Yamaha Vector RS90RX 2008 Manual

RS90RX
RS90GTX
RS90GTAX
RS90LTX
RS90LTGTX
LIT-12618-02-70
SUPPLEMENTARY SERVICE MANUAL
8GM-28197-10
2008

FOREWORD
This Supplementary Service Manual has been
prepared to introduce new service and new
data for the RS90RX/RS90GTX/RS90GTAX/
RS90LTX/RS90LTGTX.
For complete information, on service proce-
dures, it is necessary to use this Supplementary
Service Manual together with following manual:
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
applicable, appear in future editions of this
manual.
HOW TO USE THIS MANUAL
Particularly important information is distin-
guished in this manual by the following notations:
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 snowmobile.
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 refer-
ence that contains comprehensive explana-
tions 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
problem will follow the symbol, e.g.,
• Bearings
Pitting/damage →Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams
before each disassembly section to facilitate
correct disassembly and assembly procedures.
RS90K/RS90RK/RSG90K/RS90MK/RST90K/
RST90TFK
SERVICE MANUAL:
8FJ-28197-10 (981096) (LIT-12618-02-38)
RS90NL/RS90NRL/RS90RSL/RS90GTL/RS90MSL
SUPPLEMENTARY SERVICE MANUAL:
8GE-28197-10 (LIT-12618-02-47)
RSG90GTW/RST90GTW
SUPPLEMENTARY SERVICE MANUAL:
8GX-28197-10 (LIT-12618-02-51)
RS90RX/RS90GTX
RS90GTAX/RS90LTX
RS90LTGTX
SUPPLEMENTARY SERVICE MANUAL
©2007 by Yamaha Motor
Corporation, U.S.A.
1st Edition, May 2007
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-12618-02-70
WARNING
CAUTION:
NOTE:

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols to are designed as
thumb tabs to indicate the chapter’s number
and content.
General information
Periodic inspections and adjustments
Chassis
Power train
Engine
Cooling system
Carburetion
Electrical
Specifications
Illustrated symbols to are used to iden-
tify the specifications which appear.
Filling fluid
Lubricant
Tightening
Wear limit, clearance
Engine speed
Special tool
Ω, V, A
Illustrated symbols to in the exploded
diagram indicate grade of lubricant and loca-
tion of lubrication point.
Apply locking agent (LOCTITE®)
Apply Yamabond No.5®
Apply engine oil
Apply gear oil
Apply molybdenum disulfide oil
Apply wheel bearing grease
Apply low-temperature lithium-soap base
grease
Apply molybdenum disulfide grease
Use new one

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

CHAPTER 2.
PERIODIC INSPECTION
AND ADJUSTMENT
INTRODUCTION............................................1
PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM ...........1
GENERAL MAINTENANCE AND
LUBRICATION CHART .................................2
ENGINE..........................................................3
ENGINE IDLE SPEED ADJUSTMENT .....3
THROTTLE CABLE FREE PLAY
ADJUSTMENT ..........................................4
ENGINE OIL LEVEL INSPECTION...........4
CYLINDER HEAD BREATHER HOSE
INSPECTION ............................................6
OIL TANK BREATHER HOSE
INSPECTION ............................................6
CHASSIS .......................................................7
LUBRICATION ..........................................7
ELECTRICAL.................................................8
HEADLIGHT BEAM ADJUSTMENT .........8
FUSE INSPECTION..................................9
TUNING........................................................11
CARBURETOR TUNING ........................11
CLUTCH..................................................15
GEAR SELECTION.................................17
FRONT SUSPENSION ...........................24
REAR SUSPENSION..............................26
CHAPTER 3.
CHASSIS
COWLINGS..................................................30
STEERING ...................................................31
FRONT SUSPENSION ................................35
CHAPTER 4.
POWER TRAIN
DRIVE CHAIN HOUSING............................ 37
SLIDE RAIL SUSPENSION ........................ 40
RS90RX/RS90GTX/RS90GTAX ........... 40
RS90LTX/RS90LTGTX .......................... 44
CHAPTER 5.
ENGINE
SEAT AND FUEL TANK ............................. 49
OIL TANK.................................................... 50
CAMSHAFTS .............................................. 51
CYLINDER HEAD COVER..................... 51
AC MAGNETO ROTOR AND STARTER
CLUTCH ...................................................... 52
CHAPTER 7.
CARBURETION
CARBURETORS AND FUEL PUMP .......... 53
CHAPTER 9.
SPECIFICATIONS
GENERAL SPECIFICATIONS .................... 55
MAINTENANCE SPECIFICATIONS ........... 58
ENGINE .................................................. 58
POWER TRAIN ...................................... 64
CHASSIS ................................................ 68
ELECTRICAL.......................................... 69
HIGH ALTITUDE SETTINGS ................. 71
TIGHTENING TORQUE .............................. 72
ENGINE .................................................. 72
POWER TRAIN ...................................... 74
CHASSIS ................................................ 76
GENERAL TORQUE SPECIFICATIONS.... 77
DEFINITION OF UNITS............................... 77
CABLE ROUTING....................................... 78

INSP
ADJ
1
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
operation 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 CHART FOR THE EMISSION CONTROL
SYSTEM
Item Remarks
Initial Every
1 month
or
800 km
(500 mi)
(40 hr)
Seasonally
or
4,000 km
(2,500 mi)
(200 hr)
Spark plugs
• Check condition.
• Adjust gap and clean.
• Replace if necessary.
Valve clearance • Check and adjust valve clearance when engine is cold. Every 40,000 km (25,000 mi)
Cylinder head/oil tank
breather system
• Check breather hose for cracks or damage.
• Replace if necessary.
Fuel filter • Check condition.
• Replace if necessary.
Fuel line • Check fuel hose for cracks or damage.
• Replace if necessary.
Idle speed • Check and adjust idle speed.
Carburetors
• Adjust synchronization.
• Adjust the jets. Whenever operating condition
(elevation/temperature) is changed.
Exhaust system • Check for leakage.
• Tighten or replace gasket if necessary.
INTRODUCTION/PERIODIC MAINTENANCE
CHART FOR THE EMISSION CONTROL SYSTEM

INSP
ADJ
2
GENERAL MAINTENANCE AND LUBRICATION CHART
N
O
TE:
Brake system:
1. After disassembling the master cylinder or caliper cylinder, always change the brake fluid. Regu-
larly check the brake fluid level and add fluid if necessary.
2. Replace the oil seals of the master cylinder and caliper cylinder every two years.
3. Replace the brake hose every four years, or if cracked or damaged.
Item Remarks
Initial Every
1 month or
800 km
(500 mi)
(40 hr)
Seasonally
or 4,000 km
(2,500 mi)
(200 hr)
Engine oil • Change (warm engine before draining)
Engine oil filter cartridge • Replace.
Every
20,000 km
(12,000 mi)
Cooling system • Check coolant level.
• Air bleed the cooling system if necessary.
Primary and secondary
clutches
• Check engagement and shift speed.
• Adjust if necessary. Whenever operating elevation is changed.
• Inspect sheaves for wear and damage.
• Inspect weights/rollers and bushings for wear for pri-
mary.
• Inspect ramp shoes/bushings for wear for secondary.
• Replace if necessary.
• Lubricate with specified grease.
Drive chain • Check chain slack.
• Adjust if necessary.
Initial at 500 km (300 mi) and every 800 km
(500 mi) thereafter.
Drive chain oil • Check oil level.
• Change.
Brake and parking brake • Adjust free play and/or replace pads if necessary.
• Change brake fluid. See NOTE following this chart.
Control cables • Make sure that operation is smooth.
• Lubricate if necessary.
Disc brake installation • Check for slight free play.
• Lubricate shaft with specified grease as required. Every 1,600 km (1,000 mi)
Slide runners • Check for wear and damage.
• Replace if necessary.
Skis and ski runners • Check for wear and damage.
• Replace if necessary.
Steering system • Check toe-out.
• Adjust if necessary.
Steering bearings • Check bearing assemblies for looseness.
• Lubricate with specified grease.
Ski and front suspension • Lubricate with specified grease.
Suspension component • Lubricate with specified grease.
Fittings and fasteners
• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.
Battery • Check condition.
• Charge if necessary.
GENERAL MAINTENANCE AND LUBRICATION CHART

INSP
ADJ
3
ENGINE
ENGINE IDLE SPEED ADJUSTMENT
N
O
TE:N
O
TE:
Prior to adjusting the engine idling speed, the
carburetor synchronization should be adjusted
properly, the air filter should be clean, and the
engine should have adequate compression.
1. Start the engine and let it warm up for sev-
eral minutes.
2. Install:
• Engine tachometer
(near the spark plug)
3. Measure:
• Engine idle speed
Out of specification →Adjust.
4. Adjust:
• Engine idle speed
Adjustment steps:
• Turn the throttle stop screw in or out until
the specified engine idle speed is obtained.
Turning in →Idle speed is increased.
Turning out →Idle speed is decreased.
N
O
TE:N
O
TE:
After adjusting the engine idle speed, the throt-
tle cable free play should be adjusted.
Engine tachometer
90793-80010, YU-8036-C
Engine idle speed:
1,300 ~ 1,500 r/min
ENGINE IDLE SPEED ADJUSTMENT

INSP
ADJ
4
THROTTLE CABLE FREE PLAY
ADJUSTMENT
N
O
TE:N
O
TE:
• Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
• Adjust the throttle cable free play while the
cable is in the cable guide.
1. Measure:
• Throttle cable free play
Out of specification →Adjust.
2. Adjust:
• Throttle cable free play
Adjustment steps:
• Loosen the locknut .
• Turn the adjusting nut in or out until the
specified free play is obtained.
Turning in →Free play is increased.
Turning out →Free play is decreased.
• Tighten the locknut.
N
O
TE:N
O
TE:
After adjusting the free play, turn the handlebar
to right and left, and make sure that the engine
idling does not run faster.
ENGINE OIL LEVEL INSPECTION
1. Inspect:
• Engine oil level
CAUTION:
Do not run the engine with too much or not
enough oil in the oil tank. Oil could flow
into the air filter and the engine could be
damaged.
Throttle cable free play:
2.0 ~ 3.0 mm (0.08 ~ 0.12 in)
THROTTLE CABLE FREE PLAY ADJUSTMENT /
ENGINE OIL LEVEL INSPECTION

INSP
ADJ
5
Inspection steps:
• Place the snowmobile on a level surface and
apply the parking brake.
• Start the engine, warm it up for 10 ~ 15 min-
utes, and then turn off.
• Disconnect the oil level switch coupler .
CAUTION:
Disconnect the oil level switch coupler
before removing the oil level gauge. Other-
wise the lead can twist and become sev-
ered.
• Remove the oil level gauge/dipstick , wipe
it clean, insert it back into the filler hole (with-
out screwing it in), and then remove it again
to check the oil level.
• The engine oil level should be between the
maximum level mark and minimum level
mark .
Below the minimum level mark →Add the rec-
ommended engine oil to the proper level.
CAUTION:
When adding the engine oil, be careful not
to fill above the maximum level mark and
minimum level mark on the oil level gauge.
CAUTION:
Do not allow foreign materials to enter the
crankcase.
N
O
TE:N
O
TE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
Recommended engine oil type
SAE 0W-30
Recommended engine oil grade
API service SG type or higher
JASO standard MA
ENGINE OIL LEVEL INSPECTION

INSP
ADJ
6
• Start the engine, warm it up for several min-
utes, and then turn it off.
• Check the engine oil level again.
N
O
TE:N
O
TE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
CAUTION:
• Use only 4-stroke engine oil.
• Engine oil also lubricates the starter
clutch. In order to prevent starter clutch
slippage, do not mix any chemical addi-
tives with the oil.
• Do not use oils with a diesel specification
of “CD” or oils of a higher quality than
specified.
CYLINDER HEAD BREATHER HOSE
INSPECTION
1. Inspect:
• Cylinder head breather hose
Cranks/damage →Replace.
Loosen connection →Connect properly.
CAUTION:
Make sure that the cylinder head breather
hose is routed correctly.
OIL TANK BREATHER HOSE INSPECTION
1. Inspect:
• Oil tank breather hose
Cranks/damage →Replace.
Loosen connection →Connect properly.
CAUTION:
Make sure that the oil tank breather hose is
routed correctly.
ENGINE OIL LEVEL INSPECTION/CYLINDER HEAD BREATHER
HOSE INSPECTION/OIL TANK BREATHER HOSE INSPECTION

INSP
ADJ
7
CHASSIS
LUBRICATION
Front and rear suspension
1. Use a grease gun to inject grease into the
nipples and (Both sides).
2. Apply grease .
Apply grease
Apply grease (Both sides)
Apply grease (Both sides)
Front
Rear (RS90RX/RS90GTX/RS90GTAX)
Rear (RS90LTX/RS90LTGTX)
Recommended lubricant:
Esso Beacon 325 Grease or
Aeroshell Grease #7A
(Both sides)
LUBRICATION

INSP
ADJ
8
ELECTRICAL
HEADLIGHT BEAM ADJUSTMENT
1. Place the machine on a level surface.
2. Place the machine from the wall at a dis-
tance indicated by the chart below.
3. Measure the distance from the floor to the
center of the headlight and place a mark
on the wall equal to distance from the
floor.
4. With a person sitting on the machine, apply
the parking brake, start the engine and let it
idle.
5. Turn the headlight to high beam and check
the headlight projection height on the wall.
The projection should be at the parallel
mark on the wall to 1/2° down from
the mark. If not, adjust the headlight angle.
: Distance : Height : Set range
6. Adjust:
• Headlight beam (vertically)
Vertical adjustment
Higher Turn the adjusting screw
counter clockwise.
Lower Turn the adjusting screw
clockwise.
3.0 m (10 ft) 7.6 m (25 ft)
26 mm (1.0 in) 66 mm (2.6 in)
HEADLIGHT BEAM ADJUSTMENT

INSP
ADJ
9
FUSE INSPECTION
The following procedure applies to all of the
fuses.
CAUTION:
To avoid a short circuit, always set the main
switch to “OFF” when checking or replac-
ing a fuse.
1. Inspect:
• Continuity
Inspection steps:
• Connect the pocket tester to the fuse and
check the continuity.
N
O
TE:N
O
TE:
Set the pocket tester selector to “Ω×1”.
• If the pocket tester indicates “∞”, replace the
fuse.
Pocket tester:
90890-03112, YU-03112-C
FUSE INSPECTION

INSP
ADJ
10
2. Replace:
• Blown fuse
Replacing steps:
• Set the main switch to “OFF”.
• Install a new fuse of the correct amperage.
• Set the main switch to “ON” and verify if the
electrical circuit is operational.
• If the fuse immediately blows again, check
the electrical circuit.
WARNING
Never use a fuse with an amperage other
than that specified. Improvising or using a
fuse with the wrong amperage rating may
cause extensive damage to the electrical
system, cause the lighting, ignition, grip
warmer, signal and meter systems to mal-
function and could possibly cause a fire.
Item Amperage Q’ty
Main fuse 30 A 1
Headlight fuse 20 A 1
Signal fuse 10 A 1
Ignition fuse 20 A 1
Carburetor
heater fuse 20 A 1
DC terminal
fuse 3 A 1
Reserve fuse
20 A 1
10 A 1
3 A 1
Reserve fuse 30 A 1
FUSE INSPECTION

INSP
ADJ
11
TUNING
CARBURETOR TUNING
The carburetors are set at the factory to run at
temperatures of 0°C ~ –20°C (32°F ~ –4°F) at
sea level. If the machine is to be operated
under conditions other than those specified
above, the carburetors must be properly
adjusted. Special care should be taken in car-
buretor setting so that the pistons will not be
damaged or will not seize.
CAUTION:
Before performing the carburetor tuning,
make sure that the following items are set
to specification.
• Engine idle speed
• Throttle cable free play
• Carburetor synchronization
Carburetor tuning data
• Standard specifications
Type CVK40
Manufacturer KEIHIN
I.D. Mark 8GM1 00
Main jet (M.J.) #148
Pilot jet (P.J.) #45
Float height 16 mm (0.63 in)
Idle speed 1,300 ~ 1,500 r/min
CARBURETOR TUNING

INSP
ADJ
12
Mid-range and high speed tuning
Adjustments are normally not required, but
may sometimes be necessary, depending on
temperatures, altitude or both.
Mid-range speed and high speed tuning (from
1/4 to full-throttle) can be done by adjusting
the main jet.
CAUTION:
Never run the engine without the air filter
case installed. Severe engine damage may
result.
1. Start the engine and operate the machine
under normal conditions to make sure that
the engine operates smoothly. Stop the
engine.
2. Remove:
• Spark plugs
3. Check:
• Spark plug insulator color
A medium to light tan color indicates nor-
mal conditions.
Distinctly different color →Replace the
main jet.
4. The main jet should be adjusted on the
basis of the “Main jet selection chart”.
N
O
TE:N
O
TE:
By checking the condition of the spark plugs, it
is easy to get some idea of the condition of the
engine. This may diagnose potential problems
before engine damage occurs.
High altitude tuning
Use the chart in CHAPTER 9 to select main
jets according to variations in elevation and
temperature.
N
O
TE:N
O
TE:
These jetting specifications are subject to
change.
Consult the latest technical information from
Yamaha to be sure you have the most up-to-
date jetting specifications.
Main jet
Pilot jet
CARBURETOR TUNING

INSP
ADJ
13
Guide for carburetion
CARBURETOR TUNING

INSP
ADJ
14
Standard main jet
Main jet whose diameter is 10% smaller than
standard
Main jet whose diameter is 10% larger than
standard
CAUTION:
If the air filter case is removed from the car-
buretors, the change in pressure in the
intake will create a lean mixture that may
cause severe engine damage. The air filter
case has no effect on performance charac-
teristics and must be secured to the carbu-
retors during carburetor tuning and
adjustment. Also, it must always be in
place when the engine is operated. Regu-
larly clean the air filter and keep it free from
obstructions.
Low-speed tuning
The carburetors are built so that low speed
tuning can be done by adjusting the throttle
stop screw .
CAUTION:
Never run the engine without the air filter
case installed. Severe engine damage may
result.
1. Set the engine idle speed by turning the
throttle stop screw in (to increase engine
speed) or out (to decrease engine speed).
2. If low-speed performance is still poor at
higher elevations under extreme conditions,
the standard pilot jets may need to be
replaced. In this way, the proper air/fuel
mixture is obtained.
N
O
TE:N
O
TE:
In this case, use a larger numbered pilot jet to
enrich the air/fuel mixture.
Standard pilot jet:
#45
Engine idle speed:
1,300 ~ 1,500 r/min
CARBURETOR TUNING

INSP
ADJ
15
Specifications Model: RS90RX/RS90GTX/RS90GTAX
CLUTCH
High altitude
G Green O Orange P Pink
S Silver Y Yellow
Elevation ~ 800 m
(~ 2,500 ft)
600 ~ 1,400 m
(2,000 ~ 4,500 ft)
1,200 ~ 2,000 m
(4,000 ~ 6,500 ft)
1,800 ~ 2,600 m
(6,000 ~ 8,500 ft)
2,400 ~ 3,000 m
(8,000 ~ 10,000 ft)
Engine idle speed 1,400 ± 100 r/min ←←← ←
Engagement r/min Approx.
3,500 r/min ←Approx. 3,600 r/min
Approx.
3,700 r/min ←
Shift r/min Approx.
8,500 r/min ←←←←
Secondary reduction
ratio (number of links) 22/38 (68 L) ←21/38 (68 L) 20 / 38 (68 L) ←
Primary sheave spring 90501-582L1 ←90501-582L2 90501-624L8 ←
Color Y-S-Y ←G-S-G O-S-O ←
Free length 87.4 mm (3.44 in) ←86.1 mm (3.39 in) 84.2 mm (3.31 in) ←
Preload 343 N (35 kg, 77 lb) ←←←←
Spring rate
24.5 N/mm
(2.50 kg/mm,
140 lb/in)
←
27.0 N/mm
(2.75 kg/mm,
154 lb/in)
31.9 N/mm
(3.25 kg/mm,
182 lb/in)
←
Wire diameter 5.8 mm (0.228 in) ←←6.2 mm (0.244 in) ←
Outside diameter 59.5 mm (2.34 in) ←←←←
Weight (ID) 8ES-17605-00
(8ES00) ←←←←
Weight
rivet
OUT Steel 13.9 Steel 13.3 Steel 10.3 ←None
IN Steel 13.9 Steel 13.3 Steel 10.3 Aluminum 10.3 None
Weight bushing VESPEL TP-8549 ←←← ←
Roller outer dia. 15.6 mm (0.61 in) ←←←←
Roller bushing VESPEL TP-8549 ←←← ←
Pri. clutch shim None ←←←←
Secondary sheave spring 90508-60012 ←←←←
Color P ←←←←
Free length 75 mm (2.95 in) ←←←←
Preload rate 60° (3-3)
1,211 kg•mm/rad ←←←←
Wire diameter 6.0 mm (0.236 in) ←←←←
Outside diameter 69.5 mm (2.736 in) ←←←←
Sec. torque cam angle 43° ←←←←
Sec. clutch shim 1.0 mm (0.04 in) ←←←←
CLUTCH