INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL
'-
ENG
COOLING SYSTEM CARBURETION
POWER TRAIN CHASSIS CHAS
ELECTRICAL APPENDICES
III ~,
APPX
CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ..................................... 1-1 FRAME SERIAL NUMBER .................................... 1-1 ENGINE SERIAL NUMBER .................................... 1-1 STORAGE .................................................... 1-2 PRE-SEASON PREPARATION .................................... 1-2 IMPORTANT INFORMATION ..................................... 1-3 NO FLAME SOURCES ........................................ 1-3 WASHING AND CLEANING ................................... 1-3 RIGHT TOOLS .............................................. 1-3 MAKING IT NEAT ........................................... 1-3 TIGHTENING TORQUE ...................................... 1-3 ALL REPLACEMENT PARTS .................................. 1-4 GASKETS, OIL SEALS, AND O-RINGS .......................... 1-4 LOCK WASHERS/PLATES AND COTTER PINS .................... 1-4 BEARINGS AND OIL SEALS ............... " ................. 1-4 Cl RCLIPS ..................... ',' ........................... 1-5 NOTES ON DISASSEMBLY AND ASSEMBLY ..................... 1-5 SPECIAL TOOLS ............................................... 1-6 FOR TUNE UP .............................................. 1-6 FOR ENGINE SERVICE ...................................... 1-6 FOR POWER TRAIN SERViCE ................................. 1-7 FOR ELECTRICAL SERVICE .................................. 1-8
GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number CD is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number CD is located on the 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 82M·000101 NOTE: _________________________
Designs and specifications are subject to change without notice.
1·1
STORAGE/PRE-SEASON PREPARATION
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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.
1-3
IMPORTANTlNFORMATION
1tm:~I-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.
D GASKETS, OIL SEALS, AND a-RINGS 1. All gaskets, seals, and a-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and a-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 seaJ(s) ÂŽ 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 seaJ(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
'-4
SPECIAL TOOLS CIRCLlPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD , make sure that the sharp edged corner 00 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. Vacuum Gauge PIN Y U-08030 This gauge is used for carburetor synchronization.
2. Sheave Gauge PIN YS-91 047 This gauge is used for sheave distance and offset adjustment.
3. Dial Gauge PIN Y U-03097 This gauge is used for ignition timing adjustment.
1-5
SPECIAL TOOLS 4. Dial Gauge Stand Set PIN YU-01256 These tools are used for ignition timing adjustment.
FOR ENGINE SERVICE 1. Universal Clutch Holder PIN YM-91042 This tool is used to hold starter pulley.
2. Piston Pin Puller PIN YU-01304 This tool is used to remove piston pin.
3. Universal Rotor Holder PIN YU-01235 This tool is used to hold CD I magneto.
4. Rotor Puller PIN YU-33270 This tool is used to remove COl magneto.
1-6
SPECIAL TOOLS 5_ Cooling System Tester PIN YU-22460-01 This tester is used for checking cooling system.
FOR POWER TRAIN SERVICE 1. Primary Sheave Holder PIN YS-01880 This tool is used to hold primary sheave.
2. Primary Shave Puller PIN YS-01882-A This tool is used for removing primary sheave.
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.
1-7
SPECIAL TOOLS
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5. Clutch Separator Adapter PIN YS-34480 This tool is used for disassembling and assembling primary sheave.
6. Track Clip Installer PIN YS-91045 This tool is used for installing the track clip.
FOR ELECTRICAL SERVICE 1. Pocket Tester PIN YU-03112 This instrument is necessary for checking the electrical components.
2. Electro Tester PIN Y U-33260 This instrument is invaluable for checking the electrical system.
1-8
CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ............................................... 2-1 PERIODIC MAINTENANCE TABLE ................. , " ............ 2-1 LUBRICATION INTERVALS ..................................... 2-3 COWLS, COVERS, SEAT AND HANDLEBAR ........................ 2-4 SHROUD OPENING .......................................... 2-4 SIDE COWL ................................................ 2-4 SEAT ..................................................... 2-5 HANDLEBAR COVER, HEADLIGHT AND METER ASSEMBLY ...... 2-6 HANDLEBAR ............................................... 2-7 COVERS ................................................... 2-9 ENGINE ..................................................... 2-12 ENGINE OIL LEVEL INSPECTION ............................. 2-12 COOLANT LEVEL INSPECTION .............................. 2-12 COOLANT REPLACEMENT .................................. 2-13 COOLING SYSTEM INSPECTION .............................. 2-17 FUEL LINE INSPECTION .................................... 2-18 ENGINE OIL LINE INSPECTION .............................. 2-18 ENGINE IDLE SPEED ADJUSTMENT .......................... 2-18 THROTTLE CABLE FREE PLAY ADJUSTMENT ................. 2-19 CARBURETOR SYNCHRONIZATION. " ....................... 2-20 STARTER CABLE ADJUSTMENT ............................. 2-22 DECOMPRESSION CABLE ADJUSTMENT....................... 2-23 OIL PUMP CABLE FREE PLAY ADJUSTMENT ................... 2-24 OIL PUMP STROKE ADJUSTMENT ............................ 2-25 OIL PUMP AIR BLEEDING ................................... 2-30 OIL FILTER INSPECTION ................................... 2-34 FUEL FILTER INSPECTION .................................. 2-35 FUEL PUMP OPERATION CHECK ............................. 2-36 WATER PUMP DRIVE BELT TENSION ADJUSTMENT............. 2-40 POWER TRAIN ............. , ................................. 2·41 DRIVE V·BELT INSPECTION ................................. 2·41 SHEAVE DISTANCE AND OFFSET ADJUSTMENT ............... 2·42 DRIVE CHAIN HOUSING OIL LEVEL INSPECTION ............... 2-46 DRIVE CHAIN HOUSING OIL REPLACEMENT .................. 2-47 DRIVE CHAIN SLACK ADJUSTMENT .......................... 2·48 BRAKE PAD INSPECTION ................................... 2·50 BRAKE ADJUSTMENT ...................................... 2·51 TRACK TENSION ADJUSTMENT.............................. 2·53
CHASSIS..................................................... 2-55 SKI ADJUSTMENT ......................................... 2-55 BRAKE CABLE END LUBRICATION ........................... 2-57 FRONT SUSPENSION LUBRICATION .......................... 2-57 STABILIZER SLlDER MAINTENANCE ......................... 2-57 SLIDE RUNNER INSPECTION ................................ 2-58 ELECTRICAL................................................. 2-58 SPARK PLUG INSPECTION .................................. 2-58 IGNITION TIMING ADJUSTMENT ............................. 2-59 HEADLIGHT BULB REPLACEMENT ........................... 2-61 HEADLIGHT BEAM ADJUSTMENT ............................ 2-62 TAIL/BRAKE LIGHT BULB REPLACEMENT .................... 2-63 METER LIGHT REPLACEMENT............................... 2-63
TUNING . .................................................... 2-64 CARBURETOR TUNING ..................................... 2-64 CLUTCH TUNING .......................................... 2-72 GEARING SELECTION ...................................... 2-73 SLIDE RAIL SUSPENSION TUNING ........................... 2-75 HIGH ALTITUDE TUNING ................................... 2-77
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INTRODUCTION/PERIODIC MAINTENANCE TABLE
PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE Check point
20 hrs. or 400 km (250 mj)
Every When 40 hrs. or 80 hrs. or Seasonally 800 km 1,600 km necessary (500 mj) (1,000 mi)
ENGINE: Tightness of bolts and nuts Bends, cracks and wear Abnormal noise Loose connection and breaks of fuel and pulser hoses Loose connection and breaks of oil pipes Loose connection and breaks of oil delivery pipe Manual rope starter system Carburetor: Operation of starter jet Mixing adjuster (pilot screw) Idling speed adjustment Throttle valve synchronization Operation and adjustment of oil pump Ignition timing Engine compression Cylinder head/exhaust pipe decarbonization Spark plug condition, gap and cleaning Tightening of the cylinder head** Coolant leakage Operation of water pump and fuel pump Water pump drive belt tension/damage Coolant level DRIVE: Tightness of bolts and nuts Wear on slide runners Primary drive system V-belt Secondary drive system Sheave distance Sheave offset Brake pad wear Brake operation and adjustment Guide wheel rubber Wear of drive track wheel sprocket 2-1
0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0
0 0 0 0 0
0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
INTRODUCTJONIPERIODIC MAINTENANCE TABLE
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Every Check point
20 hrs. or 400 km (250 mj)
Seasonally
0 0 0 0 0 0
Drive track adjustment Breaks in drive track ,
When 40 hrs. or 80 hrs. or 800 km 1,600 km necessary (500 mj) (1,000 mi)
Bends in front and rear axles Checking of lock washers Drive cha:n adjustment Drive chain oil level BODY: Tightness of bolts and nuts Bends and cracks Welded/riveted, joints
0 0 0 0 0
Ski adjustment Breaks in fuel tank
0 0
Cleaning of fuel tank Fuel filter
0 0
Loose connection and breaks in fuel pipe Breaks in oil tank
0
Oil filter ELECTRICAL:
0
Wear, breakage of wire covering Breaks in high·tension cord
0 0
Voltage regulator workil)g voltage Operation of engine stop switch Operation of throttle override system Headlight Taillight Brake light
**
0 0 0 0 0
0
Retighten every 10 hours from the first use.
2·2
LUBRICATION INTERVALS LUBRICATION INTERVALS Every lubrication point
When 20 hrs. or 40 hrs. or 80 hrs. or Seasonally 1,600 km necessary 400 km 800 km (250 mj) (500 mi) (1,000 mi)
ENGINE: Recoil starter case Starter plunger Oil pump plunger
0 0 0
Aeroshell grease #7A or Esso Beacon 325 grease YAMAlUBE2 or equivalent
0
Engine oil tank
Oil/Grease Brand name
DRIVE: Secondary shaft and sliding sheave Shaft 1 and shaft 2 (Slide rail)
0
Drive chain oil replacement CHASSIS: Steering column lower bearing Steering column upper bearing Steering links Brake wire end stopper and brake lever Telescopic strut suspension
0
Stabilizer slider
2-3
0
Molybdenum disulfide snowmobile grease light weight lithium soap base grease Gear oil API Gl-3 SAE #75 or #80
0
light weight lithium soap base grease
0
Motor oil
0
Esso Beacon 325 grease or Aerosell grease #7A
0 0
0 0
SHROUD OPENING/SIDE COWL
I~ Ifill
COWLS, COVERS, SEAT AND HANDLEBAR SHROUD OPENING
When the engine requires a check or service, the shroud can be opened forward. 1. Unhook: • Shroud latches <D Right and left of the shroud. 2. Should be slowly raised until shroud stops.
SIDE COWL
Removal 1. Open the shroud. Refer to the "SHROUD OPENING" section. 2. Remove: .Screws <D
3. Open the side cowl and remove it .
.1
4. Remove: • Bracket
<D
2-4
Ir&r Itll_SE_AT__________ 5. Remove: eHood CD
Installation Reverse the removal procedure. Note the following points. 1. Install: eHood eSide cowl Screw (Hood): 3 Nm (0.3 m路 kg, 2.2 ft路lb) Bolt (Hood): 3 Nm (0.3 m路 kg, 2.2 ft路lb)
SEAT Removal 1. Remove: eSeat
2-5
HANDLEBAR COVER, HEADLIGHT AND METER ASSEMBLY
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2. Disconnect: • Tail/Brake light leads
Installation Reverse the removal procedure. Note the following points. 1. Install: • Seat Screws (Seat - Front): 3 Nm (0.3 m· kg, 2.2 ft·lb) ........... Nuts (Seat - Rear): 9 Nm (0.9 m· kg, 6.5 ft·lb)
HANDLEBAR COVER, METER ASSEMBLY
HEADLIGHT AND
Removal 1. Remove: • Handlebar cover (Rear)
CD
2. Remove: • Handlebar cover (Front)
CD
3. Remove: • Meter cover
CD
2-6
1~14it1_H_A_ND_L_EB_A_R_______________________ 4. Disconnect: • Meter leads • Speedometer cable
5. Remove: • Front cowl
6. Remove: • Headlight • Meter assembly
Installation Reverse the removal procedure. Note the following points. 1. Install: • Front cowl Screw (Front cowl): 3 Nm (0.3 m· kg, 2.2 ft·lb)
HANDLEBAR Removal 1. Remove: • Handlebar covers • Meter assembly • Headlight Refer to the "HANDLEBAR COVER, HEADLIGHT AND METER ASSEMBLY" section. 2-7
________________________H_A_ND_L_EB_A_Rlrgfl4il1 2. Open the shroud. Refer to the "SHROUD OPENING" section. 3. Disconnect: • Handlebar switch leads
4. Unhook the throttle cable holder CD and remove the throttle cable end from the throttle lever.
5. Remove: • Brake cable Removal steps: • Loosen the locknut CD • Turn in the adjuster <ID • Remove the brake cable end from the brake lever.
6. Remove: .Band CD
7. Remove: • Handlebar • Upper handlebar holders • Lower handlebar holder
2-8
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COVERS Installation Reverse the removal procedure. Note the following points. 1. I nstal/: eHandlebar e Lower handlebar holder e Upper handlebar holders NOTE: __________________________ eThe upper handlebar holder should be installed with the punch mark CD forward. e Align the punch marks CV with the handlebar holder gaps respectively. e Tighten the bolts to specification so that the front clearance "a" is smaller than rear clearance "b".
_r--.....J-1 b T
Bolts (Handlebar holder): 15 Nm (1.5 m'kg, 11 ft¡lb)
First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.
2. Adjust: e Brake Refer to "BRAKE ADJUSTMENT" section.
COVERS
Removal 1. Open the shroud. Refer to the "SHROUD OPENING" section. 2. Open the side cowls.
2-9
________________________C_O_VE_R_sl~I4il1 3. Remove: • Screw (Seat - Front)
4. Remove: • Handlebar cover • Headlight • Meter assembly Refer to the "HANDLEBAR COVER, HEADLIGHT AND METER ASSEMBLY" section.
5. Remove: .Handlebar Refer to the "HANDLEBAR" section. 6. Remove: • Side cover (Left) CD
7. Remove: • Main switch holding nut CD ."STARTER" lever holding nut CV • Decompression lever holding nut @
8. Remove: .Cover (Center)
CD
2-10
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COVERS 9. Disconnect: eOil pipe CD eFuel pipe CID e Gauge light leads @ NOTE: __________________________ Plug the oil pipe and fuel pipe so that the oil and fuel will not run out of each tanks.
10. Remove: eCover (Right)
CD
Installation Reverse the removal procedure. Note the following points. 1. Install: e Cover (R ight and left) NOTE: __________________________ Mate the projections on the covers (R ight and left) with the corresponding holes in the cover (Center).
2. Install: eOil pipe CD eFuel pipe CID NOTE: ________________________ Install the oil pipe and the fuel pipe to the cover (Right). Refer to the "CHAPTER 9 - CABLE ROUTING" section.
2-11
_ ________________E_N_G_IN_E_O_I_L_L_EV_E_L_I_N_SP_E_C_T_IO_N_ COOLANT LEVEL INSPECTIONI .IIANDSJPI~I .~. ENGINE ENGINE OIL LEVEL INSPECTION 1. Place the machine on a level place. 2. Inspect: • Engine oil level Oil level low ~ Add sufficient oil.
CD "F" (Full) level mark ® "E" (Empty) level mark 3. Open the shroud. Refer to the "SHROUD OPENING" section. 4. Add the engine oil until the oil level reaches "F" level mark. ~
·U CD
Recommended oil: YAMALUBE "2" or equivalent
Oil tank cap
Always use the same type of engine oil; mixing oils may result in a hurmful chemical reaction and lead to poor performance.
COOLANT LEVEL INSPECTION 1. Place the machine on a level place. 2. Start the engine and let it warm up. 3. Stop the engine.
2·12
I IANDSJPI.I_~~~~~~~~ _
_ ~ _ COOLANT REPLACEMENT
4. Open the shroud. Refer to the "SHROUD OPENING" section. 5. Open the side cowl (R ight) CD
6. Inspect: • Coolant level Coolant level is under "LOW" level mark CD ~ Add top water. 7. Add the top water (Soft water) until the coolant level reaches "FULL" level mark CID .
• Hard water or salt water is harmful to the engine parts; use boiled or distilled water if you can't get soft water . • Do not use water containing impurities or oil.
@ Reservoir tank cap
COOLANT REPLACEMENT NOTE: __________________________ The coolant should be changed at last seasonally. 1. Place the machine on a level place.
2. Open the shroud. Refer to the "SHROUD OPENING" section. 3. Remove: .Side cowls Refer to the "SI DE COWL" section.
2-13
_~~~~~~~~liANDSJPI.1 COOLANT REPLACEMENT . 4. Remove: • Muffler
. ~.
CD
5. Remove: • Exhaust pipe CD 6. Remove: • Seat Refer to the "SEAT" section.
7. Remove: .Coolant filler cap
CD
WARNING:
Do not remove the coolant filler cap CD especially 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 thick rag like a towel over the radiator 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.
8. Place an open container under the drain bolts CD. 9. Remove: • Drain bolts
2·14
I IANDSJPlel_~~~~~~~~
.
. ~. COOLANT REPLACEMENT
10. Drain the coolant. NOTE: ___________________________ When draining the coolant completely, lift up the tail of the machine .
• When coolant splashes to your eye; Thoroughly wash your eye with water and see your doctor. • When coolant splashes to your clothes; Quickly wash it away with water and then with soap . • When coolant is swallowed; Quickly make him vomit and take him to a doctor.
11. Remove the reservoir tank coolant; 12. Install: • Reservoir tank
CD
and drain the
13. Inspect: • Gasket (Drain bolt) Damage""* Replace. 14. Install: • Gaskets • Drain bolts • Exhaust pipe • Muffler Drain Bolt: 32 Nm (3.2 m'kg, 23 ft·lb) Bolts (Exhaust pipe): 10 Nm (1.0 m'kg, 7.2 ft·lb)
2·15
COOLANT REPLACEMENT 15. Fill: .Cooling system Recommended Coolant: High Quality Ethylene Glycol Anti-freeze Containing Anti-corrosion for Aluminum Engine Inhibitors Coolant and Water Mixed Ratio: 60% :40% Total Amount: 4.2 L (3.7 Imp qt, 4.4 US qt) Reservoir Tank Capacity: 0.25 L (0.22 Imp qt, 0.26 US qt)
• Hard water or salt water is harmful to the engine parts; use boiled or distilled water if you can't get soft water . • Do not use water containing impurities or oil.
Coolant filling steps: • Fill the coolant into the conduit. • Loosen the bleed bolt CD of heat exchanger. • Keep the coolant running out until air bubbles disappear. • Tighten the bleed bolt. Bleed Bolt: 6 Nm (0.6 m' kg, 4.3 ft·lb) • Fill the coolant again into the conduit. • Loosen the bleed bolt CID of cylinder head. • Keep the coolant running out until air bubbles disappear. • Tighten the bleed bolt. Bleed Bolt: 6 Nm (0.6 m'kg, 4.3 ft·lb)
2-16
COOLING SYSTEM INSPECTION - Fill the coolant into the conduit to specified level CD. - With the track off the ground, run the engine at 4,000 rpm until the thermostat opens and the coolant freely circulates. If the coolant level decreases in the filler pipe, with the engine running, add coolant until the level is once again at the top of the filler neck, and install the cap. WARNING:
Avoid contact with the moving track. Entanglement in the machinery of shop towels, clothing, or body parts could result in serious injury.
- Fill the coolant again into the conduit to specified level. -I nstall the filler cap. - Fill the coolant into the reservoir tank until the coolant level reaches "FULL" level mark
CV¡ 16. Inspect: - Cooling system Coolant leakage -+ Repair. 17. Install: -Seat Refer to the "SEAT" section. 18. Install: -Side cowls Refer to the "SI DE COWL" section.
COOLING SYSTEM INSPECTION 1. Open the shroud. Refer to the "SHROUD OPENING" section. 2. Remove: -Seat Refer to the "SEAT" section.
2-17
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FUEL LINE INSPECTION/ENGINE OIL LINE INSPECTION/ ~ ~ ENGINE IDLE SPEED ADJUSTMENT . . ~_ 3. Inspect: • Hoses Crack/Damage ~ Replace . • Heat exchanger Crack/Damage ~ Replace. Refer to the "CHAPTER 4 - COOLING SYSTEM" for replacement. 4. Install: .Seat Refer to the "SEAT" section.
FUEL LINE INSPECTION 1. Open the shroud. Refer to the "SHROUD OPENING" section. 2. Inspect: • Fuel hose Crack/Damage ~ Replace.
ENGINE OIL LINE INSPECTION 1. Open the shroud. Refer to the "SHROUD OPENING" section. 2. Inspect: • Engine oil hose Crack/Damage ~ Replace.
ENGINE IDLE SPEED ADJUSTMENT 1. Open the shroud. Refer to the "SH ROUD OPEN I NG" section.
2·18
THROTTLE CABLE FREE PLAY ADJUSTMENT 2_ Adjust: -Pilot screw
CD
Pilot screw adjustment steps: -Turn in the both pilot screw until they are lightly seated. -Turn out the both pilot screw to specification. Pilot Screw: 5/8 turns out 3. Start the engine and let it warm up.
4. Adjust: - Engine idle speed Adjustment steps: - Turn the throttle stop screw CD in or out until the specified engine speed is obtained. Turn in Turn out
C\
Idle speed becomes higher. Idle speed becomes lower.
Engine Idle Speed: 1,400 - 1,600 rlmin
NOTE: After adjusting the engine idle speed, the throttle cable free play should be adjusted.
THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: _ _ _ _ _ _ _ _ _ _ _ __ Before adjusting the throttle cable free play, the engine idle speed should be adjusted.
2-19
CARBURETOR SYNCHRONIZATION
I~ Ijii I
1. Measure: • Throttle cable free play ® Out of specification -? Adjust. Throttle Cable Free Play: 1.0 '" 2.0 mm (0.04 '" 0.08 in)
2. Adjust: • Throttle cable free play Free play adjustment steps: • Open the shroud. Refer to the "SHROUD OPENING" section. • Loosen the locknut CD . • Turn the adjuster @ in or out until the specified free play is obtained. Turn in
Free play is increased.
Turn out
Free play is decreased.
• Tighten the locknut.
CARBURETOR SYNCHRONIZATION 1. Open the shroud. Refer to "SHROUD OPENING" section. 2. Remove: .Plugs CD
3. Attach: • Vacuum Gauge (YU-08030) CD to the vacuum plugs. 4. Start the engine and let it warm up. WARNING: Do not move the throttle lever more than necessary so that the engine will not run faster than the following revolutions at which the snowmobiles starts to more off. Engine revolutions: 3,000 r/min 2-20
I I~I _________ NOSJP . ~. CARBURETOR SYNCHRONIZATION . lA
5. Adjust: • Engine idle speed Refer to the "ENGINE ADJUSTMENT" section.
IDLE SPEED
Engine Idle Speed: 1,400""" 1,600 r/min
6. Adjust: • Carburetor synchronization Carburetor synchronization adjustment steps: • Turn the synchronizing screw CD in or out until both gauges read the same.
7. Check: • Engine idle speed Out of specification
-+
Adjust.
Idle speed adjustment steps: • Turn the throttle stop screw CD in or out until specified idle speed is obtained. Turn in
Idle speed becomes higher.
Turn out
Idle speed becomes lower.
NOTE: Do not adjust the pilot screws.
2·21
DECOMPRESSION CABLE ADJUSTMENT DECOMPRESSION CABLE ADJUSTMENT 1. Open the shroud. Refer to the "SHROUD OPENING" section. 2. Pull the outer tube of decompression cable upward.
3. Check:
• Decompression cable free play ® Out of specification ~ Adjust. Free Play:
0.5 '" 1.5 mm (0.02 '" 0.06 in)
4. Adjust: • Decompression cable free play Free play adjustment steps: • Remove the rubber caps CD. • Loosen the locknut CID • • Turn the adjuster @ in or out until the specified free play is obtained. Turn in
Free play is increased.
Turn out
Free play is decreased •
• Tighten the locknut and install the both rubber cap.
5. Close the shroud.
2·23
OIL PUMP CABLE FREE PLAY ADJUSTMENT
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OIL PUMP CABLE FREE PLAY ADJUSTMENT
NOTE: _ _ _ _ _ _ _ _ _ _ _ __ Before adjusting the oil pump cable free play, the throttle cable free play should be adjusted. 1. Open the shroud. Refer to the "SHROUD section. 2. Remove: • Rubber cap
OPENING"
CD
3. Pull: • Oil pump outer cable 4. Measure: • Oil pump cable free play ® Out of specification -+ Adjust.
~
I
Free Play:
24 - 26 mm (0.94 - 1.02 inl
5. Adjust: • Oil pump cable free play Free play adjustment steps: • Loosen the locknut CD . • Turn the adjuster ® in or out until the specified free play is obtained. Turn in
Free play is increased.
Turn out
Free play is decreased •
• Tighten the locknut and install the rubber cap. 6. Close the shroud.
2-24
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OIL PUMP STROKE ADJUSTMENT OIL PUMP STROKE ADJUSTMENT 1. Open the shroud and side cowl (Left). 2. Remove: • Drive V-belt guard CD
3. Remove: • Blind cover
CD
4. Remove: • Bolts (I ntake silencer)
5. Loosen: .Screws (Carburetor joints)
6. Remove: • Carburetors NOTE: _ _ _ _ _ _ _ _ _ _ _ __ The throttle cable, starter cables and carburetor switch leads do not need removing.
2-25
_~~~~~~~~_IIANDSJPI_I OIL PUMP STROKE ADJUSTMENT . . . ~
7. Disconnect: • Fuel hoses
CD
NOTE: ___________________________ Plug the fuel hoses so that fuel does not run out.
8. Loosen: • Locknut
CD (Oil pump cable)
9. Remove: .Adjuster CD (Oil pump cable) • Oil pump cable ®
10. Disconnect: .Oil hoses CD .Oil delivery hoses
®
NOTE: __________________________ Plug the oil hoses and oil delivery hoses so that oil does not run out.
11. Place a rug under the oil pump assembly. 12. Remove: • Oil pump assembly CD
2·26
l iANDSJPlel_~~~~~~~~ . ~. OIL PUMP STROKE ADJUSTMENT
.
13. Remove: e Oil pump cover CD 14. Wipe off the grease from the plunger top.
®~
®
@
5
15. Measure: eMinimum pump stroke ® Out of specification -+ Adjust. Minimum Pump Stroke: 0.15 - 0.20 mm (0.006 - 0.008 in) Minimum pump stroke measurement steps: eTurn the pump worm gear CD with your fingers, until the plunger top ® is at its maximum distance from the pump body mating surface @ of the pump cover. e Using a Feeler Gauge, measure the minimum pump stroke ® between the adjusting plate @ and the raised boss @ on the adjusting pulley . . elf minimum pump stroke is not within the specified limits, perform the adjustment steps.
16. Measure: eMaximum pump stroke @ Out of specification -+ Adjust. Maximum Pump Stroke: 1.62 - 1.80 mm (0.064 - 0.071 in)
Maximum pump stroke measurement steps: ePull the oil pump cable CD out of its sheather as far as it will go. The cable must be held in this taut position when measuring the maximum pump stroke. NOTE: _______________________ It may be helpful to securely warp duct tape ® around the cable where it enters the sheath.
2·27
OIL PUMP STROKE ADJUSTMENT
mr G.I
1
1
• Turn the pump worm gear @ with your fingers, until the plunger top @ is at its maximum distance from the pump body <ID. • Using a Feeler Gauge, measure the maximum pump stroke @ . • If maximum pump stroke is not within the specified limits, perform the adjustment steps. 17. Adjust: • Oil pump stroke Adjustment steps: • Remove the locknut ill , spring washer CV and adjusting plate @ . • Adjust the pump stroke by adding or removing a shim. Add shim
Pump stroke is increased.
Remove shim Pump stroke is decreased. • Reinstall the adjusting plate, spring washer and locknut.
I®
Locknut: 7 Nm (0.7 m·kg, 5.1 ft·lb)
• Recheck the minimum and maximum pump stroke .. If out of specification limits, perform the above steps again.
18. Apply: • Lithium soap base grease To out side of pump pulley.
2-28
I IANDSJPIBI_~~~~~~~~ .
. ~ _ OIL PUMP STROKE ADJUSTMENT
19. Install: • Oil pump cover NOTE: _ _ _ _ _ _ _ _ _ _ _ __ Apply the Yamabond No. 5® (ACC-11001-3100) to the mating surface of the oil pump cover.
20. Tighten: .Screws (Oil pump cover) Screws (Oil pump cover): 2 Nm (0.2 m ° kg, 1.4 ftolb)
21. Inspect: • Gasket (Oil pump) Damage ~ Replace.
22. Install: • Oil pump assembly Bolts (Oil pump assembly): 4 Nm (0.4 mokg, 2.9 ftolb) NOTE: _ _ _ _ _ _ _ _ _ _ _ ___ After installing the oil pump assembly, the oil pump, oil hose and oil delivery hose should be bleed. Refer to the "01 L PUMP AI R BLEEDING" section.
2·29
OIL PUMP AIR BLEEDING 23. Install: • Oil pump cable .Oil hoses • Oil delivery hoses • Fuel hoses • Carburetors • Bolts (Intake silencer) • Blind cover • Drive V-belt guard
24. Adjust: .Oil pump cable free play Free Play:
24'" 26 mm (0.94'" 1.02 in) Refer to the "01 L PUMP CABLE FREE PLAY ADJUSTMENT" section.
25. Close the side cowl (Left) and shroud.
OIL PUMP AIR BLEEDING
The oil pump and delivery line must be bled on the following occasions: • Any portion of the oil system has been disconnected. • The machine has been turned on its side. • Whenever the oil tank has been run empty. • During predelivery.
1. Open the shroud and side cowl (Left). 2. Remove: • Drive V-belt guard
CD
2-30
I~IQI
OIL PUMP AIR BLEEDING 3. Remove: • Blind cover
ill
4. Remove: • Bolts (Intake silencer)
5. Loosen: .Screws (Carburetor joints)
6. Remove: • Carburetors
NOTE: __________________________ The throttle cable, starter cables and carburetor switch leads do not need removing.
7. Disconnect: • Fuel hoses
ill
NOTE: __________________________ Plug the fuel hoses so that fuel does not run out of the fuel pump.
2-31
OIL PUMP AIR BLEEDING 8. Loosen: • Locknut
Imr IQ I
CD (Oil pump cable)
9. Remove: .Adjuster CD (Oil pump cable) • Oil pump cable ®
10. Disconnect: • Oil hoses CD .Oil delivery hoses
®
11. Place a rug under the oil pump assembly.
12. Fill: .Oil tank Recommended Oil: Yamalube "2" or equivalent
2-32
OIL PUMP AIR BLEEDING 13. Connect: .Oil hoses
NOTE: __________________________ Make sure that the oil hoses are completly bleed of air. Then, connect them with the oil pump.
14. Put Yamalube "2" or equivalent into the oil delivery hoses for complete air bleeding. Then, connect them with the oil pump.
15. Remove: • Bleed screw CD 16. Inspect: • Gasket (Bleed screw) Damage ~ Replace.
17. Keep the oil running out until air bubbles disappear. 18. Install: • Gasket (Bleed screw) • Bleed screw
19. Connect: • Fuel hoses
2-33
_~~~~~~~~.IIANDSJPlel OIL FILTER INSPECTION. . ~. 20. Install: • Carburetors • Bolts (I ntake silencer) • Blind cover • Drive V-belt guard
21. Start the engine and keep it running at idle for two minutes or so. NOTE: __________________________ Pull the oil pump cable all the way out to set the oil pump stroke to a maximum.
22. Close the side cowl (Left) and shroud.
OIL FILTER INSPECTION 1. Open the shroud. 2. Remove: • Oil tank stay CD
3. Disconnect: .Oil hoses NOTE: __________________________ Plug the oil hoses so that the oil will not run out of the oil tank and oil pump.
2·34
FUEL FILTER INSPECTION 4_ Inspect: -Oil filter CD Contamination
11
-+
Replace.
Recommended replacement interval: Every season
11 5. Install: -Oil filter 6. Connect: -Oil hoses 7. Install: -Oil tank stay Bolts (Oil tank stay): 7 Nm (0.7 m-kg, 5.1 ft-Ib)
FUEL FILTER INSPECTION 1. Remove the seat. Refer to the "SEAT" section. 2. Remove: -Springs CD
3. Remove: -Cap CD - Fuel filter CID
2-35
_~~~~~~~~liANDSJPIBI FUEL PUMP OPERATION CHECK. 4. Inspect: • Fuel filter Contamination
~
. ~_
Replace.
Recommended replacement interval: Every season
5. Install: • Fuel filter .Cap .Springs .Seat Screws (Seat - Front): 3 Nm (0.3 m' kg, 2.2 ft·lb) Nuts (Seat - Rear): 9 Nm (0.9 m' kg, 6.5 ft·lb) FUEL PUMP OPERATION CHECK 1. Open the shroud and side cowl (Left). 2. Remove: • Drive V-belt guard CD • Drive V-belt Drive V-belt removal steps: • Turn the secondary sliding sheave <ID clockwise and push it towards the engine . • While holding the secondary sliding sheave in this compressed position, remove the drive V-belt @ from the secondary sheave . • Then, remove the drive V-belt from the primary sheave.
2·36
FUEL PUMP OPERATION CHECK 3. Apply the brake to lock the secondary sheave.
4. Remove: • Secondary sheave
5. Remove: • Blind cover
CD
CD
6. Remove: • Bolts (I ntake silencer)
7. Loosen: .Screws (Carburetor joints)
2-37
FUEL PUMP OPERATION CHECK 8. Remove: • Carburetors
NOTE: __________________________ The throttle cable, starter cables and carburetor switch leads do not need removing.
9. Disconnect: • Fuel hoses
CD
NOTE: __________________________ Plug the fuel hoses so that fuel does not run out of the fuel pump.
10. Disconnect: • Pulser hose
CD
11. Remove: • Fuel pump CD 12. Inspect: • Fuel hoses • Pulser hose Clog/Damage ~ Replace.
13. Check: • Fuel pump operation Operation checking steps: .Connect a suitable hose to the joint CD of the fuel pump. Put the other end of the hose into a container of fresh fuel.
2-38
FUEL PUMP OPERATION CHECK • Connect a hand-operated vacuum pump (such as Mighty - Vac®) to the pulser hose
CD . • When operating a hand-operated vacuum pump, fuel flows out of the fuel hoses CID and@ . • If fuel does not flow out, replace the fuel pump.
14. Install: .Fuel pump Bolts (Fuel pump): 10 Nm (1.0 m'kg, 7.2 ft·lb) 15. Connect: • Pu Iser hose • Fuel hoses 16. Install: • Carburetors • Bolts (I ntake silencer) • Blind cover • Secondary sheave • Drive V-belt • Drive V-belt guard Bolt (Secondary sheave): 60 Nm (6.0 m'kg, 43 ft·lb) 17. Close the side cowl (Left) and shroud.
2-39
WATER PUMP DRIVE BELT TENSION ADJUSTMENT WATER PUMP DRIVE BELT TENSION ADJUSTMENT 1. Open the shroud and side cowl (R ight). 2. Remove: eMuffler CD
3. Check: e Drive belt tension Out of specification
-+
Adjust.
Drive Belt Tension: 8...., 15 mm (0.3...., 0.6 in)! 5 kg (11 Ib)
4. Adjust: e Drive belt tension Drive belt tension adjustment steps: e Remove the recoil starter CD . eAttach the Primary Sheave Holder (YS01880) to hold the primary sheave. e Remove the starter pulley CID . e Remove the screws @ of the starter pulley. e Adjust the drive belt tension by adding or removing a shim @. Add shim
Tension becomes lower.
Remove shim Tension becomes higher. Shim size Part Number
Thickness
82M-15721-00
0.5 mm (0.02 in)
82M-15722-00
1.0 mm (0.04 in)
elnstall the starter pulley and drive belt. e Recheck the drive belt tension. If out of the specification, readjust the drive belt tension.
2-40
DRIVE V-BELT INSPECTION 5. Install: eStarter pulley e Drive belt e Recoil starter eMuffler Bolts (Starter pulley): 20 Nm (2.0 m路kg, 14 ft路lb) Bolts (Recoil starter): 10 Nm (1.0 m路kg, 7.2 ft路lb) 6. Close the side cowl (Right) and shroud.
POWER TRAIN DRIVE V-BELT INSPECTION 1. Open the shroud and side cowl (Left). 2. Remove: e Drive V-belt guard CD e Drive V-belt Drive V-belt removal steps: eTurn the secondary sliding sheave CID clockwise and push it towards the engine. eWhile holding the secondary sliding sheave in this compressed position, remove the drive V-belt @ from the secondary sheave. eThen, remove the drive V-belt from the primary sheave.
3. Inspect: e Drive V-belt Crack/Wear/Damage -+ Replace. Oil or grease adhered to the V-belt -+ Check the primary and secondary sheaves.
2-41
_~~~~~~~~IIANDSJPI~I SHEAVE DISTANCE AND OFFSET ADJUSTMENT .
. ~.
4. Inspect: • Primary sheave • Secondary sheave Oil or grease adhered to the primary and secondary sheaves ~ Remove the oil or grease using a rug soaked in lacquer thinner or solvent.
5. Measure: • Drive V-belt width ® Out of specification ~ Replace. New Belt Width: 31.6 mm (1.24 in) I--:W Belt Wear Limit: 28.0 mm (1.10 in)
6. Measure: • Drive V-belt length ® Out of specification ~ Replace. Drive V-belt Length: 1,099 mm (43.3 in)
7. Install: • Drive V-belt • Drive V·belt guard 8. Close the side cowl (Left) and shroud.
SHEAVE DISTANCE AND OFFSET ADJUSTMENT 1. Open the shroud and side cowl (Left). 2. Remove: • Drive V-belt guard CD • Drive V-belt
2·42
SHEAVE DISTANCE AND OFFSET ADJUSTMENT Drive V-belt removal steps: .Turn the secondary sliding sheave <ID clockwise and push it towards the engine . • While holding the secondary sliding sheave in this compressed position, remove the drive V-belt @ from the secondary sheave . • Then, remove the drive V-belt from the primary sheave.
3. Measure: • Sheave distance ® Use the Sheave Gauge (YS-91047). Out of specification ~ Adjust. Sheave Distance: 267 - 270 mm (10.5 - 10.6 in)
4. Adjust: • Sheave distance Sheave distance adjustment steps: • Check the engine mounting bracket, dampers and frame for bend, crack and weathering. Replace as required. • Loosen the engine mounting nuts CD . • Adjust the position of the engine so that the sheave distance is within the specification. • Tighten the engine mounting nuts.
I® 2-43
Mounting Nut: 40 Nm (4.0 m-kg, 29 ft·lb)
_~~~~~~~~IIANDSJPI.I SHEAVE DISTANCE AND OFFSET ADJUSTMENT. .
~.
5. Measure: e Sheave offset ® Use the Sheave Gauge (YS-91047). Out of specification -+ Replace. Sheave Offset: 9.5 - 12.5 mm (0.37 - 0.49 in)
6. Adjust: e Sheave offset Sheave offset adjustment steps: eApply the brake to lock the secondary sheave. e Remove the bolt (Secondary sheave) and secondary sheave CD . eAdjust the sheave offset by adding or removing a shim CID. Add shim Offset is increased. Remove shim Offset is decreased. Shim size Thickness Part Number 0.5 mm (0.02 in) 90201-252F1 1.0 mm (0.04 in) 90201-25527 2.0 mm (0.08 in) 90201-25526 elnstall the secondary sheave and (Secondary sheave).
~
bolt
Bolt (Secondary sheave): 60 Nm (6.0 m'kg, 43 ft-Ib)
e Recheck the sheave offset. If out of specification, readjust the sheave offset. NOTE: When adjusting the sheave offset, the secon· dary sheave free play (Clearance) should be adjusted.
2·44
Ir8f Ifill
SHEAVE DISTANCE AND OFFSET ADJUSTMENT 7. Measure: eSecondary sheave free play (Clearance) ® Use a feeler gauge. Out of specification ~ Adjust. Secondary Sheave Free Play (Clearance) : 0.5 '" 1.0 mm (0.02 '" 0.04 in)
8. Adjust: eSecondary sheave free play (Clearance) Secondary sheave free play (Clearance) adjustment steps: eApply the brake to lock the secondary sheave. e Remove the bolt (Secondary sheave CD ). eAdjust the secondary sheave free play (Clearance) by adding or removing a shim
®. Add shim
Free play is decreased.
Remove shim
Free play is increased. Shim size
Part Number
Thickness
90201-222FO
0.5 mm (0.02 in)
90201-225A4
1.0 mm (0.04 in)
elnstall the bolt (Secondary sheave).
I®
Bolt (Secondary sheave): 60 Nm (6.0 m'kg, 43 ft·lb)
e Recheck the secondary sheave free play (Clearance). If out of specification, readjust the free play (Clearance).
2-45
.
DRIVE CHAIN HOUSING OIL LEVEL INSPECTION 9. Install: • Drive V-belt • Drive V-belt guard 10. Close the side cowl (Left) and shroud.
DRIVE CHAIN HOUSING OIL LEVEL INSPECTION 1. Place the machine on a level place and open the shroud. NOTE: __________________________
Be sure the machine is positioned straight up when inspecting the oil level.
2. Place a rug under the checking bolt 3. Remove:
CD .
• Checking bolt
4. Inspect: .Oillevel Oil flows out -+ Oil level is correct. Oil does not flow out -+ Oil level is low. Add oil until oil flows out. Recommended Oil: Gear oil API GL-3 SAE #75 or #80
5. Inspect: • Gasket (Checking bolt) Damage -+ Replace.
2·46
DRIVE CHAIN HOUSING OIL REPLACEMENT 6. Install: • Gasket (Checking bolt) • Checking bolt Checking Bolt: 7 Nm (0.7 m' kg, 5.1 ft·lb) 7. Close the shroud.
DRIVE CHAIN HOUSING OIL REPLACEMENT 1. Open the shroud and side cowl (Right). 2. Remove: • Muffler CD
3. Place some rugs under the drive chain housing. 4. Remove the chain housing cover CD and drain the oil.
5. Replace: • Gasket (Chain housing cover) Use new one. 6. Install: • Gasket (Chain housing cover) • Chain housing cover
Be sure no foreign material enters the chain housing case.
Bolts (Chain housing cover); Small diameter (M6) 10 Nm (1.0 m'kg, 7.2 ft·lb) Large diameter (M8) 23 Nm (2.3 m·kg, 17 ft·lb)
2-47
_~~~~~~~~_IIANDSJPlel DRIVE CHAIN SLACK ADJUSTMENT . . . ~
7. Fill: e Drive chain housing Recommended Oil: Gear oil API GL-3 SAE #75 or #80 Oil Capacity: 250 cm 3 (8.8 Imp OZ, 8.5 US oz)
8. Inspect: e Drive chain housing oil level Refer to the "DRIVE CHAIN HOUSING OIL LEVEL INSPECTION".
9. Install: eMuffler 10. Close the side cowl (Right) and shroud.
DRIVE CHAIN SLACK ADJUSTMENT 1. Open the shroud and side cowl (R ight). 2. Remove: eMuffler CD
3. Place some rugs under the chain housing. 4. Remove the chain housing cover CD and drain the oil.
2·48
I IANDsJPlel_~~~~~~~~
.
. ~. DRIVE CHAIN SLACK ADJUSTMENT
5. Check: • Drive chain slack ® Out of specification -+ Adjust. Drive Chain Slack: S - 15 mm (0.31 - 0.59 in)
6. Adjust: • Drive chain slack Drive chain slack adjustment steps: • Loosen the locknut CD . • Turn the adjuster CID in or out until the specified slack is obtained. Turn in
Slack is decreased.
Turn out
Slack is increased.
• Tighten the locknut. 7. Replace: • Gasket (Chain housing cover) Use new one. 8. Install: • Gasket (Chain housing cover) .Chain housing cover
Be sure no foreign material enters the chain housing case. Bolts (Chain housing cover): Small diameter (M6) 10 Nm (1.0 m-kg, 7.2 ft-Ib) Large diameter (MS) 23 Nm (2.3 m-kg, 17 ft-Ib) 9. Fill: • Drive chain housing Recommended Oil: Gear oil API GL-3 SAE #75 or#SO Oil Capacity: 250 cm 3 (S.S Imp oz, S.5 US oz)
2·49
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