Page 1 SUPPLEMENTARY SERVICE MANUAL LIT-12618-02-39...
Page 2 A CAUTION indicates special precautions that must be taken to avoid damage to the snowmo- bile. NOTICE This manual was written by the Yamaha Motor NOTE: Company primarily for use by Yamaha dealers A NOTE provides key information that can and their qualified mechanics.
Page 3 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. POWR 1 General information CHAS 2 Periodic inspections and adjustments 3 Chassis 4 Power train 5 Engine COOL 6 Cooling system...
Page 4 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTIONS AND INSP ADJUSTMENTS CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 5: Table Of Contents
........MAINTENANCE SPECIFICATIONS ..RX10K, RX10RK, RX10RSK ..ENGINE .
Page 6: Periodic Inspections
BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION/ INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) PERIODIC INSPECTIONS AND ADJUSTMENTS POWER TRAIN BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Inspect: S Brake pad wear a Wear indicator 1 nearly contacts the brake disc ! Replace as a set. Wear limit: 7.5 mm (0.30 in) BRAKE HOSE INSPECTION...
Page 7 INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) a. Slowly apply the brake lever several times. b. Pull the lever in, then hold the lever in posi- tion. c. Loosen the bleed screws and allow the brake lever to travel towards its limit. d.
Page 8: Track Tension Adjustment
Turn in Right adjuster Turn in Turn out 8 Slide runner 9 Track Track metal Forward A RX10K, RX10RK, RX10RSK B RX10MK, RX10MSK c. Adjust the track deflection until the specified amount is obtained. More than Less than Track deflection specified...
Page 9: Lubrication
INSP LUBRICATION LUBRICATION Brake lever, throttle lever and throttle cable 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables. Recommended lubricant: ESSO Beacon 325 Grease WARNING Apply a dab of grease onto only the end of the cables.
Page 10: Clutch
CLUTCH CLUTCH G Green P Pink High altitude S Silver Y Yellow Specifications Model: RX10K, RX10RK, RX10RSK X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft)
Page 11 INSP CLUTCH S Silver O Orange W White P Pink Specifications Model: RX10MK, RX10MSK X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft) (X 2,500 ft)
Page 12: Gear Selection
39 teeth 8FB-47587-90 40 teeth 8DW-47587-01 RX10MK, RX10MSK 68 links 94890-09068 Chain RX10K, RX10RK, RX10RSK, RXW10K, 70 links 94890-09070 RXW10SK, RX10MK, RX10MSK 2 Gear ratio Drive gear 19 teeth 20 teeth 21 teeth 22 teeth 23 teeth 24 teeth Driven gear 1.76...
Page 13 INSP GEAR SELECTION 5 Torque cam (secondary spring seat) Identification mark Effects Part no. Cam angle Identification mark Standard RX10K, RX10RK, Quicker upshifting RX10RSK, during acceleration 8FA-17604-00 51-43_ 8BVFA RXW10K, RXW10SK 8BV-17604-71 8BV71 RX10MK, 8BV-17604-51 8BV51 RX10MSK 8BV-17604-31 8BV31 Quicker...
Page 14 5.8 (0.228) 59.5 (2.34) 4.92 85.4 (3.36) 90501-581L6 27 (2.75) 294 (30) Green-Pink-Green 5.8 (0.228) 59.5 (2.34) 4.66 84.3 (3.32) RX10K, RX10RK, 90501-582L1 24.5 (2.50) 343 (35) Yellow-Silver-Yellow 5.8 (0.228) 59.5 (2.34) 4.92 87.4 (3.44) RX10RSK, RXW10K, RXW10SK 90501-582L2 27 (2.75)
Page 15 Weight g (oz) Parts no. without bush Shape & ID mark Standard and rivets 45.41 8BU-17605-20 RX10MK, RX10MSK (1.60) 34.26 8DG-17605-00 (1.209) 37.77 8DJ-17605-00 (1.333) 39.76 8DN-17605-10 (1.40) 39.00 8EK-17605-00 (1.376) 54.6 8ES-17605-00 (1.93) RX10K, RX10RK, 63.8 8FA-17605-10 RX10RSK, RXW10K, (2.25) RXW10SK...
Page 16 Parts No. Material Standard Effects mm (in) g (oz) Increased 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) IN: RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK Force 3.6 (0.127) 90269-06006 Steel 17.2 (0.677) OUT: RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK with hole 90261-06019 Steel 13.3 (0.524) 3.1 (0.109)
Page 17: Front Suspension
FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: S Spring preload Adjustment steps: S Loosen the lock nut 1 S Turn the spring seat 2 in or out. RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK Spring seat Standard Shorter z ! Longer...
Page 18: Rear Suspension
Shorter (Maximum) (Minimum) Effects Less weight More weight on skis; on skis; More weight Less weight transfer transfer S Tighten the stopper band nut. Stopper band nut: 4 Nm (0.4 mSkg, 2.9 ftSlb) A RX10K, RX10RK, RX10RSK B RX10MK, RX10MSK...
Page 19 INSP REAR SUSPENSION Spring preload (RX10K, RX10RK, RX10RSK) 1. Adjust: S Spring preload Adjustment step: WARNING This shock absorber contains highly pres- surized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assem- bly to flames or high heat, which could cause it to explode.
Page 20 Preload Soft Medium Hard Rear Standard Control rod (RX10K, RX10RK, RX10RSK) 1. Adjust: S Control rod stroke a Adjustment steps: S Loosen the locknut 1 . S Check the adjusting rod length using the scale on the special wrench 2 included in the own- er’s tool kit.
Page 21 INSP REAR SUSPENSION Control rod (RX10MK, RX10MSK) 1. Adjust: S Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: S Loosen the lock nut 1 . S Turn the adjusting nut 2 in or out to adjust the control rod stroke.
Page 22: Chapter 3. Chassis
CHAS STEERING CHASSIS STEERING RX10MK, RX10MSK 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11ftSlb) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Thumb warmer lead coupler Disconnect.
Page 23 CHAS STEERING 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11ftSlb) Order Job name/Part name Q’ty Remarks Master cylinder assembly NOTE: Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” in CHAPTER 9, to check the Handlebar cable, lead and hose routings.
Page 24: Ski
CHAS RX10K, RX10RK, RX10RSK 19 Nm (1.9 mSkg, 14 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty...
Page 25: Rx10Mk, Rx10Msk
CHAS RX10MK, RX10MSK 19 Nm (1.9 mSkg, 14 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below.
Page 26: Chapter 4. Power Train
POWR DRIVE CHAIN HOUSING POWER TRAIN DRIVE CHAIN HOUSING RX10K, RX10MK, RX10MSK 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb)
Page 27: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the fol- lowing. A Make sure that the bearing seals face towards the drive chain as shown. B Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps.
Page 28: With Reverse Model Rx10Rk, Rx10Rsk
POWR DRIVE CHAIN HOUSING WITH REVERSE MODEL RX10RK, RX10RSK 16 Nm (1.6 mSkg, 12 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 29 POWR DRIVE CHAIN HOUSING 16 Nm (1.6 mSkg, 12 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 30: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the fol- lowing. A Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. B Make sure that the bearing seals face towards the drive chain as shown.
Page 31 POWR DRIVE CHAIN HOUSING 4. Install: S Shift rod 1 5. Adjust: S Shift rod length a Adjustment steps: S Move the shift lever to the “FWD.” position. S Loosen the locknuts 2 . S Turn the shift rod 1 so that shift rod free play is 0 mm (in direction where a can be short- ened appropriately) and then turn back the shift rod 1/4 turns.
Page 32: Brake
POWR BRAKE BRAKE 6 Nm (0.6 mSkg, 4.3 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring Brake pad Brake caliper assembly For installation, reverse the removal procedure.
Page 33: Brake Pad Replacement
POWR BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: S Do not disassemble components unless absolutely necessary. S Do not use solvents on internal brake com- ponents. S Do not use contaminated brake fluid for cleaning. Use only clean brake fluid. S Do not allow brake fluid to contact the eyes, otherwise eye injury may occur.
Page 34 POWR BRAKE 2. Install: S Brake pads S Pad spring Installation steps: S Connect a suitable hose 1 tightly to the cali- per bleed screw 2 . Put the other end of this hose into an open container. S Loosen the caliper bleed screw and push the pistons into the caliper with your finger.
Page 35 POWR BRAKE 30 Nm (3.0 mSkg, 22 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) Order Job name/Part name Q’ty Remarks Brake caliper and parking brake Remove the parts in the order listed below. removal Brake fluid Drain.
Page 36: Brake Caliper Disassembly
POWR BRAKE BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: S Pistons S Piston oil seals 1 Removal steps: S Using a piece of wood 2 , lock the right pis- ton.
Page 37: Brake Caliper Assembly
POWR BRAKE 1. Inspect: S Caliper piston 1 Scratches/rust/wear ! Replace the caliper assembly. S Caliper cylinder 2 Wear/scratches ! Replace the caliper as- sembly. S Caliper body 3 Cracks/damage ! Replace. S Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and dust seals whenever a caliper is disassembled.
Page 38: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION RX10K, RX10RK, RX10RSK 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen.
Page 39 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below. Shock absorber adjuster assembly Stopper band Shaft Rubber collar Shock absorber Spacer Collar Oil seal Bearing Control rod assembly Spacer Collar Oil seal...
Page 40 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Front pivot arm Bushing Collar Sliding runner Suspension wheel Suspension wheel bracket Shaft Collar Front pivot arm bracket Bushing Collar Shaft Rear pivot arm Circlip Guide wheel Bushing Shaft Rear pivot arm bracket...
Page 41 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Guide wheel Collar Tension adjuster Rear axle shaft For assembly, reverse the disassembly procedure.
Page 42: Rx10Mk, Rx10Msk
POWR SLIDE RAIL SUSPENSION RX10MK, RX10MSK 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Slide rail suspension Collar For installation, reverse the removal procedure.
Page 43 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below. Stopper band Shaft Rubber collar Front shock absorber Collar Bushing Front pivot arm Shaft Bushing Collar Suspension wheel assembly Shaft Suspension bracket Bushing...
Page 44 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Suspension wheel Hook assembly Rear shock absorber Collar Reay rod Collar Bushing Shaft Collar Bushing Braket Collar Guide wheel Spacer Rear spring Shaft Bushing Rear pivot arm protector Rear pivot arm...
Page 45 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Circlip Hook Control rod assembly Shaft Pivot shaft Suspension wheel Suspension bracket Guide wheel Rear axle shaft Collar Tension adjuster For assembly, reverse the disassenbly procedure.
Page 46: Inspection
S Bushings Wear/cracks/damage ! Replace. S Front pivot arm 4 S Rear pivot arm 5 S Suspension wheel bracket 6 S Sliding frame 7 Cracks/damage ! Replace. S Slide runner 8 Wear/damage ! Replace. A RX10K, RX10RK, RX10RSK B RX10MK, RX10MSK...
Page 47 POWR SLIDE RAIL SUSPENSION Control rod parts number A RX10K, RX10RK, RX10RSK B RX10MK, RX10MSK Control rod 1 Length mm (in) Length mm (in) Length mm (in) RX10K, RX10RK, 292.3 (11.51) 150.5 (5.93) – RX10RSK 2.5P 2 = 5 RX10MK, RX10MSK 228.8 (9.01)
Page 48: Front Axle And Track
S Position each sprocket wheel on the axle as shown in the illustration. A RX10K, RX10RK, RX10RSK B RX10MK, RX10MSK 2. Place the track in the chassis. NOTE: For track with a direction of rotation mark a : Install the track with the mark pointing in the direction of track rotation.
Page 49: Engine
SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK Order Job name/Part name Q’ty Remarks Seat and fuel tank removal Remove the parts in the order listed below. Muffler end pipe Rear cover Muffler side cover Tail/brake light cover Seat Fuel tank cover Side cover Fuel tank...
Page 50: Exhaust Pipe And Muffler
EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER 20 Nm (2.0 mSkg, 14 ftSlb) 25 Nm (2.5 mSkg, 18 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 11 Nm (1.1 mSkg, 8 ftSlb) Order Job name/Part name Q’ty Remarks Exhaust pipe and muffler removal Remove the parts in the order listed below.
Page 51: Heat Exchanger
COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER RX10MK, RX10MSK 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAPTER 2. Primary sheave assembly Refer to “PRIMARY SHEAVE AND DRIVE V-VELT”...
Page 52 COOL HEAT EXCHANGER 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Coolant pipe 1 Coolant pipe 2 Coolant hose 7 Coolant hose 8 Thermostat assembly Coolant hose 9 Coolant hose 10 Oil cooler outlet hose Oil cooler Oil cooler inlet hose Pipe 3 Water pump hose...
Page 53 COOL HEAT EXCHANGER 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Coolant hose 11 Coolant hose 12 For installation, reverse the removal procedure.
Page 54: Chapter 9. Specifications
1,210 mm (47.6 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 1,165 mm (45.8 in) (RX10MK, RX10MSK) Overall height 1,215 mm (47.8 in) (RX10K, RX10RK, RXW10K, RX10MK) 1,150 mm (45.3 in) (RX10RSK, RXW10SK, RX10MSK) Weight: Dry weight 247 kg (545.0 lb) (RX10K) 254 kg (560.1 lb) (RX10RK, RX10RSK)
Page 55 Gear oil API “GL-3” SAE#75 or #80 Capacity 0.25 L (8.8 lmp oz, 8.5 US oz) Coolant: Capacity 4.9 L (4.32 lmp qt, 5.18 US qt) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 6.4 L (5.64 lmp qt, 6.76 US qt) (RX10MK, RX10MSK) Fuel: Type Regular unleaded gasoline (Pump Octane ;...
Page 56 944 mm (37.2 in) (RXW10K, RXW10SK) 1,068 mm (42.0 in) (RX10MK, RX10MSK) 25 X 30 mm (0.98 X 1.18 in) (RXW10K, RXW10SK) Track deflection at 30 X 35 mm (1.18 X 1.38 in) (RX10K, RX10RK, 100 N (10 kg, 22 lb) RX10RSK, RX10MK, RX10MSK) Brake:...
Page 57: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Cylinder head: 13.45 X 14.05 cm (0.82 X 0.86 cu. in) Volume (with spark plug) <Warpage limit> 0.1 mm (0.004 in) Lines indicate straight edge measurement.
Page 58 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Valve dimensions: Valve head diameter A 22.9 X 23.1 mm (0.9016 X 0.9094 in) Intake 24.4 X 24.6 mm (0.9606 X 0.9685 in) Exhaust Head Diameter Valve face width B 1.76 X 2.90 mm (0.0693 X 0.1142 in)
Page 59 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Valve spring: Free length Intake 38.90 mm (1.53 in) Exhaust 40.67 mm (1.60 in) Installed length (valve closed) Intake 34.50 mm (1.36 in) Exhaust 35.00 mm (1.38 in) Compressed spring force (installed) 82 X 96 N (8.2 X 9.6 kg, 18.1 X 21.2 lb)
Page 60 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Piston pin: 16.991 X 17.000 mm (0.6689 X 0.6693 in) Piston pin outside diameter 51.4 X 51.5 mm (2.0236 X 2.0276 in) Piston pin length 0.002 X 0.022 mm (0.00008 X 0.0009 in)
Page 61 High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors Coolant mixing ratio (coolant: water) 3 : 2 (60% : 40%) Capacity 4.9 L (4.32 Imp qt, 5.18 US qt) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 6.4 L (5.64 Imp qt, 6.76 US qt) (RX10MK, RX10MSK)
Page 62: Power Train
Type V-belt automatic 3.8 X 1.0 : 1 Range of ratio 3,600 ± 200 r/min (3,400 X 3,800 r/min) (RX10K, RX10RK, Engagement speed r/min RX10RSK, RXW10K, RXW10SK) 4,200 ± 200 r/min (4,000 X 4,400 r/min) (RX10MK, RX10MSK) 10,250 ± 250 r/min (10,000 X 10,500 r/min)
Page 63 90269-06006 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) Material Steel (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) Size 17.2 mm (0.677 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) Quantity 3 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) Hole quantity...
Page 64 Height “B” 31.8 mm (1.25 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 50.8 mm (2.00 in) (RX10MK, RX10MSK) 30 X 35 mm (1.18 X 1.38 in) (RX10K, RX10RK, Track deflection at 100 N (10 kg, 22 lb) RX10RSK, RX10MK, RX10MSK) 25 X 30 mm (0.98 X 1.18 in) (RXW10K, RXW10SK)
Page 65 RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Suspension setting position: 25 ± 0.5 mm (0.98 ± 0.02 in) (RX10K, RX10RK, Hook setting length (Standard) RX10RSK) 15 ± 0.5 mm (0.59 ± 0.02 in) (RXW10K, RXW10SK) 10 ± 0.5 mm (0.39 ± 0.02 in) (RX10MK, RX10MSK) (Maximum) 35 mm (1.37 in) (RXW10K, RXW10SK)
Page 66: Chassis
RXW10K, RXW10SK) 182.0 mm (7.17 in) (RX10MK, RX10MSK) Ski suspension (Front suspension): Type Double wishbone system Travel 221 mm (8.70 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 175 mm (6.89 in) (RX10MK, RX10MSK) Spring type Coil spring Spring rate 19 N/mm (1.9 kg/mm, 108 lb/in) (RX10K, RX10RK, RX10RSK) 21 N/mm (2.1 kg/mm, 120 lb/in) (RXW10K, RXW10SK,...
Page 67 Withstand voltage 40 V Battery: Specific gravity 1.32 Manufacture YUASA Type YTX14L-BS 12V-12Ah (RX10K, RX10MK, RX10MSK) YTX20L-BS 12V-18Ah (RX10RK, RX10RSK, RXW10K, RXW10SK) Ten hour rate amperage 12 A (RX10K, RX10MK, RX10MSK) 18 A (RX10RK, RX10RSK, RXW10K, RXW10SK) Electric starter system: Type...
Page 68 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Starter relay: Model/Manufacturer MS5F-421/JIDECO Amperage rating 180 A 4.2 X 4.6 Ω at 20_C (68_F) Coil resistance T.P.S. (throttle position sensor): Model/Manufacturer TS67/02-1C/MIKUNI 4 X 6 kΩ at 20_C (68_F) Resistance (Blue –...
Page 69: High Altitude Settings
SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK Tempera- –40_C –20_C 16_C ture (–40_F) (–4_F) (32_F) (60_F) Idling speed (r/min) Altitude 0 X 200 m #140 #137.5 #135 (0 X 670 ft) 1350 200 X 1000 m #137.5...
Page 70: Tightening Torque
SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Spark plug 20 + 121_ 2.0 + 121_ 14 + 121_ Cylinder head nut (M10 1.25) Cylinder head nut (M10 1.25) 20 + 105_ 2.0 + 105_...
Page 71 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Fuel pump Fuel pump stay NOTE: 1. First, tighten the bolt to approximately 15 Nm (1.5 mSkg, 11 ftSlb) with a torque wrench, then loosen the bolt completely.
Page 72: Power Train
 Bearing set screw (Secondary shaft) Apply LOCTITE Parking brake Parking brake assembly and lever (RX10K, RX10RK, RX10RSK) Shock absorber adjuster assembly and frame Front pivot arm and frame Front pivot arm and shockabsorber Front pivot arm and stopper band...
Page 73 SPEC TIGHTENING TORQUE Tightening torque Parts be tightened Parts be tightened Remarks Remarks mSkg ftSlb (RXW10K, RXW10SK) Stopper band Hook and front pivot arm (RXW10K, RXW10SK)  Wheel bracket and sliding frame Apply LOCTITE  Bracket bolt (front) Apply LOCTITE ...
Page 74: Chassis
SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Handlebar holder Steering column Upper Lower Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod...
Page 75: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (nut) (bolt) (bolt) This chart specifies torque for standard fasteners mSkg ftSlb with standard I.S.O. pitch threads. Torque speci- 10 mm 6 mm fications for special components or assemblies 12 mm 8 mm are included in the applicable sections of this...
Page 76: Cable Routing
SPEC CABLE ROUTING...
Page 77 SPEC CABLE ROUTING CABLE ROUTING FOR RX10K, RX10MK, RX10MSK To the headlight and meter as- sembly Clamp the lead at the position of white tape. Clamp the wire harness and A.C.magneto lead. Battery negative lead Battery positive lead Main harness...
Page 78 SPEC CABLE ROUTING...
Page 79 SPEC CABLE ROUTING Route the starter cable above the left handlebar switch lead. Brake hose Fuel sender lead coupler Clamp the ignition coil lead un- der the fuel hose. Clamp the fuel hose. Route the coolant hose be- tween the upper vacuum hose and lower vacuum hose.
Page 80 SPEC CABLE ROUTING...
Page 81 SPEC CABLE ROUTING 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securely fit in the rubber cover) Put the boots of the meter cou- pler in the boss root on the side of the meter.
Page 82 SPEC CABLE ROUTING...
Page 83 SPEC CABLE ROUTING 1 Clamp the grip warmer lead and the right handlebar switch lead. Clamp the main harness, main switch and harness. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Ex- cept for brake hose and parking brake cable.) Pass the brake hose and the parking brake cable through...
Page 84 SPEC CABLE ROUTING...
Page 85 SPEC CABLE ROUTING Carburetor air vent hose To the parking brake. To the brake caliper Brake hose Clamp the wire harness and fuel tank breather hose from the top. Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side.
Page 86 SPEC CABLE ROUTING...
Page 87 SPEC CABLE ROUTING Headlight wire harness Tighten the frame ground and voltage regulator upper bolt to- gether. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through be- tween engine and heat ex- changer.
Page 88 SPEC CABLE ROUTING...
Page 89 SPEC CABLE ROUTING 1 Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the up- ward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross mem- ber and frame. Wire harness clamp Rivets Speed sensor Nylon nuts...
Page 90 SPEC CABLE ROUTING...
Page 91 SPEC CABLE ROUTING 1 Battery positive lead CDI unit Battery negative lead Air box drain hose Starter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat CDI unit bracket Latch Battery band Battery cover...
Page 92 SPEC CABLE ROUTING...
Page 93 SPEC CABLE ROUTING FOR RX10RK, RX10RSK, RXW10K, RXW10SK To the headlight and meter as- sembly Clamp the lead at the position of white tape. Clamp the wire harness and A.C.magneto lead. Battery positivee lead Battery negative lead Main harness Negative lead connector Carburetor heater lead coupler Oil level switch lead coupler Oil level switch...
Page 94 SPEC CABLE ROUTING...
Page 95 SPEC CABLE ROUTING Route the starter cable above the left handlebar switch lead. Brake hose Fuel sender lead coupler Clamp the ignition coil lead un- der the fuel hose. Clamp the fuel hose. Route the coolant hose be- tween the upper vacuum hose and lower vacuum hose.
Page 96 SPEC CABLE ROUTING...
Page 97 SPEC CABLE ROUTING 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securely fit in the rubber cover) Put the boots of the meter cou- pler in the boss root on the side of the meter.
Page 98 SPEC CABLE ROUTING...
Page 99 SPEC CABLE ROUTING 1 Clamp the grip warmer lead and the right handlebar switch lead. Clamp the main harness, main switch and harness. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Ex- cept for brake hose and parking brake cable.) Pass the brake hose and the parking brake cable through...
Page 100 SPEC CABLE ROUTING...
Page 101 SPEC CABLE ROUTING Carburetor air vent hose To the parking brake. To the brake caliper Brake hose Clamp the wire harness and fuel tank breather hose from the top. Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side.
Page 102 SPEC CABLE ROUTING...
Page 103 SPEC CABLE ROUTING Headlight wire harness Tighten the frame ground and voltage regulator upper bolt to- gether. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through be- tween engine and heat ex- changer.
Page 104 SPEC CABLE ROUTING...
Page 105 SPEC CABLE ROUTING 1 Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the up- ward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross mem- ber and frame. Wire harness clamp Rivets Speed sensor Nylon nuts...
Page 106 SPEC CABLE ROUTING...
Page 107 SPEC CABLE ROUTING 1 Battery negative lead CDI unit Battery positive lead Air box drain hose Starter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat CDI unit bracket Latch Battery band Battery cover...
Page 108 WIRING DIAGRAM - L/R G/B Sb Y/B G Y/G Lg/B Lg/B R/B G/R - W/R - B/L Y/L L/R Lg/W G G/R - Br/Y Y/B Lg/B Y/G B/W B - - - - - - - W/G - - B/Y Y/W W/Y L Lg/L L/R Br/W Lg Y/R Sb Br/W B/R B/W - Y W Gy O SUB-WIRE SUB-WIRE SUB-WIRE...
Page 109 1 A.C. magneto 2 Rectifier / regulator 3 Main switch 4 Main relay 5 Fuse (MAIN) 6 Starter relay 7 Starter motor 8 Battery 9 Engine stop switch 10 Throttle switch 11 Carburetor switch 12 Carburetor heater relay 13 Carburetor heater 14 Grip warmer 15 Thumb warmer 16 CDI unit...
Page 110 05. 11 PRINTED ON RECYCLED PAPER...
Page 111 SERVICE MANUAL...
Page 112 NOTICE HOW TO USE THIS MANUAL This manual was written by the Yamaha Motor Particularly important information is distin- Company primarily for use by Yamaha dealers guished in this manual by the following nota- and their qualified mechanics. It is not possible tions: to put an entire mechanic’s education into one...
Page 113 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. POWR 1 General information CHAS 2 Periodic inspections and adjustments 3 Chassis 4 Power train 5 Engine COOL 6 Cooling system...
Page 114 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTIONS AND INSP ADJUSTMENTS CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 115 CHAPTER 1. ENGINE OIL LEVEL INSPECTION ....2-20 GENERAL INFORMATION ENGINE OIL REPLACEMENT ..2-22 CRANKCASE BREATHER HOSE MACHINE IDENTIFICATION .
Page 116 CHAPTER 3. BRAKE CALIPER INSPECTION AND REPAIR ....4-32 CHASSIS BRAKE CALIPER ASSEMBLY ..4-33 BRAKE CALIPER INSTALLATION 4-33 STEERING .
Page 117 A.C. MAGNETO AND STARTER CHAPTER 8. CLUTCH ......5-31 ELECTRICAL REMOVAL ..... . 5-33 INSTALLATION .
Page 118 SIGNAL SYSTEM ....8-25 CHAPTER 9. CIRCUIT DIAGRAM ....8-25 SPECIFICATIONS TROUBLESHOOTING...
Page 119: Chapter 1. General Information
MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number 1 is located on the left-hand side of the crankcase.
Page 120: Important Information
ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and ad- justments.
Page 121: Gaskets, Oil Seals, And O-Rings
IMPORTANT INFORMATION INFO GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an en- gine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Ap- ply grease to the oil seal lips.
Page 122: Special Tools
SPECIAL TOOLS INFO SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent dam- age that can be caused by the use of improper tools or improvised techniques. NOTE: Be sure to use the correct part number when ordering the tool, since the part number may differ according to country.
Page 123: For Engine Service
SPECIAL TOOLS INFO FOR ENGINE SERVICE S Piston pin puller P/N: YU-01304 (for U.S.A./Canada) 90890-01304 (for Europe) This tool is used to remove the piston pin. S Rotor holding puller, attachment P/N: YU-33270 (for U.S.A./Canada) 90890-01362 (for Europe) P/N: YM-33282 90890-04089 This tool is used to remove the magneto rotor.
Page 124 SPECIAL TOOLS INFO S Valve guide remover (ø4, ø4.5) P/N: YM-04111 (ø4) (for U.S.A./Canada) 90890-04111 (for Europe) P/N: YM-4116 (ø4.5) (for U.S.A./Canada) 90890-04116 (for Europe) These tools are used to remove or install the valve guides. S Valve guide installer (ø4, ø4.5) P/N: YM-04112 (ø4) (for U.S.A./Canada) 90890-04112 (for Europe) P/N: YM-4117 (ø4.5) (for U.S.A./Canada)
Page 125: For Power Train Service
SPECIAL TOOLS INFO FOR POWER TRAIN SERVICE S Primary sheave holder P/N: YS-01880 (for U.S.A./Canada) 90890-01701 (for Europe) This tool is used to hold the primary sheave. S Primary sheave puller (18 mm) P/N: YS-01881-1 1 , YS-01882-1 2 (for U.S.A./Canada) 90890-01898 (for Europe) This tool is used for removing the primary sheave.
Page 126: For Carburetion Service
SPECIAL TOOLS INFO FOR CARBURETION SERVICE S Mity vac P/N: YB-35956 (for U.S.A./Canada) 90890-06756 (for Europe) This tool is used to check the fuel pump. FOR ELECTRICAL SERVICE S Pocket tester P/N: YU-03112 (for U.S.A./Canada) 90890-03112 (for Europe) This instrument is necessary for checking the electrical components. S Electro tester P/N: YU-33260-A (for U.S.A./Canada) 90890-03021 (for Europe)
Page 127: Periodic Inspection And Adjustment
INSP INTRODUCTION/PERIODIC MAINTENANCE TABLE PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine op- eration and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being pre- pared for sale.
Page 128 INSP PERIODIC MAINTENANCE TABLE Every Initial 1 month Seasonally Preopera- Item Remarks tion check 800 km 3,200 km (Daily) (500 mi) (2,000 mi) (40 hr) (160 hr) Check operation and fluid leakage. Brake and parking brake Adjust free play and/or replace pads if necessary. Repair brake fluid.
Page 129: Engine
INSP SPARK PLUGS ENGINE SPARK PLUGS 1. Remove: S Spark plug caps S Spark plugs 2. Inspect: S Electrodes 1 Damage/wear ! Replace the spark plug. S Insulator color 2 3. Measure: S Spark plug gap a Out of specification ! Regap. Use a wire thickness gauge.
Page 130: Fuel Line Inspection
INSP FUEL LINE INSPECTION/COOLING SYSTEM FUEL LINE INSPECTION 1. Remove: S Intake silencer Refer to “CARBURETORS” in CHAPTER 7. 2. Inspect: S Fuel hoses 1 S Fuel delivery hoses 2 Cracks/damage ! Replace. 3. Install: S Intake silencer Refer to “CARBURETORS” in CHAPTER 7. COOLING SYSTEM Coolant replacement NOTE:...
Page 131 INSP COOLING SYSTEM 4. Place an open container under the coolant hose. 5. Disconnect: S Coolant hose 1 6. Drain the coolant. NOTE: Lift up the tail of the machine to drain the cool- ant. 7. Remove: S Rear cover 1 8.
Page 132 INSP COOLING SYSTEM 12. Install: S Coolant hose 1 13. Install: S Intake silencer Refer to “CARBURETORS” in CHAPTER 7. 14. Fill: S Cooling system Recommended coolant: High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors Coolant mixing ratio (coolant:water) 3:2 (60%:40%) Total amount: 4.7 L (4.14 lmp qt, 4.97 US qt)
Page 133 INSP COOLING SYSTEM Inspection steps: S Attach the cooling system tester 1 and adapt- er 2 to the coolant filler 3 . Cooling system tester: 90890-01325, YU-24460-01 Adapter: 90890-01352, YU-24460-01 S Apply 100 kPa (1.0 kg/cm , 14 psi). S Measure the pressure with the gauge. Air bleeding 1.
Page 134 INSP COOLING SYSTEM WARNING To avoid severe injury or death: S Make sure the machine is securely sup- ported with a suitable stand. S Do not exceed 3,000 r/min. Drive line dam- age and excessive V-belt wear could occur, or the machine could unexpectedly move forward if the clutch engages.
Page 135: Valve Clearance Adjustment
INSP VALVE CLEARANCE ADJUSTMENT VALVE CLEARANCE ADJUSTMENT NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 136 INSP VALVE CLEARANCE ADJUSTMENT NOTE: S If the valve clearance is incorrect, record the measured reading. S Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #1 ! #2 ! #4 ! #3 A Front For each cylinder, starting with cylinder #1 at TDC, turn the crankshaft clockwise as specified in the following table.
Page 137 INSP VALVE CLEARANCE ADJUSTMENT NOTE: S Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. S Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place.
Page 138 INSP VALVE CLLEARANCE ADJUSTMENT VALVE PAD SELECTION TABLE INTAKE Measured INSTALLED PAD NUMBER clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
Page 139 INSP VALVE CLEARANCE ADJUSTMENT S Install the new valve pad 1 and the valve lifter NOTE: S Apply molybdenum disulfide oil to the valve pad and the valve lifter. S The valve lifter must turn smoothly when ro- tated by hand. S Install the valve lifter and the valve pad in the correct place.
Page 140: Carburetor Synchronization
INSP CARBURETOR SYNCHRONIZATION CARBURETOR SYNCHRONIZATION NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Remove: S Vacuum cap 2. Install: S Carburetor synchronizer 1 S Engine tachometer (near the spark plug) Carburetor synchronizer 90890-03094, YU-8030...
Page 141 INSP CARBURETOR SYNCHRONIZATION NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. S Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same.
Page 142: Engine Idle Speed Adjustment
INSP ENGINE IDLE SPEED ADJUSTMENT ENGINE IDLE SPEED ADJUSTMENT NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes.
Page 143: Throttle Cable Free Play Adjustment
INSP THROTTLE CABLE FREE PLAY ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: S Before adjusting the throttle cable free play, the engine idle speed should be adjusted. S Adjust the throttle cable free play while the cable is in the cable guide. 1.
Page 144: Throttle Override System (T.o.r.s.) Check
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK/ INSP COMPRESSION PRESSURE MEASUREMENT THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK WARNING When checking T.O.R.S.: S Be sure the parking brake is applied. S Be sure the throttle lever moves smoothly. S Do not run the engine up to the clutch en- gagement speed.
Page 145 INSP COMPRESSION PRESSURE MEASUREMENT CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 4. Install: S Compression gauge 1 Compression gauge set 90890-03081, YU-33223 Compression gauge adapter...
Page 146: Engine Oil Level Inspection
COMPRESSION PRESSURE MEASUREMENT/ INSP ENGINE OIL LEVEL INSPECTION Measurement steps: S Turn the main switch to “ON”. S With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground all spark plug leads before cranking the engine.
Page 147 INSP ENGINE OIL LEVEL INSPECTION S The engine oil level should be between the minimum level mark a and maximum level mark b . Below the minimum level mark ! Add the rec- ommended engine oil to the proper level. CAUTION: When adding the engine oil, be careful not to fill above the maximum level mark and mini-...
Page 148: Engine Oil Replacement
INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT 1. Start the engine, warm up for several min- utes, and then turn it off. 2. Place a containers under the engine oil drain bolt and oil tank. 3. Remove: S Bottom panel S Right side cover S Oil level gauge coupler S Oil level gauge/dipstick...
Page 149 INSP ENGINE OIL REPLACEMENT S Apply a thin coat of engine oil onto the O-ring 1 of the new oil filter cartridge. CAUTION: Make sure that the O-ring 1 is positioned correctly in the groove of the oil filter car- tridge.
Page 150: Crankcase Breather Hose Inspection
ENGINE OIL REPLACEMENT/CRANKCASE BREATHER INSP HOSE INSPECTION/CARBURETOR JOINTS INSPECTION 10. Inspect: S Engine oil pressure Inspection steps: S Slightly loosen the oil gallery bolt 1 . S Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.
Page 151: Exhaust System Inspection
INSP EXHAUST SYSTEM INSPECTION EXHAUST SYSTEM INSPECTION 1. Remove: S Seat S Exhaust system S Refer to “EXHAUST PIPE AND MUFFLER” in CHAPTER 5. 2. Inspect: S Exhaust joint 1 S Tightening torque Bolt (exhaust joint): 25 Nm (2.5 mSkg, 18 ftSlb) S Muffler 2 S Tightening torque Bolt (muffler):...
Page 152: Power Train
INSP SHEAVE OFFSET ADJUSTMENT POWER TRAIN SHEAVE OFFSET ADJUSTMENT 1. Measure: S Sheave offset a Use the sheave gauge. Out of specification ! Adjust. Sheave offset: 15 ± 1.5 mm (0.59 ± 0.06 in) (13.5 X 16.5 mm (0.53 X 0.65 in)) Sheave gauge: YS-42421-1 NOTE:...
Page 153 INSP SHEAVE OFFSET ADJUSTMENT/DRIVE V-BELT 3. Measure: S Secondary sheave freeplay (clearance) a Use a feeler gauge. Out of specification ! Adjust. Secondary sheave free play (clearance): 1.0 X 2.0 mm (0.04 X 0.08 in) 4. Adjust: S Secondary sheave freeplay (clearance) Adjustment steps: S Apply the brake to lock the secondary sheave.
Page 154: Drive V-Belt
INSP DRIVE V-BELT New belt width: 34.5 mm (1.36 in) Belt wear limit width: 32.5 mm (1.28 in) 1. Measure: S V-belt position a NOTE: Install the new V-belt onto the secondary sheave only. Do not force the V-belt between the sheaves;...
Page 155: Engagement Speed Check
INSP DRIVE V-BELT/ENGAGEMENT SPEED CHECK 4. Inspect: S Drive V-belt Cracks/damage/wear ! Replace. Oil or grease on the V-belt ! Check the pri- mary and secondary sheaves. 5. Inspect: S Primary sheave S Secondary sheave Oil or grease on the primary and secondary sheaves ! Use a rag soaked in lacquer thin- ner or solvent to remove the oil or grease.
Page 156: Parking Brake Adjustment
PARKING BRAKE ADJUSTMENT/ INSP BRAKE LEVER ADJUSTMENT PARKING BRAKE ADJUSTMENT 1. Measure: S Parking brake cable distance a Out of specification ! Adjust. Parking brake cable distance: 43.5 X 46.5 mm (1.713 X 1.831 in) 2. Adjust: S Parking brake cable Adjustment steps: S Loosen the locknut 1 S Turn the adjuster 2 in or out until the specified...
Page 157: Brake Fluid Level Inspection
BRAKE LEVER ADJUSTMENT/ INSP BRAKE FLUID LEVEL INSPECTION Adjustment steps: S Loosen the locknut 1 . S While lightly pushing the brake lever in direc- tion a , turn the adjusting bolt 2 by fingers to set the brake lever to the desired position. S Tighten the locknut securely after adjusting.
Page 158: Brake Pad Inspection
BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION/ INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Inspect: S Brake pad wear a Wear indicator 1 nearly contacts the brake disc ! Replace as a set. Wear limit: 7.5 mm (0.30 in) BRAKE HOSE INSPECTION 1.
Page 159 INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) a. Slowly apply the brake lever several times. b. Pull the lever in, then hold the lever in posi- tion. c. Loosen the bleed screws and allow the brake lever to travel towards its limit. d.
Page 160: Drive Chain
INSP DRIVE CHAIN DRIVE CHAIN Oil level inspection WARNING The engine and muffler will be very hot after the engine has run. Avoid touching a hot en- gine and muffler while they are still hot with any part of your body or clothing during in- spection or repair.
Page 161 INSP DRIVE CHAIN Recommended oil: Gear oil API “GL-3” SAE #75 or #80 CAUTION: Make sure that no foreign material enters the gear case. S Reinsert the dipstick 2 . Oil replacement Oil replacement steps: S Place the oil pan under the drain hole. S Remove the oil drain bolt 1 and drain the oil.
Page 162: Track Tension Adjustment
INSP TRACK TENSION ADJUSTMENT TRACK TENSION ADJUSTMENT WARNING A broken track or track fittings, and debris thrown by the track could be dangerous to an operator or by standers. Observe the fol- lowing precautions. S Do not allow anyone to stand behind the machine when the engine is running.
Page 163: Slide Runner Inspection
TRACK TENSION ADJUSTMENT/ INSP SLIDE RUNNER INSPECTION Shifted Shifted Track alignment to right to left Left adjuster Turn out Turn in Right adjuster Turn in Turn out 8 Slide runner 9 Track Track metal Forward A RX10, RX10S , RX10R, RX10RS B RX10M, RX10MS c.
Page 164: 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 pos- sible damage, consult your stud manufacturer for installation and stud pattern recommenda- tions. Yamaha does not recommend track stud- ding. 2-38...
Page 165: Chassis
INSP SKI/SKI RUNNER CHASSIS SKI/SKI RUNNER 1. Inspect: S Ski S Ski runner Damage/wear ! Replace. S Ski runner thickness a S Plastic ski thickness b Out of specification ! Replace. Ski runner wear limit: 8 mm (0.31 in) Plastic ski wear limit: 24 mm (0.95 in) CAUTION: To avoid scratching, wearing and damaging...
Page 166: Steering System
INSP STEERING SYSTEM STEERING SYSTEM Free play check 1. Check: S Steering system free play Move the handlebar up and down and back and forth. Turn the handlebar slightly to the right and left. Excessive free play ! Check that the han- dlebar, tie rod ends and relay rod ends are installed securely in position.
Page 167 INSP STEERING SYSTEM/LUBRICATION 3. Adjust: S Ski toe-out Adjustment steps: S Loosen the locknuts (tie-rod) 1 . S Turn the tie rods 2 in or out until the specified toe-out is obtained. S Tighten the locknuts (tie-rod) 1 . Locknut (rod end): 25 Nm (2.5 mSkg, 18 ftSlb) ...
Page 168: Lubrication
INSP LUBRICATION Front and rear suspension 1. Use a grease gun to inject grease into the nipples 1 . Recommended lubricant: Esso Beacon 325 Grease or Aeroshell Grease #7A A Front B Rear (RX10, RX10S, RX10R, RX10RS) C Rear (RX10M, RX10MS) 2-42...
Page 169: Electrical
INSP HEADLIGHT BEAM ADJUSTMENT ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Place the machine in front of a wall at the rec- ommended distance D . Refer to the table below. 3. Measure the distance H from the floor to the center of the headlight and place a mark on the wall at that height.
Page 170: Battery Inspection
INSP BATTERY INSPECTION EAS00178 BATTERY INSPECTION WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries. S Charge batteries in a well-ventilated area.
Page 171 INSP BATTERY INSPECTION NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 172 INSP BATTERY INSPECTION 4. Charge: Charging S battery Ambient temperature 20_C (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Make sure that the battery vent is free of obstructions.
Page 173 INSP BATTERY INSPECTION Charging method using a variable voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V. and start charging.
Page 174 INSP BATTERY INSPECTION Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on...
Page 175 INSP BATTERY INSPECTION 5. Install: S Battery 6. Connect: S Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 7. Check: S Battery terminals Dirt ! Clean with a wire brush. Loose connection ! Connect properly.
Page 176: Fuse Inspection
INSP FUSE INSPECTION FUSE INSPECTION The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Inspect: S Continuity Inspection steps: S Connect the pocket tester to the fuse and check the continuity.
Page 177: Speedometer Unit Inspection
INSP FUSE INSPECTION/SPEEDOMETER UNIT INSPECTION WARNING Never use a fuse with an amperage other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting, ignition, grip warmer, signal and meter systems to mal- function and could possibly cause a fire.
Page 178: Tuning
INSP CARBURETOR TUNING TUNING CARBURETOR TUNING The carburetors are set at the factory to run at temperatures of 0_C X–20_C (32_F X–4_F) at sea level. If the machine is to be operated un- der conditions other than those specified above, the carburetors must be properly ad- justed.
Page 179 NOTE: These jetting specifications are subject to change. Consult the latest technical information from Yamaha to be sure you have the most up-to- date jetting specifications. 1 Clip 2 Jet needle 3 Pilot screw 4 Main jet...
Page 180 INSP CARBURETOR TUNING Guide for carburetion Piston valve opening Mid-range speed tuning High speed turning Fully opened Closed Low speed tuning Closed Fully opened Piston valve opening 2-54...
Page 181 INSP CARBURETOR TUNING A Standard main jet B Main jet whose diameter is 10% smaller than standard C Main jet whose diameter is 10% larger than stan- dard Fully opened Piston valve opening A No. 2 position B No. 1 position C No.
Page 182 INSP CARBURETOR TUNING Low-speed tuning The carburetors are built so that low speed tun- ing can be done by adjusting the pilot mixture screw 1 and throttle stop screw 2 . CAUTION: Never run the engine without the air intake silencer installed.
Page 183 INSP CARBURETOR TUNING Main jet selection chart Spark plug color Diagnosis Remedy Light tan or gray Carburetors are tuned properly. Dry black or fluffy Mixture is too rich. Replace the main jet with the next smaller deposits size. White or light gray Mixture is too lean.
Page 184 INSP CARBURETOR TUNING Trouble Diagnosis Adjustment S Remove the pilot jet, clean it with Poor performance at Clogged or loose pilot jet mid-range speeds: compressed air, and then install it. S Momentary slow S Make sure that the pilot jet is fully tightened. response to the throttle Lean mixture...
Page 185: Clutch
INSP CLUTCH CLUTCH G Green P Pink High altitude S Silver Y Yellow Specifications Model: RX10, RX10S, RX10R, RX10RS X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft)
Page 186 INSP CLUTCH S Silver O Orange W White Specifications Model: RX10M, RX10MS X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft) (X 2,500 ft)
Page 187 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the de- sired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the en- gine speed at which the machine first begins to move from a complete stop.
Page 188: Gear Selection
INSP GEAR SELECTION 1 Chain and sprocket part number Parts name Teeth & links Parts no. Standard 20 teeth 8FA-17682-00 21 teeth 8FA-17682-10 RX10M, RX10MS Drive sprocket 22 teeth 8FA-17682-20 23 teeth 8FA-17682-30 24 teeth 8FA-17682-40 RX10, RX10S, RX10R, RX10RS 37 teeth 8DW-47587-70 38 teeth...
Page 189 INSP GEAR SELECTION 5 Torque cam (secondary spring seat) Identification mark Effects Part no. Cam angle Identification mark Standard Quicker upshifting RX10, RX10S, 8FA-17604-00 51-43_ 8BVFA during acceleration RX10R, RX10RS 8BV-17604-71 8BV71 8BV-17604-51 8BV51 RX10M, RX10MS 8BV-17604-31 8BV31 Quicker 8BV-17604-11 8BV11 backshifting backshifting...
Page 190 INSP GEAR SELECTION 6 Primary spring Spring identification color code Spring rate color Preload color Spring rate Wire Outside Free Preload No. of Color Standard Parts No. N / mm gauge diameter length N (kg) coils (kg / mm) mm (in) mm (in) mm (in) 90501-551L3...
Page 191 INSP GEAR SELECTION 7 Clutch weight Parts no. Weight g (oz) Shape & ID mark Standard without bush and rivets 35.32 8CH-17605-10 (1.247) 38.09 8CR-17605-10 (1.345) 34.26 8DG-17605-00 (1.209) 37.77 8DJ-17605-00 (1.333) 42.09 8DN-17605-20 (1.486) 39.00 8EK-17605-00 (1.376) RX10, RX10S, 69.43 8FA-17605-00 RX10M, RX10MS,...
Page 192 INSP GEAR SELECTION 8 Weight rivets Parts No. Material Length Weight Standard Effects mm (in) g (oz) 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) IN: RX10, RX10S, RX10R, RX10RS 3.6 (0.127) 90269-06006 Steel 17.2 (0.677) OUT: RX10, RX10S, RX10R, RX10RS Increased with hole Force Force...
Page 193: High Altitude Tuning
INSP HIGH ALTITUDE TUNING HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below. Check STD settings S Carburetors S Spark plugs Adjust the main jet size according to the chart Test the main jet Not OK Adjust the size of the main jet...
Page 194: Front Suspension
INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: S Spring preload Adjustment steps: S Turn the spring seat 1 in or out. RX10, RX10S, RX10R, RX10RS Spring seat Standard Shorter z ! Longer distance Harder z ! Softer Preload Min.
Page 195: Rear Suspension
INSP REAR SUSPENSION REAR SUSPENSION Stopper band 1. Adjust: S Stopper band tension CAUTION: Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. NOTE: This adjustment affects the handling character- istics of the machine. Adjustment steps: S Loosen the locknut 1 .
Page 196 INSP REAR SUSPENSION Spring preload (RX10, RX10S, RX10R, RX10RS) 1. Adjust: S Spring preload Adjustment step: S Turn the spring seat 1 in or out. Front A Spring seat Standard Shorter z ! Longer distance Harder z ! Softer Preload Min.
Page 197 INSP REAR SUSPENSION Spring preload (RX10M, RX10MS) 1. Adjust: S Spring preload Adjustment steps: S Turn the adjusting ring 1 to the proper posi- tion. Spring adjuster position Softer z ! Harder Preload Front Standard Spring adjuster position Softer z ! Harder Preload Rear Standard...
Page 198 INSP REAR SUSPENSION S Turn the adjusting bolt 2 to the desired posi- tion. CAUTION: Be sure the adjusting bolt ends are set at the same position on each side. S While holding the adjusting bolt securely, tighten the nut 1 . Nut (shock absorber): 49 Nm (4.9 mSkg, 35 ftSlb) CAUTION:...
Page 199 INSP REAR SUSPENSION Control rod 1. Adjust: S Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: S Loosen the lock nut 1 . S Turn the adjusting nut 2 in or out to adjust the control rod stroke.
Page 200: Chapter 3. Chassis
CHAS STEERING CHASSIS STEERING RX10, RX10S, RX10R, RX10RS 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Thumb warmer lead coupler Disconnect.
Page 201 CHAS STEERING 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) Order Job name/Part name Q’ty Remarks NOTE: Master cylinder assembly Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” in CHAPTER 9, to check the Handlebar cable, lead and hose routings.
Page 202 CHAS STEERING RX10M, RX10MS 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11ftSlb) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Thumb warmer lead coupler Disconnect. Thumb warmer switch lead coupler Disconnect.
Page 203 CHAS STEERING 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11ftSlb) Order Job name/Part name Q’ty Remarks NOTE: Master cylinder assembly Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” in CHAPTER 9, to check the Handlebar cable, lead and hose routings.
Page 204 CHAS STEERING 25 Nm (2.5 mSkg, 18 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 67 Nm (6.7 mSkg, 49 ftSlb) ESSO beacon 325 grease or 23 Nm (23 mSkg, 17 ftSlb) Aeroshell grease #7A Order Job name/Part name...
Page 205 CHAS STEERING 25 Nm (2.5 mSkg, 18 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 67 Nm (6.7 mSkg, 49 ftSlb) ESSO beacon 325 grease or 23 Nm (23 mSkg, 17 ftSlb) Aeroshell grease #7A Order Job name/Part name...
Page 206: Inspection
CHAS STEERING INSPECTION 1. Inspect: S Handlebar (RX10, RX10S, RX10R, RX10RS) S Handlebar 2 (RX10M, RX10MS) S Steering column 3 Bends/cracks/damage ! Replace. WARNING Do not attempt to straighten a bent column. This may dangerously weaken the column. 2. Inspect: S Bearings (steering column) 1 S Collars 2 Wear/damage ! Replace.
Page 207: Installation
CHAS STEERING INSTALLATION 1. Install: S Relay arms 1 S Bushings S Washers 2 Bolt (relay arm): 67 Nm (6.7 mSkg, 49 ftSlb) S Clips 3 2. Install: S Idler arm 4 S Bushings S Washers S Relay rod 5 Nut (idler arm): 35 Nm (3.5 mSkg, 25 ftSlb) Nut (relay rod):...
Page 208 CHAS STEERING CAUTION: Always use new cotter pins. Locknut (rod end): 25 Nm (2.5 mSkg, 18 ftSlb)  LOCTITE Nut (tie rod-idler arm): 30 Nm (3.0 mSkg, 22 ftSlb) Nut (tie rod-steering arm): 35 Nm (3.5 mSkg, 25 ftSlb) 5. Install: S Steering shaft 1 S Locknuts 2 S Joints 3...
Page 209 CHAS STEERING 6. Adjust: S Skis Adjustment steps: S Temporarily install the handlebar. S Hold the handlebar straight and check that the skis and relay arms are at right angles to the handlebar. S Loosen the locknuts (steering shaft) 1 . S Hold the handlebar straight.
Page 210: Ski
CHAS 11 Nm (1.1 mSkg, 8.0 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 19 Nm (1.9 mSkg, 14 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below.
Page 211: Inspection
CHAS INSPECTION 1. Inspect: S Ski 1 S Ski runner 2 S Ski stopper 3 S Ski column lower bracket 4 S Ski handle 5 Wear/cracks/damage ! Replace. S Mounting bolt 6 S Collar 7 S Bolts 8 S Collars 9 Wear/damage ! Replace.
Page 212: Front Suspension
CHAS FRONT SUSPENSION FRONT SUSPENSION 45 Nm (4.5 mSkg, 33 ftSlb) 37 Nm (3.7 mSkg, 27 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 65 Nm (6.5 mSkg, 47 ftSlb) 34 Nm (3.4 mSkg, 25 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 213 CHAS FRONT SUSPENSION 45 Nm (4.5 mSkg, 33 ftSlb) 37 Nm (3.7 mSkg, 27 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 65 Nm (6.5 mSkg, 47 ftSlb) 34 Nm (3.4 mSkg, 25 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order...
Page 214: Handling Notes
CHAS FRONT SUSPENSION HANDLING NOTES WARNING This shock absorber contains highly com- pressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.
Page 215: Installation
CHAS FRONT SUSPENSION 4. Inspect: S Connecting rod 1 S Stabilizer 2 S Stabilizer arm 3 Cracks/bends/damage ! Replace. S Bushing 4 Wear/scratches/damage ! Replace. INSTALLATION 1. Install: S Steering arm 1 NOTE: S Align the punch mark a on the ski column with the punch mark b on the steering arm.
Page 216 CHAS FRONT SUSPENSION Ski alignment NOTE: Be sure to verify the spring preload setting and the ski spindle camber before adjusting the ski toe out since either of those adjustments may affect the ski toe out setting. Point the skis straight forward and measure the amount of ski toe out. A Ski toe out: 0 X 15 mm (0 X 0.59 in) a –...
Page 217: Chapter 4. Power Train
POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT 120 Nm (12 mSkg, 85 ftSlb) 60 Nm (6.0 mSkg, 43 ftSlb) Order Job name/Part name Q’ty Remarks Primary sheave removal Remove the parts in the order listed below. Left side cover V-belt Primary sheave assembly...
Page 218 POWR PRIMARY SHEAVE AND DRIVE V-BELT 6 Nm (0.6 mSkg, 4.3 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) 200 Nm (20.0 mSkg, 145 ftSlb) Clean the threads. Apply LOCTITE648 as illustrated in And then tighten the spider. (The spider must be a 16 mm (0.63 in) turned counterclockwise to be tightened.) b 30 mm (1.18 in)
Page 219: Removal
POWR PRIMARY SHEAVE AND DRIVE V-BELT REMOVAL 1. Remove: S Primary sheave assembly 1 NOTE: Use the primary sheave holder 2 and primary sheave puller 3 . Primary sheave holder: 90890-01701, YS-01880 Primary sheave puller: 90890-01898 YS-01881-1, YS-01882-1 DISASSEMBLY 1. Remove: S Fixed sheave 1 S Stopper 2 S Sliding sheave 3...
Page 220 POWR PRIMARY SHEAVE AND DRIVE V-BELT S Fit the primary sheave assembly onto the adapter and secure the supporting plates 8 . NOTE: Securely fit the projections on the adapter into the fixed sheave holes. S Set the bar wrench 9 onto the spider and turn the special tool clockwise to loosen the spider.
Page 221: Inspection
POWR PRIMARY SHEAVE AND DRIVE V-BELT INSPECTION 1. Inspect: S Spider 1 S Sliding sheave 2 S Fixed sheave 3 S Primary sheave cap 4 Cracks/damage ! Replace. 2. Inspect: S Primary sheave spring 1 Cracks/damage ! Replace. 3. Measure: S Primary sheave spring free length a Out of specification ! Replace the primary sheave spring.
Page 222 POWR PRIMARY SHEAVE AND DRIVE V-BELT 5. Inspect: S Weight 1 S Roller 2 S Bushing 3 S Slider 4 S Rivet 5 S Collar Wear/scratches/damage ! Replace. Slider inside clearance Min. 0 mm (0 in) Max. 0.3 mm (0.0118 in) Rivet replacement steps: S Remove old rivet with the appropriate drill.
Page 223 POWR PRIMARY SHEAVE AND DRIVE V-BELT ASSEMBLY 1. Install: S Sliding sheave (onto the spider) NOTE: Be sure the sliding sheave match mark (X) is aligned with the spider match mark (X). 2. Install: S Fixed sheave (onto the spider) NOTE: S Clean the threads.
Page 224 POWR PRIMARY SHEAVE AND DRIVE V-BELT S Tighten the spider to specification using the bar wrench 3 . Spider: 200 Nm (20 mSkg, 145 ftSlb) CAUTION: The spider has a left-handed thread. WARNING S Do not operate the primary sheave until the ...
Page 225 POWR PRIMARY SHEAVE AND DRIVE V-BELT INSTALLATION 1. Install: S Primary sheave assembly CAUTION: Be sure to remove any oil or grease from the tapered portion of the crankshaft and spider using a cloth dampened with thinner. 2. Apply: S Engine oil or an equivalent grease (to threads of primary sheave bolt) 3.
Page 226: Assembly
POWR SECONDARY SHEAVE SECONDARY SHEAVE 64 Nm (6.4 mSkg, 46 ftSlb) Order Job name/Part name Q’ty Remarks Secondary sheave removal Remove the parts in the order listed below. Left side cover Refer to “PRIMARY SHEAVE AND V-belt V-BELT”. Washer and bolt –...
Page 227 POWR SECONDARY SHEAVE 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Secondary sheave disassembly Remove the parts in the order listed below. Spring seat Secondary sheave spring Fixed sheave...
Page 228: Disassembly
POWR SECONDARY SHEAVE DISASSEMBLY WARNING S Use extreme CAUTION when disassem- bling the secondary sheave since serious injury can occur due to the sudden release of spring tension. Use the sheave com- pressor to contain the spring tension be- fore removing the nuts (spring seat). S Do not attempt this procedure unless you have the proper tools and understand the instructions thoroughly.
Page 229: Assembly
POWR SECONDARY SHEAVE 5. Measure: S Ramp shoe thickness a Out of specification ! Replace the ramp shoe. Wear limit: 1.0 mm (0.04 in) ASSEMBLY 1. Install: S Stopper S Sliding sheave Screw (stopper): 7 Nm (0.7 mSkg, 5.1 ftSlb) 2.
Page 230 POWR SECONDARY SHEAVE Installation steps: S Hold the spring seat 1 and turn the fixed sheave 2 counterclockwise to the specified angle a . NOTE: The holes in the spring seat should align with the bolts on the sliding sheave. a = (sheave hole number + spring seat hole number) Twist angle:...
Page 231: Installation
S Install new shims of the proper thickness and reassemble the secondary sheave. S Measure the secondary sheave clearance again. Repeat these steps until the clearance is within specification. NOTE: Yamaha recommends keeping the original shims. Shims: Part number Thickness 90201-061H1 0.5 mm (0.02 in) 90201-06037 1.0 mm (0.04 in)
Page 232: Drive Chain Housing
POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 233: Inspection
POWR DRIVE CHAIN HOUSING INSPECTION 1. Inspect: S Drive chain housing 1 S Drive chain housing cover 2 Cracks/damage ! Replace. S Oil seals (drive chain housing) Wear/damage ! Replace. S Bearings (drive chain housing and cover) 3 Pitting/damage ! Replace. S Bearing (chain tensioner) 4 Pitting/damage ! Replace the bearing and the inner race holder as a set.
Page 234 POWR DRIVE CHAIN HOUSING 3. Measure: S 14 link section a of the drive chain Using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b . Out of specification ! Replace the drive chain.
Page 235: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the fol- lowing. A Make sure that the bearing seals face towards the drive chain as shown. B Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps.
Page 236: With Reverse Model
POWR DRIVE CHAIN HOUSING WITH REVERSE MODEL 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 237 POWR DRIVE CHAIN HOUSING 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 238: Inspection
POWR DRIVE CHAIN HOUSING INSPECTION 1. Inspect: S Drive chain housing 1 S Drive chain housing cover 2 Cracks/damage ! Replace. S Shift fork 3 Pitting/wear/damage ! Replace. S Oil seals (drive chain housing) Wear/damage ! Replace. S Bearings (drive chain housing and cover) 4 Pitting/damage ! Replace.
Page 239: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the fol- lowing. A Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. B Make sure that the bearing seals face towards the drive chain as shown.
Page 240 POWR DRIVE CHAIN HOUSING 4. Install: S Shift rod 1 5. Adjust: S Shift rod length a Adjustment steps: S Move the shift lever to the “FWD.” position. S Loosen the locknuts 2 . S Turn the shift rod 1 so that shift rod free play is 0 mm (in direction where a can be short- ened appropriately) and then turn back the shift rod 1/4 turns.
Page 241: Secondaryshaft
POWR SECONDARYSHAFT SECONDARYSHAFT Order Job name/Part name Q’ty Remarks Secondaryshaft removal Remove the parts in the order listed below. Secondary sheave Refer to “SECONDARY SHEAVE”. Drive chain housing Refer to “DRIVE CHAIN HOUSING”. Circlip Secondaryshaft Bearing For installation, reverse the removal procedure.
Page 242: Inspection
POWR SECONDARYSHAFT INSPECTION 1. Inspect: S Secondaryshaft 1 Scratches (excessive)/damage ! Replace. S Splines 2 Wear/damage ! Replace the secondary- shaft. S Bearing contact surface 3 Scratches/wear/damage ! Replace the secondaryshaft. 2. Inspect: S Bearing 1 Pitting/damage ! Replace. 3. Measure: S Brake disc thickness a Out of specification ! Replace.
Page 243: Secondaryshaft And Drive Chain Housing Installation
POWR SECONDARYSHAFT SECONDARYSHAFT AND DRIVE CHAIN HOUSING INSTALLATION 1. Install: S Secondaryshaft S Drive chain housing Installation steps: S Install the secondaryshaft. S Install the drive chain housing 1 . S Tighten the bolts. Bolt (drive chain housing): 48 Nm (4.8 mSkg, 35 ftSlb) S Install the drive chain, drive sprocket and driven sprocket.
Page 244: Brake
POWR BRAKE BRAKE 6 Nm (0.6 mSkg, 4.3 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring Brake pad Brake caliper assembly For installation, reverse the removal procedure.
Page 245: Brake Pad Replacement
POWR BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: S Do not disassemble components unless absolutely necessary. S Do not use solvents on internal brake com- ponents. S Do not use contaminated brake fluid for cleaning. Use only clean brake fluid. S Do not allow brake fluid to contact the eyes, otherwise eye injury may occur.
Page 246 POWR BRAKE 2. Install: S Brake pads S Pad spring Installation steps: S Connect a suitable hose 1 tightly to the cali- per bleed screw 2 . Put the other end of this hose into an open container. S Loosen the caliper bleed screw and push the pistons into the caliper with your finger.
Page 247 POWR BRAKE 30 Nm (3.0 mSkg, 22 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) Order Job name/Part name Q’ty Remarks Brake caliper and parking brake Remove the parts in the order listed below. removal Brake fluid Drain.
Page 248: Brake Caliper Disassembly
POWR BRAKE BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: S Pistons S Piston oil seals 1 Removal steps: S Using a wood of piece 2 , lock the right pis- ton.
Page 249: Brake Caliper Assembly
POWR BRAKE 1. Inspect: S Caliper piston 1 Scratches/rust/wear ! Replace the caliper assembly. S Caliper cylinder 2 Wear/scratches ! Replace the caliper as- sembly. S Caliper body 3 Cracks/damage ! Replace. S Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and dust seals whenever a caliper is disassembled.
Page 250 POWR BRAKE 10 Nm (1.0 mSkg, 7.2 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job name/Part name Q’ty Remarks Brake master cylinder removal Remove the parts in the order listed below. Brake fluid Drain. Parking brake cable Brake switch Brake lever Parking brake lever Union bolt...
Page 251: Inspection
POWR BRAKE INSPECTION 1. Inspect: S Master cylinder 1 Wear/scratches ! Replace the master cyl- inder assembly. S Master cylinder body 2 Cracks/damage ! Replace. S Oil delivery passage (master cylinder body) Blow out with compressed air. 2. Inspect: S Master cylinder kit 1 Scratches/wear/damage ! Replace as a set.
Page 252: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION RX10, RX10S, RX10R, RX10RS 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen.
Page 253 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 mSkg, 2.9 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 254 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Suspension wheel Collar Wheel bracket Circlip Suspension wheel Collar...
Page 255 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear shock absorber Bushing Collar Pull rod Collar Bushing Guide wheel Control rod assembly Bushing Bushing...
Page 256 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear pivot arm Bushing Shaft Shaft Rear pivot arm bracket...
Page 257: Rx10M, Rx10Ms
POWR SLIDE RAIL SUSPENSION RX10M, RX10MS 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Left side cover Refer to “PRIMARY SHEAVE AND DRIVE VELT”.
Page 258 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 mSkg, 2.9 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 259 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Suspension wheel Collar Wheel bracket Front pivot arm bracket Circlip Suspension wheel...
Page 260 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear shock absorber Bushing Collar Pull rod Collar Bushing Guide wheel Control rod assembly Bushing Bushing...
Page 261 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear pivot arm Bushing Collar Collar Rear pivot arm bracket...
Page 262: Inspection
POWR SLIDE RAIL SUSPENSION INSPECTION 1. Inspect: S Suspension wheel S Guide wheel Cracks/damage ! Replace. S Wheel bearing Wheel turns roughly ! Replace. 2. Inspect: S Stopper band 1 Frayed/damage ! Replace. S Pull rod 2 Bends/damage ! Replace. S Shock absorber 3 Oil leaks/damage ! Replace.
Page 263: Assembly
POWR SLIDE RAIL SUSPENSION ASSEMBLY 1. Install: S Stopper band 1 NOTE: S For RX10, RX10S, RX10R, RX10RS: Install the stopper band with a toward the hook and b toward the front suspension bracket. S For RX10M, RX10MS: Install the stopper band with a toward the hook and b toward the shaft.
Page 264 POWR SLIDE RAIL SUSPENSION Control rod parts number Control rod 1 Length mm (in) Length mm (in) Length mm (in) RX10, RX10S, 301.0 (11.85) 155.5 (6.12) 2.5P 3 = 7.5 RX10R, RX10RS (0 098P (0.098P 3 = 0 295) 3 = 0.295) RX10M, RX10MS 257.5 (10.14) 165.0 (6.50)
Page 265: Front Axle And Track
POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK 9 Nm (0.9 mSkg, 6.5 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job name/Part name Q’ty Remarks Front axle and track removal Remove the parts in the order listed below. Drive chain housing Refer to “DRIVE CHAIN HOUSING”.
Page 266: Inspection
POWR FRONT AXLE AND TRACK INSPECTION 1. Inspect: S Track 1 S Slide metal 2 Wear/cracks/damage ! Replace. 2. Inspect: S Sprocket wheel 1 Wear/break/damage ! Replace. S Front axle 2 Bends/scratches (excessive)/damage ! Re- place. INSTALLATION 1. Install: S Sprocket wheels S Guide wheels NOTE: S When pressing the sprocket wheels onto the...
Page 267 POWR FRONT AXLE AND TRACK 2. Place the track in the chassis. NOTE: For track with a direction of rotation mark a : Install the track with the mark pointing in the direction of track rotation. A RX10, RX10S, RX10R, RX10RS B RX10M, RX10MS 4-51...
Page 268: Chapter 5. Engine
SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK Order Job name/Part name Q’ty Remarks Seat and fuel tank removal Remove the parts in the order listed below. Rear cover Muffler end pipe Muffler side cover Tail/brake light cover Seat Fuel tank cover Side cover Fuel tank...
Page 269: Exhaust Pipe And Muffler
EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER 20 Nm (2.0 mSkg, 14 ftSlb) 25 Nm (2.5 mSkg, 18 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 11 Nm (1.1 mSkg, 8 ftSlb) Order Job name/Part name Q’ty Remarks Exhaust pipe and muffler removal Remove the parts in the order listed below.
Page 270: Installation
EXHAUST PIPE AND MUFFLER INSTALLATION 1. Install: S Muffler 1 2. Install: S Exhaust pipe 1 NOTE: Hang the exhaust pipe to the frame a . 3. Tighten: S Exhaust pipe bolts 1 Bolt (band): 9 Nm (0.9 mSkg, 7 ftSlb) 4.
Page 271: Engine Assembly
ENGINE ASSEMBLY ENGINE ASSEMBLY 7 Nm (0.7 mSkg, 5.1 ftSlb) 65 Nm (6.5mSkg, 47 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job name/Part name Q’ty Remarks Engine assembly removal Remove the parts in the order listed below. Intake silencer Refer to “CARBURETORS”...
Page 272 ENGINE ASSEMBLY INSPECTION 1. Inspect: S Engine mounting adjust bolts Cracks/damage ! Replace. INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routing. 1. Install: S Engine mounting adjust bolts S Engine S Engine mounting bolts and nuts NOTE:...
Page 273 CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) Order Job name/Part name Q’ty Remarks Cylinder head cover removal Remove the parts in the order listed below. Coolant Drain. Coolant hose and pipe Refer to “HEAT EXCHANGER”...
Page 274 CAMSHAFTS CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job name/Part name Q’ty Remarks Camshaft removal Remove the parts in the order listed below. Oil tank Refer to “A.C.
Page 275 CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job name/Part name Q’ty Remarks Intake camshaft Exhaust camshaft For installation, reverse the removal procedure.
Page 276 CAMSHAFTS REMOVAL 1. Remove: S Timing plug 2. Align: S “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) NOTE: S Turn the crankshaft clockwise. S When piston #4 is at TDC on the compression stroke, align the “I”...
Page 277 CAMSHAFTS 7. Remove: S Timing chain guide (exhaust side) 1 S Camshaft caps S Dowel pins CAUTION: To prevent damage to the cylinder head, camshafts or camshafts caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 8.
Page 278 CAMSHAFTS INSPECTION 1. Inspect: S Camshaft lobes Blue discoloration/pitting/scratches ! Re- place the camshaft. 2. Measure: S Camshaft lobe dimensions a and b Out of specification ! Replace the cam- shaft. Camshaft dimensions: Intake: <Limit>: a 32.40 mm (1.2756 in) b 24.85 mm (0.9783 in) Exhaust: <Limit>: a 32.85 mm (1.2933 in)
Page 279 CAMSHAFTS Measurement steps: S Install the camshaft into the cylinder head (without the dowel pins and camshaft caps).  S Position a strip of Plastigauge 1 onto the camshaft journal. S Install the dowel pins and camshaft caps. NOTE: S Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
Page 280 CAMSHAFTS 8. Inspect: S Timing chain tensioner Cracks/damage ! Replace. Inspection steps: S While lightly pressing the timing chain tension- er rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . S Remove the screwdriver and slowly release the timing chain tensioner rod.
Page 281 CAMSHAFTS INSTALLATION 1. Install: S Exhaust camshaft 1 S Intake camshaft 2 NOTE: Install the camshafts with the punch mark a facing up. 2. Install: S Dowel pins S Intake camshaft caps S Exhaust camshaft caps NOTE: Make sure that the punch marks a on the cam- shafts are aligned with the arrow marks b on the camshaft caps.
Page 282 CAMSHAFTS S Place the timing chain onto both camshaft sprockets and then install the camshaft sprockets onto the camshafts. NOTE: When installing the camshaft sprockets, start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the ex- haust side.
Page 283 CAMSHAFTS S Tighten the timing chain tensioner bolts 3 to the specified torque. Bolt (timing chain tensioner): 10 Nm (1.0 mSkg, 7.2 ftSlb) S Remove the screwdriver, make sure that the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. Bolt (cap): 6 Nm (0.6 mSkg, 4.3 ftSlb) S Turn the crankshaft...
Page 284: Cylinder Head
CYLINDER HEAD CYLINDER HEAD 20 Nm (2.0 mSkg, 14 ftSlb) + 121_ 20 Nm (2.0 mSkg, 14 ftSlb) + 105_ 20 Nm (2.0 mSkg, 14 ftSlb) + 140_ 12 Nm (1.2 mSkg, 8.7 ftSlb) 25 Nm (2.5 mSkg, 18 ftSlb) Order Job name/Part name Q’ty...
Page 285 CYLINDER HEAD REMOVAL 1. Remove: S Cylinder head nuts 1 S Cylinder head cap nut 2 S Cylinder head bolts 3 NOTE: S Loosen the nuts in the proper sequence as shown. S Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
Page 286 CYLINDER HEAD INSPECTION 1. Eliminate: S Carbon deposits (from the combustion chambers) Use the rounded scraper. NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: S Spark plug threads S Valve seats 2. Inspect: S Cylinder head Damage/scratches ! Replace.
Page 287 CYLINDER HEAD INSTALLATION 1. Install: S Gasket (cylinder head) S Dowel pins 2 S Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 2. Tighten: S Cylinder head nuts 1 X S Cylinder head bolts NOTE: S First, tighten the nuts 1 X to approximate- ly 20 Nm (2.0 mSkg, 15 ftSlb) with a torque wrench.
Page 288: Valves And Valve Springs
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job name/Part name Q’ty Remarks Valves and valve springs removal Remove the parts in the order listed below. Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve retainer Intake valve spring Intake valve stem seal...
Page 289 VALVES AND VALVE SPRINGS Order Job name/Part name Q’ty Remarks Exhaust valve spring Exhaust valve stem seal Exhaust valve spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure. 5-22...
Page 290 VALVES AND VALVE SPRINGS REMOVAL NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Remove: S Valve lifter 1 S Valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place.
Page 291 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment Intake valve 90890-04114, YM-4114 Exhaust valve 90890-04108, YM-4108 4. Remove: S Valve retainer 1 S Valve spring 2 S Stem seal 3 S Valve spring seat 4 S Valve 5 NOTE: Identify the position of each part very carefully...
Page 292 VALVES AND VALVE SPRINGS Replacement steps: S Remove the valve guide with a valve guide remover 1 . S Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . S After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem-valve-guide clearance.
Page 293 VALVES AND VALVE SPRINGS 6. Measure: S Valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide. S If the valve is removed or replaced, always re- place the oil seal. Valve stem runout: 0.01 mm (0.0004 in) 7.
Page 294 VALVES AND VALVE SPRINGS Lapping steps: S Apply a coarse lapping compound a to the valve face. CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. S Apply molybdenum disulfide oil onto the valve stem.
Page 295 VALVE AND VALVE SPRINGS 12. Measure: S Compressed spring force a Out of specification ! Replace the valve spring. b Installed length Compressed spring force: Intake 82 X 96 N at 34.5 mm (8.2 X 9.6 kg at 34.5 mm, 18.1 X 21.2 lb at 1.36 in) Exhaust 110 X 126 N at 35.0 mm...
Page 296 VALVES AND VALVE SPRINGS INSTALLATION 1. Deburr: S Valve stem end (with an oil stone) 2. Lubricate: S Valve stem 1 S Valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: S Valve 1 S Lower spring seat 2 S Oil seal 3 S Valve spring 4...
Page 297 VALVES AND VALVE SPRINGS 4. Install: S Valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor: 90890-04019, YM-04019 Attachment: Intake valve 90890-04114, YM-4114 Exhaust valve 90890-04108, YM-4108 5.
Page 298 A.C. MAGNETO AND STARTER CLUTCH A.C. MAGNETO AND STARTER CLUTCH A.C. MAGNETO ROTOR COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 19 Nm (1.9 mSkg, 14 ftSlb) Order Job name/Part name Q’ty Remarks A.C. magneto rotor cover removal Remove the parts in the order listed below.
Page 299 A.C. MAGNETO AND STARTER CLUTCH A.C. MAGNETO ROTOR AND STARTER CLUTCH 130 Nm (13.0 mSkg, 94 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job name/Part name Q’ty Remarks A.C. magneto rotor and starter clutch Remove the parts in the order listed below. removal A.C.
Page 300: Removal
A.C. MAGNETO AND STARTER CLUTCH REMOVAL 1. Remove: S A.C. magneto rotor bolt S Washer NOTE: S While holding the A.C. magneto rotor 1 with the sheave holder 2 , loosen the magneto ro- tor bolt. S Do not allow the sheave holder to touch the projection on the A.C.
Page 301 A.C. MAGNETO AND STARTER CLUTCH 3. Remove: S Starter clutch NOTE: S While holding the magneto rotor with the sheave holder, remove the starter clutch bolt S Do not allow the sheave holder to touch the projection on the magneto rotor. Sheave holder 90890-01701, YS-01880 4.
Page 302: Installation
A.C. MAGNETO AND STARTER CLUTCH INSTALLATION 1. Install: S Starter clutch NOTE: S While holding the magneto rotor with the sheave holder, tighten the starter clutch bolt. S Do not allow the sheave holder to touch the projection on the magneto rotor. Sheave holder 90890-01701, YS-01880-A 2.
Page 303 A.C. MAGNETO AND STARTER CLUTCH 5. Apply: S Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505  Quick gasket ACC-1100-15-01 5-36...
Page 304: Oil Pan And Oil Pump
OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job name/Part name Q’ty Remarks Oil pan and oil pump removal Remove the parts in the order listed below. Engine Refer to “ENGINE ASSEMBLY”.
Page 305 OIL PAN AND OIL PUMP Order Job name/Part name Q’ty Remarks Oil pump disassembly Disassemble the parts in the order listed below. Oil pump cover 1 Oil pump inner rotor 1 Oil pump outer rotor 1 Oil pump cover 2 Oil pump inner rotor 2 Oil pump outer rotor 2 Oil pump shaft...
Page 306: Removal
OIL PAN AND OIL PUMP REMOVAL 1. Remove: S Pipe 1 S Oil pan 2 S Oil pump NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 5-39...
Page 307: Inspection
OIL PAN AND OIL PUMP INSPECTION 1. Inspection: S Oil pump housing 1 S Oil pump cover 2 Cracks/damage/wear ! Replace the de- fective part(-s). 2. Measure: S Inner-rotor-to-outer-rotor-tip clearance a (between inner rotor 1 and outer rotor 2 ) S Outer-rotor-to-oil-pump-housing clearance (between outer rotor 2 and pump housing Out of specifications ! Replace oil pump as-...
Page 308: Installation
OIL PAN AND OIL PUMP INSTALLATION 1. Lubricate: S Inner rotor S Outer rotor S Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S Pin 1 S Inner rotor 2 S Outer rotor 3 S Housing 4 NOTE: When installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a on the...
Page 309: Crankcase
CRANKCASE CRANKCASE CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) E Tighten these bolts first. F Tighten these bolts second. Order Job name/Part name Q’ty Remarks Crankcase removal...
Page 310 CRANKCASE CONNECTING RODS AND PISTONS 20 Nm (2.0 mSkg, 14 ftSlb) + 120_ Order Job name/Part name Q’ty Remarks Connecting rods and pistons Remove the parts in the order listed below. removal Connecting rod cap Big end bearing Piston pin clip Piston pin Piston Connecting rod...
Page 311 CRANKCASE CRANKSHAFT AND COUNTER SHAFT 75 Nm (7.5 mSkg, 54 ftSlb) A This bolt has a left-hand thread. Order Job name/Part name Q’ty Remarks Crankshaft and counter shaft Remove the parts in the order listed below. removal Crankshaft Crankshaft journal bearing Drive gear Lock plate Counter shaft assembly...
Page 312: Removal
CRANKCASE REMOVAL 1. Remove: S Crankcase bolts NOTE: S Place the engine upside down. S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).
Page 313 CRANKCASE 5. Remove: S Piston pin clips 1 S Piston pin 2 S Piston 3 S Connecting rod 4 CAUTION: Do not use a hammer to drive the piston pin out. NOTE: S For reference during installation, put identifi- cation marks on the piston crown. S Before removing the piston pin, deburr the pis- ton pin clip’s groove and the piston’s pin bore area.
Page 314: Inspection
CRANKCASE INSPECTION 1. Inspect: S Piston wall and cylinder wall Vertical scratches ! Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: S Piston-to-cylinder clearance Measurement steps: 1st step: S Measure cylinder bore “C” with the cylinder bore gauge 1 .
Page 315 CRANKCASE 2nd step: S Measure piston skirt diameter “P” with the micrometer. a 5 mm (0.20 in) from the bottom edge of the piston. Piston size (standard) (P): 73.955 X 73.970 mm (2.9116 X 2.9122 in) S If out of specification, replace the piston and piston rings as a set.
Page 316 CRANKCASE 4. Install: S Piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the pis- ton crown. a 5 mm (0.20 in) 5. Measure: S End gap (piston rings) Out of specification ! Replace the piston rings as a set.
Page 317 CRANKCASE 8. Measure: S Piston pin bore inside diameter Out of specification ! Replace the piston. Piston pin bore inside diameter: 17.002 X 17.013 mm (0.6694 X 0.6698 in) 9. Calculate: S Piston pin to piston pin bore clearance Out of specification ! Replace the piston pin and piston as a set.
Page 318 CRANKCASE 11. Inspect: S Crankshaft journal surfaces S Crankshaft pin surfaces S Bearing surfaces Scratches/wear ! Replace the crankshaft. 12. Measure: S Crankshaft-journal-to-crankshaft-journal- bearing clearance Out of specification ! Replace the crank- shaft journal bearings. Crankshaft-journal-to-crankshaft- journal-bearing clearance: 0.004 X 0.028 mm (0.0002 X 0.0011 in) Measurement steps: CAUTION:...
Page 319 CRANKCASE S Install the crankshaft journal lower bearings 1 into the lower crankcase and assemble the crankcase halves. NOTE: S Align the projections a of the crankshaft jour- nal lower bearings with the notches b in the crankcase. S Do not move the crankshaft until the clearance measurement has been completed.
Page 320 CRANKCASE 13. Select: S Crankshaft journal bearings (J1 X J5) NOTE: S The numbers A stamped into the crankshaft web and the numbers B stamped into the low- er crankcase are used to determine the re- placement crankshaft journal bearing sizes. S “J1 X J5”...
Page 321 CRANKCASE Measurement steps: CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear- ance and prevent engine damage, the big end bearings must be installed in their origi- nal positions. S Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods.
Page 322 CRANKCASE S Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. S Clean the connecting rod bolts and nuts. S Tighten the connecting rod nuts. S Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3 .
Page 323 CRANKCASE 15. Select: S Big end bearings (P NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. S “P1” X “P4” refer to the bearings shown in the crankshaft illustration.
Page 324 CRANKCASE 17. Inspect: S Bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement ! Replace. 18. Inspect: S Oil seals Damage/wear ! Replace. 19. Inspect: S Primary drive gear 1 S Oil pump driven gear 2 Cracks/damage/wear ! Replace the de- fective part(-s).
Page 325: Installation
CRANKCASE INSTALLATION 1. Install: S Crankshaft journal bearing 1 (into the upper crankcase) NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the crankcase. S Be sure to install each crankshaft journal up- per bearing in its original place.
Page 326 CRANKCASE 5. Lubricate: S Piston S Piston rings S Cylinder S Crankshaft pins S Big end bearings (with the recommended lubricant) Recommended lubricant Engine oil 6. Offset: S Piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander...
Page 327 CRANKCASE 8. Align: S Bolt heads (with the connecting rod caps) 9. Tighten: S Connecting rod nuts Nut (connecting rod): 20 Nm (2.0 mSkg, 14 ftSlb)+120_ S Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method.
Page 328 Recommended lubricant Engine oil 11. Apply: S Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505, ACC-1100-15-01 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings.
Page 329 CRANKCASE 14. Install: S Crankcase bolts NOTE: S Lubricate the bolt threads with engine oil. S Tighten the bolts in increasing numerical or- der. S Install washers on bolts 1 X Crankcase bolt Bolt 1 X 1st: 15 Nm (1.5 mSkg, 11 ftSlb) 2nd: 15 Nm (1.5 mSkg, 11 ftSlb) + 45 X 50_...
Page 330 COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAPTER 2. Primary sheave assembly Refer to “PRIMARY SHEAVE AND DRIVE V-VELT”...
Page 331 COOL HEAT EXCHANGER 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Coolant pipe 2 Coolant hose 7 Coolant hose 8 Thermostat assembly Coolant hose 9 Coolant hose 10 Oil cooler outlet hose Oil cooler Oil cooler inlet hose Pipe 3 Water pump hose Carburetor heater hose...
Page 332: Heat Exchanger
COOL HEAT EXCHANGER INSPECTION 1. Inspect: S Coolant hoses S Heat exchangers S Oil cooler S Coolant pipes Cracks/damage ! Replace. 2. Measure: S Filler cap opening pressure Cap opens with a pressure below the speci- fied pressure ! Replace. Filler cap opening pressure: 95 X 125 kPa (0.95 X 1.25 kg/cm...
Page 333: Installation
COOL HEAT EXCHANGER INSTALLATION 1. Install: S Heat exchangers Use the rivet gun. 2. Install: S O-ring S Oil cooler S Lock washer S Bolt (oil cooler bolt) Bolt (oil cooler): 35 Nm (3.5 mSkg, 25 ftSlb) NOTE: S Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with a thin coat of engine oil.
Page 334: Thermostat
COOL THERMOSTAT THERMOSTAT 10 Nm (1.0 mSkg, 7.2 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job name/Part name Q’ty Remarks Thermostat disassembly Disassemble the parts in the order listed below. Thermostat housing cover Thermostat Thermostat housing Water temperature sensor For assembly, reverse the disassembly procedure.
Page 335 COOL THERMOSTAT INSPECTION 1. Inspect: S Thermostat Does not open at 71 X 85_C (160 X 185_F) ! Replace. Inspection steps: S Suspend the thermostat in a container filled with water. S Slowly heat the water. Place a thermometer in the water. S While stirring the water, observe the thermo- stat and thermometer’s indicated tempera- ture.
Page 336: Installation
COOL THERMOSTAT INSTALLATION 1. Install: S Thermostat (into the thermostat housing) NOTE: Install the thermostat with its breather hole a aligned with the this place b on the thermostat housing. 2. Install: S Thermostat cover S Bolts (thermostat housing) Bolt (thermostat housing): 10 Nm (1.0 mSkg, 7.2 ftSlb) 3.
Page 337: Water Pump
COOL WATER PUMP WATER PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job name/Part name Q’ty Remarks Water pump disassembly Disassembly the parts in the order listed below. Oil pan Refer to “OIL PAN AND OIL PUMP”. Water pump cover Plate Circlip Impeller shaft...
Page 338: Disassembly
COOL WATER PUMP DISASSEMBLY 1. Remove: S Impeller S Water pump seal 1 NOTE: Remove the water pump seal 1 from the inside of the water pump housing 2 . 2. Remove: S Bearing 1 S Oil seal 2 NOTE: Remove the bearing 1 and oil seal 2 from the inside of the water pump housing 3 .
Page 339: Inspection
COOL WATER PUMP INSPECTION 1. Inspect: S Water pump housing cover 1 S Water pump housing 2 S Impeller 3 S Rubber damper 4 S Rubber damper holder 5 S Water pump seal S Oil seal Cracks/damage/wear ! Replace. 2. Inspect: S Bearing Rough movement ! Replace.
Page 340 S Install the water pump seal 1 with the water pump seal installers 4 5 . S Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3 . Water pump seal installer: 90890-04078, YM-33221...
Page 341: Chapter 7. Carburetion
CARB CARBURETORS CARBURETION CARBURETORS 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job name/Part name Q’ty Remarks Carburetors removal Remove the parts in the order listed below. Intake silencer Fuel pump Carburetor switch (T.O.R.S.) lead Disconnect. Starter cable Throttle position sensor coupler Disconnect.
Page 342 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Carburetor separation Remove the parts in the order listed below. Carburetor heater harness Carburetor heating hose Starter plunger link Connecting bolt Spacer Fuel inlet pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Carburetor For installation, reverse the removal...
Page 343 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Carburetor disassembly Disassemble the parts in the order listed below. NOTE: The following procedure applies to all of the carburetors. Starter plunger Pilot air jet Vacuum chamber cover Piston valve spring Piston valve Jet needle holder Jet needle kit Pilot screw...
Page 344 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet Carburetor switch (T.O.R.S.) Carburetor heater Starter jet For assembly, reverse the disassembly procedure.
Page 345: Inspection
CARB CARBURETORS INSPECTION 1.Inspect: S Carburetor body S Float chamber S Jet housing Cracks/damage ! Replace. 2. Inspect: S Fuel passages Obstruction ! Clean. NOTE: S Use a petroleum based solvent for cleaning. S Blow out all passage and jets with compressed air.
Page 346 CARB CARBURETORS 8. Inspect: S Piston valve 1 Damage/scratches/wear ! Replace. S Rubber diaphragm 2 Cracks/tears ! Replace. 9. Inspect: S Vacuum chamber cover 1 S Piston valve spring 2 S Jet needle holder 3 Cracks/damage ! Replace. 10. Inspect: S Jet needle kit 1 S Starter jet 2 S Main jet 3...
Page 347: Assembly
CARB CARBURETORS ASSEMBLY NOTE: S Before assembling the carburetors, wash all of the parts in a petroleum based solvent. S Always use a new gasket and O-rings. 1. Install: S Jet needle kit S Needle jet S Pilot jet S Main jet 2.
Page 348: Installation
CARB CARBURETORS INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routing. 1. Adjust: S Carburetor synchronization Refer to “SYNCHRONIZING THE CARBU- RETORS” in CHAPTER 2. 2. Adjust: S Engine idling speed Engine idle speed: 1,350 ±...
Page 349: Fuel Lebel Adjustment
CARB CARBURETORS FUEL LEVEL ADJUSTMENT 1. Measure: S Fuel level a Out of specification ! Adjust. Fuel level (below the line on the float chamber): 3.0 X 4.0 mm (0.118 X 0.157 in) Measurement steps: S Install the fuel level gauge 1 to the fuel drain pipe 2 .
Page 350: Throttle Position Sensor
CARB CARBURETORS THROTTLE POSITION SENSOR (T.P.S.) INSPECTION AND ADJUSTMENT NOTE: Before adjusting the throttle position sensor, properly adjust the idle speed. 1. Inspect: S Throttle position sensor. Inspection steps: S Disconnect throttle position sensor coupler. S Connect the pocket tester (Ω 1k) to the throttle position sensor coupler.
Page 351 CARB CARBURETORS 2. Adjust: S Throttle position sensor position Adjustment steps: S Disconnect the throttle position sensor cou- pler. S Connect the test coupler to the throttle position sensor. S Connect three dry cells (1.5 V 3 pcs.) in se- ries to the test coupler.
Page 352: Fuel Pump
CARB FUEL PUMP INSPECTION 1. Inspect: S Fuel hose 1 S Vacuum hose 2 Clogs/damage ! Replace. 2. Inspect: S Fuel pump operation. Inspection steps: S Connect the Mity vac 1 to the vacuum hose Mity vac: 90890-06756, YB-35956 S Place a container 3 under the end of the fuel hoses 4 .
Page 353: Chapter 8. Electrical
ELEC SWITCH INSPECTION ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: 90890-03112, YU-03112 NOTE: S Set the pocket tester to “0” before starting a test.
Page 354: Ignition System
ELEC IGNITION SYSTEM...
Page 355: Circuit Diagram
ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery Engine stop switch Throttle switch Carburetor switch CDI unit ignition coil Spark plug Fuse (IGNITION)
Page 356: Troubleshooting
ELEC IGNITION SYSTEM TROUBLESHOOTING NO SPARK OR WEAK SPARK. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 357: A.c. Magneto
ELEC IGNITION SYSTEM A.C. MAGNETO 1. Disconnect: S A.C. magneto coupler 1 2. Connect: S Pocket tester (to the A.C. magneto coupler) 3. Measure: S Stator coil resistance b /pickup coil resis- tance a Out of specification ! Replace. Pickup coil resistance: (Gray –...
Page 358: Ignition Spark Gap
ELEC IGNITION SYSTEM IGNITION SPARK GAP 1. Remove: S Ignition coil 2. Measure: S Ignition spark gap Out of specification ! Replace the ignition coil Measurement steps: S Disconnect the ignition coil 2 from the spark plug. S Connect the dinamic spark tester 1 . S Set the main switch to “ON”.
Page 359: Throttle Override System (T.o.r.s.)
ELEC IGNITION SYSTEM THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should mal- function during operation, T.O.R.S. will operate when the throttle lever is released. T.O.R.S. is designed to interrupt the ignition and keep the engine revolutions between 2,800 and 3,000 r/min if the carburetor fails to return to idle when the lever is released.
Page 360: Handlebar Switch (Right)
ELEC IGNITION SYSTEM HANDLEBAR SWITCH (RIGHT) Engine stop switch and throttle switch 1. Disconnect: S Handlebar switch (right) coupler 1 2. Connect: S Pocket tester 3. Inspect: S Engine stop switch continuity Faulty ! Replace the handlebar switch (right). Switch position Continuity RUN (pulled out) OFF (pushed in)
Page 361: Main Switch
ELEC IGNITION SYSTEM MAIN SWITCH 1. Disconnect: S Main switch coupler 1 2. Connect: S Pocket tester 3. Inspect: S Main switch continuity Faulty ! Replace. Switch position Continuity Color code Switch position Br/W START Continuity MAIN RELAY 1. Inspect: S Main relay 1 Inspection steps: S Disconnect the main relay from the coupler.
Page 362: Electrical Starting System
ELEC ELECTRICAL STARTING SYSTEM 8-10...
Page 363: Troubleshooting
ELEC ELECTRICAL STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. WARNING Before starter motor operation, push the engine stop switch to “OFF”. 1. Connect: S Starter relay terminals (battery side and starter motor side) Check the battery and connectors. Refer to “BATTERY INSPECTION” in CHAP- TER 2.
Page 364: Main Switch
ELEC ELECTRICAL STARTING SYSTEM FAULTY Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the main switch. Replace the main switch. Correct the connection. MAIN SWITCH 1.
Page 365: Starter Motor
ELEC ELECTRICAL STARTING SYSTEM STARTER MOTOR 27 Nm (2.7 mSkg, 20 ftSlb) Order Job name/Part name Q’ty Remarks Starter motor disassembly Disassemble the parts in the order listed below. Starter motor removal Refer to “ENGINE REMOVAL” in CHAPTER 5. Rear bracket Bearing Starter motor yoke O-ring...
Page 366 ELEC ELECTRICAL STARTING SYSTEM Inspection 1. Inspect: S Commutator (outer surface) Dirty ! Clean with #600 grit sandpaper 1 . Hold the armature in a vise 2 and copper or aluminium plate 3 . CAUTION: Lightly grip the armature with a vise. 2.
Page 367 ELEC ELECTRICAL STARTING SYSTEM 5. Measure: S Brush length a Out of specification ! Replace the starter motor. Brush wear limit: 5 mm (0.20 in) 6. Measure: S Brush spring pressure Fatigue/out of specification ! Replace as a set. Brush spring pressure: 7.36 X 11.04 N (736 X 1,104 g, 26.0 X 38.9 oz) Assembly...
Page 368: Charging System
ELEC CHARGING SYSTEM 8-16...
Page 369: Troubleshooting
ELEC CHARGING SYSTEM TROUBLESHOOTING BATTERY IS NOT CHARGED. 1. Connect: S Pocket tester (to the battery terminals) OUT OF SPECIFICATIONS 2. Measure: S Battery voltage S Check the battery. Battery voltage: S Replace and/or charge the battery. more than 12 V at 20_C (68_F) Refer to “BATTERY INSPECTION”...
Page 370: Battery
ELEC CHARGING SYSTEM BATTERY Inspection 1. Inspect: S Battery condition Refer to “BATTERY INSPECTION” in CHAPTER 2. Battery Storage The battery should be stored if the vehicle is not going to be used for a long period. 1. Remove: S Battery WARNING When removing the battery, disconnect the negative lead first.
Page 371: Lighting System
ELEC LIGHTING SYSTEM 8-19...
Page 372: Circuit Diagram
ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery CDI unit Tail / brake light Fuse (HEADLIGHT) Fuse (SIGNAL) Fuse (IGNITION) Headlight beam switch Headlight relay Headlight Meter light Hi beam indicator light 8-20...
Page 373: Troubleshooting
ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT AND/OR METER LIGHT DO NOT COME ON. Check the bulb(s). NO CONTINUITY Replace the bulb(s). Check the main fuse, ignition fuse and headlight fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or headlight fuse.
Page 374 ELEC LIGHTING SYSTEM TAIL LIGHT DOES NOT COME ON. Check the tail/brake light bulb(s). NO CONTINUITY Replace the tail/brake light bulb(s). Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 375: Bulb(S)
ELEC LIGHTING SYSTEM BULB(S) 1. Remove: S Headlight bulb a S Tail/brake light bulb b S Meter light bulb c 2. Connect: S Pocket tester (to the bulb terminals) WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot.
Page 376: Headlight Relay
ELEC LIGHTING SYSTEM HEADLIGHT RELAY 1. Inspect: S Headlight relay (black coupler) 1 Inspection steps: S Disconnect the headlight relay from the cou- pler. S Connect the pocket tester (Ω 1) and battery (12 V) to the headlight relay terminals as shown.
Page 377: Signal System
ELEC SIGNAL SYSTEM 8-25...
Page 378: Circuit Diagram
ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery CDI unit Water temperature sensor Back buzzer Gear position switch Brake light switch Tail / brake light Fuse (SIGNAL) Fuse (IGNITION) Water temperature indicator light Multi-function meter Warning light Oil level switch...
Page 379: Troubleshooting
ELEC SIGNAL SYSTEM TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. Check the tail/brake light bulb(s). Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the tail/brake light bulbs. Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 380 ELEC SIGNAL SYSTEM WATER TEMPERATURE INDICATOR LIGHT DOES NOT COME ON. Check the water temperature indicator light bulb(s). Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb(s). Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 381 ELEC SIGNAL SYSTEM FUEL METER AND/OR WARNING LIGHT DO NOT OPERATE. Check the warning light bulb. Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb. Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 382 ELEC SIGNAL SYSTEM ENGINE OIL INDICATOR LIGHT AND/OR WARNING LIGHT DO NOT COME ON. Check the warning light bulb. Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb. Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 383 ELEC SIGNAL SYSTEM SPEEDOMETER DO NOT OPERATE. Check the speedometer unit. Refer to “SPEEDOMETER UNIT INSPECTION” in CHAPTER 2. FAULTY Replace the speedometer unit. Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 384 ELEC SIGNAL SYSTEM BACK BUZZER DOES NOT SOUND. (RX10R, RX10RS) Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 385: Brake Light Switch
ELEC SIGNAL SYSTEM BRAKE LIGHT SWITCH 1. Disconnect: S Brake light switch coupler 1 2. Inspect: S Brake light switch continuity Faulty ! Replace. Switch position Continuity Brake lever operates Brake lever does not operate GEAR POSITION SWITCH (RX10R, RX10RS) 1.
Page 386: Water Temperature
ELEC SIGNAL SYSTEM WATER TEMPERATURE SENSOR 1. Disconnect the water temperature sensor coupler 1 and remove the water tempera- ture sensor. CAUTION: Handle the water temperature sensor with special care. Never subject it to shock or al- low it to be dropped. If it is dropped, it must be replaced.
Page 387: Engine Oil Level Switch
ELEC SIGNAL SYSTEM ENGINE OIL LEVEL SWITCH 1. Remove: S Oil level gauge 1 2. Connect: S Pocket tester (to the oil level switch coupler) 3. Inspect: S Oil level switch continuity Faulty ! Replace. Switch Good position condition condition Down position Up position f : Continuity...
Page 388: Speed Sensor
ELEC SIGNAL SYSTEM SPEED SENSOR 1. Inspect: S Speed sensor Inspection steps: S Connect the pocket tester (DC 20 V) to the speed sensor coupler 1 (wire harness side) as shown. Positive tester probe ! White Negative tester probe ! Black/Green Positive battery terminal ! Blue/Yellow Negative battery terminal ! Black/Green S Elevate the track and slowly rotate it.
Page 389: Grip Warmer System
ELEC GRIP WARMER SYSTEM 8-37...
Page 390: Circuit Diagram
ELEC GRIP WARMER SYSTEM GRIP WARMER SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery Grip warmer Thumb warmer CDI unit Grip warmer switch Thumb warmer switch Fuse (SIGNAL) Fuse (IGNITION) Multi-function meter 8-38...
Page 391: Troubleshooting
ELEC GRIP WARMER SYSTEM TROUBLESHOOTING GRIP WARMER AND THUMB WARMER DO NOT OPERATE. Check the main fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 392: Grip And Thumb Warmer Coil
ELEC GRIP WARMER SYSTEM GRIP AND THUMB WARMER COIL 1. Disconnect: S Grip warmer leads 1 S Thumb warmer coupler 2 2. Connect: S Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads) 3. Inspect: S Grip warmer 1 continuity S Thumb warmer 2 continuity No continuity ! Replace both grips together or separately and/or the handlebar switch.
Page 393: Grip Warmer Switch
ELEC GRIP WARMER SYSTEM GRIP WARMER SWITCH 1. Disconnect: S Grip warmer switch coupler 1 2. Connect: S Pocket tester (to the switch coupler) 3. Inspect: S Grip warmer switch continuity Switch is operated. Faulty ! Replace the handlebar switch (left).
Page 394: Carburetor Heater System
ELEC CARBURETOR HEATER SYSTEM 8-42...
Page 395: Circuit Diagram
ELEC CARBURETOR HEATER SYSTEM CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery Carburetor heater relay Carburetor heater CDI unit Water temperature sensor Fuse (SIGNAL) Fuse (CARBURETOR HEATER) Fuse (IGNITION) 8-43...
Page 396: Troubleshooting
ELEC CARBURETOR HEATER SYSTEM TROUBLESHOOTING CARBURETOR HEATER DO NOT OPERATE. Check the main fuse, signal fuse, carburetor heater fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or signal fuse, and/or carburetor heater fuse and/or ignition fuse.
Page 397: Carburetor Heater Relay
ELEC CARBRETER HEATER SYSTEM CARBURETOR HEATER RELAY 1. Inspect: S Carburetor heater relay 1 Inspection steps: S Disconnect the carburetor heater relay from the coupler. S Connect the pocket tester (Ω 1) and battery (12 V) to the carburetor heater relay terminals as shown.
Page 398: Self-Diagnosis
ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS This model features a self-diagnosing system for following displays. 1. Fuel meter, fuel level warning indicator 1 and the warning light 4 2. Coolant temperature warning light 2 and the warning light 4 3. Self-diagnosis warning indicator 3 and the warning light 4 NOTE: The oil level warning indicator and the warning light come on when the engine oil level is low.
Page 399: Coolant Temperature Warning Light And The Warning Light
ELEC SELF-DIAGNOSIS 2. COOLANT TEMPERATURE WARNING LIGHT AND THE WARNING LIGHT The coolant temperature warning light and the warning light faults are displayed as follows S Thermo sensor Item Thermo sensor Condition Disconnected Short-circuit 3. SELF-DIAGNOSIS WARNING INDICATOR AND THE WARNING LIGHT The self-diagnosis warning indicator and the warning light faults are displayed as follows S Throttle position sensor (T.P.S.) S Variable resistor (grip and thumb warmer)
Page 400 ELEC ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS Item Grip warmer Condition Short-circuit Item Thumb warmer switch Condition Disconnected Item Thumb warmer Condition Short-circuit Item Voltage Condition Wrong Warning light ON Warning light OFF s Time (second) 8-48...
Page 401: Chapter 9. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Model code number: 8FA1 (RX10 for U.S.A/Canada) 8EU1 (RX10S for U.S.A/Canada) 8ER1 (RX10R for U.S.A/Canada) 8EW1 (RX10RS for U.S.A/Canada) 8EP1 (RX10M for U.S.A/Canada) 8EV1 (RX10MS for U.S.A/Canada) 8FA2 (RX10 for Europe) 8ER2 (RX10R for Europe) 8EW2 (RX10RS for Europe)
Page 402 SPEC GENERAL SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Oil filter: Oil filter type Cartridge (paper) Drive chain housing oil: Type Gear oil API “GL-3” SAE#75 or #80 Capacity 0.25 L (8.8 lmp oz, 8.5 US oz) Coolant: Capacity 4.7 L (4.1 lmp qt, 5.0 US qt) Fuel: Type...
Page 403 SPEC GENERAL SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Track: Track type Internal drive type Track width 381 mm (15.0 in) Length on ground 752 mm (29.6 in) (RX10, RX10S, RX10R, RX10RS) 1,071 mm (42.2 in) (RX10M, RX10MS) 25 X 30 mm (0.98 X 1.18 in) Track deflection mm/ 100 N (10 kg, 22 lb) Brake:...
Page 404: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Cylinder head: 13.45 X 14.00 cm (0.82 X 0.85 cu. in) Volume (with spark plug) <Warpage limit> 0.1 mm (0.004 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating 74.000 X 74.010 mm (2.9134 X 2.9138 in)
Page 405 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Valve dimensions: Valve head diameter A 22.9 X 23.1 mm (0.9016 X 0.9094 in) Intake 24.4 X 24.6 mm (0.9606 X 0.9685 in) Exhaust Head Diameter Valve face width B 1.76 X 2.90 mm (0.0693 X 0.1142 in) Intake 1.76 X 2.90 mm (0.0693 X 0.1142 in)
Page 406 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Valve spring: Free length Intake 38.90 mm (1.53 in) Exhaust 40.67 mm (1.60 in) Installed length (valve closed) Intake 34.50 mm (1.36 in) Exhaust 35.00 mm (1.38 in) Compressed spring force (installed) 82 X 96 N (8.2 X 9.6 kg, 18.1 X 21.2 lb) Intake...
Page 407 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Piston pin: 16.991 X 17.000 mm (0.6689 X 0.6693 in) Piston pin outside diameter 51.4 X 51.5 mm (2.0236 X 2.0276 in) Piston pin length 0.002 X 0.022 mm (0.00008 X 0.0009 in) Piston pin to piston pin bore clearance <Limit>...
Page 408 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Carburetor: Type/Quantity BSR37/4 Manufacturer MIKUNI I.D. mark 8FA100 Main jet (M.J) #135 Main air jet (M.A.J) #120 Jet needle (J.N) Ab-3 Needle jet (N.J) Pilot jet (P.J) #17.5 Pilot air jet (P.A.J.1) (P.A.J.2) #125...
Page 409: Power Train
SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Transmission: Type V-belt automatic 3.8 X 1.0 : 1 Range of ratio 3,600 ± 200 r/min (3,400 X 3,800 r/min) Engagement speed r/min (RX10, RX10S, RX10R, RX10RS) 4,200 ± 200 r/min (4,000 X 4,400 r/min) (RX10M, RX10MS) 10,250 ±...
Page 410 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Secondary sheave spring: Part number 90508-60012 (RX10, RX10S, RX10R, RX10RS) 90508-60007 (RX10M, RX10MS) Color code PINK (RX10, RX10S, RX10R, RX10RS) White (RX10M, RX10MS) Outside diameter 69.5 mm (2.736 in) Wire diameter 6 mm (0.236 in) Hole position Sheave side-spring side (twist angle)
Page 411 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Slide rail suspension (Rear suspension): Center travel 221 mm (8.70 in) (RX10, RX10S, RX10R, RX10RS) 188 mm (7.40 in) (RX10M, RX10MS) Rear travel 298 mm (11.73 in) (RX10, RX10S, RX10R, RX10RS) 237 mm (9.33 in) (RX10M, RX10MS) Suspension spring rate Front...
Page 412 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Slide runner: Thickness 17.8 mm (0.70 in) Wear limit 10 mm (0.39 in) Track sprocket wheel: Material High molecular weight polyethylene Number of teeth 9 T (RX10, RX10S, RX10R, RX10RS) 8 T (RX10M, RX10MS) Rear guide wheel: Material...
Page 413: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Frame: Frame material Aluminum Seat height 738 mm (29.1 in) Luggage box location Front Steering: Lock-to-lock angle (left) 30.0_ (R ski) 34.7_ (L ski) (right) 34.7_ (R ski) 30.0_ (L ski) Ski alignment Toe-out 0 X 15 mm (0 X 0.59 in)
Page 414: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5_ at 1,450 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T54973 /MITSUBISHI 0.16 X 0.22 Ω at 20_C (68_F) Primary coil resistance 5.0 X 6.8 kΩ...
Page 415 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Starter relay: Model/Manufacturer MS5F-441/JIDECO Amperage rating 180 A 4.2 X 4.6 Ω at 20_C (68_F) Coil resistance T.P.S. (throttle position sensor): Model/Manufacturer TS67/02-1C/MIKUNI 4 X 6 KΩ at 20_C (68_F) Resistance (Blue –...
Page 416: High Altitude Settings
SPEC HIGH ALTITUDE SETTINGS HIGH ALTITUDE SETTINGS RX10, RX10S, RX10R, RX10RS Tempera- –40_C –20_C 16_C ture (–40_F) Idling speed (r/min) (–4_F) (32_F) (60_F) Altitude 0 X 200 m #140 #137.5 #135 (0 X 670 ft) 1350 200 X 1000 m #137.5 #135 #132.5...
Page 417 SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Spark plug Cylinder head nut (M10 1.25) 20 + 121_ 2.0 + 121_ 14 + 121_ Cylinder head nut (M10 1.25) 20 + 105_ 2.0 + 105_...
Page 418: Tightening Torque
SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Fuel pump Fuel pump stay NOTE: 1. First, tighten the bolt to approximately 15 Nm (1.5 mSkg, 11 ftSlb) with a torque wrench, then loosen the bolt completely.
Page 419: Power Train
SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Primary sheave (1st) Tighten the bolt in two (2nd) stages. See NOTE. Spider and sliding sheave 20.0 Left-hand thread.  Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave...
Page 420 SPEC TIGHTENING TORQUE Tightening torque Parts be tightened Parts be tightened Remarks Remarks mSkg ftSlb  Wheel bracket shaft and sliding frame Apply LOCTITE Set bolt (front axle) Speed sensor Gear unit (speed sensor) NOTE: Tightening steps: 1. Tighten the bolt to a torque at 155 Nm (15.5 mSkg, 112 ftSlb). 2.
Page 421 SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Handlebar holder Steering column Upper Lower Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod...
Page 422: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (nut) (bolt) (bolt) This chart specifies torque for standard fasteners mSkg ftSlb with standard I.S.O. pitch threads. Torque speci- 10 mm 6 mm fications for special components or assemblies 12 mm 8 mm are included in the applicable sections of this...
Page 423: Cable Routing
SPEC CABLE ROUTING 9-23...
Page 424 SPEC CABLE ROUTING 1 To the headlight and meter as- sembly Battery negative lead Battery positive lead Oil level switch lead coupler Oil level switch Carburetor switch lead connec- Coolant temperature sensor lead coupler To the brake caliper To the heat exchanger Main switch Joint connector Tail/ brake light lead coupler...
Page 425 SPEC CABLE ROUTING 9-25...
Page 426 SPEC CABLE ROUTING Connect the battery negative lead to the starter motor mount- ing bolt Voltage regulator Relay Back buzzer (RX10R, RX10RS) Bolt Battery negative lead Clamp the vacuum hose to the coolant hose Clamp the ignition coil lead to the frame Route the fuel hose under the clamp...
Page 427 SPEC CABLE ROUTING 9-27...
Page 428 SPEC CABLE ROUTING 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securety fit in the rubber cover) 9-28...
Page 429 SPEC CABLE ROUTING 9-29...
Page 430 SPEC CABLE ROUTING 1 Do not clamp the throttle cable Throttle cable Handlebar holder All leads and cables except brake hose and parking brake cable Clamp the tail / brake light lead, headlight beam switch lead and grip warmer lead Parking brake cable Left handlebar switch Brake hose and parking brake...
Page 431 SPEC CABLE ROUTING 9-31...
Page 432 SPEC CABLE ROUTING Right handlebar switch Clamp the wire harness only Clamp the fuel sender head and speed sensor lead Less than 50 mm (2.0 in) Clamp the wire harness Route the carburetor air vent hose under the fuel hose Push into the end of clamp be- tween frame and fuel tank Breather tank...
Page 433 SPEC CABLE ROUTING 9-33...
Page 434 SPEC CABLE ROUTING Coolant reservoir tank Reservoir tank hose Parking brake cable Brake hose Clamp the hose at the white paint position. Point the clamp position to the front outside Clamp the battery positive lead Headlight lead Tighten the frame ground and voltage regulator upper bolt to- gether Engine oil tank hose...
Page 435 SPEC CABLE ROUTING 9-35...
Page 436 SPEC CABLE ROUTING 1 Fuel pump Coolant reservoir tank Point the pawl of clip to the up- ward Clamp the fuel tank breather and speed sensor lead. Thigh- ten the frame cross member and frame together Wire harness clamp Rivets Speed sensor Point the pawl of clip to the downward...
Page 437 SPEC CABLE ROUTING 9-37...
Page 438 SPEC CABLE ROUTING 1 CDI unit Battery negative lead Starter motor Position the negative lead on the engine at 45_ Battery positive lead CDI unit bracket Battery band Battery cover To the carburetor Equip it with the frame cross member Wire harness holder Battery bracket Battery seat...
Page 439 1 A.C. magneto 2 Rectifier / regulator 3 Main switch 4 Main relay 5 Fuse (MAIN) 6 Starter relay 7 Starter motor 8 Battery 9 Engine stop switch 10 Throttle switch 11 Carburetor switch 12 Carburetor heater relay 13 Carburetor heater 14 Grip warmer 15 Thumb warmer 16 CDI unit...
Page 440 01. 05 PRINTED ON RECYCLED PAPER...
Page 442 (LIT-12618-02-28) ing or repairing the snowmobile. NOTICE CAUTION: This manual was written by the Yamaha Motor A CAUTION indicates special precautions that Company primarily for use by Yamaha dealers must be taken to avoid damage to the snowmo- and their qualified mechanics. It is not possible bile.
Page 443 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. POWR 1 General information CHAS 2 Periodic inspections and adjustments 3 Chassis 4 Power train 5 Engine COOL 6 Cooling system...
Page 444 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTIONS AND INSP ADJUSTMENTS CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 445 CHAPTER 1. INSTALLATION ....GENERAL INFORMATION CHAPTER 5. SPECIAL TOOLS ..... . ENGINE FOR TUNE UP .
Page 446: Special Tools
SPECIAL TOOLS SPECIAL TOOLS INFO INFO SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent dam- age that can be caused by the use of improper tools or improvised techniques.
Page 447: Chapter 2. Periodic Inspection And Adjustment
Drive track and idler Check deflection, and for wear and damage. wheels *Adjust / replace if necessary. Check for wear and damage. Slide runners Slide runners *Replace if necessary. * It is recommended that these items be serviced by a Yamaha dealer.
Page 448 Tool kit and recommended Check for proper placement. equipment * It is recommended that these items be servised by a Yamaha dealer. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required.
Page 449: Power Train
INSP PARKING BRAKE ADJUSTMENT POWER TRAIN PARKING BRAKE ADJUSTMENT 1. Measure: S Parking brake cable distance a Out of specification ! Adjust. Parking brake cable distance: 43.5 X 46.5 mm (1.713 X 1.831 in) 2. Adjust: S Parking brake cable Adjustment steps: S Loosen the locknut 1 S Turn the adjuster 2 in or out until the specified...
Page 450: Chassis
INSP LUBRICATION CHASSIS LUBRICATION Brake lever, throttle lever and throttle cable 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables. Recommended lubricant: ESSO Beacon 325 Grease WARNING Apply a dab of grease onto only the end of the cables.
Page 451: Tuning
INSP CLUTCH TUNING G Green P Pink W White CLUTCH S Silver Y Yellow High altitude X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft)
Page 452 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the de- sired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the en- gine speed at which the machine first begins to move from a complete stop.
Page 453: Gear Selection
INSP GEAR SELECTION 1 Chain and sprocket part number Parts name Teeth & links Parts no. Standard 20 teeth 8FA-17682-00 21 teeth 8FA-17682-10 Drive sprocket 22 teeth 8FA-17682-20 23 teeth 8FA-17682-30 RXW10J, RXW10SJ 24 teeth 8FA-17682-40 38 teeth 8FB-47587-80 RXW10J, RXW10SJ Driven sprocket 39 teeth 8FB-47587-90...
Page 454 INSP GEAR SELECTION 5 Torque cam (secondary spring seat) Identification mark Effects Part no. Cam angle Identification mark Standard Quicker upshifting RXW10J, 8FA-17604-00 51-43_ 8BVFA during acceleration RXW10SJ 8BV-17604-71 8BV71 8BV-17604-51 8BV51 8BV-17604-31 8BV31 Quicker 8BV-17604-11 8BV11 backshifting backshifting 8BV-17604-91 8BV91 under load...
Page 455 INSP GEAR SELECTION 6 Primary spring Spring identification color code Spring rate color Preload color Spring rate Wire Outside Free Preload Color No. of Standard Parts No. N / mm gauge diameter length N (kg) coils (kg / mm) mm (in) mm (in) mm (in) 90501-551L3...
Page 456 INSP GEAR SELECTION 7 Clutch weight Weight g (oz) Parts no. without bush Shape & ID mark Standard and rivets 35.32 8CH-17605-10 (1.247) 38.09 8CR-17605-10 (1.345) 34.26 8DG-17605-00 (1.209) 37.77 8DJ-17605-00 (1.333) 42.09 8DN-17605-20 (1.486) 39.00 8EK-17605-00 (1.376) 63.8 8FA-17605-00 (2.25)
Page 457 INSP GEAR SELECTION 7 Clutch weight Weight g (oz) Parts no. without bush Shape & ID mark Standard and rivets 39.76 8DN-17605-10 (1.40) 63.8 RXW10J, 8FA-17605-10 (2.25) RXW10SJ...
Page 458 INSP GEAR SELECTION 8 Weight rivets Length Weight Parts No. Material Standard Effects mm (in) g (oz) Increased 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) IN: RXW10J, RXW10SJ Force 3.6 (0.127) 90269-06006 Steel 17.2 (0.677) OUT: RXW10J, RXW10SJ with hole 90261-06019 Steel 13.3 (0.524) 3.1 (0.109)
Page 459: Front Suspension
INSP FRONT SUSPENSION/REAR SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: S Spring preload Adjustment steps: S Turn the spring seat 1 in or out. Spring seat Standard Shorter z ! Longer distance Harder z ! Softer Preload Min. Max. Length 248 mm 258 mm 258 mm...
Page 460: Rear Suspension
INSP REAR SUSPENSION Adjustment steps: S Loosen the locknut 1 . S Turn the adjusting nut 2 in or out to adjust the stopper band tension. 15 ± 0.5 mm (0.59 ± 0.02 in) Adjuster thread Maximum: 35 mm (1.37 in) length Minimum: 10 mm (0.40 in) Effects...
Page 461 INSP REAR SUSPENSION Control rod 1. Check S Control rod bolt a Bolt (control rod bolt): 32 Nm (3.2 mSkg, 23 ftSlb) 2. Adjust: S Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: S Loosen the lock nut 1 .
Page 462: Chapter 3. Chassis
CHAS STEERING CHASSIS STEERING INSTALLATION 1. Install: S Relay arms 1 S Bushings S Washers 2 Bolt (relay arm): 67 Nm (6.7 mSkg, 49 ftSlb) S Clips 3 2. Install: S Idler arm 4 S Bushings S Washers S Relay rod 5 Nut (idler arm): 35 Nm (3.5 mSkg, 25 ftSlb) Nut (relay rod):...
Page 463 CHAS STEERING 5. Install: S Tie rods 1 NOTE: S Make sure that the indentation a on the tie rod faces out. S The threads on both rod ends must be the same length. CAUTION: Always use new cotter pins. Locknut (rod end): 25 Nm (2.5 mSkg, 18 ftSlb) ...
Page 464 CHAS STEERING 7. Adjust: S Handlebar Adjustment steps: S Temporarily install the handlebar. S Install the steering linkage alignment plate Steering linkage alignment plate 90890-01487, YS-01487 S Loosen the locknuts (steering shaft) 1 . S Turn the steering shaft 2 clockwise or coun- terclockwise and then secure the handle bar in the straight position.
Page 465 CHAS STEERING 9. Install: S Handlebar CAUTION: S Be sure the projection on the handlebar is not installed into the area a shown. S Be sure the side of the holder with the small gap b faces forward. b = 0 mm (0 in) S First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.
Page 466: Front Suspension
CHAS FRONT SUSPENSION FRONT SUSPENSION 45 Nm (4.5 mSkg, 33 ftSlb) 37 Nm (3.7 mSkg, 27 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 65 Nm (6.5 mSkg, 47 ftSlb) 34 Nm (3.4 mSkg, 25 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 467 CHAS FRONT SUSPENSION 45 Nm (4.5 mSkg, 33 ftSlb) 37 Nm (3.7 mSkg, 27 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 65 Nm (6.5 mSkg, 47 ftSlb) 34 Nm (3.4 mSkg, 25 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order...
Page 468: Chapter 4. Power Train
POWR SECONDARYSHAFT POWER TRAIN SECONDARYSHAFT Order Job name/Part name Q’ty Remarks Secondary shaft removal Remove the parts in the order listed below. Secondary sheave Refer to “SECONDARY SHEAVE”. Drive chain housing Refer to “DRIVE CHAIN HOUSING”. Collar nut Collar Circlip Secondary shaft Bearing For installation, reverse the removal...
Page 469: Removal
POWR POWR SECONDARYSHAFT SECONDARYSHAFT REMOVAL 1. Remove: S Drive chain housing parts Refer to “DRIVE CHAIN HOUSING WITH REVERSE MODEL” in CHAPTER 4 S Secondary sheave assembly Refer to “SECONDARY SHEAVE” in CHAP- TER 4 2. Install: S Secondary shaft slide & holder 2 A Outside B Inside NOTE:...
Page 470: Inspection
POWR SECONDARYSHAFT INSPECTION 1. Inspect: S Secondary shaft 1 Scratches (excessive)/damage ! Replace. S Splines 2 Wear/damage ! Replace the secondary shaft. S Bearing contact surface 3 Scratches/wear/damage ! Replace the secondary shaft. 2. Inspect: S Bearing 1 Pitting/damage ! Replace. NOTE: When install the bearing 1 , larger side of the in- ner race 2 is outside of the frame.
Page 471: Installation
POWR SECONDARYSHAFT INSTALLATION 1. Install S Drive chain housing parts Refer to “DRIVE CHAIN HOUSING WITH REVERSE MODEL” in CHAPTER 4. 2. Install: S Bearing collar nut 1 S Secondary shaft 2 A Engine side B Secondary clutch side 3. Install: S Drive gear socket 3 Drive gear socket 90890–01490, YU–01490...
Page 472 POWR SECONDARYSHAFT 7. Install: S Secondary sheave mounting bolt 7 NOTE: S Use the secondary sheave mounting bolt 7 and washer which tighten the secondary clutch. 8. Tighten: S Secondary sheave mounting bolt 7 Secondary sheave mounting bolt 30 NSm (3.0 mSkg, 22 ftSlb) 9.
Page 473: Brake
POWR BRAKE BRAKE 30 Nm (3.0 mSkg, 22 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) Order Job name/Part name Q’ty Remarks Brake caliper and parking brake Remove the parts in the order listed below. removal Brake fluid Drain.
Page 474: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Left side cover Refer to “PRIMARY SHEAVE AND DRIVE VELT”.
Page 475 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 mSkg, 2.9 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 476 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Suspension wheel Collar Wheel bracket Circlip Suspension wheel Collar...
Page 477 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear shock absorber Collar Bushing Pull rod Collar Bushing Collar Suspension wheel Control rod Bushing...
Page 478 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear pivot arm Bushing Shaft Shaft Rear pivot arm bracket...
Page 479 POWR SLIDE RAIL SUSPENSION INSTALLATION Control rod parts number Control rod 1 Length mm (in) Length mm (in) Length mm (in) 2.5P 3 = 7.5 RXW10J, RXW10SJ 303.5(11.95) 160.0(6.30) (0.098P 3 = 0.295) Washer plate parts number Control rod 1 Control rod 2 Washer plate thickness mm (in) parts number...
Page 480: Chapter 5. Engine
ENGINE ASSEMBLY ENGINE ENGINE ASSEMBLY INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routing. 1. Install: S Engine mounting adjust bolts S Engine S Engine mounting bolts and nuts NOTE: S Use the pivot shaft wrench to tighten the en- gine mounting adjust bolts.
Page 481 ENGINE ASSEMBLY 2. Fill: S Coolant Refer to “COOLING SYSTEM” in CHAPTER 3. Fill: S Engine oil Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 2.
Page 482: Carburetors
CARB CARBURETORS CARBURETORS Order Job name/Part name Q’ty Remarks Carburetor separation Remove the parts in the order listed below. Carburetor heater harness Carburetor heating hose Starter plunger link Connecting bolt Spacer Fuel inlet pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Carburetor...
Page 483 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Carburetor disassembly Disassemble the parts in the order listed below. Starter plunger NOTE: Pilot air jet The following procedure applies to all of Vacuum chamber cover the carburetors. Piston valve spring Piston valve Jet needle holder Jet needle kit Pilot screw...
Page 484 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet Carburetor switch (T.O.R.S.) Carburetor heater Starter jet For assembly, reverse the disassembly procedure.
Page 485: Chapter 9. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model RXW10J, RXW10SJ Model code number: 8FG1 (for U.S.A./Canada) 8FH1 (for U.S.A./Canada) 8FG2 (for Europe) 8FH2 (for Europe) Dimensions: Overall length 3,000 mm (118.1 in) Overall width 1,210 mm (47.6 in) Overall height 1,190 mm (46.9 in) Weight: Dry weight 264 kg (581 lb)
Page 486 SPEC GENERAL SPECIFICATIONS Model RXW10J, RXW10SJ Carburetors: BSR37 4 Type/Quantity Manufacture MIKUNI Spark plug: Type CR9E Manufacture 0.7 X 0.8 mm (0.028 X 0.031 in) Primary reduction: Primary reduction system Spur gear Primary reduction ratio 1.19 (37/31) Transmission: Primary reduction system V-Belt 3.8 : 1 X 1 : 1 Primary reduction ratio...
Page 487: Camshafts
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model RXW10J, RXW10SJ Cylinder head: 13.45 X 14.00 cm (0.82 X 0.85 cu. in) Volume (with spark plug) <Warpage limit> 0.1 mm (0.004 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating 74.000 X 74.010 mm (2.9134 X 2.9138 in) Bore size <Taper limit>...
Page 488 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Valve dimensions: Valve head diameter A 22.9 X 23.1 mm (0.9016 X 0.9094 in) Intake 24.4 X 24.6 mm (0.9606 X 0.9685 in) Exhaust Head Diameter Valve face width B 1.76 X 2.90 mm (0.0693 X 0.1142 in) Intake 1.76 X 2.90 mm (0.0693 X 0.1142 in) Exhaust...
Page 489 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Valve spring: Free length Intake 38.90 mm (1.53 in) Exhaust 40.67 mm (1.60 in) Installed length (valve closed) Intake 34.50 mm (1.36 in) Exhaust 35.00 mm (1.38 in) Compressed spring force (installed) 82 X 96 N (8.2 X 9.6 kg, 18.1 X 21.2 lb) Intake 110 X 126 N Exhaust...
Page 490 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Piston pin: 16.991 X 17.000 mm (0.6689 X 0.6693 in) Piston pin outside diameter 51.4 X 51.5 mm (2.0236 X 2.0276 in) Piston pin length 0.002 X 0.022 mm (0.00008 X 0.0009 in) Piston pin to piston pin bore clearance <Limit>...
Page 491 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Carburetor: Type/Quantity BSR37/4 Manufacturer MIKUNI I.D. mark 8FA101 Main jet (M.J) #135 Main air jet (M.A.J) #120 Jet needle (J.N) 5DHP50 - 53 - 3 Needle jet (N.J) Pilot jet (P.J) #17.5 Pilot air jet (P.A.J.1) #140 Pilot outlet...
Page 492: Power Train
SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model RXW10J, RXW10SJ Transmission: Type V-belt automatic 3.8 X 1.0 : 1 Range of ratio 3,600 ± 200 r/min (3,400 X 3,800 r/min) Engagement speed r/min 10,250 ± 250 r/min (10,000 X 10,500 r/min) Shift r/min 268.5 ±...
Page 493 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Secondary sheave spring: Part number 90508-60007 Color code White Outside diameter 69.5 mm (2.736 in) Wire diameter 6 mm (0.236 in) Hole position Sheave side-spring side (twist angle) 3-3 (60_) Spring rate 13.45 N/mm (1.372 kg/mm, 76.84 lb/in) Number of coils 5.19 Free length...
Page 494 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Suspension setting position: 15 ± 0.5 mm (0.59 ± 0.02 in) Hook setting length *(Standard) (Maximum) 35 mm (1.37 in) (Minimum) 10 mm (0.40 in) Full rate adjusting position ** Shock absorber: Damping force Center Extension 910 N/0.3 m/s (93 kg/0.3 m/s, 204 lb/0.3 m/s)
Page 495: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model RXW10J, RXW10SJ Frame: Frame material Aluminum Seat height 680 mm (26.8 in) Luggage box location Front Steering: Lock-to-lock angle (left) 30.0_ (R ski) 34.7_ (L ski) (right) 34.7_ (R ski) 30.0_ (L ski) Ski alignment Toe-out 0 X 15 mm (0 X 0.59 in) Toe-out size...
Page 496: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model RXW10J, RXW10SJ Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5_ at 1,350 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T54973 /MITSUBISHI 0.16 X 0.22 Ω at 20_C (68_F) Primary coil resistance 5.0 X 6.8 kΩ at 20_C (68_F) Secondary coil resistance Charging system: Type...
Page 497 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Starter relay: Model/Manufacturer MS5F-441 /JIDECO Amperage rating 180 A 4.2 X 4.6 Ω at 20_C (68_F) Coil resistance T.P.S. (throttle position sensor): Model/Manufacturer TS67/02-1C/MIKUNI 4 X 6 KΩ at 20_C (68_F) Resistance (Blue – Black) 0 X 4 KΩ...
Page 498: High Altitude Settings
SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS Tempera- –40_C –20_C 16_C ture (–40_F) (–4_F) (32_F) (60_F) Idling speed (r/min) Altitude 0 X 200 m #140 #137.5 #135 (0 X 670 ft) 1350 200 X 1000 m #137.5 #135 #132.5 1350 (X 3300 ft) 1000 X 2000 m #135 #132.5...
Page 499: Tightening Torque
SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Spark plug 20 + 121_ 2.0 + 121_ 14 + 121_ Cylinder head nut (M10 1.25) Cylinder head nut (M10 1.25) 20 + 105_ 2.0 + 105_...
Page 500 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Fuel pump Fuel pump stay NOTE: 1. First, tighten the bolt to approximately 15 Nm (1.5 mSkg, 11 ftSlb) with a torque wrench, then loosen the bolt completely.
Page 501: Power Train
SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Primary sheave (1st) Tighten the bolt in two (2nd) stages. See NOTE. Spider and sliding sheave 20.0 Left-hand thread.  Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave...
Page 502 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb  Wheel bracket shaft and sliding frame Apply LOCTITE Set bolt (front axle) Speed sensor Gear unit (speed sensor) Bearing nut NOTE: Tightening steps: 1.
Page 503: Chassis
SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Handlebar holder Steering column (Upper) Steering column (Lower) Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod...
Page 504: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (nut) (bolt) (bolt) This chart specifies torque for standard fasteners mSkg ftSlb with standard I.S.O. pitch threads. Torque speci- 10 mm 6 mm fications for special components or assemblies 12 mm 8 mm are included in the applicable sections of this...
Page 505: Cable Routing
SPEC CABLE ROUTING...
Page 506 SPEC CABLE ROUTING CABLE ROUTING To the headlight and meter as- sembly Clamp the lead at the position of white tape. Battery positive lead Battery negative lead Main harness Negative lead connector Carburetor heater lead coupler Oil level switch lead coupler Oil level switch Starter motor positive lead (un- der the battery bracket)
Page 507 SPEC CABLE ROUTING...
Page 508 SPEC CABLE ROUTING Brake hose Fuel sender lead coupler Set the coupler in the rear space of the instrument panel Clamp the ignition coil lead un- der the fuel hose. Clamp the fuel hose. There should be no slack of leads.
Page 509 SPEC CABLE ROUTING...
Page 510 SPEC CABLE ROUTING 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Clamp 1 Clamp Meter coupler (Securely fit in the rubber cover)
Page 511 SPEC CABLE ROUTING...
Page 512 SPEC CABLE ROUTING 1 Right handlebar switch Clamp the main harness, main switch and harness. Clamp the grip warmer lead and the right handlebar switch lead. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Ex- cept for brake hose and parking brake cable.) Clamp the tail / brake light lead,...
Page 513 SPEC CABLE ROUTING...
Page 514 SPEC CABLE ROUTING Carburetor air vent hose To the parking brake. To the brake caliper Brake hose Clamp the wire harness and fuel tank breather hose from the top. Less than 50 mm (2.0 in). Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side.
Page 515 SPEC CABLE ROUTING...
Page 516 SPEC CABLE ROUTING Headlight wire harness Tighten the frame ground and voltage regulator upper bolt to- gether. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through be- tween engine and heat ex- changer.
Page 517 SPEC CABLE ROUTING...
Page 518 SPEC CABLE ROUTING 1 Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the up- ward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross mem- ber and frame. Wire harness clamp Rivets Speed sensor Nylon nuts...
Page 519 SPEC CABLE ROUTING...
Page 520 SPEC CABLE ROUTING 1 Starter motor Battery positive lead CDI unit Battery negative lead Air box drain hose Battery band Battery cover 0 X 5 mm (0 X 0.20 in) Wire harness Plate cover Clip it to the frame cross mem- To the carburetor.
Page 521 1 A.C. magneto 2 Rectifier / regulator 3 Main switch 4 Main relay 5 Fuse (MAIN) 6 Starter relay 7 Starter motor 8 Battery 9 Engine stop switch 10 Throttle switch 11 Carburetor switch 12 Carburetor heater relay 13 Carburetor heater 14 Grip warmer 15 Thumb warmer 16 CDI unit...
Page 523 WIRING DIAGRAM RXW10J, RXW10SJ - L/R G/B Sb Y/B G Y/G Lg/B Lg/B R/B G/R - W/R - B/L Y/L L/R Lg/W G G/R - Br/Y Y/B Lg/B Y/G B/W B - - - - - - - W/G - - B/Y Y/W W/Y L Lg/L L/R Br/W Lg Y/R Sb Br/W B/R B/W - Y W Gy O SUB-WIRE SUB-WIRE SUB-WIRE...

This manual is also suitable for:

Rx10rsk Rx10rk Rx10mk Rxw10k Rx10msk Rxw10sk

Yamaha RX10K Supplementary Service Manual

Index 1 Gen Info Periodic Inspections and

Chapter 3. Chassis

Chapter 6

Chapter 4. Power Train

Chapter 9. Specifications

Index 1 Gen Info

Chapter 1. General Information

Chapter 5. Engine

Chapter 7. Carburetion

Chapter 8. Electrical

Index 1 Gen Info Periodic Inspections and

Chapter 2. Periodic Inspection and Adjustment

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha RX10K