Yamaha RX10J User manual

OWNER’S MANUAL
SNOWMOBILE
RX10J/RX10SJ
RX10MJ/RX10MSJ
RX10RJ/RX10RSJ
RXW10J/RXW10SJ
8FA-28199-11
LIT-12628-02-33
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2003.04-2.0×1 CR
(E)
YAMAHA MOTOR CO., LTD.

ESU00286
1-
MACHINE IDENTIFICATION
Identification number records
A. FRAME NUMBER:
CZ-01E
B. ENGINE NUMBER (PRIMARY ID):
CZ-01E
C. KEY NUMBER:
CZ-01E
Record the frame number, engine number (Primary ID),
and key number in the spaces provided for assistance
when ordering spare parts from a Yamaha dealer.
1The frame number is the seventeen-digit number
stamped on the frame of the snowmobile. (See
fig. È.)
2The engine number is stamped in the location as
shown. (See fig. É.)
3Key number (See fig. Ê.)
Also, record and keep the ID numbers in a separate
place in case the snowmobile is stolen.
A
B
C
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ESU00011
2-
INTRODUCTION
Congratulations on your purchase of a Yamaha snowmo-
bile. This model is the result of Yamaha’s vast experience
in the production of fine sporting and touring snowmo-
biles. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these
fields.
This manual will give you an understanding of the opera-
tion, inspection, and basic maintenance of this snowmo-
bile. If you have any questions concerning the operation
or maintenance of your snowmobile, please consult a
Yamaha dealer.
To maintain the high quality and performance of this
snowmobile, it is important that you and your Yamaha
dealer pay close attention to the recommended mainte-
nance schedules and operating instructions contained
within this manual.
RX10J/RX10SJ
RX10MJ/RX10MSJ
RX10RJ/RX10RSJ
RXW10J/RXW10SJ
OWNER’S MANUAL
©2003 by Yamaha Motor Corporation, U.S.A.
1st Edition, March 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan
P/N LIT-12628-02-33
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WARNING
@
PLEASE READ AND UNDERSTAND THIS MANUAL
COMPLETELY BEFORE OPERATING THE SNOWMO-
BILE.
@
NOTE:
@
●Yamaha continually seeks advancements in product
design and quality. Therefore, while this manual con-
tains the most current product information available
at the time of printing, there may be minor discrepan-
cies between your snowmobile and this manual. If
there is any question concerning this manual, please
consult a Yamaha dealer.
●This manual should be considered a permanent part
of this snowmobile and should remain with the snow-
mobile when resold.
@
Particularly important information is distinguished in this
manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
WARNING
@
Failure to follow WARNING instructions could result in
severe injury or death to the snowmobile operator, a
bystander, or a person inspecting or repairing the snow-
mobile.
CAUTION:
@
A CAUTION indicates special precautions that must be
taken to avoid damage to the snowmobile.
NOTE:
@
A NOTE provides key information to make procedures
easier or clearer.
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ESU00003
CONTENTS
YAMAHA MOTOR
CORPORATION, U.S.A.
SNOWMOBILE LIMITED
WARRANTY .......................................1-1
YAMAHA EXTENDED SERVICE
(Y.E.S.) ...............................................1-4
LOCATION OF THE
IMPORTANT LABELS .......................2-1
SAFETY INFORMATION ...................3-1
DESCRIPTION ...................................4-1
CONTROL FUNCTIONS ....................5-1
Main switch......................................5-1
Starter lever (choke) ........................5-2
Throttle lever....................................5-2
Engine overheating prevention
system .............................................5-2
Throttle override system
(T.O.R.S.) ........................................5-3
Speedometer unit ............................5-4
High beam indicator light .................5-4
Fuel meter and grip/thumb
warmer heat level indicator..............5-5
Fuel level warning indicator .............5-6
Oil level warning indicator................5-6
Low coolant temperature
indicator light ...................................5-7
Coolant temperature warning
indicator ...........................................5-7
Self-diagnosis warning indicator......5-8
Engine stop switch.........................5-10
Brake lever ....................................5-10
Parking brake lever........................5-11
Shift lever.......................................5-11
Headlight beam switch ..................5-12
Shroud latches...............................5-12
Drive guard ....................................5-12
V-belt holders ................................5-13
Storage compartment....................5-13
PRE-OPERATION CHECKS..............6-1
Fuel .................................................6-1
Engine oil.........................................6-2
Engine oil level ................................6-3
Coolant ............................................6-4
Throttle lever ...................................6-5
Throttle override system
(T.O.R.S.) ........................................6-5
Brake ...............................................6-6
Brake fluid leakage..........................6-7
V-belt ...............................................6-7
Drive guard......................................6-7
Drive track .......................................6-8
51-mm (2.0-in) high-profile
pattern drive track............................6-8
Slide runners ...................................6-8
Skis and ski runners ........................6-9
Steering system...............................6-9
Lights...............................................6-9
Air filter ..........................................6-10
Fittings and fasteners ....................6-10
Tool kit and recommended
equipment......................................6-10
OPERATION ......................................7-1
Starting the engine ..........................7-1
Break-in ...........................................7-2
Riding your snowmobile ..................7-3
Getting to know your snowmobile ...7-3
Learning to ride your snowmobile ...7-3
To start out and accelerate..............7-3
Braking ............................................7-3
Turning ............................................7-4
Riding uphill.....................................7-4
Riding downhill ................................7-5
Traversing a slope...........................7-5
Ice or icy surface .............................7-5
Hard-packed snow ..........................7-6
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Operation on surfaces other than
snow or ice ......................................7-6
Maximizing drive track life ...............7-7
Strap ................................................7-8
Driving .............................................7-9
Stopping the engine.......................7-10
Transporting ..................................7-11
PERIODIC MAINTENANCE ...............8-1
Periodic maintenance chart .............8-1
Tool kit .............................................8-4
Spark plug inspection ......................8-4
Engine idle speed adjustment .........8-6
Throttle cable adjustment ................8-6
Carburetor adjustment.....................8-7
High altitude adjustments ..............8-10
Adjusting the valve clearance........8-10
Changing the engine oil.................8-11
Cooling system ..............................8-13
V-belt replacement ........................8-15
Checking the oil level of the drive
chain housing ................................8-17
Checking the brake pads...............8-19
Checking the parking brake
pads...............................................8-19
Checking the brake fluid level........8-20
Brake fluid replacement.................8-20
Suspension....................................8-20
Drive track adjustment...................8-28
Ski alignment .................................8-30
Handlebar adjustment ...................8-30
Lubrication .....................................8-32
Headlight bulb replacement...........8-33
Headlight beam adjustment...........8-33
Battery ...........................................8-34
Fuse replacement..........................8-34
TROUBLESHOOTING .......................9-1
STORAGE ........................................10-1
SPECIFICATIONS............................11-1
Dimensions....................................11-1
Engine ...........................................11-1
Chassis..........................................11-2
Electric...........................................11-3
WIRING DIAGRAM ..........................12-1
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1-1
ESU00004
1-
YAMAHA MOTOR CORPORATION, U.S.A.
SNOWMOBILE LIMITED WARRANTY
CW-01E
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1-2
CW-02E
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1-3
CW-03E
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1-4
ESU00373
YAMAHA EXTENDED SERVICE (Y.E.S.)
Keep your Yamaha protected even after your
warranty expires with genuine Yamaha Extended
Service (Y.E.S.).
•Y.E.S. is designed and administered by
Yamaha Motor Corporation to provide maxi-
mum owner satisfaction. You get uninter-
rupted factory-backed coverage for extra
peace of mind.
•Y.E.S. is flexible. You choose the plan that’s right
for you: 12 months, 24 months, 36 months, or
(on the RX-1 only) even 48 months beyond your
warranty period.
•Y.E.S. is designed and administered by the
same Yamaha people who handle your war-
ranty—and it shows in the comprehensive
coverage benefits. There are no mileage limi-
tations. Coverage isn’t limited to “moving
parts”or the “drive train”like many so-called
“third party extended warranty”programs.
And Y.E.S. covers manufacturing defects just
like the warranty. See the sample contract at
your Yamaha dealer to see how comforting
uninterrupted factory-backed protection can
be.
•You don’t have to pay anything for covered
repairs. There’s no deductible to pay, and
repairs aren’t “pro-rated.”You don’t have any
“out-of pocket”expenses for covered repairs.
•In addition, Travel and Recreation Interruption
Protection (TRIP) is included at no extra cost.
TRIP gives you up to $150 reimbursement
per occurrence for any reasonable expenses
you incur because your Yamaha needs cov-
ered service: replacement vehicle rental,
emergency towing, phone calls, even food
and lodging when you are away from home.
This superb coverage goes into effect when
you purchase Y.E.S., so it applies to any war-
ranty repairs as well as covered repairs dur-
ing your entire Y.E.S. plan period.
•Y.E.S. coverage is honored at any authorized
Yamaha dealer nationwide.
•Y.E.S. coverage is transferable to a new
owner if you sell or trade-in. That can make
your Yamaha much more valuable!
This excellent Y.E.S. plan coverage is only avail-
able to Yamaha owners like you, and only while
your Yamaha is still within the Yamaha Limited
Warranty period. So visit your authorized
Yamaha dealer to get all the facts. He can show
you how easy it is to protect your investment with
Yamaha Extended Service.
We urge you to act now. You’ll get the excellent
benefits of TRIP coverage right away, and you’ll
rest easy knowing you’ll have strong factory-
backed protection even after your Yamaha Lim-
ited Warranty expires. See your dealer today!
A special note:
If visiting your dealer isn’t convenient, contact
Yamaha toll free at 1-866-937-3983 (866 YES-
EXTD) or visit our web site. All you need to do is
provide your vehicle’s Primary ID number (your
Tunnel number). We’ll be happy to help you get
the Y.E.S. coverage you need.
Yamaha Service Marketing
P.O. Box 6555
Cypress, CA 90630
1-866-937-3983
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2-1
ESU00007
2-
LOCATION OF THE
IMPORTANT LABELS
Please read the following labels carefully before operat-
ing this snowmobile.
NOTE:
Maintain or replace safety and instruction labels, as nec-
essary.
1RX10J/RX10S/RX10M/RX10MS
1RX10R/RX10RS/RXW10/RXW10S
23
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2-2
4RX10M/RX10MS
5RX10M/RX10MS
6
7RXW10/RXW10S
8RX10M/RX10MS/RXW10/RXW10S
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3-1
ESU00008
3-
SAFETY INFORMATION
When you ride your snowmobile, you must know and use
the following for your safety. Severe injury or death may
result if you ignore any of the following.
Before operating
1. Read the Owner’s Manual and all labels before oper-
ating this snowmobile. Become familiar with all of the
operating controls and their function. Consult a
Yamaha dealer about any control or function you do
not understand.
2. This snowmobile was not manufactured for use on
public streets, roads, or highways. Such use is pro-
hibited by law, and you could collide with another
vehicle.
3. This snowmobile is designed to carry the OPERA-
TOR ONLY.
Passengers are prohibited. Carrying a passenger
can cause loss of control.
4. Do not operate the snowmobile after drinking alcohol
or taking drugs. Your ability to operate the snowmo-
bile is reduced by the influence of alcohol or drugs.
5. For safety and proper care of the snowmobile, always
perform the pre-operation checks on pages 6-1–6-10
before starting the engine. Check the throttle, brake,
and steering for proper operation every time before
starting the engine. Make sure that the throttle lever
moves freely and it returns to the home position when
it is released.
6. Apply the parking brake before starting the engine.
Never drive the snowmobile with the parking brake
applied. This may overheat the brake disc and reduce
braking ability.
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3-2
7. Do not allow anyone to stand behind the snowmobile
when starting, inspecting, or adjusting the snowmo-
bile. A broken track, track fittings, or debris thrown by
the track could be dangerous to the operator or
bystanders.
8. Handle fuel with care; it is HIGHLY FLAMMABLE.
●Never add fuel when the engine is running or hot.
Allow the engine to cool for several minutes after
running.
●Use an approved fuel container.
●Fill the fuel tank outdoors with extreme care.
Never remove the fuel cap indoors. Never fill the
fuel tank indoors.
●Never refuel while smoking or in the vicinity of an
open flame.
●Make sure that the fuel tank cap is closed securely
after refueling. Wipe up any spilled fuel immedi-
ately.
9. If you swallow some gasoline, inhale a lot of gasoline
vapor, or get some gasoline into your eyes, see your
doctor immediately. If any gasoline spills on your skin
or clothing, immediately wash your skin with soap
and water, and change your clothes.
10. Wear protective clothing. Wear an approved helmet,
and a face shield or goggles. Also, wear a good qual-
ity snowmobile suit, boots, and a pair of gloves or mit-
tens that will permit use of your thumbs and fingers
for operation of the controls.
Operation
1. Do not run the engine indoors, except when starting
the engine to transport the snowmobile in or out of
the building. Open the outside doors; exhaust fumes
are dangerous.
2. Be careful where you ride. There may be obstacles
hidden beneath the snow. Stay on established trails
to minimize your exposure to hazards. Ride slowly
and cautiously when you ride off of established trails.
Hitting a rock or stump, or running into wires could
cause an accident and injury.
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3-3
3. This snowmobile is not designed for use on surfaces
other than snow or ice. Use on dirt, sand, grass,
rocks, or bare pavement may cause loss of control
and may damage the snowmobile.
4. Avoid operating on glare ice, or on snow which has a
lot of dirt or sand mixed in. Operation under such
conditions will damage or result in rapid wear of ski
runners, drive track, slide runners, and drive sprock-
ets.
5. Always ride with other snowmobilers when going on a
ride. You may need help if you run out of fuel, have an
accident, or damage your snowmobile.
6. Many surfaces such as ice and hard-packed snow
require much longer stopping distances. Be alert,
plan ahead and begin decelerating early. The best
braking method on most surfaces is to release the
throttle and apply the brake gently—not suddenly.
Maintenance and storage
1. Do not leave the snowmobile on its left side for an
extended period of time. Fuel may leak out from the
fuel breather hose.
2. Modifications made to the snowmobile not approved
by Yamaha, or the removal of original equipment may
render your snowmobile unsafe for use that may
cause severe personal injury. Modifications may also
make the snowmobile illegal to use.
3. Never store the snowmobile with fuel in the fuel tank
inside a building where ignition sources are present
such as hot water and space heaters, an open flame,
sparks, clothes dryers, and the like. Allow the engine
to cool off before storing the snowmobile in an
enclosed space.
4. Always refer to the “STORAGE”section if the snow-
mobile is to be stored for an extended period.
5. Maintain or replace safety and instruction labels, as
necessary.
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4-1
ESU00012
4-
DESCRIPTION
1Windshield
2Steering handlebar
3Seat
4Frame
5Slide rail suspension
6Drive track
7Skis
8Headlights
9Shroud
0Storage compartment
RX10/RX10S/RX10R/RX10RS
RX10M/RX10MS
RXW10/RXW10S
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4-2
ATail/brake lights
BSnow flap
CBrake lever
DParking brake lever
EGrip warmer adjustment switch
FHeadlight beam switch
GStrap (RX10M/RX10MS)
HEngine stop switch
IThumb warmer adjustment switch
JThrottle lever
KShift lever
(RX10R/RX10RS/RXW10/RXW10S)
LShroud latch
MMain switch
NStarter lever
OTachometer
PLow coolant temperature indicator light
QHigh beam indicator light
RWarning light
SSelf-diagnosis warning indicator
TCoolant temperature warning indicator
UFuel level warning indicator
VOil level warning indicator
WSpeedometer
XGrip warmer indicator
YSelect/reset button
ZThumb warmer indicator
[Fuel meter and grip/thumb warmer heat
level indicator
\Odometer/tripmeter
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5-1
ESU00013
5-
CONTROL FUNCTIONS
ESU00362
Main switch
The main switch controls the following items.
1“OFF”
The ignition circuit is switched off.
The key can be removed only in this position.
2“ON”
The ignition circuit is switched on.
3“START”
The starting circuit is switched on.
The starter motor starts.
CAUTION:
@
Release the switch immediately after the engine
starts.
@
NOTE:
@
The headlights, meter lights, and taillights come on after
the engine starts.
@
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5-2
ESU00020
Starter lever (choke)
Use the starter lever (choke) when starting and warming
up a cold engine.
1Starter lever (choke)
2When starting a cold engine.
3Warming up
4When the engine is warm.
NOTE:
@
Refer the “Starting the engine”section for proper opera-
tion.
@
ESU00022
Throttle lever
Once the engine is running cleanly, squeezing athe throt-
tle lever 1will increase the engine speed and cause
engagement of the drive system. Regulate the speed of
the snowmobile by varying the throttle position. Because
the throttle is spring-loaded, the snowmobile will deceler-
ate, and the engine will return to idle when it is released b.
WARNING
@
Check the throttle, brake, and steering for proper
operation before starting the engine.
@
ESU00361
Engine overheating prevention system
This model is equipped with an engine overheating pre-
vention system to prevent overheating when the engine
is idling.
When the engine has been idling for at least 3 minutes
and the coolant temperature has risen above 100 °C
(212 °F), the engine automatically shuts off to prevent
overheating.
NOTE:
The engine can be started after it shuts off.
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