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Yamaha VK540EK Owner's Manual

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SNOWMOBILE
OWNER'S MANUAL
VK540EK
LIT-12628-02-34
8AC-28199-1B

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Summary of Contents for Yamaha VK540EK

  • Page 1 SNOWMOBILE OWNER’S MANUAL VK540EK LIT-12628-02-34 8AC-28199-1B...

  • Page 3: Machine Identification

    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.
  • Page 4 ESU00011 INTRODUCTION Congratulations on your purchase of a Yamaha snowmo- bile. This model is the result of Yamaha’s vast experience in the production of fine sporting and touring snowmo- biles. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 5 PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE SNOWMO- BILE. NOTE: Yamaha continually seeks advancements in product design and quality. Therefore, while this manual con- tains the most current product information available at the time of printing, there may be minor discrepan- cies between your snowmobile and this manual.

  • Page 6: Table Of Contents

    ESU00030 CONTENTS YAMAHA MOTOR CORPORATION, Throttle override system U.S.A. SNOWMOBILE LIMITED (T.O.R.S.) ........6-3 WARRANTY ........1-1 Brake ..........6-4 V-belt ..........6-4 Drive guard ........6-5 YAMAHA EXTENDED SERVICE Drive track ........6-5 (Y.E.S.) ..........1-4 Slide runners ........6-5 Skis and ski runners ......6-6 LOCATION OF THE IMPORTANT Steering system.......6-6...
  • Page 7 Throttle cable adjustment ....8-6 Oil pump cable adjustment ....8-6 Carburetor adjustment.....8-7 High altitude adjustments ....8-9 Checking the fan belt deflection ..8-10 V-belt replacement ......8-11 Checking the drive chain housing oil level and the drive chain tension ...........8-13 Checking the brake pads....8-14 Suspension........8-14 Drive track adjustment....8-18 Ski alignment .........8-20...

  • Page 8: Yamaha Motor Corporation, U.s.a. Snowmobile Limited Warranty

    ESU00040 Y AMAHA MOTOR CORPORATION, U.S.A. SNOWMO- BILE LIMITED WARRANTY CW-01E...
  • Page 9 CW-02E...
  • Page 10 CW-03E...

  • Page 11: Yamaha Extended Service (Y.e.s.)

    ESU04280 YAMAHA EXTENDED SERVICE (Y.E.S.) CW-06E...

  • Page 12: Location Of The Important Labels

    ESU00070 L OCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operat- ing this snowmobile. NOTE: Maintain or replace safety and instruction labels, as nec- essary. WARNING SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF THE FOLLOWING: DRIVE SELECT LEVER •...

  • Page 13: Safety Information

    1. Read the Owner’s Manual and all labels before oper- ating 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.
  • Page 14 7. 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.
  • Page 15 Maintenance and storage 1. 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.

  • Page 16: Description

    ESU00120 D ESCRIPTION 1 Windshield 2 Steering handlebar 3 Seat 4 Drive track 5 Slide rail suspension 6 Frame 7 Telescopic strut suspension 8 Skis 9 Headlight 0 Engine compartment plate A Shroud B Tail/brake light C Snow flap D Tow hitch E Storage compartment F Headlight adjusting knob G Engine stop switch...

  • Page 17: Control Functions

    ESU00130 C ONTROL FUNCTIONS ESU00180 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. The engine can be started. NOTE: The headlight, meter lights, and taillight will come on after the engine starts.

  • Page 18: Throttle Lever

    ESU00220 Throttle lever Once the engine is running cleanly, squeezing a the throt- tle 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 deceler- ate, and the engine will return to idle when it is released b.

  • Page 19: Engine Stop Switch

    ESU00310 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.

  • Page 20: Parking Brake Button

    ESU00341 Parking brake button When parking the snowmobile or starting the engine, apply the parking brake. Squeeze the brake lever 1, push and hold the parking brake button 2 down 3, and then release the brake lever. To release the parking brake, squeeze the brake lever. WARNING Always set the parking brake before attempting to start the engine.

  • Page 21: Headlight Beam Switch

    ESU00390 Headlight beam switch Push the headlight beam switch to change the headlight beam to high or low. 1 Headlight beam switch 2 Push 3 High beam 4 Low beam ESU00401 Headlight adjusting knob Use the headlight adjusting knob to adjust the headlight vertically.

  • Page 22: Shroud Latches

    ESU00481 Shroud latches To open the shroud, unhook the shroud latches, and then slowly raise the shroud forward until it stops. When clos- ing 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...

  • Page 23: Engine Compartment Plates

    ESU00641 Engine compartment plates This snowmobile is equipped with an engine compart- ment plate 1 in the shroud that can be opened and engine compartment plates 2 in the belly pan that can be removed to cool down the engine. CAUTION : Make sure that the engine compartment plate in the shroud is closed and the engine compartment...

  • Page 24: Tow Hitch

    ESU00712 Tow hitch Use the tow hitch within the specified weight limits. 1 Tow hitch Tow weight limit: 120 kg (265 lb) Vertical weight limit: 15 kg (33.1 lb) CAUTION : Avoid towing for long periods under 10 km/h (6.2 mph) to prevent early wear of the V-belt.

  • Page 25: Pre-Operation Checks

    ESU00720 P RE-OPERATION CHECKS 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.

  • Page 26: Engine Oil

    5% of ethanol can be used, although richer jetting may be required to prevent engine dam- age. Consult a Yamaha dealer. Gasohol contain- ing methanol is not recommended. Make sure that snow or ice do not enter the fuel tank when refueling.

  • Page 27: Throttle Override System (T.o.r.s.)

    3 gradually. The T.O.R.S. will operate and the engine should stop immediately. WARNING If the engine does not stop, stop the engine by turn- ing the main switch to the “OFF” position and con- sult a Yamaha dealer.

  • Page 28: Brake

    Do not operate the snowmobile if you find any prob- lems 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 sys- tem. CAUTION : Make sure that the brake lever end does not project out over the handlebar end.

  • Page 29: Drive Guard

    ESU03990 Drive guard Check the drive guard mounts for damage. Make sure that the wing bolt is tightened securely and the drive guard is firmly in place. ESU00970 Drive track Check the drive track for deflection, wear, or damage. Adjust or replace if necessary. (See pages 8-18–8-20 for more details.) WARNING Do not operate the snowmobile if you find damage to...

  • Page 30: Skis And Ski Runners

    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. ESU01041 Lights Check the lights.

  • Page 31: Tool Kit And Recommended Equipment

    ESU01111 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 neces- sary. The following should be carried at all times: Tool kit Flashlight Roll of plastic tape...

  • Page 32: Operation

    ESU01120 O PERATION ESU01140 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 posi- tion.

  • Page 33: Emergency Engine Starting

    Also avoid lugging the engine, such as laborious opera- tion in wet snow. If any abnormal condition is noticed, such as excessive vibration or noise, consult a Yamaha dealer. NOTE: To ensure proper engine break-in, use a 50:1 gasoline/oil mixture when filling the fuel tank of a new snowmobile for the first time.

  • Page 34: Riding Your Snowmobile

    totally familiar with the snowmobile’s han- ESU02733 Riding your snowmobile dling and performance characteristics. The beginning operator should select a Getting to know your snowmobile large flat area to become familiar with the A snowmobile is a rider active vehicle, and snowmobile.

  • Page 35: Turning

    Improper use of the brake can cause Riding uphill the drive track to lose traction, reduce control, and increase the possibility of an accident. Turning You should practice first on gentle slopes. Try more difficult climbs only after you have developed your skill.

  • Page 36: Riding Downhill

    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.

  • Page 37: Hard-Packed Snow

    Hard-packed snow WARNING It can be more difficult to negotiate on Drive track damage or failure could hard-packed snow as both the skis and result in loss of braking ability and drive track do not have as much traction as snowmobile control, which could cause when the snowmobile is operated on fresh an accident.

  • Page 38: Maximizing Drive Track Life

    Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible dam- age, consult your stud manufacturer for installation and stud pattern recommendations. Yamaha does not recommend track studding.

  • Page 39: Driving

    ESU03381 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. 1. Select the desired operating position by moving the drive select lever.

  • Page 40: Stopping The Engine

    6. Apply the parking brake — squeeze the brake lever, push and hold the parking brake button down, and then release the brake lever. ESU01360 Stopping the engine Turn the main switch to the “OFF” position to stop the engine. 1 “OFF”...

  • Page 41: Transporting

    ESU01380 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 carbure- tors into the crankcase.

  • Page 42: Periodic Maintenance

    ∗ Repair if necessary. system (T.O.R.S.) Check operation. Throttle lever 5-2, 6-2 ∗ Repair if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer. ∗∗ Apply “initial 1 month or 400 km (250 mi, 20 hr)”.
  • Page 43 6-6, 8-24 essary. Battery ∗ Check specific gravity and breather hose operation. Charge/correct if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer. ∗∗ Apply “initial 1 month or 400 km (250 mi, 20 hr)”.
  • Page 44 Fittings and fasteners ∗ Repair if necessary. Tool kit and recom- Check for proper placement. mended equipment ∗ It is recommended that these items be serviced by a Yamaha dealer. ∗∗ Apply “initial 1 month or 400 km (250 mi, 20 hr)”.

  • Page 45: Tool Kit

    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. ESU01441 Spark plug inspection The spark plug is an important engine component and is easy to inspect.

  • Page 46: Engine Idle Speed Adjustment

    Spark plug tightening torque: 20 Nm (2.0 m·kgf, 14 ft·lb) ESU01461 Engine idle speed adjustment CAUTION : Be sure to have a Yamaha dealer make this adjustment. Make sure that the throttle lever moves smoothly. 1. Start the engine. NOTE: Refer to the “Starting the engine”...

  • Page 47: Throttle Cable Adjustment

    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: 1.0–2.0 mm (0.04–0.08 in) 1 Locknut 2 Adjuster...

  • Page 48: Carburetor Adjustment

    ESU01523 Carburetor adjustment CAUTION : Be sure to have a Yamaha dealer make this adjustment. Make sure that the carburetor silencer is installed before 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.,...
  • Page 49 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.

  • Page 50: High Altitude Adjustments

    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.

  • Page 51: Checking The Fan Belt Deflection

    (5 kg, 11 lb) of force at the center of belt. 1 Deflection 2 50 N (5 kg, 11 lb) Standard belt deflection: 8 mm (0.31 in) / 50 N (5 kg, 11 lb) If the deflection exceeds the specification, consult a Yamaha dealer. 8-10...

  • Page 52: V-Belt Replacement

    Have a Yamaha dealer replace the V-belt and adjust the gap between the secondary fixed sheave and the secondary sliding sheave. Serious injury can occur from the sudden release of spring tension during sheave disassembly.
  • Page 53 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. 3. Pull 3 the V-belt up over the secondary fixed sheave. 4.

  • Page 54: Checking The Drive Chain Housing Oil Level And The Drive Chain Tension

    ESU01674 Checking the drive chain housing oil level and the drive chain tension Oil level check 1. Check the oil level by removing the oil level check bolt 1 and filler cap 2. The oil level is correct if a small amount of oil flows out of the oil level check hole.

  • Page 55: Checking The Brake Pads

    Checking the brake pads Check the brake pads for wear by measuring the thick- ness of each pad. If the brake pads reach the wear limit, have a Yamaha dealer replace them. Wear limit a: 9.5 mm (0.37 in) Adjustment This snowmobile has a self-adjusting brake caliper.
  • Page 56 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. 8-15...
  • Page 57 Extension spring preload adjustment Adjust the extension spring preload by turning the adjuster 1. CD-22E Adjuster Turn in Turn out Preload Hard Soft Snow condition Soft a Standard length 16 mm (0.63 in) CAUTION : Be sure the left and right extension spring preloads are the same.
  • Page 58 Rear suspension full rate adjustment The total suspension spring rate and damping character- istics can be adjusted by changing the installed position of the shock absorber. WARNING Be sure to have a Yamaha dealer make this adjust- ment. CD-07E Installation position Spring rate and...

  • Page 59: Drive Track Adjustment

    ESU03530 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 snow- mobile 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 snowmo-...
  • Page 60 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 snowmo- bile. 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.

  • Page 61: Ski Alignment

    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 (0–0.6 in) 3. If the alignment is not correct, consult a Yamaha dealer. 8-20...

  • Page 62: Handlebar Adjustment

    ESU02011 Handlebar adjustment 1. Remove the handlebar cover 1. 2. Loosen the handlebar bolts. Move the handlebar up or down to adjust the handlebar height to the desired position. 3. Tighten the handlebar bolts and install the handlebar cover. Handlebar bolt tightening torque: 15 Nm (1.5 m·kgf, 11 ft·lb) CAUTION : Make sure that the small gap a side of the handlebar...

  • Page 63: Lubrication

    ESU02042 Lubrication Lubricate the following points. Lubricant:Low-temperature grease 1 Brake/throttle cable ends WARNING Apply a dab of grease onto the cable ends only. Do not grease the brake and throttle cables themselves because they could become frozen, which could cause loss of control. 2 Front suspension 3 Rear suspension 8-22...

  • Page 64: Headlight Bulb Replacement

    ESU02112 Headlight bulb replacement 1. Lift up the shroud. 2. Disconnect the lead coupler. 3. Remove the socket cover and bulb set spring. 1 Socket cover 4. Remove the bulb. WARNING Keep flammable products or your hands away from the hot bulb until it cools down. 5.

  • Page 65: Battery

    ESU02130 Battery Replenishing the battery fluid 1. Check the fluid level. The level should be between the upper and lower level marks. a “UPPER LEVEL” b “LOWER LEVEL” 2. Add only distilled water if necessary. CAUTION : Normal tap water contains minerals which are harm- ful to a battery;...

  • Page 66: Fuse Replacement

    Make sure that the main switch is turned off to pre- vent accidental short circuiting. 1. Lift up the shroud. 2. Replace the blown fuse with one of proper amperage. NOTE: If the fuse immediately blows again, ask a Yamaha dealer to inspect the snowmobile. Fuse type: 10 A 8-25...

  • Page 67: Troubleshooting

    Worn or damaged piston and cylinder No fuel in tank ... Supply fuel..Ask a Yamaha dealer to inspect. Clogged fuel line ... Clean fuel line. Clogged carburetor ... Clean carbure- B. Engine does not turn over with the tor.
  • Page 68 E. Engine constantly backfires or mis- 3. Worn sticking primary sheave fires assembly ... Ask a Yamaha dealer to 1. Faulty spark plugs ... Replace the inspect. spark plugs. 4. Worn or sticking secondary sheave 2. Clogged fuel system ... See A.1. above.

  • Page 69: Storage

    Store it in a cool, dry place that is above hol) is used, completely drain the fuel 0 °C (32 °F), but less than 30 °C (90 °F). system. Ask a Yamaha dealer if further Check the condition of the battery with a information is needed.
  • Page 70 For peak performance, it is recommended securely attached to the battery. that you have your snowmobile checked and tuned by a Yamaha dealer. They have CAUTION : the experience and training to help you get the maximum performance and use of your Do not charge the battery quickly.

  • Page 71: Specifications

    ESU02280 S PECIFICATIONS 1 1 - ESU02290 Dimensions CS-01E VK540E Overall length 3,125 mm (123.0 in) Overall width 1,140 mm ( 44.9 in) Overall height 1,350 mm ( 53.1 in) Dry weight 289 kg ( 637 lb) Ski tread 960 mm ( 37.8 in) ESU02300 Engine CS-02E...

  • Page 72: Chassis

    ESU02310 Chassis CS-03E VK540E Drive track and suspension: Track Molded rubber, fiber glass rod reinforced Width 500 mm (19.7 in) Track deflection 35–45 mm (1.38–1.77 in)/ 100 N (10 kg, 22 lb) Length on ground 1,204 mm (47.4 in) Suspension type Slide Rail Suspension Drive sprocket Triple polyethylene, 9 teeth...

  • Page 73: Electric

    ESU02320 Electric CS-04E VK540E Ignition system Spark plug Type BR9ES (NGK) 0.7–0.8 mm (0.028–0.031 in) Battery Capacity YB16AL-A2/12 V 16 A·h Maximum charge rate 1.6 Amperes/hr for 10 hrs Bulb × Quantity 12 V, 60/55 W × 1 Headlight Bulb × Quantity 12 V, 8/23 W ×...
  • Page 74 (10A) 12-1...
  • Page 75 12-2...
  • Page 76 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2004.04 - 0.3×1 CR...

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