Yamaha | RSG90K | Owner`s manual | Yamaha RSG90K Owner`s manual

SNOWMOBILE
OWNER’S MANUAL
RS90K
RS90MK
RS90RK
RSG90K
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2004.04-2.8×1 CR
(E)
LIT-12628-02-38
8ES-28199-10
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM
A
ESU00286
1-
MACHINE IDENTIFICATION
Identification number records
A. FRAME NUMBER:
CZ-01E
B
B. ENGINE NUMBER (PRIMARY ID):
CZ-01E
C. KEY NUMBER:
C
CZ-01E
Record the frame number, engine number (Primary ID),
and key number in the spaces provided for assistance
when ordering spare parts from a Yamaha dealer.
1 The frame number is the seventeen-digit number
stamped on the frame of the snowmobile. (See
fig. È.)
2 The engine number is stamped in the location as
shown. (See fig. É.)
3 Key number (See fig. Ê.)
Also, record and keep the ID numbers in a separate
place in case the snowmobile is stolen.
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ESU00011
INTRODUCTION
2-
Congratulations on your purchase of a Yamaha snowmobile. This model is the result of Yamaha’s vast experience
in the production of fine sporting and touring snowmobiles. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these
fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this snowmobile. If you have any questions concerning the operation
or maintenance of your snowmobile, please consult a
Yamaha dealer.
To maintain the high quality and performance of this
snowmobile, it is important that you and your Yamaha
dealer pay close attention to the recommended maintenance schedules and operating instructions contained
within this manual.
RS90K
RS90MK
RS90RK
RSG90K
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation, U.S.A.
1st Edition, April 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan
P/N LIT-12628-02-38
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM
WARNING
@
PLEASE READ AND UNDERSTAND THIS MANUAL
COMPLETELY BEFORE OPERATING THE SNOWMOBILE.
@
NOTE:
@
●
●
Yamaha continually seeks advancements in product
design and quality. Therefore, while this manual contains the most current product information available
at the time of printing, there may be minor discrepancies between your snowmobile and this manual. If
there is any question concerning this manual, please
consult a Yamaha dealer.
This manual should be considered a permanent part
of this snowmobile and should remain with the snowmobile when resold.
@
Particularly important information is distinguished in this
manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
WARNING
@
Failure to follow WARNING instructions could result in
severe injury or death to the snowmobile operator, a
bystander, or a person inspecting or repairing the snowmobile.
CAUTION:
@
A CAUTION indicates special precautions that must be
taken to avoid damage to the snowmobile.
NOTE:
@
A NOTE provides key information to make procedures
easier or clearer.
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ESU00003
CONTENTS
YAMAHA MOTOR
CORPORATION, U.S.A.
SNOWMOBILE LIMITED
WARRANTY .......................................1-1
YAMAHA EXTENDED SERVICE
(Y.E.S.) ...............................................1-4
LOCATION OF THE
IMPORTANT LABELS .......................2-1
SAFETY INFORMATION ...................3-1
DESCRIPTION ...................................4-1
CONTROL FUNCTIONS ....................5-1
Main switch......................................5-1
Starter lever (choke) ........................5-2
Throttle lever....................................5-2
Engine overheating prevention
system .............................................5-2
Throttle override system
(T.O.R.S.) ........................................5-3
Speedometer unit ............................5-4
High beam indicator light .................5-4
Fuel meter and grip/thumb
warmer level indicator......................5-5
Fuel level warning indicator .............5-6
Oil level warning indicator................5-6
Low coolant temperature
indicator light ...................................5-6
Coolant temperature warning
indicator ...........................................5-7
Engine stop switch...........................5-8
Brake lever ......................................5-8
Parking brake lever..........................5-9
Shift lever.........................................5-9
Headlight beam switch ..................5-10
Shroud latches...............................5-10
Drive guard ....................................5-10
V-belt holders ................................5-11
Carburetor coolant shut-off
lever...............................................5-11
Storage compartment ....................5-11
PRE-OPERATION CHECKS..............6-1
Fuel .................................................6-1
Engine oil.........................................6-2
Engine oil level ................................6-3
Coolant ............................................6-4
Throttle lever ...................................6-5
Throttle override system
(T.O.R.S.) ........................................6-5
Brake ...............................................6-6
Brake fluid leakage ..........................6-7
V-belt ...............................................6-7
Drive guard ......................................6-7
Drive track .......................................6-8
51-mm (2.0-in) high-profile
pattern drive track............................6-8
Slide runners ...................................6-9
Skis and ski runners ........................6-9
Steering system.............................6-10
Lights .............................................6-10
Air filter ..........................................6-10
Fittings and fasteners ....................6-11
Tool kit and recommended
equipment......................................6-11
OPERATION ......................................7-1
Starting the engine ..........................7-1
Break-in ...........................................7-2
Riding your snowmobile ..................7-3
Getting to know your snowmobile ...7-3
Learning to ride your snowmobile ...7-3
To start out and accelerate..............7-3
Braking ............................................7-3
Turning ............................................7-4
Riding uphill .....................................7-4
Riding downhill ................................7-5
Traversing a slope ...........................7-5
Ice or icy surface .............................7-5
Hard-packed snow ..........................7-6
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM
Operation on surfaces other than
snow or ice ......................................7-6
Maximizing drive track life ...............7-7
Strap ................................................7-8
Driving .............................................7-9
Stopping the engine.......................7-10
Transporting ..................................7-11
PERIODIC MAINTENANCE ...............8-1
Periodic maintenance chart .............8-1
Tool kit .............................................8-4
Spark plug inspection ......................8-4
Engine idle speed adjustment .........8-6
Throttle cable adjustment ................8-6
Carburetor adjustment.....................8-7
High altitude adjustments ................8-9
Adjusting the valve clearance..........8-9
Changing the engine oil.................8-10
Cooling system ..............................8-13
V-belt replacement ........................8-15
Checking the drive chain
housing oil level and the drive
chain tension .................................8-17
Checking the brake pads...............8-19
Checking the parking brake
pads...............................................8-19
Checking the brake fluid level........8-20
Brake fluid replacement.................8-20
Suspension....................................8-20
Drive track adjustment...................8-29
Ski alignment .................................8-31
Handlebar adjustment ...................8-31
Lubrication .....................................8-34
Headlight bulb replacement...........8-35
Headlight beam adjustment...........8-35
Battery ...........................................8-36
Fuse replacement..........................8-36
TROUBLESHOOTING .......................9-1
STORAGE ........................................10-1
SPECIFICATIONS............................11-1
Dimensions....................................11-1
Engine ...........................................11-1
Chassis..........................................11-2
Electric...........................................11-3
WIRING DIAGRAM ..........................12-1
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ESU00004
YAMAHA MOTOR CORPORATION, U.S.A.
SNOWMOBILE LIMITED WARRANTY
1-
CW-01E
1-1
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CW-02E
1-2
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CW-03E
1-3
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ESU04280
YAMAHA EXTENDED SERVICE (Y.E.S.)
CW-06E
1-4
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ESU04050
LOCATION OF THE IMPORTANT
LABELS
2-
Please read the following labels carefully before operating this snowmobile.
NOTE:
@
Maintain or replace safety and instruction labels, as necessary.
@
1 RS90/RS90M
1 RS90R/RSG90
2
3
2-1
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4 RS90M
5 RS90M
6 RSG90
7 RSG90
8 RS90M/RSG90
2-2
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NOTE:
@
The following suspension adjustment charts are included
with the Owner’s Manual.
@
RS90/RS90M/RS90R
2-3
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ESU00008
SAFETY INFORMATION
3-
When you ride your snowmobile, you must know and use
the following for your safety. Severe injury or death may
result if you ignore any of the following.
Before operating
1. Read the Owner’s Manual and all labels before operating this snowmobile. Become familiar with all of the
operating controls and their function. Consult a
Yamaha dealer about any control or function you do
not understand.
2. This snowmobile was not manufactured for use on
public streets, roads, or highways. Such use is prohibited by law, and you could collide with another
vehicle.
3. This snowmobile is designed to carry the OPERATOR ONLY.
Passengers are prohibited. Carrying a passenger
can cause loss of control.
4. Do not operate the snowmobile after drinking alcohol
or taking drugs. Your ability to operate the snowmobile is reduced by the influence of alcohol or drugs.
5. For safety and proper care of the snowmobile, always
perform the pre-operation checks on pages 6-1–6-11
before starting the engine. Check the throttle, brake,
and steering for proper operation every time before
starting the engine. Make sure that the throttle lever
moves freely and it returns to the home position when
it is released.
6. Apply the parking brake before starting the engine.
Never drive the snowmobile with the parking brake
applied. This may overheat the brake disc and reduce
braking ability.
3-1
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7. Do not allow anyone to stand behind the snowmobile
when starting, inspecting, or adjusting the snowmobile. A broken track, track fittings, or debris thrown by
the track could be dangerous to the operator or
bystanders.
8. Handle fuel with care; it is HIGHLY FLAMMABLE.
● Never add fuel when the engine is running or hot.
Allow the engine to cool for several minutes after
running.
● Use an approved fuel container.
● Fill the fuel tank outdoors with extreme care.
Never remove the fuel cap indoors. Never fill the
fuel tank indoors.
● Never refuel while smoking or in the vicinity of an
open flame.
● Make sure that the fuel tank cap is closed securely
after refueling. Wipe up any spilled fuel immediately.
9. If you swallow some gasoline, inhale a lot of gasoline
vapor, or get some gasoline into your eyes, see your
doctor immediately. If any gasoline spills on your skin
or clothing, immediately wash your skin with soap
and water, and change your clothes.
10. Wear protective clothing. Wear an approved helmet,
and a face shield or goggles. Also, wear a good quality snowmobile suit, boots, and a pair of gloves or mittens that will permit use of your thumbs and fingers
for operation of the controls.
Operation
1. Do not run the engine indoors, except when starting
the engine to transport the snowmobile in or out of
the building. Open the outside doors; exhaust fumes
are dangerous.
2. Be careful where you ride. There may be obstacles
hidden beneath the snow. Stay on established trails
to minimize your exposure to hazards. Ride slowly
and cautiously when you ride off of established trails.
Hitting a rock or stump, or running into wires could
cause an accident and injury.
3-2
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3. This snowmobile is not designed for use on surfaces
other than snow or ice. Use on dirt, sand, grass,
rocks, or bare pavement may cause loss of control
and may damage the snowmobile.
4. Avoid operating on glare ice, or on snow which has a
lot of dirt or sand mixed in. Operation under such
conditions will damage or result in rapid wear of ski
runners, drive track, slide runners, and drive sprockets.
5. Always ride with other snowmobilers when going on a
ride. You may need help if you run out of fuel, have an
accident, or damage your snowmobile.
6. Many surfaces such as ice and hard-packed snow
require much longer stopping distances. Be alert,
plan ahead and begin decelerating early. The best
braking method on most surfaces is to release the
throttle and apply the brake gently—not suddenly.
Maintenance and storage
1. Do not leave the snowmobile on its left side for an
extended period of time. Fuel may leak out from the
fuel breather hose.
2. Modifications made to the snowmobile not approved
by Yamaha, or the removal of original equipment may
render your snowmobile unsafe for use that may
cause severe personal injury. Modifications may also
make the snowmobile illegal to use.
3. Never store the snowmobile with fuel in the fuel tank
inside a building where ignition sources are present
such as hot water and space heaters, an open flame,
sparks, clothes dryers, and the like. Allow the engine
to cool off before storing the snowmobile in an
enclosed space.
4. Always refer to the “STORAGE” section if the snowmobile is to be stored for an extended period.
5. Maintain or replace safety and instruction labels, as
necessary.
3-3
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ESU00012
DESCRIPTION
4-
1
2
3
4
5
6
7
8
9
0
RS90/RS90R
RS90M
RSG90
4-1
Windshield
Steering handlebar
Seat
Frame
Slide rail suspension
Drive track
Skis
Headlights
Shroud
Storage compartment
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
4-2
Tail/brake lights
Snow flap
Brake lever
Parking brake lever
Grip warmer adjustment switch
Headlight beam switch
Strap (RS90M)
Engine stop switch
Thumb warmer adjustment switch
Throttle lever
Shift lever
(RS90R/RSG90)
Shroud latch
Main switch
Starter lever
Tachometer
Low coolant temperature indicator light
High beam indicator light
Warning light
Self-diagnosis warning indicator
Coolant temperature warning indicator
Fuel level warning indicator
Oil level warning indicator
Speedometer
Grip warmer indicator
Select/reset button
Thumb warmer indicator
Fuel meter and grip/thumb warmer level
indicator
Odometer/tripmeter
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM
ESU00013
5-
CONTROL FUNCTIONS
ESU00362
Main switch
The main switch controls the following items.
1 “OFF”
The ignition circuit is switched off.
The key can be removed only in this position.
2 “ON”
The ignition circuit is switched on.
3 “START”
The starting circuit is switched on.
The starter motor starts.
CAUTION:
@
Release the switch immediately after the engine
starts.
@
NOTE:
@
The headlights, meter lights, and taillights come on after
the engine starts.
@
5-1
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ESU00201
Starter lever (choke)
Use the starter lever (choke) when starting and warming
up a cold engine.
1
2
3
4
Starter lever (choke)
When starting a cold engine.
Warming up
When the engine is warm.
NOTE:
@
Refer the “Starting the engine” section for proper operation.
@
ESU00022
Throttle lever
Once the engine is running cleanly, squeezing a the throttle lever 1 will increase the engine speed and cause
engagement of the drive system. Regulate the speed of
the snowmobile by varying the throttle position. Because
the throttle is spring-loaded, the snowmobile will decelerate, and the engine will return to idle when it is released b.
WARNING
@
Check the throttle, brake, and steering for proper
operation before starting the engine.
@
ESU00361
Engine overheating prevention system
This model is equipped with an engine overheating prevention system to prevent overheating when the engine
is idling.
When the engine has been idling for at least 3 minutes
and the coolant temperature has risen above 100 °C
(212 °F), the engine automatically shuts off to prevent
overheating.
NOTE:
The engine can be started after it shuts off.
5-2
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ESU04151
Throttle override system (T.O.R.S.)
If the carburetor or throttle cable should malfunction during operation, the T.O.R.S. will operate when the throttle
lever is released.
The T.O.R.S. is designed to interrupt the ignition and
keep the engine speed between 2,800 and 3,000 r/min if
the carburetor fails to return to idle when the lever is
released.
WARNING
@
●
●
A
If the T.O.R.S. is activated, make sure that the
cause of the malfunction has been corrected and
that the engine can be operated without a problem before restarting the engine.
Be sure to use the specified spark plug and spark
plug cap. Otherwise, the T.O.R.S. will not work
properly.
@
CA-19E
Mode A
Item
Throttle switch
Throttle position
sensor
B
Engine
C
È
É
Ê
1
2
3
a
b
c
d
Idling/
starting
B
Running
C
Trouble
Off
On
Off
Closed
Open
Open
Run
Run
T.O.R.S.
will operate
Idling/starting
Running
Trouble
Throttle position sensor (throttle valve position)
Throttle switch
Throttle cable
On
Off
Open
Closed
NOTE:
@
When the T.O.R.S. is activated, the warning light 4 and
self-diagnosis warning indicator 5 will flash and the twodigit code “84” 6 will flash in the tripmeter/odometer display.
@
5-3
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ESU04160
Speedometer unit
The speedometer unit is equipped with the following:
● a digital speedometer (which shows riding speed)
● an odometer (which shows the total distance traveled)
● a tripmeter (which shows the distance traveled since
it was last set to zero)
● warning indicators (which show self-diagnosis, coolant temperature, fuel level, and oil level warnings)
● a fuel meter (which shows the fuel remaining in the
fuel tank)
● a grip/thumb warmer level indicator (which shows the
grip warmer level or the thumb warmer level)
After the engine is started, the tachometer 1 makes one
sweep, and the low coolant temperature indicator
light 2, the warning light 3, and all segments of the
meter 4 turn on and off once.
The grip warmer level is initially displayed for 5 seconds,
then switches to the fuel meter display.
Odometer and tripmeter modes
Pushing the select/reset button 5 switches the display
between the odometer mode “ODO” and the tripmeter
mode “TRIP”.
To reset the tripmeter, push the select/reset button for at
least one second while the tripmeter is displayed.
NOTE:
@
To switch the speedometer, odometer, and tripmeter displays between kilometers and miles, select the odometer
mode “ODO”, and then push the select/reset button 5
for at least 10 seconds while the snowmobile is stopped.
@
ESU00363
High beam indicator light
The high beam indicator light 1 comes on when the high
beams of the headlights are switched on. (See page 5-10
for headlight beam switch operation.)
5-4
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ESU03821
Fuel meter and grip/thumb warmer level indicator
The fuel meter and grip/thumb warmer level indicator
have eight segments 1 which show the amount of fuel
remaining in the fuel tank, the grip warmer level, or the
thumb warmer level.
Fuel meter
As the fuel level decreases in the fuel tank, the segments
disappear until the level goes down to the last segment
“E” (Empty). When this occurs, the fuel level warning
indicator 2 and the warning light 3 come on.
If the fuel level warning indicator and the warning light
come on, fill the fuel tank at the first opportunity.
NOTE:
@
The snowmobile must be stopped on a level surface to
obtain an accurate fuel meter reading. The fuel meter
reading changes as the snowmobile moves and depending on the inclination of the snowmobile.
@
Grip/thumb warmer level indicator
The grip warmer adjustment switch 1 and the thumb
warmer adjustment switch 2 control the electrically
heated handlebar grips and throttle lever respectively.
To raise the temperature, press each switch to “HI”. To
lower the temperature, press each switch to “LO”.
NOTE:
@
●
●
●
●
●
The grip warmer indicator 3 comes on and the display switches to the grip warmer level when the grip
warmer adjustment switch is pressed.
The thumb warmer indicator 4 comes on and the
display switches to the thumb warmer level when the
thumb warmer adjustment switch is pressed.
The grip/thumb warmer level is displayed for 5 seconds after releasing the grip/thumb warmer adjustment switch, then switches to the fuel meter.
The top segment of the grip/thumb warmer level indicator flashes once if the grip/thumb warmer adjustment
switch is continually pressed at the maximum level. The
bottom segment of the grip/thumb warmer level indicator flashes once if the grip/thumb warmer adjustment
switch is continually pressed at the minimum level.
When the engine is started, the grip/thumb warmer
levels are set to the levels saved when the engine
was stopped.
@
5-5
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ESU04260
Fuel level warning indicator
The fuel level warning indicator indicates a malfunctioning sensor, disconnected coupler, broken lead, or short
circuit when detected by the self-diagnosis device of the
snowmobile.
The fuel level warning indicator 1, warning light 2, and
all segments of the fuel meter 3 warn the rider of the
above problems by flashing continuously.
When this occurs, have a Yamaha dealer inspect the
snowmobile as soon as possible.
ESU00377
Oil level warning indicator
The oil level warning indicator 1 and the warning light 2
come on when the engine oil level is low.
If the oil level warning indicator and the warning light
come on, place the snowmobile on a level surface and
allow it to idle for one minute.
If the oil level warning indicator and the warning light go
off, the engine oil level is sufficient, however it is getting
low. Add engine oil as soon as possible.
If the oil level warning indicator and the warning light do
not go off, check the engine oil level in the oil tank (see
page 6-3), and add engine oil if necessary.
ESU04171
Low coolant temperature indicator light
The low coolant temperature indicator light 1 comes on
when the coolant temperature is low and informs the
rider that the snowmobile must be warmed up. After the
engine is started, warm it up until the indicator light goes
off.
The snowmobile can be operated normally after the indicator light goes off.
NOTE:
@
Operate the snowmobile at low speeds when the low
coolant temperature indicator light is on. If the engine
speed is too high, the warning light 2 and self-diagnosis
warning indicator 3 will flash and the two-digit code
“86” 4 will flash slowly in the tripmeter/odometer display.
When this occurs, the engine control system prevents
the engine speed from rising.
@
5-6
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ESU04180
Coolant temperature warning indicator
If the engine overheats, the coolant temperature warning
indicator 1 and the warning light 2 come on. When this
occurs, stop the engine immediately and allow the
engine to cool down, and then check the coolant level in
the coolant reservoir. (See page 6-4.)
CAUTION:
@
Do not operate the engine if it overheats.
@
ESU04251
Self-diagnostic system
This model is equipped with a self-diagnostic system for
various electrical circuits.
If any of those circuits are defective, the warning light 1
and the self-diagnosis warning indicator 2 will flash, and
then an error code (e.g., Er_1, Er_2, 16, 81) 3 will flash
slowly in the tripmeter/odometer display.
WARNING
@
●
●
●
If the self-diagnosis warning indicator and warning light flash continuously, and an error code is
displayed during operation, there may be some
problem with the electrical circuit, lead couplers,
etc.
Stop the engine and allow it to cool off. Then,
check that the wire harness couplers in the
engine compartment are connected properly.
If the self-diagnosis warning indicator, warning
light, and an error code flash after the engine has
been restarted, note the error code, and then
have a Yamaha dealer inspect the snowmobile as
soon as possible.
@
5-7
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ESU00031
Engine stop switch
The engine stop switch 1 is used to stop the engine in
an emergency. Simply push 2 the stop switch to stop the
engine. To start the engine, pull 3 the stop switch and
proceed with starting the engine. (See page 7-1 for more
details.)
During the first few rides, practice using the stop switch
so that you can react quickly in an emergency.
ESU00320
Brake lever
The snowmobile is stopped by braking the entire drive
system.
Squeeze the brake lever towards the handlebar grip to
stop the snowmobile.
1 Brake lever
2 Brake lever end
3 Handlebar end
NOTE:
@
When the brake lever is operated, the brake light will illuminate.
@
CAUTION:
@
Make sure that the brake lever end does not project
out over the handlebar end. This will help prevent
brake lever damage when the snowmobile is placed
on its side for service.
@
5-8
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A
ESU00035
Parking brake lever
When parking the snowmobile or starting the engine,
apply the parking brake by moving the brake lever 1 to
the left.
To release the parking brake, move the parking brake
lever 1 to the right.
B
È To apply the parking brake
É To release the parking brake
WARNING
@
●
●
Always set the parking brake before attempting to
start the engine.
Never run the snowmobile with the parking brake
applied. This may overheat the brake disc and
reduce braking ability.
@
ESU00341
Shift lever
For RS90R/RSG90
The shift lever is used to put the snowmobile into forward
or reverse. After coming to a complete stop, pull the shift
lever out, slide it to “FWD” or to “REV” until it stops, and
then release it.
1
2
3
4
5
Shift lever
Pull out
Slide to “FWD” (Forward)
Slide to “REV” (Reverse)
Release
CAUTION:
@
Do not shift from “FWD” to “REV” or from “REV” to
“FWD” while the snowmobile is moving. Otherwise,
the drive system could be damaged.
@
5-9
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ESU00039
Headlight beam switch
Push the headlight beam switch to change the headlight
beam to high or low.
1
2
3
4
Headlight beam switch
Push
High beam
Low beam
ESU00481
Shroud latches
To open the shroud, unhook the shroud latches, and then
slowly raise the shroud forward until it stops. When closing the shroud, slowly lower it to its home position, and
then hook the shroud latches.
1 Shroud latch
2 Shroud
CAUTION:
@
Make sure that all cables and wires are in place when
closing the shroud.
@
WARNING
@
●
●
●
Do not drive the snowmobile with the shroud
open, unlatched, or removed.
Keep your body and clothing away from rotating
parts when servicing with the shroud open.
Do not touch the hot muffler and engine during or
immediately after operation.
@
ESU00521
Drive guard
The drive guard is designed to cover the V-belt clutch
and V-belt in case parts break or come loose.
WARNING
@
●
●
Make sure that the drive guard is tightened
securely before operating the snowmobile.
Never run the engine with the V-belt or drive
guard removed.
@
5-10
U8ES10.book Page 11 Monday, April 12, 2004 1:25 PM
ESU00053
V-belt holders
Keep a spare V-belt for emergency use by placing it into
the V-belt holders provided.
CAUTION:
@
Make sure that the V-belt is installed securely in the
holders.
@
ESU04080
Carburetor coolant shut-off lever
For RS90M
The carburetor coolant shut-off lever controls the flow of
coolant through the carburetor.
Make sure that the lever is in the “ON” position to allow
the coolant to flow and warm the carburetor while the
ambient temperature is below 0 °C (32 °F).
1 Carburetor coolant shut-off lever
2 “ON” (open)
3 “OFF” (closed)
CAUTION:
@
When operating the snowmobile in temperatures
above 0 °C (32 °F), move the carburetor coolant shutoff lever to the “OFF” position to stop the flow of
coolant, since the carburetor does not need to be
warmed.
@
ESU00342
Storage compartment
The storage compartment is located under the shroud.
Open the storage compartment to store the tool kit,
spare parts, or other small items.
5-11
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM
ESU00072
PRE-OPERATION CHECKS
6-
NOTE:
@
Pre-operation checks should be made each time the
snowmobile is used.
@
WARNING
@
The engine and muffler will be very hot after the
engine has been run.
Avoid touching the engine and muffler while they are
still hot with any part of your body or clothing during
inspection or repair.
@
ESU00075
Fuel
Make sure that there is sufficient fuel in the fuel tank.
Recommended fuel:
Unleaded gasoline
Pump octane R+M ; 88 or higher
2
Fuel tank capacity:
38.0 L (8.4 Imp gal, 10.0 US gal)
WARNING
@
●
●
●
Fuel is HIGHLY FLAMMABLE and poisonous.
Check the “SAFETY INFORMATION” section
carefully before refueling. (See page 3-2.)
Do not fill the fuel tank above the bottom of the
filler tube 1. Fuel could overflow if the snowmobile is tilted on its side or if the ambient temperature rises, causing the fuel to warm up and
expand.
Make sure that the fuel tank cap is closed
securely after refueling. Leaking fuel can catch
fire.
@
2 Fuel level
6-1
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM
CAUTION:
@
●
●
●
●
Oxygenated fuels (gasohol) containing a maximum 5% of ethanol can be used, although richer
jetting may be required to prevent engine damage. Consult a Yamaha dealer. Gasohol containing methanol is not recommended.
Make sure that snow or ice does not enter the fuel
tank when refueling.
Do not use alcohol deicers or water absorbing
additives with oxygenated fuel.
The fuel tank should be filled with straight gasoline as specified.
@
ESU04030
Engine oil
Use a combination of the recommended SAE and API oil
classifications shown in the chart below.
CB-02E
SAE
-40˚
-20˚
0˚
20˚
API
40˚
60˚ F
4˚
16˚ C
SE, SF, SG
or
higher
SAE 0W-30
-40˚
-29˚
-18˚
-7˚
CAUTION:
@
●
●
Use only 4-stroke engine oil.
Engine oil also lubricates the starter clutch. In
order to prevent clutch slippage, do not mix any
chemical additives with the oil or use oils of a
higher grade than “CD”. In addition, do not use
oils labeled “ENERGY CONSERVING II” or higher.
@
6-2
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM
ESU03441
Engine oil level
The engine oil level should be checked before each use.
CAUTION:
@
Do not run the engine with too much or not enough
oil in the oil tank. Oil could flow into the air filter case
and the engine could be damaged.
@
Checking the engine oil level
1. Place the snowmobile on a level surface and apply
the parking brake.
2. Start the engine, warm it up for 10–15 minutes, and
then turn it off.
NOTE:
@
●
●
The engine can also be warmed up by operating the
snowmobile for 10–15 minutes.
After operating the snowmobile, allow the engine to
idle for at least 10 seconds before turning it off.
@
3. Disconnect the oil level gauge coupler 1.
CAUTION:
@
Disconnect the oil level gauge coupler before removing the oil level gauge/dipstick. Otherwise, the cable
can twist and break.
@
4. Remove the oil level gauge/dipstick 2, wipe it clean,
insert it back into the filler hole (without screwing it
in), and then remove it again to check the oil level.
NOTE:
@
The engine oil should be between the “F” 3 and “E” 4
level marks on the oil level gauge/dipstick.
@
5. If the engine oil is below the “E” level mark, add sufficient oil of the recommended type to raise it to the “F”
level mark. (See page 6-2 for the recommended oil.)
CAUTION:
@
●
●
When adding the engine oil, be careful not to fill
above the “F” level mark on the oil level
gauge/dipstick.
Make sure that no foreign material enters the
engine oil tank.
@
6-3
U8ES10.book Page 4 Monday, April 12, 2004 1:25 PM
6. Insert the oil level gauge/dipstick into the oil filler
hole, and then tighten it securely.
7. Connect the oil level gauge coupler.
ESU00086
Coolant
Check the coolant level in the coolant reservoir when the
engine is cold. If the coolant level is below the
“COLD LEVEL” mark, add soft water until it reaches the
“COLD LEVEL” mark. (See pages 8-13–8-14 for more
details.)
1 “COLD LEVEL” mark
WARNING
@
Do not remove the coolant reservoir cap when the
engine is hot.
@
CAUTION:
@
●
●
Hard water or salt water is harmful to the engine
parts. You may use boiled or distilled water, if soft
water is not available.
Tap water can be used temporarily in an emergency.
@
6-4
U8ES10.book Page 5 Monday, April 12, 2004 1:25 PM
ESU00087
Throttle lever
Check the throttle lever operation before starting the
engine.
The throttle lever must open smoothly and spring back to
its home position when released.
ESU00090
Throttle override system (T.O.R.S.)
Check the T.O.R.S. for proper operation.
WARNING
@
When checking T.O.R.S.:
● Make sure that the parking brake is applied.
● Make sure that the throttle lever moves smoothly.
● Do not run the engine up to clutch engagement
r/min. Otherwise, the snowmobile could start
moving forward unexpectedly, which could cause
an accident.
@
1. Start the engine.
NOTE:
@
Refer to the “Starting the engine” section.
@
2. Hold the pivot point of the throttle lever away from the
throttle switch by putting your thumb (above) and
forefinger (below) between the throttle lever pivot 1
and the engine stop switch housing 2.
While holding the pivot point as described above,
press the throttle lever 3 gradually.
The T.O.R.S. will operate and the engine should run
between 2,800 and 3,000 r/min.
WARNING
@
If the engine does not run between 2,800 and
3,000 r/min, stop the engine by turning the main switch
to the “OFF” position and consult a Yamaha dealer.
@
6-5
U8ES10.book Page 6 Monday, April 12, 2004 1:25 PM
ESU00091
Brake
1. Brake lever
Test the brake at a low speed when starting out to
make sure that it is working properly. If the brake
does not provide proper braking performance,
inspect the brake for wear or brake fluid leakage.
(See pages 8-19–8-20 for more details.)
WARNING
@
●
●
A soft, spongy feeling in the brake lever indicates
a failure in the brake system.
Do not operate the snowmobile if you find any
problems in the brake system. You could lose
braking ability, which could lead to an accident.
Ask a Yamaha dealer to inspect and repair the
brake system.
@
CAUTION:
@
Make sure that the brake lever end does not project
out over the handlebar end. This is to prevent brake
lever damage when the snowmobile is placed on its
side.
@
2. Brake fluid
Check the brake fluid level. (See page 8-20.)
Add fluid if necessary.
1 Lower level
Specified brake fluid: DOT 4
6-6
U8ES10.book Page 7 Monday, April 12, 2004 1:25 PM
ESU00093
Brake fluid leakage
Apply the brake for a few minutes. Check to see if any
brake fluid leaks out from the brake hose joints or the
master cylinder.
WARNING
@
If brake fluid leakage is found, ask a Yamaha dealer
for immediate repairs.
@
CAUTION:
@
Brake fluid may deteriorate painted surfaces or plastic parts. Never spill any brake fluid. If any is spilled,
clean it up immediately.
@
ESU00941
V-belt
Open the shroud and remove the drive guard.
Check the V-belt for wear and damage. Replace if necessary.
Wear limit a: 32.5 mm (1.28 in)
WARNING
@
●
●
Make sure that the drive guard is tightened
securely before operating the snowmobile.
Never run the engine without the V-belt or with
the drive guard removed.
@
ESU00096
Drive guard
Check the drive guard mounts for damage. Make sure
that the drive guard is firmly in place.
6-7
U8ES10.book Page 8 Monday, April 12, 2004 1:25 PM
ESU00097
Drive track
Check the drive track for deflection, wear, or damage.
Adjust or replace if necessary. (See pages 8-29–8-31 for
more details.)
WARNING
@
Do not operate the snowmobile if you find damage to
the drive track, or if it has been maladjusted. Drive
track damage or failure could result in loss of braking ability and snowmobile control, which could
cause an accident.
@
ESU00243
51-mm (2.0-in) high-profile pattern drive track
For RS90M
This snowmobile is originally equipped with a 51-mm
(2.0-in) high-profile pattern drive track specifically for use
in deep snow riding conditions.
Therefore, avoid prolonged operation on hard surfaces
such as ice, hard-packed snow, dirt, etc., to extend the
life of the track and slide runners.
CAUTION:
@
●
●
Only use in deep snow riding conditions.
Operation on areas with light snowfall, ice, hardpacked snow, dirt, or grass will result in rapid
wear or damage to the track and slide runners
from lack of snow which serves as a lubricant.
@
6-8
U8ES10.book Page 9 Monday, April 12, 2004 1:25 PM
ESU00982
Slide runners
Check the slide runners for wear and damage.
If the slide runners reach the wear limit, they should be
replaced.
1 Slide runners
a Wear limit
Wear limit height:
For RS90/RS90M/RS90R
10.5 mm (0.41 in)
For RSG90
10.0 mm (0.39 in)
È RS90/RS90M/RS90R
É RSG90
CAUTION:
@
Ride on fresh snow frequently. Operating on ice or
hard packed snow will rapidly wear the slide runners.
@
ESU03201
Skis and ski runners
Check the skis and ski runners for wear and damage.
Replace if necessary.
For RS90/RS90R
Ski runner wear limit a:
8 mm (0.31 in)
Ski wear limit b:
12 mm (0.47 in)
For RS90M/RSG90
Ski runner wear limit a:
8 mm (0.31 in)
Ski wear limit b:
24 mm (0.94 in)
CAUTION:
@
Avoid scratching the skis when loading and unloading the snowmobile, when riding in areas with little
or no snow, or on sharp edges such as concrete,
curbs, etc. This will wear or damage the skis.
@
6-9
U8ES10.book Page 10 Monday, April 12, 2004 1:25 PM
ESU00103
Steering system
Check the handlebar for excessive free play:
1. Push the handlebar up and down and back and forth.
2. Turn the handlebar slightly to the right and left.
If excessive free play is noticed, consult a Yamaha
dealer.
ESU00378
Lights
Check the lights.
Replace any burned out bulbs.
CAUTION:
@
Avoid using a scraper or hot water for cleaning the
plastic lenses 1.
@
ESU00350
Air filter
Always check that no snow is under the air filter element.
Remove the air filter case cover and take out the air filter
element. If there is any snow under the air filter element,
remove the snow. Then install the air filter element
beneath the holding guides on the case and install the air
filter case cover.
NOTE:
@
After riding the snowmobile, make sure that there is no
snow under the air filter element.
@
6-10
U8ES10.book Page 11 Monday, April 12, 2004 1:25 PM
ESU00110
Fittings and fasteners
Check the tightness of the fittings and fasteners.
Tighten in proper sequence and torque if necessary.
ESU00345
Tool kit and recommended equipment
It is good practice to carry the tool kit, spare parts, and
other necessary equipment with you while riding the
snowmobile so that minor repairs can be done if necessary. The following should be carried at all times:
●
●
●
●
●
●
●
●
●
Tool kit
Flashlight
Roll of plastic tape
Steel wire
Towrope
Jumper cables
V-belt
Light bulbs
Spark plugs
When you start out for a long distance trip, extra fuel and
oil should be carried as well.
6-11
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM
ESU00112
OPERATION
7-
ESU00366
Starting the engine
WARNING
@
●
●
Be sure to check the “SAFETY INFORMATION”
section carefully before starting the engine.
Make sure that the parking brake is applied.
@
NOTE:
@
Make sure that the engine stop switch is in the on position. The starter motor cannot be operated when the
engine stop switch is in the off position.
@
1. Fully open the starter lever (choke).
1
2
3
4
Starter lever (choke)
Fully open (cold engine starting)
Half-open (warm engine up)
Closed (warm engine starting)
NOTE:
@
The starter lever (choke) is not required when the engine
is warm. Put the starter lever (choke) in the closed position.
@
2. Turn the main switch to the “START” position. After
the engine starts, put the starter lever (choke) in the
half-open position. Warm up the engine until it does
not run roughly or begin to stall when the starter lever
is returned to the closed position.
1 “START”
CAUTION:
@
●
●
Release the switch immediately after the engine
starts.
If the engine fails to start, release the switch, wait
a few seconds, then try again. Each attempt
should be as short as possible to preserve the
battery. Do not crank the engine more than 10
seconds on any one attempt.
@
7-1
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM
ESU00380
Break-in
There is never a more important period in the life of your
engine than the period between 0 and 500 km (300 mi).
For this reason, you should read the following material
carefully.
Since the engine is brand new, do not put an excessive
load on it for the first 500 km (300 mi). The various parts
in the engine wear and polish themselves to the correct
operating clearances. During this period, prolonged fullthrottle operation or any condition that might result in
engine overheating must be avoided.
Operating your snowmobile for the first time
Start the engine and let it idle for 15 minutes.
0–160 km (0–100 mi)
Avoid prolonged operation above 6,000 r/min.
160–500 km (100–300 mi)
Avoid prolonged operation above 8,000 r/min.
500 km (300 mi) and beyond
The snowmobile can now be operated normally.
CAUTION:
@
●
●
After 800 km (500 mi) of operation, the engine oil
must be changed and the oil filter cartridge
replaced.
If any engine trouble should occur during the
engine break-in period, immediately have a
Yamaha dealer check the snowmobile.
@
7-2
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM
totally familiar with the snowmobile’s handling and performance characteristics.
Set the parking brake and follow the
instructions on pages 7-1–7-2 to start the
engine. Once the engine has warmed up,
you are ready to begin riding your snowmobile.
ESU01272
Riding your snowmobile
Getting to know your snowmobile
A snowmobile is a rider active vehicle, and
your riding position and your balance are
the two basic factors of maneuvering your
snowmobile.
Riding your snowmobile requires skills
acquired through practice over a period of
time. Take the time to learn the basic techniques well before attempting more difficult
maneuvers.
Riding your new snowmobile can be a very
enjoyable activity, providing you with hours
of pleasure. However, it is essential to
familiarize yourself with the operation of
the snowmobile to achieve the skill necessary to enjoy riding safely. Before operating
the snowmobile, read this Owner’s Manual
completely and understand the operation
of the controls.
Pay particular attention to the safety information on pages 3-1–3-3.
Please read all warning and caution labels
on your snowmobile. Also, read the Snowmobiler’s Safety Handbook that is supplied
with your snowmobile.
To start out and accelerate
1. With the engine idling, release the
parking brake.
2. Apply the throttle slowly and smoothly.
The V-belt clutch will engage and you
will start to accelerate.
WARNING
@
The operator should always keep both
hands on the handlebar. Never put your
feet outside the running boards. Avoid
high speeds until you have become
thoroughly familiar with your snowmobile and all of its controls.
@
Braking
When slowing down or stopping, release
the throttle and apply the brake gently—not
suddenly.
WARNING
Learning to ride your snowmobile
@
●
Before you ride, always perform the preoperation checks listed on pages 8-1–8-3.
The short time spent checking the condition of the snowmobile will be rewarded
with added safety and a more reliable
snowmobile. Always wear the proper clothing for both warmth and to help protect you
from injury if an accident occurs.
Become familiar with operating your snowmobile at low speeds, even if you are an
experienced rider. Do not attempt to operate at maximum performance until you are
●
@
7-3
Many surfaces such as ice and hardpacked snow require much longer
stopping distances. Be alert, plan
ahead, and begin decelerating early.
Improper use of the brake can cause
the drive track to lose traction,
reduce control, and increase the
possibility of an accident.
U8ES10.book Page 4 Monday, April 12, 2004 1:25 PM
Turning
Riding uphill
For most snow surfaces, “body English” is
the key to turning.
As you approach a curve, slow down and
begin to turn the handlebar in the desired
direction. As you do so, put your weight on
the running board to the inside of the turn
and lean your upper body into the turn.
This procedure should be practiced at low
speeds many times, in a large flat area
with no obstacles. Once you have learned
this technique, you should be able to perform it at higher speeds or in tighter
curves. Lean more as the turn gets
sharper or is made at higher speeds.
Improper riding techniques such as abrupt
throttle changes, excessive braking, incorrect body movements, or too much speed
for the sharpness of the turn may cause
the snowmobile to tip.
If your snowmobile begins to tip while turning, lean more into the turn to regain balance. If necessary, gradually let off on the
throttle or steer to the outside of the turn.
Remember:
Avoid higher speeds until you are thoroughly familiar with the operation of your
snowmobile.
You should practice first on gentle slopes.
Try more difficult climbs only after you have
developed your skill. As you approach a
hill, accelerate before you start the climb,
and then reduce the throttle to prevent
track slippage. It is also important to keep
your weight on the uphill side at all times.
On climbs straight up the hill, this can be
accomplished by leaning forward and, on
steeper inclines, standing on the running
boards and leaning forward over the handlebar. (Also see “Traversing a slope.”)
Slow down as you reach the crest of the
hill, and be prepared to react to obstacles,
sharp drops, or other vehicles or people
which may be on the other side. If you are
unable to continue up a hill, do not spin the
track. Stop the engine and set the parking
brake. Then pull the rear of the snowmobile around to point the snowmobile back
down the hill. When the snowmobile is
pointed downhill, mount your snowmobile
from the uphill side. Restart the engine,
release the parking brake, and descend
the hill.
WARNING
@
Side hills and steep slopes are not recommended for a novice snowmobiler.
@
7-4
U8ES10.book Page 5 Monday, April 12, 2004 1:25 PM
Riding downhill
downhill leg on the seat and the foot of
your uphill leg on the running board. This
position will make it easier for you to shift
your body weight as needed.
Snow and ice are slippery, so be prepared
for the possibility that your snowmobile
could begin to slip sideways on the slope. If
this happens, steer in the direction of the
slide if there are no obstacles in your path.
As you regain proper balance, gradually
steer again in the direction you wish to
travel.
If your snowmobile starts to tip, steer down
the hill to regain balance.
When riding downhill, keep speed to a minimum. It is important to apply just enough
throttle to keep the clutch engaged while
descending the hill. This will allow you to
use engine compression to help slow the
snowmobile, and to keep the snowmobile
from rolling freely down the hill. Also apply
the brake frequently, with light pressure.
WARNING
@
If you are unable to maintain correct
balance, and your snowmobile is going
to tip over, dismount your snowmobile
immediately on the uphill side.
WARNING
@
Use extra caution when applying the
brake during a descent. Excessive
braking will cause the drive track to
lock, causing a loss of control.
@
Ice or icy surface
@
Operating on ice or icy surfaces can be
very dangerous. Traction for turning, stopping, and starting is much less than that on
snow.
Traversing a slope
WARNING
@
When you have to operate on ice or icy
surfaces, drive slowly and cautiously.
Avoid accelerating, turning, and braking
rapidly. Steering is minimal and uncontrolled spins are an ever-present danger.
WARNING
@
Traversing slopes is not recommended
for a novice snowmobiler.
@
@
Traversing a slope requires you to properly
position your weight to maintain proper balance. As you travel across the slope, lean
your body to position your weight towards
the uphill side. A recommended riding
position is to kneel with the knee of your
7-5
U8ES10.book Page 6 Monday, April 12, 2004 1:25 PM
Hard-packed snow
WARNING
It can be more difficult to negotiate on
hard-packed snow as both the skis and
drive track do not have as much traction as
when the snowmobile is operated on fresh
snow. Avoid rapid acceleration, turning,
and braking.
@
Drive track damage or failure could
result in loss of braking ability and
snowmobile control, which could cause
an accident.
● Always check the drive track for
damage or maladjustment before
operating the snowmobile.
● Do not operate the snowmobile if
you find damage to the drive track.
Operation on surfaces other than
snow or ice
Operation of your snowmobile on surfaces
other than snow or ice should be avoided.
Operation under such conditions will damage or result in rapid wear of the ski runners, drive track, slide runners, and drive
sprockets. Operation of the snowmobile on
the following surfaces should be avoided at
all times:
1. Dirt
2. Sand
3. Rocks
4. Grass
5. Bare pavement
Other surfaces that should be avoided for
the sake of drive track and slide runner life
are:
1. Glare ice surfaces
2. Snow mixed with a lot of dirt and sand
All of the above surfaces have one thing in
common in regard to drive track and slide
runners; little or no lubricating ability. Drive
track and all slide rail systems require
lubrication (snow or water) between the
slide runners and the slide metal. In the
absence of lubrication, the slide runners
will rapidly wear and in severe cases, literally melt away, and the drive track will be
subject to damage or failure.
Also traction aids such as studs, cleats,
etc., may cause further track damage or
failure.
@
CAUTION:
@
Ride on fresh snow frequently. Operating on ice or hard-packed snow will rapidly wear the slide runners.
@
7-6
U8ES10.book Page 7 Monday, April 12, 2004 1:25 PM
ESU00251
Maximizing drive track life
Recommendations
Track tension
During initial break-in, the new drive track will tend to
stretch quickly as the track settles. Be sure to correct the
track tension and alignment frequently. (See pages
8-29–8-31 for adjustment procedures.) A loose track can
slip (ratchet), derail or catch on suspension parts causing severe damage. Do not overtighten the drive track,
otherwise it may increase the friction between the track
and the slide runners, resulting in the rapid wear of both
components. Also, this may put an excessive load on the
suspension components, resulting in component failure.
Marginal snow
The drive track and the slide runners are lubricated and
cooled by snow and water. To prevent the drive track and
slide runners from overheating, avoid sustained highspeed usage in areas such as icy trails, frozen lakes and
rivers that have minimal snow coverage. An overheated
track will be weakened internally, which may cause failure or damage.
Off-trail riding
Avoid off-trail riding until there is sufficient snow coverage. It generally takes several feet of snow to provide a
good overall base to properly cover debris, such as
rocks, logs, etc. If snow coverage is not sufficient, stay on
trails to avoid impact damage to the drive track.
Studded track
In general, track life will be shortened when studs are
installed. Drilling stud holes into the drive track will cut
the internal fibers, which weakens the track. Avoid spinning the drive track. Studs may catch on an object and
pull out of the track, leaving tears and damage around
the already weakened area. To minimize possible damage, consult your stud manufacturer for installation and
stud pattern recommendations.
Yamaha does not recommend track studding.
7-7
U8ES10.book Page 8 Monday, April 12, 2004 1:25 PM
ESU00245
Strap
For RS90M
The strap 1 should be used only by experienced operators to assist them when traverse (side-hill) riding.
WARNING
@
Improper use of the strap on the handlebar can
result in severe injury or death.
● Use the strap only as an operator grip point when
needed to shift weight uphill to maintain balance
during traverse (side-hill) riding. Only experienced operators should traverse slopes steep
enough to require strap use.
● Keep the right hand on the right handlebar grip
for steering, and grip the strap with the left hand
to shift weight uphill for balance during traverse
riding.
● Ride cautiously while using the strap. Do not
accelerate or decelerate abruptly while holding
onto the strap.
● Do not use the strap to lift the snowmobile.
● Do not use the strap as a mounting point for
cargo or accessories.
@
7-8
U8ES10.book Page 9 Monday, April 12, 2004 1:25 PM
ESU00347
Driving
WARNING
@
Be sure to read the “SAFETY INFORMATION” and
“Riding your snowmobile” sections carefully before
operating the snowmobile.
@
NOTE:
@
Make sure that the engine is warmed up enough before
riding.
@
For RS90/RS90M
1. Release the parking brake by moving the parking
brake lever to the right.
2. Press the throttle lever slowly to move the snowmobile.
3. Turn the handlebar in the desired direction.
4. Squeeze the brake lever to stop the snowmobile.
5. Apply the parking brake by moving the parking brake
lever to the left.
For RS90R/RSG90
1. To select the desired operating position, pull the shift
lever out, slide it to “FWD” or to “REV” until it stops,
and then release it.
1
2
3
4
Pull out
Slide to “FWD” (Forward)
Slide to “REV” (Reverse)
Release
WARNING
@
●
●
●
●
Make sure that the throttle lever is fully released
and the snowmobile is at a full stop before shifting.
Be sure to slide the shift lever to “FWD” or “REV”
until it stops completely and only while the
engine is idling.
Make sure that the area behind the snowmobile is
clear before reversing. Watch behind.
Reduce speed and avoid sharp turning when
operating the snowmobile in reverse.
@
7-9
U8ES10.book Page 10 Monday, April 12, 2004 1:25 PM
CAUTION:
@
Do not shift from “FWD” to “REV” or from “REV” to
“FWD” while the snowmobile is moving. Otherwise,
the drive system could be damaged.
@
NOTE:
@
The reverse buzzer beeps while the shift lever is in
reverse.
@
2. Release the parking brake by moving the parking
brake lever to the right.
3. Press the throttle lever slowly to move the snowmobile.
4. Turn the handlebar in the desired direction.
5. Squeeze the brake lever to stop the snowmobile.
6. Apply the parking brake by moving the parking brake
lever to the left.
ESU00136
Stopping the engine
Turn the main switch to the “OFF” position to stop the
engine.
1 “OFF”
WARNING
@
●
●
Push down the engine stop switch to stop the
engine in an emergency.
Make sure that the key is removed from the main
switch whenever the operator leaves the snowmobile, to prevent accidental starting.
@
7-10
U8ES10.book Page 11 Monday, April 12, 2004 1:25 PM
ESU00367
Transporting
When transporting your snowmobile on a trailer or in a
truck, observe the following recommendations to help
protect it from damage:
● Make sure that the fuel level in the fuel tank is lower
than the bottom of the carburetors. Otherwise, the
vibration and bumps from the road surface could
make it possible for fuel to flow through the carburetors into the cylinders. This can result in “hydrostatic
lock,” a condition where the engine cannot rotate
because of fuel accumulated in the engine. Severe
engine damage can result from hydrostatic lock.
When possible, the fuel tank should be empty during
transportation, especially if the trip takes longer than
30 minutes.
● If transporting the snowmobile in an open trailer or
truck, put a tight fitting cover on the snowmobile. A
cover specifically designed for your snowmobile is
best. This will help keep foreign objects out of the
cooling vents in the shroud, and also help protect the
snowmobile against damage from debris on the road.
● If transporting the snowmobile in an open trailer or
truck in areas where road salt is used, coat metal
suspension surfaces lightly with oil or another protectant. This will help protect against corrosion. Be
sure to clean the snowmobile when you get to your
destination to remove any corrosive salts.
7-11
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM
ESU00139
PERIODIC MAINTENANCE
8-
ESU00140
Periodic maintenance chart
Regular maintenance is most important for best performance and safe operation.
CD-01E
Item
Preoperation
check
(Daily)
Remarks
Initial
1 month
or
800 km
(500 mi)
(40 hr)
Every
Seasonally
or
3,200 km
(2,000 mi)
(160 hr)
Spark plugs
Check condition.
Adjust gap and clean.
Replace if necessary.
∗ Valve clearance
Check clearance.
Adjust clearance when engine Every 40,000 km (25,000 mi)
is cold.
Engine oil
Engine oil filter
cartridge
●
●
Check oil level.
●
Replace.
●
Every
20,000 km 8-10–8-12
(12,000 mi)
●
Check fuel level.
∗ Fuel filter
Check condition.
Replace if necessary.
●
∗ Fuel line
Check fuel hose for cracks or
damage.
Replace if necessary.
●
Check throttle lever operation.
Carburetor
6-1–6-2
6-4,
8-13–8-14
●
∗ Air bleed the cooling system
if necessary.
8-9
●
Fuel
Engine coolant
8-4–8-5
6-3–6-4
∗ Replace.
Check coolant level.
Page
●
●
8-13
5-2, 6-5
Whenever operating condition
(elevation/temperature) is changed.
∗ Adjust the jets.
Engine stop switch
Check operation.
∗ Repair if necessary.
●
5-8
Throttle override
system (T.O.R.S.)
Check operation.
∗ Repair if necessary.
●
5-3, 6-5
Throttle lever
Check operation.
∗ Repair if necessary.
●
5-2, 6-5
∗ Exhaust system
Check for leakage.
Tighten or replace gasket if
necessary.
∗ It is recommended that these items be serviced by a Yamaha dealer.
8-1
●
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM
Item
Preoperation
check
(Daily)
Remarks
Initial
1 month
or
800 km
(500 mi)
(40 hr)
Every
Seasonally
or
3,200 km
(2,000 mi)
(160 hr)
Page
Drive guard
Check for cracks, bends or
damage.
∗ Replace if necessary.
●
5-10, 6-7
V-belt
Check for wear and damage.
Replace if necessary.
●
6-7,
8-15–8-17
Drive track and idler
wheels
Check deflection, and for wear
and damage.
∗ Adjust/replace if necessary.
●
6-8,
8-29–8-31
Check for wear and damage.
●
Slide runners
Brake and parking
brake
●
Check operation and fluid
leakage.
Drive chain oil
Drive chain
Skis and ski runners
Steering system
5-8–5-9,
6-6–6-7,
8-19–8-20
●
∗ Adjust free play and/or replace pads if necessary.
∗ Replace brake fluid.
∗ Disc brake
installation
6-8
∗ Replace if necessary.
●
See NOTE on page 8-3.
8-20
Every
1,600 km
(1,000 mi)
Check for slight free play.
Lubricate shaft with specified
grease as required.
●
Check oil level.
∗ Replace.
8-17–8-18
●
Check deflection.
∗ Adjust if necessary.
Initial at 500 km (300 mi) and every
800 km (500 mi) thereafter.
Check for wear and damage.
●
∗ Replace if necessary.
8-18
6-9
●
●
Check operation.
∗ Adjust toe-out if necessary.
6-9
●
Strap (RS90M)
Check for damage.
∗ Replace if necessary.
●
Lights
Check operation.
Replace bulbs if necessary.
●
∗ Battery
Check condition.
Charge if necessary.
6-9, 8-35
●
∗ It is recommended that these items be serviced by a Yamaha dealer.
8-2
8-36
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM
Item
Preoperation
check
(Daily)
Remarks
Check engagement and shift
speed.
Adjust if necessary.
Initial
1 month
or
800 km
(500 mi)
(40 hr)
Every
Seasonally
or
3,200 km
(2,000 mi)
(160 hr)
Page
●
Whenever operating elevation is changed.
Inspect sheaves for wear/
damage.
∗ Primary and second- Inspect weights/rollers and
bushings for wear-for primary.
ary clutches
Inspect ramp shoes/bushings
for wear-for secondary.
Replace if necessary.
●
Lubricate with specified
grease.
●
∗ Steering column
bearing
Lubricate with specified
grease.
●
∗ Ski and front
suspension
Lubricate with specified
grease.
●
8-34
∗ Suspension
component
Lubricate with specified
grease.
●
8-34
Lubricate with specified
grease.
●
8-34
Check cable damage.
Replace if necessary.
●
∗ Parking brake cable
end and lever end/
throttle cable end
Shroud latches
Make sure that the shroud
latches are hooked.
●
5-10
Fittings and fasteners
Check tightness.
∗ Repair if necessary.
●
6-11
Tool kit and recommended equipment
Check for proper placement.
●
6-11
∗ It is recommended that these items be serviced by a Yamaha dealer.
NOTE:
@
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid.
Normally check the brake fluid level and add the fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals
every two years.
3. Replace the brake hose every four years, or if cracked or damaged.
@
8-3
U8ES10.book Page 4 Monday, April 12, 2004 1:25 PM
ESU00376
Tool kit
The owner’s tool kit has the tools which are sufficient for
most periodic maintenance and minor repair. A torque
wrench is also necessary to properly tighten nuts and
bolts.
1 Tool kit
CAUTION:
@
Before starting the engine, make sure that the tool
kit is firmly seated in the holder and is closed
securely.
@
NOTE:
@
If you do not have a torque wrench available during a
service operation requiring one, take your snowmobile to
a Yamaha dealer to check the torque settings and adjust
them if necessary.
@
ESU00368
Spark plug inspection
The spark plug is an important engine component and is
easy to inspect. The condition of the spark plug can indicate the condition of the engine. Check the coloration on
the white porcelain insulator around the center electrode.
The ideal coloration at this point is a medium to a light
tan color for a snowmobile that is being ridden normally.
If a spark plug shows a distinctly different color, there
could be something wrong with the engine. For example,
a very white center electrode porcelain color could indicate an intake track air leak or carburetion problem for
that cylinder. Do not attempt to diagnose such problems
yourself. Instead, take the snowmobile to a Yamaha
dealer for inspection and possible repairs. You should
periodically remove and inspect the spark plug because
heat and deposits will cause a spark plug to slowly break
down and erode. Consult a Yamaha dealer before changing to a different type of spark plug.
Specified spark plug:
· R · CR8E (NGK) or CR8E (NGK)
8-4
U8ES10.book Page 5 Monday, April 12, 2004 1:25 PM
Spark plugs are produced in several different thread
lengths. The thread length or reach is the distance from
the spark plug gasket seat to the end of the threaded
portion. If the reach is too long, overheating and engine
damage may result. If the reach is too short, spark plug
fouling and poor performance may result. Also, if the
reach is too short, carbon will form on the exposed
threads resulting in combustion chamber hot spots and
thread damage. Always use a spark plug with the specified reach.
Spark plug reach a: 19.0 mm (0.75 in)
Before installing any spark plug, measure the electrode
gap with a wire thickness gauge and adjust to specification.
Spark plug gap b: 0.7–0.8 mm (0.028–0.031 in)
When installing the spark plug, always clean the gasket
surface. Wipe off any grime from the threads and tighten
the spark plug to the specified torque.
Spark plug tightening torque:
12.5 Nm (1.25 m·kgf, 9 ft·lb)
CAUTION:
@
Make sure that the spark plug caps are securely
installed. Otherwise the spark plug caps could be
damaged due to engine vibration.
@
8-5
U8ES10.book Page 6 Monday, April 12, 2004 1:25 PM
ESU00370
Engine idle speed adjustment
CAUTION:
@
●
●
●
Be sure to have a Yamaha dealer make this
adjustment.
Make sure that the throttle lever moves smoothly.
Make sure that the carburetor is synchronized
first.
@
1. Start the engine and warm it up.
NOTE:
@
Refer to the “Starting the engine” section.
@
2. Turn the throttle stop screw 1 in or out to adjust the
engine idle speed.
Standard engine idle speed: 1,400 ± 100 r/min
ESU01471
Throttle cable adjustment
CAUTION:
@
Be sure to adjust the engine idle speed first.
@
1. Loosen the locknut.
2. Turn the adjuster in or out until the proper throttle
lever free play is achieved.
Throttle lever free play a:
2.0–3.0 mm (0.08–0.12 in)
1 Locknut
2 Adjuster
3. Tighten the locknut.
8-6
U8ES10.book Page 7 Monday, April 12, 2004 1:25 PM
ESU04190
Carburetor adjustment
CAUTION:
@
●
●
Be sure to have a Yamaha dealer make this
adjustment.
Make sure that the air filter case is installed during running to prevent engine damage.
@
Under some operating conditions the carburetor setting
may have to be changed due to air temperature changes,
elevation changes, use of alcohol oxygenated fuels, etc.,
and should be set by a Yamaha dealer.
CAUTION:
@
The drive chain gears and V-belt clutch should be
adjusted when operating over a high altitude of
900 m (3,000 ft). Consult a Yamaha dealer.
@
Pilot screw adjustment
Turn the pilot screw in or out to adjust low speed tuning.
Standard pilot screw position:
2 turns out from the seated position.
CD-02E
Pilot screw 1
Mixture
Turn in
Lean
Turn out
Rich
8-7
Condition
Warm weather
High altitude
Cold weather
Low altitude
U8ES10.book Page 8 Monday, April 12, 2004 1:25 PM
Main jet replacement
Replace the main jet according to the setting chart which
is available at a Yamaha dealer.
WARNING
@
●
●
●
Never remove the drain plug or the float chamber
while the engine is hot. Fuel will flow out from the
float chamber which could ignite and cause
injury.
Place a rag under the carburetor before removing
the drain plug or float chamber to catch any
spilled fuel.
Handle fuel with care: it is HIGHLY FLAMMABLE.
@
Standard main jet:
# 148
CD-04E
Main jet 1
Mixture
Small No.
Lean
Large No.
Rich
Condition
Warm weather
High altitude
Cold weather
Low altitude
1. Loosen the carburetor clamps and remove all hoses
and cables, and then remove the carburetor.
2. Pinch the fuel hose to prevent fuel flowing.
3. Remove the float chamber and install the proper
main jet.
4. Assemble by reversing the removal steps.
WARNING
@
Make sure that all hoses and clamps are properly
installed.
@
8-8
U8ES10.book Page 9 Monday, April 12, 2004 1:25 PM
ESU00157
High altitude adjustments
Operating at high altitude reduces the performance of a
gasoline engine to about 3% for every 305 m (1,000 ft) of
elevation. This is because there is less air as altitude
increases. Less air means less oxygen available for combustion.
Your snowmobile can be adjusted to overcome most of
the problems found in high altitude riding. Carburetor
adjustments are the most important. Less air at high altitude makes the air/fuel ratio too rich, which can cause
poor performance. Common problems are hard starting,
bogging, and plug fouling. Follow the Main Jet Setting
chart which is available at a Yamaha dealer carefully.
Proper carburetion adjustments will correct the air/fuel
ratio.
Remember: less air at higher altitude means there is
less horsepower available, even with proper carburetion.
Expect acceleration and top speed to be reduced at
higher altitudes.
To overcome operating with less power at high altitudes,
your snowmobile may also require different settings for
the drive chain gears and V-belt clutch to avoid poor performance and rapid wear. If you plan to operate your
snowmobile at an altitude different from the area where
you bought it, be sure to consult a Yamaha dealer. They
can tell you if there are any changes necessary for the
altitude where you plan to ride.
CAUTION:
@
The drive chain gears and V-belt clutch should be
adjusted when operating over a high altitude of
900 m (3,000 ft). Consult a Yamaha dealer.
@
ESU00348
Adjusting the valve clearance
The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To prevent
this from occurring, the valve clearance must be adjusted
by a Yamaha dealer at the intervals specified in the periodic maintenance chart.
8-9
U8ES10.book Page 10 Monday, April 12, 2004 1:25 PM
ESU04200
Changing the engine oil
It is recommended to have a Yamaha dealer change the
engine oil.
WARNING
@
Engine oil is extremely hot immediately after the
engine is turned off. Coming into contact with or getting any engine oil on your clothes could result in
burns.
@
CAUTION:
@
●
●
●
Do not run the engine with too much or not
enough oil in the oil tank. Oil could spray out or
the engine could be damaged.
Be sure to change the engine oil after the first
800 km (500 mi) of operation, and every 3,200 km
(2,000 mi) thereafter or at the start of a new season, otherwise the engine will wear quickly.
The oil filter cartridge should be replaced every
20,000 km (12,000 mi) of operation.
@
To change the engine oil (with or without oil filter
cartridge replacement)
1. Place the snowmobile on a level surface and apply
the parking brake.
2. Remove the bottom panel 1 and right side cover 2.
3. Start the engine, warm it up for several minutes, and
then turn it off.
4. Place oil pans under both the engine and the oil tank
to collect the used oil.
5. Disconnect the oil level gauge coupler 3.
6. Remove the oil level gauge/dipstick 4 and the cylinder head cap 5, and then remove the crankcase
engine oil drain bolt 6 and the oil tank engine oil
drain bolt 7 to drain the oil from the crankcase and
the oil tank.
NOTE:
@
●
●
●
A “ ” mark 8 is stamped on the crankcase near the
crankcase engine oil drain bolt.
Dispose of used oil according to local regulations.
Skip steps 7–9 if the oil filter cartridge is not being
replaced.
@
8-10
U8ES10.book Page 11 Monday, April 12, 2004 1:25 PM
7. Remove the oil filter cartridge 9 with an oil filter
wrench.
NOTE:
@
An oil filter wrench is available at a Yamaha dealer.
@
8. Apply a thin coat of engine oil to the O-ring of the new
oil filter cartridge.
9. Install the new oil filter cartridge with an oil filter
wrench, and then tighten it to the specified torque.
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lb)
10. Install the engine oil drain bolts, and then tighten
them to the specified torques.
Tightening torques:
Crankcase engine oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lb)
Oil tank engine oil drain bolt:
16 Nm (1.6 m·kgf, 11 ft·lb)
11. Add 2.0 L (1.8 Imp qt, 2.1 US qt) of the recommended engine oil to the oil tank, and then install and
tighten the oil level gauge/dipstick and the cylinder
head cap.
Recommended engine oil:
See page 6-2.
Oil quantity:
With oil filter cartridge replacement:
3.0 L (2.6 Imp qt, 3.2 US qt)
Without oil filter cartridge replacement:
2.8 L (2.5 Imp qt, 3.0 US qt)
Total amount:
3.7 L (3.3 Imp qt, 3.9 US qt)
12. Start the engine, warm it up for several minutes, and
then turn it off.
8-11
U8ES10.book Page 12 Monday, April 12, 2004 1:25 PM
13. Add sufficient oil of the recommended type to raise it
to the “F” level mark on the oil level gauge/dipstick.
(See page 6-3 for the checking procedure.)
CAUTION:
@
●
●
When adding the engine oil, be careful not to fill
above the “F” level mark on the oil level gauge/
dipstick.
Make sure that no foreign material enters the
engine oil tank.
@
14. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking,
immediately turn the engine off and make sure the
engine oil drain bolts, cylinder head cap, and oil level
gauge/dipstick are installed correctly.
15. Turn the engine off, connect the oil level gauge coupler, and then install the bottom panel and right side
cover.
CAUTION:
@
If oil is leaking or the oil level warning indicator
comes on when the engine is running, immediately
turn the engine off and have a Yamaha dealer check
the snowmobile. Continuing to operate the engine
under such conditions could cause severe engine
damage.
@
8-12
U8ES10.book Page 13 Monday, April 12, 2004 1:25 PM
ESU00161
Cooling system
Air bleeding the cooling system
WARNING
@
●
●
Do not remove the coolant reservoir cap when
the engine is hot. Scalding hot fluid and steam
may be blown out under pressure, which could
cause serious injury.
When the engine has cooled, place a thick rag or
towel over the coolant reservoir cap, slowly rotate
the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press
down on the cap while turning counterclockwise
and remove it.
The cooling system must be bled of air if the
coolant reservoir becomes empty, if air can be
seen in the cooling system, or if there is a cooling
system leak. Consult a Yamaha dealer.
@
CAUTION:
@
Operating the engine with an improperly bled cooling system can cause overheating and severe
engine damage.
@
8-13
U8ES10.book Page 14 Monday, April 12, 2004 1:25 PM
Coolant replenishment
1. Remove the coolant reservoir cap and pour the coolant to the “COLD LEVEL” mark.
Recommended coolant:
High quality ethylene glycol antifreeze containing corrosion inhibitors.
Coolant and water mixed ratio: 60:40
Total amount: 4.7 L (4.14 Imp qt, 4.97 US qt)
1 “COLD LEVEL” mark
2 Coolant reservoir cap
2. Start the engine and add coolant until the coolant
level does not go down, and then stop the engine.
3. Fill the coolant reservoir with coolant to the “COLD
LEVEL” mark.
4. Install the coolant reservoir cap. Check for any coolant leakage.
NOTE:
@
If you find any leaks, consult a Yamaha dealer.
@
8-14
U8ES10.book Page 15 Monday, April 12, 2004 1:25 PM
ESU00166
V-belt replacement
WARNING
@
When installing the new V-belt, make sure it is positioned from 1.5 mm (0.06 in) above the edge of the
secondary sheave assembly to 0.5 mm (0.02 in)
below the edge a.
If not, the V-belt clutch engagement speed will be
changed. The snowmobile may move unexpectedly
when the engine is started.
Adjust the V-belt position by removing or adding a
spacer 1 on each adjusting bolt.
Have a Yamaha dealer make this adjustment.
@
CAUTION:
@
As the V-belt wears, adjustment may be necessary.
To ensure proper clutch performance, the V-belt
position should be adjusted by adding a spacer on
each adjusting bolt when the V-belt position reaches
1.5 mm (0.06 in) below the edge.
Have a Yamaha dealer make this adjustment.
@
CD-05E
New belt width
34.5 mm (1.36 in)
Belt wear limit width
32.5 mm (1.28 in)
NOTE:
@
Apply the parking brake before replacing the V-belt.
@
1. Remove the drive guard.
2. Rotate the secondary sliding sheave clockwise 1
and push 2 it so that it separates from the secondary
fixed sheave.
8-15
U8ES10.book Page 16 Monday, April 12, 2004 1:25 PM
3. Pull 3 the V-belt up over the secondary fixed sheave.
4. Remove the V-belt from the secondary sheave
assembly and primary sheave assembly.
5. Put the new V-belt back on the secondary sheave
assembly only. Do not force the V-belt between the
sheaves; the secondary sliding and fixed sheave
must touch each other. Measure the V-belt position.
Standard V-belt position a:
From 1.5 mm (0.06 in) above the edge of the secondary sheave to 0.5 mm (0.02 in) below the edge.
6. If the position is incorrect, adjust the V-belt position
by removing or adding a spacer 4 on each adjusting
bolt 5.
CD-06E
V-belt position
Adjustment
More than 1.5 mm (0.06 in)
above the edge
Remove spacer
From 1.5 mm (0.06 in)
above the edge to 0.5 mm
(0.02 in) below the edge
Not necessary
(It is correct.)
More than 0.5 mm (0.02 in)
below the edge
Add spacer
7. Tighten each adjusting bolt.
Adjusting bolt tightening torque:
10 Nm (1.0 m·kgf, 7.2 ft·lb)
8-16
U8ES10.book Page 17 Monday, April 12, 2004 1:25 PM
8. Install the V-belt over the primary sheave assembly.
9. Rotate the secondary sliding sheave clockwise 6
and push 7 it so that it separates from the secondary
fixed sheave.
10. Install the V-belt 8 between the secondary sliding
and secondary fixed sheaves.
11. Install the drive guard.
WARNING
@
Never run the engine with the V-belt or drive guard
removed.
@
ESU03511
Checking the drive chain housing oil level and
the drive chain tension
Oil level check
WARNING
@
The engine, oil tank, brake disc, and coolant hoses
will be very hot after the engine has been run. Avoid
contact while they are still hot with any part of your
body or clothing during inspection or repair.
@
1. Place the snowmobile on a level surface.
2. Remove the dipstick 1 and wipe it off with a clean
rag. Then put the dipstick in the hole.
8-17
U8ES10.book Page 18 Monday, April 12, 2004 1:25 PM
A
3. Remove the dipstick and check that the oil is between
the upper and lower levels. If not, add oil to the upper
level.
B
2 Upper level
3 Lower level
Drive chain oil: GL-3
75W or 80W
È For models without reverse transmissions
(RS90/RS90M)
É For models with reverse transmissions
(RS90R/RSG90)
CAUTION:
@
Make sure that no foreign material enters the drive
chain housing.
@
4. Install the dipstick and align the notch 4 of the dipstick handle with the projection 5 of the drive chain
housing.
Chain tension adjustment
1. Loosen the locknut.
2. Turn the adjusting bolt clockwise until it is finger tight,
and then loosen it 1/4 turn.
3. Hold the adjusting bolt in place while tightening the
locknut.
1 Locknut
2 Adjusting bolt
8-18
U8ES10.book Page 19 Monday, April 12, 2004 1:25 PM
ESU00174
Checking the brake pads
Check the brake pads for wear.
If the brake pads reach the wear limit, ask a Yamaha
dealer to replace them.
1 Brake pad wear indicator
Wear limit a: 1.5 mm (0.06 in)
ESU00352
Checking the parking brake pads
Check the parking brake pads for wear by measuring the
thickness of the pads. If the parking brake pads reach
the wear limit, ask a Yamaha dealer to replace them.
Wear limit a: 1.2 mm (0.05 in)
Adjustment
As the parking brake pads wear, adjustment may be necessary to ensure proper brake performance.
WARNING
@
Be sure to have a Yamaha dealer make this adjustment.
@
1. Loosen the locknut 1 and the adjusting bolt 2.
2. Loosen the cable locknut 3.
3. Turn the cable adjuster 4 in or out to adjust the cable
length.
Cable length a: 43.5–46.5 mm (1.713–1.831 in)
4. Tighten the cable locknut.
5. Turn the adjusting bolt in or out to adjust the clearance between the parking brake pads 5 and the
brake disc 6.
Clearance b + c: 1.5–2.0 mm (0.059–0.079 in)
6. Tighten the locknut.
8-19
U8ES10.book Page 20 Monday, April 12, 2004 1:25 PM
ESU00180
Checking the brake fluid level
Place the snowmobile on a level surface. Check that the
brake fluid is above the lower level and replenish when
necessary.
1 Lower level
Specified brake fluid: DOT 4
WARNING
@
Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the
boiling point of the fluid and may result in vapor
lock.
If the brake fluid level goes down, consult a Yamaha
dealer.
@
CAUTION:
@
Brake fluid may deteriorate painted surfaces or plastic parts. Never spill any fluid. If any is spilled, clean
it up immediately.
@
ESU00181
Brake fluid replacement
Brake fluid replacement is necessary when the following
components are replaced during the periodic maintenance or if they are damaged or leaking.
a. All oil seals of the master cylinder and caliper cylinder
b. The brake hose
WARNING
@
Make sure that the brake fluid and the above parts
are replaced by a Yamaha dealer.
@
ESU00183
Suspension
The suspension can be adjusted to suit rider preference.
A softer setting, for example, may provide greater rider
comfort, while a harder setting may allow more precise
handling and control over certain types of terrain or riding
conditions.
WARNING
@
Be sure to have a Yamaha dealer make this adjustment.
@
8-20
U8ES10.book Page 21 Monday, April 12, 2004 1:25 PM
ESU01911
Ski spring preload adjustment
The spring preload can be adjusted by turning the spring
preload adjuster 1.
For RS90/RS90R/RSG90
CD-11E
Spring seat length*
Standard
Increased
←
→ Decreased
Preload
Harder
←
→
a Length
Maximum
Minimum
172.0 mm 162.0 mm 155.5 mm
(6.77 in)
(6.38 in) (6.12 in)
Softer
∗ The spring seat length changes approximately 1.5 mm (0.06 in) with
each full turn of the adjuster.
For RS90M
CD-11E
Spring seat length*
Standard
Increased
←
→ Decreased
Preload
Harder
←
→
a Length
Maximum
Minimum
162.0 mm 152.0 mm 152.0 mm
(6.38 in)
(5.98 in) (5.98 in)
Softer
∗ The spring seat length changes approximately 1.5 mm (0.06 in) with
each full turn of the adjuster.
CAUTION:
@
The left and right ski spring preload must be set to
the same setting. Uneven settings can cause poor
handling and loss of stability.
@
8-21
U8ES10.book Page 22 Monday, April 12, 2004 1:25 PM
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.
● Do not dispose of a worn or damaged shock
absorber by yourself. Take the unit to a Yamaha
dealer.
@
ESU04210
Rear suspension spring preload adjustment
The rear suspension is equipped with two shock absorbers and the spring preload for each shock absorber can
be adjusted separately. One shock absorber is in the
front 1 and the other is in the rear 2 of the rear suspension assembly.
8-22
U8ES10.book Page 23 Monday, April 12, 2004 1:25 PM
The spring preload can be adjusted by turning the spring
preload adjuster 3 on the front and rear shock absorbers.
A
For RS90/RS90R
CD-17E
Spring seat length*
Standard
Increased
←
→ Decreased
Preload
Harder
←
→
È a Length (front)
Maximum
Minimum
123.5 mm 113.5 mm 103.5 mm
(4.86 in)
(4.47 in) (4.07 in)
Softer
∗ The spring seat length changes approximately 1.5 mm (0.06 in) with
each full turn of the adjuster.
B
For RSG90
CD-17E
Spring seat length*
Standard
Increased
←
→ Decreased
Preload
Harder
←
→
É a Length (front)
Maximum
Minimum
127.0 mm 117.0 mm 116.0 mm
(5.00 in)
(4.61 in) (4.57 in)
Softer
∗ The spring seat length changes approximately 1.5 mm (0.06 in) with
each full turn of the adjuster.
C
For RS90M
CD-13E
Spring adjuster position
Preload
1
2
3
Soft
Ê Standard (front)
8-23
4
5
Hard
3
U8ES10.book Page 24 Monday, April 12, 2004 1:25 PM
D
For RS90/RS90M/RS90R
CD-23E
Spring adjuster position
Preload
S
M
H
Soft
Medium
Hard
Ë Standard (rear)
E
M
For RSG90
CD-14E
Spring adjuster position
1
Preload
Soft
Ì Standard (rear)
2
3
4
5
6
7
Hard
4
WARNING
@
Be sure to have a Yamaha dealer make this adjustment.
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 sources, which could
cause it to explode.
● Do not deform or damage the shock absorber in
any way.
● Do not dispose of a worn or damaged shock
absorber by yourself. Take the unit to a Yamaha
dealer.
@
8-24
U8ES10.book Page 25 Monday, April 12, 2004 1:25 PM
ESU03890
Rear suspension damping force adjustment
For RSG90
The damping force can be adjusted by turning the
adjuster 1.
CD-20E
16 clicks
out
Adjuster position
Minimum
7 clicks
out
1 click
out
Standard
Maximum
∗
Turns out b
Damping force
Soft
Turns in a
Hard
∗ With the adjuster fully turned lightly in direction a
CAUTION:
@
●
●
●
Do not continue to turn the adjuster in
direction a after it stops. The shock absorber
can be damaged and damping force adjustments
cannot be made.
Do not turn the adjuster in direction b more than
16 clicks. Even if the adjuster is continually
turned after 16 clicks, there will be no change in
the damping force.
Be sure to stop the adjuster 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.
● Do not dispose of a worn or damaged shock
absorber by yourself. Take the unit to a Yamaha
dealer.
@
8-25
U8ES10.book Page 26 Monday, April 12, 2004 1:25 PM
ESU01973
Rear suspension full rate adjustment
For RSG90
The total suspension spring rate and damping characteristics can be adjusted by changing the installed position
of the shock absorber.
WARNING
@
Be sure to have a Yamaha dealer make this adjustment.
@
CD-07E
Installation position
Spring rate and
damping
Standard
S
M
H
Soft
Medium
Hard
M
NOTE:
@
Be sure to make this adjustment when there is no load
(rider or cargo) on the snowmobile.
@
1. Loosen the full rate adjusting nut 1 1/2 or 3/4 turn,
while holding the adjusting bolt 2 securely with a
wrench so it does not move.
CAUTION:
@
Never allow the adjusting bolt 2 to move while loosening the nut.
@
2. Turn the adjusting bolt 2 to the desired position.
CAUTION:
@
Make sure that the adjusting bolt ends are set at the
same position on each side.
@
3. While holding the adjusting bolt securely, tighten the
full rate adjusting nut 1.
Full rate adjusting nut tightening torque:
49 Nm (4.9 m·kgf, 35.4 ft·lb)
CAUTION:
@
Never allow the adjusting bolt to move while tightening the nut.
@
8-26
E_8es_Periodic.fm Page 27 Thursday, April 15, 2004 11:33 AM
A
ESU04220
Control rod adjustment
The weight transfer can be adjusted by turning the control rod adjusting nut 1.
1. Loosen the locknut 2 while holding the control rod
adjusting nut.
2. Turn the adjusting nut in direction a to increase
weight transfer or direction b to decrease weight
transfer.
3. Tighten the locknut while holding the adjusting nut in
place.
Locknut tightening torque:
25 Nm (2.5 m·kgf, 18.1 ft·lb)
A
CAUTION:
@
●
B
●
When using the two wrenches included in the
owner’s tool kit, make sure that they are situated
at a right angle to the control rod as shown, and
that they are tightly fitted to the locknut and the
control rod adjusting nut.
The left and right adjusting nuts 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 3.
@
c
d
È
É
Adjustable range
Standard position
RS90/RS90M/RS90R
RSG90
B
8-27
U8ES10.book Page 28 Monday, April 12, 2004 1:25 PM
ESU04271
Anti-bottoming stopper adjustment
For RS90/RS90R
The spring force can be adjusted by changing the installation location of the anti-bottoming stoppers.
WARNING
@
Be sure to have a Yamaha dealer make this adjustment.
@
CD-24E
Installation location
Spring force
Standard
S
M
H
Soft
Medium
Hard
M
NOTE:
@
Be sure to make this adjustment when there is no load
(rider or cargo) on the snowmobile.
@
1. Loosen the anti-bottoming stopper nut 1 while holding the anti-bottoming stopper bolt 2 securely with a
wrench so it does not move, and then remove the nut,
bolt, and anti-bottoming stopper 3.
CAUTION:
@
Never allow the bolt to move while loosening or
tightening the nut.
@
2. Install the anti-bottoming stopper in the desired location.
3. Tighten the nut while holding the bolt securely.
Anti-bottoming stopper nut tightening torque:
60 Nm (6.0 m·kgf, 43 ft·lb)
CAUTION:
@
Make sure that the anti-bottoming stoppers are
installed in the same location on both sides.
@
8-28
E_8es_Periodic.fm Page 29 Tuesday, April 13, 2004 11:28 AM
ESU03531
Drive track adjustment
WARNING
@
A broken track, track fittings or debris thrown by the
drive 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 drive 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 drive
track to spin. Never allow anyone near a rotating
drive track.
● Inspect the drive track condition frequently.
Replace damaged slide metal. Replace the drive
track if it is damaged to the depth where fabric
reinforcement material is visible or support rods
are broken. Otherwise, track damage or failure
could result in loss of braking ability and snowmobile control, which could cause an accident.
@
Drive track deflection measurement
1. Lay the snowmobile on its side.
2. Measure the drive track deflection with a spring
scale. Pull at the center of the drive track with a force
of 100 N (10 kg, 22 lb).
NOTE:
@
Measure the gap between the slide runner and the edge
of the track window. Measure both sides.
@
1 Deflection
2 100 N (10 kg, 22 lb)
Standard drive track deflection:
For RS90/RS90M/RS90R
30–35 mm (1.18–1.38 in) / 100 N (10 kg, 22 lb)
For RSG90
25–30 mm (0.98–1.18 in) / 100 N (10 kg, 22 lb)
3. If the deflection is incorrect, adjust the drive track.
8-29
U8ES10.book Page 30 Monday, April 12, 2004 1:25 PM
Drive track adjustment
WARNING
@
●
●
●
Be sure to have a Yamaha dealer make this
adjustment.
Support the snowmobile securely on a suitable
stand before working underneath the snowmobile.
Operate the engine in a well-ventilated area.
@
1. Lift the rear of the snowmobile onto a suitable stand
to raise the drive track off the ground.
2. Loosen the rear axle nut 1.
3. Start the engine and rotate the drive track one or two
turns. Stop the engine.
4. Check the drive track alignment with the slide runners
2. If the alignment is incorrect, align the drive track
by turning the left and right adjusters.
CD-08E
Drive track
alignment
5
6
5 Shifted to right
6 Shifted to left
3 Left adjuster
Turn out
Turn in
4 Right adjuster
Turn in
Turn out
7
8
9
a
b
Slide runners
Drive track
Slide metal
Gap
Forward
5. Adjust the drive track deflection to specification.
CD-09E
Drive track
deflection
More than
specified
Less than
specified
3 Left adjuster
Turn in
Turn out
4 Right adjuster
Turn in
Turn out
8-30
U8ES10.book Page 31 Monday, April 12, 2004 1:25 PM
CAUTION:
@
The right and left adjusters should be turned to an
equal amount.
@
6. Recheck alignment and deflection. If necessary,
repeat steps 3 to 5 until the proper adjustment is
achieved.
7. Tighten the rear axle nut.
Rear axle tightening torque:
75 Nm (7.5 m·kgf, 54.2 ft·lb)
ESU00200
Ski alignment
1. Turn the handlebar so the skis face straight ahead.
2. Check the following for ski alignment:
a. Skis are facing forward.
b. Ski toe-out (1 – 2) is within specification.
Ski toe-out (1 – 2): 0–15 mm (0–0.59 in)
3. If the alignment is not correct, consult a Yamaha
dealer.
A
ESU03541
Handlebar adjustment
1. Remove the handlebar cover 1.
B
È RS90/RS90R/RSG90
É RS90M
8-31
U8ES10.book Page 32 Monday, April 12, 2004 1:25 PM
2. Loosen the handlebar bolts.
A
3. Move the handlebar up or down to adjust the handlebar height to the desired position.
B
A
È RS90/RS90R/RSG90
É RS90M
B
8-32
U8ES10.book Page 33 Monday, April 12, 2004 1:25 PM
CAUTION:
@
Make sure that the projection on the handlebar is not
installed into the area a shown.
@
4. Tighten the handlebar bolts and install the handlebar
cover.
Handlebar bolt tightening torque:
14.5 Nm (1.45 m·kgf, 10.5 ft·lb)
CAUTION:
@
Make sure that the small gap b side of the handlebar
holders faces forward c.
@
8-33
U8ES10.book Page 34 Monday, April 12, 2004 1:25 PM
ESU00371
Lubrication
Lubricate the following points.
Lubricant: Low-temperature grease
1 Throttle cable end
2
WARNING
@
Apply a dab of grease onto the cable end only. Do
not grease the throttle cable because it could
become frozen, which could cause loss of control.
@
2 Front suspension
3 Rear suspension
WARNING
@
Be sure to have a Yamaha dealer lubricate the front
and rear suspensions.
@
3
3
8-34
U8ES10.book Page 35 Monday, April 12, 2004 1:25 PM
ESU00208
Headlight bulb replacement
1. Lift up the shroud.
2. Disconnect the headlight connector.
3. Remove the bulb holder cover.
4. Remove the bulb holder by depressing and turning it
counterclockwise.
1 Bulb holder cover
5. Remove the bulb.
WARNING
@
Keep flammable products or your hands away from
the hot bulb until it cools down.
@
6. Install the new bulb.
Bulb type: 12 V, 60/55 W
CAUTION:
@
Keep oil or your hands away from the glass part of
the bulb or its life and illumination will be affected.
If the glass is oil stained, thoroughly clean it with a
cloth moistened with alcohol or lacquer thinner.
@
ESU00372
Headlight beam adjustment
1. Lift up the shroud.
2. Insert a Phillips screwdriver into the hole under the
shroud to access the headlight beam adjuster 1.
3. Turn the headlight beam adjuster to adjust the headlight beam.
Headlight beam moves:
a Down
b Up
8-35
U8ES10.book Page 36 Monday, April 12, 2004 1:25 PM
ESU00355
Battery
This snowmobile is equipped with a sealed-type (MF)
battery, which does not require any maintenance. There
is no need to check the electrolyte or to add distilled
water.
To charge the battery
Have a Yamaha dealer charge the battery as soon as
possible if it seems to have discharged. Keep in mind
that the battery tends to discharge more quickly if the
snowmobile is equipped with electrical accessories.
WARNING
@
Battery electrolyte is poisonous and dangerous. It
contains sulfuric acid and can cause severe burns.
Avoid contact with skin, eyes, or clothing.
ANTIDOTE:
● EXTERNAL: Flush with water.
● INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg,
or vegetable oil. Call physician immediately.
● EYES: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when charging
or using in an enclosed space. Always shield your
eyes when working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
@
ESU04231
Fuse replacement
WARNING
@
Be sure to use the specified fuse. A wrong fuse
could cause electrical system damage or A FIRE
HAZARD.
@
CAUTION:
@
Be sure to turn the main switch off and disconnect
the negative battery lead to prevent accidental shortcircuiting.
@
8-36
U8ES10.book Page 37 Monday, April 12, 2004 1:25 PM
1. Lift up the shroud.
2. Remove the right side cover 1.
3. Unhook the latch 2.
4. Loosen the clamp screws 3.
5. Slide the oil tank breather hose clamp 4 away from
the air filter case, and then disconnect the oil tank
breather hose 5.
6. Slide the crankcase breather hose clamp 6 up, and
then disconnect the crankcase breather hose 7 from
the engine.
7. Lift up the air filter case, slide the crankcase breather
hose clamp 8 down, disconnect the crankcase
breather hose from the air filter case, and then
remove the air filter case.
8. Disconnect the negative battery lead.
9. Replace the blown fuse with one of the proper
amperage.
10. Connect the negative battery lead.
11. Install the air filter case by reversing the removal
steps.
NOTE:
@
When installing the air filter case, connect the crankcase
breather hose to the air filter case first, and then connect
it to the engine.
@
CAUTION:
@
Be sure to connect the breather hoses securely when
installing the air filter case.
@
NOTE:
@
If the fuse immediately blows again, ask a Yamaha
dealer to inspect the snowmobile.
@
8-37
U8ES10.book Page 38 Monday, April 12, 2004 1:25 PM
Specified fuses:
9Main fuse:
0“HEAD” (Headlight) fuse:
A“SIG” (Signal) fuse:
B“DC TERM” (Auxiliary DC jack) fuse:
C“C/W” (Carburetor warmer) fuse:
D“IGN” (Ignition) fuse:
E Spare fuses (20 A, 10 A, 15 A, 3 A)
F Spare main fuse
8-38
30 A
20 A
10 A
3A
20 A
15 A
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM
3. Compression
Insufficient
● Loose cylinder head nuts ... Tighten
nuts properly.
● Worn or damaged gasket ... Replace
gasket.
● Worn or damaged piston and cylinder
... Ask a Yamaha dealer to inspect.
ESU04240
TROUBLESHOOTING
9-
A. Engine turns over but does not start
1. Fuel system
No fuel supplied to combustion chamber
● No fuel in tank ... Supply fuel.
● Clogged fuel line ... Clean fuel line.
● Clogged carburetor ... Clean carburetor.
Fuel supplied to combustion chamber
● Flooded engine (too much choke) ...
Crank engine with throttle open or wipe
the spark plugs dry.
B. Starting the engine with a discharged battery
If the snowmobile battery is discharged,
the engine can be started using a 12-volt
battery and jumper cables. Two connecting
leads have been provided for jump-starting
the snowmobile. Due to the rubber engine
mounting, the snowmobile frame is not a
suitable grounding point for jump-starting
the engine.
2. Electrical system
Poor or no spark
● Spark plugs are dirty with carbon or are
wet ... Remove carbon or wipe the
spark plugs dry; replace if necessary.
● Faulty ignition system ... Ask a Yamaha
dealer to inspect.
● T.O.R.S. system malfunction ... Disconnect the throttle switch connectors and
connect the wire harness connectors
together to bypass the T.O.R.S.
WARNING
@
●
●
Connect the jumper cables only to
the connecting lead terminals. Do
not connect them to the frame or
any wire or other lead.
When connecting the jumper cables,
do not contact the jumper cables or
connecting lead terminals to each
other or to the frame or any metal
part of the snowmobile. This can
cause electrical system damage or
A FIRE HAZARD.
@
CAUTION:
@
WARNING
Use the connecting leads to jump-start
the snowmobile only. Do not use the
connecting leads for any other purpose.
@
●
●
Before bypassing the T.O.R.S., make
sure that the throttle returns properly to the fully closed position.
The T.O.R.S. is an important safety
device; in the case of a malfunction,
take the snowmobile to a Yamaha
dealer immediately for repair.
@
1. Apply the parking brake and turn the
main switch to “OFF”.
@
9-1
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM
5. Connect the other end of the red (+)
jumper cable to the positive (+) terminal
of the booster battery.
6. Connect the black (-) jumper cable to
the negative (-) terminal of the booster
battery.
7. Pull the black (-) lead cover to expose
the terminal through the slit in the
cover, and then connect the black (-)
jumper cable to the black terminal of
the discharged battery.
2. Open the shroud.
3. Remove the red (+) lead from the lead
holder and move it away from the black
(-) lead.
CAUTION:
@
Be sure to connect the red (+) jumper
cable to the red (+) lead and the black (-)
jumper cable to the black (-) lead. Do
not reverse the connections.
@
4. Pull the red (+) lead cover to expose
the terminal through the slit in the
cover, and then connect the red (+)
jumper cable to the red terminal of the
discharged battery.
8. Start the engine.
9. Disconnect the black (-) jumper cable
from the black (-) connecting lead, and
then pull the cover completely over the
lead terminal.
10. Disconnect the black (-) jumper cable
from the negative (-) terminal of the
booster battery.
11. Disconnect the red (+) jumper cable
from the positive (+) terminal of the
booster battery.
12. Disconnect the red (+) jumper cable
from the red (+) connecting lead, and
then pull the cover completely over the
lead terminal.
13. Install the red (+) lead into the lead
holder.
9-2
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM
4. Improper fuel flow ... See A.1 above.
5. Incorrect V-belt clutch settings for altitude or conditions ... Ask a Yamaha
dealer to inspect.
NOTE:
@
Make sure that both the red (+) lead and
the black (-) lead are seated securely in the
lead holders.
@
E. Engine constantly backfires or misfires
1. Faulty spark plugs ... Replace the
spark plugs.
2. Clogged fuel system ... See A.1. above.
3. Malfunctioning T.O.R.S. system ... See
A.2. above.
WARNING
@
Be sure to pull the lead covers back
over the terminals completely. If the terminals are exposed, they could come
into contact with the frame or a metal
part of the snowmobile and this can
cause electrical system damage or A
FIRE HAZARD.
F. Engine overheats
1. Insufficient coolant ... Add coolant.
2. Air in cooling system ... Bleed air or ask
a Yamaha dealer to inspect.
3. Leaking coolant ... Ask a Yamaha
dealer to inspect.
@
C. Electric starter does not operate or
operates slowly
1. Engine stop switch is pushed in ... Pull
it out.
2. Faulty wire connections ... Check connections or ask a Yamaha dealer to
inspect.
3. Discharged battery... Charge battery or
see B above.
4. Seized engine ... Seizure is caused by
poor lubrication, inadequate fuel, or an
air leak—Ask a Yamaha dealer to
inspect.
5. “Hydrostatic lock” occurs when fuel has
filled the cylinders when the vehicle
has been transported. ... Remove the
spark plugs and turn the engine over
several times with the ignition off to
expel excess fuel. Ask a Yamaha
dealer to inspect.
G. Snowmobile does not move
1. Malfunctioning V-belt clutch ... Ask a
Yamaha dealer to inspect.
2. Drive track does not move ... Foreign
object is caught in the drive track, or
slide runners have melted to the slide
metal due to lack of lubrication.
3. Tight, loose, or broken drive chain ...
Ask a Yamaha dealer to inspect.
H. V-belt twists
1. Improper V-belt ... Replace with the
correct V-belt.
2. Incorrect V-belt clutch offset ... Ask a
Yamaha dealer to inspect.
3. Loose or broken engine mount ... Ask a
Yamaha dealer to inspect.
D. Engine power is low
1. Low coolant temperature indicator light
is flashing ... Warm the engine up.
2. Faulty spark plugs ... Clean or replace
the spark plugs.
3. Incorrect jetting for altitude or temperature ... Carburetor. Ask a Yamaha
dealer to inspect.
I. V-belt slips or burns
1. Oily or dirty V-belt or primary and secondary sheave assembly surfaces ...
Clean.
2. Problem with the driveline ... See H
above.
9-3
U8ES10.book Page 4 Monday, April 12, 2004 1:25 PM
J. Engine does not upshift or downshift properly or engages harshly
1. Worn or damaged V-belt ... Replace the
V-belt or ask a Yamaha dealer to
inspect.
2. Incorrect V-belt clutch settings for altitude or conditions ... Ask a Yamaha
dealer to inspect.
3. Worn or sticking primary sheave
assembly ... Ask a Yamaha dealer to
inspect.
4. Worn or sticking secondary sheave
assembly ... Ask a Yamaha dealer to
inspect.
K. Noise or excessive vibration in drive
chain and sprockets
1. Broken V-belt clutch components ...
Ask a Yamaha dealer to inspect.
2. Worn or damaged bearings ... Ask a
Yamaha dealer to inspect.
3. Worn or damaged V-belt with flat spots
... Replace.
4. Worn or damaged idler wheels or
shafts ... Ask a Yamaha dealer to
inspect.
5. Worn or damaged drive track ... Ask a
Yamaha dealer to inspect.
9-4
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM
bustion chamber and crankshaft from
corrosion. An alternate method is to
remove the carburetor silencer and squirt
oil into the carburetor throats while the
engine is running.
ESU03593
STORAGE
10-
Long-term storage requires some preventive procedures to guard against deterioration.
1. Cleaning
Thoroughly clean the snowmobile, inside
and out, to remove the corrosive salts and
acids that can accumulate. Use Yamaha
Mud, Grease, and Engine Cleaner, or an
equivalent product, to loosen mud, grease,
and grime. Wash with mild soap, then rinse
and dry completely.
CAUTION:
@
Do not attempt to store the snowmobile
by simply starting the engine occasionally during the storage period. This can
cause more harm than good! Moisture
and acids form during combustion
which can actually increase the chance
for corrosion damage during the storage period.
2. Lubrication
Lubricate moving parts, suspension linkage, and pivot points. Use the grease or
lubricant specified in the MAINTENANCE
section, or Yamaha Lube-Zall general-purpose lubricant. Proper lubrication fights
corrosion while it reduces friction.
@
5. Protection
Apply a coat of wax to painted surfaces.
Apply suitable protectants to the exterior of
the engine, drive track, and to other metal,
plastic, and rubber parts.
6. Battery
Remove the battery from the snowmobile.
Store it in a cool, dry place that is above
0 °C (32 °F), but less than 30 °C (90 °F).
Check the condition of the battery once a
month, and charge it as necessary.
3. Fuel system preparation
Add Yamaha Fuel Stabilizer and Conditioner, or an equivalent stabilizer, to the
fuel tank to help prevent fuel oxidation and
gum and varnish deposits, and to inhibit
corrosion in the fuel system and carburetor. In areas where oxygenated fuel (gasohol) is used, completely drain the fuel
system. Ask a Yamaha dealer if further
information is needed.
WARNING
@
●
4. Engine
Proper storage of the engine is essential to
prevent costly rust and corrosion damage
to internal engine components. This is
more important in areas where oxygenated
fuel (gasohol) is used, because the alcohol
content in the fuel increases the chance for
water to enter the engine. Use Yamaha
Stor-Rite Engine Fogging Oil, or an equivalent fogging oil, to protect both the com-
●
●
@
10-1
Never smoke around the battery
while it is being charged. Sparks
may ignite the hydrogen gas created
by the battery.
Never connect the battery to or disconnect it from the snowmobile
while it is being charged. Sparks
may ignite the hydrogen gas created
by the battery.
Make sure that the battery terminals
are tight.
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM
Returning to service after storage
When returning your snowmobile to service, install the V-belt and battery and
adjust the drive track.
Remove the spark plugs and clean or
replace them if necessary. Perform all
other pre-operation and seasonal maintenance checks listed in the periodic maintenance chart.
CAUTION:
@
●
●
●
Always keep the battery charged.
Storing a discharged battery can
cause permanent battery damage.
To charge a sealed-type (MF) battery,
a special (constant-voltage) battery
charger is required. Using a conventional battery charger will damage
the battery. If you do not have
access to a sealed-type (MF) battery
charger, have a Yamaha dealer
charge your battery.
Do not charge the battery quickly.
Charge the battery for 10 hours at
1.8 amperes.
NOTE:
@
Before installing the battery, have a
Yamaha dealer inspect and fully charge it.
@
For peak performance, it is recommended
that you have your snowmobile checked
and tuned by a Yamaha dealer. The dealer
has the experience and training to help you
get the maximum performance and use of
your Yamaha snowmobile.
@
7. Drive track
Loosen the drive track and block up the
chassis so that the track is suspended
above the ground.
8. V-belt
Remove the V-belt and store separately.
9. Storage
Store the snowmobile in a dry, well-ventilated place out of direct sunlight. Put a fabric cover over the snowmobile, preferably
one that is designed for it. Do not use a
plastic or vinyl cover—condensation could
be trapped underneath which could
increase the chances of rusting.
10-2
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM
ESU00228
1-
SPECIFICATIONS
ESU00229
Dimensions
CS-01E
Overall length
Overall width
Overall height
Dry weight
Ski stance
RS90/RS90M/RS90R/RSG90
2,755 mm (108.5 in): RS90/RS90R
3,185 mm (125.4 in): RS90M
3,000 mm (118.1 in): RSG90
1,225 mm ( 48.2 in): RS90/RS90R/
RSG90
1,165 mm ( 45.9 in): RS90M
1,215 mm ( 47.8 in)
243 kg ( 536 lb): RS90
259 kg ( 571 lb): RS90M
247 kg ( 545 lb): RS90R
256 kg ( 564 lb): RSG90
1,085 mm ( 42.7 in): RS90/RS90R/
RSG90
980 mm ( 38.6 in): RS90M
ESU00230
Engine
CS-02E
Type
Cylinder arrangement
Displacement
Bore × Stroke
Idle speed
Engine oil type
Carburetor type
Fuel
RS90/RS90M/RS90R/RSG90
Liquid cooled 4-stroke, 12 valves
Parallel 3-cylinder
973 cm3
79.0 × 66.2 mm (3.12 × 2.61 in)
1,400 ± 100 r/min
API SE, SF, SG or higher
SAE 0W-30
KEIHIN, CVK40 × 3
Unleaded gasoline
Pump octane
Starting system
Electric starter
11-1
R+M
; 88 or higher
2
E_8es_Spec.fm Page 2 Tuesday, April 13, 2004 11:28 AM
ESU00231
Chassis
CS-03E
RS90/RS90M/RS90R/RSG90
Drive track and suspension:
Track
Width
Track deflection
Length on ground
Suspension type
Drive sprocket
Transmission:
Type
Sheave distance
Sheave offset
Engagement speed∗1
Shift speed∗1
Drive chain
Reduction ratio
Fuel tank:
Tank capacity
Oil quantity:
With oil filter cartridge replacement
Without oil filter cartridge replacement
Total amount
Molded rubber, fiber glass rod reinforced
381 mm (15.0 in)
30–35 mm (1.18–1.38 in)/
100 N (10 kg, 22 lb): RS90/RS90M/
RS90R
25–30 mm (0.98–1.18 in)/
100 N (10 kg, 22 lb): RSG90
723 mm (28.5 in): RS90/RS90R
759 mm (29.9 in): RS90M
946 mm (37.2 in): RSG90
Slide Rail Suspension
Quadruple polyethylene, 9 teeth:
RS90/RS90R/RSG90
Quadruple polyethylene, 8 teeth:
RS90M
Automatic centrifugal engagement, infinitely variable 3.8:1–1:1
Approx. 268.5 mm (10.57 in)
Approx. 15 mm (0.59 in)
Approx. 3,500 r/min:RS90/RS90R
Approx. 4,000 r/min:RS90M
Approx. 3,600 r/min:RSG90
Approx. 8,500 r/min∗2
Silent chain enclosed in oil bath
38/22 (1.73): RS90/RS90R
40/20 (2.00): RS90M
39/22 (1.77): RSG90
38.0 L (8.4 lmp gal, 10.0 US gal)
3.0 L (2.6 lmp qt, 3.2 US qt)
2.8 L (2.5 lmp qt, 3.0 US qt)
3.7 L (3.3 lmp qt, 3.9 US qt)
∗1 Subject to change according to elevation settings.
∗2 Usually achieved after approximately 800 m (0.5 mi) traveled.
11-2
U8ES10.book Page 3 Monday, April 12, 2004 1:25 PM
RS90/RS90M/RS90R/RSG90
Brake:
Type
Operation
Throttle:
Operation
Hydraulic disc type (ventilated disc)
Handle lever, left hand operated
Handle lever, right hand operated
ESU00232
Electric
CS-04E
Ignition system
Spark plug
Battery
Headlight
Tail/brake light
Meter light
Indicator light
Type
Gap
Capacity
Maximum charge rate
Bulb × Quantity
Bulb × Quantity
Bulb × Quantity
Bulb × Quantity
RS90/RS90M/RS90R/RSG90
TCI
· R · CR8E (NGK)
0.7–0.8 mm (0.028–0.031 in)
YTX20L-BS 12 V 18 A·h
1.8 Amperes/hr for 10 hrs
12 V, 60/55 W × 2
12 V, 5/21 W × 2
14 V, 50 mA × 6
14 V, 80 mA × 3
11-3
1-
12-1
G W/B
O/B B
A
Ch G/B
R/B B
B
c
O/B
B
R
W/R W/G
Lg L/W
L/W Lg
d
L
2
L
(20A)
L
(10A)
B
3
W W W
W W W
1
(BLACK)
R
(20A)
R
W/G
W/R
(15A)
HI
LO
O/B
Lg
L/W
L/W
L/R
f
R/W
R
HEADLIGHT
SUB-WIRE
HARNESS 2
(BLACK)
WIRE HARNESS
Y/B G L/Y
L/R Y W
B
L/Y G Y/B
W Y L/R
G
B
G
G
Lg
Y G
B
A
B
B
Br
R
L
Y
G
e
B
Y
B
f
Br/L
Br
Br/L
Y G
B
B
Y
G
B
Dg
B
B
R
L/R
X
W
V
6
(30A)
B
B
R/W
R
B R/W
Z
[
Ch
A
Ch
Ch
Y
(BLACK)
Br Br/W
Ch
R/W
Dg
L/Y B L/Y
W B W
Br/Y
Ch R/B
G/B A G/B
U
R/B
R/B
A
R/B
G/B
R/B
L/Y
W
Y/B
L/R
CLOSE
OPEN
A
Y/B B Y/B
(BLACK)
Br/W Br
(BLACK)
Br Br/W
RUN
STOP
0
L/R
L/Y
Ch R/BG/B Y/B Y W
8
7
g
R
Br/W Br
Br Br/W
R
Dg
SUB-WIRE
HARNESS
R/W R/Y
WIRE HARNESS
E
R R/W
B B
B
B
9
Br/W
R/Y R/W
L/R B L/R
L
Y
B
Y
G
5
R Br
OFF
ON
START
4
B
L/R
TAIL/BRAKE LIGHT
SUB-WIRE
HARNESS
D
WIRE HARNESS
L/R
G B
(BLACK) L/W
L/W
G
Lg Y B
R/Y
\ ] ^ a b
(3A)
(GLAY)
W W W
Gy B
HEADLIGHT
WIRE HARNESS SUB-WIRE
HARNESS 1
G/B Ch
B R/B
WIRING DIAGRAM
ESU00233
(BLACK)
Ch
(BLACK)
Ch
G/B
Ch
L/Y
W
Dg Br/Y
G
B
B
R/W L/R
Ch
B/Y
B/L
B/Y
B
B
P O/R
B/W
S
Dg
Dg
Dg
OFF
ON
Q
D D D
L/Y W
Ch
Ch G/B
C
T
E
Dg E Dg
B/Y
G
B
D
B
B
L/R G
L/R G
D D
L/R G
L/R
G/Y
L
B
L Y
R
G
L/R
L/R
P
E
E
B
G L/R
B
Y/R
Br
P
O
B
F
Lg
P
L/R
B
P
B
Lg
P
B
W
G
Y/R
Lg
Y/B
B
Br/Y
Br/L
W/G
W/R
Br/W
B/Y
Ch W/G Lg/W B/W Y/W B/L Br/W
L/G G Lg/L W/Y B/Y W/R Y/L
N
Ch
G
Lg Br/Y Y/R
Y/B Br/L B
Y
(BLACK)
L
B
L
W/Y
B/L
L/G
B/W
Y/W
Y/L
Lg/W
Lg/L
O
Gy
W
Gy
O
W
H
I
H
I
H
I
O Br
B/L
Lg/W Lg/L
B/L
(BLACK)
Ch
(BLACK)
Lg/L Lg/W
Lg/W
Ch
Lg/L
Y/W Y/L
Ch
B/W
K
L/G
M
L
L
W/Y
B/L
(BLACK)
W Br
(BLACK)
Gy Br
(BLACK)
Y/L Y/W
Y/W
Ch
Y/L
(DARK GREEN)
L/G B/W
W
Br
Gy
Br
O
Br
J
B/L
W/Y L
B
Y
(BLACK)
L
(BLACK)
U8ES10.book Page 1 Monday, April 12, 2004 1:25 PM
Crankshaft position sensor
AC magneto
Rectifier/regulator
Main switch
Load control relay
Main fuse
Starter relay
Starter motor
Battery
Engine stop switch
Throttle switch
Carburetor warmer relay
Carburetor ground
Carburetor warmer
Grip warmer
Thumb warmer
CDI unit
Ignition coil
Spark plug
Throttle position sensor
Thermo unit
Grip warmer adjustment switch
Thumb warmer adjustment switch
Frame ground
DC back buzzer (RS90R/RSG90)
Gear position switch
(RS90R/RSG90)
Q Brake light switch
R Tail/brake light
S Speed sensor
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
12-2
Fuel sender
Oil level switch
Meter assembly
Warning light
Low coolant temperature indicator
light
Multi-function meter
Meter light
High beam indicator light
“DC TERM” (Auxiliary DC jack) fuse
“HEAD” (Headlight) fuse
“SIG” (Signal) fuse
“C/W” (Carburetor warmer) fuse
“IGN” (Ignition) fuse
Auxiliary DC jack (option)
Headlight beam switch
Headlight relay
Headlight
Jumper leads
COLOR CODE
B ................... Black
Br .................. Brown
Ch ................. Chocolate
Dg ................. Dark green
G................... Green
Gy ................. Gray
L ................... Blue
Lg ................. Light green
Y
Z
[
\
]
_
a
b
c
d
e
f
g
T
U
V
W
X
O ...................Orange
P....................Pink
R ...................Red
W...................White
Y....................Yellow
B/L.................Black/Blue
B/W ...............Black/White
B/Y ................Black/Yellow
Br/L ...............Brown/Blue
Br/W ..............Brown/White
Br/Y ...............Brown/Yellow
G/B................Green/Black
G/Y................Green/Yellow
L/G ................Blue/Green
L/R ................Blue/Red
L/W................Blue/White
L/Y.................Blue/Yellow
Lg/L ...............Light green/Blue
Lg/W..............Light green/White
O/B................Orange/Black
O/R................Orange/Red
R/B ................Red/Black
R/W ...............Red/White
R/Y ................Red/Yellow
W/G...............White/Green
W/R ...............White/Red
W/Y ...............White/Yellow
Y/B ................Yellow/Black
Y/L.................Yellow/Blue
Y/R ................Yellow/Red
Y/W ...............Yellow/White
U8ES10.book Page 2 Monday, April 12, 2004 1:25 PM
SNOWMOBILE
OWNER’S MANUAL
RS90K
RS90MK
RS90RK
RSG90K
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2004.04-2.8×1 CR
(E)
LIT-12628-02-38
8ES-28199-10
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