Yamaha RX10K Manual

SUPPLEMENTARY SERVICE MANUAL
LIT-12618-02-39

WARNING
CAUTION:
NOTE:
FOREWORD
This Supplementary Service Manual has been
prepared to introduce new service and new
data for the RX10K, RX10RK, RX10RSK,
RXW10K, RXW10SK, RX10MK, RX10MSK.
For complete information, on service proce-
dures, it is necessary to use this Supplementary
Service Manual together with following manual:
RX10H/RX10SH
RX10MH/RX10MSH
RX10RH/RX10RSH
SERVICE MANUAL:
8FA-28197-10 (981073)
(LIT-12618-02-28)
RXW10J/RXW10SJ
SUPPLEMENTARY SERVICE MANUAL:
8FG-28197-10 (981089)
(LIT-12618-02-33)
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 Ya-
maha snowmobiles have a basic understanding
of the mechanical concepts and procedures in-
herent 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 specifi-
cations or procedures will be forwarded to all au-
thorized Yamaha dealers and will, where appli-
cable, appear in future editions of this manual.
RX10K
RX10RK/RX10RSK
RXW10K/RXW10SK
RX10MK/RX10MSK
SUPPLEMENTARY SERVICE MANUAL
2004 by Yamaha Motor
Corporation, U.S.A.
1st Edition, April 2004
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-12618-02-39
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 2.
PERIODIC INSPECTIONS
AND ADJUSTMENTS
POWER TRAIN 1. . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD INSPECTION 1. . . . . . . . . . .
BRAKE HOSE INSPECTION 1. . . . . . . . .
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM) 1. . . . . .
TRACK TENSION ADJUSTMENT 3. . . .
SLIDE RUNNER INSPECTION 3. . . . . . .
LUBRICATION 4. . . . . . . . . . . . . . . . . . . . .
CLUTCH 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR SELECTION 7. . . . . . . . . . . . . . . . .
FRONT SUSPENSION 12. . . . . . . . . . . . .
REAR SUSPENSION 13. . . . . . . . . . . . . .
CHAPTER 3.
CHASSIS
STEERING 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
RX10MK, RX10MSK 17. . . . . . . . . . . . . . .
SKI 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RX10K, RX10RK, RX10RSK 19. . . . . . . .
RX10MK, RX10MSK 20. . . . . . . . . . . . . . .
CHAPTER 4.
POWER TRAIN
DRIVE CHAIN HOUSING 21. . . . . . . . . . . . . .
RX10K, RX10MK, RX10MSK 21. . . . . . . .
INSTALLATION 22. . . . . . . . . . . . . . . . . . . .
WITH REVERSE MODEL RX10RK,
RX10RSK 23. . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 25. . . . . . . . . . . . . . . . . . . .
BRAKE 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD REPLACEMENT 28. . . . . . .
BRAKE CALIPER DISASSEMBLY 31. . .
BRAKE CALIPER INSPECTION AND
REPAIR 31. . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CALIPER ASSEMBLY 32. . . . . .
BRAKE CALIPER INSTALLATION 32. . .
SLIDE RAIL SUSPENSION 33. . . . . . . . . . . .
RX10K, RX10RK, RX10RSK 33. . . . . . . .
RX10MK, RX10MSK 37. . . . . . . . . . . . . . .
INSPECTION 41. . . . . . . . . . . . . . . . . . . . .
FRONT AXLE AND TRACK 43. . . . . . . . . . . .
INSTALLATION 43. . . . . . . . . . . . . . . . . . . .
CHAPTER 5.
ENGINE
SEAT AND FUEL TANK 44. . . . . . . . . . . . . . .
EXHAUST PIPE AND MUFFLER 45. . . . . . .
CHAPTER 6.
COOLING SYSTEM
HEAT EXCHANGER 46. . . . . . . . . . . . . . . . . .
RX10MK, RX10MSK 46. . . . . . . . . . . . . . .
CHAPTER 9.
SPECIFICATIONS
GENERAL SPECIFICATIONS 49. . . . . . . . . .
MAINTENANCE SPECIFICATIONS 52. . . . .
ENGINE 52. . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TRAIN 57. . . . . . . . . . . . . . . . . . . .
CHASSIS 61. . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 62. . . . . . . . . . . . . . . . . . . . .
HIGH ALTITUDE SETTINGS 64. . . . . . . .
TIGHTENING TORQUE 66. . . . . . . . . . . . . . . .
ENGINE 66. . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TRAIN 68. . . . . . . . . . . . . . . . . . . .
CHASSIS 70. . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TORQUE
SPECIFICATIONS 71. . . . . . . . . . . . . . . . . . . .
DEFINITION OF UNITS 71. . . . . . . . . . . . . . . .
CABLE ROUTING 72. . . . . . . . . . . . . . . . . . . .

1
2
BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION/
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP
ADJ
WARNING
PERIODIC INSPECTIONS
AND ADJUSTMENTS
POWER TRAIN
BRAKE PAD INSPECTION
1. Apply the brake lever.
2. Inspect:
SBrake pad wear a
Wear indicator 1nearly contacts the brake
disc !Replace as a set.
Wear limit:
7.5 mm (0.30 in)
BRAKE HOSE INSPECTION
1. Inspect:
SBrake hose
Cracks/damage/wear !Replace.
2. Check:
SFluid leakage
Apply the brake lever several times.
Fluid leakage !Replace the defective parts.
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
Bleed the brake system in the following
cases:
SThe system has been disassembled.
SA brake hose is loosened or removed.
SThe brake fluid has been very low.
SBrake operation is faulty.
If the brake system is not properly bled a
loss of braking performance may occur.
1. Bleed:
SBrake system
Air bleeding steps:
SFill the brake master cylinder reservoir with the
proper brake fluid.
SInstall the diaphragm. Be careful not to spill
any fluid or allow the brake master cylinder
reservoir to overflow.
SConnect clear plastic hoses 1tightly to the
brake caliper bleed screws 2.
SPlace the other ends of the hoses in a contain-
er.

2
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP
ADJ
NOTE:
WARNING
a. Slowly apply the brake lever several times.
b. Pull the lever in, then hold the lever in posi-
tion.
c. Loosen the bleed screws and allow the brake
lever to travel towards its limit.
d. Tighten the bleed screws when the brake le-
ver limit has been reached, then release the
lever.
SRepeat steps (a) to (d) until all of the air
bubbles have disappeared from the fluid.
STighten the bleed screws.
Bleed screw:
6 Nm (0.6 mSkg, 4.3 ftSlb)
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the system have disappeared.
SAdd brake fluid to the proper level.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION”.
After bleeding the brake system, check the
brake operation.

3
A
B
6 7
TRACK TENSION ADJUSTMENT/
SLIDE RUNNER INSPECTION INSP
ADJ
4
5
6 7
4
5
CAUTION:
TRACK TENSION ADJUSTMENT
Track alignment Shifted
to right
Shifted
to left
Left adjuster Turn out Turn in
Right adjuster Turn in Turn out
8Slide runner 9Track
10 Track metal 11 Gap 12 Forward
ARX10K, RX10RK, RX10RSK
BRX10MK, RX10MSK
c. Adjust the track deflection until the specified
amount is obtained.
Track deflection More than
specified
Less than
specified
Left adjuster Turn in Turn out
Right adjuster Turn in Turn out
The adjusters should be turned an equal
amount.
SRecheck the alignment and deflection. If
necessary, repeat steps (a) to (c) until the
specified amount is obtained.
STighten the rear axle nut.
Nut (rear axle):
75 Nm (7.5 mSkg, 54 ftSlb)
SLIDE RUNNER INSPECTION
1. Inspect:
SSlide runner 1
Cracks/damage/wear !Replace.
2. Measure:
SSlide runner thickness a
Out of specification !Replace.
Slide runner wear limit:
10 mm (0.39 in)

4
A
A
B
LUBRICATION INSP
ADJ
WARNING
LUBRICATION
Brake lever, throttle lever and throttle cable
end
1. Lubricate the brake lever pivot, throttle lever
and the ends of the throttle cables.
Recommended lubricant:
ESSO Beacon 325 Grease
Apply a dab of grease onto only the end of
the cables.
Do not grease the throttle cables.
They could freeze and cause a loss of con-
trol.
Front and rear suspension
1. Use a grease gun to inject grease into the
nipples 1.
2. Apply grease 2.
Recommended lubricant:
Esso Beacon 325 Grease or
Aeroshell Grease #7A
AFront
BRear (RX10MK, RX10MSK)

5
CLUTCH INSP
ADJ
CLUTCH
High altitude
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
a
b
c
d
NOTE:
GGreen P Pink
S Silver Y Yellow
Specifications Model: RX10K, RX10RK, RX10RSK
Elevation X800 m
(X2,500 ft)
600 X1,400 m
(2,000 X4,500 ft)
1,200 X2,000 m
(4,000 X6,500 ft)
1,800 X2,600 m
(6,000 X8,500 ft)
2,400 X3,000 m
(8,000 X10,000 ft)
Engine idle speed 1,350 ±100 r / min z z z z
Engagement r / min 3,600 ±200 r / min z z z z
Shift r / min 10,250 ±250 r / min z z z z
Main jet
Pilot jet*1Refer to “HIGH ALTITUDE SETTINGS” in “MAINTENANCE SPECIFICATIONS”.
Pilot screw
Secondary reduction
ratio (number of links) 38/ 24 (70 L) z38 / 23 (70 L) 38 / 22 (68 L) z
Primary sheave spring 90501-582L1 z90501-582L2 90501-602L3 z
Color Y-S-Y zG-S-G P-S-P z
Free length 87.4 mm (3.44 in) z z 85.1 m (3.35 in) z
Preload 343 N (35 kg, 77 lb) z z z z
S
p
ring rate
24.5 N / mm
(2 50 kg / mm
z
27 N / mm
(2 75 kg / mm
29.4 Nm
(3 00 kg / mm
z
Spring
rate
(2
.
50
kg / mm
,
140 lb / in)
z
(2
.
75
kg / mm
,
154 lb / in)
(3
.
00
kg / mm
,
168 lb / in)
z
Wire diameter 5.8 mm (0.228 in) z z 6.0 mm (0.236 in) z
Outside diameter 59.5 mm (2.34 in) z z z z
Weight (ID) 8FA-17605-10
(8FA00) z z z z
Weight
rivet
OUT Steel 17.2 with-hole Steel 13.3 Steel 13.3 with-hole Aluminum 13.3
with-hole None
rivet
IN Steel 17.2 Steel 13.3 Steel 13.3 with-hole Steel 13.3 with-hole None
Weight bushing VESPEL TP-8549 z z z z
Roller outer dia. 15.6 mm (0.61 in) z z z z
Roller bushing VESPEL TP-8549 z z z z
Pri. clutch shim None z z z z
Secondary sheave spring 90508-60012 z z z z
Color P z z z z
Free length 75 mm (2.95 in) z z z z
Preload rate 60_(3-3)
1211 kgSmm / rad z z z z
Wire diameter 6.0 mm (0.236 in) z z z z
Outside diameter 69.5 mm (2.736 in) z z z z
Sec. torque cam angle 51 – 43_z z z z
Sec. clutch shim 1.0 mm (0.04 in) z z z z
*1: Number of return rotation of pilot screw may vary depending on each cylinder.
Make sure to rotate the screw backward after listing its present number of return rotation on each
cylinder.