Page 2 RS90GTZ/RS90LTGTZ/RST90GTZ SERVICE MANUAL © 2009 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N.LIT-12618-02-91...
Page 3 MAJOR SPECIFICATIONS Model RS90GTZ RS90LTGTZ RST90GTZ Model code 8JA1 8JB1 8HF3 Catalogue name RS Vector GT RS Vector L-TX GT RS Venture GT Class Groomed Trail Trail Versatility Touring Seating Capacity Engine type Liquid cooled 4-stroke, 12 valves Cylinder arrangement/Displacement...
Page 4 If there is any question about a service procedure, it is imper- ative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his snowmobile and to conform to federal environmental quality objectives.
Page 5 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 6: Chassis
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols are designed as thumb tabs to indicate the chapter’s number and content. General information Periodic inspection and adjustment Chassis Power train Engine Cooling system Fuel injection system Electrical Specifications Illustrated symbols are used to iden- tify the specifications which appear.
Page 7: Table Of Contents
CONTENTS GENERAL INFORMATION INFO PERIODIC INSPECTION AND INSP ADJUSTMENT CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 8 BRAKE HOSE INSPECTION ....2-38 AIR BLEEDING (HYDRAULIC GENERAL MAINTENANCE AND BRAKE SYSTEM) ....... 2-39 LUBRICATION CHART......2-1 DRIVE CHAIN ........2-40 TRACK TENSION ADJUSTMENT ..2-43 SLIDE RUNNER INSPECTION... 2-45 EXTROVERT SPROCKET WHEELS (RS90GTZ/RS90LTGTZ) ....2-45 MAXIMIZING DRIVE TRACK LIFE ..2-46...
Page 9 (RS90GTZ/RS90LTGTZ) ......3-2 INSTALLATION ........4-18 WINDSHIELD AND HEADLIGHT DRIVE CHAIN HOUSING ......4-20 (RST90GTZ) ..........3-3 DRIVE CHAIN HOUSING AIR FILTER CASE .........3-4 (RS90GTZ/RS90LTGTZ) ....4-20 SEAT............3-5 DRIVE CHAIN HOUSING SEAT (RS90GTZ/RS90LTGTZ) ....3-5 (RST90GTZ)........4-23 REMOVAL ........... 4-26 BACKREST AND SEAT......3-6 INSPECTION........
Page 10 BRAKE .............4-37 EXHAUST PIPE AND MUFFLER ....5-5 BRAKE (RS90GTZ/RS90LTGTZ) ..4-37 INSTALLATION ........5-7 BRAKE (RST90GTZ) ......4-38 OIL TANK........... 5-9 BRAKE PAD REPLACEMENT ....4-39 BRAKE CALIPER AND PARKING ENGINE ASSEMBLY....... 5-10 BRAKE (RS90GTZ/RS90LTGTZ) ..4-42 LEADS AND HOSES......5-10 BRAKE CALIPER AND PARKING ENGINE ASSEMBLY ......
Page 11: Electrical
FUEL PRESSURE INSPECTION..7-37 INSPECTION AND ADJUSTMENT..7-38 CHAPTER 6. CHAPTER 8. COOLING SYSTEM ELECTRICAL HEAT EXCHANGER ........6-1 HEAT EXCHANGER (RS90GTZ/ SWITCH INSPECTION ......8-1 RS90LTGTZ) .........6-1 SWITCH INSPECTION ......8-1 HEAT EXCHANGER (RST90GTZ) ..6-4 INSPECTING A SWITCH SHOWN INSPECTION .........6-6 IN THE MANUAL........
Page 12: Specifications
CHAPTER 9. LIGHTING SYSTEM .........8-28 CIRCUIT DIAGRAM (RS90GTZ/ SPECIFICATIONS RS90LTGTZ) ........8-28 CIRCUIT DIAGRAM (RST90GTZ) ..8-30 GENERAL SPECIFICATIONS....9-1 TROUBLESHOOTING ......8-32 BULB(S)..........8-35 MAINTENANCE SPECIFICATIONS ..9-4 HEADLIGHT BEAM SWITCH ....8-35 ENGINE..........9-4 HEADLIGHT RELAY......8-36 POWER TRAIN ........9-9 LOAD CONTROL RELAY ....8-37 CHASSIS..........
Page 13: Gen Info
SNOWMOBILE IDENTIFICATION INFO GENERAL INFORMATION SNOWMOBILE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number is located on the right-hand side of the crankcase.
Page 14: Important Information
REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in...
Page 15: 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 engine is overhauled. All gasket surfaces, oil seal lips, and O- rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
Page 16: Checking The Connections
IMPORTANT INFORMATION INFO CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, mois- ture, etc. 1. Disconnect: • Lead • Coupler • Connector 2. Inspect: • Lead • Coupler • Connector Moisture → Dry with an air blower. Rust/stains →...
Page 17: Handling The Electronic Parts
IMPORTANT INFORMATION INFO 5. Inspect: • Continuity (with the analog pocket tester (pocket tester)) Analog pocket tester YU-03112-C Pocket tester 90890-03112 • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (3). •...
Page 18: 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 damage that can be caused by the use of improper tools or impro- vised techniques. •...
Page 19 SPECIAL TOOLS INFO • Crankshaft protector P/N: YM-33282 • Flywheel puller attachment P/N: 90890-04089 This tool is used to remove the magneto rotor. • Radiator pressure tester P/N: YU-24460-01 • Radiator cap tester P/N: 90890-01325 This tester is used to check the cooling system. •...
Page 20 SPECIAL TOOLS INFO • Bearing driver 40 mm P/N: YM-04058 • Middle driven shaft bearing driver P/N: 90890-04058 This tool is used to install the water pump seal. • Mechanical seal installer 30 – 10 mm P/N: 90890-01557 This tool is used to install the water pump seal. •...
Page 21: For Power Train Service
• Engine adjuster P/N: 90890-01516 Used to turn the engine mounting bolt spacer when removing/ installing engine. • Yamaha bond No. 1215 P/N: 90890-85505 ® (Three Bond No.1215 This bond is used to seal two mating surfaces (e.g., crankcase mat- ing surfaces.)
Page 22: For Fuel Injection Service
SPECIAL TOOLS INFO • Primary/Secondary bushing jig P/N: YS-42424 • Clutch bushing press P/N: 90890-01529 This tool is used for removing and installing the post bushings (pri- mary sheave cap bush, sliding sheave bush and torque cam bush). • Track clip installer P/N: YS-91045-C 90890-01533 This tool is used for installing the track clip.
Page 23 SPECIAL TOOLS INFO • Test harness S- pressure sensor (3P) P/N: 90890-03207 This tool is used to measure voltage of the pressure sensor. • Test harness- TPS (3P) P/N: 90890-03204 This tool is used to measure voltage of the throttle position sensor. •...
Page 24: Insp Adj
All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL...
Page 25: Brake System
INSP GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY 1 month Seasonally ITEM REMARKS or 800 km or 4,000 km (500 mi) (2,500 mi) (40 hr) (200 hr) • Check oil level. Drive chain oil • Change. • Adjust free play and/or replace pads if necessary. Brake and parking brake •...
Page 26: Engine
SPARK PLUGS ENGINE SPARK PLUGS 1. Remove: • Top cover • Headlight assembly Refer to “COWLINGS” in CHAPTER 3. • Coolant recovery (RS90GTZ/RS90LTGTZ) Refer to “HEAT EXCHANGER” in CHAP- TER 6. 2. Remove: • Ignition coils • Spark plugs 3. Inspect: •...
Page 27: Fuel Line Inspection
SPARK PLUGS/FUEL LINE INSPECTION / INSP COOLING SYSTEM 6. Install: • Coolant recovery (RS90GTZ/RS90LTGTZ) Refer to “HEAT EXCHANGER” in CHAP- TER 6. • Headlight assembly • Top cover Refer to “COWLINGS” in CHAPTER 3. FUEL LINE INSPECTION 1. Remove: • Top cover •...
Page 28 4. Place an open container under the coolant hoses. 5. Disconnect: • Thermostat outlet hose • Radiator outlet hose (RS90GTZ/RS90LTGTZ) • Right heat exchanger inlet hose (RST90GTZ) RS90GTZ/RS90LTGTZ RST90GTZ 6. Drain the coolant. Lift up the tail of the snowmobile to drain the...
Page 29 • If coolant splashes on your skin or clothes, quickly wash it away with soap and water. 10.Connect: • Thermostat outlet hose • Radiator outlet hose (RS90GTZ/RS90LTGTZ) • Right heat exchanger inlet hose (RST90GTZ) 11.Connect: • Rear heat exchanger inlet hose • Rear heat exchanger outlet hose...
Page 30 Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors Antifreeze/water mixing ratio: 3 : 2 (60% : 40%) Total amount: RS90GTZ 5.6 L (5.92 US qt, 4.93 Imp.qt) RS90LTGTZ 6.1 L (6.45 US qt, 5.37 Imp.qt) RST90GTZ 5.4 L (5.71 US qt, 4.75 Imp.qt)
Page 31 INSP COOLING SYSTEM 14.Inspect: • Cooling system Decrease of pressure (leaks) → Repair as required. Inspection steps: • Attach the radiator pressure tester (radiator cap tester) and radiator pressure tester adapter (radiator cap tester adapter) the coolant filler Radiator pressure tester: YU-24460-01 Radiator cap tester: 90890-01325...
Page 32 COOLING SYSTEM • Fill the coolant up to the full level in the coolant reservoir and up to the cold level coolant recovery. (RS90GTZ/ RS90LTGTZ) • Fill the coolant up to the cold level in the coolant reservoir. (RST90GTZ) RS90GTZ/RS90LTGTZ RST90GTZ •...
Page 33: Valve Clearance Adjustment
Refer to “FUEL TANK” in CHAPTER 5. • Headlight assembly • Air filter case Refer to “COWLINGS” in CHAPTER 3. • Coolant recovery (RS90GTZ/RS90LTGTZ) Refer to “HEAT EXCHANGER” in CHAP- TER 6. • Throttle body assembly Refer to “THROTTLE BODY” in CHAPTER 3.
Page 34 INSP VALVE CLEARANCE ADJUSTMENT 5. Measure: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) Exhaust valve: 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Checking steps: • Turn the crankshaft clockwise. •...
Page 35 INSP VALVE CLEARANCE ADJUSTMENT Front For each cylinder, starting with cylinder #3 at TDC, turn the crankshaft clockwise as specified in the following table. Degrees that the crankshaft is turned clockwise Cylinder Combustion cycle Cylinder #2 120° Cylinder #1 240° 6.
Page 36 INSP VALVE CLEARANCE ADJUSTMENT • Select the proper valve pad from the follow- ing table. Valve pad Available valve pads thickness range 1.20 ~ 25 thicknesses in Nos. 2.40 mm 0.05 mm (0.0020 in) 120 ~ 240 (0.047 ~ increments 0.094 in) •...
Page 37 INSP VALVE CLEARANCE 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 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.05 ~ 0.09...
Page 38 INSP VALVE CLEARANCE ADJUSTMENT • Install the new valve pad and the valve lifter • Apply molybdenum-disulfide oil to the valve pad. • Apply engine oil to the valve lifter. • Install the valve lifter and the valve pad in the correct place.
Page 39: Throttle Body Synchronization
INSP THROTTLE BODY SYNCHRONIZATION THROTTLE BODY SYNCHRONIZATION Prior to synchronizing the throttle bodies, the valve clearance should be properly adjusted. 1. Remove: • Fuel tank cover Refer to “FUEL TANK” in CHAPTER 5. • Headlight assembly Refer to “COWLINGS” in CHAPTER 3. •...
Page 40 INSP THROTTLE BODY SYNCHRONIZATION Adjustment steps: • With throttle body #1 as standard, adjust throttle body #2 and #3 using the synchroniz- ing screws After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
Page 41: Throttle Cable Free Play Adjustment
INSP THROTTLE CABLE FREE PLAY ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT Adjust the throttle cable free play while the cable is in the cable guide. 1. Measure: • Throttle cable free play Out of specification → Adjust. Throttle cable free play: 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) 2.
Page 42: Throttle Override System (T.o.r.s.) Check
The T.O.R.S. will be activated and the engine speed will be limited to less than the clutch engagement speed. Engagement speed: RS90GTZ/RS90LTGTZ 3,100 ~ 3,500 r/min RST90GTZ 2,900 ~ 3,300 r/min WARNING If the engine speed does not decrease to...
Page 43: Compression Pressure Measurement
2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Remove: • Top cover • Headlight assembly Refer to “COWLINGS” in CHAPTER 3. • Coolant recovery (RS90GTZ/RS90LTGTZ) Refer to “HEAT EXCHANGER” in CHAP- TER 6. 4. Remove: • Spark plug NOTICE...
Page 44 INSP COMPRESSION PRESSURE MEASUREMENT Compression pressure (with oil applied into cylinder) Reading Diagnosis Higher than Piston ring(-s) wear or damage → Repair. without oil Piston, valves, cylinder head gasket or piston possibly defective → Same as without oil Repair. Compression pressure (at sea level) Standard compression pressure (at sea level):...
Page 45: Engine Oil Level Inspection
COMPRESSION PRESSURE MEASUREMENT/ INSP ENGINE OIL LEVEL INSPECTION 8. Install: • All removed parts For installation, reverse the removal proce- dure. ENGINE OIL LEVEL INSPECTION 1. Inspect: • Engine oil level NOTICE Do not run the engine with too much or not enough oil in the oil tank.
Page 46: Engine Oil Replacement
ENGINE OIL LEVEL INSPECTION/ INSP ENGINE OIL REPLACEMENT Recommended brand: YAMALUBE Type: SAE 0W-30 Recommended grade: API service SG type or higher, JASO standard MA NOTICE Do not allow foreign materials to enter the oil tank. Before checking the engine oil level, wait a few minutes until the oil has settled.
Page 47 5. Remove: • Side cover (left and right) • Side under cover (right) • Headlight assembly Refer to “COWLINGS” in CHAPTER 3. • Coolant recovery (RS90GTZ/RS90LTGTZ) Refer to “HEAT EXCHANGER” in CHAP- TER 6. 6. Disconnect: • Oil level gauge coupler Refer to “ENGINE OIL LEVEL INSPEC-...
Page 48 INSP ENGINE OIL REPLACEMENT 10.Remove: • Oil tank engine oil drain bolt 11.Drain: • Engine oil (completely from the oil pan and oil tank) 12.If the oil filter cartridge is also to be replaced, perform the following procedure. Replacement steps: •...
Page 49 INSP ENGINE OIL REPLACEMENT 14.Fill: • Engine oil (with the specified amount of the recom- mended engine oil) Add 2.0 L (2.11 US qt, 1.76 Imp.qt) of the recommended engine oil to the oil tank, and then install and tighten the oil level gauge and the cylinder head cap.
Page 50: Crankcase Breather Hose Inspection
CRANKCASE BREATHER HOSE INSPECTION/ INSP CYLINDER HEAD BREATHER HOSE INSPECTION CRANKCASE BREATHER HOSE INSPECTION 1. Remove: • Side cover (left) Refer to “COWLINGS” in CHAPTER 3. 2. Inspect: • Crankcase breather hose Cracks/damage → Replace. Loosen connection → Connect properly. NOTICE Make sure that the crankcase breather hose is routed correctly.
Page 51: Oil Tank Breather Hose Inspection
OIL TANK BREATHER HOSE INSPECTION/ INSP THROTTLE BODY JOINTS INSPECTION OIL TANK BREATHER HOSE INSPECTION 1. Remove: • Side cover (right) Refer to “COWLINGS” in CHAPTER 3. 2. Inspect: • Oil tank breather hose • Cranks/damage → Replace. • Loosen connection → Connect properly. NOTICE Make sure that the oil tank breather hose is routed correctly.
Page 52: Checking The Air Filter Element
INSP CHECKING THE AIR FILTER ELEMENT CHECKING THE AIR FILTER ELEMENT 1. Remove: • Shroud • Side cover (left and right) • Headlight assembly Refer to “COWLINGS” in CHAPTER 3. 2. Remove: • Air filter case cover 3. Remove: • Air filter element frame •...
Page 53: Exhaust System Inspection
INSP EXHAUST SYSTEM INSPECTION EXHAUST SYSTEM INSPECTION 1. Remove: • Seat • Storage compartment bracket (RST90GTZ) Refer to “SEAT” in CHAPTER 3. • Fuel tank Refer to “FUEL TANK” in CHAPTER 5. • Muffler cover Refer to “EXHAUST PIPE AND MUFFLER” in CHAPTER 5.
Page 54: Power Train
INSP SHEAVE OFFSET ADJUSTMENT POWER TRAIN SHEAVE OFFSET ADJUSTMENT 1. Remove: • Shroud • Left side cover • Drive guard Refer to “PRIMARY SHEAVE AND DRIVE V-BELT” in CHAPTER 4. 2. Remove: • Drive V-belt 3. Measure: • Sheave offset Use a straightedge that is approximately 470 mm (18.5 in) long, 20 mm (0.79 in) wide, and 4 mm (0.16 in) thick.
Page 55 INSP SHEAVE OFFSET ADJUSTMENT • Install secondary sheave, shim(s), washer, and secondary sheave bolt. Secondary sheave bolt: 64 Nm (6.4 m•kgf, 46 ft•lbf) • Recheck the sheave offset. If out of specifica- tion, repeat the above steps. When adjusting the sheave offset, the second- ary sheave free play (clearance) should be adjusted.
Page 56: Drive V-Belt
INSP DRIVE V-BELT DRIVE V-BELT WARNING When installing the new V-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to –0.5 mm (–0.02 in) below the edge. If the V-belt is not positioned correctly, the clutch engagement speed will be changed.
Page 57 INSP DRIVE V-BELT 2. Adjust the position of the V-belt by remov- ing or adding a shim on each adjusting bolt V-belt position Adjustment More than 1.5 mm (0.06 in) above the Remove a shim edge From 1.5 mm (0.06 in) above the edge Not necessary to –0.5 mm (–0.02 in)
Page 58: Engagement Speed Check
• Check the engine speed when the snowmo- bile starts moving forward. Out of specification → Adjust the primary sheave. Engagement speed: RS90GTZ/RS90LTGTZ 3,100 ~ 3,500 r/min RST90GTZ 2,900 ~ 3,300 r/min PARKING BRAKE PAD INSPECTION 1. Remove: • Side cover (right) Refer to “COWLINGS”...
Page 59: Parking Brake Adjustment
INSP PARKING BRAKE ADJUSTMENT PARKING BRAKE ADJUSTMENT 1. Remove: • Side cover (right) Refer to “COWLINGS” in CHAPTER 3. 2. Measure: • Parking brake cable distance Out of specification → Adjust. Parking brake cable distance: 43.5 ~ 46.5 mm (1.713 ~ 1.831 in) 3.
Page 60: Brake Fluid Level Inspection
INSP BRAKE FLUID LEVEL INSPECTION BRAKE FLUID LEVEL INSPECTION 1. Place the snowmobile on a level surface. 2. Check: • Fluid level → Fluid level is under the lower level line Fill to the proper level. Recommended brake fluid: DOT 4 For a correct reading of the brake fluid level, make sure that the top of the handlebar brake master cylinder reservoir is horizontal.
Page 61: Brake Pad Inspection
Wear indicator grove almost disap- peared → Replace as a set. Brake pad wear limit: 4.7 mm (0.19 in) (RS90GTZ/RS90LTGTZ) 7.5 mm (0.30 in) (RST90GTZ) 4. Install: • Side cover (right) Refer to “COWLINGS” in CHAPTER 3. BRAKE HOSE INSPECTION 1.
Page 62: Air Bleeding (Hydraulic Brake System)
INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) WARNING Bleed the brake system in the following cases: • The system has been disassembled. • A brake hose is loosened or removed. • The brake fluid has been very low. •...
Page 63: Drive Chain
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP DRIVE CHAIN k. Add brake fluid to the proper level. Refer to “BRAKE FLUID LEVEL INSPEC- TION”. WARNING After bleeding the brake system, check the brake operation. 3. Install: • Side cover (right) Refer to “COWLINGS” in CHAPTER 3. DRIVE CHAIN Oil level inspection WARNING...
Page 64 If not, add oil to the upper level. For models without reverse transmissions For models with reverse transmissions (RS90GTZ/RS90LTGTZ/RST90GTZ) Recommended oil: SAE 75W or 80W API GL-3 Gear oil NOTICE Make sure that no foreign material enters the drive chain housing.
Page 65 INSP DRIVE CHAIN Oil replacement Oil replacement steps: • Place the oil pan under the drain hole. • Remove the oil drain bolt (along with the gas- ket) and drain the oil. • Install the new gasket and oil drain bolt Drive chain housing oil drain bolt: 16 Nm (1.6 m•kgf, 11 ft•lbf) Recommended oil:...
Page 66: Track Tension Adjustment
100 N (10 kgf, 22 lbf) of force. Out of specification → Adjust. Track deflection: RS90GTZ/RS90LTGTZ 30.0 ~ 35.0 mm (1.18 ~ 1.38 in) RST90GTZ 20.0 ~ 25.0 mm (0.79 ~ 0.98 in) 3. Adjust: •...
Page 67 Left adjuster Turn out Turn in Right adjuster Turn in Turn out Slide runner Track Track clip RS90GTZ/RS90LTGTZ RST90GTZ Forward e. Adjust the track deflection until the speci- fied amount is obtained. More than Less than Track deflection specified specified...
Page 68: Slide Runner Inspection
SLIDE RUNNER INSPECTION/ INSP EXTROVERT SPROCKET WHEELS (RS90GTZ/RS90LTGTZ) SLIDE RUNNER INSPECTION 1. Inspect: • Slide runner Cracks/damage/wear → Replace. 2. Measure: • Slide runner thickness Out of specification → Replace. Slide runner wear limit: 10.5 mm (0.41 in) EXTROVERT SPROCKET WHEELS (RS90GTZ/RS90LTGTZ) 1.
Page 69: 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 mini- mize possible damage, consult your stud man- ufacturer for installation and stud pattern recommendations. Yamaha does not recommend track stud- ding. 2-46...
Page 70: Chassis
• Ski runner thickness • Plastic ski thickness Out of specification → Replace. Ski runner wear limit: 6 mm (0.24 in) (RS90GTZ/RS90LTGTZ) 8 mm (0.31 in) (RST90GTZ) Plastic ski wear limit: 12 mm (0.47 in) NOTICE To avoid scratching, wearing and damaging...
Page 71 INSP STEERING SYSTEM Toe-out adjustment 1. Place the snowmobile on a level surface. 2. Measure: • Ski toe-out ( – • Ski stance Point the skis forward. Out of specification → Adjust. When measuring or adjusting the skis, turn the ends inside.
Page 72: Brake Lever Adjustment
INSP BRAKE LEVER ADJUSTMENT/LUBRICATION BRAKE LEVER ADJUSTMENT 1. Adjust: • Brake lever position Adjustment steps: • While pushing the brake lever forward, loosen the locknut • While pushing the brake lever forward, turn the adjusting bolt in direction until the brake lever is in the desired position. •...
Page 73 2. Use a grease gun to inject grease into the nipples (both sides). 3. Apply grease to the pivoting parts. Recommended lubricant: ESSO Beacon 325 grease or Aeroshell grease #7A Front Rear (RS90GTZ) Rear (RS90LTGTZ) Nipple Nipple (both sides) 2-50...
Page 74 INSP LUBRICATION Rear (RST90GTZ) Nipple Nipple (both sides) 2-51...
Page 75: Electrical
INSP HEADLIGHT BULB REPLACEMENT ELECTRICAL HEADLIGHT BULB REPLACEMENT The following procedure applies to both of the headlight bulbs. 1. Remove: • Headlight assembly Refer to “COWLINGS” in CHAPTER 3. 2. Remove: • Headlight bulb cover 3. Detach: • Headlight bulb holder 4.
Page 76: Headlight Beam Adjustment
INSP HEADLIGHT BEAM ADJUSTMENT HEADLIGHT BEAM ADJUSTMENT 1. Place the snowmobile on a level surface. 2. Place the snowmobile in front of a wall at the recommended distance . Refer to the table below. 3. Measure the distance from the floor to the center of the headlight and place a mark on the wall at that height.
Page 77 INSP BATTERY INSPECTION 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: • Wear protective eye gear when handling or working near batteries. •...
Page 78: Battery Inspection
INSP BATTERY INSPECTION NOTICE • This is an VRLA (Valve Regulated Lead Acid, battery. Never remove the sealing caps because the balance between cells will not be maintained and battery perfor- mance will deteriorate. • Charging time, charging amperage and charging voltage for an VRLA (Valve Regu- lated Lead Acid) battery are different from those of conventional batteries.
Page 79 INSP BATTERY INSPECTION 3. Disconnect: • Battery leads (from the battery terminals) NOTICE First, disconnect the negative battery lead , then the positive battery lead 4. Remove: • Battery 5. Inspect: • Battery charge Inspection steps: • Connect a analog packet tester (pocket tester) to the battery terminals.
Page 80 INSP BATTERY INSPECTION 6. Charge: • Battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. NOTICE • Make sure that the battery vent is free of obstructions. • Never remove the VRLA (Valve Regulated Lead Acid) battery sealing caps.
Page 81 INSP BATTERY INSPECTION Charging method using a variable voltage charger Charger AMP meter Voltage should be measured Measure the open-circuit 30 minutes after the snowmo- voltage prior to charging. bile is stopped. Connect a charged and Set the charging voltage at 16 AMP meter to the battery ~ 17 V.
Page 82 INSP BATTERY INSPECTION Charging method using a constant voltage charger Measure the open-circuit Voltage should be measured 30 minutes after the snowmo- voltage prior to charging. bile is stopped. Connect a charger and AMP meter to the battery and start charging. Make sure that the current is higher than the stand- ard charging current writ-...
Page 83 INSP BATTERY INSPECTION 7. Install: • Battery 8. Connect: • Battery leads (to the battery terminals) NOTICE First, connect the positive battery lead then the negative battery lead 9. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection →...
Page 84: Fuse Inspection
INSP FUSE INSPECTION FUSE INSPECTION The following procedure applies to all of the fuses. NOTICE To avoid a short circuit, always turn the main switch off when checking or replacing a fuse. 1. Inspect: • Continuity Inspection steps: • Connect the analog pocket tester (pocket tester) to the fuse and check the continuity.
Page 85 15 A 7.5 A 5 A* Reserve fuse 10 A * For RS90GTZ/RS90LTGTZ 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...
Page 86: Tuning
INSP CLUTCH TUNING CLUTCH The clutch may require tuning depending upon where the snowmobile will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the snowmobile first begins to move from a complete stop.
Page 87 INSP CLUTCH High altitude tuning Atmospheric pressure decreases and engine output becomes low at high altitude locations. Because of this, clutch engagement speed and shifting speed also decrease and unable to maximize the engine output power. To maxi- mize the engine output, tuning for increasing clutch engagement speed and shifting speed is necessary.
Page 88 INSP CLUTCH Parts that affect transmission characteristics Among the components of the V-belt transmission, those that have direct impact on the shifting function are described below. Part Element Impact on the shifting function Primary sheave Spring Preload • A larger preload increases the clutch engagement speed, and the shifting speed tends to rise accordingly.
Page 89 INSP CLUTCH Part Element Impact on the shifting function Weight rivet Quantity Rivets are fastened through the hole in the weight. Material • Using more rivets decreases the clutch engage- (iron, aluminum) ment and shifting speed. Shifting tends to become somewhat easier.
Page 90 INSP CLUTCH Part Element Impact on the shifting function Torque cam Cam angle The cam angle determines the degree of sensitivity (spring seat) of load torque detection. • A smaller cam angle increases sensitivity, which in turn increases the sheave thrust to make back shifting easier.
Page 91 90501-603L2 24.5 (2.50) 441 (45) 6.0 (0.236) 59.5 (2.34) 5.39 91.4 (3.60) Green-White-Green 90501-603L3 27.0 (2.75) 441 (45) 6.0 (0.236) 59.5 (2.34) 5.08 89.8 (3.54) RS90GTZ Orange-Silver-Orange 90501-624L8 31.9 (3.25) 343 (35) 6.2 (0.244) 59.5 (2.34) 5.00 84.2 (3.31) 2-68...
Page 92 Weight g (oz) Part number without bush Shape & ID mark Standard and rivets 8DJ-17605-00 37.77 (1.333) 8DN-17605-30 39.76 (1.404) 8ES-17605-00 54.63 (1.928) 8FA-17605-10 63.81 (2.252) 8FN-17605-00 75.28 (2.657) RS90GTZ/ 8FP-17605-00 67.81 (2.394) RS90LTGTZ 8FS-17605-00 65.52 (2.313) 8GC-17605-00 47.28 (1.669) 2-69...
Page 93 (in) g (oz) 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) Increased Steel force 90269-06006 17.2 (0.677) 3.6 (0.127) OUT: RS90GTZ/RS90LTGTZ with hole 90261-06034 Steel 13.9 (0.547) 3.6 (0.127) IN: RS90GTZ/RS90LTGTZ 90261-06019 Steel 13.3 (0.524) 3.1 (0.109) CENTER: RS90GTZ/RS90LTGTZ IN: RST90GTZ...
Page 94 No Mark 8FG-17624-20 15.6 (0.614) RST90GTZ (14.6 mm [0.57 in]) Grooved & Grooved 8FG-17624-30 16.0 (0.630) (14.6 mm [0.57 in]) Machined RS90GTZ/ 8FG-17624-40 16.5 (0.650) RS90LTGTZ Decreased (14.6 mm [0.57 in]) force Shim (primary sheave) Part number Thickness mm (in)
Page 95 69.5 (2.74) White-White 90508-60016 12654 (1290) 13.5 (1.38) 77.08 6.0 (0.236) 5.19 75 (2.95) 69.5 (2.74) Secondary spring twist angle Seat Sheave 10° 40° 70° 100° 20° 50° 80° 110° 30° 60° 90° 120° Standard : RS90GTZ/RS90LTGTZ : RST90GTZ 2-72...
Page 96 Part number Cam angle Standard Effects 8BVFA 8FA-17604-00 51-43° Quicker up shifting during 8BV71 8BV-17604-71 47° acceleration 8BV51 8BV-17604-51 45° RS90GTZ/ 8BV31 8BV-17604-31 43° RS90LTGTZ Quicker 8BV11 8BV-17604-11 41° RST90GTZ back shifting 8BV91 8BV-17604-91 39° under load Shim (secondary sheave)
Page 97: Gear Selection
19 teeth 8FA-17682-90 20 teeth 8FA-17682-00 Drive sprocket 21 teeth 8FA-17682-10 22 teeth 8FA-17682-20 23 teeth 8FA-17682-30 RST90GTZ 24 teeth 8FA-17682-40 RS90GTZ/RS90LTGTZ 38 teeth 8FB-47587-80 RS90GTZ Driven sprocket 39 teeth 8FB-47587-90 RS90LTGTZ/RST90GTZ 40 teeth 8FB-47587-00 68 links 94890-09068 Chain RS90GTZ/RS90LTGTZ...
Page 98: High Altitude Tuning
INSP HIGH ALTITUDE TUNING HIGH ALTITUDE TUNING Specifications Model: RS90GTZ ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft)
Page 99 INSP HIGH ALTITUDE TUNING Specifications Model: RS90LTGTZ ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft) Production Standard...
Page 100 INSP HIGH ALTITUDE TUNING Specifications Model: RST90GTZ ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft) Production Standard...
Page 101: Front Suspension
FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: • Spring preload Adjustment steps: • Loosen the locknut • Turn the spring seat in or out. RS90GTZ Standard Spring seat Short ← → Long distance Hard ← → Soft Preload Min.
Page 102 Rebound damping force adjustment The rebound damping force can be adjusted by turning the adjusting knob RS90GTZ/RS90LTGTZ 20 clicks out 12 clicks out 3 clicks out Adjuster knob Minimum...
Page 103 Uneven settings can cause poor handling and loss of stability. Compression damping force adjustment The compression damping force can be adjusted by turning the adjusting knob RS90GTZ/RS90LTGTZ 12 clicks out 7 clicks out 2 clicks out Adjuster knob...
Page 104 INSP FRONT SUSPENSION/REAR SUSPENSION NOTICE • Do not continue to turn the adjusting knob in direction after it stops. The shock absorber can be damaged and compres- sion damping force adjustments cannot be made. • Do not turn the adjusting knob in direction more than 12 clicks.
Page 105: Rear Suspension
• Remove the limiter strap bolts , nuts and washers. • Adjust the length of the limiter straps inserting the bolts in different holes. Standard setting: RS90GTZ/RS90LTGTZ No. 2 hole RST90GTZ No. 1 hole • Tighten the limiter strap nuts. Limiter strap nut: 4 Nm (0.4 m•kgf, 2.9 ft•lbf)
Page 106 INSP REAR SUSPENSION Spring preload 1. Adjust: • Spring preload Adjustment steps: Front side (RST90GTZ) • Loosen the locknut • Turn the spring seat in or out. RST90GTZ Standard Spring seat Short ← → Long distance Hard ← → Soft Preload Min.
Page 107 INSP REAR SUSPENSION Rear side RS90GTZ/RS90LTGTZ • Turn the adjusting ring to the proper posi- tion. Spring adjuster position Soft ← → Hard Preload Standard RST90GTZ • Turn the adjuster to proper position by the tool Spring adjuster position Spring rate...
Page 108 INSP REAR SUSPENSION Rebound damping force adjustment RS90GTZ/RS90LTGTZ The rebound damping force can be adjusted by turning the rebound damping force remote adjustment dial in direction “HARD” or direction “SOFT”. Standard position WARNING Do not turn the remote adjustment dial...
Page 109 INSP REAR SUSPENSION Compression damping force adjustment RST90GTZ The compression damping force can be adjusted by turning the adjusting knob 12 clicks out 6 clicks out 2 clicks out Adjuster knob Minimum Standard Maximum position → Direction Direction *← Compres- sion Soft ←...
Page 110 INSP REAR SUSPENSION Control rod RS90GTZ/RS90LTGTZ 1. Adjust: • Control rod stroke Adjustment steps: • Loosen the locknut • Turn the control rod adjuster in direction to adjust the control rod stroke. Adjusting position Increase Decrease ← → Effect weight...
Page 111 INSP REAR SUSPENSION Adjustment steps: • Loosen the locknut • Turn the adjusting nut in or out to adjust the control rod stroke. Adjusting position Increase Decrease ← → Effect weight weight transfer transfer Standard WARNING Never adjust the control rods beyond the maximum range indicated on the rods with red paint •...
Page 112: Troubleshooting (Ski, Suspension)
INSP TROUBLESHOOTING (SKI, SUSPENSION) TROUBLESHOOTING (SKI, SUSPENSION) This section will point you towards possible solutions for resolving handling or ride comfort com- plaints. When making adjustments, do it in a small increments. Also, in general, making just one adjustment may not correct the problem. You may need to make several small adjustments to get the best overall results.
Page 113 INSP TROUBLESHOOTING (SKI, SUSPENSION) SYMPTOM DESCRIPTION POSSIBLE CAUSE POSSIBLE REMEDY Front suspension bottoming • Not enough front shock spring • Increase spring preload and/or out frequently. preload and/or spring used is select stiffer springs. too soft. • Blown shock absorbers (oil •...
Page 114 INSP TROUBLESHOOTING (SKI, SUSPENSION) SYMPTOM DESCRIPTION POSSIBLE CAUSE POSSIBLE REMEDY Rear suspension is too harsh • Too much rear/center shock • Reduce rear/center spring pre- over small bumps. spring preload and/or the load (set rear spring preload spring used is too stiff. for correct ride height).
Page 115: Chas
CHAS COWLINGS CHASSIS COWLINGS SHROUD AND COVERS 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 7 Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job name/Part name Q’ty Remarks Covers removal Remove the parts in the order listed below. Shroud Side cover (left and right) Side under cover (left and right) For installation, reverse the removal procedure.
Page 116: Windshield And Headlight (Rs90Gtz/Rs90Ltgtz)
CHAS COWLINGS WINDSHIELD AND HEADLIGHT (RS90GTZ/RS90LTGTZ) 3 Nm (0.3 m•kgf, 2.2 ft•lbf) Order Job name/Part name Q’ty Remarks Windshield and headlight removal Remove the parts in the order listed below. Windshield Fairing Top cover Main switch Auxiliary DC jack Headlight side cover (left and right)
Page 117: Windshield And Headlight (Rst90Gtz)
CHAS COWLINGS WINDSHIELD AND HEADLIGHT (RST90GTZ) 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 14 Nm (1.4 m•kgf, 10 ft•lbf) Order Job name/Part name Q’ty Remarks Windshield and headlight removal Remove the parts in the order listed below. Rearview mirror (left and right) Windshield Windshield cover Wind deflector (left and right)
Page 118: Air Filter Case
CHAS COWLINGS AIR FILTER CASE 3 Nm (0.3 m•kgf, 2.2 ft•lbf) Order Job name/Part name Q’ty Remarks Air filter case removal Remove the parts in the order listed below. Intake air temperature sensor coupler Disconnect. Intake air temperature sensor Air filter case cover Air filter element frame Air filter element Air filter case joint clamp screw...
Page 119: Seat
CHAS SEAT SEAT SEAT (RS90GTZ/RS90LTGTZ) 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 7 Nm (0.7 m•kgf, 5.1 ft•lbf) 18 Nm (1.8 m•kgf, 13 ft•lbf) Order Job name/Part name Q’ty Remarks Seat and fuel tank removal Remove the parts in the order listed below.
Page 120: Backrest And Seat
CHAS BACKREST AND SEAT BACKREST AND SEAT BACKREST AND SEAT (RST90GTZ) 7 Nm (0.7 m•kgf, 5.1 ft•lbf) 26 Nm (2.6 m•kgf, 19 ft•lbf) 48 Nm (4.8 m•kgf, 35 ft•lbf) Order Job name/Part name Q’ty Remarks Backrest and seat removal Remove the parts in the order listed below. Backrest Seat Backrest side cover rubber seal (left...
Page 121: Storage Compartment (Rst90Gtz)
CHAS BACKREST AND SEAT STORAGE COMPARTMENT (RST90GTZ) 16 Nm (1.6 m•kgf, 11 ft•lbf) 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 18 Nm (1.8 m•kgf, 13 ft•lbf) 7 Nm (0.7 m•kgf, 5.1 ft•lbf) 19 Nm (1.9 m•kgf, 13 ft•lbf) 13 Nm (1.3 m•kgf, 9.4 ft•lbf) 30 Nm (3.0 m•kgf, 22 ft•lbf) Order Job name/Part name...
Page 122: Steering
CHAS STEERING STEERING STEERING (RS90GTZ/RS90LTGTZ) 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Top cover Refer to “COWLINGS”.
Page 123: Steering (Rst90Gtz)
CHAS STEERING 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) Order Job name/Part name Q’ty Remarks Right handlebar switch cover Throttle cable holder Throttle cable Disconnect. Helmet shield heater jack Left handlebar switch Brake lever holder Master cylinder assembly...
Page 124 CHAS STEERING STEERING (RST90GTZ) 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Rubber cover Plastic band To install the rubber cover, refer to...
Page 125 CHAS STEERING 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) Order Job name/Part name Q’ty Remarks Throttle cable holder Throttle cable Disconnect. Plastic locking tie Helmet shield heater jack Left handlebar switch Brake master cylinder holder Brake master cylinder assembly Handlebar holder...
Page 126 CHAS STEERING 23 Nm (2.3 m•kgf, 17 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 30 Nm (3.0 m•kgf, 22 ft•lbf) 35 Nm (3.5 m•kgf, 25 ft•lbf) 67 Nm (6.7 m•kgf, 48 ft•lbf) Order Job name/Part name Q’ty Remarks Steering column and tie rod removal Remove the parts in the order listed below.
Page 127 CHAS STEERING 23 Nm (2.3 m•kgf, 17 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 30 Nm (3.0 m•kgf, 22 ft•lbf) 35 Nm (3.5 m•kgf, 25 ft•lbf) 67 Nm (6.7 m•kgf, 48 ft•lbf) Order Job name/Part name Q’ty Remarks Steering column 2 Tie rod Idler arm Clip...
Page 128: Removal
CHAS STEERING REMOVAL 1. Straighten the lock washer tabs. INSPECTION 1. Inspect: • Handlebar (RS90GTZ/RS90LTGTZ) • Handlebar (RST90GTZ) • Steering column 1 • Steering column 2 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent column. This may dangerously weaken the column.
Page 129: Installation
CHAS STEERING 3. Inspect: • Relay rod • Tie rods • Steering shaft Bends/cracks/damage → Replace. WARNING Do not attempt to straighten bent rods. This may dangerously weaken the rods. 4. Check: • Rod end movement Rod end free play exists → Replace the rod end.
Page 130 CHAS STEERING 2. Install: • Idler arm • Bushings • Washers • Relay rod NOTICE Always use new cotter pins. Install the idler arm with the “R” mark on the right side facing towards the rear of the snow- mobile. Idler arm nut: 35 Nm (3.5 m•kgf, 25 ft•lbf) Relay arm-relay rod nut:...
Page 131 CHAS STEERING Tie rod end locknut: 25 Nm (2.5 m•kgf, 18 ft•lbf) ® LOCTITE Tie rod-idler arm nut: 30 Nm (3.0 m•kgf, 22 ft•lbf) Tie rod-steering arm nut: 35 Nm (3.5 m•kgf, 25 ft•lbf) 5. Install: • Steering shaft • Locknuts •...
Page 132 CHAS STEERING 6. Adjust: • Skis Adjustment steps: • Temporarily install the handlebar. • Hold the handlebar straight and check that the skis and relay arms are at right angles to the handlebar. • Install the steering linkage alignment plate to the relay arms Steering linkage alignment plate: YS-01487...
Page 133 CHAS STEERING 7. Install: • Handlebar • Handlebar holders NOTICE First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. • The handlebar holders should be installed with the punch marks facing forward. •...
Page 134: Ski
CHAS 12 Nm (1.2 m•kgf, 8.7 ft•lbf) 17 Nm (1.7 m•kgf, 12 ft•lbf) 19 Nm (1.9 m•kgf, 13 ft•lbf) 48 Nm (4.8 m•kgf, 35 ft•lbf) Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below. Cotter pin Bolt Collar...
Page 135: Inspection
CHAS INSPECTION 1. Inspect: • Ski • Ski runner • Ski stopper • Ski handle Wear/cracks/damage → Replace. • Mounting bolt • Collar • Collars Wear/damage → Replace. 3-21...
Page 136: Front Suspension
CHAS FRONT SUSPENSION FRONT SUSPENSION 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 11 Nm (1.1 m•kgf, 8.0 ft•lbf) 35 Nm (3.5 m•kgf, 25 ft•lbf) 37 Nm (3.7 m•kgf, 27 ft•lbf) 40 Nm (4.0 m•kgf, 29 ft•lbf) 45 Nm (4.5 m•kgf, 32 ft•lbf) 50 Nm (5.0 m•kgf, 36 ft•lbf) 70 Nm (7.0 m•kgf, 50 ft•lbf) Order...
Page 137 CHAS FRONT SUSPENSION 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 11 Nm (1.1 m•kgf, 8.0 ft•lbf) 35 Nm (3.5 m•kgf, 25 ft•lbf) 37 Nm (3.7 m•kgf, 27 ft•lbf) 40 Nm (4.0 m•kgf, 29 ft•lbf) 45 Nm (4.5 m•kgf, 32 ft•lbf) 50 Nm (5.0 m•kgf, 36 ft•lbf) 70 Nm (7.0 m•kgf, 50 ft•lbf) Order Job name/Part name...
Page 138: Handling The Front Shock Absorber And Gas Cylinder
CHAS FRONT SUSPENSION HANDLING THE FRONT SHOCK ABSORBER AND GAS CYLINDER WARNING This front shock absorbers and gas cylin- ders contain highly compressed nitrogen gas. Before handling the front shock absorber or gas cylinder, read and make sure you understand the following informa- tion.
Page 139: Installation
CHAS FRONT SUSPENSION 2. Inspect: • Ski column • Steering arm Cracks/bends/damage → Replace. • Bushing Wear/scratches/damage → Replace. 3. Inspect: • Upper arms • Lower arms Cracks/bends/damage → Replace. • Bushings Wear/scratches/damage → Replace. 4. Inspect: • Connecting rods •...
Page 140 CHAS FRONT SUSPENSION 2. Install: • Stabilizer • Stabilizer arm • Connecting rod • The installation angles of the left and right stabilizer arms should be within 6° of each other. • Install the connecting rod end with the width to the stabilizer arm.
Page 141 CHAS FRONT SUSPENSION Ski alignment Be sure to verify the spring preload setting before adjusting the ski toe-out since this adjustments may affect the ski toe-out setting. Point the skis straight forward and measure the amount of ski toe-out. Ski toe-out: 0 ~ 15 mm (0 ~ 0.59 in) –...
Page 142: Powr Tr
POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT 120 Nm (12.0 m•kgf, 85 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) Order Job name/Part name Q’ty Remarks Primary sheave removal Remove the parts in the order listed below.
Page 143 POWR PRIMARY SHEAVE AND DRIVE V-BELT 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 14 Nm (1.4 m•kgf, 10 ft•lbf) 200 Nm (20 m•kgf, 145 ft•lbf) : Clean the threads. ® Apply LOCTITE #648 as illustrated in And then tighten the spider.
Page 144 POWR PRIMARY SHEAVE AND DRIVE V-BELT 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 14 Nm (1.4 m•kgf, 10 ft•lbf) 200 Nm (20 m•kgf, 145 ft•lbf) : Clean the threads. ® Apply LOCTITE #648 as illustrated in And then tighten the spider.
Page 145: Removal
POWR PRIMARY SHEAVE AND DRIVE V-BELT REMOVAL 1. Remove: • Primary sheave assembly Use the Primary clutch holder (sheave holder) and primary clutch puller (primary fixed sheave puller (M18 – 32.5 mm)) Primary clutch holder: YS-01880-A Sheave holder: 90890-01701 Primary clutch puller: YS-01881-A Primary fixed sheave puller (M18 –...
Page 146: Inspection
POWR PRIMARY SHEAVE AND DRIVE V-BELT • Fit the primary sheave assembly onto the adapter and secure the supporting plates Securely fit the projections on the adapter into the fixed sheave holes. • Set the clutch spider separator (clutch sepa- rator wrench) onto the spider and turn the special tool clockwise to loosen the spider.
Page 147 • Primary sheave spring (standard) free length Out of specification → Replace the primary sheave spring. Primary sheave spring (standard) free length: RS90GTZ: 89.8 mm (3.54 in) RS90LTGTZ: 93.4 mm (3.68 in) RST90GTZ: 83.4 mm (3.28 in) When changing the primary sheave springs, refer to “GEAR SELECTION”...
Page 148 POWR PRIMARY SHEAVE AND DRIVE V-BELT 5. Inspect: • Weight • Roller • Bushings • Sliders • Rivets • Slider damper • Collar Wear/scratches/damage → Replace. Slider inside clearance Min. 0 mm (0 in) Max. 0.3 mm (0.0118 in) Rivet replacement steps: •...
Page 149: Assembly
POWR PRIMARY SHEAVE AND DRIVE V-BELT When replacing the weight and roller bushings, use the 8 mm clutch bushing jig (clutch bush- ing jig kit). 8 mm clutch bushing jig: YS-39752 Clutch bushing jig kit: 90890-01528 Removing Installing ASSEMBLY 1. Install: •...
Page 150 POWR PRIMARY SHEAVE AND DRIVE V-BELT 3. Install: • Fixed sheave stoppers Stopper tapered portion should face fixed sheave. 4. Tighten: • Spider Tightening steps: • Finger-tighten the spider until it is stopped by the fixed sheave stopper. • Hold the fixed sheave with the clutch spider separator (clutch separator adapter) Securely fit the projections on the clutch sepa- rator adapter...
Page 151 POWR PRIMARY SHEAVE AND DRIVE V-BELT • Tighten the spider to specification using the clutch spider separator (clutch separator wrench) Clutch separator adapter: YS-34480 90890-01711 Clutch spider separator: YS-28890-C Clutch separator wrench: 90890-01740 Spider: 200 Nm (20 m•kgf, 145 ft•lbf) NOTICE •...
Page 152: Installation
POWR PRIMARY SHEAVE AND DRIVE V-BELT 5. Install: • Weight • Bolt • Nut • Bolt • Nut • Set bolts Nut: 6 Nm (0.6 m•kgf, 4.3 ft•lbf) Set bolt: 4 Nm (0.4 m•kgf, 2.9 ft•lbf) ® LOCTITE To tighten the set bolts make sure that the bearing surfaces of the bolt is pressed...
Page 153 POWR PRIMARY SHEAVE AND DRIVE V-BELT 2. Apply: • Engine oil (to threads of primary sheave bolt) 3. Tighten: • Primary sheave bolt Tightening steps: • Hold the primary sheave using the pri- mary clutch holder (sheave holder) tighten the primary sheave bolt to specifica- tion.
Page 154: Secondary Sheave
POWR SECONDARY SHEAVE SECONDARY SHEAVE 64 Nm (6.4 m•kgf, 46 ft•lbf) Order Job name/Part name Q’ty Remarks Secondary sheave removal Remove the parts in the order listed below. Apply the brake to lock the secondary sheave. Shroud Refer to “COWLINGS”. Side cover (left) V-belt Refer to “PRIMARY SHEAVE AND DRIVE...
Page 155 POWR SECONDARY SHEAVE 7 Nm (0.7 m•kgf, 5.1 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) Order Job name/Part name Q’ty Remarks Secondary sheave disassembly Remove the parts in the order listed below. Spring seat Bushing Secondary sheave spring Fixed sheave...
Page 156: Disassembly
POWR SECONDARY SHEAVE DISASSEMBLY WARNING • 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 compressor to contain the spring tension before removing the spring seat nuts. •...
Page 157: Assembly
POWR SECONDARY SHEAVE 3. Inspect: • Secondary sheave spring Cracks/damage → Replace. 4. Measure: • Secondary sheave spring (standard) free length Below specification → Replace the second- ary sheave spring. Secondary sheave spring (standard) free length: 75.0 mm (2.95 in) 5.
Page 158 Hook the other end of the spring into the holes in the spring seat. Standard spring position: 1-6 (RS90GTZ/RS90LTGTZ) 3-3 (RST90GTZ) Installation steps: • Hold the spring seat and turn the fixed...
Page 159: Installation
• Install new shims of the proper thickness and reassemble the secondary sheave. • Measure the secondary sheave clearance again. Repeat these steps until the clearance is within specification. Yamaha recommends keeping the original shims. Shims: Part number Thickness 90201-061H1 0.5 mm (0.02 in)
Page 160 POWR SECONDARY SHEAVE 2. Tighten: • Secondary sheave bolt Secondary sheave bolt: 64 Nm (6.4 m•kgf, 46 ft•lbf) 3. Adjust: • V-belt position Refer to “DRIVE V-BELT” in CHAPTER 2. • Sheave offset • Secondary sheave free play (clearance) Refer to “SHEAVE OFFSET ADJUST- MENT”...
Page 161: Drive Chain Housing
POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING (RS90GTZ/RS90LTGTZ) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 43 Nm (4.3 m•kgf, 31 ft•lbf)
Page 162 POWR DRIVE CHAIN HOUSING 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 43 Nm (4.3 m•kgf, 31 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 55 Nm (5.5 m•kgf, 40 ft•lbf) Order...
Page 163 POWR DRIVE CHAIN HOUSING 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 43 Nm (4.3 m•kgf, 31 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 55 Nm (5.5 m•kgf, 40 ft•lbf) Order...
Page 164: Drive Chain Housing (Rst90Gtz)
POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING (RST90GTZ) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 43 Nm (4.3 m•kgf, 31 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 55 Nm (5.5 m•kgf, 40 ft•lbf) Order...
Page 165 POWR DRIVE CHAIN HOUSING 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 43 Nm (4.3 m•kgf, 31 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 55 Nm (5.5 m•kgf, 40 ft•lbf) Order...
Page 166 POWR DRIVE CHAIN HOUSING 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 43 Nm (4.3 m•kgf, 31 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 55 Nm (5.5 m•kgf, 40 ft•lbf) Order...
Page 167: Removal
POWR DRIVE CHAIN HOUSING REMOVAL 1. Remove: • Reverse driven gear While holding the front axle assembly with spanner wrench , loosen the reverse driven gear bolt. 2. Remove: • Drive sprocket INSPECTION 1. Inspect: • Drive chain housing • Drive chain housing cover Cracks/damage →...
Page 168 POWR DRIVE CHAIN HOUSING Use a socket that is the same size as the outside diameter of the bearing race. NOTICE Do not strike the inner race or ball bear- ings Contact only the outer race • Install a new circlip (drive chain housing and cover).
Page 169 Measure the brake disc thickness 1 ~ 3 mm (0.04 ~ 0.12 in) from the edge of the brake disc. Out of specification → Replace. Minimum thickness (RS90GTZ/ RS90LTGTZ): 3.5 mm (0.14 in) Minimum thickness (RST90GTZ) 4.5 mm (0.18 in)
Page 170: Installation (Rs90Gtz/Rs90Ltgtz)
POWR DRIVE CHAIN HOUSING INSTALLATION (RS90GTZ/RS90LTGTZ) 1. During installation, pay attention to the fol- lowing. Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. Be sure to install the collars in their orig- inal positions, otherwise the brake disc and secondary shaft will stick.
Page 171: Installation (Rst90Gtz)
POWR DRIVE CHAIN HOUSING INSTALLATION (RST90GTZ) 1. During installation, pay attention to the fol- lowing. Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. Be sure to install the collars in their original positions, otherwise the secondary shaft will stick.
Page 172 POWR DRIVE CHAIN HOUSING 4. Install: • Shift rod 5. Adjust: • Shift rod length Adjustment steps: • Move the shift lever to the “FWD.” position. • Loosen the locknuts • Turn the shift rod so that shift rod free play is 0 mm (in direction where can be length- ened appropriately) and then turn back the...
Page 173: Secondary Shaft
POWR SECONDARY SHAFT SECONDARY SHAFT 30 Nm (3.0 m•kgf, 22 ft•lbf) 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”. Bearing housing Circlip Secondary shaft...
Page 174: Removal
POWR SECONDARY SHAFT REMOVAL 1. Remove: • Drive chain housing parts Refer to “DRIVE CHAIN HOUSING”. • Secondary sheave assembly Refer to “SECONDARY SHEAVE”. 2. Remove: • Bearing housing bolts • Secondary shaft and bearing housing • Circlip • Bearing and bearing housing (Use the press machine.) •...
Page 175: Installation
POWR SECONDARY SHAFT INSTALLATION 1. Install: • Bearing (Use the press machine.) • Circlip • Bearing and bearing housing • Circlip • Secondary shaft and bearing housing • Bearing housing bolts Bearing housing bolt: 30 Nm (3.0 m•kgf, 22 ft•lbf) 4-34...
Page 176: Secondary Shaft And Drive Chain Housing Installation
POWR SECONDARY SHAFT SECONDARY SHAFT AND DRIVE CHAIN HOUSING INSTALLATION 1. Install: • Secondary shaft • Drive chain housing Installation steps: • Install the secondary shaft. • Tighten the bolts Bearing housing bolt: 30 Nm (3.0 m•kgf, 22 ft•lbf) • Install the drive chain housing •...
Page 177 • Tighten the collar set screw Collar set screw: 6 Nm (0.6 m•kgf, 4.3 ft•lbf) ® LOCTITE • Install the collar (RS90GTZ/RS90LTGTZ). • Install the brake disc. • Adjust the brake disc clearance. 2. Measure: • Brake disc clearance Out of the specification → Adjust.
Page 178: Brake
POWR BRAKE BRAKE BRAKE (RS90GTZ/RS90LTGTZ) 2.5 Nm (0.25 m•kgf, 1.8 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 18 Nm (1.8 m•kgf, 13 ft•lbf) 48 Nm (4.8 m•kgf, 35 ft•lbf) Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in the order listed below.
Page 179: Brake (Rst90Gtz)
POWR BRAKE BRAKE (RST90GTZ) 2.5 Nm (0.25 m•kgf, 1.8 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 18 Nm (1.8 m•kgf, 13 ft•lbf) 48 Nm (4.8 m•kgf, 35 ft•lbf) Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in the order listed below.
Page 180: Brake Pad Replacement
POWR BRAKE NOTICE Disc brake components rarely require dis- assembly. DO NOT: • Do not disassemble components unless absolutely necessary. • Do not use solvents on internal brake components. • Do not use contaminated brake fluid for cleaning. • Use only clean brake fluid. •...
Page 181 • Install a new brake pad spring when the brake pads are replaced. • Replace the pads as a set if either one is found to be worn to the wear limit Wear limit (RS90GTZ/ RS90LTGTZ): 4.7 mm (0.19 in) Wear limit (RST90GTZ): 7.5 mm (0.30 in)
Page 182 • Tighten the caliper bleed screws Bleed screw: 6 Nm (0.6 m•kgf, 4.3 ft•lbf) • Install the brake pads and pad spring. RS90GTZ/RS90LTGTZ RST90GTZ 3. Check: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION”...
Page 183: Brake Caliper And Parking Brake (Rs90Gtz/Rs90Ltgtz)
POWR BRAKE BRAKE CALIPER AND PARKING BRAKE (RS90GTZ/RS90LTGTZ) 30 Nm (3.0 m•kgf, 22 ft•lbf) 48 Nm (4.8 m•kgf, 35 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) Order Job name/Part name Q’ty Remarks Brake caliper and parking brake...
Page 184 POWR BRAKE 2.5 Nm (0.25 m•kgf, 1.8 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 18 Nm (1.8 m• kgf, 13 ft•lbf) Order Job name/Part name Q’ty Remarks Brake caliper disassembly Remove the parts in the order listed below. Screw plug Retaining pin Brake pad spring Brake pad...
Page 185: Brake Caliper And Parking Brake (Rst90Gtz)
POWR BRAKE BRAKE CALIPER AND PARKING BRAKE (RST90GTZ) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 30 Nm (3.0 m•kgf, 22 ft•lbf) 48 Nm (4.8 m•kgf, 35 ft•lbf) Order Job name/Part name Q’ty Remarks Brake caliper and parking brake Remove the parts in the order listed removal below.
Page 186 POWR BRAKE 2.5 Nm (0.25 m•kgf, 1.8 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 18 Nm (1.8 m• kgf, 13 ft•lbf) Order Job name/Part name Q’ty Remarks Brake caliper disassembly Remove the parts in the order listed below. Screw plug Retaining pin Brake pad spring Brake pad...
Page 187: Brake Caliper Disassembly
• Remove the piston seals and reinstall the pis- ton. • Repeat the previous steps to force out the right piston from the caliper body. WARNING • Never try to pry out the pistons. • Do not loosen the retaining bolts RS90GTZ/RS90LTGTZ RST90GTZ 4-46...
Page 188: Brake Caliper Inspection And Repair
POWR BRAKE BRAKE CALIPER INSPECTION AND REPAIR Recommended brake component replacement schedule Brake pads As required Piston seals and Every two years dust seals Brake hose Every four years Only when brakes Brake fluid are disassembled. WARNING All internal brake components should be cleaned only with new brake fluid.
Page 189: Brake Caliper Assembly
• Brake fluid delivery passage (caliper body) Blow out with compressed air. WARNING P32-1 Replace the piston seals and piston dust seals whenever a caliper is disassembled. RS90GTZ/RS90LTGTZ RST90GTZ BRAKE CALIPER ASSEMBLY WARNING • All internal parts should be cleaned only with new brake fluid.
Page 190: Brake Caliper Installation
• Brake hose NOTICE When installing the brake hose onto the brake caliper , make sure that the brake pipe touches the projection on the brake caliper. Union bolt (brake hose): 30 Nm (3.0 m•kgf, 22 ft•lbf) RS90GTZ/RS90LTGTZ RST90GTZ 4-49...
Page 191: Brake Master Cylinder (Rs90Gtz/Rs90Ltgtz)
POWR BRAKE BRAKE MASTER CYLINDER (RS90GTZ/RS90LTGTZ) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 30 Nm (3.0 m•kgf, 22 ft•lbf) Order Job name/Part name Q’ty Remarks Brake master cylinder removal Remove the parts in the order listed below.
Page 192 POWR BRAKE 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 30 Nm (3.0 m•kgf, 22 ft•lbf) Order Job name/Part name Q’ty Remarks Brake master cylinder disassembly Remove the parts in the order listed below. Brake master cylinder reservoir cap set Brake master cylinder reservoir diaphragm Brake master cylinder kit...
Page 193: Brake Master Cylinder (Rst90Gtz)
POWR BRAKE BRAKE MASTER CYLINDER (RST90GTZ) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 30 Nm (3.0 m•kgf, 22 ft•lbf) Order Job name/Part name Q’ty Remarks Brake master cylinder removal Remove the parts in the order listed below.
Page 194 POWR BRAKE 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 30 Nm (3.0 m•kgf, 22 ft•lbf) Order Job name/Part name Q’ty Remarks Brake master cylinder disassembly Remove the parts in the order listed below. Brake master cylinder reservoir cap set Brake master cylinder reservoir diaphragm Brake master cylinder kit...
Page 195: Inspection
POWR BRAKE INSPECTION 1. Inspect: • Brake master cylinder Wear/scratches → Replace the master cyl- inder assembly. • Brake master cylinder body Cracks/damage → Replace the master cyl- inder assembly. • Brake fluid delivery passage (master cylin- der body) Blow out with compressed air. 2.
Page 196: Installation
POWR BRAKE INSTALLATION 1. Install: • Brake hose NOTICE When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection shown. Union bolt (brake hose): 30 Nm (3.0 m•kgf, 22 ft•lbf) 4-55...
Page 197: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION (RS90GTZ) 12 Nm (1.2 m•kgf, 8.7 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 84 Nm (8.4 m•kgf, 61 ft•lbf) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below.
Page 198 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) 105 Nm (10.5 m•kgf, 75 ft•lbf) Order Job name/Part name...
Page 199 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) 105 Nm (10.5 m•kgf, 75 ft•lbf) Order Job name/Part name...
Page 200 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 m•kgf, 17 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) 105 Nm (10.5 m•kgf, 75 ft•lbf) Order Job name/Part name Q’ty Remarks Rear shock absorber Collar Oil seal...
Page 201 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 m•kgf, 17 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) 105 Nm (10.5 m•kgf, 75 ft•lbf) Order Job name/Part name Q’ty Remarks Shaft Shaft Shaft...
Page 202 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 m•kgf, 17 ft•lbf) 59 Nm (5.9 m•kgf, 43 ft•lbf) 75 Nm (7.5 m•kgf, 54 ft•lbf) Order Job name/Part name Q’ty Remarks Rear axle shaft Guide wheel Guide wheel Collar Collar Collar Tension adjuster Sliding frame For assembly, reverse the disassembly procedure.
Page 203: Slide Rail Suspension (Rs90Ltgtz)
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION (RS90LTGTZ) 12 Nm (1.2 m•kgf, 8.7 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 84 Nm (8.4 m•kgf, 61 ft•lbf) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below.
Page 204 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) 105 Nm (10.5 m•kgf, 75 ft•lbf) Order Job name/Part name...
Page 205 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) 105 Nm (10.5 m•kgf, 75 ft•lbf) Order Job name/Part name...
Page 206 POWR SLIDE RAIL SUSPENSION 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) 105 Nm (10.5 m•kgf, 75 ft•lbf) Order Job name/Part name Q’ty...
Page 207 POWR SLIDE RAIL SUSPENSION 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) 105 Nm (10.5 m•kgf, 75 ft•lbf) Order Job name/Part name Q’ty...
Page 208 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 m•kgf, 17 ft•lbf) 59 Nm (5.9 m•kgf, 43 ft•lbf) 75 Nm (7.5 m•kgf, 54 ft•lbf) Order Job name/Part name Q’ty Remarks Rear axle shaft Guide wheel Guide wheel Collar Collar Collar Tension adjuster Sliding frame For assembly, reverse the disassembly procedure.
Page 209: Slide Rail Suspension (Rst90Gtz)
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION (RST90GTZ) 72 Nm (7.2 m•kgf, 52 ft•lbf) 84 Nm (8.4 m•kgf, 61 ft•lbf) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen.
Page 210 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) Order Job name/Part name Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below.
Page 211 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) Order Job name/Part name Q’ty Remarks Bushing Connecting arm Collar...
Page 212 POWR SLIDE RAIL SUSPENSION 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 9 Nm (0.9 m•kgf, 6.5 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) Order Job name/Part name Q’ty...
Page 213 POWR SLIDE RAIL SUSPENSION 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 49 Nm (4.9 m•kgf, 35 ft•lbf) 9 Nm (0.9 m•kgf, 6.5 ft•lbf) 60 Nm (6.0 m•kgf, 43 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 72 Nm (7.2 m•kgf, 52 ft•lbf) Order Job name/Part name Q’ty...
Page 214 POWR SLIDE RAIL SUSPENSION 60 Nm (6.0 m•kgf, 43 ft•lbf) 75 Nm (7.5 m•kgf, 54 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) Order Job name/Part name Q’ty Remarks Suspension wheel cover Suspension wheel Collar Suspension wheel bracket Suspension wheel cover Suspension wheel Collar Suspension wheel bracket...
Page 215 POWR SLIDE RAIL SUSPENSION 60 Nm (6.0 m•kgf, 43 ft•lbf) 75 Nm (7.5 m•kgf, 54 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) Order Job name/Part name Q’ty Remarks Tension adjuster Sliding frame For assembly, reverse the disassembly procedure. 4-74...
Page 216: Removal
POWR SLIDE RAIL SUSPENSION REMOVAL 1. Unhook the torsion spring (For RST90GTZ) Rotate the spring end guide in the direction of the arrow shown to unhook the end of the torsion spring. HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorbers and gas cylin- ders contain highly compressed nitrogen...
Page 217: Disposing Of A Rear Shock Absorber And Gas Cylinder
To release the gas pressure, loosen the charg- ing valve bolt 2 ~ 3 turns, release the nitro- gen gas once, and then remove the charging valve bolt. RS90GTZ/RS90LTGTZ RST90GTZ (front) RST90GTZ (rear) 4-76...
Page 218: Inspection
Oil (gas) leaks/damage → Replace. • Bushing • Collar Wear/cracks/damage → Replace. • Front pivot arm • Rear pivot arm • Rear pivot arm bracket (RS90GTZ/RS90LTGTZ) • Control rod(s) • Suspension wheel bracket • Suspension wheel • Guide wheel • Front suspension bracket (RST90GTZ) •...
Page 219: Assembly
POWR SLIDE RAIL SUSPENSION ASSEMBLY 1. Install: • Tension adjusters (RST90GTZ) Install the tension adjusters so that they are angled outward as shown in the illustration. 2. Apply: • ESSO beacon 325 grease or Aeroshell grease #7A (RST90GTZ) Apply grease to the bushings and the shaft in the area shown in the illustration.
Page 220: Installation
SLIDE RAIL SUSPENSION 6. Install: • Limiter strap Install the limiter strap with toward the shaft toward the front pivot arm. RS90GTZ/RS90LTGTZ RST90GTZ Limiter strap nut: 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 7. Install: • Rear shock absorber adjuster assembly •...
Page 221 POWR SLIDE RAIL SUSPENSION Control rod part numbers (RS90GTZ/RS90LTGTZ) Control rod 1 Length mm (in) Length mm (in) part number 359.5 ~ 360.5 8JA-4745A-00 277.3 (10.92) (14.153 ~ 14.193) Control rod 2 Washer plate part number part number Washer plate thickness mm (in)
Page 222 POWR SLIDE RAIL SUSPENSION Control rod part numbers (RST90GTZ) Control rod 1 Length mm (in) Length mm (in) Length mm (in) 2.5P × 2 = 5 RST90GTZ 242.8 (9.56) 189.2 (7.45) (0.098P × 2 = 0.197) Washer part numbers Control rod 1 Control rod stopper Washer thickness mm (in) part number...
Page 223: Front Axle And Track
POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK 9 Nm (0.9 m•kgf, 6.5 ft•lbf) 20 Nm (2.0 m•kgf, 14 ft•lbf) 40 Nm (4.0 m•kgf, 29 ft•lbf) Order Job name/Part name Q’ty Remarks Front axle and track removal Remove the parts in the order listed below.
Page 224: Inspection
• Sprocket wheels Wear/break/damage → Replace. • Front axle Bends/scratches (excessive)/damage → Replace. 3. Inspect: • Bearing Pitting/damage → Replace. RS90GTZ/RS90LTGTZ RST90GTZ INSTALLATION 1. Install: • Track clips (to the track Install the track clip installer and track clip on the track as shown in the illustration.
Page 225 • Position each sprocket wheel on the axle as shown in the illustration. RS90GTZ/RS90LTGTZ RST90GTZ 3. Place the track in the chassis. For track with a direction of rotation mark Install the track with the mark pointing in the direction of track rotation.
Page 226: Eng
Refer to “SEAT” in CHAPTER 3. Top cover Refer to “COWLINGS” in CHAPTER 3. Fuel tank cap Fuel tank cover Damper For RS90GTZ/RS90LTGTZ Fuel tank side cover (left and right) Fuel pump coupler Disconnect. Fuel hose connector holder Fuel hose Disconnect.
Page 227: Removal
FUEL TANK REMOVAL 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose connector holder • Fuel hose WARNING Cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hoses.
Page 228: Installation
FUEL TANK 2. Inspect: • Fuel pump operation Refer to “FUEL PRESSURE INSPECTION” in CHAPTER 7. INSTALLATION 1. Install: • Fuel pump gasket • Fuel pump • Fuel pump bracket Fuel pump nut: 7 Nm (0.7 m•kgf, 5.1 ft•lbf) • Do not damage the installation surface of the fuel tank when installing the fuel pump.
Page 229 FUEL TANK 3. Install: • Fuel hose connector holder NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector holder is in the correct position, otherwise the fuel hose will not be properly installed.
Page 230: Exhaust Pipe And Muffler
EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 11 Nm (1.1 m•kgf, 8.0 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 18 Nm (1.8 m•kgf, 13 ft•lbf) 20 Nm (2.0 m•kgf, 14 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) Order Job name/Part name...
Page 231 EXHAUST PIPE AND MUFFLER 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 11 Nm (1.1 m•kgf, 8.0 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 18 Nm (1.8 m•kgf, 13 ft•lbf) 20 Nm (2.0 m•kgf, 14 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) Order Job name/Part name...
Page 232: Installation
EXHAUST PIPE AND MUFFLER INSTALLATION 1. Install: • Exhaust pipe (temporarily) Install the exhaust pipe to the brackets the frame, making sure to position it as far rearward as possible, and then temporarily tighten the exhaust pipe bolts. 2. Install: •...
Page 233 EXHAUST PIPE AND MUFFLER 5. Tighten: • Exhaust pipe band bolts Exhaust pipe band bolt: 18 Nm (1.8 m•kgf, 13 ft•lbf) 6. Tighten: • Muffler band bolt Muffler band bolt: 20 Nm (2.0 m•kgf, 14 ft•lbf) 7. Tighten: • Muffler bolts Muffler bolt: 16 Nm (1.6 m•kgf, 11 ft•lbf) 8.
Page 234: Oil Tank
OIL TANK OIL TANK 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 19 Nm (1.9 m•kgf, 13 ft•lbf) Order Job name/Part name Q’ty Remarks Oil tank removal Remove the parts in the order listed below. Side cover (right) Refer to “COWLINGS”...
Page 235: Engine Assembly
ENGINE ASSEMBLY ENGINE ASSEMBLY LEADS AND HOSES 7 Nm (0.7 m•kgf, 5.1 ft•lbf) 8 Nm (0.8 m•kgf, 5.8 ft•lbf) 18 Nm (1.8 m•kgf, 13 ft•lbf) Order Job name/Part name Q’ty Remarks Leads and hoses removal Remove the parts in the order listed below.
Page 236: Engine Assembly
ENGINE ASSEMBLY 7 Nm (0.7 m•kgf, 5.1 ft•lbf) 8 Nm (0.8 m•kgf, 5.8 ft•lbf) 18 Nm (1.8 m•kgf, 13 ft•lbf) Order Job name/Part name Q’ty Remarks Battery Refer to “BATTERY INSPECTION” in CHAPTER 2. Ignition coil coupler Disconnect. Oil pressure switch sub-lead coupler Disconnect.
Page 237 ENGINE ASSEMBLY 7 Nm (0.7 m•kgf, 5.1 ft•lbf) 8 Nm (0.8 m•kgf, 5.8 ft•lbf) 18 Nm (1.8 m•kgf, 13 ft•lbf) Order Job name/Part name Q’ty Remarks Starter relay Main fuse Negative battery lead coupler Disconnect. Fuse box Water pump inlet hose Disconnect.
Page 238 ENGINE ASSEMBLY ENGINE ASSEMBLY 9 Nm (0.9 m•kgf, 6.5 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 45 Nm (4.5 m•kgf, 32 ft•lbf) 65 Nm (6.5 m•kgf, 47 ft•lbf) Order Job name/Part name Q’ty Remarks Engine assembly removal Remove the parts in the order listed below.
Page 239 ENGINE ASSEMBLY 9 Nm (0.9 m•kgf, 6.5 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) 45 Nm (4.5 m•kgf, 32 ft•lbf) 65 Nm (6.5 m•kgf, 47 ft•lbf) Order Job name/Part name Q’ty Remarks Rear engine mounting bolt spacer For installation, reverse the removal procedure.
Page 240: Removal
ENGINE ASSEMBLY REMOVAL 1. Remove: • Rear engine mounting nut • Front engine mounting nuts • Washers Do not remove the engine mounting bolts. 2. Remove: • Engine assembly Removal steps: • Screw in the engine mounting bolt spacers (front and rear) using the engine mount spacer wrench (engine adjuster) so that there is a gap between each engine mount-...
Page 241 ENGINE ASSEMBLY • Tighten the rear engine mounting bolt spacer to specification with an engine mount spacer wrench (engine adjuster) Rear engine mounting bolt spacer: 9 Nm (0.9 m•kgf, 6.5 ft•lbf) Engine mount spacer wrench: Engine mount spacer wrench: YS-01516 YS-01516 Engine adjuster: Engine adjuster:...
Page 242: Camshafts
CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER 12 Nm (1.2 m•kgf, 8.7 ft•lbf) 13 Nm (1.3 m•kgf, 9.4 ft•lbf) Order Job name/Part name Q’ty Remarks Cylinder head cover removal Remove the parts in the order listed below. Throttle body assembly Refer to “THROTTLE BODY” in CHAPTER 7.
Page 243: Camshafts
CAMSHAFTS CAMSHAFTS 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 12 Nm (1.2 m•kgf, 8.7 ft•lbf) 24 Nm (2.4 m•kgf, 17 ft•lbf) Order Job name/Part name Q’ty Remarks Camshafts removal Remove the parts in the order listed below. Engine Refer to “ENGINE ASSEMBLY”. Timing accessing screw Crankshaft end cover Timing chain tensioner...
Page 244: Removal
CAMSHAFTS REMOVAL 1. Remove: • Timing accessing screw • Crankshaft end cover 2. Align: • “I” mark on the AC magneto rotor (with the stationary pointer on the AC magneto cover) • Turn the crankshaft clockwise. • When piston #3 is at TDC on the compres- sion stroke, align the “I”...
Page 245: Inspection
CAMSHAFTS 6. Remove: • Exhaust camshaft sprocket • Intake camshaft sprocket (Use the special tool Universal magneto & rotor holder: YU-01235 Rotor holding tool: 90890-01235 INSPECTION 1. Inspect: • Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • Camshaft lobe dimensions Out of specification →...
Page 246 CAMSHAFTS 3. Measure: • Camshaft runout Out of specification → Replace. Camshaft runout: 0.030 mm (0.0012 in) 4. Measure: • Camshaft-journal-to-camshaft-cap clear- ance Out of specification → Measure the cam- shaft journal diameter. Camshaft-journal-to-camshaft- cap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) Measurement steps: •...
Page 247 CAMSHAFTS 5. Measure: • Camshaft journal diameter • Out of specification → Replace the cam- shaft. • Within specification → Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter: 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) 6.
Page 248 CAMSHAFTS 10.Assemble: • Timing chain tensioner spring • Timing chain tensioner rod Prior to installing the timing chain tensioner rod, drain the engine oil from the timing chain tensioner housing. Assembly steps: • Install the timing chain tensioner spring and timing chain tensioner rod •...
Page 249: Installation
CAMSHAFTS 11.Inspect: • All parts Damage/wear → Replace the defective part(-s). INSTALLATION 1. Install: • Intake camshaft sprocket • Exhaust camshaft sprocket (with the special tool Universal magneto & rotor holder: YU-01235 Rotor holding tool: 90890-01235 • Camshaft sprocket bolts Camshaft sprocket bolt: 24 Nm (2.4 m•kgf, 17 ft•lbf) Make sure that the holes...
Page 250 CAMSHAFTS 2. Install: • Intake camshaft (with the camshaft sprocket) • Exhaust camshaft (with the camshaft sprocket) Installation steps: • Turn the crankshaft clockwise. • When piston #3 is at TDC on the compres- sion stroke, align the “I” mark on the AC magneto rotor with the stationary pointer on the AC magneto cover.
Page 251 CAMSHAFTS 4. Install: • Camshaft cap bolts Camshaft cap bolt: 10 Nm (1.0 m•kgf, 7.2 ft•lbf) Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. NOTICE • Lubricate the camshaft cap bolts with the engine oil.
Page 252 • Apply bond TB1541 onto the mating sur- faces of the cylinder head cover and cylinder head cover gasket. • Apply Yamaha bond No. 1215 onto the mating surfaces of the cylinder head cover gasket. • Tighten the cylinder head cover bolts stages and in a crisscross pattern.
Page 253: Cylinder Head
CYLINDER HEAD CYLINDER HEAD 12 Nm (1.2 m•kgf, 8.7 ft•lbf) 20 Nm (2.0 m•kgf, 14 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) 25 Nm (2.5 m•kgf, 18 ft•lbf) Specified angle 175 ~ 185° Final Order Job name/Part name Q’ty Remarks Cylinder head removal Remove the parts in the order listed below.
Page 254: Removal
CYLINDER HEAD REMOVAL 1. Remove: • Cylinder head bolts • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. INSPECTION 1.
Page 255: Installation
CYLINDER HEAD INSTALLATION 1. Install: • Dowel pins • Cylinder head gasket • Cylinder head Pass the timing chain through the timing chain cavity. 2. Tighten: • Cylinder head bolts (M10) The tightening procedure of the cylinder head bolts is angle controlled, therefore tighten the bolts using the following procedure.
Page 256 CYLINDER HEAD • Tighten the cylinder head bolts further to reach the specified angle 175 ~ 185° in the proper tightening sequence as shown. Cylinder head bolt (M10): Final: Specified angle 175 ~ 185° WARNING When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it.
Page 257: 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”. Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Intake valve Exhaust valve...
Page 258: Removal
VALVES AND VALVE SPRINGS REMOVAL The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: •...
Page 259: Inspection
VALVES AND VALVE SPRINGS 3. Remove: • Valve cotters Remove the valve cotters by compressing the valve spring with the valve spring compressor and valve spring compressor adapter 19.5 mm (valve spring compressor attachment) Valve spring compressor: YM-04019, 90890-04019 Valve spring compressor adapter 19.5 mm: YM-04114 Valve spring compressor...
Page 260 VALVES AND VALVE SPRINGS 2. Replace: • Valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. Replacement steps: • Remove the valve guide with the valve guide remover •...
Page 261 VALVES AND VALVE SPRINGS 4. Inspect: • Valve face Pitting/wear → Grind the valve face. • Valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve. 5. Measure: • Valve margin thickness Out of specification →...
Page 262 VALVES AND VALVE SPRINGS 9. Measure: • Valve seat width Out of specification → Replace the cylinder head. Valve seat width: Intake: 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) Exhaust: 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) Measurement steps:...
Page 263 VALVES AND VALVE SPRINGS 10.Lap: • Valve face • Valve seat After replacing the cylinder head or replacing the valves and valve guides, the valve seat and valve face should be lapped. Lapping steps: • Apply a coarse lapping compound to the valve face.
Page 264 VALVES AND VALVE SPRINGS 11.Measure: • Valve spring free length Out of specification → Replace the valve spring. Valve spring free length (intake and exhaust): 40.14 mm (1.58 in) <Limit>: 38.14 mm (1.50 in) 12.Measure: • Compressed valve spring force Out of specification →...
Page 265: Installation
VALVES AND VALVE SPRINGS INSTALLATION 1. Deburr: • Valve stem end (with an oil stone) 2. Lubricate: • Valve stem • Valve stem seal (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide oil 3. Install: • Lower spring seat • Valve stem seal •...
Page 266 VALVES AND VALVE SPRINGS 4. Install: • Valve cotters Install the valve cotters by compressing the valve spring with the valve spring compressor and valve spring compressor adapter 19.5 mm (valve spring compressor attachment) Valve spring compressor: YM-04019, 90890-04019 Valve spring compressor adapter 19.5 mm: YM-04114 Valve spring compressor...
Page 267 VALVES AND VALVE SPRINGS 7. Install: • Valve pad • Valve lifter • The valve lifter must move smoothly when rotated with a finger. • Each valve lifter and valve pad must be rein- stalled in its original position. 5-42...
Page 268: Ac Magneto Rotor And Starter Clutch
AC MAGNETO ROTOR AND STARTER CLUTCH AC MAGNETO ROTOR AND STARTER CLUTCH 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 12 Nm (1.2 m•kgf, 8.7 ft•lbf) 16 Nm (1.6 m•kgf, 11 ft•lbf) 130 Nm (13.0 m•kgf, 94 ft•lbf) Order Job name/Part name Q’ty Remarks AC magneto rotor and starter clutch...
Page 269: Removal
AC MAGNETO ROTOR AND STARTER CLUTCH REMOVAL 1. Remove: • AC magneto rotor bolt • Washer While holding the AC magneto rotor with the primary clutch holder (sheave holder) loosen the AC magneto rotor bolt. Primary clutch holder: YS-01880-A Sheave holder: 90890-01701 2.
Page 270: Inspection
AC MAGNETO ROTOR AND STARTER CLUTCH 3. Remove: • Starter clutch While holding the AC magneto rotor with the primary clutch holder (sheave holder), remove the starter clutch bolts Primary clutch holder: YS-01880-A Sheave holder: 90890-01701 INSPECTION 1. Inspect: • Stator coil Damage →...
Page 271: Installation
AC MAGNETO ROTOR AND STARTER CLUTCH 4. Inspect: • Starter clutch operation Installation steps: • Install the starter clutch gear onto the starter clutch and hold the AC magneto rotor. • When turning the starter clutch gear clock- wise , it should turn freely, otherwise the starter clutch is faulty and must be replaced.
Page 272 Primary clutch holder: YS-01880-A Sheave holder: 90890-01701 5. Apply: • Sealant (onto the AC magneto lead grommet) Yamaha bond No. 1215: ® (Three Bond No.1215 90890-85505 6. Install: • AC magneto rotor cover gasket • AC magneto rotor cover AC magneto rotor cover bolt: 12 Nm (1.2 m•kgf, 8.7 ft•lbf)
Page 273: Oil Pan And Oil Pump
OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 12 Nm (1.2 m•kgf, 8.7 ft•lbf) 15 Nm (1.5 m•kgf, 11 ft•lbf) Order Job name/Part name Q’ty Remarks Oil pan and oil pump removal Remove the parts in the order listed below.
Page 274 OIL PAN AND OIL PUMP 4 Nm (0.4 m•kgf, 2.9 ft•lbf) Order Job name/Part name Q’ty Remarks Oil pump disassembly Remove the parts in the order listed below. Oil pan divider Oil pump housing cover 1 Oil pump housing cover 2 Oil strainer Washer Oil pump inner rotor 1...
Page 275 OIL PAN AND OIL PUMP 4 Nm (0.4 m•kgf, 2.9 ft•lbf) Order Job name/Part name Q’ty Remarks Check ball Spring Spacer Relief valve cover Spring Relief valve Oil pump housing For assembly, reverse the disassembly procedure. 5-50...
Page 276: Removal
OIL PAN AND OIL PUMP REMOVAL 1. Remove: • Oil pan 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. 2. Remove: •...
Page 277 OIL PAN AND OIL PUMP 3. Measure: • Inner-rotor-to-outer-rotor-tip clearance (between inner rotor and outer rotor • Outer-rotor-to-oil-pump-housing clearance (between outer rotor and pump housing Out of specifications → Replace the oil pump assembly. Inner-rotor-to-outer-rotor-tip clearance: 0.090 ~ 0.150 mm (0.0035 ~ 0.0059 in) Limit: 0.230 mm (0.0091 in)
Page 278: Installation
OIL PAN AND OIL PUMP 6. Inspect: • Oil pump driven gear Cracks/damage/wear → Replace. 7. Inspect: • Check ball seat • Check ball • Spring • Spacer Damage/wear → Replace the oil pump assembly. 8. Inspect: • Oil strainers Damage →...
Page 279 OIL PAN AND OIL PUMP 2. Install: • Pin • Inner rotor • Outer rotor • Each set of inner and outer rotors should be installed with both punch marks facing in the same direction, either away from or towards the oil pump assembly. •...
Page 280 OIL PAN AND OIL PUMP 5. Install: • Dowel pins • Oil pan gasket • Oil pan • Gasket • Oil pan bolts Oil pan bolt: 10 Nm (1.0 m•kgf, 7.2 ft•lbf) Tighten the oil pan bolts in stages and in a crisscross pattern.
Page 281: Crankcase
15 Nm (1.5 m•kgf, 11 ft•lbf) Specified angle 65 ~ 70° Final 15 Nm (1.5 m•kgf, 11 ft•lbf) 15 Nm (1.5 m•kgf, 11 ft•lbf) Final Specified angle 85 ~ 90° Yamaha bond No.1215 ® (Three Bond No.1215 Order Job name/Part name Q’ty Remarks Crankcase separate Remove the parts in the order listed below.
Page 282 15 Nm (1.5 m•kgf, 11 ft•lbf) Specified angle 65 ~ 70° Final 15 Nm (1.5 m•kgf, 11 ft•lbf) 15 Nm (1.5 m•kgf, 11 ft•lbf) Final Specified angle 85 ~ 90° Yamaha bond No.1215 ® (Three Bond No.1215 Order Job name/Part name Q’ty Remarks...
Page 283: Removal
CRANKCASE REMOVAL 1. Remove: • Crankcase bolts • Place the engine upside down. • Loosen the bolts in decreasing numerical order of the embossed numbers on the crank- case. • Loosen each bolt 1/4 of a turn at a time. After all of the bolts are fully loosened, remove them.
Page 284: Inspection
CRANKCASE INSPECTION 1. Inspect: • Crankcase: Cracks/damage → Replace. • Thoroughly wash the crankcase halves in a mild solvent. • Thoroughly clean all the gasket surfaces and crankcase mating surfaces. • Oil delivery passages Obstruction → Blow out with compressed air.
Page 285: Installation
(with the recommended lubricant) Recommended lubricant: Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215: ® (Three Bond No.1215 90890-85505 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
Page 286 • Lubricate the bolts thread part and mating surface with engine oil. • Apply Yamaha bond No. 1215 (Three Bond ® No.1215 ) to the threads of the bolts • Finger tighten the crankcase bolts.
Page 287 CRANKCASE 5. Tighten: • Crankcase bolts (M9 × 164 mm) • Crankcase bolts (M9 × 105 mm) Tighten the bolts in the order of the embossed numbers on the crankcase. • Tighten the crankcase bolts. Crankcase bolt 1st: 15 Nm (1.5 m•kgf, 11 ft•lbf) •...
Page 288 CRANKCASE 6. Tighten: • Crankcase bolts Tighten the bolts in the order of the embossed numbers on the crankcase. Crankcase bolt 24 Nm (2.4 m•kgf, 17 ft•lbf) Crankcase bolt 12 Nm (1.2 m•kgf, 8.7 ft•lbf) 7. Install: • Primary sheave drive shaft assembly bolts Primary sheave drive shaft assembly bolt: 12 Nm (1.2 m•kgf, 8.7 ft•lbf)
Page 289 CRANKCASE 9. Install: • Engine mounting brackets • Engine mounting bracket bolts When installing the engine mounting brackets, make sure that the number on each side of the upper crankcase is aligned with the identical number on the brackets. Engine mounting bracket bolt: 25 Nm (2.5 m•kgf, 18 ft•lbf) 5-64...
Page 290: Connecting Rods And Pistons
CONNECTING RODS AND PISTONS CONNECTING RODS AND PISTONS 20 Nm (2.0 m•kgf, 14 ft•lbf) Final Specified angle 115 ~ 125° Order Job name/Part name Q’ty Remarks Connecting rods and pistons Remove the parts in the order listed below. removal Crankcase Separate.
Page 291: Removal
CONNECTING RODS AND PISTONS REMOVAL 1. Remove: • Connecting rod cap • Big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place. 2. Remove: • Piston pin clips • Piston pin •...
Page 292: Inspection
CONNECTING RODS AND PISTONS INSPECTION 1. Inspect: • Piston wall • Cylinder wall Vertical scratches → Replace the crank- case, and replace the piston and piston rings as a set. 2. Measure: • Piston-to-cylinder clearance Measurement steps: 1st step: • Measure cylinder bore “C” with the cylinder bore gauge Measure cylinder bore “C”...
Page 293 CONNECTING RODS AND PISTONS 2nd step: • Measure piston skirt diameter “P” with the micrometer. 11.0 mm (0.43 in) from the bottom edge of the piston. Piston size (standard) (P): 81.950 ~ 81.965 mm (3.2264 ~ 3.2270 in) • If out of specification, replace the piston and piston rings as a set.
Page 294 CONNECTING RODS AND PISTONS 4. Install: • Piston ring (into the cylinder) Level the piston ring in the cylinder with the piston crown. 5.0 mm (0.20 in) 5. Measure: • Piston ring end gap Out of specification → Replace the piston rings as a set.
Page 295 CONNECTING RODS AND PISTONS 8. Measure: • Piston pin bore inside diameter Out of specification → Replace the piston. Piston pin bore inside diameter: 19.004 ~ 19.015 mm (0.7482 ~ 0.7486 in) <Limit>: 19.045 mm (0.7498 in) 9. Calculate: • Piston-pin-to-piston-pin-bore clearance Out of specification →...
Page 296 CONNECTING RODS AND PISTONS Measurement steps: NOTICE 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 orig- inal positions. •...
Page 297 CONNECTING RODS AND PISTONS • Tighten the connecting rod nuts. Refer to “CONNECTING RODS AND PIS- TONS”. • Remove the connecting rod and big end bearings. ® • Measure the compressed Plastigauge width on the crankshaft pin. crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings.
Page 298: Installation
CONNECTING RODS AND PISTONS INSTALLATION 1. Install: • Top ring • 2nd ring • Upper oil ring rail • Oil ring expander • Lower oil ring rail Be sure to install the piston rings so that the manufacturer marks face up. 2.
Page 299 CONNECTING RODS AND PISTONS 4. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant: Engine oil 5. Lubricate: • Bolt threads and seats • Nut seats (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide oil 6.
Page 300 CONNECTING RODS AND PISTONS 7. Install: • Big end bearings • Connecting rod assembly (into the cylinder and onto the crankshaft pin). • Connecting rod cap (onto the connecting rod) • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps.
Page 301 CONNECTING RODS AND PISTONS 8. Align: • Bolt heads (with the connecting rod caps) 9. Tighten: • Connecting rod nuts WARNING Replace the connecting rod bolts and nuts with new ones. NOTICE Tighten the connecting rod bolts using the plastic-region tightening angle method. •...
Page 302: Crankshaft And Balancer Shaft
CRANKSHAFT AND BALANCER SHAFT CRANKSHAFT AND BALANCER SHAFT 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 35 Nm (3.5 m•kgf, 25 ft•lbf) Order Job name/Part name Q’ty Remarks Crankshaft and balancer shaft Remove the parts in the order listed below. removal Crankcase Separate.
Page 303 CRANKSHAFT AND BALANCER SHAFT 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 35 Nm (3.5 m•kgf, 25 ft•lbf) Order Job name/Part name Q’ty Remarks Balancer shaft Balancer driven gear Bearing retainer Bearing Circlip Bearing For installation, reverse the removal procedure. 5-78...
Page 304: Remove
CRANKSHAFT AND BALANCER SHAFT REMOVE 1. Remove: • Crankshaft journal lower bearings (from the lower crankcase) • Crankshaft journal upper bearings (from the upper crankcase) Identify the position of each crankshaft journal bearing so that it can be reinstalled in its origi- nal place.
Page 305: Inspection
CRANKSHAFT AND BALANCER SHAFT INSPECTION 1. Measure: • Crankshaft runout Use the V-blocks and a dial indicator gauge (dial gauge). Out of specification → Replace the crank- shaft. Dial indicator gauge: YU-A8428 Dial gauge: 90890-03097 Crankshaft runout: 0.03 mm (0.0012 in) 2.
Page 306 CRANKSHAFT AND BALANCER SHAFT 6. Measure: • Crankshaft-journal-to-crankshaft-journal- bearing clearance Out of specification → Replace the crank- shaft journal bearings. Crankshaft-journal-to-crankshaft- journal-bearing clearance: 0.027 ~ 0.045 mm (0.0011 ~ 0.0018 in) Measurement steps: NOTICE Do not interchange the crankshaft journal bearings.
Page 307 CRANKSHAFT AND BALANCER SHAFT • Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves. • Align the projections of the crankshaft journal lower bearings with the notches the crankcase. • Do not move the crankshaft until the clear- ance measurement has been completed.
Page 308 CRANKSHAFT AND BALANCER SHAFT 7. Select: • Crankshaft journal bearings (J1 ~ J4) • The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • “J1 ~ J4” refer to the bearings shown in the crankshaft web and lower crankcase illustra- tion.
Page 309: Installation
CRANKSHAFT AND BALANCER SHAFT INSTALLATION 1. Install: • Balancer driven gear • Balancer shaft • Face the punch mark on the balancer driven gear inward. • Align the projection on the balancer shaft with the slot in the balancer driven gear. 2.
Page 310 CRANKSHAFT AND BALANCER SHAFT 4. Tighten: • Balancer weight bolts Place a wood between the balancer weight and crankcase. Balancer weight bolt: 35 Nm (3.5 m•kgf, 25 ft•lbf) 5. Bend the lock washer tab. 6. Install: • Crankshaft journal upper bearings (into the upper crankcase) •...
Page 311 CRANKSHAFT AND BALANCER SHAFT 8. Install: • Primary sheave drive shaft assembly (to the crankshaft Align the shallow groove in the primary drive shaft assembly with the low spline the crankshaft. 9. Install: • Crankshaft (with primary sheave drive shaft assembly) •...
Page 312: Cool
COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER HEAT EXCHANGER (RS90GTZ/RS90LTGTZ) 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 13 Nm (1.3 m•kgf, 9.4 ft•lbf) Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below.
Page 313 COOL HEAT EXCHANGER 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 13 Nm (1.3 m•kgf, 9.4 ft•lbf) Order Job name/Part name Q’ty Remarks Rear heat exchanger outlet hose Left heat exchanger Left heat exchanger outlet hose Water pump inlet hose Front heat exchanger air bleed hose Thermostat outlet hose...
Page 314 COOL HEAT EXCHANGER 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 13 Nm (1.3 m•kgf, 9.4 ft•lbf) Order Job name/Part name Q’ty Remarks Engine outlet pipe Front heat exchanger For installation reverse the removal procedure.
Page 315: Heat Exchanger (Rst90Gtz)
COOL HEAT EXCHANGER HEAT EXCHANGER (RST90GTZ) 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 13 Nm (1.3 m•kgf, 9.4 ft•lbf) Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain.
Page 316 COOL HEAT EXCHANGER 4 Nm (0.4 m•kgf, 2.9 ft•lbf) 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 13 Nm (1.3 m•kgf, 9.4 ft•lbf) Order Job name/Part name Q’ty Remarks Oil cooler inlet hose Oil cooler Oil cooler outlet hose Thermostat assembly Coolant reservoir inlet hose Thermostat intlet hose Throttle body inlet hose Water pump air bleed hose...
Page 317: Inspection
• Heat exchangers • Oil cooler • Engine outlet pipe Cracks/damage → Replace. 2. Inspect: • Radiator fins (RS90GTZ/RS90LTGTZ) Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver.
Page 318: Installation
COOL HEAT EXCHANGER Measurement steps: • Attach the radiator pressure tester (radiator cap tester) and radiator pressure tester adapter (radiator cap tester adapter) the radiator cap Radiator pressure tester: YU-24460-01 Radiator cap tester: 90890-01325 Radiator pressure tester adapter: YU-33984 Radiator cap tester adapter: 90890-01352 •...
Page 319: Thermostat
COOL THERMOSTAT THERMOSTAT THERMOSTAT 10 Nm (1.0 m•kgf, 7.2 ft•lbf) 23 Nm (2.3 m•kgf, 17 ft•lbf) Order Job name/Part name Q’ty Remarks Thermostat disassembly Remove the parts in the order listed below. Coolant temperature sensor coupler Disconnect. Coolant temperature sensor Front heat exchanger air bleed hose Disconnect.
Page 320: Iinspection
COOL THERMOSTAT IINSPECTION 1. Inspect: • Thermostat Does not open at 69.0 ~ 73.0 °C (156.20 ~ 163.40 °F) → Replace. Inspection steps: • Suspend the thermostat in a container filled with water. • Slowly heat the water. Place a thermometer in the water. •...
Page 321 COOL THERMOSTAT 3. Install: • Coolant temperature sensor (to the thermostat housing) Coolant temperature sensor: 23 Nm (2.3 m•kgf, 17 ft•lbf) NOTICE Use extreme care when handling the cool- ant temperature sensor. Replace any part that was dropped or subjected to a strong impact.
Page 322: Water Pump
COOL WATER PUMP WATER PUMP 12 Nm (1.2 m•kgf, 8.7 ft•lbf) Order Job name/Part name Q’ty Remarks Water pump removal Remove the parts in the order listed below. Frame cross member Refer to “ENGINE ASSEMBLY” in CHAPTER 5. Water pump inlet hose Disconnect.
Page 323 COOL WATER PUMP 6 Nm (0.6 m•kgf, 4.3 ft•lbf) Order Job name/Part name Q’ty Remarks Water pump disassembly Remove the parts in the order listed below. Water pump housing cover Gasket Circlip Impeller shaft gear Impeller shaft assembly Water pump seal Oil seal Bearing Water pump housing...
Page 324: Removal
COOL WATER PUMP REMOVAL 1. Remove: • Timing mark accessing screw • Crankshaft end accessing screw 2. Align: • “I” mark on the AC magneto rotor (with the stationary pointer on the AC magneto cover) Turn the crankshaft clockwise. 3. Remove: •...
Page 325: Inspection
COOL WATER PUMP INSPECTION 1. Inspect: • Water pump housing cover • Water pump housing • Impeller • Impeller shaft gear • Rubber damper • Rubber damper holder • Water pump seal • Oil seal Cracks/damage/wear → Replace. 2. Inspect: •...
Page 326 30 – 10 mm bearing driver 40 mm (Middle driven shaft bearing driver) • Before installing the water pump seal, apply Yamaha bond No. 1215 to the water pump housing Mechanical seal installer 30 – 10 mm:...
Page 327: Installation
COOL WATER PUMP 5. Measure: • Impeller shaft tilt Out of specification → Repeat steps (4) and (5). NOTICE Make sure the rubber damper and rubber damper holder are flush with the impeller. Max. impeller shaft tilt: 0.15 mm (0.0059 in) Straightedge Impeller INSTALLATION...
Page 328: Chapter 7. Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ECU (engine control Coolant temperature Intake pressure Warning light unit) sensor sensor 2 (cylinder #1) Fuel pump Battery Cylinder-#3 ignition Oil pressure switch Fuel injection system Injector #2 coil Throttle position sen- relay Intake pressure...
Page 329 FUEL INJECTION SYSTEM Passenger grip warmer relay RS90GTZ/RS90LTGTZ RST90GTZ...
Page 330: Circuit Diagram (Rs90Gtz/Rs90Ltgtz)
FUEL INJECTION SYSTEM CIRCUIT DIAGRAM (RS90GTZ/RS90LTGTZ)
Page 331 FUEL INJECTION SYSTEM Main switch Main fuse Load control relay Battery Starter relay Fuel injection system fuse Engine stop switch Throttle switch Crankshaft position sensor Grip warmer Thumb warmer Oil pressure switch ECU (engine control unit) Cylinder-#1 ignition coil Spark plug Cylinder-#2 ignition coil Cylinder-#3 ignition coil Fuel injection system relay...
Page 332: Circuit Diagram (Rst90Gtz)
FUEL INJECTION SYSTEM CIRCUIT DIAGRAM (RST90GTZ)
Page 333 FUEL INJECTION SYSTEM Main switch Main fuse Load control relay Battery Starter relay Fuel injection system fuse Engine stop switch Throttle switch Crankshaft position sensor Grip warmer Thumb warmer Oil pressure switch ECU (engine control unit) Cylinder-#1 ignition coil Spark plug Cylinder-#2 ignition coil Cylinder-#3 ignition coil Fuel injection system relay...
Page 334: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and the warning light and self-diagnostic warning indicator on the upper LCD flash to alert the rider that a malfunction has occurred in the system.
Page 335 FUEL INJECTION SYSTEM Fault code Able/unable Able/unable Item Symptom to start to drive Cylinder-#3 ignition coil (faulty Malfunction detected in the primary Able Able ignition) lead of the cylinder-#3 ignition coil. (depending on (depending on the number of the number of faulty faulty cylinders)
Page 336: Troubleshooting Chart
FUEL INJECTION SYSTEM TROUBLESHOOTING CHART Engine operation is not normal or the warning light and self-diagnostic warning indicator on the LCD flash. * The warning light and self-diagnostic warning indicator on the upper LCD may not flash even if the engine operation is not normal.
Page 337: Diagnostic Mode
FUEL INJECTION SYSTEM DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode “RESET”...
Page 338 FUEL INJECTION SYSTEM 6. Verify the operation of the sensor or actua- tor. • Sensor operation The data representing the operating condi- tions of the sensor appears on the odometer/tripmeter/fuel reserve tripmeter/ oil change tripmeter/display. • Actuator operation Push the grip warmer side of the grip/ thumb warmer adjustment switch to oper- ate the actuator.
Page 339 FUEL INJECTION SYSTEM Fault code table Fault Diagnostic Symptom Probable cause of malfunction code No. code No. No normal signals are • Coupler defective between sensor – ECU. received from the crankshaft • Open or short circuit in wire harness. position sensor.
Page 340 FUEL INJECTION SYSTEM Fault Diagnostic Symptom Probable cause of malfunction code No. code No. Malfunction detected in the • Coupler defective between cylinder-#3 ignition coil – ECU. primary lead of the cylinder- • Open or short circuit in wire harness. #3 ignition coil.
Page 341 FUEL INJECTION SYSTEM Fault Diagnostic Symptom Probable cause of malfunction code No. code No. No signals are received from • Coupler defective between speedometer unit – ECU. the ECU within the specified • Open or short circuit in wire harness. Er-2 signal time.
Page 342 FUEL INJECTION SYSTEM Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MODE”. • Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively.
Page 343 If the grip warmer side of the grip/thumb warmer After pushing the switch, relay adjustment switch is pushed, actuates the radia- check that the radiator fan (For RS90GTZ/ tor fan motor relay and displays the self-diagno- motor relay operates five times d:51 RS90LTGTZ)
Page 344 FUEL INJECTION SYSTEM Diagnostic Checking method Item Description of action code No. or meter display Malfunction history • Displays the code numbers of past malfunc- 12 ~ 85 code display tions (i.e., a code number of a malfunction that (00) Displays when there is no occurred once and which has been corrected).
Page 345: Troubleshooting Details
FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the meter display according to the reinstatement method.
Page 346 FUEL INJECTION SYSTEM Intake air pressure sensor 1 (cylinders #1, #2, and #3): open or short circuit Fault code No. Symptom detected. Diagnostic code No. d:03 (intake air pressure sensor 1 (cylinders #1, #2, and #3)) Item/components and probable cause Check or maintenance job Reinstate- Order...
Page 347 FUEL INJECTION SYSTEM Intake air pressure sensor 1 (cylinders #1, #2, and #3): hose system malfunc- Fault code No. Symptom tion (clogged or detached hose). Diagnostic code No. d:03 (intake air pressure sensor 1 (cylinders #1, #2, and #3)) Item/components and probable cause Check or maintenance job Reinstate- Order...
Page 348 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic code No. d:01 (throttle position sensor) Item/components and probable cause Check or maintenance job Reinstate- Order ment method Installed condition of throttle position sen- Check for looseness or pinching. Starting the sor.
Page 349 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor 2 (cylinder #1): open or short circuit detected. Diagnostic code No. d:04 (intake air pressure sensor 2 (cylinder #1)) Item/components and probable cause Check or maintenance job Reinstate- Order ment method Connections Check the couplers for any pins that may have...
Page 350 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor 2 (cylinder #1): open or short circuit detected. Diagnostic code No. d:04 (intake air pressure sensor 2 (cylinder #1)) Item/components and probable cause Check or maintenance job Reinstate- Order ment method Defective intake air pressure sensor 2 (cyl- Execute the diagnostic mode (code No.
Page 351 FUEL INJECTION SYSTEM Intake air pressure sensor 2 (cylinder #1): hose system malfunction (clogged or Fault code No. Symptom detached hose). Diagnostic code No. d:04 (intake air pressure sensor 2 (cylinder #1)) Item/components and probable cause Check or maintenance job Reinstate- Order ment method...
Page 352 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the cylinder-#2 ignition coil. Diagnostic code No. d:31 (cylinder-#2 ignition coil) Item/components and probable cause Check or maintenance job Reinstate- Order ment method Connections Check the couplers for any pins that may have Starting the •...
Page 353 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. d:54 (ISC (idle speed control) unit) Item/components and probable cause Check or maintenance job Reinstate- Order ment method Throttle valve does not fully close. Check the throttle body.
Page 354 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injectors and fuel pump is not normal. Diagnostic code No. d:09 (fuel system voltage) Item/components and probable cause Check or maintenance job Reinstate- Order ment method Connections Check the couplers for any pins that may have Setting the •...
Page 355 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). Diagnostic No. d:60 (EEPROM improper cylinder indication) Item/components and probable cause Check or maintenance job Reinstate- Order ment method Malfunction in ECU. Execute the diagnostic mode (code No.
Page 356 FUEL INJECTION SYSTEM Fault code No. Symptom TORS control completed. (Throttle valve is fixed due to icing and not a failure.) Diagnostic code No. – – • If fault codes No. 15 and 84 are displayed at the same time, check and repair No. 15 first. Notice •...
Page 357 FUEL INJECTION SYSTEM Fault code No. Symptom Oil pressure switch: open circuit detected. Diagnostic code No. – – Item/components and probable cause Check or maintenance job Reinstate- Order ment method Connections Check the couplers for any pins that may have Starting the •...
Page 358: Oil Pressure Switch
FUEL INJECTION SYSTEM OIL PRESSURE SWITCH 1. Disconnect: • Oil pressure switch coupler 2. Connect: • Analog pocket tester (pocket tester) (between the engine ground and oil pres- sure switch terminal) 3. Inspect: • Oil pressure switch continuity No continuity → Replace the oil pressure switch.
Page 359: Isc (Idle Speed Control) Unit
FUEL INJECTION SYSTEM ISC (IDLE SPEED CONTROL) UNIT Do not remove the ISC (idle speed control) unit completely from the throttle body. 1. Inspect: • ISC (idle speed control) unit Inspection steps: • Disconnect the ISC (idle speed control) unit coupler from the ISC (idle speed control) unit.
Page 360: Throttle Body
THROTTLE BODY THROTTLE BODY 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 7 Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job name/Part name Q’ty Remarks Throttle body removal Remove the parts in the order listed below. Coolant Drain.
Page 361 THROTTLE BODY 3 Nm (0.3 m•kgf, 2.2 ft•lbf) 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 7 Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job name/Part name Q’ty Remarks Intake air pressure sensor 2 (cylinder Disconnect. #1) coupler Intake air pressure sensor 1 (cylinders Disconnect.
Page 362: Injectors
THROTTLE BODY INJECTORS 3.5 Nm (0.35 m•kgf, 2.5 ft•lbf) Order Job name/Part name Q’ty Remarks Injectors removal Remove the parts in the order listed below. Throttle position sensor Negative pressure hose ISC (idle speed control) unit outlet hose Intake air pressure sensor 2 (cylinder Intake air pressure sensor 1 (cylinders #1, #2, and #3) Fuel rail...
Page 363: Removal
THROTTLE BODY REMOVAL 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose WARNING Cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hoses.
Page 364: Fuel Pressure Inspection
THROTTLE BODY FUEL PRESSURE INSPECTION 1. Inspect: • Fuel pressure Measurement steps: • Remove the fuel hose connector holder, and then disconnect the fuel hose. Refer to “FUEL TANK” in CHAPTER 5. • Connect the fuel pressure adapter between the fuel hose and fuel pump •...
Page 365: Inspection And Adjustment
THROTTLE BODY INSPECTION AND ADJUSTMENT 1. Inspect: • Throttle position sensor Inspect steps: • Disconnect the throttle position sensor cou- pler. • Remove the throttle position sensor from the throttle body. • Connect the analog pocket tester (pocket tester) (Ω × 1k) to the throttle position sensor. Positive tester probe →...
Page 366 THROTTLE BODY 2. Adjust: • Throttle position sensor angle Adjustment steps: • Connect the test harness-TPS (3P) to the throttle position sensor and wire harness as shown. • Connect the model 88 multimeter with tachometer (digital circuit tester) to the test harness-TPS (3P).
Page 367: Elec
ELEC SWITCH INSPECTION ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a analog pocket tester (pocket tester) to check the terminals for continuity. If the conti- nuity is faulty at any point, replace the switch. Analog pocket tester: YU-03112-C Pocket tester: 90890-03112 •...
Page 368: Ignition System
ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM (RS90GTZ/RS90LTGTZ)
Page 369 ELEC IGNITION SYSTEM Main switch Main fuse Battery Engine stop switch Throttle switch Crankshaft position sensor ECU (engine control unit) Cylinder-#1 ignition coil Spark plug Cylinder-#2 ignition coil Cylinder-#3 ignition coil Throttle position sensor Speed sensor Frame ground Multi-function meter Ignition fuse...
Page 370: Circuit Diagram (Rst90Gtz)
ELEC IGNITION SYSTEM CIRCUIT DIAGRAM (RST90GTZ)
Page 371 ELEC IGNITION SYSTEM Main switch Main fuse Battery Engine stop switch Throttle switch Crankshaft position sensor ECU (engine control unit) Cylinder-#1 ignition coil Spark plug Cylinder-#2 ignition coil Cylinder-#3 ignition coil Throttle position sensor Speed sensor Frame ground Multi-function meter Ignition fuse...
Page 372: 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 or charge the battery.
Page 373 ELEC IGNITION SYSTEM T.O.R.S. OPERATES. Is self-diagnosis code 15, 16, or 42 displayed? Check the affected item(s). Has throttle body icing occurred or is foreign material stuck in the throttle body? Perform throttle body maintenance. Is the throttle switch malfunctioning? Repair or replace the right handlebar switch.
Page 374: Ignition Spark Gap
ELEC IGNITION SYSTEM IGNITION SPARK GAP The following procedure applies to all of the ignition coils. 1. Measure: • Ignition spark gap Out of specification → Replace the ignition coil(s). Measurement steps: • Disconnect the ignition coil from the spark plug.
Page 375: Crankshaft Position Sensor
ELEC IGNITION SYSTEM CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor coupler 2. Connect: • Analog pocket tester (pocket tester) (to the crankshaft position sensor coupler) 3. Measure: • Crankshaft position sensor resistance Out of specification → Replace. Crankshaft position sensor resistance: 336 ~ 504 Ω...
Page 376: Throttle Override System (T.o.r.s.)
Engagement speed: RS90GTZ/RS90LTGTZ 3,100 ~ 3,500 r/min RST90GTZ 2,900 ~ 3,300 r/min Mode...
Page 377: Engine Stop Switch
ENGINE STOP SWITCH 1. Disconnect: • Engine stop switch coupler RS90GTZ/RS90LTGTZ RST90GTZ 2. Connect: • Analog pocket tester (pocket tester) (to the engine stop switch coupler) 3. Inspect: •...
Page 378: Throttle Switch
ELEC IGNITION SYSTEM THROTTLE SWITCH 1. Disconnect: • Throttle switch couplers RS90GTZ/RS90LTGTZ RST90GTZ 2. Connect: • Analog pocket tester (pocket tester) (to the throttle switch couplers) 3. Inspect: • Throttle switch continuity Faulty → Replace the right handlebar switch. Throttle lever...
Page 379: Electrical Starting System
ELEC ELECTRICAL STARTING SYSTEM ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM (RS90GTZ/RS90LTGTZ) Main switch Diode Main fuse Engine stop switch Battery Frame ground Starter motor Ignition fuse Starter relay 8-13...
Page 380: Circuit Diagram (Rst90Gtz)
ELEC ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM (RST90GTZ) Main switch Diode Main fuse Engine stop switch Battery Frame ground Starter motor Ignition fuse Starter relay 8-14...
Page 381: Troubleshooting
ELEC ELECTRICAL STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. 1. Connect: • Starter relay terminals (battery side and starter motor side) Jumper lead 2. Inspect: • Starter motor operation Check the battery and connectors. Refer to “BATTERY INSPECTION” in CHAP- TER 2.
Page 382 ELEC ELECTRICAL STARTING SYSTEM 3. Disconnect: • Starter relay coupler 4. Connect: • Starter relay coupler terminals Jumper lead 5. Inspect: • Starter motor operation Replace the starter relay. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER FAULTY Replace the main fuse and/or ignition fuse.
Page 383: Starter Motor
ELEC ELECTRICAL STARTING SYSTEM STARTER MOTOR 7 Nm (0.7 m•kgf, 5.1 ft•lbf) 27 Nm (2.7 m•kgf, 19 ft•lbf) Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in the order listed below. Engine assembly Refer to “ENGINE ASSEMBLY” in CHAP- TER 5.
Page 384 ELEC ELECTRICAL STARTING SYSTEM 7 Nm (0.7 m•kgf, 5.1 ft•lbf) 27 Nm (2.7 m•kgf, 19 ft•lbf) Order Job name/Part name Q’ty Remarks Brush holder Armature assembly Starter motor yoke For assembly, reverse the disassembly procedure. 8-18...
Page 385 ELEC ELECTRICAL STARTING SYSTEM Inspection 1. Inspect: • Commutator (outer surface) Dirty → Clean with #600 grit sandpaper Hold the armature in a vise and copper or aluminium plate NOTICE Lightly grip the armature with a vise. 2. Measure: • Commutator diameter Measure the diameter of the commuta- tor at points where the brush comes in con-...
Page 386 ELEC ELECTRICAL STARTING SYSTEM 4. Measure: • Armature coil resistance (insulation/continuity) Out of specification → Replace the starter motor. Inspecting steps: • Connect the analog pocket tester (pocket tester) for the continuity check and the insulation check • Measure the armature coil resistances. Armature coil resistance: Continuity check: 0.0081 ~ 0.0099 Ω...
Page 387 ELEC ELECTRICAL STARTING SYSTEM Assembly 1. Install: • Gaskets • Starter motor yoke (to the rear bracket Align the projection on the rear bracket with the slot on the starter motor yoke. 8-21...
Page 388: Charging System
ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM (RS90GTZ/RS90LTGTZ) AC magneto Rectifier/regulator Main fuse Battery Frame ground 8-22...
Page 389: Circuit Diagram (Rst90Gtz)
ELEC CHARGING SYSTEM CIRCUIT DIAGRAM (RST90GTZ) AC magneto Rectifier/regulator Main fuse Battery Frame ground 8-23...
Page 390: Troubleshooting
ELEC CHARGING SYSTEM TROUBLESHOOTING BATTERY IS NOT CHARGED. 1. Connect: • Analog pocket tester (pocket tester) (to the battery terminals) 2. Measure: OUT OF • Battery voltage SPECIFICATION Battery voltage: More than 12 V at 20 °C (68 °F) • Check the battery. •...
Page 391 ELEC CHARGING SYSTEM Check the charging system wiring. Refer to “CIRCUIT DIAGRAM”. FAULTY Properly connect or repair the charging sys- tem wiring. Correct the connector. 8-25...
Page 392: Battery
ELEC CHARGING SYSTEM BATTERY Inspection 1. Inspect: • Battery condition Refer to “BATTERY INSPECTION” in CHAPTER 2. Battery Storage The battery should be stored if the snowmobile is not going to be used for a long period. 1. Remove: • Battery WARNING When removing the battery, disconnect the negative battery lead first.
Page 393 ELEC CHARGING SYSTEM 8-27...
Page 394: Lighting System
ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM (RS90GTZ/RS90LTGTZ) 8-28...
Page 395 ELEC LIGHTING SYSTEM Main switch Main fuse Load control relay Battery Engine stop switch ECU (engine control unit) Frame ground Tail/brake light Multi-function meter High beam indicator light Meter light Headlight Headlight relay Headlight beam switch Headlight fuse Signal fuse Ignition fuse 8-29...
Page 396: Circuit Diagram (Rst90Gtz)
ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM (RST90GTZ) 8-30...
Page 397 ELEC LIGHTING SYSTEM Main switch Main fuse Load control relay Battery Engine stop switch ECU (engine control unit) Frame ground Tail/brake light Multi-function meter High beam indicator light Meter light Headlight Headlight relay Headlight beam switch Headlight fuse Signal fuse Ignition fuse 8-31...
Page 398: Troubleshooting
ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT DO NOT COME ON. Check the headlight 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 399 ELEC LIGHTING SYSTEM METER LIGHT DO NOT COME ON. 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 or charge the battery.
Page 400 ELEC LIGHTING SYSTEM TAIL LIGHT DOES NOT COME ON. 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 or charge the battery.
Page 401: Bulb(S)
Do not touch the bulb until it cools down. 3. Inspect: • Bulb(s) Terminal Continuity – – HEADLIGHT BEAM SWITCH 1. Disconnect: • Headlight beam switch coupler RS90GTZ/RS90LTGTZ RST90GTZ 2. Connect: • Analog pocket tester (pocket tester) (to the headlight beam switch coupler) 8-35...
Page 402: Headlight Relay
Faulty → Replace the left handlebar switch. Switch position Continuity HEADLIGHT RELAY 1. Remove: • Headlight relay (with the black coupler) RS90GTZ/RS90LTGTZ RST90GTZ Inspection steps: • Connect the analog pocket tester (pocket tester) (Ω × 1) to the headlight relay terminals as shown.
Page 403: Load Control Relay
ELEC LIGHTING SYSTEM LOAD CONTROL RELAY 1. Remove: • Load control relay RS90GTZ/RS90LTGTZ RST90GTZ Inspection steps: • Connect the analog pocket tester (pocket tester) (Ω × 1) and battery (12 V) to the load control relay terminals as shown. Positive battery terminal → Brown Negative battery terminal →...
Page 404: Signal System
ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM (RS90GTZ/RS90LTGTZ) 8-38...
Page 405 ELEC SIGNAL SYSTEM Main switch Main fuse Load control relay Battery Engine stop switch ECU (engine control unit) Speed sensor Coolant temperature sensor Frame ground Brake light switch Tail/brake light DC back buzzer Gear position switch Fuel sender Oil level switch Multi-function meter Warning light Low coolant temperature...
Page 406: Circuit Diagram (Rst90Gtz)
ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM (RST90GTZ) 8-40...
Page 407 ELEC SIGNAL SYSTEM Main switch Main fuse Load control relay Battery Engine stop switch ECU (engine control unit) Speed sensor Coolant temperature sensor Frame ground Brake light switch Tail/brake light DC back buzzer Gear position switch Fuel sender Oil level switch Multi-function meter Warning light Low coolant temperature...
Page 408: Troubleshooting
ELEC SIGNAL SYSTEM TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. 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 or charge the battery.
Page 409 ELEC SIGNAL SYSTEM LOW COOLANT TEMPERATURE INDICATOR LIGHT, COOLANT TEMPERATURE WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. 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.
Page 410 ELEC SIGNAL SYSTEM FUEL METER AND/OR FUEL LEVEL WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. 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”...
Page 411 ELEC SIGNAL SYSTEM OIL LEVEL WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. 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 or charge the battery.
Page 412 ELEC SIGNAL SYSTEM SPEEDOMETER DOES NOT OPERATE. 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 or charge the battery.
Page 413 ELEC SIGNAL SYSTEM BACK BUZZER DOES NOT SOUND. 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 or charge the battery.
Page 414: Brake Light Switch
ELEC SIGNAL SYSTEM BRAKE LIGHT SWITCH 1. Disconnect: • Brake light switch coupler RS90GTZ/RS90LTGTZ RST90GTZ 2. Connect: • Analog pocket tester (pocket tester) (to the brake light switch coupler) 3. Inspect: • Brake light switch continuity Faulty → Replace. Switch position...
Page 415: Dc Back Buzzer
ELEC SIGNAL SYSTEM DC BACK BUZZER 1. Disconnect: • DC back buzzer coupler RS90GTZ/RS90LTGTZ RST90GTZ 2. Connect: • Battery (to the DC back buzzer coupler) 3. Inspect: • DC back buzzer Does not sound → Replace. COOLANT TEMPERATURE SENSOR 1. Remove the coolant temperature sensor...
Page 416: Oil Level Switch
ELEC SIGNAL SYSTEM 2. Connect: • Analog pocket tester (pocket tester) (to the coolant temperature sensor) Set the tester selector to the “Ω × 1k” position. 3. Immerse the coolant temperature sensor in coolant and check the coolant tem- perature sensor operation. Coolant temperature sensor resistance: 5.21 ~ 6.37 kΩ...
Page 417: Fuel Sender
ELEC SIGNAL SYSTEM 2. Connect: • Analog pocket tester (pocket tester) (to the oil level switch coupler) 3. Inspect: • Oil level switch continuity Faulty → Replace. Switch Good Bad condition position condition Down × × position × × Up position ×...
Page 418: Speed Sensor
ELEC SIGNAL SYSTEM SPEED SENSOR 1. Inspect: • Speed sensor Inspection steps: • Connect the test harness-speed sensor (3P) to the speed sensor coupler and wire har- ness as shown. • Connect the pocket tester (DC 20 V) to the test harness-speed sensor (3P).
Page 419 ELEC SIGNAL SYSTEM 8-53...
Page 420: Grip Warmer System
ELEC GRIP WARMER SYSTEM GRIP WARMER SYSTEM CIRCUIT DIAGRAM (RS90GTZ/RS90LTGTZ) 8-54...
Page 421 ELEC GRIP WARMER SYSTEM Main switch Main fuse Battery Engine stop switch Grip warmer Thumb warmer ECU (engine control unit) Grip/thumb warmer adjustment switch Frame ground Multi-function meter Ignition fuse 8-55...
Page 422: Circuit Diagram (Rst90Gtz)
ELEC GRIP WARMER SYSTEM CIRCUIT DIAGRAM (RST90GTZ) 8-56...
Page 423 ELEC GRIP WARMER SYSTEM Main switch Main fuse Load control relay Battery Engine stop switch Grip warmer Thumb warmer ECU (engine control unit) Grip/thumb warmer adjustment switch Frame ground Passenger grip warmer switch Passenger grip warmer relay Passenger grip warmer Multi-function meter Signal fuse Ignition fuse...
Page 424: Troubleshooting
ELEC GRIP WARMER SYSTEM TROUBLESHOOTING GRIP WARMER AND THUMB WARMER DO NOT OPERATE. 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 or charge the battery.
Page 425: Grip/Thumb Warmer Adjustment Switch
ELEC GRIP WARMER SYSTEM GRIP WARMER AND THUMB WARMER CANNOT BE ADJUSTED. Check the grip/thumb warmer adjustment switch. NO CONTINUITY Replace the left handlebar switch. Check the grip warmer system wiring. Refer to “CIRCUIT DIAGRAM”. FAULTY Properly connect or repair the grip warmer system wiring.
Page 426 ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER DOES NOT OPERATE. (RST90GTZ) 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”...
Page 427: Grip Warmer And Thumb Warmer
ELEC GRIP WARMER SYSTEM GRIP WARMER AND THUMB WARMER 1. Disconnect: • Grip warmer couplers (RS90GTZ/ RS90LTGTZ) • Grip warmer connectors (RST90GTZ) • Thumb warmer coupler RS90GTZ/RS90LTGTZ RST90GTZ 2. Connect: • Analog pocket tester (pocket tester) (to the grip warmer couplers or grip warmer connector, and/or thumb warmer coupler) 3.
Page 428: Passenger Grip Warmer (Rst90Gtz)
ELEC GRIP WARMER SYSTEM 2. Connect: • Analog pocket tester (pocket tester) (to the grip/thumb warmer adjustment switch coupler) 3. Inspect: • Grip/thumb warmer adjustment switch con- tinuity Faulty → Replace the left handlebar switch. Color code Switch position THUMB GRIP Continuity PASSENGER GRIP WARMER (RST90GTZ)
Page 429: Passenger Grip Warmer Relay (Rst90Gtz)
ELEC GRIP WARMER SYSTEM 2. Connect: • Analog pocket tester (pocket tester) (to the passenger grip warmer switch cou- pler) 3. Inspect: • Passenger grip warmer switch continuity Faulty → Replace. Color code Switch position Continuity PASSENGER GRIP WARMER RELAY (RST90GTZ) 1.
Page 430: Cooling System
ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM (RS90GTZ/RS90LTGTZ) 8-64...
Page 431 ELEC COOLING SYSTEM Main switch Main fuse Battery Engine stop switch ECU (engine control unit) Coolant temperature sensor Frame ground Radiator fan motor Radiator fan motor relay Radiator fan fuse Ignition fuse 8-65...
Page 432: Troubleshooting
ELEC COOLING SYSTEM TROUBLESHOOTING THE RADIATOR FAN MOTOR DOES NOT MOVE (RS90GTZ/RS90LTGTZ) Check the main fuse, ignition fuse, and radiator fan fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse, and/or radiator fan fuse.
Page 433: Radiator Fan Motor (Rs90Gtz/Rs90Ltgtz)
ELEC COOLING SYSTEM RADIATOR FAN MOTOR (RS90GTZ/RS90LTGTZ) 1. Disconnect: • Radiator fan motor coupler 2. Connect: • Battery (to the radiator fan motor coupler) 3. Inspect: • Radiator fan motor Positive battery terminal → Blue Negative battery terminal → Black Does not move →...
Page 434: Spec
Model code number: 8JA1 (RS90GTZ) 8JB1 (RS90LTGTZ) 8HF3 (RST90GTZ) Dimensions: Overall length 2,805 mm (110.4 in) (RS90GTZ) 3,000 mm (118.1 in) (RS90LTGTZ) 3,185 mm (125.4 in) (RST90GTZ) Overall width 1,225 mm (48.2 in) Overall height 1,160 mm (45.7 in) (RS90GTZ/RS90LTGTZ) 1,380 mm (54.3 in) (RST90GTZ)
Page 435 39/24 (1.63) (RS90LTGTZ) 39/23 (1.70) (RST90GTZ) Reverse system Reverse gear ratio 2.08 (RS90GTZ/RS90LTGTZ) 2.17 (RST90GTZ) Overall reduction ratio 6.02 ~ 1.58 : 1 (RS90GTZ) 6.18 ~ 1.63 : 1 (RS90LTGTZ) 6.44 ~ 1.70 : 1 (RST90GTZ) Chassis: Frame type Monocoque Caster angle 23.0°...
Page 436 Molded rubber, fiberglass-rod reinforced Type Internal drive type Width 381 mm (15.0 in) Length on ground 768 mm (30.2 in) (RS90GTZ) 960 mm (37.8 in) (RS90LTGTZ) 985 mm (38.8 in) (RST90GTZ) Brake: Type Hydraulic disc type (ventilated disc) Operation method...
Page 437: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Description Cylinder head: Volume (with spark plug) 25.21 ~ 26.01 cm (1.54 ~ 1.59 cu.in) <Warpage limit> 0.10 mm (0.0039 in) * Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating Bore size 82.000 ~ 82.010 mm (3.2283 ~ 3.2287 in) <Taper limit>...
Page 438 SPEC MAINTENANCE SPECIFICATIONS Item Description Valves, valve seats, valve guides: Valve clearance (cold) Intake 0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) Exhaust 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Valve dimensions Valve head diameter A Intake 30.90 ~ 31.10 mm (1.2165 ~ 1.2244 in) Exhaust 25.90 ~ 26.10 mm (1.0197 ~ 1.0276 in) Valve face width B...
Page 439 SPEC MAINTENANCE SPECIFICATIONS Item Description Valve spring: Free length Intake 40.14 mm (1.58 in) <Limit> 38.14 mm (1.50 in) Exhaust 40.14 mm (1.58 in) <Limit> 38.14 mm (1.50 in) Installed length (valve closed) Intake 34.60 mm (1.36 in) Exhaust 34.60 mm (1.36 in) Compressed spring force (installed) Intake 103.40 ~ 119.00 N (10.54 ~ 12.13 kgf, 23.24 ~ 26.75 lbf)
Page 440 SPEC MAINTENANCE SPECIFICATIONS Item Description Piston ring: Top ring Ring type Barrel Dimensions (B × T) 1.00 × 2.80 mm (0.039 × 0.110 in) End gap (installed) 0.33 ~ 0.45 mm (0.013 ~ 0.018 in) Side clearance (installed) 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) Plating/coating Chrome plated/parkerizing 2nd ring...
Page 441 High-quality ethylene glycol antifreeze containing corrosion inhibitors Antifreeze/water mixing ratio 3 : 2 (60% : 40%) Total amount 5.6 L (5.92 US qt, 4.93 Imp.qt) (RS90GTZ) 6.1 L (6.45 US qt, 5.37 Imp.qt) (RS90LTGTZ) 5.4 L (5.71 US qt, 4.75 Imp.qt) (RST90GTZ)
Page 442: Power Train
59.50 mm (2.34 in) Wire diameter 6.0 mm (0.24 in) (RS90GTZ/RST90GTZ) 5.8 mm (0.23 in) (RS90LTGTZ) Preload 441 N (45.0 kgf, 99.1 lbf) (RS90GTZ/RS90LTGTZ) 294 N (30.0 kgf, 66.1 lbf) (RST90GTZ) Set length 73.4 mm (2.89 in) Spring rate 27.0 N/mm (2.75 kgf/mm, 154.17 lbf/in) (RS90GTZ) 22.1 N/mm (2.25 kgf/mm, 126.19 lbf/in) (RS90LTGTZ)
Page 443 Quantity 3 pcs Outer Part number 90269-06006 (RS90GTZ/RS90LTGTZ) 90266-06002 (RST90GTZ) Material Steel with hole Size 17.2 mm (0.68 in) (RS90GTZ/RS90LTGTZ) 13.3 mm (0.52 in) (RST90GTZ) Quantity 3 pcs Secondary sheave spring: Part number 90508-60018 (RS90GTZ/RS90LTGTZ) 90508-60012 (RST90GTZ) Color code Pink – Pink (RS90GTZ/RS90LTGTZ)
Page 444 315.0 mm (12.40 in) (RST90GTZ) Suspension spring rate Front 26.50 N/mm (2.70 kgf/mm, 151.32 lbf/in) (RST90GTZ) Rear 44.10 N/mm (4.50 kgf/mm, 251.81 lbf/in) (RS90GTZ) 53.90 N/mm (5.50 kgf/mm, 307.77 lbf/in) (RS90LTGTZ) 2,200 N•mm/degree (224.33 kgf•mm/degree, 12,562.00 lbf•in/degree) (RST90GTZ) Spring wire diameter Front 8.0 mm (0.31 in) (RST90GTZ)
Page 445 18.3 mm (0.72 in) Wear limit 10.5 mm (0.41 in) Track sprocket wheel: Material Polyethylene Type Extrovert drive and internal drive type (RS90GTZ/ RS90LTGTZ) Internal drive type (RST90GTZ) Number of teeth Rear guide wheel: Material Polyethylene with rubber Outside diameter 178.0 mm (7.01 in)
Page 446: Chassis
Travel 219.0 mm (8.62 in) Spring type Coil spring Spring rate 26.50 N/mm (2.70 kgf/mm, 151.32 lbf/in) (RS90GTZ) 29.40 N/mm (3.00 kgf/mm, 167.87 lbf/in) (RS90LTGTZ) 32.00 N/mm (3.26 kgf/mm, 182.72 lbf/in) (RST90GTZ) Wire diameter 8.8 mm (0.35 in) (RS90GTZ) 9.0 mm (0.35 in) (RS90LTGTZ) 9.2 mm (0.36 in) (RST90GTZ)
Page 447: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Description Voltage Ignition system: Ignition timing (B.T.D.C.) 10.0° at 1,300 r/min Advancer type Digital type Ignition coil: Ignition spark gap 6.0 mm (0.24 in) 1.19 ~ 1.61 Ω at 20 °C (68 °F) Primary coil resistance Secondary coil resistance 8.5 ~ 11.5 kΩ...
Page 448 15.0 A × 1 Ignition fuse 3.0 A × 1 Auxiliary DC jack fuse 3.0 A × 1 Helmet shield heater jack fuse 5.0 A × 1 (RS90GTZ/RS90LTGTZ) Radiator fan fuse 20.0 A × 1 Reserve fuse 15.0 A × 1 Reserve fuse 10.0 A ×...
Page 449: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (bolt) This chart specifies torque for standard fasten- m•kgf ft•lbf ers with standard I.S.O. pitch threads. Torque 10 mm 6 mm specifications for special components or assem- 12 mm 8 mm blies are included in the applicable sections of...
Page 450: Tightening Torque
Cylinder head water jacket bolt Thermostat housing cover bolt Coolant temperature sensor Water pump assembly bolt Coolant hose clamp Coolant reservoir bolt Coolant recovery bolt (RS90GTZ/RS90LTGTZ) Radiator bolt (RS90GTZ/RS90LTGTZ) Radiator fan motor screw (RS90GTZ/RS90LTGTZ) Bleed bolt (heat exchanger) ® Oil cooler bolt...
Page 451 Crankcase bolt (M8 × 1.25) Apply the engine oil. Crankcase bolt (M6 × 1.0) Apply the engine oil. Crankcase bolt (M6 × 1.0) Black bolt Apply Yamaha bond No. 1215 ® (Three Bond No. 1215 Primary sheave drive shaft assembly bolt Connecting rod nut See TIP.
Page 452 SPEC TIGHTENING TORQUE Cylinder head bolt 1. Apply engine oil to the bolt thread and both sides of the washer. 2. Tighten the eight bolts to 25 Nm (2.5 m•kgf, 18 ft•lbf) in the proper tightening sequence. 3. Loosen all the bolts one by one following the tightening order and then tighten them to 25 Nm (2.5 m•kgf, 18 ft•lbf) again.
Page 453: Power Train
Parking brake cable and parking brake lever bolt Brake master cylinder holder bolt Brake master cylinder holder and parking brake lever bolt Brake lever adjusting locknut Slide rail suspension front mounting bolt (M10) (RS90GTZ/RS90LTGTZ) Apply grease* Slide rail suspension front mounting bolt (M10) (RST90GTZ) ® Apply LOCTITE ®...
Page 454 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m•kgf ft•lbf Limiter strap shaft and sliding frame bolt (RS90GTZ/RS90LTGTZ) ® Apply LOCTITE Limiter strap shaft and sliding frame bolt (RST90GTZ) ® Shaft and sliding frame bolt Apply LOCTITE Shock absorber and front pivot arm nut...
Page 455 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m•kgf ft•lbf Rear axle nut (RST90GTZ) ® Apply LOCTITE Set bolt (front axle) Speed sensor nut Bearing holder nut Gear unit (speed sensor) bolt *: ESSO beacon 325 grease or Aeroshell grease #7A 1.
Page 456: Chassis
Backrest arm locknut (RST90GTZ) Backrest side cover screw (RST90GTZ) Backrest side cover bolt (RST90GTZ) Passenger grip warmer bolt (RST90GTZ) Seat hook nut (RS90GTZ/RS90LTGTZ) Seat bolt (RST90GTZ) Seat bracket assembly bolt (RST90GTZ) Storage compartment bracket bolt (RST90GTZ) Storage compartment bracket nut (RST90GTZ)
Page 457 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m•kgf ft•lbf Shock absorber lower nut Shock absorber spring preload adjusting locknut Steering arm and ski column nut Upper arm and frame nut Apply grease* Upper arm and steering knuckle nut Lower arm and frame nut Apply grease* Lower arm and frame bolt grease nipple...
Page 458 SPEC CABLE ROUTING CABLE ROUTING 9-25...
Page 459: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING Tighten ground lead together with the flange bolt above rectifier/regulator (point the terminal with the rivet facing upward). Pass stator coil lead between the rectifier/regulator lead and the ground lead, and then route it over the leads. Fasten the wire harness and stator coil lead with the holder.
Page 460 SPEC CABLE ROUTING 9-27...
Page 461 SPEC CABLE ROUTING Insert the projection on the headlight sub-wire harness holder into the hole in the head- light stay. Throttle position sensor To engine Fasten the wire harness at the positioning tape to the fuel rail with the plastic band. Point the end of the plastic band rear- ward.
Page 462 SPEC CABLE ROUTING RS90GTZ/RS90LTGTZ 9-29...
Page 463 SPEC CABLE ROUTING #3 mark Insert the projection of the holder into the hole in the head- light stay and fasten the fuel hose. Face the catch of the holder either up/down. Fasten the wire harness to the frame cross member with the plastic band.
Page 464 SPEC CABLE ROUTING RS90GTZ/RS90LTGTZ 9-31...
Page 465 SPEC CABLE ROUTING Position the headlight sub-wire harness coupler outermost of all the other harnesses. Connect the fuel sender cou- pler, making sure that the cou- pler is positioned under the fuel hose. Route the auxiliary DC jack cou- pler above the fuel hose and below the headlight sub-wire harness and connect the cou- pler.
Page 466 SPEC CABLE ROUTING RST90GTZ 9-33...
Page 467 SPEC CABLE ROUTING #3 mark Insert the projection of the holder into the hole in the head- light stay and fasten the fuel hose. Face the catch of the holder either up/down. Route the parking brake cable under the brake hose. Insert the projection of the holder into the hole in the head- light stay and fasten the brake...
Page 468 SPEC CABLE ROUTING RST90GTZ 9-35...
Page 469 SPEC CABLE ROUTING Fasten the fuel hose and fuel pump lead with the plastic band, making sure to align the band with the positioning tape on the lead. Clearance between the plastic band and fuel pump should be 0 ~ 20 mm (0 ~ 0.79 in).
Page 470 SPEC CABLE ROUTING RST90GTZ 9-37...
Page 471 SPEC CABLE ROUTING Pass the brake hose, throttle cable corrugated tube through the lower guide. Route the throttle cable behind the brake hose. DC back buzzer Bolt Flange nut Tail sub-wire harness Less than 3 mm (0.12 in) Frame edge Damper Fuel tank 9-38...
Page 472 SPEC CABLE ROUTING RS90GTZ/RS90LTGTZ 9-39...
Page 473 SPEC CABLE ROUTING Corrugated tube (engine stop switch lead, throttle switch leads, right grip warmer lead, and thumb warmer lead) Pass the corrugated tubes and throttle cable through the upper guide. Corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) Parking brake cable...
Page 474 SPEC CABLE ROUTING RS90GTZ/RS90LTGTZ 9-41...
Page 475 SPEC CABLE ROUTING Fuel tank breather hose should not be sagged between the nip- ple and plastic band. Right handlebar switch 9-42...
Page 476 SPEC CABLE ROUTING RST90GTZ 9-43...
Page 477 SPEC CABLE ROUTING Left grip warmer lead Brake light switch lead Brake hose Helmet shield heater jack lead Parking brake cable Corrugated tube (left grip warmer lead, right grip warmer lead, grip/thumb warmer adjust- ment switch lead, headlight beam switch lead, engine stop switch lead, throttle...
Page 478 SPEC CABLE ROUTING RST90GTZ 9-45...
Page 479 SPEC CABLE ROUTING Cover the left grip warmer lead, right grip warmer lead, grip/ thumb warmer adjustment switch lead, headlight beam switch lead, engine stop switch lead, throttle switch leads, thumb warmer lead, brake light switch lead, and helmet shield heater jack lead with the rubber cover (make sure the bolt heads, metal terminals, throttle...
Page 480 SPEC CABLE ROUTING 9-47...
Page 481 SPEC CABLE ROUTING ECU band ECU (engine control unit) Put the branched ECU lead with the identifier tape on top of the other branched lead (match the connector type with the outlet). Intake air temperature sensor Fasten the oil cooler inlet hose, oil pressure switch sub-lead and crankshaft position sensor lead with a plastic band.
Page 482 SPEC CABLE ROUTING 9-49...
Page 483 Install the relay on any position. (RS90GTZ/RS90LTGTZ) Radiator motor relay (RS90GTZ/RS90LTGTZ) Headlight relay (black) (RS90GTZ/RS90LTGTZ) Load control relay (RS90GTZ/ RS90LTGTZ) Fuel injection system relay (RS90GTZ/RS90LTGTZ) Insert the projection of the plas- tic band into the frame and fas- ten the wire harness and speed sensor lead with the plastic band.
Page 484 SPEC CABLE ROUTING RS90GTZ/RS90LTGTZ 9-51...
Page 485 SPEC CABLE ROUTING Air filter case latch Route the coolant reservoir breather hose behind engine and front of the heat exchanger. Pass the plastic band through the hole in the frame, and then fasten the coolant reservoir breather hose at the white paint mark.
Page 486 SPEC CABLE ROUTING RST90GTZ 9-53...
Page 487 SPEC CABLE ROUTING Air filter case latch Route the coolant reservoir breather hose behind engine and front of the heat exchanger. Pass the plastic band through the hole in the frame, and then fasten the coolant reservoir breather hose at the white paint mark.
Page 488 SPEC CABLE ROUTING RS90GTZ/RS90LTGTZ 9-55...
Page 489 SPEC CABLE ROUTING Tail sub-wire harness Tail/brake light coupler When storing the tail sub-wire harness and tail/brake light lead, be careful not to pinch them with the bottom of the seat and tail/brake light bracket. 9-56...
Page 490 SPEC CABLE ROUTING RST90GTZ 9-57...
Page 491 SPEC CABLE ROUTING Insert the projection on each tail sub-wire harness holder into the hole in the seat bracket assem- bly. Route the tail sub-wire harness outside of the right backrest side cover bracket. Fasten the tail sub-wire harness at the positioning tape with the holder.
Page 492 SPEC CABLE ROUTING RST90GTZ 9-59...
Page 493 SPEC CABLE ROUTING Seat bracket assembly Insert the projection of the pas- senger grip warmer coupler into the hole in the seat bracket assembly. Route passenger grip warmer lead through the upper portion of the hole in the back- rest side cover. Backrest side cover Fasten the tail sub-wire harness at the positioning tape to the...
Page 494 WIRING DIAGRAM 2010 RS90GTZ/RS90LTGTZ 8JA-0F001-00 AC magneto Auxiliary DC jack Rectifier/regulator Radiator fan fuse Main switch Helmet shield heater jack fuse Main fuse Auxiliary DC jack fuse Load control relay Headlight fuse Battery Signal fuse Starter motor Ignition fuse Starter relay...
Page 495 COLOR CODE B....Black Br .... Brown Ch ... Chocolate Dg ... Dark green G ..... Green Gy ... Gray L ....Blue Lg .... Light green O ..... Orange P....Pink R ..... Red W..... White Y....Yellow B/L ..Black/Blue B/W..
Page 496 WIRING DIAGRAM 2010 RST90GTZ 8HF-0F001-00 AC magneto Helmet shield heater jack Rectifier/regulator Auxiliary DC jack Main switch Helmet shield heater jack fuse Main fuse Auxiliary DC jack fuse Load control relay Headlight fuse Battery Signal fuse Starter motor Ignition fuse Starter relay Fuel injection system fuse Diode...
Page 497 COLOR CODE B....Black Br .... Brown Ch ... Chocolate Dg ... Dark green G ..... Green Gy ... Gray L ....Blue Lg .... Light green O ..... Orange P....Pink R ..... Red W..... White Y....Yellow B/L ..Black/Blue B/W..
Page 501 WIRING DIAGRAM 2010 RS90GTZ/RS90LTGTZ (8JA-0F001-00)
Page 502 WIRING DIAGRAM 2010 RST90GTZ (8HF-0F001-00)
Page 503 WIRING DIAGRAM 2010 RS90GTZ/RS90LTGTZ (8JA-0F001-00)
Page 504 WIRING DIAGRAM 2010 RST90GTZ (8HF-0F001-00)

This manual is also suitable for:

Rs90ltgtz Rst90gtz

Yamaha RS90GTZ Service Manual

Chassis

Power Train

Engine

Cooling System

Fuel Injection System

Electrical

Specifications

Chapter 1

Snowmobile Identification

Gen Info

Important Information

Special Tools

Chapter 2

Insp Adj

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Engine

Power Train

Chassis

Electrical

Tuning

Chas

Chapter 3. Chassis

Cowlings

Seat

Backrest and Seat (Rst90Gtz)

Steering

Ski

Front Suspension

Powr Tr

Chapter 4. Power Train

Primary Sheave and Drive V-Belt

Secondary Sheave

Drive Chain Housing (Rs90Gtz/Rs90Ltgtz)

Secondary Shaft

Brake

Slide Rail Suspension (Rs90Gtz)

Front Axle and Track

Eng

Chapter 5. Engine

Fuel Tank

Exhaust Pipe and Muffler

Oil Tank

Engine Assembly

Camshafts

Cylinder Head

Valves and Valve Springs

Ac Magneto Rotor and Starter Clutch

Oil Pan and Oil Pump

Crankcase

Connecting Rods and Pistons

Crankshaft and Balancer Shaft

Chapter 6. Cooling System

Heat Exchanger

Cool

Thermostat

Water Pump

Chapter 7. Fuel Injection System

Fuel Injection System

Throttle Body

Chapter 8

Elec

Switch Inspection

Ignition System

Electrical Starting System

Charging System

Lighting System

Signal System

Grip Warmer System

Quick Links

Troubleshooting

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Summary of Contents for Yamaha RS90GTZ