Yamaha RST90TFK Manuals

Manuals and User Guides for Yamaha RST90TFK. We have 2 Yamaha RST90TFK manuals available for free PDF download: Service Manual

Yamaha RST90TFK Service Manual

Yamaha RST90TFK Service Manual (841 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 19.52 MB

Table of Contents

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Yamaha RST90TFK Service Manual

Yamaha RST90TFK Service Manual (409 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 21.67 MB

Table of Contents

Table of Contents
5
Chapter 1. General Information

9
Machine Identification

9
- Frame Serial Number
  9
- Engine Serial Number
  9
Important Information

10
- Preparation for Removal and Disassembly
  10
- All Replacement Parts
  10
- Gaskets, Oil Seals, and O-Rings
  11
- Lock Washers/Plates and Cotter Pins
  11
- Bearings and Oil Seals
  11
- Circlips
  11
- Loctite
  11
Special Tools

12
- For Tune up
  12
- For Engine Service
  12
- For Power Train Service
  15
- For Carburetion Service
  16
- For Electrical Service
  16
- Chapter 2
  
  18
- Periodic Inspection and Adjustment
  
  18
Introduction

18
Periodic Maintenance Chart

18
Engine

20
- Spark Plugs
  20
- Fuel Line Inspection
  20
- Cooling System
  21
- Valve Clearance Adjustment
  25
- Carburetor Synchronization
  30
- Engine Idle Speed Adjustment
  31
- Throttle Cable Free Play Adjustment
  32
- Throttle Override System (T.o.r.s.) Check
  33
- Compression Pressure Measurement
  34
- Engine Oil Level Inspection
  35
- Engine Oil Replacement
  37
- Crankcase Breather Hose Inspection
  40
- Carburetor Joints Inspection
  40
- Checking the Air Filter Element
  41
- Exhaust System Inspection
  41
Power Train

42
- Sheave Offset Adjustment
  42
- Drive V-Belt
  44
- Engagement Speed Check
  46
- Parking Brake Adjustment
  47
- Brake Fluid Level Inspection
  47
- Brake Pad Inspection
  48
- Brake Hose Inspection
  48
- Air Bleeding (Hydraulic Brake System)
  49
- Drive Chain
  50
- Track Tension Adjustment
  52
- Slide Runner Inspection
  54
- Maximizing Drive Track Life
  54
Chassis

56
- Ski/Ski Runner
  56
- Steering System
  57
- Lubrication
  59
Electrical

61
- Headlight Beam Adjustment
  61
- Battery Inspection
  61
- Fuse Inspection
  69
- Speedometer Unit Inspection
  71
Tuning

72
- Carburetor Tuning
  72
- Clutch
  79
- Gear Selection
  84
- High Altitude Tuning
  90
- Front Suspension
  91
- Rear Suspension
  93
- Chapter 3. Chassis
  
  100
Steering

100
- Rs90/Rs90R/Rsg90/Rst90/Rst90Tf
  100
- Rs90M
  102
- Removal
  106
- Inspection
  106
- Installation
  107
Ski

111
- RS90/RS90R/RSG90 "Usa/Canada
  111
  - RSG90 "Europe"/Rst90 "Europe"/Rst90Tf
    112
  - Rs90M
    113
  - RST90 "Usa/Canada
    114
  - Inspection
    115
  - INSTALLATION (RST90 "Usa/Canada")
    116
Front Suspension

117
- Handling Notes
  119
- Inspection
  119
- Installation
  120
- Chapter 4. Power Train
  
  123
Primary Sheave and Drive V-Belt

123
- Removal
  125
- Disassembly
  125
- Inspection
  126
- Assembly
  128
- Installation
  131
Secondary Sheave

132
- Disassembly
  134
- Inspection
  134
- Assembly
  135
- Installation
  137
Drive Chain Housing

138
- Without Reverse Model
  138
- Removal
  140
- Inspection
  140
- Installation
  142
- With Reverse Model
  143
- Removal
  146
- Inspection
  146
- Installation
  147
Secondary Shaft

149
- Removal
  150
- Inspection
  151
- Installation
  151
- Secondary Shaft and Drive Chain Housing Installation
  154
Brake

156
- Brake Pad Replacement
  157
- Brake Caliper Disassembly
  160
- Brake Caliper Inspection and Repair
  160
- Brake Caliper Assembly
  161
- Brake Caliper Installation
  161
- Inspection
  163
- Brake Master Cylinder Assembly
  163
- Installation
  163
Slide Rail Suspension

164
- Rs90/Rs90R
  164
- Rsg90
  170
- Rs90M
  175
- Rst90
  181
- Rst90Tf
  187
- Removal
  194
- Inspection
  194
- Assembly
  195
- Installation
  197
Front Axle and Track

200
- Inspection
  201
- Installation
  201
- Chapter 5. Engine
  
  203
Seat and Fuel Tank

203
- Rs90/Rs90R/Rsg90/Rs90M
  203
Backrest and Passenger Seat

204
- Rst90/Rst90Tf
  204
Rider Seat and Fuel Tank

205
- Rst90/Rst90Tf
  205
- Removal
  206
- Installation
  206
Oil Tank

207
Engine Assembly

208
- Hose and Leads
  208
- Engine Assembly
  209
- Removal
  211
- Installation
  211
Exhaust Pipe and Muffler

213
- Installation
  214
Camshafts

216
- Cylinder Head Cover
  216
- Camshafts
  217
- Removal
  218
- Inspection
  219
- Installation
  222
Cylinder Head

226
- Removal
  227
- Inspection
  227
- Installation
  228
Valves and Valve Springs

230
- Removal
  231
- Inspection
  232
- Installation
  236
A.C. Magneto Rotor and Starter Clutch

239
- Removal
  240
- Inspection
  241
- Installation
  242
Oil Pan and Oil Pump

244
- Removal
  247
- Inspection
  247
- Installation
  249
Crankcase

251
- Connecting Rods and Pistons
  253
- Crankshaft and Balancer Shaft
  254
- Removal
  256
- Inspection
  258
- Installation
  269
Heat Exchanger

276
- Chapter 6
  
  279
  - Inspection
    279
  - Installation
    280
Thermostat

281
- Inspection
  282
- Installation
  282
Water Pump

284
- Removal
  286
- Disassembly
  286
- Inspection
  287
- Assembly
  287
- Installation
  288
- Chapter 7. Carburetion
  
  289
Carburetors and Fuel Pump

289
- Inspection
  294
- Assembly
  296
- Installation
  297
- Fuel Level Adjustment
  298
- Throttle Position Sensor (T
  299
- Inspection and Adjustment
  299
- Inspection
  300
- Installation
  301
- Chapter 8. Electrical
  
  302
Switch Inspection

302
- Inspecting a Switch Shown in the Manual
  302
Ignition System

303
- Circuit Diagram
  304
- Troubleshooting
  305
- Ignition Spark Gap
  307
- Ignition Coil
  307
- Pickup Coil
  308
- Throttle Override System (T.o.r.s.)
  309
- Engine Stop Switch
  309
- Throttle Switch
  310
- Main Switch
  310
Electrical Starting System

311
- Circuit Diagram
  313
- Starter Motor
  314
Charging System

319
- Circuit Diagram
  320
- Troubleshooting
  320
- Battery
  321
- A.C. Magneto
  321
Lighting System

322
- Circuit Diagram
  323
- Troubleshooting
  324
- Bulb(S)
  326
- Headlight Beam Switch
  326
- Headlight Relay
  326
- Load Control Relay
  327
Signal System

328
- Circuit Diagram
  329
- Troubleshooting
  330
- Brake Light Switch
  336
- Gear Position Switch (Rs90R/Rsg90/Rst90/Rst90Tf)
  336
- DC Back Buzzer (Rs90R/Rsg90/Rst90/Rst90Tf)
  336
- Coolant Temperature Sensor
  337
- Oil Level Switch
  338
- Fuel Sender
  338
- Speed Sensor
  339
Grip Warmer System

340
- Circuit Diagram
  341
- Troubleshooting
  342
- Grip and Thumb Warmer Coil
  344
- Thumb Warmer Adjustment Switch
  344
- Grip Warmer Adjustment Switch
  345
- Passenger Grip Warmer (Rst90/Rst90Tf)
  345
- Passenger Grip Warmer Switch (Rst90/Rst90Tf)
  346
- Passenger Grip Warmer Relay (Rst90/Rst90Tf)
  346
Carburetor Heater System

347
- Circuit Diagram
  348
- Troubleshooting
  349
- Carburetor Heater Relay
  350
- Carburetor Heater
  350
Self-Diagnosis

351
- Self-Diagnosis Code
  352
- Chapter 9. Specifications
  
  354
General Specifications

354
Maintenance Specifications

357
- Engine
  357
- Power Train
  362
- Chassis
  368
- Electrical
  370
- High Altitude Settings
  372
Tightening Torque

373
- Engine
  373
- Power Train
  375
- Chassis
  378
General Torque Specifications

379
Definition of Units

379
Cable Routing

380

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