INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL
CARBURETION
POWER TRAIN ~
.....rtIIIJ.!IS
CHASSIS
ELECTRICAL
APPENDICES
iiii ELEC ~,
CHAPTER 1. GENERAL INFORMATION MACHINE IDENTifiCATION ..................................... 1-' FRAME SERIAL NUMBER .................................... '-1 ENGINE SERIAL NUMBER .................................... 1-1 STORAGE .................................................... 1-2 PRE-SEASON PREPARATION .................................... '-2 IMPORTANT INfORMATION ..................................... 1-3 NO FLAME SOURCES ........................................ 1-3 WASHING AND CLEANING ................................... 1-3 RIGHT TOOLS .............................................. '-3 MAKING IT NEAT ........................................... 1-3 TIGHTENING TORQUE ...................................... 1-3 ALL REPLACEMENT PARTS .................................. 1-4 GASKETS, Of L SEALS, AND O-RINGS .......................... 1-4 LOCK WASHERS/PLATES AND COTTER PINS .................... 1-4 BEARINGS AND OIL SEALS .................................. 1-4 Cl RCLIPS .................................................. 1-5 SPECIAL TOOLS ............................................... FOR TUNE UP .............................................. FOR ENGINE SERVICE ...................................... FOR POWE R TRAI N SERVICE ................................. FOR ELECTRICAL SERVICE ..................................
1-5 1-5 1-6 1-6 1-7
SPECIAL TOOLS CROSS REFERENCE LIST ......................... 1-9
D
IM'j:~I~IMACHINE
IDENTIFICATION
GENERAL INFORMATION MACHINE IDENTI FICATION FRAME SERIAL NUMBER The frame serial number ill is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number ill, is located on thp right-hand side of the crankcase. NOTE: __________________________ The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.
Starting Serial Number: For (OK, N, NL, S, SF): 83R-000101 For (CON): 84R-000101 NOTE: _________________________ Designs and specifications are subject to change without notice.
1-1
STORAGE/PRE-SEASON PREPARATION
I~l:~I
STORAGE If a snowmobile will not be used for several months, it should be stored in a proper place so that both the engine and the track are not damaged . • Completely drain the fuel tank, and disconnect the fuel line from the carburetor . • With the engine running at idle, squirt oil into the carburetor until the engine dies. This will distribute oil evenly throughout the engine, and protect it against rust. • Disassemble the suspension, clean and grease all parts, and reassemble the suspension. • Lightly coat all shafts and axles with grease. • Oil all fittings and cable controls with a lightly oiled cloth. • Loosen the track. • Block the chassis so that the track is off the floor . • Protect the snowmobile with a covering.
PRE-SEASON PREPARATION Perform the predelivery service as described in the predelivery check list before operating any snowmobile that has been stored for several months. (Refer to CHAPTER 2. "PERIODIC MAINTENANCE TABLE", page 2-1.)
1-2
IMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. While cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc., from high pressure water splashes. 2. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS".
3. When disassembling the machine, keep mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.
4. During the machines disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire.
6. Be sure to keep to tightening torque specifications. When tightening bolts, nuts, and screws, start with a larger-diameter one and from an inner-positioned one to an outerpositioned one in a criss-cross pattern.
'-3
IMPORTANT INFORMATION
I~1f=~1-
ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.
GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates CD and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.
300-000
300-002
BEARINGS AND OIL SEALS 1. Install the bearing(s) CD and oil seal(s) CV with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seallip(s). Oil the bearings liberally when installing.
Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.
300-003
1-"
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si
SPECIAL TOOLS Cl RC LI PS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one -use. R.eplace distorted circlips. When installing a circlip <D , make sure that the sharp edged corner <ID is positioned opposite to the thrust @ it receives. See the sectional view. 300-001
@Shaft
SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.
FOR TUNE UP 1. Sheave Gauge PIN YS-91047 This gauge is used for sheave distance and offset adjustment.
2. Dial Gauge PIN YU-03097 This gauge is used for ignition timing adjustment.
3. Dial Gauge Stand Set PIN YU-01256 These tools are uSed for ignition timing adjustment.
1-5
SPECIAL TOOLS
IMIf=~I-
FOR ENGINE SERVICE 1. Universal Rotor Holder PIN YU-01235 This tool is used to hold starter pulley and COl magneto.
2. Piston Pin Puller PIN YU-01304 This tool is used to remove piston pin.
3. Rotor Puller PIN YU-33270 This tool is used to remove COl magneto.
FOR POWER TRAIN SERVICE 1. Primary Sheave Holder PIN YS-01880 This tool is used to hold primary sheave.
2. Primary Sheave Puller PIN YS-01882-A This tool is used for removing primary sheave.
1-6
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SPECIAL TOOLS 3. Sheave Compressor PIN YS-28891 This tool is used for disassembling and assembling sheave.
4. Clutch Spider Separator PIN YS-28890-A These tools are used for disassembling and assembling primary sheave.
5. Clutch Separator Adapter PIN Y5-34480 This tool is used for disassembling and assembling primary sheave.
6. Track Clip Installer PIN Y5-91045 This tool is used for installing the track clip.
FOR ELECTRICAL SERVICE 1. Pocket Tester PIN Y U-03112 This instrument is necessary for checking the electrical components.
1-7
SPECIAL TOOLS 2. Electro Tester PIN Y U-33260 This instrument is invaluable for checking the electrical system.
1-8
SPECIAL TOOLS CROSS REFERENCE LIST SPECIAL TOOLS CROSS REFERENCE LIST SPECIAL TOOL NAME
PART NUMBER
PART NUMBER
FOR TUNE UP
-
1.
Sheave Gauge
YS-91 047
2.
Dial Gauge
YU-03097
90890-03097
3.
Dial Gauge Stand Set
YU-01256
90890-01256
FOR ENGINE SERVICE
1.
Universal Rotor Holder
YU-01235
90890-01235
2.
Piston Pin Puller
YU-01304
90890-01304
3.
Rotor Puller
YU-33270
-
FOR POWER TRAIN SERVICE 1.
Primary Sheave Holder
YS-01880
90890-01701
2.
Primary Sheave Puller
YS-01882-A
90890-01898
3.
Sheave Compressor
YS-28891
90890-01712
4.
Clutch Spider Separator
YS-28890-A
90890-01711
5.
Clutch Separator Adapter
YS-34480
6.
Track Clip Installer
YS-91 045
TLS90-91 045
-
FOR ELECTRICAL SERVICE 1.
Pocket Tester
YU-03112
90890-03112
2.
Electra Tester
YU-33260
90890-03021
1-9
CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-1 PERIODIC MAINTENANCE TABLE ............................... 2-1 LUBRICATION INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-3 SHROUD COVERS AND SEAT ........... , ....................... SHROUD OPENING .. " ...... " .. " ., .. " ................... SHROUD ................................................. SEAT ........ , .. " ............... , ....................... HANDLEBAR COVER ....................................... WIND SHIELD SPEEDOMETER AND HEADLIGHT ............... COVERS ..................................................
2-4 2-4 2-4 2-4 2-5 2-6 2-7
ENGINE .................... ; .............................. " 2-9 ENGINE OIL LEVEL INSPECTION ............................. 2-9 FUEL LINE INSPECTION .................................... 2-10 ENGINE OIL LINE INSPECTION .............................. 2-10 ENGINE IDLE SPEED ADJUSTMENT ........ , ................. 2-10 THROTTLE CABLE FREE PLAY ADJUSTMENT ... , ............. 2-11 STARTER CABLE ADJUSTMENT ... , ......................... 2-12 OIL PUMP CABLE FREE PLAY ADJUSTMENT ................... 2-12 OIL PUMP STROKE ADJUSTMENT ............................ 2-13 OIL PUMP AIR BLEEDING ................................... 2-18 OIL FILTER INSPECTION ................................... 2-19 FUEL FILTER INSPECTION .................................. 2-20 FUEL PUMP OPERATION CHECK ............................. 2-20 COOLING FAN BELT INSPECTION ............................ 2-22 COOLING FAN BELT TENSION ADJUSTMENT .................. 2-23 POWER TRAIN ........... ',' .................................. 2-25 DRIVE V-BELTINSPECTION ..................... , ........... 2-25 SHEAVE DISTANCE AND OFFSET ADJUSTMENT ............... 2-27 DRIVE CHAIN HOUSING OIL LEVEL INSPECTION ..... , ......... 2-30 DRIVE CHAIN HOUSING OIL REPLACEMENT ...... , ... , ....... 2-31 DRIVE CHAIN SLACK ADJUSTMENT ................ , ......... 2-32 BRAKE PAD INSPECTION ................................... 2-34 BRAKE ADJUSTMENT ...................................... 2-34 TRACK TENSION ADJUSTMENT.............................. 2-36 HINGED EXTENSION ADJUSTMENT .......................... 2-38
....
CHASSIS..................................................... SKI ADJUSTMENT ......................................... BRAKE CABLE END LUBRICATION ........................... SLlDER RUNNER INSPECTION ...............................
2-39 2-39 2-40 2-41
ELECTRICAL................................................. SPARK PLUG INSPECTION .............. , . '" .............. , IGNITION TIMING ADJUSTMENT ......................... , ... HEADLIGHT BULB REPLACEMENT ........................... HEADLIGHT BEAM ADJUSTMENT ............................ TAIL/BRAKE LIGHT REPLACEMENT.......................... METER LIGHT REPLACEMENT ...............................
2-41 2-41 2-42 2-44 2-45 2-46 2-46
TUNING . .................................................... CARBURETOR TUNING ..................................... CLUTCH TUNING .................. , ....................... SLIDE RAIL SUSPENSION TUNING ... , ....................... HIGH ALTITUDE TUNING ........... , .......................
2-47 2-47 2-55 2-57 2-59