SERVICE MANUAL RST90TFKRS90MKRSG90KRS90RKRS90KRST90K LIT-12618-02-38 8FJ-28197-10981096
INDEX GENERAL INFORMATION INFOGEN 1 PERIODIC INSPECTION AND ADJUSTMENT INSPADJ 2 CHASSIS CHAS 3 POWER TRAIN POWRTR 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 CARBURETION CARB 7 ELECTRICAL ELEC 8 SPECIFICATIONS SPEC 9 – +
CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ............................1-1 FRAME SERIAL NUMBER.........................1-1 ENGINE SERIAL NUMBER........................1-1 IMPORTANT INFORMATION ..........................1-2 PREPARATION FOR REMOVAL LOCTITECIRCLIPS...................................................1-3BEARINGSANDLOCKGASKETS,ALLDISASSEMBLY...........................................1-2ANDREPLACEMENTPARTS.....................1-2OILSEALS,ANDO-RINGS.....1-3WASHERS/PLATESCOTTERPINS...................................1-3ANDOILSEALS.....................1-3®..................................................1-3 SPECIAL TOOLS .............................................1-4 FOR TUNE UP............................................1-4 FOR ENGINE SERVICE.............................1-4 FOR POWER TRAIN SERVICE.................1-7 FOR CARBURETION SERVICE................1-8 FOR ELECTRICAL SERVICE....................1-8 CHAPTER 2. PERIODIC INSPECTION AND INTRODUCTIONADJUSTMENT...............................................2-1 PERIODIC MAINTENANCE CHART ................2-1 ENGINEEXHAUSTELEMENT.................................................2-23CHECKINGCARBURETORINSPECTION............................................2-23CRANKCASEENGINEENGINEMEASUREMENT......................................2-17COMPRESSION(T.O.R.S.)THROTTLEADJUSTMENT..........................................2-15THROTTLEENGINECARBURETORVALVECOOLINGFUELSPARK............................................................2-3PLUGS...........................................2-3LINEINSPECTION...........................2-3SYSTEM....................................2-4CLEARANCEADJUSTMENT........2-7SYNCHRONIZATION.....2-13IDLESPEEDADJUSTMENT.....2-14CABLEFREEPLAYOVERRIDESYSTEMCHECK....................................2-16PRESSUREOILLEVELINSPECTION..........2-18OILREPLACEMENT.................2-20BREATHERHOSEJOINTSINSPECTION....2-23THEAIRFILTERSYSTEMINSPECTION..........2-24 POWER TRAIN ...............................................2-25 SHEAVE OFFSET ADJUSTMENT...........2-25 DRIVE MAXIMIZINGSLIDETRACKDRIVESYSTEM)..................................................2-32AIRBRAKEBRAKEBRAKEPARKINGENGAGEMENTV-BELT..........................................2-27SPEEDCHECK..............2-29BRAKEADJUSTMENT............2-30FLUIDLEVELINSPECTION.......2-30PADINSPECTION.......................2-31HOSEINSPECTION....................2-31BLEEDING(HYDRAULICBRAKECHAIN...........................................2-33TENSIONADJUSTMENT............2-35RUNNERINSPECTION................2-37DRIVETRACKLIFE...........2-37 CHASSISLUBRICATION..........................................2-41STEERINGSKI/SKI........................................................2-39RUNNER.....................................2-39SYSTEM................................2-40 ELECTRICALSPEEDOMETERFUSEBATTERYHEADLIGHT.................................................2-44BEAMADJUSTMENT.........2-44INSPECTION...........................2-44INSPECTION..................................2-52UNITINSPECTION......2-54 TUNINGREARFRONTHIGHGEARCLUTCH....................................................2-62CARBURETOR..........................................................2-55TUNING..........................2-55SELECTION...................................2-67ALTITUDETUNING........................2-73SUSPENSION.............................2-74SUSPENSION................................2-75 CHAPTERCHASSIS3. STEERINGINSTALLATION...........................................3-8INSPECTION..............................................3-7REMOVAL...................................................3-7RS90M........................................................3-3RS90/RS90R/RSG90/RST90/RST90TF.....3-1........................................................3-1 SKI (RST90INSTALLATIONINSPECTION............................................3-16RST90RS90M......................................................3-14RST90TF...................................................3-13RSG90RS90/RS90R/RSG90..................................................................3-12“USA/Canada”.......3-12“Europe”/RST90“Europe”/“USA/Canada”...............................3-15“USA/Canada”)............................3-17
FRONT SUSPENSION ...................................3-18 HANDLING INSTALLATION........................................3-21INSPECTION............................................3-20NOTES..................................3-20 CHAPTER 4. POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT INSTALLATION..........................................4-9ASSEMBLY.................................................4-6INSPECTION..............................................4-4DISASSEMBLY...........................................4-3REMOVAL..................................................4-3.......4-1 SECONDARY SHEAVE INSTALLATION........................................4-15ASSEMBLY...............................................4-13INSPECTION............................................4-12DISASSEMBLY.........................................4-12.................................4-10 DRIVE CHAIN HOUSING ...............................4-16 WITHOUT REVERSE INSTALLATION........................................4-25INSPECTION............................................4-24REMOVAL................................................4-24WITHINSTALLATION........................................4-20INSPECTION............................................4-18REMOVAL................................................4-18MODEL.................4-16REVERSEMODEL.........................4-21 SECONDARY SHAFT HOUSINGSECONDARYINSTALLATION........................................4-29INSPECTION............................................4-29REMOVAL................................................4-28....................................4-27SHAFTANDDRIVECHAININSTALLATION.......................4-32 BRAKEINSTALLATION........................................4-41ASSEMBLY...............................................4-41BRAKEINSPECTION............................................4-41BRAKEBRAKEANDBRAKEBRAKEBRAKE...........................................................4-34PADREPLACEMENT.................4-35CALIPERDISASSEMBLY...........4-38CALIPERINSPECTIONREPAIR............................................4-38CALIPERASSEMBLY.................4-39CALIPERINSTALLATION...........4-39MASTERCYLINDER SLIDE RAIL SUSPENSION INSTALLATION.........................................4-75ASSEMBLY...............................................4-73INSPECTION............................................4-72REMOVAL.................................................4-72RST90TF...................................................4-65RST90.......................................................4-59RS90M......................................................4-53RSG90......................................................4-48RS90/RS90R.............................................4-42............................4-42 FRONT AXLE AND TRACK INSTALLATION.........................................4-79INSPECTION............................................4-79...........................4-78 CHAPTER 5. ENGINE SEAT AND FUEL TANK RS90/RS90R/RSG90/RS90M.....................5-1...................................5-1 BACKREST AND PASSENGER SEAT RST90/RST90TF........................................5-2...........5-2 RIDER SEAT AND FUEL TANK INSTALLATION...........................................5-4REMOVAL...................................................5-4RST90/RST90TF........................................5-3......................5-3 OIL TANK .........................................................5-5 ENGINE ASSEMBLY .......................................5-6 HOSE AND LEADS.....................................5-6 ENGINE INSTALLATION...........................................5-9REMOVAL...................................................5-9ASSEMBLY..................................5-8 EXHAUST PIPE AND MUFFLER INSTALLATION.........................................5-12...................5-11 CAMSHAFTSINSTALLATION.........................................5-20INSPECTION............................................5-17REMOVAL.................................................5-16CAMSHAFTS............................................5-15CYLINDER..................................................5-14HEADCOVER.......................5-14 CYLINDER HEAD INSTALLATION.........................................5-26INSPECTION............................................5-25REMOVAL.................................................5-25...........................................5-24 VALVES AND VALVE SPRINGS INSTALLATION.........................................5-34INSPECTION............................................5-30REMOVAL.................................................5-29...................5-28
A.C. MAGNETO ROTOR AND STARTER CLUTCH INSTALLATION........................................5-40INSPECTION............................................5-39REMOVAL................................................5-38...............................5-37 OIL PAN AND OIL PUMP INSTALLATION........................................5-47INSPECTION............................................5-45REMOVAL................................................5-45..............................5-42 CRANKCASEINSTALLATION........................................5-67INSPECTION............................................5-56REMOVAL................................................5-54ANDCRANKSHAFTCONNECTINGCRANKCASE............................................5-49.................................................5-49RODSANDPISTONS.....5-51BALANCERSHAFT.........................5-52 CHAPTER 6. COOLING SYSTEM HEAT EXCHANGER INSTALLATION..........................................6-5INSPECTION..............................................6-4........................................6-1 THERMOSTATINSTALLATION..........................................6-7INSPECTION..............................................6-7.................................................6-6 WATER PUMP INSTALLATION........................................6-13ASSEMBLY...............................................6-12INSPECTION............................................6-12DISASSEMBLY.........................................6-11REMOVAL................................................6-11..................................................6-9 CHAPTER CARBURETORSCARBURETION7.ANDFUELPUMPINSTALLATION........................................7-13INSPECTION............................................7-12INSPECTIONTHROTTLEFUELINSTALLATION..........................................7-9ASSEMBLY.................................................7-8INSPECTION..............................................7-6................7-1LEVELADJUSTMENT...................7-10POSITIONSENSOR(T.P.S.)ANDADJUSTMENT..........7-11 CHAPTER ELECTRICAL8. SWITCH INSPECTION .....................................8-1 SWITCH ININSPECTINGINSPECTION...............................8-1ASWITCHSHOWNTHEMANUAL........................................8-1 IGNITION SYSTEM ..........................................8-2 CIRCUIT MAINTHROTTLEENGINE(T.O.R.S.)....................................................8-8THROTTLEPICKUPIGNITIONIGNITIONTROUBLESHOOTING................................8-4DIAGRAM....................................8-2SPARKGAP..............................8-6COIL...........................................8-6COIL.............................................8-7OVERRIDESYSTEMSTOPSWITCH............................8-8SWITCH..................................8-9SWITCH............................................8-9 ELECTRICAL STARTING SYSTEM ..............8-10 CIRCUIT STARTERTROUBLESHOOTING..............................8-11DIAGRAM..................................8-10MOTOR...................................8-13 CHARGING SYSTEM .....................................8-18 CIRCUIT A.C.BATTERY..................................................8-20TROUBLESHOOTING..............................8-19DIAGRAM..................................8-18MAGNETO........................................8-20 LIGHTING SYSTEM .......................................8-22 CIRCUIT LOADHEADLIGHTHEADLIGHTBULB(S)....................................................8-26TROUBLESHOOTING..............................8-24DIAGRAM..................................8-22BEAMSWITCH...................8-26RELAY.................................8-26CONTROLRELAY.........................8-27 SIGNAL SYSTEM ...........................................8-28 CIRCUIT SPEEDFUELOILCOOLANT(RS90R/RSG90/RST90/RST90TF)...........8-36DC(RS90R/RSG90/RST90/RST90TF)...........8-36GEARBRAKETROUBLESHOOTING..............................8-30DIAGRAM..................................8-28LIGHTSWITCH...........................8-36POSITIONSWITCHBACKBUZZERTEMPERATURESENSOR....8-37LEVELSWITCH.................................8-38SENDER.........................................8-38SENSOR......................................8-39
GRIP WARMER SYSTEM ..............................8-40 CIRCUIT (RST90/RST90TF)....................................8-46PASSENGER(RST90/RST90TF)....................................8-46PASSENGER(RST90/RST90TF)....................................8-45PASSENGERSWITCH....................................................8-45GRIPSWITCH....................................................8-44THUMBGRIPTROUBLESHOOTING..............................8-42DIAGRAM..................................8-40ANDTHUMBWARMERCOIL........8-44WARMERADJUSTMENTWARMERADJUSTMENTGRIPWARMERGRIPWARMERSWITCHGRIPWARMERRELAY CARBURETOR HEATER SYSTEM ...............8-48 CIRCUIT CARBURETORCARBURETORTROUBLESHOOTING..............................8-50DIAGRAM..................................8-48HEATERRELAY............8-51HEATER.........................8-51 SELF-DIAGNOSISSELF-DIAGNOSIS..........................................8-52CODE........................8-53 CHAPTER SPECIFICATIONS9. GENERAL SPECIFICATIONS .........................9-1 MAINTENANCE SPECIFICATIONS HIGHELECTRICAL............................................9-17CHASSIS..................................................9-15POWERENGINE......................................................9-4................9-4TRAIN...........................................9-9ALTITUDESETTINGS....................9-19 TIGHTENING TORQUE CHASSIS..................................................9-25POWERENGINE....................................................9-20..................................9-20TRAIN.........................................9-22 GENERAL TORQUE SPECIFICATIONS .......9-26 DEFINITION OF UNITS ..................................9-26 CABLE ROUTING ..........................................9-28
1-1 GEN INFO GENERAL INFORMATION
FRAME SERIAL NUMBER
MACHINE IDENTIFICATION
ENGINE SERIAL NUMBER
1
The frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat).
The engine serial number 1 is located on the right-hand side of the crankcase.
NOTE: Designs and specifications are subject to change without notice.1
MACHINE IDENTIFICATION http://ReadManuals.com
1-2 GEN INFOIMPORTANT INFORMATION
ALL REPLACEMENT PARTS
We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments. 1 http://ReadManuals.com
IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY
2.Usesplashes.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 parts that have been “mated” through normal wear. Mated parts must be reused or replaced as an
6.Be sure to keep to the tightening torque specifications. When tightening bolts, nuts, and screws, start with those that have larger diameters, and proceed from the inside to the outside in a crisscross pattern.
4.Duringassembly.disassembly of the machine, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help ensure that all parts are reinstalled correctly. 5.Keep all parts away from any source of fire.
1.Remove all dirt, mud, dust, and foreign material before removal and Whiledisassembly.cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc., from high pressure water
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DoCAUTION:notusecompressed air to spin the bearings dry. This causes damage to the surface of the bearings. CIRCLIPS
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 2.Properlycleaned.
LOCK WASHERS/PLATES AND COTTER PINS
All lock washers/plates 1 and cotter pins must be replaced if 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.
4 Shaft LOCTITE® After installing fasteners that have LOCTITE® applied, wait 24 hours before using the machine. This will give the LOCTITE® time to dry properly. http://ReadManuals.com
BEARINGS AND OIL SEALS
All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing a circlip 1, make sure that the sharp edged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view.
1-3 GEN INFOIMPORTANT INFORMATION
Install the bearings 1 and oil seals 2 with their manufacturer’s marks or numbers facing outwards. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil the bearings liberally when installing.
oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
GASKETS, OIL SEALS, AND O-RINGS
GEN INFOSPECIAL TOOLS
1-4
Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques.
• Angle gauge Use goods on the market. This tool is used to tightening the torque.
• Piston pin P/N:YU-01304puller90890-01304
• For others, use part number starting with “90890-”
This gauge is used for run out measurement.
• Dial P/N:YU-03097gauge90890-03097
• Steering linkage alignment plate
• For USA and Canada, use part number starting with “YB-”, “YM-”, “YU-”, “YS-” or “ACC-”.
This gauge is used to measure the fuel level in the float chamber.
NOTE: • Be sure to use the correct part number when ordering the tool, since the part number may differ according to country.
SPECIAL TOOLS
LocksP/N:YS-0148790890-01487steeringrelayarms in place while adjusting the steering linkage for front-end alignment.
FOR ENGINE SERVICE
This tool is used to remove the piston pin. http://ReadManuals.com
FOR TUNE UP
• Fuel level P/N:YM-01312-Agauge90890-01312
This tool is needed to loosen or tighten the oil filter cartridge.
•Compression gauge set P/N:YU-33223 (compression gage)
•Cooling system
1-5
GEN INFOSPECIAL TOOLS
•Rotor holding
This•AdapterP/N:YU-24460-01tester90890-01325P/N:YU-3398490890-01352testeranditsadapterare
This guide is used to synchronize the carburetors.
These•FlywheelP/N:YU-33270-Bpuller90890-01362pullerattachmentP/N:YM-3328290890-04089toolsareusedtoremove the magneto rotor.
•VacuumP/N:YU-44456gauge90890-03094
used for checking the cooling system.
install the valve assemblies. http://ReadManuals.com
•Valve spring compressor set P/N:YM-04019 (valve spring compressor)
•Oil filter P/N:YM-01469wrench90890-01469
TheseP/N:YU-33223-490890-03081(adapter)90890-04136toolsareusedtomeasure engine compression.
TheseP/N:YM-0410890890-04019(attachment)90890-04108toolsareusedtoremoveor
•Rotor holding P/N:YU-01235tool90890-01235
•Valve guide reamer (ø5) P/N:YM-0409990890-04099
This tool is used to rebore the new valve guides.
•ValveP/N:90890-04101lapper
•Piston ring P/N:YM-08037compressor90890-05158
This tool is used to compress the piston rings when installing the piston into the cylinder. http://ReadManuals.com
This tool is needed to remove and install the valve lifters.
This tool is used to install the valve guides.
•Valve guide installer (ø5) P/N:YM-0409890890-04098
the water pump seal.
1-6 GEN INFOSPECIAL TOOLS •40 and 50 mm bearing driver These•MechanicalP/N:YM-0405890890-04058sealinstallerP/N:YM-0414590890-04145toolsareusedtoinstall
•Valve guide remover (ø5) P/N:YM-0409790890-04097
This tool is used to hold the camshaft sprocket.
This tool is used to remove or install the valve guides.
This tool is used for removing the primary sheave.
• Clutch spider P/N:YS-28890-Cseparator90890-01711
• Yamaha bond No. 1215 P/N:90890-85505
Used to turn the engine mounting bolts when removing/installing engine.
1-7
• YXR clutch bushing jig kit P/N:YS-39752
This tool is used to hold the primary sheave and A.C. magneto rotor.
• Clutch separator adapter P/N:YS-3448090890-01740
• Ignition P/N:90890-06754checker
This tool is used to check the ignition system component.
• Engine mount spacer wrench P/N:YS-0148990890-01489
FOR POWER TRAIN SERVICE
This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces.)
GEN INFOSPECIAL TOOLS
• Dynamic spark tester P/N:YM-34487
• Sheave P/N:YS-01880-Aholder90890-01701
This tool is used for removal and installation of primary clutch weight and roller bushings. http://ReadManuals.com
This tool is used when disassembling and assembling the primary sheave.
• Quick P/N:ACC-QUICK-GS-KTgasket®
This tool is used when disassembling and assembling the primary sheave.
• Primary sheave puller (18 mm) P/N:YS-01881-A 1, YS-01881-1 2 90890-01898