Yamaha RX10H User manual

SERVICE MANUAL

WARNING
CAUTION:
NOTE:
NOTICE
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 under-
standing of the mechanical concepts and pro-
cedures inherent in snowmobile repair. Without
such knowledge, attempted repairs or service
to this model may render it unfit and/or unsafe
to use.
Yamaha Motor Company, Ltd. is continually
striving to improve all models manufactured by
Yamaha.
Modifications and significant changes in speci-
fications or procedures will be forwarded to all
authorized Yamaha dealers and will, where ap-
plicable, appear in future editions of this manu-
al.
RX10H/RX10SH
RX10MH/RX10MSH
RX10RH/RX10RSH
SERVICE MANUAL
2002 by Yamaha Motor
Corporation, U.S.A.
1st Edition, June 2002
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N.LIT-12618-02-28
HOW TO USE THIS MANUAL
Particularly important information is distin-
guished in this manual by the following nota-
tions:
The Safety Alert Symbol means ATTENTION!
BE ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the snowmo-
bile operator, a bystander, or a person inspect-
ing or repairing the snowmobile.
A CAUTION indicates special precautions that
must be taken to avoid damage to the snowmo-
bile.
A NOTE provides key information that can
make procedures easier or clearer.
MANUAL FORMAT
All of the procedures in this manual are orga-
nized in a sequential, step-by-step format. The
information has been compiled to provide the
mechanic with an easy to read, handy reference
that contains comprehensive explanations of all
inspection, repair, assembly, and disassembly
operations.
In this revised format, the condition of a faulty
component will precede an arrow symbol and
the course of action required to correct the prob-
lem will follow the symbol, e.g.,
SBearings
Pitting/damage !Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams be-
fore each disassembly section to facilitate cor-
rect disassembly and assembly procedures.

10
SPEC
ELEC
CARB
8
1 2
3 4
56
7
11 12
13 14 15
16 17 18
19 20 21
22 23 24
25
GEN
INFO
INSP
ADJ
ENG
CHAS POWR
TR
9
COOL
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1to 9are designed as
thumb tabs to indicate the chapter’s number
and content.
1General information
2Periodic inspections and adjustments
3Chassis
4Power train
5Engine
6Cooling system
7Carburetion
8Electrical
9Specifications
Illustrated symbols 10 to 16 are used to identify
the specifications which appear.
10 Filling fluid
11 Lubricant
12 Tightening
13 Wear limit, clearance
14 Engine speed
15 Special tool
16 Ω, V, A
Illustrated symbols 17 to 25 in the exploded dia-
gram indicate grade of lubricant and location of
lubrication point.
17 Apply locking agent (LOCTITE)
18 Apply Yamabond No.5
19 Apply engine oil
20 Apply gear oil
21 Apply molybdenum disulfide oil
22 Apply wheel bearing grease
23 Apply low-temperature lithium-soap base grease
24 Apply molybdenum disulfide grease
25 Use new one

1
9
8
6
5
4
INSP
ADJ
GENERAL INFORMATION
PERIODIC INSPECTIONS AND
ADJUSTMENTS
POWER TRAIN
ENGINE
COOLING SYSTEM
ELECTRICAL
SPECIFICATIONS
GEN
INFO
2
3
POWR
TR
ENG
COOL
ELEC
SPEC
CHASSIS CHAS
7
CARBURETION CARB
INDEX

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 1-2. . . . . . . .
GASKETS, OIL SEALS, AND
O-RINGS 1-3. . . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND
COTTER PINS 1-3. . . . . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-3. . . . . . . .
CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . .
LOCTITE1-3. . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-4. . . . . . . . . . . . . . . . . . . . .
FOR TUNE UP 1-4. . . . . . . . . . . . . . . . . . . .
FOR ENGINE SERVICE 1-5. . . . . . . . . . . .
FOR POWER TRAIN SERVICE 1-7. . . . . .
FOR CARBURETION SERVICE 1-8. . . . .
FOR ELECTRICAL SERVICE 1-8. . . . . . .
CHAPTER 2.
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION 2-1. . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE TABLE 2-1. . . . .
ENGINE 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARK PLUGS 2-3. . . . . . . . . . . . . . . . . . . .
FUEL LINE INSPECTION 2-4. . . . . . . . . . .
COOLING SYSTEM 2-4. . . . . . . . . . . . . . . .
VALVE CLEARANCE
ADJUSTMENT 2-9. . . . . . . . . . . . . . . . . . . .
CARBURETOR
SYNCHRONIZATION 2-14. . . . . . . . . . . . .
ENGINE IDLE SPEED
ADJUSTMENT 2-16. . . . . . . . . . . . . . . . . .
THROTTLE CABLE FREE PLAY
ADJUSTMENT 2-17. . . . . . . . . . . . . . . . . .
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK 2-18. . . . . . . . . . . . . . .
COMPRESSION PRESSURE
MEASUREMENT 2-18. . . . . . . . . . . . . . . .
ENGINE OIL LEVEL
INSPECTION 2-20. . . . . . . . . . . . . . . . . . . .
ENGINE OIL REPLACEMENT 2-22. . . . .
CRANKCASE BREATHER HOSE
INSPECTION 2-24. . . . . . . . . . . . . . . . . . . .
CABURETOR JOINTS
INSPECTION 2-24. . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM
INSPECTION 2-25. . . . . . . . . . . . . . . . . . . .
POWER TRAIN 2-26. . . . . . . . . . . . . . . . . . . . .
SHEAVE OFFSET
ADJUSTMENT 2-26. . . . . . . . . . . . . . . . . .
DRIVE V-BELT 2-27. . . . . . . . . . . . . . . . . .
ENGAGEMENT SPEED CHECK 2-29. . .
PARKING BRAKE ADJUSTMENT 2-30. .
BRAKE LEVER ADJUSTMENT 2-30. . . .
BRAKE FLUID LEVEL
INSPECTION 2-31. . . . . . . . . . . . . . . . . . . .
BRAKE PAD INSPECTION 2-32. . . . . . . .
BRAKE HOSE INSPECTION 2-32. . . . . .
AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM) 2-32. . . . . . . . . . . . . . . .
DRIVE CHAIN 2-34. . . . . . . . . . . . . . . . . . .
TRACK TENSION ADJUSTMENT 2-36. .
SLIDE RUNNER INSPECTION 2-37. . . .
MAXIMIZING DRIVE TRACK LIFE 2-38.
CHASSIS 2-39. . . . . . . . . . . . . . . . . . . . . . . . . .
SKI/SKI RUNNER 2-39. . . . . . . . . . . . . . .
STEERING SYSTEM 2-40. . . . . . . . . . . . .
LUBRICATION 2-41. . . . . . . . . . . . . . . . . .
ELECTRICAL 2-43. . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BEAM
ADJUSTMENT 2-43. . . . . . . . . . . . . . . . . .
BATTERY INSPECTION 2-44. . . . . . . . . .
FUSE INSPECTION 2-50. . . . . . . . . . . . . .
SPEEDOMETER UNIT
INSPECTION 2-51. . . . . . . . . . . . . . . . . . . .
TUNING 2-52. . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR TUNING 2-52. . . . . . . . . .
CLUTCH 2-59. . . . . . . . . . . . . . . . . . . . . . . .
GEAR SELECTION 2-61. . . . . . . . . . . . . .
HIGH ALTITUDE TUNING 2-67. . . . . . . .
FRONT SUSPENSION 2-68. . . . . . . . . . .
REAR SUSPENSION 2-69. . . . . . . . . . . . .

CHAPTER 3.
CHASSIS
STEERING 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION 3-7. . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 3-8. . . . . . . . . . . . . . . . . . . .
SKI 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION 3-12. . . . . . . . . . . . . . . . . . . .
INSTALLATION 3-12. . . . . . . . . . . . . . . . . .
FRONT SUSPENSION 3-13. . . . . . . . . . . . . .
HANDLING NOTES 3-15. . . . . . . . . . . . . .
INSPECTION 3-15. . . . . . . . . . . . . . . . . . . .
INSTALLATION 3-16. . . . . . . . . . . . . . . . . .
CHAPTER 4.
POWER TRAIN
PRIMARY SHEAVE AND DRIVE
V-BELT 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL 4-3. . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY 4-3. . . . . . . . . . . . . . . . . . . .
INSPECTION 4-5. . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY 4-7. . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 4-9. . . . . . . . . . . . . . . . . . . .
SECONDARY SHEAVE 4-10. . . . . . . . . . . . . .
DISASSEMBLY 4-12. . . . . . . . . . . . . . . . . .
INSPECTION 4-12. . . . . . . . . . . . . . . . . . . .
ASSEMBLY 4-13. . . . . . . . . . . . . . . . . . . . .
INSTALLATION 4-15. . . . . . . . . . . . . . . . . .
DRIVE CHAIN HOUSING 4-16. . . . . . . . . . . .
WITHOUT REVERSE MODEL 4-16. . . . .
INSPECTION 4-17. . . . . . . . . . . . . . . . . . . .
INSTALLATION 4-19. . . . . . . . . . . . . . . . . .
WITH REVERSE MODEL 4-20. . . . . . . . .
INSPECTION 4-22. . . . . . . . . . . . . . . . . . . .
INSTALLATION 4-23. . . . . . . . . . . . . . . . . .
SECONDARYSHAFT 4-25. . . . . . . . . . . . . . . .
INSPECTION 4-26. . . . . . . . . . . . . . . . . . . .
SECONDARYSHAFT AND DRIVE
CHAIN HOUSING INSTALLATION 4-27.
BRAKE 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD REPLACEMENT 4-29. . . . .
BRAKE CALIPER DISASSEMBLY 4-32. .
BRAKE CALIPER INSPECTION
AND REPAIR 4-32. . . . . . . . . . . . . . . . . . . .
BRAKE CALIPER ASSEMBLY 4-33. . . . .
BRAKE CALIPER INSTALLATION 4-33.
INSPECTION 4-35. . . . . . . . . . . . . . . . . . . .
BRAKE MASTER CYLINDER
ASSEMBLY 4-35. . . . . . . . . . . . . . . . . . . . .
INSTALLATION 4-35. . . . . . . . . . . . . . . . . .
SLIDE RAIL SUSPENSION 4-36. . . . . . . . . .
RX10, RX10S, RX10R, RX10RS 4-36. . .
RX10M, RX10MS 4-41. . . . . . . . . . . . . . . .
INSPECTION 4-46. . . . . . . . . . . . . . . . . . . .
ASSEMBLY 4-47. . . . . . . . . . . . . . . . . . . . .
INSTALLATION 4-47. . . . . . . . . . . . . . . . . .
FRONT AXLE AND TRACK 4-49. . . . . . . . . .
INSPECTION 4-50. . . . . . . . . . . . . . . . . . . .
INSTALLATION 4-50. . . . . . . . . . . . . . . . . .
CHAPTER 5.
ENGINE
SEAT AND FUEL TANK 5-1. . . . . . . . . . . . . . .
EXHAUST PIPE AND MUFFLER 5-2. . . . . . .
INSTALLATION 5-3. . . . . . . . . . . . . . . . . . . .
ENGINE ASSEMBLY 5-4. . . . . . . . . . . . . . . . . .
INSPECTION 5-5. . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 5-5. . . . . . . . . . . . . . . . . . . .
CAMSHAFTS 5-6. . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL 5-9. . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION 5-11. . . . . . . . . . . . . . . . . . . . .
INSTALLATION 5-14. . . . . . . . . . . . . . . . . .
CYLINDER HEAD 5-17. . . . . . . . . . . . . . . . . . .
REMOVAL 5-18. . . . . . . . . . . . . . . . . . . . . .
INSPECTION 5-19. . . . . . . . . . . . . . . . . . . .
INSTALLATION 5-20. . . . . . . . . . . . . . . . . .
VALVES AND VALVE SPRINGS 5-21. . . . . .
REMOVAL 5-23. . . . . . . . . . . . . . . . . . . . . .
INSPECTION 5-24. . . . . . . . . . . . . . . . . . . .
INSTALLATION 5-29. . . . . . . . . . . . . . . . . .

A.C. MAGNETO AND STARTER
CLUTCH 5-31. . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL 5-33. . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 5-35. . . . . . . . . . . . . . . . . .
OIL PAN AND OIL PUMP 5-37. . . . . . . . . . . .
REMOVAL 5-39. . . . . . . . . . . . . . . . . . . . . .
INSPECTION 5-40. . . . . . . . . . . . . . . . . . . .
INSTALLATION 5-41. . . . . . . . . . . . . . . . . .
CRANKCASE 5-42. . . . . . . . . . . . . . . . . . . . . .
REMOVAL 5-45. . . . . . . . . . . . . . . . . . . . . .
INSPECTION 5-47. . . . . . . . . . . . . . . . . . . .
INSTALLATION 5-58. . . . . . . . . . . . . . . . . .
CHAPTER 6.
COOLING SYSTEM
HEAT EXCHANGER 6-1. . . . . . . . . . . . . . . . . .
INSPECTION 6-3. . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 6-4. . . . . . . . . . . . . . . . . . . .
THERMOSTAT 6-5. . . . . . . . . . . . . . . . . . . . . . .
INSPECTOIN 6-6. . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 6-7. . . . . . . . . . . . . . . . . . . .
WATER PUMP 6-8. . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY 6-9. . . . . . . . . . . . . . . . . . . .
INSPECTION 6-10. . . . . . . . . . . . . . . . . . . .
ASSEMBLY 6-10. . . . . . . . . . . . . . . . . . . . .
CHAPTER 7.
CARBURETION
CARBURETORS 7-1. . . . . . . . . . . . . . . . . . . . .
INSPECTION 7-5. . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY 7-7. . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 7-8. . . . . . . . . . . . . . . . . . . .
FUEL LEBEL ADJUSTMENT 7-9. . . . . . . .
THROTTLE POSITION SENSOR
(T.P.S.) INSPECTION AND
ADJUSTMENT 7-10. . . . . . . . . . . . . . . . . .
FUEL PUMP 7-12. . . . . . . . . . . . . . . . . . . . . . .
INSPECTION 7-12. . . . . . . . . . . . . . . . . . . .
INSTALLATION 7-12. . . . . . . . . . . . . . . . . .
CHAPTER 8.
ELECTRICAL
SWITCH INSPECTION 8-1. . . . . . . . . . . . . . . .
SWITCH INSPECTION 8-1. . . . . . . . . . . . .
INSPECTING A SWITCH SHOWN IN
THE MANUAL 8-1. . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM 8-2. . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-2. . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-4. . . . . . . . . . . . . .
A.C. MAGNETO 8-5. . . . . . . . . . . . . . . . . . .
SPARK PLUG 8-5. . . . . . . . . . . . . . . . . . . . .
IGNITION SPARK GAP 8-6. . . . . . . . . . . . .
IGNITION COIL 8-6. . . . . . . . . . . . . . . . . . . .
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) 8-7. . . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR SWITCH (RIGHT) 8-8. . . . .
CARBURETOR SWITCH 8-8. . . . . . . . . . .
MAIN SWITCH 8-9. . . . . . . . . . . . . . . . . . . .
MAIN RELAY 8-9. . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL STARTING SYSTEM 8-10. . .
CIRCUIT DIAGRAM 8-10. . . . . . . . . . . . . .
TROUBLESHOOTING 8-11. . . . . . . . . . . . .
MAIN SWITCH 8-12. . . . . . . . . . . . . . . . . .
STARTER MOTOR 8-13. . . . . . . . . . . . . . .
CHARGING SYSTEM 8-16. . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-16. . . . . . . . . . . . . .
TROUBLESHOOTING 8-17. . . . . . . . . . . .
BATTERY 8-18. . . . . . . . . . . . . . . . . . . . . . .
STATOR COIL 8-18. . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 8-19. . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-19. . . . . . . . . . . . . .
TROUBLESHOOTING 8-21. . . . . . . . . . . .
BULB(S) 8-23. . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BEAM SWITCH 8-23. . . . . .
HEADLIGHT RELAY 8-24. . . . . . . . . . . . .

SIGNAL SYSTEM 8-25. . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-25. . . . . . . . . . . . . .
TROUBLESHOOTING 8-27. . . . . . . . . . . .
BRAKE LIGHT SWITCH 8-33. . . . . . . . . .
GEAR POSITION SWITCH (RX10R,
RX10RS) 8-33. . . . . . . . . . . . . . . . . . . . . . .
BACK BUZZER (RX10R,
RX10RS) 8-33. . . . . . . . . . . . . . . . . . . . . . .
WATER TEMPERATURE
SENSOR 8-34. . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LEVEL SWITCH 8-35. . . . .
FUEL SENDER 8-35. . . . . . . . . . . . . . . . . .
SPEED SENSOR 8-36. . . . . . . . . . . . . . . .
GRIP WARMER SYSTEM 8-37. . . . . . . . . . . .
CIRCUIT DIAGRAM 8-37. . . . . . . . . . . . . .
TROUBLESHOOTING 8-39. . . . . . . . . . . .
GRIP AND THUMB WARMER
COIL 8-40. . . . . . . . . . . . . . . . . . . . . . . . . . .
THUMB WARMER SWITCH 8-40. . . . . . .
GRIP WARMER SWITCH 8-41. . . . . . . . .
CARBURETOR HEATER SYSTEM 8-42. . .
CIRCUIT DIAGRAM 8-42. . . . . . . . . . . . . .
TROUBLESHOOTING 8-44. . . . . . . . . . . .
CARBURETOR HEATER RELAY 8-45. .
CARBURETOR HEATER 8-45. . . . . . . . .
SELF-DIAGNOSIS 8-46. . . . . . . . . . . . . . . . . .
FUEL METER, FUEL LEVEL
WARNING INDICATOR AND THE
WARNING LIIGHT 8-46. . . . . . . . . . . . . . .
COOLANT TEMPERATURE
WARNING LIGHT AND THE
WARNING LIGHT 8-47. . . . . . . . . . . . . . . .
SELF-DIAGNOSIS WARNING
INDICATOR AND THE WARNING
LIGHT 8-47. . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 9.
SPECIFICATIONS
GENERAL SPECIFICATIONS 9-1. . . . . . . . . .
MAINTENANCE SPECIFICATIONS 9-4. . . . .
ENGINE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TRAIN 9-9. . . . . . . . . . . . . . . . . . . .
CHASSIS 9-13. . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 9-14. . . . . . . . . . . . . . . . . . .
HIGH ALTITUDE SETTINGS 9-16. . . . . .
TIGHTENING TORQUE 9-17. . . . . . . . . . . . . .
ENGINE 9-17. . . . . . . . . . . . . . . . . . . . . . . .
POWER TRAIN 9-19. . . . . . . . . . . . . . . . . .
CHASSIS 9-21. . . . . . . . . . . . . . . . . . . . . . .
GENERAL TORQUE
SPECIFICATIONS 9-22. . . . . . . . . . . . . . .
DEFINITION OF UNITS 9-22. . . . . . . . . . . . . .
CABLE ROUTING 9-23. . . . . . . . . . . . . . . . . .

1-1
MACHINE IDENTIFICATION GEN
INFO
NOTE:
GENERAL INFORMATION
MACHINE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number 1is located on the right-hand side of the
frame (just below the front of the seat).
ENGINE SERIAL NUMBER
The engine serial number 1is located on the left-hand side of the
crankcase.
Designs and specifications are subject to change without notice.

1
1-2
IMPORTANT INFORMATION GEN
INFO
IMPORTANT INFORMATION
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 pres-
sure water splashes.
2. Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling the machine, keep mated parts together.
This includes gears, cylinders, pistons, and other parts that have
been “mated” through normal wear. Mated parts must be reused
or replaced as an assembly.
4. During disassembly of the machine, clean all parts and place
them in trays in the order of disassembly. This will speed up as-
sembly time and help ensure that all parts are reinstalled correctly.
5. Keep all parts away from any source of fire.
6. Be sure to keep to the tightening torque specifications. When
tightening bolts, nuts, and screws, start with those that have larger
diameters, and proceed from the inside to the outside in a criss-
cross pattern.
ALL REPLACEMENT PARTS
We recommend using genuine Yamaha parts for all replacements.
Use oil and grease recommended by Yamaha for assembly and ad-
justments.

1-3
IMPORTANT INFORMATION GEN
INFO
CAUTION:
GASKETS, OIL SEALS, AND O-RINGS
1. All gaskets, seals, and O-rings should be replaced when an en-
gine is overhauled. All gasket surfaces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and bearings during reassembly. Ap-
ply grease to the oil seal lips.
LOCK WASHERS/PLATES AND COTTER PINS
All lock washers/plates 1and cotter pins must be replaced if they
are removed. Lock tab(s) should be bent along the bolt or nut flat(s)
after the bolt or nut has been properly tightened.
BEARINGS AND OIL SEALS
Install the bearings 1and oil seals 2with their manufacturer’s
marks or numbers facing outwards. (In other words, the stamped let-
ters must be on the side exposed to view.) When installing oil seals,
apply a light coating of lightweight lithium base grease to the seal lips.
Oil the bearings liberally when installing.
Do not use compressed air to spin the bearings dry. This causes
damage to the surface of the bearings.
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
2is positioned opposite to the thrust 3it receives. See the section-
al view.
4Shaft
LOCTITE 
After installing fasteners that have LOCTITE applied, wait 24 hours
before using the machine. This will give the LOCTITE time to dry
properly.

1-4
SPECIAL TOOLS GEN
INFO
NOTE:
SPECIAL TOOLS
Some special tools are necessary for a completely accurate tune-up
and assembly. Using the correct special tool will help prevent dam-
age that can be caused by the use of improper tools or improvised
techniques.
Be sure to use the correct part number when ordering the tool, since
the part number may differ according to country.
FOR TUNE UP
SSheave gauge
P/N: YS-42421-1 (15 mm offset) (for U.S.A./Canada)
This gauge is used to measure the sheave distance and for offset ad-
justment.
SDial gauge
P/N: YU-03097 (for U.S.A./Canada)
90890-03097 (for Europe)
This gauge is used for run out measurement.
SFuel level gauge
P/N: YM-01312-A (for U.S.A./Canada)
90890-01312 (for Europe)
This gauge is used to measure the fuel level in the float chamber.
SCarburetor angle driver:
P/N: 90890-03173 (for Europe)
This tool is used to adjust the pilot screw when synchronizing the ca-
buretor.
SAngle gauge:
Use goods on the market.
This tool is used to tightening the torque.

1-5
SPECIAL TOOLS GEN
INFO
FOR ENGINE SERVICE
SPiston pin puller
P/N: YU-01304 (for U.S.A./Canada)
90890-01304 (for Europe)
This tool is used to remove the piston pin.
SRotor holding puller, attachment
P/N: YU-33270 (for U.S.A./Canada)
90890-01362 (for Europe)
P/N: YM-33282
90890-04089
This tool is used to remove the magneto rotor.
SCooling system tester, adapter
P/N: YU-24460-01 (for U.S.A./Canada)
90890-01325 (for Europe)
P/N: YU-33984 (for U.S.A./Canada)
90890-01352 (for Europe)
This tester is used for checking the cooling system.
SOil filter wrench
P/N: YU-38411 (for U.S.A./Canada)
90890-01426 (for Europe)
This tool is needed to loosen or tighten the oil filter cartridge.
SCarburetor synchronizer
P/N: YU-8030 (for U.S.A./Canada)
90890-03094 (for Europe)
This guide is used to synchronize the carburetors.
SCompression gauge set
P/N: YU-33223 (compression gage) (for U.S.A./Canada)
90890-03081 (for Europe)
P/N: YU-33223-3 (adapter) (for U.S.A./Canada) (for Europe)
90890-04136 (for Europe)
These tools are used to measure engine compression.
SValve spring compressor set, quick release, attachment
P/N: YM-04019 (valve spring compresser) (for U.S.A./Canada)
90890-04019 (for Europe)
P/N: YM-4108, YM-4114 (attachment) (for U.S.A./Canada)
90890-04108, 90890-04114 (for Europe)
These tools are used-to remove or install the valve assemblies.
S40 and 50 mm bearing driver.
Water pump seal installer.
P/N: YM-4058 (40 and 50 mm bearing driver) (for U.S.A./Canada)
90890-04058 (for Europe)
P/N: YM-33221 (water pump seal installer) (for U.S.A./Canada)
90890-04078 (for Europe)
These tools are used to install the water pump seal.

1-6
SPECIAL TOOLS GEN
INFO
SValve guide remover (ø4, ø4.5)
P/N: YM-04111 (ø4) (for U.S.A./Canada)
90890-04111 (for Europe)
P/N: YM-4116 (ø4.5) (for U.S.A./Canada)
90890-04116 (for Europe)
These tools are used to remove or install the valve guides.
SValve guide installer (ø4, ø4.5)
P/N: YM-04112 (ø4) (for U.S.A./Canada)
90890-04112 (for Europe)
P/N: YM-4117 (ø4.5) (for U.S.A./Canada)
90890-04117 (for Europe)
These tools are used to install the valve guides.
SValve guide reamer (ø4, ø4.5)
P/N: YM-04113 (ø4) (for U.S.A./Canada)
90890-04113 (for Europe)
P/N: YM-4118 (ø4.5) (for U.S.A./Canada)
90890-04118 (for Europe)
These tools are used to rebore the new valve guides.
SValve lapper
P/N: 90890-04101 (for Europe)
This tools is needed to remove and install the valve lifter.
SPiston ring compresser
P/N: YM-8037 (for U.S.A./Canada)
90890-05158 (for Europe)
This tool is used to compress the piston rings when installing the pis-
ton into the cylinder.
SDynamic spark tester
P/N: YM-34487 (for U.S.A./Canada)
90890-06754 (for Europe)
This tool is used to check the ignition system component.
SQuick gasket 
P/N: ACC-1100-15-01 (for U.S.A./Canada)
90890-85505 (for Europe)
This bond is used to seal two mating surfaces (e.g., crankcase mat-
ing surfaces.)

1-7
SPECIAL TOOLS GEN
INFO
FOR POWER TRAIN SERVICE
SPrimary sheave holder
P/N: YS-01880 (for U.S.A./Canada)
90890-01701 (for Europe)
This tool is used to hold the primary sheave.
SPrimary sheave puller (18 mm)
P/N: YS-01881-1 1, YS-01882-1 2(for U.S.A./Canada)
90890-01898 (for Europe)
This tool is used for removing the primary sheave.
SClutch spider separator
P/N: YS-28890-B (for U.S.A./Canada)
90890-01711 (for Europe)
This tool is used when disassembling and assembling the primary
sheave.
SClutch 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.
SYXR clutch bushing jig kit
P/N: YS-39752 (for U.S.A./Canada)
This tool is used for removal and installation of primary clutch weight
and roller bushings.
SClutch bushing press
P/N: YS-42424 (for U.S.A./Canada)
This tool is used for removing and installing the post bushings (prima-
ry sheave cap bush, sliding sheave bush and torque cam bush).
STrack 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.

1-8
SPECIAL TOOLS GEN
INFO
FOR CARBURETION SERVICE
SMity vac
P/N: YB-35956 (for U.S.A./Canada)
90890-06756 (for Europe)
This tool is used to check the fuel pump.
FOR ELECTRICAL SERVICE
SPocket tester
P/N: YU-03112 (for U.S.A./Canada)
90890-03112 (for Europe)
This instrument is necessary for checking the electrical components.
SElectro tester
P/N: YU-33260-A (for U.S.A./Canada)
90890-03021 (for Europe)
This instrument is invaluable for checking the electrical system.
SSpeedometer unit test coupler.
P/N: YS-45686 (for U.S.A./Canada)
8EK-82507-09 (For Europe)
This tool is used for checking the speedometer unit.
SInductive self-powered tachometer
P/N: YU-8036-B (for U.S.A./Canada)
90793-80009 (for Europe)
This tool is used to check engine speed.

2-1
INTRODUCTION/PERIODIC MAINTENANCE TABLE INSP
ADJ
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable machine op-
eration and a longer service life. In addition, the need for costly overhaul work will be greatly reduced.
This information applies to machines already in service as well as new machines that are being pre-
pared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE
Initial Every
Item Remarks
Preopera-
tion check
(Daily)
1 month
or
800 km
(500 mi)
(40 hr)
Seasonally
or
3,200 km
(2,000 mi)
(160 hr)
Spark plugs
Check condition.
Adjust gap and clean.
Replace if necessary.
F
Valves Check valve clearance.
Adjust clearance when engine is cold. Every 40,000 km (25,000 mi)
Engine oil
Check oil level. F
Engine
oil
Replace. F F
Engine oil filter cartridge Replace. F
Every
20,000 km
(12,000 mi)
Fuel Check fuel level. F
Fuel filter Check condition.
Replace if necessary. F
Fuel line Check fuel hose for cracks or damage.
Replace if necessary. F
Engine coolant
Check coolant level. F
Engine
coolant
Air bleed the cooling system if necessary. F
Check the throttle lever operation. F
Carburetor Adjust the jets. Whenever operating condition
(elevation/ temperature) is changed.
Engine stop switch Check operation.
Repair if necessary. F
Throttle override system
(T.O.R.S.)
Check operation.
Repair if necessary. F
Throttle lever Check operation.
Repair if necessary. F
Exhaust system Check for leakage.
Tighten or replace gasket if necessary. F
Drive guard Check for cracks, bends or damage.
Replace if necessary. F
V-belt Check for wear and damage.
Replace if necessary. F
Drive track and idler
wheels
Check deflection, and for wear and damage.
Adjust/ replace if necessary. F
Slide runners
Check for wear and damage. F
Slide
runners
Replace if necessary. F

2-2
PERIODIC MAINTENANCE TABLE INSP
ADJ
2
NOTE:
Initial Every
Item Remarks
Preopera-
tion check
(Daily)
1 month
or
800 km
(500 mi)
(40 hr)
Seasonally
or
3,200 km
(2,000 mi)
(160 hr)
Check operation and fluid leakage. F
Brake and parking brake Adjust free play and/or replace pads if necessary. F
Repair brake fluid. See note.
Disc brake installation
Check for slight free play.
Lubricate shaft with specified grease as
required.
Every
1,600 km
(1,000 mi)
Drive chain oil
Check oil level. F
Drive
chain
oil
Replace. F
Drive chain Check deflection.
Adjust if necessary.
Initial at 500 km (300 mi) and every
800 km (500 mi) thereafter.
Skis and ski runners
Check for wear and damage. F
Skis
and
ski
runners
Repair if necessary. F
Steering system
Check operation. F
Steering
system
Adjust toe-out if necessary. F
Lights Check operation.
Replace bulbs if necessary. F
Check engagement and shift speed. F
Adjust if necessary. Whenever operating elevation is
changed.
Primary and secondary
clutches
Inspect sheaves for wear/ damage.
Inspect weights/ rollers and bushings for
wear-for primary.
Inspect ramp shoes/ bushings for wear-for
secondary.
Replace if necessary.
F
Lubricate with specified grease. F
Steering column bearing Lubricate with specified grease. F
Ski and front suspension Lubricate with specified grease. F
Suspension component Lubricate with specified grease. F
Parking brake cable end Lubricate with specified grease. F
g
and lever end/ throttle
cable end Check cable damage.
Replace if necessary. F
Shroud latches Make sure that the shroud latches and hooked. F
Fittings and fasteners Check tightness.
Replace if necessary. F
Tool kit and recommended
equipment Check for proper placement. F
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add the fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.

2-3
SPARK PLUGS INSP
ADJ
NOTE:
ENGINE
SPARK PLUGS
1. Remove:
SSpark plug caps
SSpark plugs
2. Inspect:
SElectrodes 1
Damage/wear !Replace the spark plug.
SInsulator color 2
3. Measure:
SSpark plug gap a
Out of specification !Regap.
Use a wire thickness gauge.
Spark plug gap:
0.7 X0.8 mm
(0.028 X0.031 in)
If necessary, clean the spark plugs with a spark
plug cleaner.
Standard spark plug:
CR9E (NGK)
Before installing a spark plug, clean the gasket
surface and spark plug surface.
4. Install:
SSpark plugs
Spark plug:
13 Nm (1.3 mSkg, 9.4 ftSlb)
Finger-tighten athe spark plug before torquing
bit to specification.

2-4
FUEL LINE INSPECTION/COOLING SYSTEM INSP
ADJ
NOTE:
WARNING
FUEL LINE INSPECTION
1. Remove:
SIntake silencer
Refer to “CARBURETORS” in CHAPTER 7.
2. Inspect:
SFuel hoses 1
SFuel delivery hoses 2
Cracks/damage !Replace.
3. Install:
SIntake silencer
Refer to “CARBURETORS” in CHAPTER 7.
COOLING SYSTEM
Coolant replacement
The coolant should be changed at least every
season.
1. Place the machine on a level surface.
2. Remove:
SIntake silencer
Refer to “CARBURETORS” in CHAPTER 7.
3. Remove:
SCoolant filler cap 1
Do not remove the coolant filler cap 1when
the engine is hot. Pressurized scalding hot
fluid and steam may be blown out, which
could cause serious injury. When the engine
has cooled, place a thick rag or a towel over
the coolant filler cap.
Slowly turn the cap counterclockwise until it
stop. This allows any residual pressure to
escape. When the hissing sound has
stopped, press down on the cap while turn-
ing it counterclockwise to remove it.