Yamaha RST90GTZ Offroad Vehicle Manuals

Manuals and User Guides for Yamaha RST90GTZ Offroad Vehicle. We have 1 Yamaha RST90GTZ Offroad Vehicle manual available for free PDF download: Service Manual

Yamaha RST90GTZ Service Manual (504 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 26.84 MB

Chassis

6
Power Train

6
- Table of Contents
  7
Engine

6
Cooling System

6
Fuel Injection System

6
Electrical

11
Specifications

12
Chapter 1

13
- General Information
  13
Snowmobile Identification

13
- Frame Serial Number
  13
- Engine Serial Number
  13
Gen Info

13
Important Information

14
- Preparation for Removal and Disassembly
  14
- Replacement Parts
  14
- Gaskets, Oil Seals, and O-Rings
  15
- Lock Washers/Plates and Cotter Pins
  15
- Bearings and Oil Seals
  15
- Circlips
  15
- Loctite
  15
- Checking the Connections
  16
- Handling the Electronic Parts
  17
Special Tools

18
- For Tune up
  18
- For Engine Service
  18
- For Power Train Service
  21
- For Fuel Injection Service
  22
- For Electrical Service
  22
Chapter 2

24
- Periodic Inspection and Adjustment
  24
Insp Adj

24
Introduction

24
Periodic Maintenance Chart for the Emission Control System

24
General Maintenance and Lubrication Chart

24
- Brake System
  25
Engine

26
Power Train

54
- Sheave Offset Adjustment
  54
- Drive V-Belt
  56
- Engagement Speed Check
  58
- Parking Brake Pad Inspection
  58
- Parking Brake Adjustment
  59
- Brake Fluid Level Inspection
  60
- Brake Pad Inspection
  61
- Brake Hose Inspection
  61
- Air Bleeding (Hydraulic Brake System)
  62
- Drive Chain
  63
- Track Tension Adjustment
  66
- Slide Runner Inspection
  68
- Extrovert Sprocket Wheels (Rs90Gtz/Rs90Ltgtz)
  68
- Maximizing Drive Track Life
  69
Chassis

70
- Ski/Ski Runner
  70
- Steering System
  70
- Brake Lever Adjustment
  72
- Lubrication
  72
Electrical

75
- Headlight Bulb Replacement
  75
- Headlight Beam Adjustment
  76
- Battery Inspection
  78
- Fuse Inspection
  84
Tuning

86
- Clutch
  86
- Gear Selection
  97
- High Altitude Tuning
  98
- Front Suspension
  101
- Rear Suspension
  105
- Troubleshooting (Ski, Suspension)
  112
Chas

115
Chapter 3. Chassis

115
Cowlings

115
- Shroud and Covers
  115
- Windshield and Headlight (Rs90Gtz/Rs90Ltgtz)
  116
- Windshield and Headlight (Rst90Gtz)
  117
- Air Filter Case
  118
Seat

119
- Seat (Rs90Gtz/Rs90Ltgtz)
  119
- Backrest and Seat
  120
Backrest and Seat (Rst90Gtz)

120
- Storage Compartment (Rst90Gtz)
  121
Steering

122
- Steering (Rs90Gtz/ Rs90Ltgtz)
  122
- Steering (Rst90Gtz)
  123
- Removal
  128
- Inspection
  128
- Installation
  129
Ski

134
- Inspection
  135
Front Suspension

136
- Handling the Front Shock Absorber and Gas Cylinder
  138
- Disposing of a Front Shock Absorber and Gas Cylinder
  138
- Inspection
  138
- Installation
  139
Powr Tr

142
Chapter 4. Power Train

142
Primary Sheave and Drive V-Belt

142
- Removal
  145
- Disassembly
  145
- Inspection
  146
- Assembly
  149
- Installation
  152
Secondary Sheave

154
- Disassembly
  156
- Inspection
  156
- Assembly
  157
- Installation
  159
- Drive Chain Housing
  161
Drive Chain Housing (Rs90Gtz/Rs90Ltgtz)

161
- Drive Chain Housing (Rst90Gtz)
  164
- Removal
  167
- Inspection
  167
- Installation (Rs90Gtz/Rs90Ltgtz)
  170
- Installation (Rst90Gtz)
  171
Secondary Shaft

173
- Removal
  174
- Inspection
  174
- Installation
  175
- Secondary Shaft and Drive Chain Housing Installation
  176
Brake

178
- Brake (Rs90Gtz/Rs90Ltgtz)
  178
- Brake (Rst90Gtz)
  179
- Brake Pad Replacement
  180
- Brake Caliper and Parking Brake (Rs90Gtz/Rs90Ltgtz)
  183
- Brake Caliper and Parking Brake (Rst90Gtz)
  185
- Brake Caliper Disassembly
  187
- Brake Caliper Inspection and Repair
  188
- Brake Caliper Assembly
  189
- Brake Caliper Installation
  190
- Brake Master Cylinder (Rs90Gtz/Rs90Ltgtz)
  191
- Brake Master Cylinder (Rst90Gtz)
  193
- Inspection
  195
- Brake Master Cylinder Assembly
  195
- Installation
  196
- Slide Rail Suspension
  197
Slide Rail Suspension (Rs90Gtz)

197
- Slide Rail Suspension (Rs90Ltgtz)
  203
- Slide Rail Suspension (Rst90Gtz)
  209
- Removal
  216
- Handling the Rear Shock Absorber and Gas Cylinder
  216
- Disposing of a Rear Shock Absorber and Gas Cylinder
  217
- Inspection
  218
- Assembly
  219
- Installation
  220
- Troubleshooting
  220
Front Axle and Track

223
- Inspection
  224
- Installation
  224
Eng

226
Chapter 5. Engine

226
Fuel Tank

226
- Removal
  227
- Inspection
  227
- Installation
  228
Exhaust Pipe and Muffler

230
- Installation
  232
Oil Tank

234
Engine Assembly

235
- Leads and Hoses
  235
- Engine Assembly
  236
- Removal
  240
- Installation
  240
Camshafts

242
- Cylinder Head Cover
  242
- Camshafts
  243
- Removal
  244
- Inspection
  245
- Installation
  249
Cylinder Head

253
- Removal
  254
- Inspection
  254
- Installation
  255
Valves and Valve Springs

257
- Removal
  258
- Inspection
  259
- Installation
  265
Ac Magneto Rotor and Starter Clutch

268
- Removal
  269
- Inspection
  270
- Installation
  271
Oil Pan and Oil Pump

273
- Removal
  276
- Inspection
  276
- Installation
  278
Crankcase

281
- Removal
  283
- Inspection
  284
- Installation
  285
Connecting Rods and Pistons

290
- Removal
  291
- Inspection
  292
- Installation
  298
Crankshaft and Balancer Shaft

302
- Remove
  304
- Inspection
  305
- Installation
  309
Chapter 6. Cooling System

312
Heat Exchanger

312
- Heat Exchanger (Rs90Gtz/Rs90Ltgtz)
  312
- Heat Exchanger (Rst90Gtz)
  315
- Inspection
  317
- Installation
  318
Cool

312
Thermostat

319
- Iinspection
  320
- Installation
  320
Water Pump

322
- Removal
  324
- Disassembly
  324
- Inspection
  325
- Assembly
  325
- Installation
  327
Chapter 7. Fuel Injection System

328
Fuel Injection System

328
- Circuit Diagram (Rs90Gtz/Rs90Ltgtz)
  330
- Circuit Diagram (Rst90Gtz)
  332
- Ecu Self-Diagnostic Function
  334
- Self-Diagnostic Function Table
  334
- Troubleshooting Chart
  336
- Diagnostic Mode
  337
- Troubleshooting Details
  345
- Oil Pressure Switch
  358
- Intake Air Temperature Sensor
  358
- Isc (Idle Speed Control) Unit
  359
Throttle Body

360
- Injectors
  362
- Removal
  363
- Inspection
  363
- Fuel Pressure Inspection
  364
- Inspection and Adjustment
  365
Chapter 8

367
Elec

367
Switch Inspection

367
- Inspecting a Switch Shown in the Manual
  367
Ignition System

368
- Circuit Diagram (Rs90Gtz/Rs90Ltgtz)
  368
- Circuit Diagram (Rst90Gtz)
  370
- Troubleshooting
  372
- Ignition Spark Gap
  374
- Ignition Coil
  374
- Crankshaft Position Sensor
  375
- Throttle Override System (T.o.r.s.)
  376
- Engine Stop Switch
  377
- Throttle Switch
  378
- Main Switch
  378
Electrical Starting System

379
- Circuit Diagram (Rs90Gtz/Rs90Ltgtz)
  379
- Circuit Diagram (Rst90Gtz)
  380
- Troubleshooting
  381
- Starter Motor
  383
Charging System

388
- Circuit Diagram (Rs90Gtz/Rs90Ltgtz)
  388
- Circuit Diagram (Rst90Gtz)
  389
- Troubleshooting
  390
- Battery
  392
- Stator Coil
  392
Lighting System

394
- Circuit Diagram (Rs90Gtz/Rs90Ltgtz)
  394
- Circuit Diagram (Rst90Gtz)
  396
- Troubleshooting
  398
- Bulb(S)
  401
- Headlight Beam Switch
  401
- Headlight Relay
  402
- Load Control Relay
  403
Signal System

404
- Circuit Diagram (Rs90Gtz/Rs90Ltgtz)
  404
- Circuit Diagram (Rst90Gtz)
  406
- Troubleshooting
  408
- Brake Light Switch
  414
- Gear Position Switch
  414
- DC Back Buzzer
  415
- Coolant Temperature Sensor
  415
- Oil Level Switch
  416
- Fuel Sender
  417
- Speed Sensor
  418
Grip Warmer System

420
- Circuit Diagram (Rs90Gtz/Rs90Ltgtz)
  420
- Circuit Diagram (Rst90Gtz)
  422
- Troubleshooting
  424
- Grip/Thumb Warmer Adjustment Switch
  425
- Grip Warmer and Thumb Warmer
  427
- Grip/Thumb Warmer Adjustment Switch
  427
- Passenger Grip Warmer (Rst90Gtz)
  428
- Passenger Grip Warmer Switch (Rst90Gtz)
  428
- Passenger Grip Warmer Relay (Rst90Gtz)
  429
Cooling System

430
Chapter 9

434
Spec

434
General Specifications

434
Maintenance Specifications

437
- Engine
  437
- Power Train
  442
- Chassis
  446
- Electrical
  447
General Torque Specifications

449
Definition of Units

449
Tightening Torque

450
- Engine
  450
- Power Train
  453
- Chassis
  456
Cable Routing

459

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Yamaha RST90GTZ Offroad Vehicle Manuals

Yamaha RST90GTZ Service Manual (504 pages)

Table of Contents

Chassis

Power Train

Engine

Cooling System

Fuel Injection System

Electrical

Specifications

Chapter 1

Snowmobile Identification

Gen Info

Important Information

Special Tools

Chapter 2

Insp Adj

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Engine

Power Train

Chassis

Electrical

Tuning

Chas

Chapter 3. Chassis

Cowlings

Seat

Backrest and Seat (Rst90Gtz)

Steering

Ski

Front Suspension

Powr Tr

Chapter 4. Power Train

Primary Sheave and Drive V-Belt

Secondary Sheave

Drive Chain Housing (Rs90Gtz/Rs90Ltgtz)

Secondary Shaft

Brake

Slide Rail Suspension (Rs90Gtz)

Front Axle and Track

Eng

Chapter 5. Engine

Fuel Tank

Exhaust Pipe and Muffler

Oil Tank

Engine Assembly

Camshafts

Cylinder Head

Valves and Valve Springs

Ac Magneto Rotor and Starter Clutch

Oil Pan and Oil Pump

Crankcase

Connecting Rods and Pistons

Crankshaft and Balancer Shaft

Chapter 6. Cooling System

Heat Exchanger

Cool

Thermostat

Water Pump

Chapter 7. Fuel Injection System

Fuel Injection System

Throttle Body

Chapter 8

Elec

Switch Inspection

Ignition System

Electrical Starting System

Charging System

Lighting System

Signal System

Grip Warmer System

Cooling System

Chapter 9

Spec

General Specifications

Maintenance Specifications

General Torque Specifications

Definition of Units