAR SELECTION INSP ADJ 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.
GEAR SELECTION INSP ADJ 1 Chain and sprocket pat number B Teeth & links A Part name C Part no. D Standard E Drive sprocket 17 teeth 83R-17682-00 VK540E F Driven sprocket 39 teeth 83R-47548-00 VK540E G Chain 70 links 94880-06070 VK540E 2 Gear ratio A Drive gear 17 teeth B Driven gear 39 teeth 2.29 70 links 3 Secondary spring A Part no. B Spring rate NSmm / rad (kgSmm/rad) 90508-50746 7066 (721) C Preload N / m (kg / mm) (lb / in) 8.7 (0.89), 48.
INSP ADJ GEAR SELECTION 6 Primary spring A Spring identification color code B Spring rate color C Preload color D Parts No. E F H I Spring rate N / mm (kg / mm) Preload N (kg) Wire gauge mm (in) Outside diameter mm (in) G Color K J No. of coils Free length mm (in) L Standard 90501-481J1 9.8 (1.0) 196 (20) Silver-Blue-Silver 4.8 (0.188) 60 (2.362) 5.16 85.4 (3.362) 90501-556G6 19.6 (2.0) 196 (20) Blue 5.5 (0.216) 60 (2.362) 4.95 75.4 (2.969) 90501-581J7 24.5 (2.
GEAR SELECTION INSP ADJ 9 Rollers I.D. 8 mm (0.3 in) A ROLLER with BUSHING PART NUMBER 88R-17624-01 B OUTSIDE DIAMETER C BUSHING TYPE (P / N) D IDENTIFICATION MARK (Width) 15.6 mm (0.61 in) Vespel F No Mark E Standard VK540E 90380-08183 2-42 14.6 mm (0.
HIGH ALTITUDE TUNING INSP ADJ ESS00096 HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below.
INSP ADJ REAR SUSPENSION ESS00100 REAR SUSPENSION ESS00101 Stopper band 1. Adjust: S Stopper band tension CAUTION: Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. NOTE: This adjustment affects the handling characteristics of the machine. Adjustment steps: S Loosen the locknut 1 . S Turn the adjusting nut 2 in or out to adjust the stopper band tension. Adjuster thread length a 25 ± 0.5 mm (0.98 ± 0.
REAR SUSPENSION INSP ADJ Extension spring preload 1. Adjust: S Extension spring preload Adjuster A Preload Turn in Turn out Harder Softer Snow Condition Icy Soft Standard Length B 16 mm (0 (0.63 63 in) CAUTION: Be sure the left and right spring preload is same.
REAR SUSPENSION INSP ADJ ESS00103 Rear suspension-full rate 1. Adjust: S Full rate adjuster Adjustment steps: S Loosen the nut 1 1/2 or 3/4 turns, while holding the adjusting bolt 2 securely with a wrench so it does not move. CAUTION: Never allow the adjusting bolt 2 to move while loosening the nut. S Turn the adjusting bolt 2 to the desired position.
REAR SUSPENSION INSP ADJ This model has a “Easy adjust” system for the Full rate adjuster. The bolt has teeth on it. So when the bolt is turned, it rides up and down the bracket. NOTE: S The nut has to be loosen first, while the bolt is held in place with a wrench. S Then the bolt can be turned to adjust the shock position up or down. S If the bolt is turned with the nut tight, it is possible to strip the teeth off the bolt.
STEERING CHAS ESS00104 CHASSIS ESS00105 STEERING A : 15 Nm (1.5 m kg, 11 ft lb) 3 Order Job name/Part name Q’ty Remove the parts in the order listed below. Handlebar removal 1 2 3 4 5 Remarks 1 1 2 1 1 Steering pad (rear) Steering pad (front) Handlebar holder (upper) Handlebar Handlebar holder (lower) For installation, reverse the removal procedure.
STEERING CHAS : 1 ESSO beacon 325 grease or Aeroshell greaes #7A A : 19 Nm (1.9 m kg, 14 ft lb) B : 27 Nm (2.7 m kg, 20 ft lb) C : 43 Nm (4.3 m kg, 31 ft lb) D : 25 Nm (2.5 m kg, 18 ft lb) Order Job name/Part name Q’ty Removing the parts in the order listed below. Steering column and tie rod removal 1 2 3 4 5 6 7 Handlebar Cotter pin Relay rod Tie rod Lock washer Bearing holder Plane bearing Steering column Remarks 3 1 1 4 2 4 1 For installation, reverse the removal procedure.
STEERING CHAS ESS00106 INSPECTION 1. Inspect: Handlebar 1 Steering column 2 Bends/cracks/damage Replace. WARNING Do not attempt to straighten a bent column. This may dangerously weaken the column. 2. Inspect: Bearings (steering column) 1 Steering column 2 (bearing contact surfaces) Scratches/wear/damage Replace. 3. Inspect: Relay rod 1 Tie-rods 2 Bends/cracks/damage Replace. WARNING Do not attempt to straighten bent rods. This may dangerously weaken the rods. 4.
STEERING CHAS ESS00107 INSTALLATION 1. Install: Tie-rod 1 Relay rod 2 NOTE: Install the rod end 3 with the left-hand thread onto the tie-rod on the right side. The threads on both a rod ends must be the same length. CAUTION: Always use new cotter pins. Locknut (rod end): 25 Nm (2.5 m kg, 18 ft lb) LOCTITE Nut (suspension arm-tie-rod): 43 Nm (4.3 m kg, 31 ft lb) 2. Apply Low temperature lithium soap base grease (to bearing inner surface) 3. Tighten: Bearing holder nut: 19 Nm (1.
STEERING CHAS 4. Adjust: Skis Adjustment steps: Temporarily install the handlebar. Hold the handlebar straight and check that the skis are at right angles to the handlebar. Loosen the locknuts (relay rod) 1 . Position the skis parallel in the riding direction. With the skis in this position, turn the relay rod 2 in either direction until the handlebars at right angles with respect to the direction of movement.
SKI CHAS ESS00108 SKI A : 43 Nm (4.3 m kg, 31 ft lb) B : 21 Nm (2.1 m kg, 15 ft lb) : 1 ESSO beacon 325 grease or Aeroshell greaes #7A C : Fit the stopper with its raised portion positioned in front. D : Be careful not to reverse the mounting positions of the left and right ski assemblies. Order 1 2 3 4 5 Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Ski removal Cotter pin Ski stopper Collar Ski Ski runner 1 1 1 1 1 For installation, reverse the removal procedure.
SKI CHAS ESS00109 INSPECTION 1. Inspect: Ski 1 Ski runner 2 Ski stopper 3 Wear/cracks/damage Replace. Mounting bolt 4 Collar 5 Wear/damage Replace.
FRONT SUSPENSION CHAS ESS00111 FRONT SUSPENSION A : 43 Nm (4.3 m kg, 31 ft lb) B : 21 Nm (2.1 m kg, 15 ft lb) C : 2 Nm (0.2 m kg, 1.4 ft lb) D : 16 Nm (1.6 m kg, 11 ft lb) E : 5 Nm (0.5 m kg, 3.6 ft lb) F : 10 Nm (1.0 m kg, 7.2 ft lb) : 1 ESSO beacon 325 grease or Aeroshell greaes #7A Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Refer to “SKI”.
FRONT SUSPENSION CHAS ESS00112 HANDLING NOTES WARNING This shock absorber contains highly compressed nitrogen gas. Befor handling the shock absorber read and make sure that you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handlind. Do not tamper or attempt to open the gas chamber. Do not subject the shock absorber to flames or any other source of high heat.
FRONT SUSPENSION CHAS 4. Inspect: Spring Wear/cracks/damage Replace. 5. Measure: Spring free length a Out of specification Replace. Spring free length limit: 235.0 mm (9.25 in) 6. Inspect: Oil seals Damage Replace. ESS00114 INSTALLATION 1. Lubricate: Bushing (suspension support 1 ) Bushing (suspension arm 2 ) Oil seal lips 3 Recommended grease: ESSO beacon 325 grease or Aeroshell grease #7A 2. Install: Suspension arm CAUTION: Always use a new circlip.
FRONT SUSPENSION CHAS 3. Tighten: Suspension bracket nut: 43 Nm (4.3 m kg, 31 ft lb) Set screw: 2 Nm (0.2 m kg, 1.4 ft lb) LOCTITE NOTE: Install the suspension bracket so that the “L” mark is on the left side and the “R” mark is on the right side. 4. Tighten: Absorber holder bolt: 10 Nm (1.0 m kg, 7.2 ft lb) Shock absorber nut: 5 Nm (0.5 m kg, 3.6 ft lb) Locknut (shock absorber): 16 Nm (1.6 m kg, 11 ft lb) Front arm nut: 43 Nm (4.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR ESS00117 POWER TRAIN ESS00118 PRIMARY SHEAVE AND DRIVE V-BELT A : 1st 120 Nm (12.0 m kg, 85 ft lb) 2nd 60 Nm (6.0 m kg, 43 ft lb) Order 1 2 3 Job name/Part name Q’ty Primary sheave removal V-belt Blind cap Primary sheave assembly Remarks Remove the parts in the order listed below. 1 1 1 For installation, reverse the removal procedure.
PRIMARY SHEAVE AND DRIVE V-BELT A : 6 Nm (0.6 m kg, 4.3 ft lb) B : 14 Nm (1.4 m kg, 10 ft lb) C : 200 Nm (20 m kg, 145 ft lb) POWR TR 4 D : Clean the threads. Apply LOCTITE #648 as illustrated in E . And then tighten the spider. (The spider must be turned counterclockwise to be tightened.) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job name/Part name a 16 mm (0.63 in) b 30 35 mm (1.18 1.38 in) Q’ty Remarks Remove the parts in the order listed below.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR ESS00119 REMOVAL 1. Remove: Drive V-belt guard Drive V-belt Grommet 1 2. Remove: Primary sheave assembly 1 NOTE: Use the primary sheave holder 2 and primary sheave puller 3 .
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR ESS00120 DISASSEMBLY 1. Remove: D Fixed sheave 1 D Stopper 2 D Sliding sheave 3 D Bushing 4 D Spider 5 Removal steps: D Immerse the primary sheave assembly in 80_ 100_C (176_ 212_F) water for several minutes. D Attach the lower piece of the clutch spider separator 6 onto a rigid table using suitable mounting bolts. Then, install the clutch separator adapter 7 onto the separator.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR ESS00121 INSPECTION 1. Inspect: Spider 1 Sliding sheave 2 Fixed sheave 3 Primary sheave cap 4 Cracks/damage Replace. 2. Inspect: Primary sheave spring 1 Cracks/damage Replace. 3. Measure: Primary sheave spring free length a Out of specification Replace the primary sheave spring. Primary sheave spring free length a: 85.4 mm (3.36 in) NOTE: When changing the primary sheave springs, refer to “GEAR SELECTION” in CHAPTER 2. A 4.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR 6. Inspect: Weight 1 Roller 2 Bushing 3 Slider 4 Rivet 5 Collar Wear/scratches/damage Replace. Slider inside clearance A1 + Min. 0 mm (0 in) Max. 0.3 mm (0.0118 in) A A2 : Rivet replacement steps: Remove old rivet with the appropriate drill. Insert the rivet 1 from the ID mark 2 side. Press or peen the rivet head so that the diameter a of the rivet head measures 8.5 mm (0.33 in) or larger. 7.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR ESS00122 ASSEMBLY 1. Install: Sliding sheave (onto the spider) NOTE: Be sure the sliding sheave match mark (X) is aligned with the spider match mark (X). 2. Install: Fixed sheave (onto the spider) NOTE: Apply LOCTITE to the fixed sheave as shown. CAUTION: LOCTITE should be applied only to the specified area. Never apply it to the bushings and other areas. a 16 mm (0.63 in) b 30 35 mm (1.18 1.38 in) 3.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR Tighten the spider to specification using the clutch spider separator (bar wrench) 3 . Spider: 200 Nm (20 m kg, 145 ft lb) CAUTION: The spider has a left-handed thread. WARNING Do not operate the primary sheave until the LOCTITE has dried completely. Wait 24 hours before operating the primary sheave. Since a high torque is required to tighten the spider, make sure the spider, fixed sheave, and special tool are well secured.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR ESS00123 INSTALLATION 1. Install: Primary sheave assembly CAUTION: Be sure to remove any oil or grease from the tapered portion of the crankshaft and spider using a cloth dampened with thinner. 2. Apply: YAMALUBE 2-cycle oil or an equivalent grease (to threads of primary sheave bolt) 3. Tighten: Bolt (primary sheave) 1 Tightening steps: Hold the primary sheave 3 using the primary sheave holder 2 and tighten the bolt (primary sheave) to specification.
SECONDARY SHEAVE POWR TR ESS00124 SECONDARY SHEAVE Order Job name/Part name Q’ty A : 60 Nm (6.0 m kg, 43 ft lb) B : 21 Nm (2.1 m kg, 15 ft lb) Remarks Remove the parts in the order listed below. 1 2 3 4 Secondary sheave removal V-belt Secondary shaft (jackshaft) Washer Shim 1 1 1 – 5 Secondary sheave assembly 1 With secondary sheave Refer to “SHEAVE DISTANCE AND OFFSET ADJUSTMENT” in CHAPTER 2. For installation, reverse the removal procedure.
SECONDARY SHEAVE A B POWR TR Standard position: No. 2 Standard twist angle: 40_ C Standard position: “C” : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Secondary sheave disassembly Circlip Washer Spring seat Secondary spring Sliding sheave Shim Fixed sheave 1 1 1 1 1 2 1 For assembly, reverse the removal procedure.
SECONDARY SHEAVE POWR TR ESS00125 DISASSEMBLY WARNING Use extreme CAUTION when disassembling the secondary sheave since serious injury can occur due to the sudden release of spring tension. Use the sheave compressor to contain the spring tension before removing the nuts (spring seat). Do not attempt this procedure unless you have the proper tools and understand the instructions thoroughly. 1.
SECONDARY SHEAVE POWR TR ESS00126 INSPECTION 1. Inspect: Sliding sheave 1 Fixed sheave 2 Spring seat 3 Shims 4 Cracks/damage Replace. 2. Inspect: Bushing (spring seat) 1 Sliding sheave (V-belt contact surface) 2 Scratches/wear/damage Replace. Sliding bushing 3 Unsymmetrical wear/damage Replace. 3. Inspect: Secondary sheave spring 1 Cracks/damage Replace. 4. Measure: Secondary sheave spring free length a Below specification Replace the secondary sheave spring.
SECONDARY SHEAVE POWR TR ESS00127 ASSEMBLY 1. Install: D Secondary sheave spring 1 D Spring seat 2 NOTE: Hook the end of the secondary sheave spring into the spring holes in the sliding sheave. Hook the other end of the spring into the holes in the spring seat. Standard spring position: C-2 Installation steps: D Turn in the screw for the sheave compressor so that the spring seat splines engage with the fixed sheave splines.
SECONDARY SHEAVE POWR TR ESS00128 INSTALLATION 1. Lubricate: Splines (fixed sheave) Recommended grease: Esso beacon 325 grease or Aeroshell grease #7A 2. Tighten: Secondary sheave bolt: 60 Nm (6.0 m kg, 43 ft lb) 3. Adjust: V-belt position Refer to “DRIVE V-BELT” in CHAPTER 2. Sheave distance Sheave offset Secondary sheave freeplay (clearance) Refer to “SHEAVE DISTANCE AND OFFSET ADJUSTMENT” in CHAPTER 2.
DRIVE CHAIN HOUSING POWR TR ESS00132 DRIVE CHAIN HOUSING Order 1 2 3 Job name/Part name Q’ty Drive chain housing removal Brake caliper Drain bolt Bolt Drive chain housing assembly 1 4 1 A : 10 Nm (1.0 m kg, 7.2 ft lb) B : 21 Nm (2.1 m kg, 15 ft lb) C : 10 Nm (1.0 m kg, 7.2 ft lb) Remarks Remove the parts in the order listed below. Refer to “BRAKE” Drain the oil For installation, reverse the removal proceudre.
DRIVE CHAIN HOUSING Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name/Part name Q’ty POWR TR A : 10 Nm (1.0 m kg, 7.2 ft lb) B : 100 Nm (10.0 m kg, 72 ft lb) Remarks Remove the parts in the order listed below.
DRIVE CHAIN HOUSING POWR TR ESS00133 INSPECTION 1. Inspect: Drive chain housing 1 Drive chain housing cover 2 Cracks/damage Replace. Oil seals (drive chain housing) Wear/damage Replace. Bearings (drive chain housing and cover) 3 Pitting/damage Replace. Bearing (chain tensioner) 4 Pitting/damage Replace the bearing and the inner race holder as a set. Replacement steps: Remove the bearing(s) 3 using a general bearing puller. Install the new bearing(s).
DRIVE CHAIN HOUSING POWR TR 3. Inspect: Shift forks 1 On the gear and shift cam contact surfaces. Wear/chafing/bends/damage Replace. 4. Check: Shift fork movement On its guide bar. Unsmooth operation Replace fork and/or guide bar. 5. Inspect: Shift cam grooves 1 Wear/damage/scratches Replace. Shift cam segment Damage/wear Replace. Stopper ball 2 Damage/wear Replace. 6. Inspect: Gears Damage/wear Replace. 7. Check: Gear movement Unsmooth operation Replace. 8.
DRIVE CHAIN HOUSING POWR TR 11. Inspect: Axle bearings Shift cam bearing Pitting/damage Replace. 12. Inspect: Shift linkage levers 1 Spacer 2 Torsion spring 3 Wear/damage Replace. 13. Inspect: Circlips Washers Damage/looseness/bends Replace.
DRIVE CHAIN HOUSING POWR TR 14. Measure: 14 link section a of the drive chain Using a spring scale, pull on the drive chain with 36 kg (80 lbs) of force b . Out of specification Replace the drive chain. Maximum 14 link drive chain section length a : 133.35 mm (5.25 in) Limit 137.35 mm (5.41 in) NOTE: Measure the length between drive chain pin 1 and 15 as shown. Perform this measurement at two or three different places.
DRIVE CHAIN HOUSING POWR TR ESS00134 INSTALLATION 1. During installation, pay attention to the following. A Make sure that the bearing seals face towards the drive chain as shown. B1 B2 Be sure to install the spacers in their origi- nal positions, otherwise the brake disc and jackshaft will stick. : ESSO beacon 325 grease or Aeroshell grease #7A 2. Adjust: Shift rod Adjustment steps: Move the shift lever to the “R” position. Loosen the locknut 1 .
SECONDARY SHAFT (JACKSHAFT) POWR TR ESS00135 SECONDARY SHAFT (JACKSHAFT) Order Job name/Part name Q’ty 1 2 3 Secondary shaft (jackshaft) removal V-belt Secondary shaft (jackshaft) Secondary sheave 1 1 1 A : 60 Nm (6.0 m kg, 43 ft lb) B : 21 Nm (2.1 m kg, 15 ft lb) Remarks With secondary sheave For installation, reverse the removal procedure.
SECONDARY SHAFT (JACKSHAFT) Order 1 2 3 4 5 Job name/Part name Q’ty POWR TR Remarks Remove the parts in the order listed below. Secondary shaft (jackshaft) disassembly Secondary sheave Circlip Bearing housing Circlip Bearing Secondary shaft (jackshaft) 1 1 1 1 1 For assembly, reverse the removal procedure.
SECONDARY SHAFT (JACKSHAFT) POWR TR ESS00136 INSPECTION 1. Inspect: Secondary shaft (jackshaft) 1 Scratches (excessive)/damage Replace. Splines 2 Wear/damage Replace the jackshaft. Bearing 3 Scratches/wear/damage Replace the jackshaft. INSTALLATION 1. Install: Secondary sheave 1 Secondary sheave bolt 2 : 60 Nm (6.0 m kg, 43 ft lb) 2. Install: Secondary shaft (jackshaft) assembly Bolt (Secondary shaft (jackshaft) assembly) 1 : 21 Nm (2.1 m kg, 15 ft lb) 3.
BRAKE POWR TR ESS00138 BRAKE A : Order 1 2 3 Job name/Part name Q’ty Brake pad removal Brake caliper assembly Brake disc Brake pads 48 Nm (4.8 m kg, 34.7 ft lb) Remarks Remove the parts in the order listed below. 1 1 2 For installation, reverse the removal procedure.
BRAKE POWR TR ESS00139 BRAKE PAD REPLACEMENT 1. Remove: Brake caliper NOTE: Do not depress the brake lever when the caliper or disc is off the machine otherwise the brake pads will be forced shut. Replace the pads as a set if either one is found to be worn to the wear limit a . Wear limit a : 10 mm (0.39 in) 2. Measure: Brake disc thickness a Out of specification Replace the brake disc. Minimum thickness a : 3.5 mm (0.14 in) Measuring point: 1 3 mm (0.04 0.
BRAKE POWR TR Screw in the adjusting screw 1 , and when it contacts lightly with the end of the back up plate, then back out the adjusting screw 1 1/2 to turn. Fit the end of the adjusting ratchet 1 into the adjusting screw 2 , and align the cut in the guide 3 with the projection of the stationary cover 4 , then install the guide 3 , which is fitted to the end cover 5 twisting the end cover clockwise approximately 30 degress and tighten the screws (end cover) 6 . Screw (end cover) 6 : 2 Nm (0.
BRAKE A : 2 Nm (0.2 m kg, 1.4 ft lb) B : 9 Nm (0.9 m kg, 6.5 ft lb) POWR TR : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order 1 2 3 4 5 6 Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Brake caliper disassembly Back up plate End cover Adjusting ratchet Stationary cover Lever Adjusting screw 1 1 1 1 1 1 For assembly, reverse the removal procedure.
BRAKE POWR TR BRAKE CALIPER INSPECTION 1. Inspect: One way lock 2 1 Stationary cover 2 Lever 3 Spiral gear 4 (lever) Cracks/wear/damage Replace. Replacement steps: Remove the one way lock 2 1 using a thin flathead screw driver. Remove the washer 2 and stationary cover 3. Replace a damaged part(s) use a new one. Reassemble the removed part(s) and reverse the above steps. CAUTION: Always use a new one way lock 2. 2. Inspect: Torsion spring 1 Fatigue/damage Replace end cover unit.
BRAKE POWR TR INSTALLATION 1. Assemble: Caliper body Assemblage steps: Lubricate the spiral gears 1 on the caliper body and lever 2 with silicone grease. Align the projection mark 1 on the lever with the “86” mark 2 on the caliper body, screw the lever 3 counterclockwise to the caliper body. Install the stopper pin 1 into the holes on the caliper body and stationary cover, then tighten the bolts (stationary cover). Bolt (stationary cover): 9 Nm (0.9 m kg, 6.
BRAKE POWR TR Screw in the adjusting screw 1 , and when it contacts lightly with the end of the back up plate, then back out the adjusting screw 1 1/2 to turn. Fit the end of the adjusting ratchet 1 into the adjusting screw 2 , and align the cut in the guide 3 with the projection of the stationary cover 4 , then install the guide 3 , which is fitted to the end cover 5 twisting the end cover clockwise approximately 30 degrees and tighten the screws (end cover) 6 . Screw (end cover) 6 : 2 Nm (0.
SLIDE RAIL SUSPENSION POWR TR SLIDE RAIL SUSPENSION A : Order 1 2 72 Nm (7.2 m kg, 52 ft lb) Job name/Part name Q’ty Slide rail suspension removal Tension adjuster Blind cap Slide rail suspension Remarks Remove the parts in the order listed below. Loosen. 2 1 For installation, reverse the removal procedure.
SLIDE RAIL SUSPENSION POWR TR A : 4 Nm (0.4 m kg, 2.9 ft lb) B : 16 Nm (1.6 m kg, 11 ft lb) C : 49 Nm (4.9 m kg, 35 ft lb) D : 72 Nm (7.2 m kg, 52 ft lb) E : 30 Nm (3.
SLIDE RAIL SUSPENSION A : 72 Nm (7.2 m kg, 52 ft lb) B : 49 Nm (4.9 m kg, 35 ft lb) C : 24 Nm (2.4 m kg, 17 ft lb) D : 80 Nm (8.
SLIDE RAIL SUSPENSION A : 50 Nm (5.0 m kg, 36 ft lb) B : 34 Nm (3.4 m kg, 25 ft lb) C : 27 Nm (2.7 m kg, 20 ft lb) D : 80 Nm (8.0 m kg, 58 ft lb) POWR TR : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order 31 32 33 34 35 36 37 38 39 40 Job name/Part name Q’ty Remarks 2 1 2 1 2 1 3 2 2 2 Pivot arm Base bolt Pivot shaft Coller Cotter pin Rear axle Guide wheel Coller Tension adjuster Coller For installation, reverse the removal procedure.
SLIDE RAIL SUSPENSION POWR TR ESS00148 INSPECTION 1. Inspect: Suspension wheel Guide wheel Cracks/damage Replace. Wheel bearing Wheel turns roughly Replace. 2. Inspect: Stopper band 1 Frayed/damage Replace. Pull rods 2 Bends/damage Replace. Shock absorbers 3 Oil leaks/damage Replace. Bushings Wear/cracks/damage Replace. Front pivot arm 4 Rear pivot arm 5 Rear pivot arm bracket 6 Suspension wheel bracket 7 Sliding frame 8 Cracks/damage Replace.
FRONT AXLE AND TRACK POWR TR ESS00149 FRONT AXLE AND TRACK Order 1 2 3 4 5 Job name/Part name Q’ty A : 21 Nm (2.1 m kg, 15 ft lb) B : 85 Nm (8.5 m kg, 61 ft lb) Remarks Remove the parts in the order listed below. Refer to “DRIVE CHAIN HOUSING”. Refer to “SLIDE RAIL SUSPENSION”. Refer to “SECONDARY SHEAVE”.
FRONT AXLE AND TRACK A : Order 1 2 3 Job name/Part name Q’ty Front axle disassembly Front axle housing Bearing Sprocket wheel POWR TR 85 Nm (8.5 m kg, 61 ft lb) Remarks Remove the parts in the order listed below. 2 1 3 For assembly, reverse the removal procedure.
FRONT AXLE AND TRACK POWR TR ESS00150 INSPECTION 1. Inspect: Track 1 Slide metal 2 Wear/cracks/damage Replace. 2. Inspect: Sprocket wheel 1 Wear/break/damage Replace. Front axle 2 Bends/scratches (excessive)/damage Replace. ESS00151 INSTALLATION 1. Install: Sprocket wheels Guide wheels NOTE: When pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel. Position each sprocket wheel on the axle as shown in the illustration. 2.
EXHAUST ASSEMBLY ENG ESS00152 ENGINE ESS00153 EXHAUST ASSEMBLY A : Order 1 2 3 4 5 Job name/Part name Q’ty 30 Nm (3.0 m kg, 22 ft lb) Remarks Remove the parts in the order listed below. Exhaust assembly removal Spring 1 Spring 2 Spring 3 Exhaust assembly Exhaust pipe joint 2 1 1 1 1 For installation, reverse the removal procedure.
EXHAUST ASSEMBLY ENG ESS00154 INSPECTION 1. Inspect: Exhaust joint 1 Exhaust pipe 2 Exhaust silencer 3 Cracks/damage Replace. Exhaust gaskets 4 Exhaust gas leaks Replace.
ENGINE ASSEMBLY ENG ESS00156 ENGINE ASSEMBLY A : 53 Nm (5.3 m kg, 38 ft lb) B : 103 Nm (10.3 m kg, 74 ft lb) Order Job name/Part name Q’ty Remove the parts in the order listed below. Refer to “EXHAUST ASSEMBLY”. Refer to “CARBURETOR” in CHAPTER 6. Refer to “RECOIL STARTER”. Refer to “ENGINE COOLING FAN”. Refer to “PRIMARY SHEAVE AND DRIVE V-BELT” in CHAPTER 4.
ENGINE ASSEMBLY ENG ESS00157 INSPECTION 1. Inspect: Engine bracket (front) 1 Engine bracket (rear) 2 Cracks/damage Replace. ESS00158 INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUTING” in CHAPTER 8, to check the cable, lead and hose routings. 1. Install: Engine assembly 1 Front engine mount (left) 103 Nm (10.3 m kg, 74 ft lb) Front engine mount (right) 53 Nm (5.3 m kg, 38 ft lb) Rear engine mount 53 Nm (5.
CYLINDER HEAD AND CYLINDER ENG ESS00159 CYLINDER HEAD AND CYLINDER A : 20 Nm (2.0 m kg, 14 ft lb) B : 1st 13 Nm (1.3 m kg, 9.4 ft lb) 2nd 25 Nm (2.5 m kg, 18 ft lb) Order Job name/Part name Q’ty 1 2 3 4 5 6 7 8 9 10 Cylinder head and cylinder removal Spark plug Cylinder head Cylinder head gasket Cylinder Cylinder gasket Piston pin Piston Piston ring Carburetor joint Reed valve 2 2 2 2 1 2 2 4 1 2 C : 1 Nm (0.1 m kg, 0.7 ft lb) D : 25 Nm (2.5 m kg, 18 ft lb) E : 14 Nm (1.
CYLINDER HEAD AND CYLINDER ENG ESS00160 REMOVAL 1. Remove: Piston pin clips Piston pins Pistons Small end bearings NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag so that you will not accidentally drop the clip into the crankcase. Before removing the piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller.
CYLINDER HEAD AND CYLINDER ENG 3. Eliminate: Carbon deposits (from the cylinders) Use the rounded scraper 1 . CAUTION: Do not use a sharp instrument. Avoid damaging or scratching the surface. 4. Eliminate: Carbon deposits (from the piston crown and ring grooves) 5. Inspect: Piston crown Burrs/nicks/damage Replace. 6. Eliminate: Score marks and lacquer deposits (from the piston wall) Use 600 800 grit wet sandpaper. NOTE: Sand in a crisscross pattern. Do not sand excessively. 7.
ENG CYLINDER HEAD AND CYLINDER Standard Wear limit Cylinder bore (C) 73.00 73.02 mm (2.874 2.875 in) 73.10 mm (2.878 in) Taper (T) – Out of round (R) – 0.05 mm (0.002 in) 0.01 mm (0.0004 in) C = Maximum D T = (Maximum of D1 or D2) – (Maximum of D5 or D6) R = (Maximum of D1, D3 or D5) – (Minimum of D2, D4 or D6) If out of specification, replace cylinder, and replace piston and piston rings as a set. 2nd step: Measure the piston skirt diameter (P) with a micrometer. a 10 mm (0.
CYLINDER HEAD AND CYLINDER ENG 8. Measure: Side clearance (piston rings) Use the feeler gauge 1 . Out of specification Replace the piston and/or rings. NOTE: Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance. Side clearance (top): 0.02 0.06 mm (0.00079 0.0024 in) Side clearance (2nd): 0.02 0.06 mm (0.00079 0.0024 in) 9. Install: Piston ring (into the cylinder) Push in the ring with the piston crown.
CYLINDER HEAD AND CYLINDER ENG 11. Measure: Outside diameter (piston pin) a Out of specification Replace the piston pin. a Outside diameter (piston pin) a : 19.995 20.000 mm (0.7872 0.7874 in) 12. Measure: Piston pin-to-piston clearance Out of specification Replace the piston. Piston pin-to-piston clearance = Bore size (piston pin) b – Outside diameter (piston pin) a b Piston pin-to-piston clearance = 0.004 0.0065 mm (0.00016 0.00026 in) 13.
CYLINDER HEAD AND CYLINDER ENG ESS00162 INSTALLATION 1. Install: Reed valves Reed valve stoppers NOTE: Place the reed valve 1 with its concave surface facing toward the reed valve seat 2 . Fit the reed valve stopper cut a into the corresponding cut b on the reed valve. 2. Tighten: Screws (reed valve) 1 Screws (reed valve) 1 : 1 Nm (0.1 m kg, 0.7 ft lb) LOCTITE NOTE: Tighten each screw gradually to avoid warping. 3. Install: Gasket (read valve) 4.
CYLINDER HEAD AND CYLINDER ENG CAUTION: Always use new piston pin clips. Do not allow the clip gap to align with the piston pin slot. 5. Check: Piston ring position CAUTION: Make sure that the ring ends are properly fitted around the ring locating pins in the piston grooves. Be sure to check that the manufacturer’s marks or numbers stamped on the rings face upward. 6. Install: Gasket (cylinder) 7.
CYLINDER HEAD AND CYLINDER ENG 9. Install: Gasket (cylinder head) Cylinder heads 10. Tighten: Nuts (cylinder head) Tightening steps: Temporarily tighten the cylinder head nuts 1 6 as follows. 1st step: Tighten the nuts 1 6 Nut (cylinder head) 1 6 : 13 Nm (1.3 m kg, 9.4 ft lb) 2nd step: Retighten the nuts 1 6 Nut (cylinder head) 1 6 : 25 Nm (2.5 m kg, 18.
OIL PUMP, CRANKCASE AND CRANKSHAFT ENG ESS00167 OIL PUMP, CRANKCASE AND CRANKSHAFT A : 1st 13 Nm (1.3 m kg, 9.4 ft lb) 2nd 21 Nm (2.1 m kg, 15 ft lb) Order Job name/Part name Q’ty 1 2 3 4 5 6 7 8 Oil pump, crankcase and crankshaft removal Oil pump Oil pump drive gear Lower crank case Crankshaft Stopper ring Oil seal Oil seal Upper crankcase Remarks Remove the parts in the order listed below. 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
OIL PUMP, CRANKCASE AND CRANKSHAFT ENG ESS00168 INSPECTION 1. Measure: Runout Use the V-blocks and a dial gauge. Out of specification Replace or repair the crankshaft. Dial gauge: 90890-03097, YU-03097 Runout limit: C1 : 0.03 mm (0.0012 in) C2, C3: 0.04 mm (0.0016 in) C4 : 0.05 mm (0.0020 in) a 97 mm (3.82 in) b 93 mm (3.66 in) 2. Measure: Small end freeplay a Use the dial gauge. Out of specification Replace the defective parts. Small end freeplay a : 0.8 1.0 mm (0.03 0.
OIL PUMP, CRANKCASE AND CRANKSHAFT ENG 4. Inspect: Lower crankcase 1 Upper crankcase 2 Front left brackets 3 Front right brackets 4 Rear bracket 5 Dampers 6 Cracks/damage Replace. 5. Inspect: Oil pump Cracks/damage Replace. Oil hoses Clogs/damage Replace. OIL PUMP STROKE ADJUSTMENT 1. Remove: Oil pump cover 1 2. Wipe off the grease from the plunger top. 3. Measure: Minimum pump stroke a Out of specification Adjust. Minimum pump stroke a : 0.20 0.25 mm (0.008 0.
OIL PUMP, CRANKCASE AND CRANKSHAFT ENG 4. Measure: Maximum pump stroke b Out of specification Adjust. Maximum pump stroke b : 1.65 1.87 mm (0.065 0.074 in) Maximum pump stroke measurement steps: Pull the oil pump cable 1 out of its sheath 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 wrap duct tape 2 around the cable where it enters the sheath.
OIL PUMP, CRANKCASE AND CRANKSHAFT ENG ESS00169 INSTALLATION 1. Install: Stopper rings 1 (onto the lower crankcase bearing as shown) 2 Knock pin A Lower crankcase B Upper crankcase 2. Install: Crankshaft assembly (to upper crankcase) NOTE: Set the knock pins 1 on the upper crankcase and labyrinth seal into the pin holes 2 of the bearings and upper crankcase by turning the bearings and labyrinth seal. At the same time, align the bearing punched marks 3 with the crankcase mating surface 4 .
OIL PUMP, CRANKCASE AND CRANKSHAFT OIL PUMP 1.
CDI MAGNETO ENG ESS00170 CDI MAGNETO A : Order 1 2 3 4 5 6 Job name/Part name Q’ty 85 Nm (8.5 m kg, 61 ft lb) Remarks Remove the parts in the order listed below. CDI magneto removal Rotor Stator assembly Charge coil Lighting coil 1 Lighting coil 2 Pulser coil 1 1 1 1 1 1 For installation, reverse the removal procedure.
CDI MAGNETO ENG ESS00171 REMOVAL 1. Remove: Nut 1 (CDI magneto) NOTE: Attach the universal rotor holder 2 to hold the CDI magneto. Universal rotor holder: 90890-01235, YU-01235 2. Remove: Rotor 1 NOTE: Attach the rotor holding puller 2 to the CDI magneto and fully tighten the tool holding bolts, but make sure the tool body is parallel with the CDI magneto. Rotor holding puller: 90890-01362, YU-33270 3.
CDI MAGNETO ENG ESS00172 INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUTING” in CHAPTER 8, to check the cable, lead and hose routings. 1. Pass the magneto leads 1 throught the hole, and install the grommet 2 to the crankcase. 2. Install: S Stator assembly 3 NOTE: Align the timing mark (") 4 on the stator plate with the seam line 5 of the crankcase. 3.
ENGINE COOLING FAN ENG ESS00173 ENGINE COOLING FAN A : Order Job name/Part name Q’ty 43 Nm (4.3 m kg, 3.1 ft lb) Remarks Removing the parts in the order listed below. Engine cooling fan removal 1 2 3 Cooling fan cover Fan belt driven pulley Shim 1 2 – 4 5 6 7 Fan belt Fan belt drive pulley Cooling fan housing Cooling fan 1 1 1 1 Refer to “COOLING FAN BELT TENSION ADJUSTMENT” in CHAPTER 2. For installation, reverse the removal procedure.
ENGINE COOLING FAN ENG ESS00174 REMOVAL 1. Remove: Cylinder air shroud 1 Seal rubber stay 2 (air duct) Cooling fan cover 3 2. Remove: Recoil starter 1 3. Remove: Starter pulley 1 Fan belt drive pulley 3 Fan belt 4 NOTE: Attach the universal rotor holder 2 to hold the starter pulley. Universal rotor holder: 90890-01235, YU-01235 4.
ENGINE COOLING FAN ENG ESS00175 INSPECTION 1. Inspect: Upper air shroud 1 Cracks/damage Replace. 2. Inspect: Cooling fan grill 1 Cooling fan housing 2 Cracks/damage Replace. 3. Inspect: Cooling fan belt 1 Wear/cracks/damage Replace. 4. Inspect: Cooling fan 1 Cracks/damage Replace. Bearings (cooling fan housing) 2 Pitting/damage Replace. Replacement steps: Remove the bearing(s) 2 using a general bearing puller. Install the new bearing(s).
ENGINE COOLING FAN ENG ESS00176 INSTALLATION 1. Install: Seal rubber 1 Cooling fan housing 2 Engine mounting bracket 3 Starter motor 4 2. Install: Fan belt 1 Fan belt drive pulley 2 Starter pulley 3 NOTE: Attach the universal rotor holder 4 to hold the starter pulley. Universal rotor holder: 90890-01235, YU-01235 3. Measure: Cooling fan belt deflection. Out of specification Adjust. Refer to “COOLING FAN BELT INSPECTION” in CHAPTER 2. Cooling fan belt deflection: 8 mm (0.31 in.
RECOIL STARTER ENG ESS00177 RECOIL STARTER A : 10 Nm (1.0 m kg, 7.2 ft lb) B : 23 Nm (2.3 m kg, 17 ft lb) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Refer to “EXHAUST ASSEMBLY”. Recoil starter removal Exhaust assembly Recoil starter assembly Nut Special washer Drive plate Spring seat Spring Drive pawl Sheave drum Starter spring 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
RECOIL STARTER ENG ESS00178 REMOVAL 1. Remove: Starter handle 1 Ground lead 2 NOTE: To remove the starter handle, untie the knot 3 in the starter rope and then re-tie a knot 4 in the rope end so that it is not pulled into the recoil starter case 5 . ESS00179 INSPECTION 1. Inspect: Drive plate 1 Cracks/bends/damage Replace. Spring 2 (drive plate) Wear/damage Replace. Starter rope 3 Wear/breaks/damage Replace. Starter spring 4 Cracks/bends/damage Replace.
RECOIL STARTER ENG ESS00180 INSTALLATION 1. Hook the starter spring around the post in the starter case. Carefully wind the spring counterclockwise, and fit the spring into the case. NOTE: After installing the spring thoroughly apply lowtemperature grease. 2. Pass the starter rope end into the sheave drum, and knot the rope end. Then fit the knot into the cutout in the sheave drum. 3. Wind: Starter rope (2 turns counterclockwise) (to sheave drum) 4.
RECOIL STARTER ENG 7. Install: Spring (drive plate) Spring seat Drive plate Special washer Washer Spring washer Nut NOTE: Be sure the cutout portion in the drive plate fits over the post on the drive pawl. Nut (drive plate): 10 Nm (1.0 m kg, 7.2 ft lb) LOCTITE 8. Pull about four inches of starter rope from out of the cutout portion in the sheave drum, and rotate the sheave drum five times counterclockwise to preload the starter spring.
CARBURETOR CARB ESS00197 CARBURETION ESS00198 CARBURETOR Order 1 2 3 4 5 6 Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Carburetor removal T.O.R.S. lead Starter cable Throttle cable Oil pump cable Fuel hose Clamp 1 1 1 1 1 2 For installation, reverse the removal procedure.
CARBURETOR A : 3 Nm (0.3 m kg, 2.2 ft lb) B : 2 Nm (0.2 m kg, 1.4 ft lb) C : 0.8 Nm (0.08 m kg, 0.58 ft lb) D : 5 Nm (0.5 m kg, 3.6 ft lb) E : 9 Nm (0.9 m kg, 6.5 ft lb) F : 3.5 Nm (0.35 m kg, 2.53 ft lb) Order 1 2 3 4 5 6 7 8 Job name/Part name Q’ty CARB Remarks Remove the parts in the order listed below.
CARBURETOR CARB ESS00201 INSPECTION 1. Inspect: Carburetor body Fuel passage Contamination Clean. NOTE: Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. 2. Inspect: Float 1 Damage Replace. 3. Inspect: Valve seat 1 Needle valve 2 Wear/contamination Replace. NOTE: Always replace the needle valve and valve seat as a set. 4. Inspect: Main jet 1 Main nozzle 2 Pilot jet 3 Contamination Clean or replace. 5.
CARBURETOR CARB 6. Check: Throttle valve movement Stick Replace carburetor body. ESS00202 ASSEMBLY NOTE: Before reassembling, wash all parts in clean gasoline. Always use new gaskets and O-rings. 1. Tighten: Inner parts Main nozzle: 3 Nm (0.3 m kg, 2.2 ft lb) Valve seat: 5 Nm (0.5 m kg, 3.6 ft lb) Main jet: 2 Nm (0.2 m kg, 1.4 ft lb) Pilot jet: 0.8 Nm (0.08 m kg, 0.58 ft lb) Starter plunger cap: 3.5 Nm (0.35 m kg, 2.53 ft lb) 2. Measure: Float height a Out of specification Adjust.
CARBURETOR CARB If the float height is not within specification, inspect the valve seat and needle valve. If either is worn, replace them both. If both are fine, adjust the float height by bending the float arm tang 1 on the float. Recheck the float height. ESS00204 INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUTING” in CHAPTER 8, to check the cable, lead and hose routings. 1. Adjust: Starter cable freeplay Refer to “STARTER (CHOKE) CABLE ADJUSTMENT” in CHAPTER 2.
FUEL PUMP CARB ESS00206 FUEL PUMP Order 1 2 3 4 Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Fuel pump removal Fuel hose Fuel delivery hose Vacuum hose Fuel pump assembly 1 1 1 1 For installation, reverse the removal procedure.
FUEL PUMP CARB ESS00207 INSPECTION 1. Inspect: Fuel hose 1 Fuel delivery hoses 2 Vacuum hose 3 Clogs/damage Replace. 2. Check: Fuel pump operation Checking steps: Connect the Mity vac 1 to the pulser hose 2 . Mity vac: 90890-06756, YB-35956 Place a container 3 under the end of the fuel delivery hoses 4 . Operate the Mity vac 1 while checking that fuel flows from the fuel delivery hoses 4 . If fuel does not flow out, replace the fuel pump.
SWITCH INSPECTION ELEC ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: 90890-03112, YU-03112 NOTE: Set the pocket tester to “0” before starting a test. When testing the switch for continuity the pocket tester should be set to the “ 1” Ω range. When checking the switch turn it on and off a few times.
19 CDI unit 16 Spark plug 17 Ignition coil 10 Main switch 23 Throttle switch 24 Carburetor switch 20 CDI magneto 22 Engine stop switch IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM 7-2 ELEC
IGNITION SYSTEM ELEC TROUBLESHOOTING NO SPARK OR WEAK SPARK. Check the spark plug gap. OK OUT OF SPECIFICATION Repair or replace the spark plug. Check the spark plug cap resistance. OK OUT OF SPECIFICATION Replace the spark plug cap. Check the ignition coil resistance. OK OUT OF SPECIFICATION Replace the ignition coil. Check the source coil. OK FAULTY Replace the source coil. Check the engine stop switch, throttle switch, carburetor switch and main switch.
IGNITION SYSTEM ELEC SPARK PLUG CAP 1. Remove: D Spark plug cap 2. Connect: D Pocket tester (to the spark plug cap) 3. Measure: D Spark plug cap resistance Out of specification Replace. Spark plug cap resistance: 5 kΩ at 20_C (68_F) IGNITION COIL 1. Disconnect: D Ignition coil lead D Spark plug lead 2. Connect: D Pocket tester (to the ignition coil and spark plug lead) 3. Measure: D Primary coil resistance 1 D Secondary coil resistance 2 Out of specification Replace. Primary coil resistance 1 : 0.
IGNITION SYSTEM ELEC SPARK PLUG 1. Remove: Spark plugs 2. Measure: Spark plug gap Standard spark plug: BR9ES (NGK) Spark plug gap: 0.7 0.8 mm (0.028 0.031 in) THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should malfunction during operation, T.O.R.S. will operate when the throttle lever is released. T.O.R.S.
IGNITION SYSTEM ELEC HANDLEBAR SWITCH (RIGHT) Engine stop switch and throttle switch 1. Disconnect: Handlebar switch (right) coupler 2. Connect: Pocket tester 3. Check: Engine stop switch continuity Faulty Replace the handlebar switch (right). Switch position Continuity RUN (pulled out) Yes OFF (pushed in) No 4. Check: Throttle switch continuity Faulty Replace the handlebar switch (right). Throttle switch position Continuity Throttle lever is operated.
IGNITION SYSTEM ELEC MAIN SWITCH 1. Disconnect: Main switch coupler 2. Connect: Pocket tester 3. Check: Main switch continuity Faulty Repalce.
7-8 25 Dimmer switch 21 Voltage regulator 20 CDI magneto 5 Headlight 15 Tail/brake light 3 Tachometer light 2 Speedometer light LIGHTING SYSTEM ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM
LIGHTING SYSTEM ELEC TROUBLESHOOTING HEADLIGHT, TAIL LIGHT AND/OR METER LIGHT DO NOT COME ON. Check the bulb(s). OK NO CONTINUITY Replace the bulb(s). Check the headlight beam switch and lighting coil. OK FAULTY Replace the headlight beam switch and/or lighting coil. Correct the connection and/or replace the rectifier/regulator.
LIGHTING SYSTEM a ELEC BULB(S) 1. Remove: D Headlight bulb a D Tail/brake light bulb b D Meter light bulb c 2. Connect: D Pocket tester (to the bulb terminals) b WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot. Do not touch the hulb until it cools down. c 3. Check: D Bulb(s) Terminal Continuity 1 – 2 1 – 3 Yes Yes HEADLIGHT BEAM SWITCH 1. Disconnect: D Headlight beam switch coupler 2.
7-11 26 Brake light switch 21 Voltage regulator 20 CDI magneto 15 Tail/brake light 14 Battery 11 Fuse 10 Main switch 6 Gear position switch 1 Back buzzer SIGNAL SYSTEM ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM
SIGNAL SYSTEM ELEC TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. Check the tail/brake light bulb. OK NO CONTINUITY Replace the bulb. Check the brake light switch. OK FAULTY Replace the brake light switch. Check the main switch and fuse. OK FAULTY Replace the main switch and/or fuse. Replace and/or charge battery and/or correct connection.
SIGNAL SYSTEM ELEC 8E181 TROUBLESHOOTING BACK BUZZER DOES NOT SOUND. Check the gear positon switch. OK FAULTY Replace the gear position switch. Check the lighting coil. OK OUT OF SPECIFICATION Replace the lighting coil. Check the back buzzer. OK DOES NOT SOUND Adjust and/or replace the back buzzer. Correct connection and/or replace the rectifier/regulator.
SIGNAL SYSTEM ELEC TAIL/BRAKE LIGHT BULB 1. Remove: Tail/brake light bulb Terminal Continuity 1 – 2 1 – 3 Yes Yes BRAKE LIGHT SWITCH 1. Check: Brake light switch continuity Faulty Replace. Switch position Continuity Brake lever operates Yes Brake lever does not operate No GEAR POSITION SWITCH 1. Check: Gear position switch continuity Faulty Replace. Shift lever position Continuity FORWARD No REVERSE Yes BACK BUZZER 1. Disconnect: Back buzzer coupler 2. Connect: Battery 3.
7-15 20 CDI magneto 9 Grip warmer switch 8 Grip warmer 7 Thumb warmer GRIP WARMER SYSTEM ELEC GRIP WARMER SYSTEM CIRCUIT DIAGRAM
GRIP WARMER SYSTEM ELEC 8E281 TROUBLESHOOTING GRIP WARMER DOES NOT OPERATE. Check the resistor. OK NO CONTINUITY Replace the resistor. Check the grip and thumb warmer. OK NO CONTINUITY Replace the grip warmer and/or thumb warmer. Check the grip warmer switch. CORRECT INCORRECT Replace the grip warmer switch. Replace the grip warmer coil and/or correct connection.
ELEC GRIP WARMER SYSTEM GRIP AND THUMB WARMER COIL 1. Disconnect: Grip warmer leads 1 Thumb warmer coupler 2 2. Connect: Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads) 3. Check: Grip warmer 1 continuity Thumb warmer 2 continuity No continuity Replace both grips together or separately and/or the handlebar switch. GRIP WARMER SWITCH 1. Check: Grip warmer switch continuity Faulty Replace.
ELECTRICAL STARTING SYSTEM ELEC ELECTRICAL STARTING SYSTEM 7-18 18 Starter motor 14 Battery 11 Fuse 13 Starter relay 10 Main switch CIRCUIT DIAGRAM
ELECTRICAL STARTING SYSTEM ELEC TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. WARNING Before starter motor operation, push the “ENGINE STOP” switch to “OFF”. NO A 1. Connect: Starter relay terminals (battery side and starter motor side) Check the battery and connectors. OK NO Replace and/or charge the battery. 1 Jumper lead 2. Check: Starter motor operation Repair and/or replace the starter motor.
ELEC ELECTRICAL STARTING SYSTEM FAULTY Check the main switch, fuse and rectifier. OK Replace the main switch, fuse and/or rectifier. Correct connection. MAIN SWITCH 1. Disconnect: Main switch coupler 1 2. Connect: Pocket Tester (to main switch coupler) 3. Check: Main switch continuity Faulty Replace. Color code Switch position Br B B/W R/W OFF ON START Continuity RECTIFIER 1. Disconnect: Rectifier lead 2. Connect: Rocket tester (to rectifier terminal) 3.
ELECTRICAL STARTING SYSTEM ELEC STARTER MOTOR Order Job name/Part name Q’ty Remove the parts in the order listed below. Starter motor disassembly 1 2 3 4 5 6 Remarks 1 1 1 1 1 1 Rear cover Brush plate Starter yoke Clip Pinion gear Front cover 7-21 For assembly, reverse the removal procedure.
ELECTRICAL STARTING SYSTEM ELEC STARTER MOTOR Inspection 1. Inspect: Commutator (outer surface) Dirty Clean with #600 grit sandpaper 1 . Hold the armature in a vise 2 and copper or aluminium plate 3 . CAUTION: Lightly grip the armature with a vise. 2. Measure: Commutator (diameter) Measure the diameter a of the commutator at points where the brush comes in contact. Out of specification Replace. Commutator wear limit a : 27.0 mm (1.06 in) 3.
ELECTRICAL STARTING SYSTEM ELEC 5. Measure: Brush length a Out of specification Replace. Brush length limit a : 8.5 mm (0.33 in) 6. Measure: Brush spring pressure Fatigue/Out of specification Replace as a set. Brush spring pressure: 800 ± 150 g (28.22 ± 5.30 oz) ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, Assembly 1. Before installing the front and rear covers, apply bearing grease to the bearings of the front and rear covers. 2.
7-24 21 Voltage regulator 20 CDI magneto 14 Battery 11 Fuse 12 Rectifire regulator CHARGING SYSTEM ELEC CHARGING SYSTEM CIRCUIT DIAGRAM
CHARGING SYSTEM ELEC 8E011 TROUBLESHOOTING BATTERY IS NOT CHARGED. OUT OF SPECIFICATIONS A 1. Connect: Pocket tester (to battery terminals) 2. Measure: Battery voltage Fluid gravity Check the battery. Replace and/or charge battery. Battery voltage: more than 12 V at 20 C (68 F) OK OUT OF SPECIFICATION B 1. Start the engine and accelerate to 3,000 rpm. 2. Measure: Charging voltage Check the fuse and charging coil. Charging voltage: 13.3 14.3 V/3,000 rpm.
CHARGING SYSTEM ELEC BATTERY Inspection 1. Inspect: D Battery fluid level Below lower level Refill.
GENERAL SPECIFICATIONS SPEC 9E001 SPECIFICATIONS GENERAL SPECIFICATIONS Model VK540E Model code number: 8AC Dimensions: Overall length Overall width Overall height 3,120 mm (122.8 in) 1,130 mm (44.5 in) 1,350 mm (53.1 in) Weight: Dry weight (Without fuel and oil) 291 kg (642 lb) Minimum turning radius: Clockwise Counterclockwise 3.9 mm (12.8 ft) 4.1 mm (13.
GENERAL SPECIFICATIONS Model Transmission: Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio Reverse system SPEC VK540E V-Belt 3.8 0.95 : 1 Automatic centrifugal engagement Chain Low: Gear, chain 39/17 (2.29) Low: 28/22 28/22 39/17 (3.71) Yes Chassis: Frame type Caster Ski stance (center to center) Monocock 22.5 960 mm (37.
MAINTENANCE SPECIFICATIONS SPEC 9E011 MAINTENANCE SPECIFICATIONS ENGINE Model Cylinder head: Volume (With spark plug) VK540E 30.2 30.8 cm3 <0.03 mm (0.0012 in)> Lines indicate straightedge measurement. Cylinder: Material Bore size Aluminum alloy with cast iron sleeve 73.00 73.02 mm (2.874 2.875 in) <0.05 mm (0.0019 in)> <0.01 mm (0.0004 in)> Piston: Piston size “D” Measuring point a 72.942 72.950 mm (2.871 2.872 in) 19.0 mm (0.
MAINTENANCE SPECIFICATIONS Model SPEC VK540E Crankshaft: Crank width “A” Crank width “B” Crankshaft deflection “C”: C1 C2, C3 C4 Measuring points: 1 2 Connecting rod big end side clearance “D” Connecting rod small end free play “F” 59.95 60.00 mm (2.360 2.362 in) 199.75 200.25 mm (7.86 7.88 in) Below 0.03 mm (0.0012 in) Below 0.04 mm (0.0016 in) Below 0.05 mm (0.0020 in) 97.0 mm (3.82 in) 93.0 mm (3.66 in) 0.25 0.75 mm (0.01 0.03 in) 0.8 1.0 mm (0.03 0.
MAINTENANCE SPECIFICATIONS Model SPEC VK540E Fuel pump: Type Manufacturer DIAPHRAM MIKUNI Oil pump: Color code Plunger diameter Worm gear ratio Minimum stroke Maximum stroke Pump cable free play White 5.5 mm (0.22 in) 1/44 (0.023) 0.20 0.25 mm (0.008 0.010 in) 1.65 1.87 mm (0.065 0.074 in) 25 ± 1 mm (0.98 ± 0.039 in) Cooling system: Cooling fan belt tension 8 mm/4 6 kg (0.3 in/8.8 13.
MAINTENANCE SPECIFICATIONS SPEC POWER TRAIN VK540E Model Transmission: Type Range of ratio Engagement r/min Shift r/min Sheave center distance “A” Sheave offset “B” V-belt automatic 3.8 0.95 : 1 2,600 ± 300 r/min 6,700 ± 300 r/min 267 270 mm (10.5 10.6 in) 14.5 17.5 mm (0.57 0.69 in) V-belt: Part number/manufacturer Outside circumference Width “A” 87X-17641-00 /DAYCO 1,118 1,128 mm (44.0 44.4 in) 35.0 mm (1.38 in) 32.0 mm (1.
MAINTENANCE SPECIFICATIONS Model Secondary sheave spring: Part number Color code Outside diameter Wire diameter Twist angle Hole position Sheave side-spring side Spring rate Number of coils Free length Torque cam angle SPEC VK540E 90508-50746 White 65 mm (2.6 in) 5 mm (0.20 in) 40 C-2 8.7 Nmm/rad (0.89 kg/mm, 48.7 lb/in) 4.74 93.5 mm (3.
MAINTENANCE SPECIFICATIONS Model Shock absorber: Damping force (Extension) Front Rear Damping force (Compression) Front Rear SPEC VK540E 510 N/0.3 m/s (52 kg/0.3 m/s, 115 lb/0.3 m/s) 2650 N/0.3 m/s (270.4 kg/0.3 m/s, 596 lb/0.3 m/s) 1780 N/0.3 m/s (181.6 kg/0.3 m/s, 400 lb/0.3 m/s) 780 N/0.3 m/s (79.6 kg/0.3 m/s, 176 lb/0.3 m/s) Slide runner: Thickness 17.8 mm (0.70 in) <10 mm (0.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Model VK540E 8-9 Frame: Frame material Seat height Laggage box location Steering: Lock-to-lock angle Ski alignment Toe-out size Ski stance (center to center) Steel 713 mm (28.1 in) Under seat (Left) (Right) 24.9 (R ski) 26.6 (L ski) 28.4 (R ski) 25.9 (L ski) Toe-out 0 15 mm (0 0.6 in) 960 mm (37.8 in) Ski: Ski material Length Width Thickness Ski ground length Steel 1,094 mm (43 in) 145 mm (5.71 in) 1.6 mm (0.06 in) 514 mm (20.
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL VK540E Model Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) 17 (1.55 mm) at 7,000 r/min CDI: Magneto model/manufacturer Pulser coil resistance (Color code) Source coil resistance (Color code) CDI unit model/manufacturer F8AT/YAMAHA 16.0 24.
MAINTENANCE SPECIFICATIONS Model SPEC VK540E Flywheel magneto: Model/manufacturer Lighting voltage (minimum) Lighting coil resistance: (Color code) Charging coil resistance: (Color code) Coil resistance for grip warmer (Color code) F8AT/YAMAHA 11.8 V at 3,000 r/min 0.24 0.36 Ω at 20 C (68 F) (Yellow – Black) 0.32 0.48 Ω at 20 C (68 F) (White – Black) 0.64 0.
MAINTENANCE SPECIFICATIONS SPEC HIGH ALTITUDE SETTINGS VK540E Temperature Altitude – 30 C (– 22 F) –20 C (– 4 F) – 10 C (14 F) 0 C (32 F) 10 C (50 F) 20 C (68 F) #141.3 (STD) 0 100 m (300 ft) #142.5 #140 #141.3 (STD) 100 600 m (2000 ft) 600 1200 m (4000 ft) 1200 1800 m (6000 ft) #140 #141.3 (STD) #140 #137.5 #140 1800 2400 m (8000 ft) #137.5 PJ: #100, PS: 1-3 / 4 2400 3000 m (10000 ft) #135 PJ: #100, PS: 1-3 / 4 #135 #135 PJ: #100, PS: 1-3 / 4 #132.
MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUE Part to be tightened Crankcase (First) (Final) Front engine mount bolt (left) Front engine mount bolt (right) Rear engine mount bolt Cylinder head (First) (Final) Cylinder Exhaust pipe and cylinder Carburetor joint and cylinder Reed valve Spark plug Cooling fan driven pulley nut CDI magneto and crankshaft Recoil starter case Recoil starter drive plate Recoil starter pulley Throttle cable locknut Carburetor Main nozzle Main jet Pilot jet Valve seat Float c
MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Steering bearing holder (bolt) Handlebar holder Relay-rod and steering colum Relay-rod and suspension arm Relay-rod end locknut Tie-rod and suspension arm Tie-rod end locknut Ski and suspension bracket Ski runner and ski Front arm and suspension arm Front arm and suspension bracket Suspension bracket nut Suspension bracket set screw Front shock absorber holder Front shock absorber Front shock absorber locknut Slide rail suspension and frame
GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads.
CABLE ROUTING 8-16 SPEC
CABLE ROUTING CABLE ROUTING 1 Fasten the wire harness and 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 speedometer cable with a steel clamp. Ground lead Fasten the wire lead and wire negative lead with a steel clamp. Fasten the wire harness and wire lead with a steel clamp. Wire harness Starting motor Fasten the wire harness and wire negative lead with a steel clamp.
CABLE ROUTING 8-18 SPEC
CABLE ROUTING 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Battery Fuse box Secondary shaft (jackshaft) Battery positive lead Starter switch Carburetor Delivery hose Fasten the wire lead, wire negative lead and speedometer cable with a plastic clamp. Route the oil hose under the engine mount bracket. Engine Wire negative lead Wire lead Speedometer cable Do not be loosen. Wire negative lead Do not fasten in this position. Recoil starter cable Oil hose To the oil pump.
CABLE ROUTING 8-20 SPEC
CABLE ROUTING 1 Engine stop switch coupler 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Route the engine stop switch lead backward the handlebar. Thumb warmer coupler Clamp Route the throttle cable frontward the handlebar. Fuel tank Grip warmer connector Brake cable Clamp Do not fasten the throttle cable and brake cable. Headlight switch coupler Route the headlight switch lead backward the handlebar.
CABLE ROUTING 8-22 SPEC
CABLE ROUTING 25 Fasten the wire wariness, fuel 26 27 28 29 30 31 32 33 34 35 36 tank breather hose and oil tank breather hose with a plastic band. Oil tank Gear position switch Wire harness sub lead Drive chain case Fasten the wire harness and fuel tank breather hose at the white tape mark, with a clamp. Route the fuel tank breather hose outside the wire harness. 40 mm (1.
CABLE ROUTING 8-24 SPEC
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 Speedometer Back buzzer Headlight Tachometer (option) Set the clamp at the illustrated. Clamp the tachometer lead for a model without tachometer. Headlight lead Speedometer cable Fasten the headlight lead and speedometer cable at white tape mark, with a plastic clamp. Clamp Fasten the headlight lead and speedometer cable with a plastic band.
CABLE ROUTING 8-26 SPEC
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Clamp on the frame Clamp in the cargo space Do not be loosen. Grommet Grommet Route the tail / stop light lead into the pipe.
CABLE ROUTING 8-28 SPEC
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Oil hose Joint Oil level hose Clip Hose protector Oil strainer Oil tank breather hose Oil tank Clamp on the oil tank After routing the fuel hoses, push the clamp to broken, and hold the hoses. Protector Fuel delivery hose Fuel hose Screw Steering gate Wire harness sub lead Fuel tank breather hose Wire harness To the tail / brake light Band Band along the bracket of under the steering gate.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Back buzzer Speedometer light Tachometer light Tachometer Headlight Gear position switch Thumb warmer Grip warmer Grip warmer switch Main switch Fuse Rectifier regulator Starter relay Battery Tail/ brake light Spark plug Ignition coil Starter motor CDI unit CDI magneto Voltage regulator Engine stop switch Throttle switch Carburetor switch Dimmer switch Brake light switch COLOR CODE B ........... Br . . . . . . . . . . Ch . . . . . . . .
WIRING DIAGRAM VK540E
PRINTED ON RECYCLED PAPER 2000. 05 1. E. ITP PRINTED IN U.S.A.
