Untitled - Snowmobile.ru

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new data for
the RX10PA, RX10PSA, RX10PXTA. For complete information, on service procedures, it is necessary to use this Supplementary Service Manual together with following manual:
RX10H, RX10SH, RX10MH, RX10MSH, RX10RH, RX10RSH SERVICE MANUAL:
8FA-28197-10 (LIT-12618-02-28)
RXW10J, RXW10SJ SUPPLEMENTARY SERVICE MANUAL:
8FG-28197-10 (LIT-12618-02-33)
RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
SUPPLEMENTARY SERVICE MANUAL:
8FV-28197-10 (LIT-12618-02-39)
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
SUPPLEMENTARY SERVICE MANUAL:
8FS-28197-10 (LIT-12618-02-44)
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW SUPPLEMENTARY SERVICE MANUAL:
8GY-28197-10 (LIT-12618-02-53)
RX10PA, RX10PSA, RX10PXTA
SUPPLEMENTARY SERVICE MANUAL
©2010 by Yamaha Motor
Corporation, U.S.A.
1st Edition, April 2010
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-12618-02-97
MAJOR SPECIFICATIONS
Model
RX10PA
RX10PSA
RX10PXTA
Model code
8HG1
8JC1
8HN1
Catalogue name
Apex
Apex SE
Apex XTX
Class
Trail
Cross Country
Seating capacity
One
Engine type
Liquid cooled 4-stroke, 20 valves
Cylinder arrangement/
Displacement
Backward-inclined parallel 4-cylinder/998 cm3
Fuel system type
Electronic fuel injection
Track length
3,264.4 mm (128 in)
Front suspension
Independent, double wishbone
Front shock
absorber
Fox® FLOATTM 2
(air shock)
40 mm aluminum HPG
Rear suspension
Dual Shock® CK 144
—
40 mm aluminum HPG
®
Rear
40 mm aluminum HPG
Mono Shock® II RA 128
Front
Rear shock
absorber
3,648.5 mm (144 in)
46 mm KYB aluminum
HPG with remote
damping force adjuster
Fox® MEGA-FLOATTM
(air shock)
40 mm aluminum HPG
Ski type
Lightweight plastic, saddleless design
Electric start
Standard
Reverse
Standard
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
snowmobiles should have a basic understanding of mechanics and the techniques to repair these
types of snowmobiles. Repair and maintenance work attempted by anyone without this knowledge
is likely to render the snowmobile unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
snowmobile will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model.
This policy is intended to provide the customer with the most satisfaction from his snowmobile and
to conform to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
TIP
• This Service Manual contains information regarding periodic maintenance to the emission control
system.
Please read this material carefully.
• Designs and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
WARNING
A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
NOTICE
A NOTICE indicates special precautions that must be taken to avoid
damage to the snowmobile or other property.
TIP
A TIP provides key information to make procedures easier or clearer.
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 inspection and adjustment
Chassis
Power train
Engine
Cooling system
Fuel injection system
Electrical
Specifications
Illustrated symbols
to
are used to identify the specifications which appear.
Filling fluid
Lubricant
Tightening torque
Wear limit, clearance
Engine speed
Special tool
Electrical data (Ω, V, A)
Illustrated symbols
to
in the exploded
diagram indicate grade of lubricant and location of lubrication point.
Apply locking agent (LOCTITE®)
Apply Yamabond No. 5®
Apply engine oil
Apply gear oil
Apply molybdenum disulfide oil
Apply brake fluid
Apply wheel bearing grease
Apply low-temperature lithium-soap-based
grease
Apply molybdenum disulfide grease
Apply silicone grease
ESSO beacon 325 grease or Aeroshell
grease #7A
Use new one
CONTENTS
GENERAL INFORMATION
PERIODIC INSPECTION AND
ADJUSTMENT
CHASSIS
POWER TRAIN
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
ELECTRICAL
SPECIFICATIONS
GEN
INFO
1
INSP
ADJ
2
CHAS
3
POWR
TR
4
ENG
5
COOL
6
FI
7
ELEC
8
SPEC
9
CHAPTER 1.
GENERAL INFORMATION
CHAPTER 4.
POWER TRAIN
FEATURES.................................................... 1
OIL PRESSURE SENSING SYSTEM ...... 1
SLIDE RAIL SUSPENSION ........................ 66
INSPECTION.......................................... 68
INSTALLATION ...................................... 68
SPECIAL TOOLS .......................................... 2
FOR FUEL INJECTION SERVICE ........... 2
CHAPTER 2.
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE ......................................................... 3
THROTTLE BODY
SYNCHRONIZATION ............................... 3
ENGINE OIL REPLACEMENT ................. 5
EXHAUST SYSTEM INSPECTION ........ 10
EXUP CABLE ADJUSTMENT ................ 12
EXUP SERVO MOTOR
INSPECTION .......................................... 15
TRACK TENSION ADJUSTMENT.......... 16
EXTROVERT SPROCKET
WHEELS................................................. 18
LUBRICATION ........................................ 19
TUNING ....................................................... 20
CLUTCH ................................................. 20
GEAR SELECTION ................................ 31
HIGH ALTITUDE TUNING ...................... 32
FRONT SUSPENSION ........................... 34
REAR SUSPENSION ............................. 38
TROUBLESHOOTING
(SKI, SUSPENSION) .............................. 49
CHAPTER 3.
CHASSIS
GENERAL CHASSIS................................... 52
WINDSHIELD AND HEADLIGHT ........... 52
AIR FILTER CASE.................................. 53
SEAT AND TAIL/BRAKE LIGHT ............ 54
STEERING................................................... 55
STEERING.............................................. 55
REMOVAL .............................................. 57
INSPECTION .......................................... 57
INSTALLATION ...................................... 58
CHAPTER 5.
ENGINE
EXHAUST PIPE AND MUFFLER ............... 70
INSTALLATION ...................................... 73
CAMSHAFTS .............................................. 79
INSPECTION.......................................... 79
INSTALLATION ...................................... 83
CRANKCASE.............................................. 87
CHAPTER 7.
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM ....................... 88
WIRING DIAGRAM ................................ 89
ECU SELF-DIAGNOSTIC
FUNCTION ............................................. 91
SELF-DIAGNOSTIC FUNCTION
TABLE .................................................... 91
TROUBLESHOOTING CHART .............. 94
DIAGNOSTIC MODE ............................. 95
TROUBLESHOOTING DETAILS ......... 104
OIL PRESSURE SENSING SYSTEM
TROUBLESHOOTING ......................... 108
ISC (IDLE SPEED CONTROL) UNIT ... 109
THROTTLE BODY .................................... 110
THROTTLE BODY ............................... 110
INJECTORS ......................................... 112
REMOVAL ............................................ 113
INSPECTION........................................ 113
INSPECTION AND ADJUSTMENT...... 114
CHAPTER 8.
ELECTRICAL
SWITCH INSPECTION .............................. 116
SWITCH INSPECTION ......................... 116
KNOCK SENSOR...................................... 117
EPS (ELECTRIC POWER STEERING)
SYSTEM .................................................... 118
CIRCUIT DIAGRAM.............................. 118
EPS CONTROL UNIT’S
SELF-DIAGNOSTIC FUNCTION .......... 119
EPS WARNING DISPLAY DURING
NORMAL OPERATION ........................ 120
DIAGNOSTIC MODE ............................ 121
SELF-DIAGNOSTIC FUNCTION
TABLE (EPS SYSTEM) ........................ 124
TROUBLESHOOTING DETAILS
(EPS SYSTEM)..................................... 125
EPS MOTOR INSPECTION ................. 129
EPS TORQUE SENSOR
INSPECTION ........................................ 129
CHAPTER 9.
SPECIFICATIONS
GENERAL SPECIFICATIONS .................. 131
MAINTENANCE SPECIFICATIONS ......... 132
ENGINE ................................................ 132
POWER TRAIN..................................... 132
CHASSIS .............................................. 135
ELECTRICAL........................................ 136
GENERAL TORQUE
SPECIFICATIONS ..................................... 137
DEFINITION OF UNITS ............................. 137
TIGHTENING TORQUE............................. 138
ENGINE ................................................ 138
POWER TRAIN..................................... 139
CHASSIS .............................................. 140
CABLE ROUTING ..................................... 141
FEATURES
GEN
INFO
GENERAL INFORMATION
FEATURES
OIL PRESSURE SENSING SYSTEM
This model is equipped with an oil pressure sensing system. When the oil pressure drops, the rpm
limiter is activated, and the engine rpm is reduced, or the engine is shut off, if necessary.
If the oil pressure is incorrect upon starting the engine
1. “OP-LO”
appears and the oil level/pressure warning indicator
illuminates on the meter display.
2. When the two items, above, are displayed, they indicate the rpm limiter is in operation; the rpm is
reduced to less than or equal to the clutch engagement rpm, even though the throttle is open. If
the incorrect oil pressure persists, the engine stops automatically after approximately one
minute.
3. When the oil pressure stabilizes to the correct level, the limiter is automatically canceled as long
as the throttle is not operated and then “OP-LO” disappears and the oil level/pressure warning
indicator goes off.
4. Note that it may take a few seconds for the oil pressure to rise to the optimum level after the
engine is started, even in normal conditions. If the meter display described in (1.) is no longer
displayed after a few seconds, this indicates that everything is normal.
TIP
When disassembling the engine, replacing the engine oil or oil filter, etc., if the oil is drained entirely
from the piping, there may be delay before the oil pressure rises.
1
SPECIAL TOOLS
GEN
INFO
SPECIAL TOOLS
Some special tools are necessary for a completely accurate tuneup and assembly. Using the correct special tool will help prevent
damage that can be caused by the use of improper tools or improvised techniques.
TIP
• Be sure to use the correct part number when ordering the tool,
since the part number may differ according to country.
• For USA and Canada, use part number starting with “YB-”, “YM-”,
“YU-” or “YS-”.
• For others, use part number starting with “90890-”.
FOR ELECTRICAL SERVICE
• Test harness-TPS (3P)
P/N: YU-03204
P/N: 90890-03204
This tool is used to measure voltage of the throttle position sensor.
2
THROTTLE BODY SYNCHRONIZATION
INSP
ADJ
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE
THROTTLE BODY SYNCHRONIZATION
TIP
Prior to synchronizing the throttle bodies, the
valve clearance should be properly adjusted.
1. Remove:
• Shroud
Refer to “COWLINGS” in CHAPTER 3.
• Top cover
• Headlight assembly
Refer to “GENERAL CHASSIS”.
• Headlight stay
Refer to “THROTTLE BODY”.
2. Remove:
• Vacuum caps
3. Install:
• Vacuummate (vacuum gauge)
• Digital tachometer
(Use goods on the market.
Recommended goods: Kaise SK-8401)
Vacuummate:
YU-44456
Vacuum gauge:
90890-03094
4. Start the engine and let it warm up for several minutes, and then let it run at specified
engine idling speed.
Engine idle speed:
1,550 ~ 1,650 r/min
5. Adjust:
• Throttle body synchronization
3
THROTTLE BODY SYNCHRONIZATION
INSP
ADJ
Adjustment steps:
• With throttle body #1 as standard, adjust
throttle body #2, #3 and #4 using the synchronizing screws .
TIP
After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
Vacuum pressure at engine idling
speed:
20.97 ~ 23.63 kPa (157 ~ 177
mmHg, 6.2 ~ 7.0 inHg)
TIP
The difference in vacuum pressure between
two throttle bodies should not exceed 1.3 kPa
(10 mmHg, 0.4 inHg).
6. Check the engine idle speed.
Engine idle speed:
1,550 ~ 1,650 r/min
7. Stop the engine and remove the measuring
equipment.
8. Adjust:
• Throttle cable free play
Refer to “THROTTLE CABLE FREE PLAY
ADJUSTMENT”.
9. Install:
• Headlight stay
Refer to “THROTTLE BODY”.
• Headlight assembly
• Top cover
Refer to “GENERAL CHASSIS”.
• Shroud
Refer to “COWLINGS” in CHAPTER 3.
4
ENGINE OIL REPLACEMENT
INSP
ADJ
ENGINE OIL REPLACEMENT
This model is equipped with an oil pressure
sensing system. When the oil pressure drops,
the rev limiter is activated, and the engine is
stopped, if necessary. If the oil pressure is
incorrect when the engine is started, “OP-LO”
appears and the oil level/pressure warning
indicator illuminates. Note that it may take a
few seconds for the oil pressure to rise to the
optimum level after the engine is started, even
in normal conditions.
Refer to “OIL PRESSURE SENSING SYSTEM”.
TIP
If “OP-LO” remains on and the oil level/
pressure warning indicator remains illuminated
for more than a few seconds after starting the
engine, this indicates that oil pressure is incorrect. In this case, check the oil pressure sensing system.
1. Place the snowmobile on a level surface
and apply the parking brake.
2. Start the engine, warm up for several minutes, and then turn it off.
3. Place a containers under the engine oil
drain bolt and oil tank.
4. Remove:
• Bottom panel
5
ENGINE OIL REPLACEMENT
INSP
ADJ
5. Remove:
• Shroud
• Side cover (left and right)
• Side under cover (right)
Refer to “COWLINGS” in CHAPTER 3.
• Headlight assembly
• Air filter case
Refer to “GENERAL CHASSIS”.
• Battery
• Battery bracket
6. Disconnect:
• Oil level gauge coupler
Refer to “ENGINE OIL LEVEL INSPECTION” in CHAPTER 2.
7. Remove:
• Oil level gauge/dipstick
Refer to “ENGINE OIL LEVEL INSPECTION” in CHAPTER 2.
8. Remove:
• Cylinder head oil filler cap
9. Remove:
• Oil pan engine oil drain bolt
10.Remove:
• Oil tank engine oil drain bolt
11.Drain:
• Engine oil
(completely from the oil pan and oil tank)
12.If the oil filter cartridge is also to be
replaced, perform the following procedure.
6
ENGINE OIL REPLACEMENT
INSP
ADJ
Replacement steps:
• Remove the oil filter cartridge
filter wrench .
with an oil
TIP
Make sure that the O-ring is removed together
with the oil filter cartridge. If the O-ring remains
attached to the crankcase, oil leakage may
occur.
Oil filter wrench:
YM-01469
90890-01469
• Apply a thin coat of engine oil onto the O-ring
of the new oil filter cartridge.
NOTICE
Make sure that the O-ring is positioned correctly in the groove of the oil filter cartridge.
• Tighten the new oil filter cartridge to specification with an oil filter wrench.
Oil filter cartridge:
17 Nm (1.7 m•kgf, 12 ft•lbf)
13.Install:
• Drain bolts
(along with the new gaskets)
Oil tank engine oil drain bolt:
16 Nm (1.6 m•kgf, 12 ft•lbf)
Oil pan engine oil drain bolt:
30 Nm (3.0 m•kgf, 22 ft•lbf)
7
ENGINE OIL REPLACEMENT
INSP
ADJ
14.Fill:
• Engine oil
(with the specified amount of the recommended engine oil)
Add 2.0 L (2.11 US qt, 1.76 Imp.qt) of the
recommended engine oil to the oil tank, and
then install and tighten the oil level gauge/
dipstick and the cylinder head oil filter cap.
Quantity:
Total amount:
3.8 L (4.02 US qt, 3.34 Imp.qt)
Without oil filter cartridge
replacement:
2.8 L (2.96 US qt, 2.46 Imp.qt)
With oil filter cartridge
replacement:
3.0 L (3.17 US qt, 2.64 Imp.qt)
15.Inspect:
• Engine and oil tank
(for engine oil leaks)
16.Inspect:
• Engine oil level
Refer to “ENGINE OIL LEVEL INSPECTION” in CHAPTER 2.
TIP
If “OP-LO” remains on and the oil level/
pressure warning indicator remains illuminated
for more than a few seconds after starting the
engine, this indicates that oil pressure is incorrect. In this case, check the oil pressure sensing system.
Refer to “OIL PRESSURE SENSING SYSTEM
TROUBLESHOOTING”.
8
ENGINE OIL REPLACEMENT
INSP
ADJ
17.Inspect:
• Engine oil pressure
Inspection steps:
• Slightly loosen the oil check bolt .
• Start the engine and keep it idling until engine
oil starts to seep from the oil check bolt.
If no engine oil comes out after one minute,
turn the engine off so that it will not seize.
• Check the engine oil passages, the oil filter
and the oil pump for damage or leakage.
• Start the engine after solving the problem(-s)
and check the engine oil pressure again.
• Tighten the oil check bolt to specification.
Oil check bolt:
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
18.Install:
• Bottom panel
Bottom panel bolt:
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
19.Install:
• All removed parts
TIP
For installation, reverse the removal procedure.
9
EXHAUST SYSTEM INSPECTION
INSP
ADJ
EXHAUST SYSTEM INSPECTION
1. Remove:
• Left side cover
Refer to “COWLINGS” in CHAPTER 3.
• Seat
• Rear cover
Refer to “GENERAL CHASSIS”.
• Fuel tank
Refer to “FUEL TANK” in CHAPTER 5.
• Muffler cover plate
• Muffler cover
Refer to “EXHAUST PIPE AND MUFFLER”.
2. Inspect:
• Exhaust pipe joints
• Muffler
• Exhaust pipe
• Muffler band
• Exhaust pipe bands
• EXUP cable holder
• EXUP valve housing
• EXUP valve pulley
• Collar
• Plate
• Spring
• EXUP valve
• Collar
Cracks/damage → Replace.
10
EXHAUST SYSTEM INSPECTION
INSP
ADJ
3. Inspect:
• Tightening torque
Exhaust pipe joint bolt :
25 Nm (2.5 m•kgf, 18 ft•lbf)
Muffler bolt :
16 Nm (1.6 m•kgf, 12 ft•lbf)
Exhaust pipe bolt (front side)
25 Nm (2.5 m•kgf, 18 ft•lbf)
Exhaust pipe bolt (rear side)
16 Nm (1.6 m•kgf, 12 ft•lbf)
Muffler band bolt :
20 Nm (2.0 m•kgf, 14 ft•lbf)
Exhaust pipe band bolt :
18 Nm (1.8 m•kgf, 13 ft•lbf)
EXUP valve housing bolt :
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
EXUP valve bolt :
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
:
:
4. Inspect:
• EXUP cable (black metal)
• EXUP cable (white metal)
Damage → Replace.
5. Install:
• All removed parts
Refer to “EXHAUST PIPE AND MUFFLER”.
11
EXUP CABLE ADJUSTMENT
INSP
ADJ
EXUP CABLE ADJUSTMENT
1. Remove:
• Left side cover
Refer to “COWLINGS” in CHAPTER 3.
• Seat
Refer to “GENERAL CHASSIS”.
• Fuel tank
Refer to “FUEL TANK” in CHAPTER 5.
2. Remove:
• EXUP valve pulley cover
3. Inspect:
• EXUP system operation
Inspection steps:
• Activate the diagnostic mode and select the
diagnostic code number d: 53.
Refer to “DIAGNOSTIC MODE”.
• Check that the EXUP valve operates properly.
TIP
Check that the ø4 pin (93604-29184) can be
inserted into the boss
of the EXUP valve
housing. If the rod cannot be inserted, adjust
the EXUP cable.
12
EXUP CABLE ADJUSTMENT
INSP
ADJ
4. Adjust:
• EXUP cable
Adjustment steps:
a. Turn the main switch to “ON”
b. Slide the rubber cover
of the EXUP
cable (white metal).
c. Loosen the locknut .
d. Turn the EXUP valve pulley to the left so
that the notch
of the EXUP valve pulley
is positioned further to the left than the boss
of the EXUP valve housing.
e. Turn the adjusting nut
of the EXUP cable
(white metal) to direction
or
so that
the end of the snowmobile front notch
of
the EXUP valve pulley is aligned with the
alignment mark
of the exhaust pipe.
Direction
EXUP cable (white metal) free play is
increased
Direction
EXUP cable (white metal) free play is
decreased
f. Slide the rubber cover
of the EXUP
cable (black metal).
g. Loosen the locknut .
h. Turn the adjusting nut
of the EXUP cable
(black metal) in direction
or
so that
the notch
of the EXUP valve pulley is
aligned with the boss
of the EXUP valve
housing.
Direction
EXUP cable (black metal) free play is
increased
Direction
EXUP cable (black metal) free play is
decreased
13
EXUP CABLE ADJUSTMENT
INSP
ADJ
i. Check that the ø4 pin (93604-29184) can
be inserted into the boss of the EXUP valve
housing. If the rod cannot be inserted,
repeat the procedure from step (a).
j. Tighten the locknut, and then restore the
rubber cover to its original position.
k. Activate the diagnostic mode and select the
diagnostic code number d: 53.
Refer to “DIAGNOSTIC MODE”.
l. Again, check that the ø4 pin (93604-29184)
can be inserted into the boss of the EXUP
valve housing. If the rod cannot be inserted,
repeat the procedure from step (a).
TIP
The center of the notch of the EXUP valve pulley and the center of the boss of the EXUP
valve housing may be misaligned up to 2 mm
(0.08 in).
2 mm (0.08 in)
5. Install:
• EXUP valve pulley cover
EXUP valve pulley cover bolt:
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
6. Install:
• Fuel tank
Refer to “FUEL TANK” in CHAPTER 5.
• Seat
• Left side cover
Refer to “COWLINGS” in CHAPTER 3.
14
EXUP SERVO MOTOR INSPECTION
INSP
ADJ
EXUP SERVO MOTOR INSPECTION
1. Inspect:
• EXUP servo motor operation
Rough movement → Replace.
Inspection steps:
a. Check that the EXUP valve is not firmly
fixed.
• Disconnect the EXUP cable and check that
the EXUP valve is moved smoothly by
hand.
• When the valve is not moved smoothly,
repair or replace it.
Refer to “EXUP CABLE ADJUSTMENT”.
b. With the EXUP cable installed, check that
the EXUP valve is neither smoothly nor
manually moved.
• When the EXUP valve is moved smoothly,
replace the EXUP servo motor.
c. Perform the self-diagnosis mode and check
the operation of EXUP valve by visual
inspection (code number d: 53).
Refer to “DIAGNOSTIC MODE”.
15
TRACK TENSION ADJUSTMENT
INSP
ADJ
TRACK TENSION ADJUSTMENT
WARNING
A broken track or track fittings, and debris
thrown by the track could be dangerous to
an operator or bystanders. Observe the following precautions.
• Do not allow anyone to stand behind the
snowmobile when the engine is running.
• When the rear of the snowmobile is raised
to allow the track to spin, a suitable stand
must be used to support the rear of the
snowmobile. Never allow anyone to hold
the rear of the snowmobile off the ground
to allow the track to spin. Never allow anyone near a rotating track.
• Inspect the condition of the track frequently. Replace the track if it is damaged
to a level where the fabric reinforcement
material is visible.
1. Lift the rear of the snowmobile onto a suitable stand to raise the track off the ground.
2. Measure:
• Track deflection
Using a spring scale
, pull down on the
center of the track with 100 N (10 kgf, 22
lbf) of force.
Out of specification → Adjust.
Track deflection:
30.0 ~ 35.0 mm (1.18 ~ 1.38 in)
3. Adjust:
• Track deflection
Adjustment steps:
a. Place the snowmobile onto a suitable stand
to raise the track off of the ground.
b. Loosen the rear axle nut .
c. Start the engine and rotate the track once
or twice. Stop the engine.
16
TRACK TENSION ADJUSTMENT
INSP
ADJ
d. Check the track alignment with the slide
runner . If the alignment is incorrect, turn
the left and right adjusters to adjust.
Track alignment
Left adjuster
Right adjuster
Shifted to
right
Turn out
Turn in
Shifted to
left
Turn in
Turn out
Slide runner
Track
Track clip
Gap
RX10PA, RX10PSA
RX10PXTA
Forward
e. Adjust the track deflection until the specified amount is obtained.
Track deflection
Left adjuster
Right adjuster
More than Less than
specified specified
Turn in
Turn out
Turn in
Turn out
NOTICE
The adjusters should be turned an equal
amount.
f. Recheck the alignment and deflection. If
necessary, repeat steps (c) to (e) until the
specified amount is obtained.
g. Apply ESSO beacon 325 grease or Aeroshell grease #7A to the rear axle nut.
h. Tighten the rear axle nut.
Rear axle nut:
75 Nm (7.5 m•kgf, 54 ft•lbf)
17
EXTROVERT SPROCKET WHEELS
INSP
ADJ
EXTROVERT SPROCKET WHEELS
1. Inspect:
• Extrovert sprocket wheels
Cracks/damage → Replace.
2. Measure:
• Teeth
a. Measuring point
20 mm (0.79 in)
b. Extrovert sprocket wheel wear limit
Out of specification → Replace.
Extrovert sprocket wheel wear
limit :
13 mm (0.51 in)
18
LUBRICATION
INSP
ADJ
LUBRICATION
Front and rear suspension
1. Remove:
• Front cover
Refer to “FRONT SUSPENSION” in CHAPTER 3.
2. Use a grease gun to inject grease into the
nipples (both sides)
and nipples .
3. Apply grease to the pivoting parts.
Recommended lubricant:
ESSO Beacon 325 grease or
Aeroshell grease #7A
Front
Rear (RX10PA, RX10PSA)
Rear (RX10PXTA)
Nipple (both sides)
Nipple
19
CLUTCH
INSP
ADJ
TUNING
CLUTCH
The clutch may require tuning depending upon
where the snowmobile will be operated and the
desired handling characteristics. The clutch
can be tuned by changing the engagement
and shifting speeds.
Clutch engagement speed is defined as the
engine speed at which the snowmobile first
begins to move from a complete stop.
Shifting speed is defined as the engine speed
reached when the snowmobile has travelled
800 m (2,500 ft) after being started at full-throttle from a dead stop.
Normally, when a snowmobile reaches shifting
speed, the snowmobile speed increases but
the engine speed remains nearly constant.
Under unfavorable conditions (wet snow, icy
snow, hills, or rough terrain), however, engine
speed may decrease after the shifting speed
has been reached.
Engine speed
Good condition
Shifting speed
Clutch engagement speed
Starting position
Distance travelled
20
CLUTCH
INSP
ADJ
High altitude tuning
Atmospheric pressure decreases and engine
output becomes low at high altitude locations.
Because of this, clutch engagement speed and
shifting speed also decrease and unable to
maximize the engine output power. To maximize the engine output, tuning for increasing
clutch engagement speed and shifting speed
is necessary. This setting is called high altitude
tuning.
The following changes are usually performed
in high altitude tuning.
• To increase the clutch engagement and shifting speed, changing to a larger spring constant or using lighter weights and rivets.
(decreasing primary sheave thrust)
• Increasing the reduction ratio of the driven
gear/drive gear. (increasing the driving performance)
Refer to “HIGH ALTITUDE TUNING”.
Engine speed
Speed at maximum output
Low speed
Distance travelled
21
CLUTCH
INSP
ADJ
Parts that affect transmission characteristics
Among the components of the V-belt transmission, those that have direct impact on the shifting
function are described below.
Part
Primary sheave
Spring
Element
Preload
Spring rate
Weight
Shape, weight
Impact on the shifting function
• A larger preload increases the clutch engagement
speed, and the shifting speed tends to rise
accordingly. Shifting tends to become somewhat
harder. (increasing the spring reaction force)
• A smaller preload decreases the clutch engagement speed, and the shifting speed tends to drop
accordingly. Shifting tends to become somewhat
easier. (decreasing the spring reaction force)
• A larger spring rate increases the shifting speed. It
also slightly increases the clutch engagement
speed. Shifting tends to become somewhat
harder. (increasing the spring reaction force)
• A smaller spring rate decreases the shifting
speed. It also slightly decreases the clutch
engagement speed. Shifting tends to become
somewhat easier. (decreasing the spring reaction
force)
Shape and weight determine, the size of moment
about the center of the weight rotation when the
sheave is running.
• Heavier weight decreases the clutch engagement
and shifting speed. Shifting tends to become
somewhat easier. (increasing the sheave thrust)
• Lighter weight increases the clutch engagement
and shifting speed. Shifting tends to become
somewhat harder. (decreasing the sheave thrust)
22
CLUTCH
Part
Weight rivet
Element
Quantity
Material
(iron, aluminum)
Roller
Outside diameter
Shim
Quantity
Secondary sheave
Spring
Fixed sheave
Spring seat
Preload
Spring rate
(compression,
torsion)
Spring fitting hole
INSP
ADJ
Impact on the shifting function
Rivets are fastened through the hole in the weight.
• Using more rivets decreases the clutch engagement and shifting speed. Shifting tends to become
somewhat easier. (increasing the sheave thrust)
• Using less rivets increases the clutch engagement
and shifting speed. Shifting tends to become
somewhat harder. (decreasing the sheave thrust)
The outside diameter affects the contact angle with
the weight.
• A smaller diameter decreases the clutch engagement speed. (increasing the sheave thrust)
• A larger diameter increases the clutch engagement speed. (decreasing the sheave thrust)
• Using more shims increases the preload and
clutch engagement speed.
(increasing the spring reaction force)
• Using less shim decreases the preload and clutch
engagement speed.
(decreasing the spring reaction force)
• A larger preload, spring rate or twist angle
increases the shifting speed and makes shifting
somewhat harder. (increasing the sheave thrust)
• A smaller preload, spring rate or twist angle
decreases the shifting speed and makes shifting
somewhat easier.
(decreasing the sheave thrust)
One of the holes may be used selectively to change
the spring twist angle (preload).
Refer to “ Spring”.
23
CLUTCH
Part
Torque cam
(spring seat)
Element
Cam angle
Shim
Quantity
INSP
ADJ
Impact on the shifting function
The cam angle determines the degree of sensitivity
of load torque detection.
• A smaller cam angle increases sensitivity, which in
turn increases the sheave thrust to make back
shifting easier. The shifting speed tends to
increase and shifting becomes somewhat harder.
(increasing the sheave thrust)
• A larger cam angle makes back shifting harder.
The shifting speed tends to decrease and shifting
becomes somewhat easier.
(decreasing the sheave thrust)
Size of the secondary sheave clearance (between
fixed sheave and sliding sheave) can be adjusted
by the number of shims used.
Adjust the clearance when the V-belt wear deteriorates and belt width becomes smaller.
• Using more shims makes secondary sheave
clearance smaller.
• Using less shim makes secondary sheave clearance larger.
When the V-belt width is smaller, wrap-around
diameter of the V-belt on the primary sheave is
larger and clutch engagement speed is slightly
increased.
24
CLUTCH
INSP
ADJ
Primary spring
Spring
identification
color code
Actual coloring
Part
number
Blue-Blue-Blue
90501-550A2
19.6 (2.00)
196 (20)
5.5 (0.217)
59.5 (2.34)
4.89
83.4 (3.28)
Blue-Pink-Blue
90501-551L3
19.6 (2.00)
294 (30)
5.5 (0.217)
59.5 (2.34)
4.91
88.4 (3.48)
Blue-Silver-Blue
90501-551L9
19.6 (2.00)
343 (35)
5.5 (0.217)
59.5 (2.34)
4.91
90.9 (3.58)
Spring rate
N/mm
(kgf/mm)
Preload
N (kgf)
Wire
gauge
mm (in)
Outside
diameter
mm (in)
Number
of coils
Free
length
mm (in)
Blue-Green-Blue
90501-552L5
19.6 (2.00)
392 (40)
5.5 (0.217)
59.5 (2.34)
4.91
93.4 (3.68)
Yellow-Blue-Yellow
90501-580A1
24.5 (2.50)
196 (20)
5.8 (0.228)
59.5 (2.34)
4.91
81.4 (3.20)
Yellow-Pink-Yellow
90501-581L5
24.5 (2.50)
294 (30)
5.8 (0.228)
59.5 (2.34)
4.92
85.4 (3.36)
84.3 (3.32)
Green-Pink-Green
90501-581L6
27.0 (2.75)
294 (30)
5.8 (0.228)
59.5 (2.34)
4.66
Yellow-Silver-Yellow
90501-582L1
24.5 (2.50)
343 (35)
5.8 (0.228)
59.5 (2.34)
4.92
87.4 (3.44)
Green-Silver-Green
90501-582L2
27.0 (2.75)
343 (35)
5.8 (0.228)
59.5 (2.34)
4.66
86.1 (3.39)
White-Green-White
90501-582L6
22.1 (2.25)
392 (40)
5.8 (0.228)
59.5 (2.34)
5.25
91.2 (3.59)
Yellow-Green-Yellow
90501-582L7
24.5 (2.50)
392 (40)
5.8 (0.228)
59.5 (2.34)
4.92
89.4 (3.52)
Blue-White-Blue
90501-583L0
19.6 (2.00)
441 (45)
5.8 (0.228)
59.5 (2.34)
5.65
95.9 (3.78)
White-White-White
90501-583L1
22.1 (2.25)
441 (45)
5.8 (0.228)
59.5 (2.34)
5.25
93.4 (3.68)
White-Silver-White
90501-583L4
22.1 (2.25)
343 (35)
5.8 (0.228)
59.5 (2.34)
5.25
89.0 (3.50)
White-Pink-White
90501-583L5
22.1 (2.25)
294 (30)
5.8 (0.228)
59.5 (2.34)
5.25
86.7 (3.41)
Pink-Blue-Pink
90501-600A1
29.4 (3.00)
196 (20)
6.0 (0.236)
59.5 (2.34)
4.81
80.1 (3.15)
Pink-Pink-Pink
90501-601L7
29.4 (3.00)
294 (30)
6.0 (0.236)
59.5 (2.34)
4.82
83.4 (3.28)
Orange-Pink-Orange
90501-601L8
31.9 (3.25)
294 (30)
6.0 (0.236)
59.5 (2.34)
4.60
82.6 (3.25)
Pink-Silver-Pink
90501-602L3
29.4 (3.00)
343 (35)
6.0 (0.236)
59.5 (2.34)
4.82
85.1 (3.35)
Green-Green-Green
90501-602L8
27.0 (2.75)
392 (40)
6.0 (0.236)
59.5 (2.34)
5.08
87.9 (3.46)
Pink-Green-Pink
90501-602L9
29.4 (3.00)
392 (40)
6.0 (0.236)
59.5 (2.34)
4.82
86.7 (3.41)
Yellow-White-Yellow
90501-603L2
24.5 (2.50)
441 (45)
6.0 (0.236)
59.5 (2.34)
5.39
91.4 (3.60)
Green-White-Green
90501-603L3
27.0 (2.75)
441 (45)
6.0 (0.236)
59.5 (2.34)
5.08
89.8 (3.54)
Orange-Silver-Orange
90501-624L8
31.9 (3.25)
343 (35)
6.2 (0.244)
59.5 (2.34)
5.00
84.2 (3.31)
25
Standard
RX10PA,
RX10PSA,
RX10PXTA
CLUTCH
INSP
ADJ
Weight
Part number
Weight g (oz)
without bush
and rivets
8DN-17605-30
39.76 (1.403)
8ES-17605-00
54.63 (1.927)
8FN-17605-00
75.28 (2.655)
8FP-17605-00
67.81 (2.392)
8FS-17605-00
65.52 (2.312)
8GC-17605-00
47.28 (1.668)
8GL-17605-00
49.43 (1.745)
Shape & ID mark
26
Standard
INSP
ADJ
CLUTCH
Part number
Weight g (oz)
without bush
and rivets
8HF-17605-00
81.51 (2.875)
8HG-17605-00
82.96 (2.926)
Shape & ID mark
Standard
RX10PA, RX10PSA,
RX10PXTA
Weight rivet
Part
number
Material
Length
mm (in)
Weight
g (oz)
Standard
90261-06033
Steel
17.2 (0.677)
4.5 (0.159)
CENTER: RX10PA, RX10PSA, RX10PXTA
90269-06006
Steel
with hole
17.2 (0.677)
3.6 (0.127)
IN: RX10PA, RX10PSA, RX10PXTA
90261-06034
Steel
13.9 (0.547)
3.6 (0.127)
90261-06019
Steel
13.3 (0.524)
3.1 (0.109)
OUT: RX10PXTA
90266-06002
Steel
with hole
13.3 (0.524)
2.44 (0.086)
OUT: RX10PA, RX10PSA
90261-06015
Steel
10.3 (0.406)
2.44 (0.086)
90261-06028
Aluminum
10.3 (0.406)
0.85 (0.030)
90266-06001
Aluminum
with hole
13.3 (0.524)
0.85 (0.030)
Effects
Increased
force
Decreased
force
27
CLUTCH
INSP
ADJ
Roller
I.D. 9 mm (0.354 in)
Roller with
bushing part
number
Outside
diameter
mm (in)
Identification mark
(Width)
Standard
Effects
Grooved & Machined
8FG-17624-00
Increased
force
RX10PA, RX10PSA,
RX10PXTA
14.5 (0.571)
(14.6 mm [0.57 in])
Grooved
8FG-17624-10
15.0 (0.591)
(14.6 mm [0.57 in])
No Mark
8FG-17624-20
15.6 (0.614)
(14.6 mm [0.57 in])
Grooved & Grooved
8FG-17624-30
16.0 (0.630)
(14.6 mm [0.57 in])
Machined
8FG-17624-40
16.5 (0.650)
Decreased
force
(14.6 mm [0.57 in])
Shim (primary sheave)
Part number
Thickness mm (in)
90201-483P9
Standard
1.0 (0.039)
RX10PA, RX10PSA,
RX10PXTA
None
28
CLUTCH
INSP
ADJ
Secondary sheave spring
Spring rate
Spring
identification
color code
Actual coloring
Part number
Torsion
N•mm/rad
(kgf•mm/rad)
Compression
N/mm (kgf/mm)
(lbf/in)
Wire
gauge
mm (in)
No. of
coils
Free
length
mm (in)
Outside
diameter
mm (in)
69.5 (2.74)
Brown
90508-500B1
6003 (613)
6.2 (0.63), 35.40
5.0 (0.197)
5.19
75 (2.95)
Red
90508-536A9
7147 (729)
7.3 (0.74), 41.68
5.3 (0.209)
5.53
75 (2.95)
69.5 (2.74)
Green
90508-556A2
8314 (848)
8.5 (0.87), 48.53
5.5 (0.217)
5.53
75 (2.95)
69.5 (2.74)
Silver
90508-556A7
9460 (965)
10.2 (1.04), 58.24
5.5 (0.217)
4.86
75 (2.95)
69.5 (2.74)
Pink
90508-60012
11876 (1211)
12.3 (1.26), 70.23
6.0 (0.236)
5.53
75 (2.95)
69.5 (2.74)
Pink-Pink
90508-60018
11876 (1211)
12.3 (1.26), 70.23
6.0 (0.236)
5.53
75 (2.95)
69.5 (2.74)
White
90508-60007
12654 (1290)
13.5 (1.38) 77.08
6.0 (0.236)
5.19
75 (2.95)
69.5 (2.74)
White-White
90508-60016
12654 (1290)
13.5 (1.38) 77.08
6.0 (0.236)
5.19
75 (2.95)
69.5 (2.74)
Standard
RX10PA,
RX10PSA,
RX10PXTA
Secondary spring twist angle
Seat
0
3
6
9
1
10°
40°
70°*
100°
2
20°
50°
80°
110°
3
30°
60°
90°
120°
Sheave
*:
Standard
RX10PA, RX10PSA, RX10PXTA
29
CLUTCH
INSP
ADJ
Torque cam (secondary spring seat)
Identification mark
Part number
Cam angle
8BVFA
8FA-17604-00
51°-43°
8BV71
8BV-17604-71
47°
8BV51
8BV-17604-51
45°
8BV31
8BV-17604-31
43°
8BV11
8BV-17604-11
41°
8BV91
8BV-17604-91
39°
Standard
RX10PA,
RX10PSA,
RX10PXTA
Effects
Quicker
up shifting during
acceleration
Quicker
back shifting
under load
Shim (secondary sheave)
Part number
Thickness mm (in)
90201-061H1
0.5 (0.020)
90201-06037
1.0 (0.039)
30
Standard
RX10PA, RX10PSA,
RX10PXTA
GEAR SELECTION
INSP
ADJ
GEAR SELECTION
The reduction ratio of the driven gear to the drive gear must be set according to where the snowmobile will be operated and driving conditions. If the load on the snowmobile is big such as driving at
high altitude mountain or towing, the driven/drive gear ratio should be increased. If the load on the
snowmobile is small such as driving on the fairly smooth surfaces or hard-compacted snow,
decrease the ratio.
Chain and sprocket
The drive and driven gears and the chains shown in the gear ratio chart are available as options.
Part name
Teeth & links
Drive sprocket
Driven sprocket
Chain
Part number
Standard
18 teeth
8FA-17682-80
19 teeth
8FA-17682-90
20 teeth
8FA-17682-00
21 teeth
8FA-17682-10
22 teeth
8FA-17682-20
23 teeth
8FA-17682-30
RX10PXTA
24 teeth
8FA-17682-40
RX10PA, RX10PSA
37 teeth
8FB-47587-70
RX10PA, RX10PSA, RX10PXTA
38 teeth
8FB-47587-80
39 teeth
8FB-47587-90
40 teeth
8FB-47587-00
68 links
94890-09068
RX10PXTA
70 links
94890-09070
RX10PA, RX10PSA
Gear ratio
The figures containing a decimal point represent the driven/drive gear ratios, while the bottom numbers designate the number of links in the chain.
Drive gear
18 teeth 19 teeth 20 teeth 21 teeth 22 teeth 23 teeth 24 teeth
Driven gear
1.76
68 links
1.68
1.61
1.54
68 links 68 links 70 links
1.90
1.81
68 links 68 links
1.73
1.65
1.58
68 links 70 links 70 links
39 teeth
2.17
2.05
1.95
1.86
68 links 68 links 68 links 68 links
1.77
1.70
1.63
70 links 70 links 70 links
40 teeth
2.22
2.11
2.00
1.90
68 links 68 links 68 links 70 links
1.82
1.74
1.67
70 links 70 links 70 links
37 teeth
—
—
38 teeth
—
—
—
31
INSP
ADJ
HIGH ALTITUDE TUNING
HIGH ALTITUDE TUNING
Specifications
Model: RX10PA, RX10PSA
~ 800 m
(~ 2,500 ft)
Elevation
Production
specification
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)
←
←
←
Standard
Engine idle speed
1,550 ~ 1,650
r/min
←
Engagement speed
Approx. 3,400
r/min
←
Shift speed
Approx. 10,500
r/min
←
Secondary reduction
ratio (number of links)
24/37 (70 L)
←
Primary sheave
spring
90501-551L9
←
←
←
90501-624L8
Color*
L-S-L
←
←
←
O-S-O
Free length
90.9 mm (3.58 in)
←
←
←
84.2 mm (3.31 in)
Preload
343 N (35 kgf,
77 lbf)
←
←
←
←
Spring rate
19.6 N/mm
(2.00 kgf/mm,
111.9 lbf/in)
←
←
←
31.9 N/mm
(3.25 kgf/mm,
182.2 lbf/in)
Wire diameter
5.5 mm (0.217 in)
←
←
←
6.2 mm (0.244 in)
Outside diameter
59.5 mm (2.34 in)
←
←
←
←
8HG-17605-00
(8HG00)
←
←
←
←
Steel with hole
13.3 (OUT)
←
←
←
Weight (ID)
Weight rivet
Approx. 3,600
r/min
←
23/37 (68 L)
None (OUT)
Steel 17.2
(CENTER)
Steel with hole
13.3 (CENTER)
Steel with hole
17.2 (IN)
Steel 13.3 (IN)
←
Steel with hole
13.3 (IN)
←
Approx. 3,800
r/min
←
←
←
22/37 (68 L)
None (CENTER)
←
None (IN)
←
Roller outer diameter
14.5 mm (0.571 in)
←
←
←
←
Primary sheave shim
None
←
←
←
←
Secondary sheave
spring
90508-60012
←
←
←
←
P
←
←
←
←
Free length
75 mm (2.95 in)
←
←
←
←
Preload rate
70° (1-6)
11,876 N•mm/rad
(1,211 kgf•mm/rad)
←
←
←
←
Wire diameter
6.0 mm (0.236 in)
←
←
←
←
Outside diameter
69.5 mm (2.74 in)
←
←
←
←
Secondary torque
cam angle
51°–43°
←
←
←
←
Secondary sheave
shim
1.0 mm (0.039 in)
←
←
←
←
Color*
*: Color code
L
P
Blue
Pink
O Orange
S Silver
32
INSP
ADJ
HIGH ALTITUDE TUNING
Specifications
Model: RX10PXTA
~ 800 m
(~ 2,500 ft)
Elevation
Production
specification
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)
←
←
←
Standard
Engine idle speed
1,550 ~ 1,650
r/min
←
Engagement speed
Approx. 3,400
r/min
←
Shift speed
Approx. 10,500
r/min
←
Secondary reduction
ratio (number of links)
23/37 (68 L)
←
Primary sheave
spring
90501-551L9
←
←
←
90501-624L8
L-S-L
←
←
←
O-S-O
Free length
90.9 mm (3.58 in)
←
←
←
84.2 mm (3.31 in)
Preload
343 N (35 kgf,
77 lbf)
←
←
←
←
Spring rate
19.6 N/mm
(2.00 kgf/mm,
111.9 lbf/in)
←
←
←
31.9 N/mm
(3.25 kgf/mm,
182.2 lbf/in)
Wire diameter
5.5 mm (0.217 in)
←
←
←
6.2 mm (0.244 in)
Outside diameter
59.5 mm (2.34 in)
←
←
←
←
8HG-17605-00
(8HG00)
←
←
←
←
←
←
Color*
Weight (ID)
Weight rivet
Approx. 3,600
r/min
←
22/37 (68 L)
Steel 13.3 (OUT)
Steel with hole
13.3 (OUT)
None (OUT)
Steel 17.2
(CENTER)
Steel 13.3
(CENTER)
Steel with hole
13.3 (CENTER)
Steel with hole
17.2 (IN)
Steel 13.3 (IN)
←
←
Approx. 3,800
r/min
←
←
←
21/37 (68 L)
None (CENTER)
←
None (IN)
←
Roller outer diameter
14.5 mm (0.571 in)
←
←
←
←
Primary sheave shim
None
←
←
←
←
Secondary sheave
spring
90508-60012
←
←
←
←
Color*
P
←
←
←
←
Free length
75 mm (2.95 in)
←
←
←
←
Preload rate
70° (1-6)
11,876 N•mm/rad
(1,211 kgf•mm/rad)
←
←
←
←
Wire diameter
6.0 mm (0.236 in)
←
←
←
←
Outside diameter
69.5 mm (2.74 in)
←
←
←
←
Secondary torque
cam angle
51°–43°
←
←
←
←
Secondary sheave
shim
1.0 mm (0.039 in)
←
←
←
←
*: Color code
L
P
Blue
Pink
O Orange
S Silver
33
INSP
ADJ
FRONT SUSPENSION
FRONT SUSPENSION
Spring Preload
RX10PA, RX10PXTA
WARNING
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or
attempt to open the shock absorber assemblies.
Do not subject the shock absorber assemblies to open flame or high heat, which
could cause it to explode.
1. Adjust:
• Spring preload
Adjustment steps:
• Loosen the locknut .
• Turn the spring seat
in or out.
NOTICE
Be sure that the left and right spring preloads are the same.
RX10PA
Spring seat
distance
Preload
Length
Standard
Short ←
Hard ←
Minimum
→ Long
→ Soft
Maximum
242.5 mm 252.5 mm
(9.55 in)
(9.94 in)
264.5 mm
(10.41 in)
RX10PXTA
Spring seat
distance
Preload
Length
Standard
Short ←
Hard ←
Minimum
247.0 mm
(9.72 in)
• Tighten the locknut
→ Long
→ Soft
Maximum
257.0 mm
(10.12 in)
257.0 mm
(10.12 in)
.
Shock absorber spring preload
adjusting locknut:
42 Nm (4.2 m•kgf, 30 ft•lbf)
34
FRONT SUSPENSION
INSP
ADJ
Air Pressure
RX10PSA
NOTICE
The left and right shock absorber air pressure must be set to the same setting.
Uneven settings can cause poor handling
and loss of stability.
This snowmobile is equipped with FOX shock
absorbers as standard equipment.
The air pressure of the shock absorbers can
be adjusted using the shock absorber pump
included with your snowmobile.
This shock absorber pump has low pressure
gauge
and high pressure gauge .
Low pressure gauge measuring range:
0 kPa (0 kgf/cm², 0 psi) to 620 kPa
(6.2 kgf/cm², 90 psi)
High pressure gauge measuring range:
0 kPa (0 kgf/cm², 0 psi) to 2,068 kPa
(20.7 kgf/cm², 300 psi)
Adjustment steps:
WARNING
Support the snowmobile securely on a suitable stand before adjusting the shock
absorbers.
NOTICE
Make sure that there is no load on the
shock absorbers and that they are fully
extended before making any air pressure
adjustments.
• Place the snowmobile on a level surface and
apply the parking brake.
• Lift the front of the snowmobile onto a suitable stand to raise the skis off the ground.
• Remove the air valve cap
from the shock
absorber.
35
FRONT SUSPENSION
INSP
ADJ
• Install the hose connector
of the shock
absorber pump to the shock absorber air
valve.
TIP
When installing, make sure the shock absorber
pump lever
is down as shown in the illustration.
NOTICE
Do not overtighten the connector onto the
air valve as this will damage the connector
seal.
• Lift up the shock absorber pump lever
.
TIP
• Use the low pressure gauge
of the shock
absorber pump and measure.
• If the shock absorber has no air pressure, the
gauge reading will be zero.
• To increase the air pressure, operate the
pump a few times. The pressure should
increase slowly. If the pressure increases
rapidly, check to make sure that the pump is
properly connected and tightened onto the air
valve. To decrease the air pressure, push the
bleed valve button .
TIP
To allow pressure to escape from the pump
and the shock absorber, push the button halfway down and hold it. To allow only a small
amount of pressure to escape, push the button
all the way down and quickly release it.
• Lay flat the shock absorber pump lever.
• Remove the hose connector from the air
valve.
TIP
When removing the connector, the sound of air
escaping may be heard, but this is from the
pump hose, not the shock absorber.
Air pressure range:
448 ~ 1,034 kPa (4.5 ~ 10.3 kgf/cm²,
65 ~ 150 psi)
Standard air pressure:
586 kPa (5.9 kgf/cm², 85 psi)
36
FRONT SUSPENSION
INSP
ADJ
NOTICE
Do not exceed 1,034 kPa (10.3 kgf/cm², 150
psi).
• Install the air valve cap.
TIP
If the front suspension bottoms too easily or
rolls too much during cornering, increase the
air pressure by 34 kPa (0.3 kgf/cm², 5 psi). If
the suspension is too firm and you want a
more compliant ride, decrease the air pressure
by 34 kPa (0.3 kgf/cm², 5 psi).
37
REAR SUSPENSION
INSP
ADJ
REAR SUSPENSION
Limiter strap
1. Adjust:
• Limiter strap length
NOTICE
Make sure the left and right rear suspension limiter straps are adjusted evenly.
(RX10PXTA)
TIP
This adjustment affects the handling characteristics of the snowmobile.
Adjustment steps:
• Remove the limiter strap bolts
, nuts and
washers.
• Adjust the length of the limiter strap
by
inserting the bolts in different holes.
Standard setting:
No. 1 hole
• Tighten the limiter strap nuts.
Limiter strap nut:
4.0 Nm (0.40 m•kgf, 2.9 ft•lbf)
RX10PA, RX10PSA
RX10PXTA
38
INSP
ADJ
REAR SUSPENSION
Choosing other settings:
NOTICE
The standard settings work well under
most general riding conditions. The suspension can be adjusted to work better in
one condition, but only at the expense of
another. Keep this in mind when you adjust
the suspension.
: No. 5 hole
: No. 4 hole
(shortest)
More weight on skis:
• Heavy steering/
oversteer
• More maneuverability
Favors: hardpack
snow, ice, smooth
trails, tight turns
No. 1 hole
(longest)
Less weight on skis:
• Light steering/
understeer
• Better acceleration
and speed
Favors: deep snow,
straight line acceleration, top speed
RX10PA, RX10PSA
RX10PXTA
Spring preload
WARNING
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or
attempt to open the shock absorber assembly.
Do not subject the shock absorber assembly to open flame or high heat, which could
cause it to explode.
39
INSP
ADJ
REAR SUSPENSION
1. Adjust:
• Spring preload
Adjustment steps:
Front side
RX10PXTA
• Loosen the locknut .
• Adjust the spring preload by turning the
spring seat .
Spring
Standard
seat
→ Long
distance Short ←
Preload Hard ←
→ Soft
Min.
Max.
Length
181.0 mm 191.0 mm 207.0 mm
(7.13 in)
(7.52 in)
(8.15 in)
• Tighten the locknut
.
Shock absorber spring preload
adjusting locknut:
42 Nm (4.2 m•kgf, 30 ft•lbf)
40
INSP
ADJ
REAR SUSPENSION
Rear side
RX10PA
• Turn the adjusting ring
tion.
Spring adjuster
1
position
Preload
2
tool
3
4
Soft ←
Standard
RX10PXTA
• Turn the adjuster
to the proper posi-
5
6
7
→ Hard
4
to proper position by the
.
Spring preload
adjuster
position
Spring preload
Standard
S
M
H
Soft
Medium
M
Hard
WARNING
Always adjust both spring preload (left and
right) to the same setting. Uneven adjustment can cause poor handling and loss of
stability.
41
INSP
ADJ
REAR SUSPENSION
Rebound damping force
RX10PA
The rebound damping force can be adjusted
by turning the rebound damping force remote
adjustment dial
in direction
“HARD” or
direction
“SOFT”.
Standard position
WARNING
Do not turn the remote adjustment dial
while the snowmobile is moving as this
could cause loss of control, an accident,
and injury.
22 clicks
Dial
position
“MAX SOFT”
Direction
Damping
force
Soft ←
0 click
0 click
Standard
*←
“MAX HARD”
→ Direction
→ Hard
* With the adjustment dial fully turned lightly in
direction .
NOTICE
Be sure to stop the remote adjustment dial
at a marked position around the dial where
there is a click.
WARNING
This shock absorber contains highly pressurized nitrogen gas. It could explode by
improper handling, causing injury, or property damage.
• Do not tamper with or attempt to open the
shock absorber.
• Do not subject the shock absorber to an
open flame or other high heat source,
which could cause it to explode.
• Do not deform or damage the shock
absorber in any way.
42
INSP
ADJ
REAR SUSPENSION
Compression damping force
RX10PXTA
Adjust the damping force by turning the adjusting knob .
12 clicks out 6 clicks out 2 clicks out
Adjusting
knob
position
Minimum
Direction
CompresSoft ←
sion force
Standard
*←
Maximum
→ Direction
→ Hard
* With the adjusting knob fully turned lightly in
direction .
NOTICE
• Do not continue to turn the adjusting knob
in direction
after it stops. The shock
absorber can be damaged and compression damping force adjustments cannot
be made.
• Do not turn the adjusting knob in direction
more than 12 clicks. Even if the adjusting knob is continually turned after 12
clicks, there will be no change in the compression damping force.
• Be sure to stop the adjusting knob at a
position where there is a click.
WARNING
This shock absorber contains highly pressurized nitrogen gas. It could explode by
improper handling, causing injury, or property damage.
• Do not tamper with or attempt to open the
shock absorber.
• Do not subject the shock absorber to an
open flame or other high heat source,
which could cause it to explode.
• Do not deform or damage the shock
absorber in any way.
43
REAR SUSPENSION
INSP
ADJ
Air pressure
RX10PSA
This snowmobile is equipped with FOX shock
absorbers as standard equipment.
The air pressure of the shock absorbers can
be adjusted using the shock absorber pump
included with your snowmobile.
This shock absorber pump has low pressure
gauge
and high pressure gauge .
Low pressure gauge measuring range:
0 kPa (0 kgf/cm², 0 psi) to 620 kPa
(6.2 kgf/cm², 90 psi)
High pressure gauge measuring range:
0 kPa (0 kgf/cm², 0 psi) to 2,068 kPa
(20.7 kgf/cm², 300 psi)
Adjustment steps:
WARNING
Support the snowmobile securely on a suitable stand before adjusting the shock
absorbers.
NOTICE
Make sure that there is no load on the
shock absorbers and that they are fully
extended before making any air pressure
adjustments.
• Place the snowmobile on a level surface and
apply the parking brake.
• Lift the rear of the snowmobile onto a suitable
stand to raise the track off the ground.
• Remove the air valve cap
from the shock
absorber.
• Install the hose connector
of the shock
absorber pump to the shock absorber air
valve.
TIP
When installing, make sure the shock absorber
pump lever
is down as shown in the illustration.
NOTICE
Do not overtighten the connector onto the
air valve as this will damage the connector
seal.
44
REAR SUSPENSION
INSP
ADJ
• Lift up the shock absorber pump lever
.
TIP
• When measuring the front shock absorber,
use the low pressure gauge
of the shock
absorber pump and measure.
• When measuring the rear shock absorber,
use the high pressure gauge
of the shock
absorber pump and measure.
• If the shock absorber has no air pressure, the
gauge reading will be zero.
• To increase the air pressure, operate the
pump a few times. The pressure should
increase slowly. If the pressure increases
rapidly, check to make sure that the pump is
properly connected and tightened onto the air
valve. To decrease the air pressure, push the
bleed valve button .
TIP
To allow pressure to escape from the pump
and the shock absorber, push the button halfway down and hold it. To allow only a small
amount of pressure to escape, push the button
all the way down and quickly release it.
• Lay flat the shock absorber pump lever.
• Remove the hose connector from the air
valve.
TIP
When removing the connector, the sound of air
escaping may be heard, but this is from the
pump hose, not the shock absorber.
Air pressure range:
965 ~ 1,551 kPa (9.7 ~ 15.5 kgf/cm²,
140 ~ 225 psi)
Standard air pressure:
1,138 kPa (11.4 kgf/cm², 165 psi)
45
INSP
ADJ
REAR SUSPENSION
NOTICE
Do not exceed 1,551 kPa (15.5 kgf/cm², 225
psi).
• Install the air valve cap.
TIP
If the slide rail suspension bottoms too easily,
increase the air pressure by 34 kPa (0.3 kgf/
cm², 5 psi). If the suspension is too firm and
you want a more compliant ride, decrease the
air pressure by 34 kPa (0.3 kgf/cm², 5 psi).
Control rod
RX10PA, RX10PSA
The weight transfer can be adjusted by turning
the control rod adjuster .
1. Adjust:
• Control rod stroke
Adjustment steps:
• Loosen the locknut .
• Turn the control rod adjuster
in direction
or
to adjust the control rod stroke.
Adjusting
position
Effect
MIN
Decrease
Pitching
STD
←
MAX
→
Standard Fourth mark to the left of MAX
46
Increase
weight
transfer
REAR SUSPENSION
INSP
ADJ
• Check the adjuster length
using the
scale on the special wrench
included in
the owner’s tool kit as shown. Make sure
that the rim
of the control rod body is
within the range
of the scale.
• While holding the adjuster securely, tighten
the locknut.
Control rod adjusting locknut:
35 Nm (3.5 m•kgf, 25 ft•lbf)
NOTICE
When using the special wrench, make sure
that it is situated at a right angle to the control rod, and that it is tightly fitted to the
locknut or the control rod adjuster.
WARNING
Never adjust the control rod beyond the
range of the scale on the special wrench.
RX10PXTA
The weight transfer can be adjusted by turning
the control rod adjusting nut .
1. Adjust:
• Control rod stroke
Adjustment steps:
• Loosen the locknut
while holding the control rod adjusting nut .
• To increase weight transfer, turn the adjusting
nut in direction . To decrease weight transfer, turn the adjusting nut in direction .
Adjusting
nut position
Effect
Standard
47
1
2
Increase
←
weight
transfer
3
→
1
Decrease
weight
transfer
REAR SUSPENSION
INSP
ADJ
• Tighten the locknut.
Control rod adjusting locknut:
25 Nm (2.5 m•kgf, 18 ft•lbf)
NOTICE
The left and right adjusting nut must be set
to the same position. Uneven settings can
cause poor handling and loss of stability.
WARNING
Never adjust the control rods beyond the
maximum range indicated on the rods with
red paint .
48
TROUBLESHOOTING (SKI, SUSPENSION)
INSP
ADJ
TROUBLESHOOTING (SKI, SUSPENSION)
This section will point you towards possible solutions for resolving handling or ride comfort complaints. When making adjustments, do it in a small increments. Also, in general, making just one
adjustment may not correct the problem. You may need to make several small adjustments to get
the best overall results.
Keep in mind that how the snowmobile handles going down the trail is usually controlled by the front
suspension, the center shock, and the limiter straps. How the snowmobile rides (ride comfort) is
usually controlled by the rear shock.
Also, remember that snowmobile suspension adjustments may involve compromises. Tuning a
snowmobile to do one thing very well may come at the sacrifice of something else. For example, if
the snowmobile is setup to provide optimum weight transfer for best acceleration, this same setting
will not be ideal for trail riding, because excessive under steering may be experienced during cornering. You must have a good working knowledge of the suspension and tune the suspension to
provide best overall balance for specific conditions and usages.
SYMPTOM DESCRIPTION
POSSIBLE CAUSE
Front of the snowmobile darts • Too much weight on skis.
from side to side on a straightaway.
• Skis out of alignment.
• Loose steering ball joints.
• Too much carbide on ski runners.
Under steering – front end
• Worn or missing carbides on
(skis) pushes when cornering. ski runners.
• Not enough weight on skis.
POSSIBLE REMEDY
• Extend limiter straps and/or
increase center shock spring
preload or reduce rear shock
spring preload or reduce front
shock spring preload.
• Adjust “ski-toe-out.”
• Replace worn ball joints.
• Use ski runners with less carbide.
• Replace carbide runners.
• Reduce center shock spring
preload and/or shorten limiter
straps. Increase front shock
spring preload.
Over steering. Front end (skis) • Too much weight on skis.
• Extend limiter straps and/or
bites too much during cornerincrease center shock spring
ing – rear of the snowmobile
preload or reduce rear shock
starts to come around.
spring preload or reduce front
shock spring preload.
• Too much carbides on ski run- • Use ski runners with less carners.
bides.
Heavy steering – excessive
• Too much weight on skis.
• Extend limiter straps and/or
force is needed to turn the
increase center shock spring
handlebars.
preload or reduce rear shock
spring preload or reduce front
shock spring preload.
• Too much carbides on ski run- • Use ski runners with less carners.
bides.
• Steering linkage binding.
• Clean and lubricate steering
ball joints and column.
49
TROUBLESHOOTING (SKI, SUSPENSION)
SYMPTOM DESCRIPTION
Front suspension bottoming
out frequently.
POSSIBLE CAUSE
• Not enough front shock spring
preload and/or spring used is
too soft.
• Blown shock absorbers (oil
leaking out of shocks).
• Loss of nitrogen gas pressure
in the shocks.
Front suspension is too harsh • Too much front shock spring
over small bumps.
preload and/or the spring used
is too stiff.
• The shock absorber oil is contaminated.
Front suspension bouncing
• Blown shock absorbers (oil
over bumps.
leaking out of shocks).
• Loss of nitrogen gas pressure
in the shocks.
Excessive inside ski lift during • Stabilizer bar binding or damcornering. Front end is tippy.
aged joint linkage bushings.
Rear suspension bottoming
out frequently.
Rear suspension bouncing
over bumps (feels like spring
only).
INSP
ADJ
POSSIBLE REMEDY
• Increase spring preload and/or
select stiffer springs.
• Replace shocks.
• Replace shocks.
• Reduce spring preload and/or
select softer spring.
• Replace shocks.
• Replace shocks.
• Replace shocks.
• Check for free movement of
stabilizer bar. Check the condition of the joint linkage bushing
and replace as necessary.
• Control rod adjusted to pro• Adjust control rod to allow less
vide too much weight transfer.
weight transfer.
• Too much front shock spring
• Reduce spring preload and/or
preload and/or the spring used select a softer spring.
is too stiff.
• Center shock limiter straps are • Shorten limiter straps.
too long.
• Not enough rear shock spring • Increase rear spring preload
preload and/or the spring used (set rear spring preload for coris too soft.
rect ride height). If necessary,
select stiffer springs.
• Blown shock absorbers (oil
• Replace shocks.
leaking out of shocks).
• Loss of nitrogen gas pressure • Replace shocks.
in the shocks.
• Blown shock absorbers (oil
• Replace shocks.
leaking out of shocks).
• Loss of nitrogen gas pressure • Replace shocks.
in the shocks.
50
TROUBLESHOOTING (SKI, SUSPENSION)
SYMPTOM DESCRIPTION
Rear suspension is too harsh
over small bumps.
Not enough weight transfer.
Track won’t hook up.
POSSIBLE CAUSE
• Too much rear/center shock
spring preload and/or the
spring used is too stiff.
INSP
ADJ
POSSIBLE REMEDY
• Reduce rear/center spring preload (set rear spring preload
for correct ride height). If necessary, select softer spring.
• Shock absorber oil is contami- • Replace shocks.
nated.
• Rear suspension linkages and/ • Inspect for free movement of
or pivot arms binding.
rear suspension linkages and
arms. Replace damaged components and apply grease to all
pivot areas.
• Limiter straps length has been • Lengthen limiter straps length.
shortened.
• Control rod adjustment does
• Adjust control rod to allow
not provide enough weight
more weight transfer.
transfer.
• Not enough center shock
• Increase center shock spring
spring preload and/or the limpreload and lengthen limiter
iter straps are too short.
straps.
• Too much rear shock spring
• Reduce rear shock spring prepreload.
load.
51
GENERAL CHASSIS
CHAS
CHASSIS
GENERAL CHASSIS
WINDSHIELD AND HEADLIGHT
0.4 Nm (0.04 m•kgf, 0.29ft•lbf)
1.5 Nm (0.15 m•kgf, 1.1 ft•lbf)
3.0 Nm (0.30 m•kgf, 2.2 ft•lbf)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job name/Part name
Windshield and headlight removal
Windshield
Fairing
Top cover
Main switch coupler
Auxiliary DC jack coupler
Main switch
Auxiliary DC jack
Headlight cover
Headlight side cover
Speedometer coupler
Speedometer
Headlight coupler
Headlight
Q’ty
1
2
1
1
1
1
1
1
2
1
1
2
1
Remarks
Remove the parts in the order listed below.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
52
GENERAL CHASSIS
CHAS
AIR FILTER CASE
3.0 Nm (0.30 m•kgf, 2.2 ft•lbf)
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Air filter case removal
Headlight
Shroud
Side cover (left and right)
Intake air temperature sensor coupler
Intake air temperature sensor
Air filter case cover
Crankcase breather hose 1
Air filter element frame
Air filter element
Air filter case joint clamp screw
Crankcase breather hose 2
ISC (idle speed control) unit inlet hose
Air filter case
Q’ty
Remarks
Remove the parts in the order listed below.
Refer to “GENERAL CHASSIS”.
Refer to “COWLINGS” in CHAPTER 3.
1
1
1
1
1
1
4
1
1
1
Disconnect.
Loosen.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
53
GENERAL CHASSIS
CHAS
SEAT AND TAIL/BRAKE LIGHT
1.0 Nm (0.10 m•kgf, 0.72 ft•lbf)
8 Nm (0.8 m•kgf, 5.8 ft•lbf)
1.5 Nm (0.15 m•kgf, 1.1 ft•lbf)
30 Nm (3.0 m•kgf, 22 ft•lbf)
Order
1
2
3
4
5
6
7
Job name/Part name
Seat and fuel tank removal
Fuel tank side cover (right)
Seat
Tail/brake light coupler
Rear cover
Muffler end cap
Muffler side cover
Tail/brake light cover
Tail/brake light
Q’ty
1
1
1
2
2
1
1
Remarks
Remove the parts in the order listed below.
Refer to “FUEL TANK” in CHAPTER 5.
Disconnect.
For installation, reverse the removal
procedure.
54
STEERING
CHAS
STEERING
STEERING
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
23 Nm (2.3 m•kgf, 17 ft•lbf)
25 Nm (2.5 m•kgf, 18 ft•lbf)
30 Nm (3.0 m•kgf, 22 ft•lbf)
35 Nm (3.5 m•kgf, 25 ft•lbf)
67 Nm (6.7 m•kgf, 48 ft•lbf)
205 Nm (20.5 m•kgf, 148 ft•lbf)
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Q’ty
Remarks
Steering column and tie rod removal
Remove the parts in the order listed below.
Fuel tank
Refer to “FUEL TANK” in CHAPTER 5.
Oil tank
Refer to “OIL TANK” in CHAPTER 5.
Shift lever assembly
Refer to “DRIVE CHAIN HOUSING” in
CHAPTER 4.
Clip
3
Relay rod
1
Cotter pin
12
Steering shaft
1
Lock washer
2
Bearing
4
Bearing holder
4
Plate
2
Collar
4
Steering column 1
1
55
STEERING
CHAS
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
23 Nm (2.3 m•kgf, 17 ft•lbf)
25 Nm (2.5 m•kgf, 18 ft•lbf)
30 Nm (3.0 m•kgf, 22 ft•lbf)
35 Nm (3.5 m•kgf, 25 ft•lbf)
67 Nm (6.7 m•kgf, 48 ft•lbf)
205 Nm (20.5 m•kgf, 148 ft•lbf)
Order
11
12
13
14
15
16
17
18
19
20
21
22
23
Job name/Part name
EPS motor cover
Steering column 2
Pitman arm
EPS motor
Tie rod
Idler arm
Clip
Washer
Washer
Collar
Bushing
Collar
Relay arm
Q’ty
1
1
1
1
2
1
2
4
2
2
4
2
2
Remarks
For installation, reverse the removal
procedure.
56
STEERING
CHAS
REMOVAL
1. Straighten the lock washer tabs.
INSPECTION
1. Inspect:
• Handlebar
• Steering column 1
• Steering column 2
• Pitman arm
• EPS motor splines
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent column.
This may dangerously weaken the column.
2. Inspect:
• Bearings (steering column)
• Collars
Wear/damage → Replace.
• Steering column 1
(bearing contact surfaces)
• Steering column 2
(bearing contact surfaces)
Scratches/wear/damage → Replace.
57
STEERING
CHAS
3. Inspect:
• Relay rod
• Tie rods
• Steering shaft
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten bent rods. This
may dangerously weaken the rods.
4. Check:
• Rod end movement
Rod end free play exists → Replace the rod
end.
Rod end turns roughly → Replace the rod
end.
5. Inspect:
• Right relay arm
• Left relay arm
• Idler arm
Cracks/damage → Replace.
• Bearings
Wear/damage → Replace.
INSTALLATION
1. Install:
• Relay arms
• Bushings
• Washers
• Clips
Relay arm bolt:
67 Nm (6.7 m•kgf, 48 ft•lbf)
58
STEERING
CHAS
2. Install:
• Idler arm
• Bushings
• Washers
• Relay rod
• Locknuts
• Joints
Relay rod part
number
8HG-23821-00
Set
length
183.3 mm
(7.22 in)
Shaft
length
125.3 mm
(4.93 in)
NOTICE
Always use new cotter pins.
TIP
Install the idler arm with the “R” mark
on the
right side facing towards the rear of the snowmobile.
Idler arm nut:
35 Nm (3.5 m•kgf, 25 ft•lbf)
Relay arm-relay rod nut:
30 Nm (3.0 m•kgf, 22 ft•lbf)
3. Install:
• Tie rod
• Locknuts
• Joints
Tie rod part
number
8ES-23831-00
59
Set
length
424.0 mm
(16.69 in)
Tie rod
length
361.0 mm
(14.21 in)
STEERING
CHAS
4. Install:
• Tie rods
TIP
Make sure that the indentation
rod faces out.
on the tie
NOTICE
• After tightening the inside and outside ball
joint locknut , make sure the tie rod
can be rotated freely through the ball joint
travel. If not, loosen the locknut
and reposition the ball joint so that the tie rod
can be rotated freely.
Tighten the locknut to specification.
• Always use new cotter pins.
Tie rod end locknut:
25 Nm (2.5 m•kgf, 18 ft•lbf)
LOCTITE®
Tie rod-idler arm nut:
30 Nm (3.0 m•kgf, 22 ft•lbf)
Tie rod-steering arm nut:
35 Nm (3.5 m•kgf, 25 ft•lbf)
60
STEERING
CHAS
5. Install:
• Pitman arm
TIP
Align the punch mark
on the EPS unit with
the groove
in the pitman arm.
• Nut
Pitman arm nut
205 Nm (20.5 m•kgf, 148 ft•lbf)
NOTICE
Always use new cotter pin.
TIP
Restrict the rotation of the pitman arm and
then tighten the nut.
6. Install (temporary tighten):
• EPS motor
• Steering column 2
TIP
Align the punch mark
on the EPS unit with
the groove
in the steering column 2.
• Bearing
• Collar
• Plate
• Bearing holder
• Lock washer
61
STEERING
CHAS
7. Tighten:
(Tighten in the order below.)
1.EPS motor nut
EPS motor nut
30 Nm (3.0 m•kgf, 22 ft•lbf)
2.Bearing holder nut
Bearing holder nut
23 Nm (2.3 m•kgf, 17 ft•lbf)
3.Steering column 2 bolt
Steering column 2 bolt
35 Nm (3.5 m•kgf, 25 ft•lbf)
LOCTITE®
NOTICE
Always use new cotter pins.
8. Bend:
1.Bending the lock washer tabs
62
STEERING
CHAS
9. Install:
• Steering shaft
• Locknuts
• Joints
Steering Shaft
part number
8FA-23828-00
Set
length
227.8 mm
(8.97 in)
Shaft
length
169.8 mm
(6.69 in)
TIP
• Install the pink-colored end of the joint
to
the steering column 1.
• Install the “C” measure side of the steering
shaft to the steering column 1.
50 mm (1.97 in)
65 mm (2.56 in)
NOTICE
Always use new cotter pins.
Steering shaft end locknut:
25 Nm (2.5 m•kgf, 18 ft•lbf)
LOCTITE®
Steering shaft nut:
35 Nm (3.5 m•kgf, 25 ft•lbf)
63
STEERING
CHAS
10.Adjust:
• Skis
Adjustment steps:
• Temporarily install the handlebar.
• Hold the handlebar straight and check that
the skis and relay arms are at right angles to
the handlebar.
• Install the steering linkage alignment plate
to the relay arms .
Steering linkage alignment plate:
YS-01487
Steering link holder:
90890-01487
• Loosen the locknuts (steering shaft) .
• Turn the steering shaft
left to right and
adjust the handle so that it is set in a straight
line.
Turning the steering
shaft in direction
Turning the steering
shaft in direction
Turning the
handlebar
in direction
Turning the
handlebar
in direction
• Tighten the locknuts (steering shaft)
.
Steering shaft locknut:
25 Nm (2.5 m•kgf, 18 ft•lbf)
LOCTITE®
• Adjust each angle of right and left skis by
turning the tie rod respectively.
• Measure the ski toe-out.
Refer to “STEERING SYSTEM” in CHAPTER
2.
• Remove the steering linkage alignment plate
(steering link holder) .
64
STEERING
CHAS
11.Install:
• Handlebar
• Handlebar holders
NOTICE
First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
TIP
• The handlebar holders should be installed
with the punch marks
facing forward.
• Align the match mark
on the handlebar
with the upper surface of the steering joint.
Handlebar holder bolt:
23 Nm (2.3 m•kgf, 17 ft•lbf)
65
POWR
TR
SLIDE RAIL SUSPENSION
POWER TRAIN
SLIDE RAIL SUSPENSION
Control rod part numbers (RX10PA, RX10PSA)
Control rod 1
part number
8JA-4745A-00
Length
mm (in)
277.3 (10.92)
Control rod 2
part number
Length
359.5 ~ 360.5
(14.15 ~ 14.19)
Washer plate part number
Washer plate thickness mm (in)
8GM-47384-10
15.0 (0.59)
8JA-4745B-00
Standard position
66
mm (in)
SLIDE RAIL SUSPENSION
POWR
TR
Control rod part numbers (RX10PXTA)
Control rod 1
RX10PXTA
Control rod 1
part number
8HL-4745A-00
Standard position
Length
mm (in)
Length
238.3 (9.38)
8ES-4745D-00
mm (in)
Washer part numbers
Washer thickness mm (in)
Upper
Q’ty
9020225001
2.0 (0.079)
1
9020124015
2.0 (0.079)
1
Plastic washer
67
Length
2.5P × 2 = 5
(0.098P × 2 = 0.196)
199.7 (7.86)
Control rod stopper
part number
Metal washer
mm (in)
Lower
90202-25001
2.0 (0.079)
Q’ty
1
SLIDE RAIL SUSPENSION
POWR
TR
INSPECTION
1. Inspect:
• Track
• Track clips
Wear/cracks/damage → Replace.
2. Inspect:
• Sprocket wheels
Wear/break/damage → Replace.
• Front axle
Bends/scratches (excessive)/damage →
Replace.
3. Inspect:
• Bearing
Pitting/damage → Replace.
INSTALLATION
1. Install:
• Track clips
(to the track
)
TIP
Install the track clip installer
and track clip
on the track as shown in the illustration.
Track clip installer:
YS-91045-C
90890-01533
outside
68
SLIDE RAIL SUSPENSION
POWR
TR
2. Install:
• Sprocket wheels
TIP
• When pressing the sprocket wheels onto the
front axle, align the “R” mark
and “L” mark
on the sprocket wheels as shown in the
illustration.
• When pressing the sprocket wheels onto the
front axle, align the arrow mark on each
sprocket wheel.
• Position each sprocket wheel on the axle as
shown in the illustration.
3. Place the track in the chassis.
TIP
For track with a direction of rotation mark :
Install the track with the mark pointing in the
direction of track rotation.
4. Install:
• Bearing holder
TIP
Align the punch mark
with the rivet .
69
on the bearing holder
EXHAUST PIPE AND MUFFLER
ENG
ENGINE
EXHAUST PIPE AND MUFFLER
Order
2.0 Nm (0.20 m•kgf, 1.5 ft•lbf)
16 Nm (1.6 m•kgf, 12 ft•lbf)
6 Nm (0.6 m•kgf, 4.3 ft•lbf)
18 Nm (1.8 m•kgf, 13 ft•lbf)
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
20 Nm (2.0 m•kgf, 14 ft•lbf)
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
25 Nm (2.5 m•kgf, 18 ft•lbf)
Job name/Part name
Exhaust pipe and muffler removal
Q’ty
Slide rail suspension
1
2
3
4
5
6
7
Shroud
Left side cover
Seat
Fuel tank
EXUP servo motor coupler
EXUP maintenance window cover
EXUP valve pulley cover
EXUP servo motor
EXUP servo motor pulley cover
EXUP cable (black metal)
EXUP cable (white metal)
Remarks
Remove the parts in the order listed
below.
Refer to “SLIDE RAIL SUSPENSION” in
CHAPTER 4.
Refer to “COWLINGS” in CHAPTER 3.
1
1
1
1
1
1
1
70
Refer to “GENERAL CHASSIS”.
Refer to “FUEL TANK” in CHAPTER 5.
Disconnect.
EXHAUST PIPE AND MUFFLER
Order
8
9
10
11
12
13
14
15
16
17
18
19
20
ENG
2.0 Nm (0.20 m•kgf, 1.5 ft•lbf)
16 Nm (1.6 m•kgf, 12 ft•lbf)
6 Nm (0.6 m•kgf, 4.3 ft•lbf)
18 Nm (1.8 m•kgf, 13 ft•lbf)
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
20 Nm (2.0 m•kgf, 14 ft•lbf)
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
25 Nm (2.5 m•kgf, 18 ft•lbf)
Job name/Part name
Muffler cover plate
Muffler cover
Muffler band bolt
Muffler
Muffler band
Muffler gasket
Exhaust pipe joint cover
Exhaust pipe band
Exhaust pipe joint
Exhaust pipe gasket
Exhaust pipe joint gasket
Frame protector
Exhaust pipe
Q’ty
1
1
1 Loosen.
1
1
1
1
4
4
4
1
2
1
71
Remarks
EXHAUST PIPE AND MUFFLER
Order
21
22
23
24
25
26
27
ENG
2.0 Nm (0.20 m•kgf, 1.5 ft•lbf)
16 Nm (1.6 m•kgf, 12 ft•lbf)
6 Nm (0.6 m•kgf, 4.3 ft•lbf)
18 Nm (1.8 m•kgf, 13 ft•lbf)
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
20 Nm (2.0 m•kgf, 14 ft•lbf)
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
25 Nm (2.5 m•kgf, 18 ft•lbf)
Job name/Part name
EXUP cable holder
EXUP valve housing
EXUP valve pulley
Plate
Collar
Spring
EXUP valve
Q’ty
1
1
1
1
1
1
1
Remarks
For installation, reverse the removal
procedure.
72
EXHAUST PIPE AND MUFFLER
ENG
INSTALLATION
1. Assemble:
• Collar
• EXUP valve
• EXUP valve housing
• Spring
• Plate
• Collar
• EXUP valve pulley
• Washer
• EXUP valve nut
Assembly steps:
• Install the collar to the EXUP valve and then,
install the EXUP valve to the EXUP valve
housing.
• Install the spring, plate, collar, EXUP valve
pulley, washer, and EXUP valve nut to the
EXUP valve housing.
TIP
Before installation, set the plate and collar to
the EXUP valve pulley.
EXUP valve nut:
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
2. Install:
• Gasket
• EXUP valve assembly
TIP
• Install the gasket with tabs
down and
install the EXUP valve housing with boss
up.
• Temporarily tighten the EXUP valve housing
bolt , do not torque them at this point.
73
EXHAUST PIPE AND MUFFLER
ENG
3. Install:
• EXUP cable holder
TIP
• Align the projection
on the EXUP valve
housing
with the hole
in the EXUP
cable holder.
• Temporarily tighten the EXUP valve housing
bolts , do not torque them at this point.
4. Tighten:
• EXUP valve housing bolts
EXUP valve housing bolt:
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
5. Install:
• Exhaust pipe
(temporarily)
• Frame protectors
TIP
Install the exhaust pipe to the brackets
on
the frame, making sure to position it as far
rearward as possible, and then temporarily
tighten the exhaust pipe bolts.
Frame protector bolt:
16 Nm (1.6 m•kgf, 12 ft•lbf)
74
EXHAUST PIPE AND MUFFLER
ENG
6. Install:
• Exhaust pipe joint gasket
• Exhaust pipe joints
Exhaust pipe joint bolt:
25 Nm (2.5 m•kgf, 18 ft•lbf)
• Exhaust pipe gaskets
• Exhaust pipe bands
TIP
• After installing the exhaust pipe joints, fit the
exhaust pipe into them.
• Temporarily tighten the exhaust pipe band
bolts, do not torque them at this point.
7. Install:
• Muffler gasket
(to muffler)
TIP
When installing the muffler gasket, insert it
with the carbon side
facing to the rear of the
snowmobile.
8. Install:
• Muffler band
• Muffler
TIP
• Align the projection
on the muffler band
with the slot
on the muffler.
• During installation, projection
of the muffler band should not make contact with end
of the muffler gasket.
• Temporarily tighten the muffler band bolt and
muffler bolts; do not torque them at this point.
75
EXHAUST PIPE AND MUFFLER
ENG
9. Tighten:
• Exhaust pipe band bolts
Exhaust pipe band bolt:
18 Nm (1.8 m•kgf, 13 ft•lbf)
10.Install:
• Exhaust pipe joint cover
Exhaust pipe joint cover bolt:
6 Nm (0.6 m•kgf, 4.3 ft•lbf)
11.Tighten:
• Exhaust pipe bolts (front side)
• Exhaust pipe bolts (rear side)
Exhaust pipe bolt (front side):
25 Nm (2.5 m•kgf, 18 ft•lbf)
Exhaust pipe bolt (rear side):
16 Nm (1.6 m•kgf, 12 ft•lbf)
12.Tighten:
• Muffler bolts
Muffler bolt:
16 Nm (1.6 m•kgf, 12 ft•lbf)
TIP
Before tightening muffler bolts
center of the bolt with the marks
fler seating surface.
76
, align the
on the muf-
EXHAUST PIPE AND MUFFLER
ENG
13.Tighten:
• Muffler band bolt
Muffler band bolt:
20 Nm (2.0 m•kgf, 14 ft•lbf)
14.Install:
• Muffler cover
• Muffler cover plate
Muffler cover nut:
16 Nm (1.6 m•kgf, 12 ft•lbf)
Muffler cover plate bolt:
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
15.Install:
• EXUP cable (white metal)
• EXUP cable (black metal)
(to EXUP servo motor)
Installation steps:
• Install the EXUP cable (white metal) to the
EXUP servo motor pulley . (Install it on the
side with embossed number “2” .)
• Install the EXUP cable (black metal) to the
EXUP servo motor pulley. (Install it on the
side with embossed number “1” .)
• Install the EXUP servo motor pulley cover
and EXUP servo motor pulley cover bolt.
EXUP servo motor pulley cover
bolt:
2.0 Nm (0.20 m•kgf, 1.5 ft•lbf)
16.Install
• EXUP servo motor
EXUP servo motor bolt:
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
77
EXHAUST PIPE AND MUFFLER
ENG
17.Install:
• EXUP cable (white metal)
• EXUP cable (black metal)
(to EXUP valve pulley )
TIP
• Cross the EXUP cable (black metal) and
EXUP cable (white metal) between the EXUP
servo motor and frame clamp once . Route
the cables to the EXUP cable holder with the
EXUP cable (black metal) on the top in the
frame clamp area .
• First install the EXUP cable (white metal) to
the EXUP valve pulley , and then install the
EXUP cable (black metal) to the EXUP valve
pulley.
EXUP servo motor
18.Tighten:
• EXUP cable locknuts
EXUP cable locknut:
6 Nm (0.6 m•kgf, 4.3 ft•lbf)
19.Adjust:
• EXUP cable
Refer to “EXUP CABLE ADJUSTEMENT”.
20.Install:
• EXUP valve pulley cover
EXUP valve pulley cover bolt:
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
78
CAMSHAFTS
ENG
CAMSHAFTS
INSPECTION
1. Inspect:
• Camshaft lobes
Blue discoloration/pitting/scratches
Replace the camshaft.
→
2. Measure:
• Camshaft lobe dimensions
and
• Out of specification → Replace the camshaft.
Camshaft dimensions:
Intake:
<Limit>:
32.851 mm (1.2933 in)
24.862 mm (0.9788 in)
Exhaust:
<Limit>:
33.500 mm (1.3189 in)
24.856 mm (0.9786 in)
3. Measure:
• Camshaft runout
Out of specification → Replace.
Camshaft runout:
0.03 mm (0.0012 in)
79
CAMSHAFTS
ENG
4. Measure:
• Camshaft-journal-to-camshaft-cap
clearance
Out of specification → Measure the camshaft journal diameter.
Camshaft-journal-to-camshaftcap clearance:
0.028 ~ 0.062 mm
(0.0011 ~ 0.0024 in)
Measurement steps:
• Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
• Position a strip of Plastigauge®
onto the
camshaft journal.
• Install the dowel pins and camshaft caps.
TIP
• Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the inner
caps out.
• Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge®.
Camshaft cap bolt:
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
• Remove the camshaft caps and then measure the width of the Plastigauge® .
80
CAMSHAFTS
ENG
5. Measure:
• Camshaft journal diameter
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and the camshaft caps as a set.
Camshaft journal diameter:
24.459 ~ 24.472 mm
(0.9630 ~ 0.9635 in)
6. Inspect:
• Camshaft sprocket
More than 1/4 tooth
wear → Replace
the camshaft sprockets and the timing
chain as a set.
1/4 tooth
Correct
Timing chain
Camshaft sprocket
7. Inspect:
• Timing chain guide (exhaust side
and
top side )
Damage/wear → Replace the timing chain
guide.
81
CAMSHAFTS
ENG
8. Inspect:
• Timing chain tensioner
Cracks/damage → Replace.
Inspection steps:
• Using a hand press, push and insert timing
chain tensioner rod
into the timing chain
tensioner housing.
TIP
Push the timing chain tensioner rod in direction
, and turn the timing chain tensioner body
in direction
until it stops.
Hand press
Bearing
• Keep pressing the timing chain tensioner rod,
mount clip
into groove
, and lock the
timing chain tensioner rod.
• Push the timing chain tensioner rod in direction .
• Make sure that the timing chain tensioner rod
can smoothly move out from the timing chain
tensioner housing in direction
. If not
smooth, replace the timing chain tensioner
assembly.
9. Inspect:
• All parts
Damage/wear → Replace the defective
part (-s).
82
CAMSHAFTS
ENG
INSTALLATION
1. Install:
• Exhaust camshaft
• Intake camshaft
TIP
Install the camshafts with the punch mark
facing up.
2. Install:
• Dowel pins
• Intake camshaft caps
• Exhaust camshaft caps
TIP
Make sure that the punch marks
on the
camshafts are aligned with the arrow marks
on the camshaft caps.
Out of alignment → Reinstall.
3. Install:
• Camshaft cap bolts
Camshaft cap bolt:
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
TIP
Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the inner
caps out.
NOTICE
The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
83
CAMSHAFTS
ENG
4. Install:
• Intake camshaft sprocket
• Exhaust camshaft sprocket
Installation steps:
• Turn the crankshaft counterclockwise.
• When piston #4 is at TDC on the compression stroke, align the “I” mark
on the AC
magneto rotor with the stationary pointer
on the AC magneto rotor cover.
• Place the timing chain onto both camshaft
sprockets and then install the camshaft
sprockets onto the camshafts.
TIP
When installing the camshaft sprockets, start
with the exhaust camshaft and be sure to keep
the timing chain as tight as possible on the
exhaust side.
NOTICE
Do not turn the crankshaft when installing
the camshaft sprockets to avoid damage or
improper valve timing.
• Make sure that the punch marks
on the
camshafts are aligned with the arrow marks
on the camshaft caps.
• While holding the camshafts, tighten the
camshaft sprocket bolts.
Camshaft sprocket bolt:
24 Nm (2.4 m•kgf, 17 ft•lbf)
84
CAMSHAFTS
ENG
5. Install:
• Timing chain tensioner gasket
• Timing chain tensioner
Installation steps:
• Using a hand press, push and insert timing
chain tensioner rod
into the timing chain
tensioner housing.
TIP
Push the timing chain tensioner rod in direction
, and turn the timing chain tensioner body
in direction
until it stops.
Hand press
Bearing
• Pressing and holding the timing chain
tensioner rod, set clip
to groove
and
then lock the timing chain tensioner rod.
• With the timing chain tensioner rod locked,
install the timing chain tensioner to the cylinder block.
TIP
Always use a new gasket.
Timing chain tensioner bolt:
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
• Unlock the timing chain tensioner by turning
the crankshaft clockwise, and tension the timing chain.
6. Turn:
• Crankshaft
(several turns counterclockwise)
85
CAMSHAFTS
ENG
7. Inspect:
Inspection steps:
• “I” mark
Make sure that the “I” mark on the AC magneto rotor is aligned with the stationery
pointer
on the AC magneto rotor cover.
• Camshaft punch marks
Make sure that the punch marks
on the
camshafts are aligned with the arrow marks
on the camshaft caps.
Out of alignment → Adjust.
Refer to the installation steps above.
8. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “VALVE CLEARANCE ADJUSTMENT” in CHAPTER 2.
86
CRANKCASE
ENG
CRANKCASE
10 Nm (1.0 m•kgf, 7.2 ft•lbf)
12 Nm (1.2 m•kgf, 8.7 ft•lbf)
27 Nm (2.7 m•kgf, 20 ft•lbf)
1st 15 Nm (1.5 m•kgf, 11 ft•lbf)
2nd 15 Nm (1.5 m•kgf, 11 ft•lbf)
Final Specified angle 65-70°
Tighten these bolts first.
Order
Tighten these bolts second.
Job name/Part name
Crankcase separate
Q’ty
Engine
Cylinder head
AC magneto rotor/Starter clutch gear
1
2
3
4
5
6
Oil pump
Water pump
Starter motor
Knock sensor
Water pump outlet hose/Joint
Countershaft cover
Dowel pin
Lower crankcase
Dowel pin
Remarks
Remove the parts in the order listed
below.
Refer to “ENGINE ASSEMBLY”.
Refer to “CYLINDER HEAD”.
Refer to “AC MAGNETO ROTOR AND
STARTER CLUTCH”.
Refer to “OIL PAN AND OIL PUMP”.
Refer to “WATER PUMP”.
Refer to “STARTER MOTOR”.
1
1/1
1
2
1
2
For installation, reverse the removal
procedure.
∗ Yamaha bond No.1215 (Three bond No. 1215®)
87
FUEL INJECTION SYSTEM
FI
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
Ignition coil
Spark plug
Thumb warmer adjustment switch
Fuel pump
Fuel tank
Grip warmer adjustment switch
Fuel injection system
relay
Speed sensor
Engine trouble warning light
Fuel hose
Cylinder identification
sensor
Throttle position sensor
Intake
temperature
sensor
88
Atmospheric pressure
sensor
Fuel injector
Oil pressure switch
ECU
Knock sensor
Battery
Intake air pressure
sensor
Oil level switch
Intake silencer
Crankshaft
position
sensor
Coolant temperature
sensor
FUEL INJECTION SYSTEM
WIRING DIAGRAM
89
FI
FUEL INJECTION SYSTEM
Crankshaft position sensor
Main switch
Main fuse
Fuel injection system fuse
Starter relay
Battery
Engine stop switch
Throttle switch
Grip warmer
Thumb warmer
Grip warmer adjustment switch
Thumb warmer adjustment
switch
Oil pressure switch
CO adjustment coupler
ECU (engine control unit)
Ignition coil sub-wire harness
Cylinder-#1 ignition coil
Spark plug
Cylinder-#2 ignition coil
Cylinder-#3 ignition coil
Cylinder-#4 ignition coil
Fuel injection system relay
Fuel pump
Injector #1
Injector #2
Injector #3
Injector #4
Throttle position sensor
Speed sensor
Cylinder identification sensor
Atmospheric pressure sensor
Intake air pressure sensor
Coolant temperature sensor
Intake air temperature sensor
Knock sensor
ISC (idle speed control) unit
EXUP servo motor
Speedometer unit
Multi-function meter
Warning light
Radiator fan motor
Radiator fan motor relay
Ignition fuse
Radiator fan motor fuse
90
FI
FI
FUEL INJECTION SYSTEM
ECU SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system
is operating normally. If this function detects a malfunction in the system, it immediately operates the
engine under substitute characteristics and the warning light and self-diagnostic warning indicator
on the upper LCD flash to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an
appropriate substitute characteristic operation, and the warning light and self-diagnostic warning
indicator on the upper LCD flash to alert the rider of the detected malfunction.
• The lowest fault code number appears on the lower LCD. Once a fault code has been displayed,
it remains stored in the memory of the ECU until it is deleted.
SELF-DIAGNOSTIC FUNCTION TABLE
If the ECU detects an abnormal signal from a sensor while the snowmobile is being driven, the
warning light and self-diagnostic warning indicator on the upper LCD flash to alert the rider that a
malfunction has occurred and the ECU provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that
are programmed for each sensor in order to provide the engine with alternate operating instructions
that enable the engine to continue to operate or stop operating, depending on the conditions.
Self-Diagnostic-Function table
Fault code
No.
Item
Cylinder identification sensor
11
12
13
14
15
16
17
18
20
21
22
Symptom
No normal signals are received from
the cylinder identification sensor.
Crankshaft position sensor
No normal signals are received from
the crankshaft position sensor.
Intake air pressure sensor (cylin- No normal signals are received from
ders #1, #2, #3, and #4) (open or the intake air pressure sensor.
short circuit)
Intake air pressure sensor (cylin- Intake air pressure sensor: hose sysders #1, #2, #3, and #4) (hose tem malfunction (clogged or detached
line)
hose).
Intake air system failure (the pressure
is not supplied to the intake air pressure sensor in a stable condition.)
Throttle position sensor (open or No normal signals are received from
short circuit)
the throttle position sensor.
Throttle position sensor (stuck)
Signal from throttle position sensor will
not change.
EXUP servo motor circuit (open or No normal signals are received from
short circuit)
the EXUP servo motor circuit.
EXUP servo motor (stuck)
Signal from EXUP servo motor position
will not change.
Intake air pressure or atmospheric When turning the main switch to “ON”,
pressure
the voltage value shows great difference between the intake air pressure
sensor and atmospheric pressure sensor.
Coolant
temperature
sensor No normal signals are received from
(open or short circuit)
the coolant temperature sensor.
Intake air temperature sensor No normal signals are received from
(open or short circuit)
the intake air temperature sensor.
91
Able/unable
to start
Unable
Able/unable
to drive
Able
(under certain
conditions)
Unable
Unable
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
FUEL INJECTION SYSTEM
Fault code
No.
23
30
33
34
35
36
37
42
43
44
46
50
65
80
81
82
83
84
85
Item
Symptom
FI
Able/unable
to start
Atmospheric pressure sensor No normal signals are received from
Able
(open or short circuit)
the atmospheric pressure sensor.
Oil pressure dropped
Detection of the low oil pressure signal
Unable
Cylinder-#1 ignition coil (faulty No normal signals are received from
Able
ignition)
the ignition circuit.
(depending on
the number of
faulty
cylinders)
Cylinder-#2 ignition coil (faulty No normal signals are received from
Able
ignition)
the ignition circuit.
(depending on
the number of
faulty
cylinders)
Cylinder-#3 ignition coil (faulty No normal signals are received from
Able
ignition)
the ignition circuit.
(depending on
the number of
faulty
cylinders)
Cylinder-#4 ignition coil (faulty No normal signals are received from
Able
ignition)
the ignition circuit.
(depending on
the number of
faulty cylinders)
ISC (idle speed control) valve Engine speed is high when the engine
Able
(stuck fully open)
is idling.
Speed sensor
No normal signals are received from
Able
the speed sensor.
Fuel system voltage (monitor volt- ECU is unable to monitor the battery
age)
voltage (an open or short circuit in the
Able
line to the ECU).
Error in writing the amount of CO Error is detected while reading or writUnder certain
adjustment on EEPROM
ing on EEPROM (CO adjustment
conditions
value).
Snowmobile system power supply The rectifier/regulator does not funcAble
(monitor voltage)
tion properly.
ECU internal malfunction (mem- Faulty ECU memory. (When this malory check error)
function is detected in the ECU, the
Unable
fault code number might not appear on
the meter.)
Knock sensor (open or short cir- No normal signals are received from
Able
cuit)
the knock sensor.
Grip warmer switch (short circuit) No normal signals are received from
Able
the grip warmer switch.
Grip warmer
Grip warmer: open or short circuit
Able
detected.
Thumb warmer switch (short cir- No normal signals are received from
Able
cuit)
the thumb warmer switch.
Thumb warmer (short circuit)
Thumb warmer: short circuit detected.
Able
T.O.R.S.
Conditions requiring T.O.R.S. operation
Able
are detected.
Oil pressure switch (open circuit) Oil pressure switch: open circuit
Able
detected.
92
Able/unable
to drive
Able
Unable
Able
(depending on
the number of
faulty
cylinders)
Able
(depending on
the number of
faulty
cylinders)
Able
(depending on
the number of
faulty
cylinders)
Able
(depending on
the number of
faulty cylinders)
Able
Unable
Able
Under certain
conditions
Able
Unable
Able
Able
Able
Able
Able
Unable
Able
FI
FUEL INJECTION SYSTEM
Communication error with the meter
Fault code
No.
Er-1
Er-2
Er-3
Er-4
Item
Symptom
ECU internal malfunction (output No signals are received from the ECU.
signal error)
ECU internal malfunction (output
signal error)
ECU internal malfunction (output
signal error)
ECU internal malfunction (input
signal error)
No signals are received from the ECU
within the specified signal time.
Data from the ECU cannot be received
correctly.
Non-registered data has been received
from the meter.
93
Able/unable
Able/unable
to start
to drive
Able or unable Able or unable
when ECU is when ECU is
defective
defective
Able
Able
Able
Able
Able
Able
FI
FUEL INJECTION SYSTEM
TROUBLESHOOTING CHART
Engine operation is not normal or the warning light and self-diagnostic warning indicator on the LCD flash.
* The warning light and self-diagnostic warning indicator on the upper LCD may not flash even if the engine
operation is not normal.
The warning light and self-diagnostic warning indicator on the upper LCD flash.
The warning light and self-diagnostic warning indicator on the upper LCD does not flash.
Check the fault code number displayed on the meter.
Check the operation of the following sensors and
actuators in the diagnostic mode. (Refer to “Diagnostic mode table”.)
d:01:Throttle position sensor (throttle angle)
d:02:Atmospheric pressure
d:03:Intake air pressure
d:05:Intake air temperature
d:06:Coolant temperature
d:07:Snowmobile speed pulse
d:09:Fuel system voltage (battery voltage)
d:30:Cylinder-#1 ignition coil
d:31:Cylinder-#2 ignition coil
d:32:Cylinder-#3 ignition coil
d:33:Cylinder-#4 ignition coil
d:36:Injector #1
d:37:Injector #2
d:38:Injector #3
d:39:Injector #4
Identify the system with the malfunction. (Refer to
“Self-Diagnostic-Function table”.)
Identify the probable cause of the malfunction.
(Refer to “Fault code table”.)
Check and repair the probable cause of the malfunction.
Fault code No.
No fault code No.
Check and repair.
Check and repair.
(Refer to “TROUBLESHOOTING
DETAILS”.)
Monitor the operation
of the sensors and actuators in the diagnostic mode. (Refer to
“Diagnostic mode table”.)
OK
Perform the fuel injection system reinstatement
action. (Refer to “Reinstatement method” in
“TROUBLESHOOTING DETAILS”.)
NG
Engine malfunction
Defective sensor or
actuator
Check and repair
the inner parts of the
engine. (Refer to
CHAPTER 5.)
Check and repair the
corresponding sensor or actuator.
OK
NG
OK
Check the engine condition.
Turn the main switch off, turn the main switch
back on, and then check if the fault code number
is still displayed.
Fault code number
displayed
OK
Fault code number not displayed
Repairs completed
Erasing the malfunction history:*
The malfunction history is stored even if the main switch is turned off.
The malfunction history must be erased in the diagnostic mode. (Refer to the “Diagnostic mode table (Diagnostic code No. 62)”.)
* Operated when the warning light and self-diagnosis warning indicator flash.
94
FUEL INJECTION SYSTEM
FI
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators without
connecting the measurement equipment by
simply switching the meter indication from the
normal mode to the diagnostic monitoring
mode.
Setting the diagnostic mode
1. Turn the main switch off and set the engine
stop switch to “RUN”.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Simultaneously press and hold the
“SELECT” and “RESET” buttons, turn the
main switch on, and continue to press the
buttons for 8 seconds or more.
TIP
• All displays on the LCDs disappear except
the clock display.
• “dI” appears on the clock display.
4. Check that “dI” appears, and then simultaneously press the “SELECT” and “RESET”
buttons for 2 seconds or more to activate
the diagnostic mode. The diagnostic code
number “d:01” appears on the clock display.
5. Select the diagnostic code number corresponding to the fault code number by
pressing the “SELECT” and “RESET” buttons.
TIP
• To decrease the selected diagnostic code
number, press the “RESET” button. Press the
“RESET” button for 1 second or longer to
automatically decrease the diagnostic code
numbers.
• To increase the selected diagnostic code
number, press the “SELECT” button. Press
the “SELECT” button for 1 second or longer
to automatically increase the diagnostic code
numbers.
95
FUEL INJECTION SYSTEM
FI
6. Verify the operation of the sensor or actuator.
• Sensor operation
The data representing the operating conditions of the sensor appears on the
odometer/tripmeter/fuel reserve tripmeter/
oil change tripmeter/display.
• Actuator operation
Push the grip warmer side of the grip/
thumb warmer adjustment switch to operate the actuator.
If the grip warmer side of the switch is
pushed again while the actuator is operating, the actuator operation will stop and
restart from the beginning.
7. Turn the main switch off to cancel the diagnostic mode.
TIP
To perform a reliable diagnosis, make sure to
turn off the power supply before every check
and then start right from the beginning.
96
FUEL INJECTION SYSTEM
FI
Fault code table
Fault
code No.
11
Symptom
No normal signals are
received from the cylinder
identification sensor.
No normal signals are
received from the crankshaft
position sensor.
12
13
14
15
No normal signals are
received from the intake air
pressure sensor.
Intake air pressure sensor:
hose system malfunction
(clogged or detached hose).
Intake air system failure (the
pressure is not supplied to the
intake air pressure sensor in a
stable condition)
No normal signals are
received from the throttle position sensor.
Signal from throttle position
sensor will not change.
16
17
18
20
Probable cause of malfunction
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Coupler defective between sensor – ECU.
Open or short circuit in wire harness.
Defective cylinder identification sensor.
Malfunction in pickup rotor.
Malfunction in ECU.
Improperly installed cylinder identification sensor.
Coupler defective between sensor – ECU.
Open or short circuit in wire harness.
Defective crankshaft position sensor.
Malfunction in pickup rotor (primary sheave drive shaft
assembly).
Malfunction in ECU.
Improperly installed crankshaft position sensor.
Coupler defective between sensor – ECU.
Open or short circuit in wire harness.
Defective intake air pressure sensor.
Malfunction in ECU.
• Intake air pressure sensor hoses are detached, clogged,
kinked, or pinched.
• Defective intake air pressure sensor.
•
•
•
•
•
•
•
•
•
No normal signals are
•
received from the EXUP servo •
motor circuit.
•
•
Signal from EXUP servo motor •
position will not change.
•
•
•
•
•
When turning the main switch
•
to “ON”, the voltage value
•
shows great difference
between the intake air pres•
sure sensor and atmospheric
pressure sensor.
Coupler defective between sensor – ECU.
Open or short circuit in wire harness.
Defective throttle position sensor.
Malfunction in ECU.
Improperly installed throttle position sensor.
Defective throttle position sensor.
Improperly installed throttle position sensor.
Mechanical connection malfunction between sensor – throttle body.
Malfunction in ECU.
Coupler defective between motor – ECU.
Open or short circuit in wire harness.
Defective EXUP servo motor.
Malfunction in ECU.
Coupler defective between motor – ECU.
Open or short circuit in wire harness.
Improperly installed EXUP servo motor.
Defective EXUP cable.
Defective EXUP servo motor. (stuck)
Malfunction in ECU.
Malfunction in ECU.
Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.
Defective intake air pressure sensor or atmospheric pressure
sensor.
97
Diagnostic
code No.
—
—
d:03
d:03
d:01
d:01
d:53
d:53
d:02
d:03
FUEL INJECTION SYSTEM
Fault
code No.
21
22
23
30
33
34
35
36
37
Symptom
FI
Probable cause of malfunction
No normal signals are
• Coupler defective between sensor – ECU.
received from the coolant tem- • Open or short circuit in wire harness.
perature sensor.
• Defective coolant temperature sensor.
• Malfunction in ECU.
• Improperly installed coolant temperatue sensor.
No normal signals are
• Coupler defective between sensor – ECU.
received from the intake air
• Open or short circuit in wire harness.
temperature sensor.
• Defective intake air temperature sensor.
• Malfunction in ECU.
• Improperly installed intake air temperatue sensor.
No normal signals are
• Coupler defective between sensor – ECU.
received from the atmo• Open or short circuit in wire harness.
spheric pressure sensor.
• Improperly installed atmospheric pressure sensor.
• Defective atmospheric pressure sensor.
• Malfunction in ECU.
Detection of the low oil pres• Oil pressure dropped.
sure signal
• Defective oil pressure switch.
No normal signals are
• Coupler defective between cylinder-#1 ignition coil – ECU.
received from the ignition cir- • Open or short circuit in wire harness.
cuit.
• Open or short circuit in ignition system sub-wire harness.
• Improperly installed cylinder-#1 ignition coil.
• Malfunction in cylinder-#1 ignition coil.
• Malfunction in ECU.
• Malfunction in a component of ignition system.
No normal signals are
• Coupler defective between cylinder-#2 ignition coil – ECU.
received from the ignition cir- • Open or short circuit in wire harness.
cuit.
• Open or short circuit in ignition system sub-wire harness.
• Improperly installed cylinder-#2 ignition coil.
• Malfunction in cylinder-#2 ignition coil.
• Malfunction in ECU.
• Malfunction in a component of ignition system.
No normal signals are
• Coupler defective between cylinder-#3 ignition coil – ECU.
received from the ignition cir- • Open or short circuit in wire harness.
cuit.
• Open or short circuit in ignition system sub-wire harness.
• Improperly installed cylinder-#3 ignition coil.
• Malfunction in cylinder-#3 ignition coil.
• Malfunction in ECU.
• Malfunction in a component of ignition system.
No normal signals are
• Coupler defective between cylinder-#4 ignition coil – ECU.
received from the ignition cir- • Open or short circuit in wire harness.
cuit.
• Open or short circuit in ignition system sub-wire harness.
• Improperly installed cylinder-#4 ignition coil.
• Malfunction in cylinder-#4 ignition coil.
• Malfunction in ECU.
• Malfunction in a component of ignition system.
Engine speed is high when the • Coupler defective between ISC – ECU.
engine is idling.
• Open or short circuit in wire harness.
• Defective speed sensor.
• Malfunction in throttle valve.
• Malfunction in throttle cable.
• ISC hose is detached, clogged, kinked, or pinched.
• Improperly installed ISC unit.
• ISC valve is stuck fully open due to disconnected ISC unit
hose or coupler. (High engine idle speed is detected with the
ISC valve stuck fully open even though signals for the valve
to close are continuously being transmitted by the ECU.)
• Malfunction in ECU.
98
Diagnostic
code No.
d:06
d:05
d:02
—
d:30
d:31
d:32
d:33
d:54
FUEL INJECTION SYSTEM
Fault
code No.
42
43
44
46
50
65
80
Symptom
No normal signals are
received from the speed
sensor.
ECU is unable to monitor the
battery voltage (an open or
short circuit in the line to the
ECU).
Error is detected while reading
or writing on EEPROM (CO
adjustment value).
The rectifier/regulator does
not function properly.
Faulty ECU memory. (When
this malfunction is detected in
the ECU, the fault code
number might not appear on
the meter.)
No normal signals are
received from the knock sensor.
No normal signals are
received from the grip warmer
switch.
Grip warmer: open or short
circuit detected.
81
82
No normal signals are
received from the thumb
warmer switch.
Thumb warmer: short circuit
detected.
83
Conditions requiring T.O.R.S.
operation are detected.
84
Oil pressure switch: open
circuit detected.
85
Er-1
No signals are received from
the ECU.
FI
Probable cause of malfunction
•
•
•
•
•
•
•
Open or short circuit in sensor – ECU.
Defective speed sensor.
Malfunction in ECU.
Open or short circuit in main relay – ECU.
Open circuit in ECU monitor voltage lead.
Defective main relay.
Malfunction in ECU.
Diagnostic
code No.
d:07
d:09
• Malfunction in ECU. (The CO adjustment value is not properly written on or read from the internal memory.)
d:60
• Malfunction in the charging system. (Refer to “CHARGING
SYSTEM” in CHAPTER 8.)
d:09
• Malfunction in ECU. (The program and data are not properly
written on or read from the internal memory.)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Open or short circuit in sensor - ECU.
Defective knock sensor.
Malfunction in ECU.
Short circuit in switch - ECU.
Defective grip warmer switch.
Malfunction in ECU.
Coupler defective between grip warmer – ECU.
Open or short circuit in wire harness.
Improperly installed grip warmer.
Malfunction in grip warmer.
Malfunction in ECU.
Short circuit in switch - ECU.
Defective thumb warmer switch.
Malfunction in ECU.
Coupler defective between thumb warmer – ECU.
Open or short circuit in wire harness.
Improperly installed thumb warmer.
Malfunction in thumb warmer.
Malfunction in ECU.
Open or short circuit in wire harness.
Defective throttle position sensor.
Defective throttle switch.
Defective speed sensor.
Malfunction in ECU.
Improperly installed throttle position sensor.
Coupler defective between switch – ECU.
Open or short circuit in wire harness.
Open or short circuit in oil pressure switch sub-lead.
Defective oil pressure switch.
Improperly installed oil pressure switch.
Malfunction in ECU.
Coupler defective between speedometer unit – ECU.
Open or short circuit in wire harness.
Malfunction in speedometer unit.
Malfunction in ECU.
99
—
—
—
d:57
—
d:27
—
—
—
FUEL INJECTION SYSTEM
Fault
code No.
Er-2
Er-3
Er-4
Symptom
No signals are received from
the ECU within the specified
signal time.
•
•
•
•
Data from the ECU cannot be •
received correctly.
•
•
•
Non-registered data has been •
received from the meter.
•
•
•
Probable cause of malfunction
Coupler defective between speedometer unit – ECU.
Open or short circuit in wire harness.
Malfunction in speedometer unit.
Malfunction in ECU.
Coupler defective between speedometer unit – ECU.
Open or short circuit in wire harness.
Malfunction in speedometer unit.
Malfunction in ECU.
Coupler defective between speedometer unit – ECU.
Open or short circuit in wire harness.
Malfunction in speedometer unit.
Malfunction in ECU.
100
FI
Diagnostic
code No.
—
—
—
FUEL INJECTION SYSTEM
FI
Diagnostic mode table
Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer
to “DIAGNOSTIC MODE”.
TIP
• Check the intake air temperature and coolant temperature as close as possible to the intake air
temperature sensor and the coolant temperature sensor respectively.
• If it is not possible to check the intake air temperature, use the ambient temperature as reference.
Diagnostic
code No.
d:01
d:02
Item
Throttle position sensor Displays the throttle angle.
(throttle angle)
• Check with throttle fully closed.
• Check with throttle fully open.
Atmospheric pressure Displays the atmospheric pressure.
* Use an atmospheric pressure gauge to check
the atmospheric pressure.
Intake air pressure
sensor
d:03
Intake air temperature
d:05
Coolant temperature
d:06
d:07
d:09
d:24
d:27
d:30
d:31
Description of action
Displays the intake air pressure for cylinders #1,
#2, #3, and #4.
• Check the intake manifold pressure.
• Push the starter switch and check the change
in the intake air pressure.
Displays the intake air temperature.
• Check the temperature in the intake manifold.
Displays the coolant temperature.
• Check the temperature of the coolant.
Snowmobile speed
pulse
Displays the cumulative number of snowmobile
pulses that are generated when the track is
spun.
Fuel system voltage
Displays the fuel system voltage (battery volt(battery voltage)
age).
Throttle switch
Displays that the switch is on or off.
• Check the throttle switch.
Thumb warmer opera- If the grip warmer side of the grip/thumb warmer
tion
adjustment switch is pushed, actuates the thumb
warmer and displays the self-diagnosis warning
indicator for 120 seconds.
Cylinder-#1 ignition coil If the grip warmer side of the grip/thumb warmer
adjustment switch is pushed, actuates the cylinder-#1 ignition coil and displays the self-diagnosis warning indicator (five times at one-second
intervals).
Cylinder-#2 ignition coil If the grip warmer side of the grip/thumb warmer
adjustment switch is pushed, actuates the cylinder-#2 ignition coil and displays the self-diagnosis warning indicator (five times at one-second
intervals).
101
Checking method
or meter display
0 ~ 125 degrees
• Fully closed position (12 ~
22)
Atmospheric pressure at the
current altitude and weather
conditions is indicated. 0 m
above sea level: Approx.101
kPa 3000 m above sea level:
Approx. 70 kPa
• Not cranking: atmospheric
pressure
• Cranking: intake air pressure decreases to less than
the atmospheric pressure.
Compare it to the value displayed on the meter. (Minimum displayed value: –30
[°C])
Compare it to the value displayed on the meter. (Minimum displayed value: –30
[°C])
(0 ~ 999; resets to 0 after 999)
OK if the numbers appear on
the meter.
0 ~ 18.7 V
Normally, approximately 12.0 V
Throttle open: on
Throttle closed: off
After pushing the switch,
check that the warmer
becomes warm.
After pushing the switch,
check that a spark is produced
five times.
After pushing the switch,
check that a spark is produced
five times.
FUEL INJECTION SYSTEM
Diagnostic
code No.
d:32
d:33
d:36
d:37
d:38
d:39
d:50
d:51
d:52
d:53
d:54
FI
Checking method
or meter display
Cylinder-#3 ignition coil If the grip warmer side of the grip/thumb warmer After pushing the switch,
adjustment switch is pushed, actuates the cylin- check that a spark is produced
der-#3 ignition coil and displays the self-diagno- five times.
sis warning indicator (five times at one-second
intervals).
Cylinder-#4 ignition coil If the grip warmer side of the grip/thumb warmer After pushing the switch,
adjustment switch is pushed, actuates the cylin- check that a spark is produced
der-#4 ignition coil and displays the self-diagno- five times.
sis warning indicator (five times at one-second
intervals).
Injector #1
If the grip warmer side of the grip/thumb warmer After pushing the switch,
adjustment switch is pushed, actuates injector
check that the injector oper#1 and displays the self-diagnosis warning indi- ates five times by listening to
its operating sound.
cator (five times at one-second intervals).
Injector #2
If the grip warmer side of the grip/thumb warmer After pushing the switch,
adjustment switch is pushed, actuates injector
check that the injector oper#2 and displays the self-diagnosis warning indi- ates five times by listening to
cator (five times at one-second intervals).
its operating sound.
Injector #3
If the grip warmer side of the grip/thumb warmer After pushing the switch,
adjustment switch is pushed, actuates injector
check that the injector oper#3 and displays the self-diagnosis warning indi- ates five times by listening to
cator (five times at one-second intervals).
its operating sound.
Injector #4
If the grip warmer side of the grip/thumb warmer After pushing the switch,
adjustment switch is pushed, actuates injector
check that the injector oper#4 and displays the self-diagnosis warning indi- ates five times by listening to
cator (five times at one-second intervals).
its operating sound.
Main relay
If the grip warmer side of the grip/thumb warmer After pushing the switch,
adjustment switch is pushed, actuates the fuel
check that the fuel injection
injection system relay and displays the self-diag- system relay operates five
nosis warning indicator (five times at one-sectimes by listening to its operatond intervals). (The indicator is off when the
ing sound.
relay is on and it is on when the relay is off.)
Radiator fan motor
If the grip warmer side of the grip/thumb warmer After pushing the switch,
relay
adjustment switch is pushed, actuates the radia- check that the radiator fan
tor fan motor relay and displays the self-diagno- motor relay operates five times
by listening to its operating
sis warning indicator (for five cycles of five
seconds each). (The relay and indicator are on sound.
for two seconds and off for three seconds.)
Headlight relay
If the grip warmer side of the grip/thumb warmer After pushing the switch,
adjustment switch is pushed, actuates the head- check that the headlight relay
light relay (on/off) and displays the self-diagno- operates five times by listening
sis warning indicator (for five cycles of five
to its operating sound. (At that
seconds each). (The relay and indicator are on time, the headlight and taillight
for two seconds and off for three seconds.)
come on.)
EXUP servo motor
Actuate the servo motor turns to open side and Check the operating sound of
to close side and then stop standard position for the EXUP servo motor.
appoximately 3 seconds. Illuminates the engine
trouble warning light only while the motor is running.
After pushing the switch,
ISC (idle speed control) Actuate the ISC (idle speed control) valve to
unit
close side and to open side and then stop stan- check that the ISC unit
vibrates. The ISC vibrates
dard position for approximately 3 seconds.
when the ISC valve operates.
Item
Description of action
102
FUEL INJECTION SYSTEM
Diagnostic
code No.
Item
Grip warmer operation
d:57
EEPROM fault code
display
d:60
Malfunction history
code display
d:61
Malfunction history
code erasure
d:62
d:70
Control number
FI
Checking method
or meter display
If the grip warmer side of the grip/thumb warmer After pushing the switch,
adjustment switch is pushed, actuates the grip
check that the warmer
warmer and displays the self-diagnosis warning becomes warm.
indicator for 120 seconds.
• Displays the cylinder number if an error is
(01 ~ 04) Displays the cylinder
detected in the EEPROM CO adjustment
number.
value for the cylinder as fault code No. 44.
(00) Displays when there is no
• If multiple cylinders are defective, the display malfunction.
alternates every 2 seconds.
• Displays the code numbers of past malfunc11 ~ 85
tions (i.e., a code number of a malfunction that (00) Displays when there is no
occurred once and which has been corrected). malfunction.
• If more than one code number is detected, the
display alternates every 2 seconds to show all
the detected code numbers. When all code
numbers are shown, the display repeats the
same process.
• Displays the total number of codes that are
00 ~ 27
being detected through self diagnosis and the (00) Displays when there is no
fault codes in the past history.
malfunction.
• Erases only the history codes when the grip
warmer side of the grip/thumb warmer adjustment switch is pushed.
• Displays the program control number.
00 ~ 254
Description of action
103
FUEL INJECTION SYSTEM
FI
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order
given.
After the check and service of the malfunctioning part have been completed, reset the meter display
according to the reinstatement method.
Fault code No.:
Code number displayed on the meter when the engine failed to work normally. (Refer to “Fault
code table”.)
Diagnostic code No.:
Code number to be used when the diagnostic mode is operated. (Refer to “Diagnostic mode
table”.)
Fault code No.
17
Symptom EXUP servo motor circuit: open or short circuit detected.
Diagnostic code No. d:53
Item/components and probable cause
Check or maintenance job
Order
1
Connections
EXUP servo motor coupler
Wire harness ECU coupler
Open or short circuit in wire harness.
2
3
Defective EXUP servo motor (potention
circuit).
4
Malfunction in ECU.
Reinstatement method
Check the couplers for any pins that may be pulled Turning the
out.
main switch
Check the locking condition of the couplers.
on.
If there is a malfunction, repair it and connect the
coupler securely.
Repair or replace if there is an open or short circuit.
Between EXUP servo motor coupler and ECU coupler
(Blue – Blue)
(White/Red – White/Red)
(Black/Blue – Black/Blue)
Execute the diagnostic mode. (code No. d:53)
Replace if defective.
Refer to “EXUP SERVO MOTOR INSPECTION”.
Replace the ECU.
TIP
If fault codes 17 and 18 are indicated simultaneously, take the actions specified for fault code 17
first.
104
FUEL INJECTION SYSTEM
FI
Fault code No.
18
Symptom EXUP servo motor is stuck.
Diagnostic code No. d:53
Item/components and probable cause
Check or maintenance job
Order
1
Connections
EXUP servo motor coupler
Wire harness ECU coupler
Open or short circuit in wire harness.
2
Defective EXUP servo motor
3
4
5
Defective EXUP valve, pulley, and cables
Malfunction in ECU.
Reinstatement method
Check the couplers for any pins that may be pulled Turning the
out.
main switch
Check the locking condition of the coupler.
on.
If there is a malfunction, repair it and connect the
coupler securely.
Repair or replace if there is an open or short circuit.
Between EXUP servo motor coupler and ECU coupler.
(Red – Red)
(Black/Red – Black/Red)
Execute the diagnostic mode. (Code No.53)
Replace if defective.
Refer to “EXUP SERVO MOTOR INSPECTION”.
Replace if defective.
Replace the ECU.
TIP
If fault codes 17 and 18 are indicated simultaneously, take the actions specified for fault code 17
first.
105
FUEL INJECTION SYSTEM
FI
Fault code No.
37
Symptom Engine speed is high when the engine is idling.
Diagnostic code No. d:54 (ISC (idle speed control) unit)
Item/components and probable cause
Check or maintenance job
Order
Check the speed sensor signal.
1
2
Connections
ISC coupler
Wire harness ECU coupler
Open or short circuit in wire harness.
3
Installed condition of ISC.
4
Throttle valve does not fully close.
5
ISC valve is not moving correctly.
7
8
TIP
• If fault
first.
• If fault
first.
• If fault
first.
• If fault
first.
• If fault
first.
• If fault
first.
• If fault
first.
• If fault
first.
• If fault
first.
Malfunction in ECU.
Reinstatement method
Check the speed sensor.
ISC valve
Check in the diagnostic code (code No. d:07).
returns to its
With the rear wheel rotated, check the pulse input. original posiIndication incorrect → Refer to “TROUBLESHOOT- tion by setING DETAIL” in fault code No. d:42.
ting the
engine stop
Check the couplers for any pins that may have
switch to
pulled out.
“RUN” and
Check the locking condition of the couplers.
turning the
If there is a malfunction, repair it and connect the
main switch
coupler securely.
Repair or replace if there is an open or short circuit. on and off.
Reinstated if
Between ISC coupler and ECU coupler.
the engine
Red/Green – Red/Green
idle speed is
Pink/Blue – Pink/Blue
within specifiWhite/Green – White/Green
cation after
Brown/Blue – Brown/Blue
starting the
Check the couplers for any pins that may have
engine.
pulled out.
Check the locking condition of the couplers.
If there is a malfunction, repair it and connect the
coupler securely.
Check the air leak.
Check the throttle body.
Refer to “THROTTLE BODY”.
Check the throttle cable.
Refer to “THROTTLE CABLE FREE PLAY
ADJUSTMENT” in CHAPTER 2.
Execute the diagnostic mode (code No. d:54).
After fully closing the ISC valve, it returns to full
open. This takes approximately 3 seconds.
Check the operating noise at this time.
If there is no operating noise, replace the throttle
body assembly.
Replace the ECU.
codes 13 and 37 are indicated simultaneously, take the actions specified for fault code 13
codes 14 and 37 are indicated simultaneously, take the actions specified for fault code 14
codes 15 and 37 are indicated simultaneously, take the actions specified for fault code 15
codes 16 and 37 are indicated simultaneously, take the actions specified for fault code 16
codes 21 and 37 are indicated simultaneously, take the actions specified for fault code 21
codes 22 and 37 are indicated simultaneously, take the actions specified for fault code 22
codes 25 and 37 are indicated simultaneously, take the actions specified for fault code 25
codes 26 and 37 are indicated simultaneously, take the actions specified for fault code 26
codes 37 and 46 are indicated simultaneously, take the actions specified for fault code 46
106
FUEL INJECTION SYSTEM
FI
• If fault codes 37 and 42 are indicated simultaneously, take the actions specified for fault code 42
first.
Fault code No.
65
Symptom Knock sensor: open or short circuit detected.
Diagnostic code No. – –
Item/components and probable cause
Check or maintenance job
Order
1
Connections
Knock sensor coupler
Wire harness ECU coupler
Open or short circuit in wire harness.
2
3
4
5
Installed condition of knock sensor
Defective knock sensor.
Malfunction in ECU.
Check the couplers for any pins that may have
pulled out.
Check the locking condition of the couplers.
If there is a malfunction, repair it and connect the
coupler securely.
Repair or replace if there is an open or short circuit.
Between knock sensor coupler and ECU coupler.
White – White
Check for looseness or pinching.
Replace if defective.
Refer to “KNOCK SENSOR”.
Replace the ECU.
107
Reinstatement method
Turning the
main switch
on.
FUEL INJECTION SYSTEM
FI
OIL PRESSURE SENSING SYSTEM TROUBLESHOOTING
If “OP – LO” display/limiter control is not canceled or the meter displays fault code No. 30.
1. Check the engine oil level in the oil tank.
Refer to “ENGINE OIL LEVEL INSPECTION” in CHAPTER2.
NG
Ensure that the engine oil level is correct,
start the engine, and then check the level
again.
OK
2. Air may have entered the oil hoses and/or oil pump.
The step below may resolve the issue.
a. With the engine shut off, tip the snowmobile 90° to the left with the oil tank facing upward and
wait 2 to 3 minutes.
b. Set the snowmobile back down on the skis on a level surface. Start the engine and rev several times without engaging the clutch, then return to idle RPM. Do this repeatedly.
NG
3. Check the engine oil pressure.
Refer to “ENGINE OIL REPLACEMENT”.
NG
4. Check the engine internal components
such as the oil pump, etc., and carry
out repairs if necessary.
Refer to CHAPTER5.
If abnormally low oil pressure is detected when the snowmobile is running (fault code No.
30), resulting in the engine stop.
1. Air may have entered the oil hoses due to the snowmobile falling over during running, etc. Carry
out steps (1) to (3) above.
2. If fault code No. 30 continues in the meter display, carry out the check and repair work.
Refer to “TROUBLESHOOTING DETAILS”.
3. Carry out step (4) above.
If the oil pressure switch error (fault code No. 85) is detected.
According to fault code No. 85 in the meter display, carry out the check and repair work.
Refer to “TROUBLESHOOTING DETAILS” in CHAPTER 7.
108
FUEL INJECTION SYSTEM
FI
ISC (IDLE SPEED CONTROL) UNIT
TIP
Do not remove the ISC (idle speed control) unit
completely from the throttle body.
1. Inspect:
• ISC (idle speed control) unit
Inspection steps:
• Disconnect the ISC (idle speed control) unit
coupler from the ISC (idle speed control) unit.
• Connect the analog pocket tester (pocket
tester) (Ω × 10) to the terminals of the ISC
(idle speed control) unit.
Positive tester probe → Red/Green
Negative tester probe → White/Green
Positive tester probe → Brown/Blue
Negative tester probe → Pink/Blue
Analog pocket tester:
YU-03112-C
Pocket tester:
90890-03112
• Measure the ISC (idle speed control) unit
resistance.
Out of specification → Replace the throttle
body.
ISC (idle speed control) unit
resistance:
57 ~ 63 Ω
109
THROTTLE BODY
FI
THROTTLE BODY
THROTTLE BODY
3.0 Nm (0.30 m•kgf, 2.2 ft•lbf)
6 Nm (0.6 m•kgf, 4.3 ft•lbf)
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
Order
Job name/Part name
Throttle body removal
Q’ty
Coolant
1
2
3
4
5
6
7
Shroud
Side cover (left and right)
Top cover
Headlight assembly
Air filter case
Headlight stay
Fuel hose
Throttle position sensor coupler
Cylinder-#1 injector coupler
Cylinder-#2 injector coupler
Cylinder-#3 injector coupler
Cylinder-#4 injector coupler
Remarks
Remove the parts in the order listed
below.
Drain.
Refer to “COOLING SYSTEM” in CHAPTER 2.
Refer to “COWLINGS” in CHAPTER 3.
Refer to “GENERAL CHASSIS”.
Refer to “AIR FILTER CASE”.
1
1
1
1
1
1
1
110
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
THROTTLE BODY
FI
3.0 Nm (0.30 m•kgf, 2.2 ft•lbf)
6 Nm (0.6 m•kgf, 4.3 ft•lbf)
7 Nm (0.7 m•kgf, 5.1 ft•lbf)
Order
8
9
10
11
12
13
14
15
16
Job name/Part name
Intake air pressure sensor coupler
ISC (idle speed control) unit coupler
ISC (idle speed control) unit inlet hose
Throttle cable
Throttle body heater inlet hose
Throttle body heater outlet hose
Throttle body joint clamp screw
Throttle body assembly
Throttle body joint
Q’ty
1
1
1
1
1
1
8
1
4
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Loosen.
For installation, reverse the removal
procedure.
111
THROTTLE BODY
FI
INJECTORS
3.5 Nm (0.35 m•kgf, 2.5 ft•lbf)
3.6 Nm (0.36 m•kgf, 2.6 ft•lbf)
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Injectors removal
Q’ty
Throttle position sensor
Negative pressure hose
ISC (idle speed control) unit outlet
hose
Intake air pressure sensor
Fuel rail
Fuel rail joint
Fuel joint
Pulsation dumper plate
Pulsation dumper
Injector
Remarks
Remove the parts in the order listed
below.
1
6
2
1
2
1
1
1
1
4
For installation, reverse the removal
procedure.
112
THROTTLE BODY
FI
REMOVAL
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel hose
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pressure in the fuel lines could cause fuel to
spurt out when removing the hoses.
NOTICE
Be sure to disconnect the fuel hose by
hand.
Do not forcefully disconnect the hose with
tools.
TIP
• To remove the fuel hose from the throttle
body, slide the fuel hose connector cover
on the end of the hose in direction of the
arrow shown, press the two buttons
on the
sides of the connector, and then remove the
hose.
• Before removing the hose, place a few rags in
the area under where it will be removed.
INSPECTION
1. Inspect:
• Fuel rails
Cracks/damage → Replace the defective
parts.
WARNING
• When disassembling the fuel joint
and
fuel rail
, do not leave the O-ring
in
the fuel rail. Remove the O-ring.
• When assembling the fuel joint and fuel
rail, install the O-ring to the fuel joint as
shown in the illustration and then install
them to the fuel rail. Do not forget to
install the O-ring. Do not pinch the O-ring.
113
THROTTLE BODY
FI
INSPECTION AND ADJUSTMENT
1. Inspect:
• Throttle position sensor
Inspect steps:
• Disconnect the throttle position sensor coupler.
• Remove the throttle position sensor from the
throttle body.
• Connect the analog pocket tester (pocket
tester) (Ω × 1k) to the throttle position sensor.
Positive tester probe → Terminal
Negative tester probe →Terminal
Analog pocket tester:
YU-03112-C
Pocket tester:
90890-03112
• Measure the maximum throttle position sensor resistance.
Out of specification → Replace the throttle
position sensor.
Throttle position sensor
resistance:
2.6 ~ 6.2 kΩ
114
THROTTLE BODY
FI
2. Adjust:
• Throttle position sensor angle
Adjustment steps:
• Connect the test harness-TPS (3P)
to the
throttle position sensor and wire harness as
shown.
• Connect the model 88 multimeter with
tachometer (digital circuit tester) to the test
harness-TPS (3P).
Positive tester probe →
Yellow (wire harness color)
Negative tester probe →
Black/blue (wire harness color)
Model 88 Multimeter with
tachometer
YU-A1927
Digital circuit tester
90890-03174
Test harness-TPS (3P)
YU-03204
90890-03204
• Measure the throttle position sensor voltage.
• Adjust the throttle position sensor angle so
that the voltage is within the specified range.
Output voltage
0.63–0.73 V
• After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws .
Throttle position sensor screw
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
115
SWITCH INSPECTION
ELEC
ELECTRICAL
SWITCH INSPECTION
SWITCH INSPECTION
Use a pocket tester to check the terminals for
continuity. If the continuity is faulty at any point,
replace the switch.
Analog pocket tester:
YU-03112-C
Pocket tester:
90890-03112
TIP
• Set the pocket tester to “0” before starting a
test.
• When testing the switch for continuity the
pocket tester should be set to the “× 1 Ω”
range.
• When checking the switch turn it on and off a
few times.
NOTICE
• For waterproof couplers, never insert the
tester probes directly into the coupler.
When performing any checks using a
waterproof coupler, use the specified test
harness or a suitable commercially available test harness.
• Precautions when removing/installing the
sensor coupler.
When removing/installing the coupler,
carefully wipe peripheral components
with a soft cloth. Be careful to prevent liquid such as water or oil from dropping
into the coupler.
If water or oil comes into contact with the
coupler, this may result in a sensor malfunction.
The same also applies to other FI-related
sensors.
116
KNOCK SENSOR
ELEC
KNOCK SENSOR
1. Remove:
• Knock sensor
NOTICE
Handle the knock sensor with special care.
Never subject it to shock or allow it to be
dropped. If it is dropped, it must be
replaced.
2. Connect:
• Pocket tester
(to the knock sensor coupler and sensor
body)
3. Measure:
• Knock sensor resistance
Out of specification → Replace.
Knock sensor resistance:
504 ~ 616 kΩ
4. Install the knock sensor and connect the
knock sensor coupler.
Knock sensor:
27 Nm (2.7 m•kgf, 20 ft•lbf)
NOTICE
Do not overtighten the knock sensor.
117
118
Lg2
19
Lg2
W 2 W Gy Y Br/W P/W B/Y O/L L Y/G Ch1 R/L R/W 1L/Y R/Y G/Y Lg1
W /R W /B Lg/B -G/W P L/W O/W B/L L/R Ch2 Lg2R/W 2 -Br/L1 Sb Y/R
R P/L -W /G B1 R/B O L/BO/G
B/R R/G Lg/W Br/L B2 G/B Gy/R O/B G
Main switch
Main fuse
Battery
ECU (engine control unit)
Speed sensor
EPS (electric power steering) control unit
EPS self-diagnosis signal connector
EPS (electric power steering) motor
EPS (electric power steering) fuse
Speedometer unit
Multi-function meter
Ignition fuse
EPS (ELECTRIC POWER STEERING) SYSTEM
EPS (ELECTRIC POWER STEERING) SYSTEM
CIRCUIT DIAGRAM
ELEC
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION
The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in the EPS system, it lights the EPS warning display to alert the rider that a malfunction has
occurred in the system. Once a malfunction has been detected, it becomes stored in the EPS control unit memory in the form of a fault code.
• The EPS warning display comes on when the
main switch is turned to “ON”, and then goes
off once the engine is started. If the warning
light remains on or comes on after the engine
is started, the EPS system may be defective.
• The electrical circuit of the warning display
can be checked by turning the main switch to
“ON”. If the warning display does not come
on, the electrical circuit may be defective.
EPS warning display
TIP
• If the engine is stopped using the engine stop switch and the main switch is in the “ON” position,
the EPS warning display comes on to indicate that the power assistance for the steering is not
functioning.
• If the steering usage is too heavy (i.e., excessive steering use when the snowmobile is traveling at
a slow speed), the power assist is reduced to protect the EPS motor from overheating.
119
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
EPS WARNING DISPLAY DURING NORMAL OPERATION
The EPS warning display comes on initially for 2 seconds after the main switch is turned to “ON”.
However, the warning display remains on until the engine is started.
In addition, if a malfunction is detected while the warning light comes on initially, the warning light
remains on.
Furthermore, the warning display comes on whenever a malfunction has occurred.
TIP
The EPS system does not operate while the EPS warning display is on.
a
b.
c.
d.
e.
f.
g.
h.
i.
Main switch
EPS warning display (no malfunction detected)
EPS warning display (malfunction detected)
OFF
ON
120
Off
Comes on.
Initial lighting: 2 seconds
Goes off.
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
DIAGNOSTIC MODE
Setting the diagnostic mode (present and
past malfunctions)
1. Turn the main switch to “ON”.
2. Disconnect the EPS self-diagnosis signal
connector
.
TIP
Do not disconnect the EPS self-diagnosis signal connector before turning the main switch to
“ON”.
3. Select the signaling mode by grounding the
EPS self-diagnosis signal connector (male
side) to the EPS control unit
or disconnecting it from the unit as follows.
a) Present malfunction signaling mode
Ground the EPS self-diagnosis signal
connector within 5 seconds after turning
the main switch to “ON”, and leave it
grounded. The signaling mode is activated after 5 seconds.
b) Past malfunction signaling mode
While the present malfunction mode is
activated, briefly disconnect the EPS
self-diagnosis signal connector, ground
it again, and leave it grounded. The signaling mode is activated after 5 seconds.
4. Turn the main switch to “OFF” to cancel the
diagnostic mode.
TIP
• The diagnostic mode can also be canceled
by riding the snowmobile at speeds above 2
km/h.
• When the diagnostic mode is selected and
during the initial lighting of the EPS warning
display, the EPS control unit does not receive
input from the EPS self-diagnosis signal connector.
121
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
Identifying fault codes
When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are
signaled by the EPS warning display as follows.
• Present malfunction signaling mode: Currently detected fault codes are signaled.
• Past malfunction signaling mode: Both previously detected fault codes and currently detected fault
codes are signaled.
Signaling method
Example 1: Fault code No. 23
g. Grounded
a EPS self-diagnosis signal connector
h. Normal mode (diagnostic mode not activated)
b. Diagnostic mode
i. Mode selection judgment
c. EPS warning display
j. Present malfunction signaling mode
d. Disconnected
k. Past malfunction signaling mode
e. On
f. Off
*1 The EPS warning display comes on for 5 seconds during the diagnostic mode selection judgment.
*2 Display of the present malfunctions stops when the past malfunction display mode is selected.
After the mode selection judgment is completed (present or past malfunction mode), the current fault code
signaling stops immediately, and then the first code of the mode is signaled 2 seconds later.
When a fault code is signaled, the EPS warning display goes off for 1 second between the units of 10
and the units of 1 for the code. After a fault code is signaled, the warning light goes off for 3 seconds, and then the next code is signaled.
Example 2: No malfunctions are detected
e. Goes off.
a EPS self-diagnosis signal connector
f. Grounded
b. EPS warning display
g. Mode selection judgment
c. Disconnected
d. Comes on.
*1 The EPS warning display comes on for 5 seconds during the diagnostic mode selection judgment.
After the mode selection judgment is completed (present display or past malfunction mode), the current fault
code signaling stops immediately, and then the EPS warning display starts flashing at 1.5-second intervals.
122
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
Deleting fault codes
To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 seconds while the present or past malfunction mode is activated. The currently selected mode remains
active after the fault codes of that mode are deleted.
a EPS self-diagnosis signal connector
c. Grounded
b. Disconnected
T1: Connector grounded - - - - 0.1 ≤ T1 ≤ 1.6 seconds
T2: Fault codes deleted - - - - - Maximum 1.5 seconds required
123
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)
Fault
code No.
Item
Symptom
Probable cause of malfunction
11
13
15
16
EPS torque sensor
No normal signals are received from
the torque sensor.
• Open or short circuit in wire harness.
• Malfunction in torque sensor.
• Malfunction in EPS control unit.
21
Speed sensor
No normal signals are received from
the speed sensor.
• Open or short circuit in wire harness.
• Malfunction in speed sensor.
• Malfunction in EPS control unit.
22
Engine speed signal
No normal signals are received from
the ECU.
• Open or short circuit in wire harness.
• Malfunction in ECU.
• Malfunction in EPS control unit.
41
42
43
45
EPS motor
No normal signals are received from
the EPS motor.
• Open or short circuit in wire harness.
• Malfunction in EPS motor.
• Malfunction in EPS control unit.
52
EPS control unit
Relay contacts in the EPS control unit
• Malfunction in EPS control unit.
are welded together.
53
EPS control unit
Battery voltage has dropped.
54
EPS control unit
Relay contacts in the EPS control unit
• Malfunction in EPS control unit.
are shorted or open.
55
EPS control unit
Battery voltage has increased.
Abnormality exists between the EPS
and the ECU.
124
• Faulty battery.
• Malfunction in the charging system.
Refer to “CHARGING SYSTEM”.
• Malfunction in EPS control unit.
• Malfunction in the charging system.
Refer to “CHARGING SYSTEM”.
• Malfunction in EPS control unit.
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
TROUBLESHOOTING DETAILS (EPS SYSTEM)
TIP
The malfunction history is stored even if the main switch is turned to “OFF”, therefore, be sure to
erase the history (present and past malfunction signaling modes) after repairing the cause of the
EPS system malfunction. The malfunction history must be erased in the diagnostic mode. Refer to
“DIAGNOSTIC MODE” and “Deleting fault codes”.
11, 13,
Symptom EPS torque sensor: open or short circuit detected.
15, 16
Item/components and probable cause
Check or maintenance
Reinstatement method
job
Connections
Check the coupler for
Turning the main switch
EPS torque sensor coupler
any pins that may have
to “OFF”.
pulled out.
Check the locking condition of the coupler.
If there is a malfunction,
repair it and connect the
coupler securely.
Defective EPS torque sensor.
Replace if defective.
Refer to “CHECKING
THE EPS TORQUE
SENSOR”.
Open or short circuit in EPS torque sensor lead.
Repair or replace if there
is an open or short circuit.
Between EPS torque
sensor coupler and EPS
control unit coupler.
(White – White)
(Red – Red)
(Green – Green)
(Black – Black)
Fault code No.
Order
1
2
3
125
EPS (ELECTRIC POWER STEERING) SYSTEM
Fault code No.
21
Symptom Speed sensor: open or short circuit detected.
Item/components and probable cause
Check or maintenance
Order
job
Connections
Check the coupler for
Speed sensor coupler
any pins that may have
EPS control unit coupler at the wire harness
pulled out.
Check the locking condi1
tion of the coupler.
If there is a malfunction,
repair it and connect the
coupler securely.
Open or short circuit in wire harness.
Repair or replace if there
is an open or short circuit.
2
Between speed sensor
coupler and EPS control
unit coupler.
(White – White)
Defective speed sensor.
Execute the diagnostic
mode. (Code No. 21)
3
Replace if defective.
Refer to “SIGNALING
SYSTEM”.
ELEC
Reinstatement method
Starting the engine and
activating the snowmobile speed sensor by
operating the snowmobile
above 5 km/h, or turning
the main switch to “OFF”,
then to “ON”, and then
deleting the fault codes.
Refer to “DIAGNOSTIC
MODE” and “Deleting
fault codes”.
Fault code No.
22
Symptom No normal signals are received from the ECU.
Item/components and probable cause
Check or maintenance
Reinstatement method
Order
job
Connections
Check the coupler for
Turning the main switch
EPS control unit coupler at the wire harness
any pins that may have
to “OFF”.
ECU coupler at the wire harness
pulled out.
Check the locking condi1
tion of the coupler.
If there is a malfunction,
repair it and connect the
coupler securely.
Open or short circuit in wire harness.
Repair or replace if there
is an open or short circuit.
2
Between ECU coupler
and EPS control unit
coupler.
(Sky blue – Sky blue)
3
Malfunction in ECU.
Replace the ECU.
126
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
41, 42,
Symptom EPS motor: open or short circuit detected.
43, 45
Item/components and probable cause
Check or maintenance
Reinstatement method
job
Connections
Check the coupler for
Turning the main switch
EPS motor coupler
any pins that may have
to “OFF”.
pulled out.
Check the locking condition of the coupler.
If there is a malfunction,
repair it and connect the
coupler securely.
Open or short circuit in EPS motor lead.
Repair or replace if there
is an open or short circuit.
Between EPS motor and
EPS control unit coupler.
(Red – Red)
(Black – Black)
Defective EPS motor.
Replace if defective.
Refer to “CHECKING
THE EPS MOTOR”.
Fault code No.
Order
1
2
3
Fault code No.
52
Symptom Relay contacts in the EPS control unit are welded together.
Item/components and probable cause
Check or maintenance
Reinstatement method
Order
job
Malfunction in EPS control unit.
Replace the EPS control Turning the main switch
1
unit.
to “OFF”.
Fault code No.
53
Symptom Power supply to the EPS control unit is not normal (low battery voltage).
Item/components and probable cause
Check or maintenance
Reinstatement method
Order
job
Faulty battery.
Replace or charge the
Turning the main switch
battery.
to “OFF”.
1
Refer to “CHECKING
AND CHARGING THE
BATTERY” in chapter 3.
Malfunction in rectifier/regulator or charging system.
Replace if defective.
2
Refer to “CHARGING
SYSTEM”.
Malfunction in EPS control unit.
Replace the EPS control
3
unit.
Fault code No.
54
Symptom Relay contacts in the EPS control unit are shorted or open.
Item/components and probable cause
Check or maintenance
Reinstatement method
Order
job
Malfunction in EPS control unit.
Replace the EPS control Turning the main switch
1
unit.
to “OFF”.
127
EPS (ELECTRIC POWER STEERING) SYSTEM
Power supply to the EPS control unit is not normal (High battery voltage).
Malfunction in control unit.
Item/components and probable cause
Check or maintenance
Reinstatement method
job
Faulty battery.
Replace the battery.
Turning the main switch
Refer to “CHECKING
to “OFF”.
AND CHARGING THE
BATTERY” in chapter 3.
Malfunction in rectifier/regulator.
Replace if defective.
Refer to “CHARGING
SYSTEM”.
Malfunction in EPS control unit.
Replace the EPS control
unit.
Fault code No.
Order
1
2
3
ELEC
55
Symptom
128
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
EPS MOTOR INSPECTION
1. Remove:
• EPS unit
2. Check:
• EPS motor
Out of specification → Replace.
TIP
The pocket tester and the analog pocket tester
readings are shown in the following table.
B
Continuity
Positive tester probe → red
Negative tester probe →
black
No continuity
Positive tester probe → red
Negative tester probe → EPS
motor body
No continuity
Positive tester probe →
black
Negative tester probe → EPS
motor body
R
a. Connect the pocket tester (Ω × 1) to the
EPS motor coupler terminal and EPS motor
body.
Analog pocket tester:
YU-03112-C
Pocket tester:
90890-03112
b. Check the EPS motor for continuity.
c. Check the EPS motor for no continuity.
EPS TORQUE SENSOR INSPECTION
1. Remove:
• EPS unit
2. Check:
• EPS torque sensor resistance
Out of specification → Replace.
EPS torque sensor resistance
1.00 ~ 1.50 kΩ
129
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
a. Connect the pocket tester (Ω × 1k) to the
EPS torque sensor coupler terminal as
shown.
Analog pocket tester:
YU-03112-C
Pocket tester:
90890-03112
Positive tester probe → red
Negative tester probe → black
b. Measure the EPS torque sensor resistance.
130
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model:
Model code number:
Dimensions:
Overall length
Overall width
Overall height
Weight:
With oil and fuel
Minimum turning radius:
Clockwise
Counterclockwise
Fuel:
Type
Minimum pump octane (R+M)/2
Fuel tank capacity
Transmission:
Secondary reduction ratio
Secondary reduction ratio [R]
Overall reduction ratio
Drive track:
Length on ground
Description
RX10PA, RX10PSA, RX10PXTA
8HG1 (RX10PA)
8JC1 (RX10PSA)
8HN1 (RX10PXTA)
2,835 mm (111.6 in) (RX10PA, RX10PSA)
3,000 mm (118.1 in) (RX10PXTA)
1,230 mm (48.4 in)
1,210 mm (47.6 in)
313 kg (690 lb) (RX10PA)
309 kg (681 lb) (RX10PSA)
317 kg (699 lb) (RX10PXTA)
3.7 m (12.14 ft) (RX10PA, RX10PSA)
3.9 m (12.80 ft) (RX10PXTA)
3.7 m (12.14 ft) (RX10PA, RX10PSA)
3.9 m (12.80 ft) (RX10PXTA)
Premium unleaded gasoline only
91
34.6 L (9.14 US gal, 7.61 Imp.gal)
37/24 (1.54) (RX10PA, RX10PSA)
37/23 (1.61) (RX10PXTA)
2.08 (RX10PA, RX10PSA)
2.17 (RX10PXTA)
5.86 ~ 1.54 : 1 (RX10PA, RX10PSA)
6.11 ~ 1.61 : 1 (RX10PXTA)
864 mm (34.0 in) (RX10PA, RX10PSA)
1,051 mm (41.4 in) (RX10PXTA)
131
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Piston ring:
Oil ring
Dimensions (B × T)
Connecting rod:
Small end diameter
Throttle body:
Idling speed
Coolant:
Total amount
Fuel pump
Fuel pressure
Description
1.50 × 2.30 mm (0.06 × 0.09 in)
17.005 ~ 17.027 mm (0.6695 ~ 0.6704 in)
1,550 ~ 1,650 r/min
6.2 L (6.55 US qt, 5.46 Imp.qt) (RX10PA, RX10PSA)
6.3 L (6.66 US qt, 5.54 Imp.qt) (RX10PXTA)
324.0 kPa (3.24 kgf/cm2, 47.0 psi)
POWER TRAIN
Item
Transmission:
Engagement speed (Subject to
change according to elevation
settings.)
V-belt:
Part number (-17641-)
Primary sheave spring:
Part number (90501-)
Color code
Outside diameter
Wire diameter
Preload
Spring rate
Number of coils
Free length
Primary sheave weight arm:
Part number
Weight
Rivet hole quantity
Description
3,200 ~ 3,600 r/min
8DN-17641-01
90501-551L9
Blue – Silver – Blue
59.5 mm (2.34 in)
5.5 mm (0.22 in)
343 N (35 kgf, 77 lbf)
19.6 N/mm (2.00 kgf/mm, 111.92 lbf/in)
4.91
90.9 mm (3.58 in)
8HG-17605-00
82.96 g (2.926 oz)
3
132
MAINTENANCE SPECIFICATIONS
Item
Rivet:
Inner
Part number (90261-)
Size
Outer
Part number (90261-)
Size
Part number (90261-)
Size
Center
Part number (90261-)
Size
Material
Quantity
Secondary sheave spring:
Part number
Color code
Outside diameter
Wire diameter
Hole position
Sheave side-spring seat side
(twist angle)
Spring rate
Compression
Torsion
Number of coils
Free length
Drive chain:
Number of links
Secondary reduction ratio
Maximum 14 link drive chain section
length
<Limit>
SPEC
Description
90269-06006
17.2 mm (0.68 in) with hole
90269-06002
13.3 mm (0.52 in) with hole (RX10PA, TX10PSA)
90261-06019
13.3 mm (0.52 in) (RX10PXTA)
90261-06033
17.2 mm (0.68 in)
Steel
3 pcs
90508-60012
Pink
69.5 mm (2.74 in)
6.0 mm (0.236 in)
1-6 (70°)
12.32 N/mm (1.26 kgf/mm, 70.35 lbf/in)
11,876 N•mm/rad (1,211 kgf•mm/rad,
67,825.6 lbf•in/rad)
5.53
75.0 mm (2.95 in)
70 (RX10PA, RX10PSA)
68 (RX10PXTA)
37/24 (1.54) (RX10PA, RX10PSA)
37/23 (1.61) (RX10PXTA)
133.35 mm (5.25 in)
137.35 mm (5.41 in)
133
MAINTENANCE SPECIFICATIONS
Item
Track:
Part number
Width
Length
Pitch
Number of links
Thickness “A”
Height “B”
Track deflection at 100 N (10 kgf, 22
lbf)
Slide rail suspension:
Rear travel
Suspension spring type
Front
Rear
Suspension spring rate
Front
Rear
Suspension spring range
Rear
Standard air pressure
Spring wire diameter
Front
Rear
Shock absorber damping force:
Rebound damping force
Front
Rear
Compression damping force
Front
Rear
SPEC
Description
8HG-47110-00 (RX10PA, RX10PSA)
8ET-47110-30 (RX10PXTA)
381.0 mm (15.0 in)
3,264.4 mm (128.52 in) (RX10PA, RX10PSA)
3,648.5 mm (143.6 in) (RX10PXTA)
64.0 mm (2.520 in)
51 (RX10PA, RX10PSA)
57 (RX10PXTA)
5.1 mm (0.20 in)
31.80 mm (1.250 in)
30.0 ~ 35.0 mm (1.18 ~ 1.38 in)
295.0 mm (11.61 in) (RX10PA, RX10PSA)
297.0 mm (11.69 in) (RX10PXTA)
Coil spring (RX10PXTA)
Coil spring (RX10PA)
Air spring (RX10PSA)
Torsion spring (RX10PXTA)
15.0 N/mm (1.53 kgf/mm, 85.65 lbf/in) (RX10PXTA)
53.9 N/mm (5.50 kgf/mm, 307.77 lbf/in) (RX10PA)
1,500 N•mm/degree (152.96 kgf•mm/degree,
8,565.00 lbf•in/degree) (RX10PXTA)
965 ~ 1,551 kPa (9.7 ~ 15.5 kgf/cm2, 140 ~ 225 psi)
(RX10PSA)
1,138 kPa (11.4 kgf/cm2, 165 psi) (RX10PSA)
7.0 mm (0.28 in) (RX10PXTA)
12.2 mm (0.48 in) (RX10PA)
10 × 10 mm (0.39 × 0.39 in) (RX10PXTA)
995.0 N/0.3 m/s (101.46 kgf/0.3 m/s, 223.68 lbf/0.3 m/s)
(RX10PXTA)
2,500 N/0.3 m/s (254.93 kgf/0.3 m/s, 562.00 lbf/0.3 m/s)
(RX10PA)
1,695 N/0.3 m/s (172.84 kgf/0.3 m/s, 381.04 lbf/0.3 m/s)
(RX10PXTA)
565.0 N/0.3 m/s (57.61 kgf/0.3 m/s, 127.01 lbf/0.3 m/s)
(RX10PXTA)
1,570 N/0.3 m/s (160.09 kgf/0.3 m/s, 352.94 lbf/0.3 m/s)
(RX10PA)
775 N/0.3 m/s (79.03 kgf/0.3 m/s, 174.22 lbf/0.3 m/s)
(RX10PXTA)
134
MAINTENANCE SPECIFICATIONS
Item
Slide runner:
Wear limit
Track sprocket wheel:
Type
Brake:
Brake pad wear limit
Parking brake pad wear limit
SPEC
Description
10.5 mm (0.41 in)
Extrovert drive and internal drive type
4.7 mm (0.19 in)
1.2 mm (0.047 in)
CHASSIS
Item
Frame:
Seat height
Ski:
Length
Width
Ski runner wear limit
Ski wear limit
Ski suspension:
Travel
Spring type
Spring rate
Spring range
Standard air pressure
Wire diameter
Shock absorber damping force:
Rebound damping force
Compression damping force
Description
755.0 mm (29.72 in)
1,050 mm (41.34 in)
136 mm (5.35 in)
8.0 mm (0.31 in)
12.0 mm (0.47 in)
219.0 mm (8.62 in)
Coil spring (RX10PA, RX10PXTA)
Air spring (RX10PSA)
22.0 N/mm (2.24 kgf/mm, 125.62 lbf/in) (RX10PA)
26.5 N/mm (2.70 kgf/mm, 151.32 lbf/in) (RX10PXTA)
448 ~ 1,034 kPa (4.5 ~ 10.3 kgf/cm2, 65 ~ 150 psi)
(RX10PSA)
586 kPa (5.9 kgf/cm2, 85 psi) (RX10PSA)
8.4 mm (0.33 in) (RX10PA)
8.8 mm (0.35 in) (RX10PXTA)
1,125 N/0.3 m/s (114.72 kgf/0.3 m/s, 252.90 lbf/0.3 m/s)
(RX10PA)
1,150 N/0.3 m/s (117.27 kgf/0.3 m/s, 258.52 lbf/0.3 m/s)
(RX10PXTA)
780 N/0.3 m/s (79.54 kgf/0.3 m/s, 175.34 lbf/0.3 m/s)
(RX10PA)
655 N/0.3 m/s (66.79 kgf/0.3 m/s, 147.24 lbf/0.3 m/s)
(RX10PXTA)
135
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Item
Ignition timing (B.T.D.C)
A.C. magneto:
Standard output
Stator coil resistance
Starter motor:
Brush overall length wear limit
Commutator diameter
<Wear limit>
Grip warmer:
Resistance
(left)
(right)
Crankshaft position sensor:
Resistance
Throttle position sensor:
Resistance
ISC (idle speed control) unit:
Resistance
Knock sensor:
Resistance
EPS torque sensor:
Resistance
Fuses:
Helmet shield heater jack fuse
Radiator fan fuse
EPS fuse
Reserve fuse
Description
5° at 1,600 r/min
14.0 V, less than 38.5 A at 5,000 r/min
0.15 ~ 0.23 Ω at 20 °C (68 °F)
4.4 mm (0.17 in)
28.0 mm (1.10 in)
27.0 mm (1.06 in)
6.75 ~ 8.25 Ω
6.75 ~ 8.25 Ω
248 ~ 372 Ω at 20 °C (68 °F)
2.6 ~ 6.2 kΩ
57 ~ 63 Ω
504 ~ 616 kΩ
1.00 ~ 1.50 kΩ
3.0 A
5.0 A
40.0 A
5.0 A
136
GENERAL TORQUE SPECIFICATIONS
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque
specifications for special components or assemblies are included in the applicable sections of
this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached.
Unless otherwise specified, torque specifications call for clean, dry threads. Components
should be at room temperature.
A
(nut)
B
(bolt)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
6 mm
8 mm
10 mm
12 mm
14 mm
16 mm
SPEC
General torque
specifications
Nm
m•kgf
ft•lbf
6
0.6
4.3
15
1.5
11
30
3.0
22
55
5.5
40
85
8.5
61
130
13
94
A: Distance across flats
B: Outside thread diameter
DEFINITION OF UNITS
Unit
mm
cm
kg
N
Nm
m•kgf
Pa
N/mm
L
cm3
r/min
Read
Millimeter
Centimeter
Kilogram
Newton
Newton meter
Meter kilogram force
Pascal
Newtons per millimeter
Liter
Cubic centimeter
Rotations per minute
Definition
meter
meter
3
10 gram
1 kg × m/sec2
N×m
m × kgf
N/m2
N/mm
Measurement
Length
Length
Weight
Force
Torque
Torque
Pressure
Spring rate
—
Volume or capacity
—
Engine speed
10-3
10-2
137
TIGHTENING TORQUE
SPEC
TIGHTENING TORQUE
ENGINE
Tightening torque
Parts to be tightened
Oil filter union bolt
Exhaust pipe bolt (rear side)
Exhaust pipe band bolt
EXUP maintenance window cover bolt
Muffler cover plate bolt
Muffler cover nut
Exhaust pipe joint cover bolt
EXUP valve pulley cover bolt
EXUP cable locknut
EXUP servo motor bolt
EXUP servo motor pulley cover bolt
EXUP valve housing bolt
EXUP valve nut
Starter clutch bolt
Crankshaft position sensor bolt
Cylinder identification sensor bolt
Knock sensor
138
Nm
m•kgf ft•lbf
80
16
18
7
7
16
6
10
6
10
2.0
10
7
16
10
8
27
8.0
1.6
1.8
0.7
0.7
1.6
0.6
1.0
0.6
1.0
0.20
1.0
0.7
1.6
1.0
0.8
2.7
58
12
13
5.1
5.1
12
4.3
7.2
4.3
7.2
1.5
7.2
5.1
12
7.2
5.8
20
Remarks
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
TIGHTENING TORQUE
SPEC
POWER TRAIN
Tightening torque
Parts to be tightened
Nm
Drive chain housing cover bolt
Drive chain housing and frame bolt
Driven sprocket bolt
Brake caliper bleed screw
RX10PA, RX10PSA
Limiter strap nut
Sliding runner and sliding frame screw
Front pivot arm and control rod nut
Front pivot arm and front pivot arm bracket bolt
Rear pivot arm bracket and sliding frame bolt
Rear pivot arm and control rod nut
RX10PXTA
Slide rail suspension mounting bolt (M10)
Limiter strap nut
Sliding runner and sliding frame screw
Set bolt (front suspension wheel collar)
Shock absorber and front pivot arm nut
Sliding frame and shaft bolt
Front pivot arm and sliding frame bolt
Shock absorber and front suspension bracket nut
Suspension wheel nut
Front suspension bracket and connecting arm nut
Front pivot arm and connecting arm nut
Set bolt (guide wheel collar)
Control rod adjusting nut and locknut
Control bracket, shaft and sliding frame bolt
(front side)
Control bracket, shaft and sliding frame bolt
(rear side)
Rear suspension bracket shaft and sliding frame
Rear suspension bracket, rear shock absorber
and pull rod nut
Rear pivot arm and pull rod nut
Rear pivot arm and rear shock absorber nut
Rear pivot arm and control rod stopper nut
Control bracket and control rod shaft bolt
Rear axle nut
139
m•kgf ft•lbf
24
43
55
5
2.4
4.3
5.5
0.5
17
31
40
3.6
3.8
2.5
105
72
72
105
0.38
0.25
10.5
7.2
7.2
10.5
2.8
1.8
76
52
52
76
72
3.8
2.5
6
49
60
60
49
60
72
72
9
25
42
7.2
0.38
0.25
0.6
4.9
6.0
6.0
4.9
6.0
7.2
7.2
0.9
2.5
4.2
52
2.8
1.8
4.3
35
43
43
35
43
52
52
6.5
18
30
42
4.2
30
60
49
6.0
4.9
43
35
49
49
60
72
75
4.9
4.9
6.0
7.2
7.5
35
35
43
52
54
Remarks
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE®
TIGHTENING TORQUE
SPEC
CHASSIS
Tightening torque
Parts to be tightened
Rear cover bolt
Seat and muffler cover bolt
Muffler side cover screw
Muffler end cap bolt
Tail/brake light screw
Frame protector nut
Handlebar holder and steering joint bolt
Steering joint cover screw
Steering column 2 and EPS motor bolt
EPS motor and frame cross member nut
EPS motor and pit man arm nut
EPS motor cover bolt
Pit man arm and steering shaft nut
Shock absorber lower nut
Upper arm and steering knucle nut
Lower arm and steering knuckle nut
Stabilizer arm and connecting rod nut
Connecting rod and lower arm nut
140
Nm
m•kgf ft•lbf
8
30
1.5
1.5
1.0
16
23
2.5
35
30
205
7
35
50
65
105
37
37
0.8
3.0
0.15
0.15
0.10
1.6
2.3
0.25
3.5
3.0
20.5
0.7
3.5
5.0
6.5
10.5
3.7
3.7
Remarks
5.8
22
1.1
1.1
0.72
12
17
1.8
25 Apply LOCTITE®
22
148
5.1
25
36
47
76
27
27
CABLE ROUTING
CABLE ROUTING
141
SPEC
CABLE ROUTING
CABLE ROUTING
Frame (top view)
Face the rivet side of the ground
lead terminal down.
EPS (electric power steering)
self-diagnosis signal connector
Clamp the AC magneto lead to
the wire harness connected the
EPS (electric power steering)
control unit.
Rectifier/regulator
Rectifier/regulator and EPS
(electric power steering) control
unit bracket
Battery negative lead coupler
Fasten the AC magneto lead
and wire harness with the
clamp.
Insert the clamp into the frame
cross member.
Main fuse
Wire harness
AC magneto lead
EPS (electric power steering)
fuse
Connect the coupler of the wire
harness to the knock sensor
lead coupler.
Connect the coupler of the wire
harness to the oil pressure
switch lead coupler.
Clamp the battery negative lead
and battery positive lead with
the clamp.
Battery negative lead
Battery positive lead
Oil level switch coupler
Oil level switch
Pass the starter motor positive
lead under the oil cooler outlet
hose.
Pass the starter motor positive
lead above the battery bracket.
Insert the clamp into the battery
bracket and then clamp the oil
pressure switch lead and knock
sensor lead (at the positioning
tape marks) with the clamp.
Face the end of the clamp to
right side of the vehicle.
Press the clamp against the
expanded section of the fuel
rail.
To the headlight
Fuel injector #4 coupler
Intake air pressure sensor coupler
Fuel injector #3 coupler
Clamp the wire harness to the
fuel delivery pipe with clamp.
Face the head of the clamp to
the front of the vehicle and the
end of the clamp to the top. Cut
off the end of the clamp so that
the length of the end is 3 mm
(0.12 in.) or shorter.
To the meter
Fuel injector #2 coupler
Clamp the headlight lead with
clamp.
Idle speed control
Fuel injector #1 coupler
Face the end of the clamp to the
bottom.
Throttle position sensor
Clamp
0 ~ 10 mm (0 ~ 0.39 in)
To the intake air temperature
sensor
Drive guard bracket
Attach the battery negative lead
to the starter motor fixing bolt.
Atmospheric pressure sensor
coupler
ECU (engine control unit) coupler 1 (Route the harness so
that the harness neither twisted
nor run off the frame.)
ECU (engine control unit) coupler 2 (Route the harness so
that the harness neither twisted
nor run off the frame.)
EPS (electric power steering)
control unit
EPS (electric power steering)
control unit upper bracket
Soapy water may be applied
during installation.
Store the couplers of the EPS
(electric power steering) control
unit under the rubber cover provided with the wire harness.
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SPEC
CABLE ROUTING
Frame (top view)
Insert the clamp from behind
into the headlight stay to clamp
the brake hose. Face the clamp
opening up.
Coolant temperature sensor
coupler
To the brake
Gear position switch
Main switch coupler
Main switch
Insert the clamp into the frame
cross member.
To the heat exchanger
Set the notch of the fuel tank
breather hose joint pipe in the
same direction as the fuel tank
breather hose is inserted (on
the fuel tank side).
Set the knob of the clip in the
same direction as the fuel tank
breather hose is inserted (on
the fuel tank side).
Install the fuel tank breather
hose so that the hose faces to
the right of the vehicle.
Pass the tail/brake light coupler
above the frame projection.
Fuel hose
Fuel hose connector holder
Fuel pump coupler
Clamp the fuel hose and fuel
pump lead at the positioning
tapes with the clamp. Face the
head of the clamp to the tank.
Face the clip knob to the front.
Route in the order of parking
brake cable, throttle cable,
brake hose and corrugated
tubes from the bottom within the
two-dot-dashed line.
Parking brake cable
Helmet shield heater jack
Brake hose
Auxiliary DC jack
Fuel sender coupler
To the handlebar switch
Auxiliary DC jack coupler
Headlight lead coupler
To the EPS (electric power
steering) actuator coupler (4P)
Ignition sub-wire harness coupler
Clamp the Back buzzer lead
and bend the holder 90°.
Clamp the radiator fan motor
lead and bend the holder 90°.
Back buzzer
Install the wire harness with
color tape on the left of the vehicle.
Headlight relay
Load control relay
Radiator fan motor relay
Clamp the wire harness and
speed sensor lead with the
clamp.
Clamp the wire harness and
EXUP servo motor lead with the
clamp.
Clamp the wire harness then
bend the holder to downward.
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SPEC
CABLE ROUTING
Handlebar (front view)
Right handlebar switch
Corrugated tube (engine stop
switch lead, throttle switch
leads, right grip warmer lead,
and thumb warmer lead)
Upper guide (Pass the corrugated tubes and throttle cable.)
Corrugated tube (left grip
warmer
lead,
grip/thumb
warmer adjustment switch lead,
brake light switch lead, and
headlight beam switch lead)
Parking brake cable
Pass the helmet shield heater
jack in behind of the brake hose.
Helmet shield heater jack lead
Route the brake light switch
lead and left grip warmer lead
under the helmet shield heater
jack and then between the
brake hose and parking brake
cable.
Left handlebar switch
Auxiliary DC jack
Clamp the rubber cover to the
bearing holder with a clamp.
After fitting, bundle the couplers of the brake light switch,
lever holder 1, lever holder 3,
thumb warmer, headlight beam
switch, lever holder 2, grip
warmer × 2, grip warmer switch
handle, terminal complete and
thumb warmer switch handle
with the cover, and then close at
two points of bosses.
Point the knob of the clip position to the upward.
Insert the fuel tank breather
hose until it contacts the projection. To insert the hose, it is
allowed to apply oils.
Pass the throttle body outlet
hose in behind of the battery
bracket.
Oil pressure switch lead
Pass the oil cooler outlet hose
above the oil tank inlet hose.
To the parking brake
To the brake
Brake hose
Main switch
Throttle cable
Clamp the frame cross member
and fuel tank breather hose.
Face the head of the clamp to
the front of the vehicle and the
end of the clamp to the bottom
of the vehicle.
The fuel tank breather hose
should not have any slack
between the exit of the fuel tank
and the clamp.
Clamp the wire harness, EPS
(electric power steering) actuator lead, and ignition sub-wire
harness with the clamp. Face
the head of the clamp to the top
of the vehicle and the end of the
clamp to the rear of the vehicle.
Auxiliary DC jack coupler
Clamp the wire harness and cylinder identification sensor lead
with the clamp.
EPS (electric power steering)
actuator coupler (4P)
Pass the cylinder identification
sensor lead under the EPS
(electric power steering) actuator (4P) lead.
Cylinder identification sensor
coupler
Completely cover the ignition
sub-wire harness coupler with
the rubber cover.
Clamp the wire harness, cylinder identification sensor lead,
EPS (electric power steering)
actuator lead, and Ignition coil
lead (with rubber cover) with the
clamp. Face the head of the
clamp to the top of the vehicle
and the end of the clamp to the
rear of the vehicle.
Clamp the wire harness and
EPS (electric power steering)
actuator lead with the clamp.
Meter coupler installation area
Put the boots of the meter coupler in the boss root on the side
of the meter.
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Engine (right side view)
Clamp the wire harness.
Tighten the frame cross member and frame together.
Clamp the fuel tank breather
hose to the hose holder.
The clamp position is above the
hose protector. Clamp it from
outside.
Pass the fuel tank breather
hose in behind of the frame
cross member.
Wire harness
Fuse box bracket
Fuse box
Coolant recovery
Coolant reservoir
Brake hose
Parking brake cable
Clamp
Clamp the parking brake cable
with the holder, and then bend
the holder 90° downward.
Air filter case latch
Oil tank outlet hose
Point the clamp tightening direction to the downward.
Route the coolant reservoir
breather hose behind the
engine and front of the heat
exchanger.
Clamp the coolant reservoir
breather hose at the white paint
mark. Face the head of the
clamp outside and the end of
the clamp to the front.
Tail/brake light coupler
To the tail/brake light
Gear position switch lead
Clamp the gear position switch
lead. Any slack is not allowed
between the terminal and
clamp.
Route the wire harness outside
of side cover 2.
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Engine (left side view)
Fasten the EPS (electric power
steering) actuator coupler to the
bracket of the frame cross
member.
Clamp the fuel pump lead and
fuel hose with the clamp.
Route the fuel tank breather
hose along the frame cross
member.
Clamp the fuel tank breather
hose to the hose holder.
Hose protector
EXUP servo motor coupler
Route the wire harness inside of
the EXUP cable.
Speed sensor coupler
Speed sensor lead holder
Align the punch mark with the
rivet.
Front axle housing
Nylon nuts
Speed sensor
Front axle assembly
Bearing holder reinforcement
Gear unit
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SPEC
WIRING DIAGRAM
2011 RX10PA, RX10PSA, RX10PXTA
Crankshaft position sensor
AC magneto
Rectifier/regulator
Main switch
Main fuse
Load control relay
Fuel injection system fuse
Starter relay
Battery
Starter motor
Diode
Engine stop switch
Throttle switch
Grip warmer
Thumb warmer
Grip warmer adjustment switch
Thumb warmer adjustment switch
Oil pressure switch
CO adjustment coupler
ECU (engine control unit)
Ignition coil sub-wire harness
Cylinder-#1 ignition coil
Spark plug
Cylinder-#2 ignition coil
Cylinder-#3 ignition coil
Cylinder-#4 ignition coil
Fuel injection system relay
Fuel pump
Injector #1
Injector #2
Injector #3
Injector #4
Throttle position sensor
Speed sensor
Cylinder identification sensor
Atmospheric pressure sensor
Intake air pressure sensor
Coolant temperature sensor
Intake air temperature sensor
Knock sensor
ISC (idle speed control) unit
EXUP servo motor
Frame ground
EPS (electric power steering) control unit
EPS self-diagnosis signal connector
EPS (electric power steering) motor
EPS (electric power steering) fuse
Back buzzer
Gear position switch
Brake light switch
Tail/brake light
Fuel sender
Oil level switch
Speedometer unit
Multi-function meter
Warning light
Low coolant temperature indicator light
High beam indicator light
Meter light
Headlight
Headlight relay
Headlight beam switch
Radiator fan motor
Radiator fan motor relay
Auxiliary DC jack
Helmet shield heater jack
Ignition fuse
Radiator fan motor fuse
Signal fuse
Headlight fuse
Auxiliary DC jack fuse
Helmet shield heater jack fuse
COLOR CODE
B.............. Black
Br ............ Brown
Ch ........... Chocolate
G ............. Green
Gy ........... Gray
L .............. Blue
Lg ............ Light green
O ............. Orange
P.............. Pink
R ............. Red
Sb............ Sky blue
W............. White
Y.............. Yellow
B/L .......... Black/Blue
B/R ......... Black/Red
B/W......... Black/White
B/Y.......... Black/Yellow
Br/G ........ Brown/Green
Br/L......... Brown/Blue
Br/W ....... Brown/White
G/B ......... Green/Black
G/R ......... Green/Red
G/W ........ Green/White
G/Y ......... Green/Yellow
Gy/R ....... Gray/Red
L/B .......... Blue/Black
L/R.......... Blue/Red
L/W ......... Blue/White
L/Y .......... Blue/Yellow
Lg/B ........ Light green/Black
Lg/L ........ Light green/Blue
Lg/W ....... Light green/White
O/B ......... Orange/Black
O/G......... Orange/Green
O/L.......... Orange/Blue
O/R ......... Orange/Red
O/W ........ Orange/White
P/L .......... Pink/Blue
P/W......... Pink/White
R/B ......... Red/Black
R/G ......... Red/Green
R/L.......... Red/Blue
R/W ........ Red/White
R/Y ......... Red/Yellow
W/B......... White/Black
W/G ........ White/Green
W/R ........ White/Red
Y/G ......... Yellow/Green
Y/R ......... Yellow/Red
Y/W......... Yellow/White
WIRING DIAGRAM
2011 RX10PA, RX10PSA, RX10PXTA
WIRING DIAGRAM
2011 RX10PA, RX10PSA, RX10PXTA