Yamaha RX10K User manual

RX10K
RX10RK/RX10RSK
RXW10K/RXW10SK
RX10MK/RX10MSK
LIT-12668-02-39
ASSEMBLY MANUAL
8FV-28107-10
981094

WARNING
CAUTION:
NOTE:
FOREWORD
This Assembly Manual contains the information
required for reassembly of the Yamaha Snow-
mobile correctly prior to delivery to the custom-
er. Since some external parts of the machine
have been removed at the Yamaha factory for
convenience of packing, assembly by the Ya-
maha dealer is required. It should be noted that
the reassembled machine should be thoroughly
cleaned, inspected, and adjusted prior to deliv-
ery to the purchaser.
NOTICE
The service specifications presented in this
manual may become outdated due to future
changes in this model. Yamaha dealers will be
notified of these changes through technical ser-
vice information that will be published by Yama-
ha.
Particularly important information is distin-
guished in this manual by the following nota-
tions.
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS IN-
VOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting or
repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the machine.
A NOTE provides key information to make pro-
cedures easier or clearer.
UNPACKING
Note on transportation
Take care not to put the machine packed in the
crate against a hard object or subject it to heavy
shocks during transportation or in the service
shop.
PREPARATION
To assemble the machine correctly, supplies
and working space are required:
Supplies
Oils, greases, shop rags.
Workshop
The workshop where the machine is assembled
should be clean and large. The floor should be
level.
Self-protection
Protect your eyes with suitable safety spec-
tacles or safety goggles when using com-
pressed air, when grinding or when doing any
operation which may cause particles to fly off.
Protect hands and feet by wearing safety gloves
or protective shoes if appropriate to the work
you are doing.
Procedure for unpacking
1. To remove the machine and parts packed in
the crate, cut the vinyl bands around the
carton using a cutter or scissors. Next, re-
move the exterior carton by lifting it straight
up.
2. Remove the bolts from each corner of the
rack, and remove the struts.
3. Remove the machine from the bottom
board.
4. Before starting the assembly, check for
damaged or missing parts. The parts are
contained in the carton and the vinyl bags in
the package. Also check the machine for
damage, scratches and other defects.
RX10K
RX10RK/RX10RSK
RXW10K/RXW10SK
RX10MK/RX10MSK
ASSEMBLY MANUAL
2004 by Yamaha Motor Corporation,
U.S.A.
1st Edition, May 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-12668-02-39

PREPARATION
To assemble the snowmobile correctly, supplies (i.e., greases, shop rags, etc.) and working space are required.
Workshop
The workshop where the snowmobile is assembled, should be clean and large. The floor should be level.
Self-protection
Protect your eyes with suitable safety glasses or goggles when using compressed air, when grinding or when
doing any operation which may cause particles to fly off.
Protect hands and feet by wearing safety gloves or shoes.
SYMBOLS USED ON TRANSPORT PACKAGE COVER
Contents of the transport package are frag-
ile therefore it must be handles with care.
Indicates correct upright position of the
transport package.
Transport package must be kept away from
rain.
Up to 9 of the transport packages can be
piled up.
Only stack this unit with transport packages
of the same size.
Made of high-density polyethylene.
Do not step anywhere on this transport
package.
a: IMPORTANT
This unit delivered to carrier in a good condition. For
protection against loss due to damage, inspect thor-
oughly. If damage is noted, make note on freight bill.
Shipper assumes no further liability to the trans-
portation company. Your claim should be filed
against carrier for damage of any nature.
b: WARNING
DOnly stack this unit with same crate size.
DAssure units are stacked securely (All four
corners fit securely onto bottom unit).
DMaximum handling (transport & movement)
stack – 3units.

CONTENTS
PARTS LOCATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS LOCATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL FROM CRATE 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SET UP PROCEDURE 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD, FAIRING, HEADLIGHT 2-1. . . . . . . . . . . . . . . . . . . . . . . .
FAIRING ASSEMBLY 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SKI ASSEMBLY (Except for RX10MK, RX10MSK) 2-3. . . . . . . . . . . . .
SKI ASSEMBLY (For RX10MK, RX10MSK) 2-4. . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BUMPER, UNDER COVER 2-6. . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE COVER (For RX10MK, RX10MSK) 2-7. . . . . . . . . . . . . . . . . . . . .
STEERING ASSEMBLY (Except for RX10MK, RX10MSK) 2-8. . . . . .
STEERING ASSEMBLY (For RX10MK, RX10MSK) 2-9. . . . . . . . . . . .
REAR BUMPER (For RX10K, RX10RK, RX10RSK) 2-11. . . . . . . . . . . .
REAR BUMPER (For RXW10K, RXW10SK) 2-12. . . . . . . . . . . . . . . . . . .
REAR BUMPER (For RX10MK, RX10MSK) 2-13. . . . . . . . . . . . . . . . . . .
ADJUSTMENTS AND PREDELIVERY SERVICE 3-1. . . . . . . . . . . . . . . . .
SHEAVE OFFSET ADJUSTMENT 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE V-BELT HEIGHT AND INSTALLATION 3-3. . . . . . . . . . . . . . . . .
ENGINE OIL 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LEVEL 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BREAK-IN 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT LEVEL 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CHAIN HOUSING OIL LEVEL INSPECTION 3-7. . . . . . . . . . .
DRIVE CHAIN TENSION ADJUSTMENT 3-8. . . . . . . . . . . . . . . . . . . . .
THROTTLE CABLE ADJUSTMENT 3-9. . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY INSTALLATION 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRACK TENSION ADJUSTMENT 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BEAM ADJUSTMENT 3-14. . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE ADJUSTMENT 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SKI ADJUSTMENT 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION SPRING PRELOAD 3-17. . . . . . . . . . . . . . . . . . .
REAR SUSPENSION STOPPER BAND TENSION
(RX10K, RX10RK, RX10RSK, RX10MK, RX10MSK) 3-18. . . . . . . . . . .
REAR SUSPENSION STOPPER BAND TENSION
(RXW10K, RXW10SK) 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION SPRING PRELOAD
(RX10K, RX10RK, RX10RSK) 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION SPRING PRELOAD
(RXW10K, RXW10SK) 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION SPRING PRELOAD
(RX10MK, RX10MSK) 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION DAMPING FORCE
(RX10K, RX10RK, RX10RSK) 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION DAMPING FORCE
(RXW10K, RXW10SK) 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FULL RATE ADJUSTER (RXW10K, RXW10SK) 3-25. . . . . . . . . . . . . . .
CONTROL ROD ADJUSTMENT
(RX10K, RX10RK, RX10RSK) 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL ROD ADJUSTMENT (RXW10K, RXW10SK) 3-27. . . . . . . .
CONTROL ROD ADJUSTMENT (RX10MK, RX10MSK) 3-28. . . . . . . . .
BRAKE FLUID LEVEL 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE FLUID REPLACEMENT 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC BRAKE AIR BLEEDING 3-30. . . . . . . . . . . . . . . . . . . . . . . .
BATTERY INSPECTION 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPENDICES 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE DATA 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINT AND GRADE OF LUBRICANT 5-1. . . . . . . . . . . . .
CABLE ROUTING 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1
Headlight unit Vinyl bag 1 X6
(For RX10MK, RX10MSK)
Vinyl bag 1 X5
(Except for RX10MK, RX10MSK)
2
13
Headlight unit
1
Battery fluid
(Electrolyte)
5
Shock absorber
4
PARTS LOCATION
PARTS LOCATION
ACarton box
(The items H, I, J, and Kare packaged
in the carton box Afor shipment.)
BCarton box
CCarton box
DVinyl bag
EVinyl bag
(For RX10MK, RX10MSK)
FWindshield
GFlap
HTool box
IOwner’s manual
(The storage location after machine assembly
is shown in the illustration)
JSafety hand book
(The storage location after machine assembly
is shown in the illustration)
KSuspension setting card
(Except for RXW10K, RXW10SK)
(The storage location after machine assembly
is shown in the illustration)
LBattery (Sealed-type (MF))
ACarton box

Fairing assembly
+ Meter assembly
Headlight cover Front bumper
Under cover Fairing
Key Upper handle
holder
Lower handle
holder
Bolts Clamp
123
5
4
12 3 4 5
Steering pad
assembly
(For RX10MK,
RX10MSK)
6
Carton box
B
Ski assembly
1
Carton box
C
Rear bumper Rear bumper bracket
(For RX10MK,
RX10MSK)
9
8
Steering pad assembly
(Except for RX10MK,
RX10MSK)
7
Left Right
Side cover
(For RX10MK,
RX10MSK)
13
Stopper flap
(For RX10K,
RX10RK, RX10RSK)
12
Rear bumper bracket
(For RXW10K,
RXW10SK)
11
Rear bumper bracket
(For RX10K, RX10RK,
RX10RSK)
10
Left
Right
1-2
DVinyl bag (Except for RX10MK, RXW10MSK)

Vinyl bag
(For RX10MK,
RX10MSK)
Tool box
H
Spanner (8-10)
2 pcs
1
Spanner (10-12)
2 pcs
2
Spanner (19-22)
3
Grip
4
Spanner (14-17)
2 pcs
9
+–
Windshield
1
Flap
G
Flap
1
Spanner (22)
2 pcs
10
Windshield
F
Key
Upper handle
holder
Lower handle
holder
Bolts Clamp
1
1 2 3 4 Handlebar
joint
5
Screw driver bit
()
5
Wrench (3)
6
Spark plug
box wrench
(16)
7
Box wrench (14)
8
For RX10K,
For RX10RK, RX10RSK
For RXW10K, RXW10SK
Spanner (14-17)
9
Spanner (30-19)
11
Spanner (14-17)
2 pcs
9
Spanner
12
Spanner
13
For RX10MK, RX10MSK
DVinyl bag (For RX10MK, RX10MSK) E
1-3

Owner’s manual
ISafety hand book J
Suspension setting card
(Except for RXW10K, RXW10SK)
K
1-4

1-5
NOTE:
REMOVAL FROM CRATE
1. Open the fastener of plastic cover.
(One side fastener)
2. Remove the plastic cover 1.
3. Remove the bolts 2and then remove the
top of the crate 3.
4. Remove the bolts 4and then remove the
sides of the crate.
5. Remove the carton box.
6. Remove the bolts 5and then remove the
brackets 6.
The bolts and brackets installed on handlebar
holder are not used for installation.
7. Remove the hook 7.
(Right side)

1-6
8. Remove the hook 8.
(Left side)
9. Remove the steel band 9.
(Right side)
10. Remove the steel band 10 .
(Left side)
11. Remove the bolt 11 and nut 12 .
(Right side)
The bolt 11 and nut 12 installed on the right
side are not used for installation.
12. Remove the bracket 13 .
The braket 13 installed on the right side are
not used for installation.
13. Remove the bolt 14 and nut 15 .
(Left side)
The bolt 14 and nut 15 installed on the left
side are not used for installation.
14. Remove the bracket 16 .
The braket 16 installed on the left side are
not used for installation.

2-1
1
2
3
4
5
6
C
A
3 Nm (0.3 mSkg, 2.2 ftSlb)
7
8
9
10
C
C
1 Nm (0.1 mSkg, 0.7 ftSlb)
CAUTION:
SET UP PROCEDURE
WINDSHIELD, FAIRING, HEADLIGHT
Parts List
No Parts Name Qty Location Remark
Windshield 1 on the shroud
Fairing assembly 1in the carton box “ ”
Headlight unit 1in the carton box “ ”
Pan head screw 2in the vinyl bag “1” M6 1.0 L = 14 mm (0.55 in)
Nut spring 2in the vinyl bag “4” L = 19 mm (0.75 in)
Screw 3 in the vinyl bag “1” M5 0.8 L = 18 mm (0.71 in)
Nut 3in the vinyl bag “1”
Headlight cover 1in the carton box “ ”
Fairing 2 in the carton box “ ”
Self-tapping screw 2in the vinyl bag “4” L = 16 mm (0.63 in)
Set up point
AInstall headlight unit 3in shroud first. BInstall windshield 1after installing headlight unit.
During installation of the headlight cover 8, take care not to scratch the shroud with the spring of the
headlight cover 8.

2-2
1
2
3
4
5
1 Nm (0.1 mSkg, 0.7 ftSlb)
3 Nm (0.3 mSkg, 2.2 ftSlb)
3 Nm (0.3 mSkg, 2.2 ftSlb)
1 Nm (0.1 mSkg, 0.7 ftSlb)
3 Nm (0.3 mSkg, 2.2 ftSlb)
FAIRING ASSEMBLY
Parts List
No Parts Name Qty Location Remark
Nut spring 2in the vinyl bag “4” L = 19.5 mm (0.77 in)
Bolt 2 in the vinyl bag “4” M6 1.0 L = 16 mm (0.63 in)
Bolt 3 in the vinyl bag “1” L = 15 mm (0.59 in)
Self-tapping screw 2in the vinyl bag “1” L = 16 mm (0.63 in)
Self-tapping screw 2in the vinyl bag “1” L = 16 mm (0.63 in)
Set up point
1. Install the wire harness rubber cover 1un-
til it contacts the meter assembly.

2-3
1
2
3
4
5
B
: ESSO beacon 325 grease
: or Aeroshell grease #7A
a
48 Nm (4.8 mSkg, 35 ftSlb)
SKI ASSEMBLY (Except for RX10MK, RX10MSK)
Parts List
No Parts Name Qty Location Remark
Ski assembly 2in the carton box “ ”
Bolt
2
in the vinyl bag
“
2
”
for RX10K, RX10RK, RX10RSK
M10 1.25 L = 130 mm (5.12 in)
Bolt
2
in
the
vinyl
bag
2
for RXW10K, RXW10SK
M10 1.25 L = 115 mm (4.53 in)
Nut 2in the vinyl bag “2” M10 1.25
Split pin 2in the vinyl bag “2”
Stopper 2 in the vinyl bag “2”
Set up point
1. Apply grease to ski collars band grease
nipple c.

2-4
1
2
3
4
5
B
: ESSO beacon 325 grease
: or Aeroshell grease #7A
a
6
48 Nm (4.8 mSkg, 35 ftSlb)
SKI ASSEMBLY (For RX10MK, RX10MSK)
Parts List
No Parts Name Qty Location Remark
Ski assembly 2in the carton box “ ”
Bolt 2 in the vinyl bag “2” M10 1.25 L = 153 mm (6.02 in)
Nut 2in the vinyl bag “2” M10 1.25
Split pin 2in the vinyl bag “2”
Stopper 2 in the vinyl bag “2”
Collar 4 in the vinyl bag “2”
Set up point
1. Apply grease to ski collars band grease
nipple c.

2-5
1
2
3
4
A
45 Nm (4.5 mSkg, 33 ftSlb)
45 Nm (4.5 mSkg, 33 ftSlb)
5
6
: ESSO beacon 325 grease
: or Aeroshell grease #7A
a
FRONT SUSPENSION
Parts List
No Parts Name Qty Location Remark
Shock absorber 2in the carton box “ ”
Nut 4in the vinyl bag “2” M10 1.25
Washer, plate 4in the vinyl bag “2” d = 10 mm (0.4 in)
D = 25 mm (0.98 in)
Bolt 2in the vinyl bag “2” M10 1.25 L=60 mm (2.36 in)
Collar 2in the vinyl bag “2”
Bolt 2in the vinyl bag “2” M10 1.25 L=90 mm (3.54 in)
Set up point
1. Apply grease to collars 5.
2. Apply grease to bolts 4.

2-6
1
2
C
C
3
4
5
17 Nm (1.7 mSkg, 12 ftSlb)
3 Nm (0.3 mSkg, 2.2 ftSlb)
FRONT BUMPER, UNDER COVER
Parts List
No Parts Name Qty Location Remark
Under cover 1in the carton box “ ”
Bolt 8 in the vinyl bag “1” M6 1.0 L = 18 mm (0.71 in)
Nut spring 6in the vinyl bag “1” L = 19 mm (0.75 in)
Front bumper 1in the carton box “ ”
Bolt 4 in the vinyl bag “3” M8 1.0 L = 16 mm (0.63 in)
Set up point
1. Install front bumper first.

2-7
1
2
C
3
0.4 Nm (0.04 mSkg, 0.3 ftSlb)
SIDE COVER (For RX10MK, RX10MSK)
Parts List
No Parts Name Qty Location Remark
Side cover 2in the carton box “ ”
Screw 8 in the vinyl bag “1” M5
Nut 8in the vinyl bag “1” M5

2-8
1
2
3
4
5
6
D
D
D
D
C
15 Nm (1.5 mSkg, 11 ftSlb)
STEERING ASSEMBLY (Except for RX10MK, RX10MSK)
Parts List
No Parts Name Qty Location Remark
Handle assembly 1on the fuel tank
Lower handle holder 1in the vinyl bag “ ”
Upper handle holder 2in the vinyl bag “ ”
Clamp 1in the vinyl bag “ ”
Bolt with washer 4in the vinyl bag “ ” M8 1.25 L = 55 mm (2.17 in)
Steering pad assembly 1in the carton box “ ”
Set up point
1. Position tab Atoward the left and install the
lower handle holder 2onto the steering
column 8.
2. Insert the projection Bon the handle 1
into the recess Cin the handle holder (low-
er) 2.
3. Pass all the leads, cables and hoses, ex-
cept the brake hose and parking brake
cable, through the clamp 4.

2-9
1
2
3
4
5
6
E
E
E
E
E
15 Nm (1.5 mSkg, 11 ftSlb)
7C
STEERING ASSEMBLY (For RX10MK, RX10MSK)
Parts List
No Parts Name Qty Location Remark
Handle assembly 1on the fuel tank
Lower handle holder 1in the vinyl bag “ ”
Handlebar joint 1in the vinyl bag “ ”
Upper handle holder 2in the vinyl bag “ ”
Clamp 1in the vinyl bag “ ” M8 1.25 L = 165 mm (6.50 in)
Bolt with washer 4in the vinyl bag “ ”
Steering pad assembly 1in the carton box “ ”
Set up point
1. Position tab Atoward the left and install the
lower handle holder 2onto the handlebar
joint 3.
2. Insert the projection Bon the handle 1
into the recess Cin the handle holder (low-
er) 2.
3. Pass all the leads, cables and hoses, ex-
cept the brake hose and parking brake
cable, through the clamp 5.