Yamaha SRX 120 2017 User manual

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017
017
OPERATOR’S MANUAL
OPERATOR’S MANUAL
SRX 120
SRX 120
www.yamaha-motor.com
8JM-F8199-74
8JM-F8199-74
LIT-12628-03-37
LIT-12628-03-37
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1
Table Of Contents
Foreword ...................................................... 2
Specifications............................................... 3
Getting Ready to Operate
the SRX120 Safely .............................. 4
Operating the SRX120 ................................. 5
General Information .................................. 6-7
Snowmobile Identification ............................6
Control Locations .........................................6
Gasoline - Oil ............................................... 6
Engine Break-In ........................................... 7
Muffler .......................................................... 7
Operating Instructions ............................... 8-9
Starting and Stopping Engine ......................8
Periodic Maintenance/Tune-Up Chart ........ 10
Maintenance ......................................... 11-20
Engine Oil ..................................................11
Carburetor ..................................................12
In-Line Fuel Filter .......................................13
Air Cleaner/Filter ........................................13
Spark Plug .................................................13
Brake..........................................................14
Drive Chain ................................................14
Drive Chain Tensioner................................15
Rear Suspension........................................15
Track Tension .............................................15
Track Alignment..........................................16
Adjusting Rear Spring Tension...................17
Ski Alignment .............................................17
Steering Alignment.....................................18
Ski Wear Bar ..............................................18
Rail Wear Strips .........................................19
Recoil Starter Air Vents..............................19
Lights..........................................................19
Preparation for Storage .............................. 21
Preparation after Storage ........................... 22
Snowmobile Safety Rules .......................... 23
Consumer Information.................................. 24
Reference Information
Write the appropriate information for your Yamaha Snowmobile in the spaces below.
Always use these numbers when referring to your snowmobile.
Model: __________________________________________________
Date of Purchase: _________________________________________
Vehicle Identification Number: _______________________________
Engine Serial Number: _____________________________________
Your Yamaha Dealer: _____________________________________
Address:________________________________________________
Phone: _________________________________________________
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2
Foreword
The SRX120 Snowmobile is intended to be a learning/recreational snowmobile for a
responsible child at least 6 years of age under adult supervision. This snowmobile is
intended to be ridden by the operator only; there should be no passenger. Also, this
snowmobile is intended for daylight use in restricted off-road areas, primarily on
snow. Use of this snowmobile on public streets, roads, and highways can be hazard-
ous and is prohibited by law in most cases. As a parent or guardian, one must accept
the responsibility of training the child in the safe operation of the snowmobile. Teach
all operators the basic principles of operation, snowmobile rules and regulations, and
especially how to stop the snowmobile in case of an emergency. Impress upon the
child a sense of snowmobile courtesy and responsibility.
This snowmobile is a quality Yamaha product designed, engineered, and assembled
to give dependable service. Be sure, as the owner, to become thoroughly familiar with
its basic operation, maintenance, and storage procedures. Read this manual and the
accompanying Snowmobile Safety Handbook to ensure safe and proper use of the
snowmobile.
This manual is divided into sections. The sections Getting Ready to Operate the
SRX120 Safely and Operating the SRX120 must be read and explained to the child/
operator. The other sections are for the owner/parent/guardian and contain informa-
tion on snowmobile identification, safe operating instructions, lubrication, mainte-
nance, storage, and after-storage preparation. If repair or service is ever required,
contact an authorized Yamaha Snowmobile dealer for professional service.
The Operator’s Manual, Snowmobile Safety Handbook, and snowmobile decals dis-
play the words Warning, Caution, and Note to emphasize important information. The
symbol ! WARNING identifies personal safety-related information. Be sure to
follow the directive because it deals with the possibility of severe personal injury or
even death. A CAUTION identifies unsafe practices which may result in snow-
mobile-related damage. Follow the directive because it deals with the possibility of
damaging part or parts of the snowmobile. The symbol NOTE: identifies supple-
mentary information worthy of particular attention.
At the time of publication, all information and illustrations refer to the product at the
time of publishing. Because Yamaha constantly refines and improves its products, no
retroactive obligation is incurred.
This Operator’s Manual should be considered a permanent part of the snowmobile
and must remain with the snowmobile at the time of resale. If the snowmobile
changes ownership more than once, contact Yamaha Customer Service (refer to page
26 for the contact information) for proper registration information. This manual was
prepared by the Product Service and Warranty Department of Yamaha.
Every Yamaha snowmobile meets or exceeds the standards of the Snowmobile Safety
and Certification Committee and displays the SSCC decal. Yamaha endorses and
encourages the safe use of all snowmobiles. Always wear a helmet and eye protec-
tion. Drive with caution, observe all state and local laws, and respect the rights of oth-
ers. International Snowmobile Manufacturers Association (ISMA) members like
Yamaha do their part to improve trails, sponsor events, and generally support the
sport of snowmobiling. As a member of the National Snowmobile Foundation,
Yamaha promotes snowmobiling through education, charity, and research programs.
© 2016 YMUS
Printed in U.S.A.
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3
Specifications
Specifications subject to change without
notice.
ENGINE AND DRIVE
Type Forced Air Cooled/4-
Cycle
Bore x Stroke 56 x 50 mm
(2.2 x 1.97 in.)
Valve Arrangement Overhead
Displacement 123 cc (7.5 cu in.)
Lighting Coil Output 12V/55W
Compression Ratio 8.3:1
Lubrication Forced Splash
Cooling System Forced Air
Drive Clutch Centrifugal
Drive Chain Ten-
sioner
Automatic
Brake Type Band
Ignition Type Transistorized
Track Width 25.4 cm (10 in.)
Track Length (On
Ground)
43 cm (17 in.)
Track Tension
(Range)
6.4-9.5 mm
(1/4-3/8 in.)
Track Style Standard-Lug
Spark Plug Type NGK BPR4ES
Spark Plug Gap 0.7-0.8 mm
(0.028-0.031 in.)
Ignition Timing
(Fixed)
24° BTDC @ 3600 RPM
CARBURETOR
Type Mikuni BV18-11-84Z1
CHASSIS
Overall Length 181.6 cm (71.5 in.)
Overall Height 78.7 cm (31 in.)
Overall Width 87.6 cm (34.5 in.)
Ski Center-to-Center
Distance (Stance)
78 cm (31 in.)
MISCELLANY
Gasoline
(Recommended)
87 Minimum Octane
Regular Unleaded
Gas Tank Capacity
(Actual)
1.7 L (0.46 U.S. gal.)
Gas Tank Capacity
(Rated)
1.5 L (0.40 U.S. gal.)
Engine Oil
(Recommended)
Synthetic 0W-40
Crankcase Oil
Capacity
600 ml (20.3 fl oz)
Air Cleaner Semi-Dry Polyure-
thane Foam Element
Suspension Grease All-Temperature
Taillight (LED) (p/n) 8JM-H4710-10
Headlight Bulb (p/n) 8JM-H4314-00
Starting System Manual Recoil
Dry Weight 75.0 kg (165 lb)
Curb Weight (approx) 76.8 kg (169 lb)
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Getting Ready to Operate the
SRX120 Safely
NOTE: This section and Operating
the SRX120 section must be read
and explained to the child/operator
by the owner/parent/guardian. Refer
to Control Locations or the snowmo-
bile while explaining this section.
Like most boys and girls, you are anx-
iously waiting to drive the snowmobile.
Remember that the snowmobile is not a
toy. It must be driven carefully at all
times!
First, you must understand the controls,
know where the controls are, and know
how to use them correctly.
A. BRAKE LEVER — To slow
down or stop the snowmobile, the
brake lever should be pulled
(squeezed) toward the handlebar
grip.
NOTE: When the brake is being
used, the throttle lever must be in
the idle (released) position.
B. THROTTLE LEVER — Controls
the speed of the snowmobile. The
closer the throttle control lever is to
the handlebar grip (the more it is
squeezed), the faster the snowmo-
bile will go.
C. IGNITION SWITCH — When
the key is in the OFF position, the
engine will neither start nor run. If
the key is in the RUN position, the
engine will start and run.
D. EMERGENCY STOP SWITCH
— If something happens that you do
not understand or if there is an emer-
gency, move the emergency stop
switch to the OFF (down) position to
immediately stop the engine.
E. TETHER SWITCH — The
engine will neither start nor run
unless the tether switch cap is con-
nected to the tether switch located
on the top right-hand side of the con-
sole. The tether cord MUST BE
clipped to the operator’s right wrist
before attempting to start the engine.
Second, you must check several things
every time before the engine is started.
A. Make sure the brake lever works
properly (moves freely) by pulling
(squeezing) the brake lever and
releasing it several times.
B. Make sure the throttle lever works
properly (moves freely) and that it
snaps back to the idle position
quickly when it is released. The idle
position is when the throttle lever is
farthest away from the handlebar
grip. If the throttle lever does not
snap back quickly, the engine must
not be started and the throttle system
must be repaired.
C. Make sure that you have enough
clothes on to keep yourself warm but
NEVER wear clothes such as long
or loose scarves or long shoe laces
that could get caught in a moving
part of the snowmobile.
Third, make sure that you can answer yes
to all of the following questions before
each ride.
A. Do you have permission from the
owner or parent or guardian to oper-
ate the snowmobile?
B. Do you have an approved safety hel-
met on?
C. Are you wearing something to pro-
tect your eyes (such as goggles or a
visor)?
D. Are you dressed warmly enough?
E. Has your parent or guardian checked
to make sure you have enough gaso-
line?
F. Do the throttle lever and brake lever
move freely?
G. Are all shields and covers in the
right place and is the hood securely
latched?
H. Do you have a safe area to ride in? Is
the area free of rocks, wires, trees,
traffic, etc.?
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Operating the SRX120
You must be a responsible, careful, and
considerate snowmobile operator at all
times. Your safety is our concern and
must always be yours.
A. When you are learning how to oper-
ate the snowmobile, have a parent or
guardian take you to an open area to
practice figure eights, starting, and
stopping. This practice is important
and will give you a good “feel” of
the snowmobile. You will also be
able to learn how the snowmobile
handles under different conditions
(deep snow, hard-packed snow, etc.).
B. Always sit on the seat and keep both
feet on the running boards when
operating the snowmobile. Do not
get off the snowmobile until it has
come to a complete stop.
C. Never drive the snowmobile faster
than a safe speed. Do not drive too
close to roads, buildings, trees, other
snowmobiles, or people. Never
show off!
D. Never operate the snowmobile
unless the headlight and taillight are
in working order.
E. The snowmobile is designed for
your enjoyment. DO NOT give rides
to your friends. It is made to carry
only one person.
F. Do not pull sleds, sleighs, etc.,
behind the snowmobile.
G. If you get stuck, shut the engine off
and get help.
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General Information
Snowmobile
Identification
This snowmobile has two identification
numbers: The Vehicle Identification
Number (VIN) is stamped into the right
side of the tunnel and the Engine Serial
Number (ESN) is stamped into the front
side of the crankcase.
0726-200
0744-926
These numbers are required by the dealer
to complete warranty claims properly. No
warranty will be allowed by Yamaha if
either the ESN or VIN is removed or
mutilated in any way.
Always provide the snowmobile model
name, VIN, and engine serial number
when contacting an authorized Yamaha
Snowmobile dealer for parts, service,
accessories, or warranty. If the complete
engine must be replaced, ask the dealer to
notify Yamaha for correct registration
information.
Control Locations
0749-930
Gasoline - Oil
This snowmobile has a four-cycle
engine; therefore, it is unnecessary to
premix gasoline and oil.
Recommended Gasoline
The recommended gasoline to use in this
snowmobile is 87 minimum octane regu-
lar unleaded. Oxygenated gasolines are
acceptable gasolines. Do not use gaso-
lines containing methanol.
NOTE: If not satisfied with gaso-
line economy of the engine when
using a gas/alcohol blend, switch to
unleaded gasoline without alcohol.
Since gasoline expands as its temperature
increases, the gas tank must be filled to
its rated capacity only. Expansion room
must be maintained in the tank particu-
larly if the tank is filled with cold gaso-
line and then moved to a warm area.
CAUTION
Do not use white gas or gasolines
containing methanol. Only Yamaha
approved gasoline additives may be
used.
! WARNING
Always fill the gas tank in a well-ven-
tilated area. Never add gasoline to
the gas tank near any open flames or
with the engine running. DO NOT
SMOKE while filling the gas tank.
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Recommended Oil
NOTE: This snowmobile comes
from the factory with SAE 0W-40
synthetic oil installed.
The recommended oil to use in the
engine is 0W-40 Synthetic oil. See the
viscosity chart for details.
OILCHARTJ
Engine Break-In
The engine requires a short break-in
period (approximately 10 operating
hours) before being subjected to heavy
load conditions or full-throttle operation.
Strict adherence to the break-in proce-
dure will contribute to optimum perfor-
mance and longevity of the engine.
During break-in, a maximum of 1/2
throttle is recommended; however, brief
full-throttle accelerations and variations
in driving speeds contribute to good
engine break-in. After the 10 hour break-
in period, the snowmobile may be taken
to an authorized Yamaha Snowmobile
dealer for a checkup and oil change. This
service is at the discretion and expense of
the snowmobile owner.
Muffler
The muffler is designed to reduce engine
noise and improve the total performance
of the engine. If the muffler is removed
from the engine, severe engine damage
will result.
CAUTION
Any oil used in place of the recom-
mended oil may cause serious
engine damage.
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Operating Instructions
Starting and Stopping
Engine
It is imperative that all safety checks
found in the accompanying Snowmobile
Safety Handbook be performed before
attempting to start the engine.
This snowmobile is equipped with a
recoil starter. The recoil starter handle is
located on the lower right-hand side of
the console.
NOTE: If the recoil starter rope
should break or if the recoil starter
should malfunction, take the snow-
mobile to an authorized Yamaha
Snowmobile dealer for service.
To start the engine, use the following pro-
cedure:
0749-930
1. Test the throttle lever by completely
compressing and releasing it several
times. The lever MUST return to the
idle position quickly and completely.
2. Open the gas tank shut-off valve
located under the gas tank by rotating
the valve counterclockwise. Open the
valve completely; otherwise, it may
close during operation of the snow-
mobile due to engine vibration.
0744-944
3. Insert the key into the ignition
switch; then rotate the key to the
RUN position.
NOTE: Make sure the emergency
stop switch is in the ON (up) position
and the tether cap is connected to
the tether switch.
4. For a cold engine, pull the choke out
completely. If the engine is warm,
choking is not normally necessary.
5. Pull the recoil starter handle slowly
until resistance is felt; then give a
short quick pull. The engine should
start; however, if the engine does not
start, repeat this step.
6. When the engine starts, push the
choke approximately half way in.
Allow a cold engine to “warm up”
for approximately 2-3 minutes. The
choke should be pushed in com-
pletely after the “warm up.”
7. Flooding - If the engine does not
start when the choke is being used
but seems ready to start, push the
choke in completely.
NOTE: Continued choking will only
cause the engine to flood more.
NOTE: If the engine fails to start
during the attempt with the throttle
lever compressed, remove the spark
plug and clean and dry it thoroughly
or install a new, properly gapped,
recommended spark plug.
! WARNING
Never allow anyone to stand in front
of the snowmobile at any time, espe-
cially when starting the engine.
CAUTION
To avoid damaging the recoil starter,
DO NOT pull the recoil starter rope to
its limit or release the recoil starter
handle from an extended position.
Allow recoil rope to rewind slowly.
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8. To shut the engine off, turn the igni-
tion key to the OFF position, move
the emergency stop switch to the
OFF (down) position, or pull the
tether cap from the tether switch.
NOTE: Unless the engine will be
started within a short period of time,
close the gas tank shut-off valve
(located under the gas tank) by rotat-
ing the valve clockwise.
CAUTION
If the snowmobile is not to be used
for an extended period of time, be
sure to close the gas tank shut-off
valve.
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Periodic Maintenance/Tune-Up Chart
C = Clean IA = Inspect and adjust (if necessary)
I = Inspect IC = Inspect and clean (replace if necessary)
R = Replace IL = Inspect and lubricate (replace if necessary)
T = Tighten * = Service more frequently if used in adverse conditions
Daily
1st 10
Hours
(2 weeks)
Every 20
Hours
(1 month)
Every 50
Hours
(3 months)
Every 100
Hours
(6 months)
Every 300
Hours
(12 months)
Valve Clearance IA
Engine
Compression
I
Spark Plug I
Fuel Supply Hose I-R Replace every
3 years
Gas Tank
Shut-Off Valve
IIC*
Carburetor Float
Chamber
IC*
Engine Oil I R* R*
Nuts/Screws/
Cap Screws
IT
Rear Suspension IL
Recoil Starter I I-IC-IL-*
Air Filter I* C*
Carburetor IC
Pilot Air Screw IA
In-Line Fuel Filter I
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Maintenance
Engine Oil
 NOTE: After the engine break-in
period, the engine oil should be
changed every 100 operating hours (6
months) and before prolonged storage.
Checking
The engine oil level should be checked
each day before operating the snowmo-
bile. To check the engine oil level, use
the following procedure:
NOTE: The front of the snowmo-
bile must be elevated until the bot-
tom of the front bumper is
approximately 47 cm (18.5 in.) off the
floor when checking the oil level.
Also, assure the engine is “cooled
down” to room temperature to allow
the oil to drain into the sump.
740-330A
1. Release the two hold-down straps and
open the hood.
2. Rotate the oil level stick counter-
clockwise; then remove the stick
from the crankcase and wipe it clean.
3. Insert the stick into the crankcase;
then remove and check oil level on
the stick.
NOTE: If the oil level is below the
oil level mark, add recommended oil
until it reaches the oil level mark.
4. Insert the oil level stick into the
crankcase; then rotate the stick
clockwise until snug.
5. Close the hood and secure with the
two straps.
Changing
To change the engine oil, use the follow-
ing procedure:
NOTE: The front of the snowmo-
bile must be elevated until the
engine is in a level position when
changing the oil.
0744-920
1. Remove the access plug; then place
a drain pan beneath the engine.
2. Release the two hold-down straps
and open the hood.
3. Loosen the oil level stick; then
remove the oil drain plug from the
crankcase and allow the oil to drain.
4. Install the drain plug.
5. Remove the oil level stick; then pour
600 ml (20.3 fl oz) of recommended
oil into the fill hole.
6. Install the oil level stick; then
tighten until snug. Install the access
plug.
7. Close the hood and secure with the
two straps.
CAUTION
Clean the area around the fill hole to
keep dirt, debris, etc., out of the
engine.
CAUTION
Seeing oil in the crankcase does not
mean the level is in the safe operating
range. Always use the oil level stick to
check engine oil. Never operate the
engine with the oil level below the
point of overflowing the fill hole.
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Carburetor
The carburetor has been calibrated for aver-
age riding conditions; however, altitude,
temperature, and general wear may necessi-
tate certain carburetor adjustments. Since
carburetor adjustments critically affect
engine performance, Yamaha recommends
that any changes in internal carburetor cali-
bration be made by an authorized Yamaha
Snowmobile dealer; however, three external
adjustments can be made on the carburetor.
These are the throttle stop screw, idle fuel
adjuster screw, and throttle cable.
0744-921
Throttle Stop Screw
This screw controls the seating position
of the throttle valve which in turn deter-
mines the proper idle speed. Rotate the
screw clockwise to increase engine idle
speed and counterclockwise to decrease
engine idle speed.
Idle Fuel Adjuster Screw
This adjuster screw determines the fuel/
air mixture for idling. To adjust, use the
following procedure:
1. Start the engine and allow to run at
half throttle 5-10 minutes to warm up.
2. Place the throttle in the idle position;
then rotate the idle fuel adjuster
screw/cap in or out within the
adjustment range to obtain smooth
low speed performance.
Throttle Cable
The correct throttle cable adjustment is
when (with the engine OFF) the carbure-
tor throttle is completely open (against its
limit) while the throttle lever lightly con-
tacts the handlebar grip. The throttle arm
on the carburetor should also contact the
speed control screw when the throttle
lever is released.
To adjust the throttle cable, use the fol-
lowing procedure:
1. Loosen the throttle cable jam nuts.
0744-922
2. Pull all slack from the throttle cable
wire and exert slight tension on the
wire.
3. Tighten the throttle cable jam nuts.
Speed Control Screw
0744-949
The maximum speed of the snowmobile
can be reduced by adjusting the speed
control screw.
To reduce the maximum speed, rotate the
speed control screw clockwise. DO NOT
EVER INCREASE THE MAXIMUM
SPEED BEYOND THE ORIGINAL 8
MPH MAXIMUM!
! WARNING
Do not attempt to adjust the throttle
cable with the engine running. Per-
sonal injury could result.
! WARNING
DO NOT operate the snowmobile
when any component in the throttle
system is damaged, frayed, kinked,
worn, or improperly adjusted. If the
snowmobile is operated when the
throttle system is not functioning
properly, personal injury could result.
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In-Line Fuel Filter
Yamaha recommends that the in-line fuel
filter be checked once a month. The filter
is located in the fuel hose between the gas
tank and carburetor. The only cleaning
possible is to back-flush the filter using
clean gasoline. To check, clean, or replace
the filter, use the following procedure:
1. Turn the gas tank shut-off valve to
the CLOSED position.
2. Remove and discard the clamps;
then pry the fuel hoses off the in-line
fuel filter and remove the filter.
3. Install the in-line fuel filter in the
fuel hose so the arrow on the filter
points toward the carburetor. Make
sure the fuel hoses fit tightly on the
filter. If a fuel hose does not fit
tightly, cut 6 mm (1/4 in.) from the
end of the fuel hose; then install on
the filter. Install new clamps.
4. Turn the gas tank shut-off valve to
the OPEN position.
Air Cleaner/Filter
The air filter inside the air cleaner housing
must be kept clean to provide good engine
power and gas mileage. If the snowmobile
is used under normal conditions, service
the filter at the intervals specified. If oper-
ated in adverse conditions, inspect and ser-
vice the filter more frequently. Use the
following procedure to remove the filter
and to inspect and/or clean it.
1. Remove the two screws securing the
air cleaner cover; then remove the
cover.
2. Remove the foam filter from the
housing.
3. Clean the foam filter in a non-flam-
mable cleaning solvent; then allow
the filter to dry.
NOTE: Foam Filter Cleaner and
Foam Filter Oil are available from
Yamaha.
4. Put the dry filter in a plastic bag;
then pour in recommended air filter
oil and work the oil into the filter.
5. Clean any debris from inside the air
cleaner. Be sure no debris enters the
carburetor.
6. Place the filter into the housing.
7. Place the air cleaner cover onto the
housing; then secure with the two
screws.
Spark Plug
This snowmobile comes equipped with a
specified spark plug. See the specifications
chart for the correct spark plug. A light
brown insulator indicates that the plug is
correct. A white or dark insulator indicates
that the engine may need to be serviced or
the carburetor may need to be adjusted.
Consult an authorized
Yamaha Snowmo-
bile dealer if the plug insulator is not a light
brown color. To help prevent cold weather
fouling, make sure to thoroughly warm up
the engine before operating.
To maintain a hot, strong spark, keep the
plug free of carbon.
! WARNING
Whenever any maintenance or
inspection is made on a fuel system
when there may be fuel leakage,
there should be no welding, smok-
ing, open flames, etc., in the area.
CAUTION
The fuel hoses must fit tightly on the
fuel filter. If the fuel hose length
doesn’t permit this procedure, replace
the fuel hose. Also, after installing the
fuel hoses on the filter, check to be
sure that the fuel hoses do not con-
tact any hot or rotating components.
CAUTION
Failure to inspect the air filter frequently
if the snowmobile is used in adverse
conditions can damage the engine.
CAUTION
A torn air filter can cause damage to
the engine. Contaminants may get
inside the engine if the filter is torn.
Carefully examine the filter for tears
before and after cleaning it. Replace
the filter with a new one if it is torn.
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Before removing the spark plug, be sure
to clean the area around the spark plug. If
you do not, dirt could enter engine when
removing or installing the spark plug.
Adjust the gap to specified amount (see
specifications chart) for proper ignition.
Use a feeler gauge to check the gap.
ATV0052B
When installing the spark plug, be sure to
tighten it securely. A new spark plug
should be tightened 1/2 turn once the
washer contacts the cylinder head. A
used spark plug should be tightened 1/8 -
1/4 turn once the washer contacts the cyl-
inder head.
Brake
Yamaha recommends that the complete
brake system be checked daily for wear
or damage and for smooth operation.
Periodically, the brake band should be
inspected for cracks and to ensure the
liner is intact and not worn excessively.
Replace the brake band if cracked or
worn excessively.
Checking Brake Lever
Travel
1. Compress the brake lever fully.
2. Check the distance between the
brake lever and the lever stop. The
distance must be within the specified
range of 6-13 mm (1/4-1/2 in.).
0725-565
3. If travel distance is not as specified,
adjust the brake.
Adjusting Brake Lever
Travel
To adjust the brake lever travel, use the
following procedure:
1. Remove the drive chain shield.
2. Loosen the rearward brake cable jam
nut; then tighten the forward jam nut
to set up the brake.
0735-457
3. Check the brake lever travel distance
periodically while tightening the for-
ward jam nut. When the distance is
within the specified range of 6-13 mm
(1/4-1/2 in.), tighten the rearward jam
nut to secure the adjustment.
Drive Chain
The drive chain should be lubricated every
10 operating hours with Yamaha Synthetic
Chain Lube. By using the recommended
chain lube or a dry, graphite-based chain
lubricant, dirt buildup on the drive chain
will be minimized. Before each lubrica-
tion, inspect the drive chain for dirt accu-
mulation.
To lubricate the drive chain, shut the engine
off and wait for all moving parts to stop,
remove the drive chain shield, and lubricate
the drive chain. After lubricating the drive
chain, install the drive chain shield.
! WARNING
DO NOT operate the snowmobile
when any component in the brake
system is damaged, worn, or
adjusted improperly.
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15
 NOTE: If the recommended chain
lube or a dry, graphite-based chain
lubricant is not available, lubricate
the drive chain with several drops of
petroleum-based oil. If the snowmo-
bile is operated in the summer with
the optional wheel kit, the drive chain
should be lubricated more frequently.
Drive Chain Tensioner
The drive chain tensioner is automatic;
therefore, no adjustment is required by
the snowmobile owner. The tensioner
and chain should be checked annually for
proper operation and excessive wear and
replaced when necessary. Check the ten-
sioner by pushing down on it and releas-
ing it. It should immediately spring back
and put tension on the drive chain.
Rear Suspension
This procedure should be done every 20
operating hours.
1. Shut engine off and wait for all mov-
ing parts to stop.
2. With the gas tank nearly empty (less
than 1/4 full), lay the snowmobile on
its side. A piece of cardboard should
be used to protect the finish on the
hood and belly pan.
3. Remove ice and snow buildup from
the skid frame to expose the two
grease fittings.
4. Lubricate the grease fittings with an
all-temperature grease.
Track Tension
NOTE: Track tension and track
alignment are interrelated; there-
fore, always check both, even if only
one adjustment seems necessary.
Track tension is directly related to the
overall performance of the snowmobile.
If the track is too loose, it may slap
against the tunnel causing wear, or it may
ratchet on the track drive sprockets.
Yamaha recommends that the track ten-
sion be checked once a month and
adjusted accordingly.
Checking Track Tension
1. Remove excess ice and snow
buildup from the track, track drive
sprockets, and the inside of the skid
frame.
2. Place the rear of the snowmobile up
on a safety stand high enough so the
track is free of the floor.
3. Without exerting any pressure on the
track, measure the distance between
the bottom of the wear strip and the
inside surface of the track. The mea-
surement must be within specifica-
tions of 6.4-9.5 mm (1/4-3/8 in.). If
the measurement is not within speci-
fications, an adjustment is necessary.
0744-945
Adjusting Track Tension
1. Loosen the idler wheel cap screws.
2. Loosen the rear idler wheel adjust-
ing bolt jam nuts.
! WARNING
Track tension must be properly main-
tained. Personal injury could result if
a track is allowed to become exces-
sively loose.
! WARNING
DO NOT attempt to check or adjust
track tension with engine running.
Turn ignition key to the OFF position.
Personal injury could result from
contact with a rotating track.
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0744-947
NOTE: To ensure proper track ten-
sion adjustment, perform all adjust-
ments on both sides of the
snowmobile.
3. If the deflection (distance between
the bottom of the wear strip and the
inside of the track) exceeds specifi-
cations, tighten the adjusting bolts to
take up excessive slack in the track.
4. If the distance between the bottom
of the wear strip and the inside sur-
face of the track is less than speci-
fied, loosen the adjusting bolts to
increase the slack in the track.
5. Check track alignment (see Track
Alignment section).
6. When proper track tension is
obtained, tighten the adjusting bolt
jam nuts against the axle housings.
7. Tighten the idler wheel cap screws
securely.
NOTE: Since track tension and
track alignment are interrelated,
always check both even if only one
adjustment seems necessary.
Track Alignment
Proper track alignment is obtained when
the rear idler wheels are equal distance
from the inner track drive lugs. Excessive
wear to the idler wheels, drive lugs, and
track will occur if the track is improperly
aligned. Yamaha recommends that the
track alignment be checked once a week
or whenever the track tension is adjusted.
Checking Track Alignment
1. Remove excess ice and snow buildup
from the track, track drive sprockets,
and the inside of the skid frame.
2. Position the tips of the skis against a
wall; then using a shielded safety
stand, raise the rear of the snowmo-
bile off the floor making sure the
track is free to rotate.
3. Start the engine and accelerate
slightly. Use only enough throttle to
turn the track several revolutions.
SHUT ENGINE OFF.
NOTE: Allow the track to coast to a
stop. DO NOT apply the brake
because it could produce an inaccu-
rate alignment condition.
4. When the track stops rotating, check
the relationship of the rear idler
wheels and the inner track drive
lugs. If the distance from the rear
idler wheels to the inner track drive
lugs is the same on both sides, no
adjustment is necessary.
! WARNING
If jam nuts are not tightened prop-
erly, the adjusting bolts could loosen
causing the track to become
extremely loose and, under some
operating conditions, allow the idler
wheels to climb over the track lugs
forcing the track against the tunnel
causing the track to “lock.” If a track
“locks” during operation, severe per-
sonal injury could result.
! WARNING
Make sure the ignition key is in the
OFF position and the track is not
rotating before checking or adjusting
track alignment. Personal injury
could result if contact is made with a
rotating track.
! WARNING
The tips of the skis must be posi-
tioned against a wall or similar
object for safety.
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17
0727-729
5. If the distances from the rear idler
wheels to the inner track drive lugs
are not the same on both sides, an
adjustment is necessary.
Adjusting Track Alignment
1. On the side of the track which has
the inner track drive lugs closer to
the rear idler wheel, loosen the idler
wheel cap screw and the adjusting
bolt jam nut; then rotate the adjust-
ing bolt clockwise 1 to 1 1/2 turns.
0744-947
2. Check track alignment and continue
adjustment until proper alignment is
obtained.
NOTE: Make sure correct track
tension is maintained after adjust-
ing track alignment (see Track Ten-
sion section).
3. After proper track alignment is
obtained, tighten both the adjusting
bolt jam nut and the idler wheel cap
screw securely.
4. Field test the track under actual con-
ditions.
5. After the field test, check the align-
ment of the track. If additional adjust-
ment is necessary, repeat Adjusting
Track Alignment procedure.
Adjusting Rear Spring
Tension
Rear spring tension adjustment is accom-
plished by rotating the adjusting cams.
Position 3 provides the stiffest ride, and
position 1 is for the light driver or slow-
speed trail riding. Position 2 is for the
average operator under normal condi-
tions. Always rotate the cam from the
lighter position to the heavier position.
0744-946
Using a 13/16 in. wrench, rotate the cam
until it is in the desired position. To
stiffen the ride, rotate the cam so as to
raise the spring end. Make the adjustment
on the other cam and be sure both cams
are adjusted equally.
Ski Alignment
The skis have been aligned during setup of
the snowmobile. Ski alignment usually will
not change unless a rock or similar hard
object is hit while the snowmobile is being
operated. Yamaha recommends that the ski
alignment be checked once a week.
Checking Ski Alignment
1. Turn the handlebar to the straight-
ahead position.
2. Measure the distances to the inside
edges of the skis. Make sure the
measurements are taken behind the
front mount bracket and ahead of the
rear mount bracket.
! WARNING
If a jam nut is not tightened properly,
the adjusting bolt could loosen causing
the track to become dangerously loose.
CAUTION
Never force the adjustment cams
from the low position to the high
position. Cam damage may occur.
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0735-446
NOTE: Ski alignment is correct
when the skis are parallel to each
other (equal measurements front
and rear) or when the skis have up to
a maximum of 6 mm (1/4 in.) “toe
out” (front measurement 6 mm (1/4
in.) more than rear measurement).
3. If ski alignment is not as specified,
the snowmobile will have a ten-
dency to wander and may be diffi-
cult to control; therefore, an
adjustment is necessary.
Adjusting Ski Alignment
1. Make sure the ignition key is in the
OFF position.
2. Visually examine the skis to deter-
mine which ski is out of alignment
with respect to the handlebar.
3. Open the hood and loosen the jam nut
on each end of the adjustment tie rod.
4. While holding the ski in position,
rotate the adjustment tie rod until the
measurement between the skis is
within specifications.
5. When the ski alignment is correct,
apply blue Loctite #243 to the jam
nut threaded areas and tighten each
jam nut securely against its adjust-
ment tie rod.
Steering Alignment
Visually examine the steering alignment
by placing the handlebar in the straight-
ahead position and checking to be sure
the skis are pointing straight ahead. If the
skis are not pointing straight ahead,
adjust using the following procedure:
NOTE: The following procedure
can be used to adjust the alignment
of either ski.
1. Determine which ski is out of align-
ment; then unlock the adjustment tie
rod by loosening the jam nuts.
0735-446
2. Adjust the ski alignment by rotating
the adjustment tie rod.
3. When steering alignment is correct,
apply blue Loctite #243 to the jam
nut threaded areas and tighten each
jam nut securely against its adjust-
ment tie rod.
Ski Wear Bar
The ski wear bar is a replaceable bar
attached to the underside of the ski. The
purpose of the wear bar is to assist in
turning the snowmobile, to minimize ski
wear, and to maintain good steering con-
trol. If the snowmobile is operated pri-
marily in deep snow, ski wear bar wear
will be minimal; however, if the snow-
mobile is operated on terrain where the
snow cover is minimal, the ski wear bar
will wear faster.
! WARNING
Neglecting to lock the tie rod by tight-
ening the jam nuts against the
adjustment tie rod may cause loss of
snowmobile control and possible
personal injury.
! WARNING
Neglecting to lock the steering tie
rod by tightening the jam nuts
against the adjustment tie rod may
cause loss of snowmobile control
and possible personal injury.
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