Page 1 SERVICE MANUAL...
Page 2 NOTICE HOW TO USE THIS MANUAL This manual was written by the Yamaha Motor Particularly important information is distin- Company primarily for use by Yamaha dealers guished in this manual by the following nota- and their qualified mechanics. It is not possible tions: to put an entire mechanic’s education into one...
Page 3 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. POWR 1 General information CHAS 2 Periodic inspections and adjustments 3 Chassis 4 Power train 5 Engine COOL 6 Cooling system...
Page 4 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTIONS AND INSP ADJUSTMENTS CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 5: Table Of Contents
CHAPTER 1. ENGINE OIL LEVEL INSPECTION ....2-20 GENERAL INFORMATION ENGINE OIL REPLACEMENT ..2-22 CRANKCASE BREATHER HOSE MACHINE IDENTIFICATION .
Page 6 CHAPTER 3. BRAKE CALIPER INSPECTION AND REPAIR ....4-32 CHASSIS BRAKE CALIPER ASSEMBLY ..4-33 BRAKE CALIPER INSTALLATION 4-33 STEERING .
Page 7 A.C. MAGNETO AND STARTER CHAPTER 8. CLUTCH ......5-31 ELECTRICAL REMOVAL ..... . 5-33 INSTALLATION .
Page 8 SIGNAL SYSTEM ....8-25 CHAPTER 9. CIRCUIT DIAGRAM ....8-25 SPECIFICATIONS TROUBLESHOOTING...
Page 9: Chapter 1. General Information
MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number 1 is located on the left-hand side of the crankcase.
Page 10: Important Information
ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and ad- justments.
Page 11: Gaskets, Oil Seals, And O-Rings
IMPORTANT INFORMATION INFO GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an en- gine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Ap- ply grease to the oil seal lips.
Page 12: Special Tools
SPECIAL TOOLS INFO SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent dam- age that can be caused by the use of improper tools or improvised techniques. NOTE: Be sure to use the correct part number when ordering the tool, since the part number may differ according to country.
Page 13: For Engine Service
SPECIAL TOOLS INFO FOR ENGINE SERVICE S Piston pin puller P/N: YU-01304 (for U.S.A./Canada) 90890-01304 (for Europe) This tool is used to remove the piston pin. S Rotor holding puller, attachment P/N: YU-33270 (for U.S.A./Canada) 90890-01362 (for Europe) P/N: YM-33282 90890-04089 This tool is used to remove the magneto rotor.
Page 14 SPECIAL TOOLS INFO S Valve guide remover (ø4, ø4.5) P/N: YM-04111 (ø4) (for U.S.A./Canada) 90890-04111 (for Europe) P/N: YM-4116 (ø4.5) (for U.S.A./Canada) 90890-04116 (for Europe) These tools are used to remove or install the valve guides. S Valve guide installer (ø4, ø4.5) P/N: YM-04112 (ø4) (for U.S.A./Canada) 90890-04112 (for Europe) P/N: YM-4117 (ø4.5) (for U.S.A./Canada)
Page 15: For Power Train Service
SPECIAL TOOLS INFO FOR POWER TRAIN SERVICE S Primary sheave holder P/N: YS-01880 (for U.S.A./Canada) 90890-01701 (for Europe) This tool is used to hold the primary sheave. S Primary sheave puller (18 mm) P/N: YS-01881-1 1 , YS-01882-1 2 (for U.S.A./Canada) 90890-01898 (for Europe) This tool is used for removing the primary sheave.
Page 16: For Carburetion Service
SPECIAL TOOLS INFO FOR CARBURETION SERVICE S Mity vac P/N: YB-35956 (for U.S.A./Canada) 90890-06756 (for Europe) This tool is used to check the fuel pump. FOR ELECTRICAL SERVICE S Pocket tester P/N: YU-03112 (for U.S.A./Canada) 90890-03112 (for Europe) This instrument is necessary for checking the electrical components. S Electro tester P/N: YU-33260-A (for U.S.A./Canada) 90890-03021 (for Europe)
Page 17: Periodic Inspection And Adjustment
INSP INTRODUCTION/PERIODIC MAINTENANCE TABLE PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine op- eration and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being pre- pared for sale.
Page 18 INSP PERIODIC MAINTENANCE TABLE Every Initial 1 month Seasonally Preopera- Item Remarks tion check 800 km 3,200 km (Daily) (500 mi) (2,000 mi) (40 hr) (160 hr) Check operation and fluid leakage. Brake and parking brake Adjust free play and/or replace pads if necessary. Repair brake fluid.
Page 19: Engine
INSP SPARK PLUGS ENGINE SPARK PLUGS 1. Remove: S Spark plug caps S Spark plugs 2. Inspect: S Electrodes 1 Damage/wear ! Replace the spark plug. S Insulator color 2 3. Measure: S Spark plug gap a Out of specification ! Regap. Use a wire thickness gauge.
Page 20: Fuel Line Inspection
INSP FUEL LINE INSPECTION/COOLING SYSTEM FUEL LINE INSPECTION 1. Remove: S Intake silencer Refer to “CARBURETORS” in CHAPTER 7. 2. Inspect: S Fuel hoses 1 S Fuel delivery hoses 2 Cracks/damage ! Replace. 3. Install: S Intake silencer Refer to “CARBURETORS” in CHAPTER 7. COOLING SYSTEM Coolant replacement NOTE:...
Page 21 INSP COOLING SYSTEM 4. Place an open container under the coolant hose. 5. Disconnect: S Coolant hose 1 6. Drain the coolant. NOTE: Lift up the tail of the machine to drain the cool- ant. 7. Remove: S Rear cover 1 8.
Page 22 INSP COOLING SYSTEM 12. Install: S Coolant hose 1 13. Install: S Intake silencer Refer to “CARBURETORS” in CHAPTER 7. 14. Fill: S Cooling system Recommended coolant: High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors Coolant mixing ratio (coolant:water) 3:2 (60%:40%) Total amount: 4.7 L (4.14 lmp qt, 4.97 US qt)
Page 23 INSP COOLING SYSTEM Inspection steps: S Attach the cooling system tester 1 and adapt- er 2 to the coolant filler 3 . Cooling system tester: 90890-01325, YU-24460-01 Adapter: 90890-01352, YU-24460-01 S Apply 100 kPa (1.0 kg/cm , 14 psi). S Measure the pressure with the gauge. Air bleeding 1.
Page 24 INSP COOLING SYSTEM WARNING To avoid severe injury or death: S Make sure the machine is securely sup- ported with a suitable stand. S Do not exceed 3,000 r/min. Drive line dam- age and excessive V-belt wear could occur, or the machine could unexpectedly move forward if the clutch engages.
Page 25: Valve Clearance Adjustment
INSP VALVE CLEARANCE ADJUSTMENT VALVE CLEARANCE ADJUSTMENT NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 26 INSP VALVE CLEARANCE ADJUSTMENT NOTE: S If the valve clearance is incorrect, record the measured reading. S Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #1 ! #2 ! #4 ! #3 A Front For each cylinder, starting with cylinder #1 at TDC, turn the crankshaft clockwise as specified in the following table.
Page 27 INSP VALVE CLEARANCE ADJUSTMENT NOTE: S Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. S Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place.
Page 28 INSP VALVE CLLEARANCE ADJUSTMENT VALVE PAD SELECTION TABLE INTAKE Measured INSTALLED PAD NUMBER clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
Page 29 INSP VALVE CLEARANCE ADJUSTMENT S Install the new valve pad 1 and the valve lifter NOTE: S Apply molybdenum disulfide oil to the valve pad and the valve lifter. S The valve lifter must turn smoothly when ro- tated by hand. S Install the valve lifter and the valve pad in the correct place.
Page 30: Carburetor Synchronization
INSP CARBURETOR SYNCHRONIZATION CARBURETOR SYNCHRONIZATION NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Remove: S Vacuum cap 2. Install: S Carburetor synchronizer 1 S Engine tachometer (near the spark plug) Carburetor synchronizer 90890-03094, YU-8030...
Page 31 INSP CARBURETOR SYNCHRONIZATION NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. S Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same.
Page 32: Engine Idle Speed Adjustment
INSP ENGINE IDLE SPEED ADJUSTMENT ENGINE IDLE SPEED ADJUSTMENT NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes.
Page 33: Throttle Cable Free Play Adjustment
INSP THROTTLE CABLE FREE PLAY ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: S Before adjusting the throttle cable free play, the engine idle speed should be adjusted. S Adjust the throttle cable free play while the cable is in the cable guide. 1.
Page 34: Throttle Override System (T.o.r.s.) Check
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK/ INSP COMPRESSION PRESSURE MEASUREMENT THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK WARNING When checking T.O.R.S.: S Be sure the parking brake is applied. S Be sure the throttle lever moves smoothly. S Do not run the engine up to the clutch en- gagement speed.
Page 35 INSP COMPRESSION PRESSURE MEASUREMENT CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 4. Install: S Compression gauge 1 Compression gauge set 90890-03081, YU-33223 Compression gauge adapter...
Page 36: Engine Oil Level Inspection
COMPRESSION PRESSURE MEASUREMENT/ INSP ENGINE OIL LEVEL INSPECTION Measurement steps: S Turn the main switch to “ON”. S With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground all spark plug leads before cranking the engine.
Page 37 INSP ENGINE OIL LEVEL INSPECTION S The engine oil level should be between the minimum level mark a and maximum level mark b . Below the minimum level mark ! Add the rec- ommended engine oil to the proper level. CAUTION: When adding the engine oil, be careful not to fill above the maximum level mark and mini-...
Page 38: Engine Oil Replacement
INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT 1. Start the engine, warm up for several min- utes, and then turn it off. 2. Place a containers under the engine oil drain bolt and oil tank. 3. Remove: S Bottom panel S Right side cover S Oil level gauge coupler S Oil level gauge/dipstick...
Page 39 INSP ENGINE OIL REPLACEMENT S Apply a thin coat of engine oil onto the O-ring 1 of the new oil filter cartridge. CAUTION: Make sure that the O-ring 1 is positioned correctly in the groove of the oil filter car- tridge.
Page 40: Crankcase Breather Hose Inspection
ENGINE OIL REPLACEMENT/CRANKCASE BREATHER INSP HOSE INSPECTION/CARBURETOR JOINTS INSPECTION 10. Inspect: S Engine oil pressure Inspection steps: S Slightly loosen the oil gallery bolt 1 . S Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.
Page 41: Exhaust System Inspection
INSP EXHAUST SYSTEM INSPECTION EXHAUST SYSTEM INSPECTION 1. Remove: S Seat S Exhaust system S Refer to “EXHAUST PIPE AND MUFFLER” in CHAPTER 5. 2. Inspect: S Exhaust joint 1 S Tightening torque Bolt (exhaust joint): 25 Nm (2.5 mSkg, 18 ftSlb) S Muffler 2 S Tightening torque Bolt (muffler):...
Page 42: Power Train
INSP SHEAVE OFFSET ADJUSTMENT POWER TRAIN SHEAVE OFFSET ADJUSTMENT 1. Measure: S Sheave offset a Use the sheave gauge. Out of specification ! Adjust. Sheave offset: 15 ± 1.5 mm (0.59 ± 0.06 in) (13.5 X 16.5 mm (0.53 X 0.65 in)) Sheave gauge: YS-42421-1 NOTE:...
Page 43 INSP SHEAVE OFFSET ADJUSTMENT/DRIVE V-BELT 3. Measure: S Secondary sheave freeplay (clearance) a Use a feeler gauge. Out of specification ! Adjust. Secondary sheave free play (clearance): 1.0 X 2.0 mm (0.04 X 0.08 in) 4. Adjust: S Secondary sheave freeplay (clearance) Adjustment steps: S Apply the brake to lock the secondary sheave.
Page 44: Drive V-Belt
INSP DRIVE V-BELT New belt width: 34.5 mm (1.36 in) Belt wear limit width: 32.5 mm (1.28 in) 1. Measure: S V-belt position a NOTE: Install the new V-belt onto the secondary sheave only. Do not force the V-belt between the sheaves;...
Page 45: Engagement Speed Check
INSP DRIVE V-BELT/ENGAGEMENT SPEED CHECK 4. Inspect: S Drive V-belt Cracks/damage/wear ! Replace. Oil or grease on the V-belt ! Check the pri- mary and secondary sheaves. 5. Inspect: S Primary sheave S Secondary sheave Oil or grease on the primary and secondary sheaves ! Use a rag soaked in lacquer thin- ner or solvent to remove the oil or grease.
Page 46: Parking Brake Adjustment
PARKING BRAKE ADJUSTMENT/ INSP BRAKE LEVER ADJUSTMENT PARKING BRAKE ADJUSTMENT 1. Measure: S Parking brake cable distance a Out of specification ! Adjust. Parking brake cable distance: 43.5 X 46.5 mm (1.713 X 1.831 in) 2. Adjust: S Parking brake cable Adjustment steps: S Loosen the locknut 1 S Turn the adjuster 2 in or out until the specified...
Page 47: Brake Fluid Level Inspection
BRAKE LEVER ADJUSTMENT/ INSP BRAKE FLUID LEVEL INSPECTION Adjustment steps: S Loosen the locknut 1 . S While lightly pushing the brake lever in direc- tion a , turn the adjusting bolt 2 by fingers to set the brake lever to the desired position. S Tighten the locknut securely after adjusting.
Page 48: Brake Pad Inspection
BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION/ INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Inspect: S Brake pad wear a Wear indicator 1 nearly contacts the brake disc ! Replace as a set. Wear limit: 7.5 mm (0.30 in) BRAKE HOSE INSPECTION 1.
Page 49 INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) a. Slowly apply the brake lever several times. b. Pull the lever in, then hold the lever in posi- tion. c. Loosen the bleed screws and allow the brake lever to travel towards its limit. d.
Page 50: Drive Chain
INSP DRIVE CHAIN DRIVE CHAIN Oil level inspection WARNING The engine and muffler will be very hot after the engine has run. Avoid touching a hot en- gine and muffler while they are still hot with any part of your body or clothing during in- spection or repair.
Page 51 INSP DRIVE CHAIN Recommended oil: Gear oil API “GL-3” SAE #75 or #80 CAUTION: Make sure that no foreign material enters the gear case. S Reinsert the dipstick 2 . Oil replacement Oil replacement steps: S Place the oil pan under the drain hole. S Remove the oil drain bolt 1 and drain the oil.
Page 52: Track Tension Adjustment
INSP TRACK TENSION ADJUSTMENT TRACK TENSION ADJUSTMENT WARNING A broken track or track fittings, and debris thrown by the track could be dangerous to an operator or by standers. Observe the fol- lowing precautions. S Do not allow anyone to stand behind the machine when the engine is running.
Page 53: Slide Runner Inspection
TRACK TENSION ADJUSTMENT/ INSP SLIDE RUNNER INSPECTION Shifted Shifted Track alignment to right to left Left adjuster Turn out Turn in Right adjuster Turn in Turn out 8 Slide runner 9 Track Track metal Forward A RX10, RX10S , RX10R, RX10RS B RX10M, RX10MS c.
Page 54: Maximizing Drive Track Life
Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize pos- sible damage, consult your stud manufacturer for installation and stud pattern recommenda- tions. Yamaha does not recommend track stud- ding. 2-38...
Page 55: Chassis
INSP SKI/SKI RUNNER CHASSIS SKI/SKI RUNNER 1. Inspect: S Ski S Ski runner Damage/wear ! Replace. S Ski runner thickness a S Plastic ski thickness b Out of specification ! Replace. Ski runner wear limit: 8 mm (0.31 in) Plastic ski wear limit: 24 mm (0.95 in) CAUTION: To avoid scratching, wearing and damaging...
Page 56: Steering System
INSP STEERING SYSTEM STEERING SYSTEM Free play check 1. Check: S Steering system free play Move the handlebar up and down and back and forth. Turn the handlebar slightly to the right and left. Excessive free play ! Check that the han- dlebar, tie rod ends and relay rod ends are installed securely in position.
Page 57 INSP STEERING SYSTEM/LUBRICATION 3. Adjust: S Ski toe-out Adjustment steps: S Loosen the locknuts (tie-rod) 1 . S Turn the tie rods 2 in or out until the specified toe-out is obtained. S Tighten the locknuts (tie-rod) 1 . Locknut (rod end): 25 Nm (2.5 mSkg, 18 ftSlb) ...
Page 58: Lubrication
INSP LUBRICATION Front and rear suspension 1. Use a grease gun to inject grease into the nipples 1 . Recommended lubricant: Esso Beacon 325 Grease or Aeroshell Grease #7A A Front B Rear (RX10, RX10S, RX10R, RX10RS) C Rear (RX10M, RX10MS) 2-42...
Page 59: Electrical
INSP HEADLIGHT BEAM ADJUSTMENT ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Place the machine in front of a wall at the rec- ommended distance D . Refer to the table below. 3. Measure the distance H from the floor to the center of the headlight and place a mark on the wall at that height.
Page 60: Battery Inspection
INSP BATTERY INSPECTION EAS00178 BATTERY INSPECTION WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries. S Charge batteries in a well-ventilated area.
Page 61 INSP BATTERY INSPECTION NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 62 INSP BATTERY INSPECTION 4. Charge: Charging S battery Ambient temperature 20_C (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Make sure that the battery vent is free of obstructions.
Page 63 INSP BATTERY INSPECTION Charging method using a variable voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V. and start charging.
Page 64 INSP BATTERY INSPECTION Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on...
Page 65 INSP BATTERY INSPECTION 5. Install: S Battery 6. Connect: S Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 7. Check: S Battery terminals Dirt ! Clean with a wire brush. Loose connection ! Connect properly.
Page 66: Fuse Inspection
INSP FUSE INSPECTION FUSE INSPECTION The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Inspect: S Continuity Inspection steps: S Connect the pocket tester to the fuse and check the continuity.
Page 67: Speedometer Unit Inspection
INSP FUSE INSPECTION/SPEEDOMETER UNIT INSPECTION WARNING Never use a fuse with an amperage other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting, ignition, grip warmer, signal and meter systems to mal- function and could possibly cause a fire.
Page 68: Tuning
INSP CARBURETOR TUNING TUNING CARBURETOR TUNING The carburetors are set at the factory to run at temperatures of 0_C X–20_C (32_F X–4_F) at sea level. If the machine is to be operated un- der conditions other than those specified above, the carburetors must be properly ad- justed.
Page 69 NOTE: These jetting specifications are subject to change. Consult the latest technical information from Yamaha to be sure you have the most up-to- date jetting specifications. 1 Clip 2 Jet needle 3 Pilot screw 4 Main jet...
Page 70 INSP CARBURETOR TUNING Guide for carburetion Piston valve opening Mid-range speed tuning High speed turning Fully opened Closed Low speed tuning Closed Fully opened Piston valve opening 2-54...
Page 71 INSP CARBURETOR TUNING A Standard main jet B Main jet whose diameter is 10% smaller than standard C Main jet whose diameter is 10% larger than stan- dard Fully opened Piston valve opening A No. 2 position B No. 1 position C No.
Page 72 INSP CARBURETOR TUNING Low-speed tuning The carburetors are built so that low speed tun- ing can be done by adjusting the pilot mixture screw 1 and throttle stop screw 2 . CAUTION: Never run the engine without the air intake silencer installed.
Page 73 INSP CARBURETOR TUNING Main jet selection chart Spark plug color Diagnosis Remedy Light tan or gray Carburetors are tuned properly. Dry black or fluffy Mixture is too rich. Replace the main jet with the next smaller deposits size. White or light gray Mixture is too lean.
Page 74 INSP CARBURETOR TUNING Trouble Diagnosis Adjustment S Remove the pilot jet, clean it with Poor performance at Clogged or loose pilot jet mid-range speeds: compressed air, and then install it. S Momentary slow S Make sure that the pilot jet is fully tightened. response to the throttle Lean mixture...
Page 75: Clutch
INSP CLUTCH CLUTCH G Green P Pink High altitude S Silver Y Yellow Specifications Model: RX10, RX10S, RX10R, RX10RS X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft)
Page 76 INSP CLUTCH S Silver O Orange W White Specifications Model: RX10M, RX10MS X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft) (X 2,500 ft)
Page 77 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the de- sired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the en- gine speed at which the machine first begins to move from a complete stop.
Page 78: Gear Selection
INSP GEAR SELECTION 1 Chain and sprocket part number Parts name Teeth & links Parts no. Standard 20 teeth 8FA-17682-00 21 teeth 8FA-17682-10 RX10M, RX10MS Drive sprocket 22 teeth 8FA-17682-20 23 teeth 8FA-17682-30 24 teeth 8FA-17682-40 RX10, RX10S, RX10R, RX10RS 37 teeth 8DW-47587-70 38 teeth...
Page 79 INSP GEAR SELECTION 5 Torque cam (secondary spring seat) Identification mark Effects Part no. Cam angle Identification mark Standard Quicker upshifting RX10, RX10S, 8FA-17604-00 51-43_ 8BVFA during acceleration RX10R, RX10RS 8BV-17604-71 8BV71 8BV-17604-51 8BV51 RX10M, RX10MS 8BV-17604-31 8BV31 Quicker 8BV-17604-11 8BV11 backshifting backshifting...
Page 80 INSP GEAR SELECTION 6 Primary spring Spring identification color code Spring rate color Preload color Spring rate Wire Outside Free Preload No. of Color Standard Parts No. N / mm gauge diameter length N (kg) coils (kg / mm) mm (in) mm (in) mm (in) 90501-551L3...
Page 81 INSP GEAR SELECTION 7 Clutch weight Parts no. Weight g (oz) Shape & ID mark Standard without bush and rivets 35.32 8CH-17605-10 (1.247) 38.09 8CR-17605-10 (1.345) 34.26 8DG-17605-00 (1.209) 37.77 8DJ-17605-00 (1.333) 42.09 8DN-17605-20 (1.486) 39.00 8EK-17605-00 (1.376) RX10, RX10S, 69.43 8FA-17605-00 RX10M, RX10MS,...
Page 82 INSP GEAR SELECTION 8 Weight rivets Parts No. Material Length Weight Standard Effects mm (in) g (oz) 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) IN: RX10, RX10S, RX10R, RX10RS 3.6 (0.127) 90269-06006 Steel 17.2 (0.677) OUT: RX10, RX10S, RX10R, RX10RS Increased with hole Force Force...
Page 83: High Altitude Tuning
INSP HIGH ALTITUDE TUNING HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below. Check STD settings S Carburetors S Spark plugs Adjust the main jet size according to the chart Test the main jet Not OK Adjust the size of the main jet...
Page 84: Front Suspension
INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: S Spring preload Adjustment steps: S Turn the spring seat 1 in or out. RX10, RX10S, RX10R, RX10RS Spring seat Standard Shorter z ! Longer distance Harder z ! Softer Preload Min.
Page 85: Rear Suspension
INSP REAR SUSPENSION REAR SUSPENSION Stopper band 1. Adjust: S Stopper band tension CAUTION: Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. NOTE: This adjustment affects the handling character- istics of the machine. Adjustment steps: S Loosen the locknut 1 .
Page 86 INSP REAR SUSPENSION Spring preload (RX10, RX10S, RX10R, RX10RS) 1. Adjust: S Spring preload Adjustment step: S Turn the spring seat 1 in or out. Front A Spring seat Standard Shorter z ! Longer distance Harder z ! Softer Preload Min.
Page 87 INSP REAR SUSPENSION Spring preload (RX10M, RX10MS) 1. Adjust: S Spring preload Adjustment steps: S Turn the adjusting ring 1 to the proper posi- tion. Spring adjuster position Softer z ! Harder Preload Front Standard Spring adjuster position Softer z ! Harder Preload Rear Standard...
Page 88 INSP REAR SUSPENSION S Turn the adjusting bolt 2 to the desired posi- tion. CAUTION: Be sure the adjusting bolt ends are set at the same position on each side. S While holding the adjusting bolt securely, tighten the nut 1 . Nut (shock absorber): 49 Nm (4.9 mSkg, 35 ftSlb) CAUTION:...
Page 89 INSP REAR SUSPENSION Control rod 1. Adjust: S Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: S Loosen the lock nut 1 . S Turn the adjusting nut 2 in or out to adjust the control rod stroke.
Page 90: Chapter 3. Chassis
CHAS STEERING CHASSIS STEERING RX10, RX10S, RX10R, RX10RS 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Thumb warmer lead coupler Disconnect.
Page 91 CHAS STEERING 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) Order Job name/Part name Q’ty Remarks NOTE: Master cylinder assembly Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” in CHAPTER 9, to check the Handlebar cable, lead and hose routings.
Page 92 CHAS STEERING RX10M, RX10MS 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11ftSlb) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Thumb warmer lead coupler Disconnect. Thumb warmer switch lead coupler Disconnect.
Page 93 CHAS STEERING 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11ftSlb) Order Job name/Part name Q’ty Remarks NOTE: Master cylinder assembly Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” in CHAPTER 9, to check the Handlebar cable, lead and hose routings.
Page 94 CHAS STEERING 25 Nm (2.5 mSkg, 18 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 67 Nm (6.7 mSkg, 49 ftSlb) ESSO beacon 325 grease or 23 Nm (23 mSkg, 17 ftSlb) Aeroshell grease #7A Order Job name/Part name...
Page 95 CHAS STEERING 25 Nm (2.5 mSkg, 18 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 67 Nm (6.7 mSkg, 49 ftSlb) ESSO beacon 325 grease or 23 Nm (23 mSkg, 17 ftSlb) Aeroshell grease #7A Order Job name/Part name...
Page 96: Inspection
CHAS STEERING INSPECTION 1. Inspect: S Handlebar (RX10, RX10S, RX10R, RX10RS) S Handlebar 2 (RX10M, RX10MS) S Steering column 3 Bends/cracks/damage ! Replace. WARNING Do not attempt to straighten a bent column. This may dangerously weaken the column. 2. Inspect: S Bearings (steering column) 1 S Collars 2 Wear/damage ! Replace.
Page 97: Installation
CHAS STEERING INSTALLATION 1. Install: S Relay arms 1 S Bushings S Washers 2 Bolt (relay arm): 67 Nm (6.7 mSkg, 49 ftSlb) S Clips 3 2. Install: S Idler arm 4 S Bushings S Washers S Relay rod 5 Nut (idler arm): 35 Nm (3.5 mSkg, 25 ftSlb) Nut (relay rod):...
Page 98 CHAS STEERING CAUTION: Always use new cotter pins. Locknut (rod end): 25 Nm (2.5 mSkg, 18 ftSlb)  LOCTITE Nut (tie rod-idler arm): 30 Nm (3.0 mSkg, 22 ftSlb) Nut (tie rod-steering arm): 35 Nm (3.5 mSkg, 25 ftSlb) 5. Install: S Steering shaft 1 S Locknuts 2 S Joints 3...
Page 99 CHAS STEERING 6. Adjust: S Skis Adjustment steps: S Temporarily install the handlebar. S Hold the handlebar straight and check that the skis and relay arms are at right angles to the handlebar. S Loosen the locknuts (steering shaft) 1 . S Hold the handlebar straight.
Page 100: Ski
CHAS 11 Nm (1.1 mSkg, 8.0 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 19 Nm (1.9 mSkg, 14 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below.
Page 101: Inspection
CHAS INSPECTION 1. Inspect: S Ski 1 S Ski runner 2 S Ski stopper 3 S Ski column lower bracket 4 S Ski handle 5 Wear/cracks/damage ! Replace. S Mounting bolt 6 S Collar 7 S Bolts 8 S Collars 9 Wear/damage ! Replace.
Page 102: Front Suspension
CHAS FRONT SUSPENSION FRONT SUSPENSION 45 Nm (4.5 mSkg, 33 ftSlb) 37 Nm (3.7 mSkg, 27 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 65 Nm (6.5 mSkg, 47 ftSlb) 34 Nm (3.4 mSkg, 25 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 103 CHAS FRONT SUSPENSION 45 Nm (4.5 mSkg, 33 ftSlb) 37 Nm (3.7 mSkg, 27 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 65 Nm (6.5 mSkg, 47 ftSlb) 34 Nm (3.4 mSkg, 25 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order...
Page 104: Handling Notes
CHAS FRONT SUSPENSION HANDLING NOTES WARNING This shock absorber contains highly com- pressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.
Page 105: Installation
CHAS FRONT SUSPENSION 4. Inspect: S Connecting rod 1 S Stabilizer 2 S Stabilizer arm 3 Cracks/bends/damage ! Replace. S Bushing 4 Wear/scratches/damage ! Replace. INSTALLATION 1. Install: S Steering arm 1 NOTE: S Align the punch mark a on the ski column with the punch mark b on the steering arm.
Page 106 CHAS FRONT SUSPENSION Ski alignment NOTE: Be sure to verify the spring preload setting and the ski spindle camber before adjusting the ski toe out since either of those adjustments may affect the ski toe out setting. Point the skis straight forward and measure the amount of ski toe out. A Ski toe out: 0 X 15 mm (0 X 0.59 in) a –...
Page 107: Chapter 4. Power Train
POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT 120 Nm (12 mSkg, 85 ftSlb) 60 Nm (6.0 mSkg, 43 ftSlb) Order Job name/Part name Q’ty Remarks Primary sheave removal Remove the parts in the order listed below. Left side cover V-belt Primary sheave assembly...
Page 108 POWR PRIMARY SHEAVE AND DRIVE V-BELT 6 Nm (0.6 mSkg, 4.3 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) 200 Nm (20.0 mSkg, 145 ftSlb) Clean the threads. Apply LOCTITE648 as illustrated in And then tighten the spider. (The spider must be a 16 mm (0.63 in) turned counterclockwise to be tightened.) b 30 mm (1.18 in)
Page 109: Removal
POWR PRIMARY SHEAVE AND DRIVE V-BELT REMOVAL 1. Remove: S Primary sheave assembly 1 NOTE: Use the primary sheave holder 2 and primary sheave puller 3 . Primary sheave holder: 90890-01701, YS-01880 Primary sheave puller: 90890-01898 YS-01881-1, YS-01882-1 DISASSEMBLY 1. Remove: S Fixed sheave 1 S Stopper 2 S Sliding sheave 3...
Page 110 POWR PRIMARY SHEAVE AND DRIVE V-BELT S Fit the primary sheave assembly onto the adapter and secure the supporting plates 8 . NOTE: Securely fit the projections on the adapter into the fixed sheave holes. S Set the bar wrench 9 onto the spider and turn the special tool clockwise to loosen the spider.
Page 111: Inspection
POWR PRIMARY SHEAVE AND DRIVE V-BELT INSPECTION 1. Inspect: S Spider 1 S Sliding sheave 2 S Fixed sheave 3 S Primary sheave cap 4 Cracks/damage ! Replace. 2. Inspect: S Primary sheave spring 1 Cracks/damage ! Replace. 3. Measure: S Primary sheave spring free length a Out of specification ! Replace the primary sheave spring.
Page 112 POWR PRIMARY SHEAVE AND DRIVE V-BELT 5. Inspect: S Weight 1 S Roller 2 S Bushing 3 S Slider 4 S Rivet 5 S Collar Wear/scratches/damage ! Replace. Slider inside clearance Min. 0 mm (0 in) Max. 0.3 mm (0.0118 in) Rivet replacement steps: S Remove old rivet with the appropriate drill.
Page 113: Assembly
POWR PRIMARY SHEAVE AND DRIVE V-BELT ASSEMBLY 1. Install: S Sliding sheave (onto the spider) NOTE: Be sure the sliding sheave match mark (X) is aligned with the spider match mark (X). 2. Install: S Fixed sheave (onto the spider) NOTE: S Clean the threads.
Page 114 POWR PRIMARY SHEAVE AND DRIVE V-BELT S Tighten the spider to specification using the bar wrench 3 . Spider: 200 Nm (20 mSkg, 145 ftSlb) CAUTION: The spider has a left-handed thread. WARNING S Do not operate the primary sheave until the ...
Page 115: Installation
POWR PRIMARY SHEAVE AND DRIVE V-BELT INSTALLATION 1. Install: S Primary sheave assembly CAUTION: Be sure to remove any oil or grease from the tapered portion of the crankshaft and spider using a cloth dampened with thinner. 2. Apply: S Engine oil or an equivalent grease (to threads of primary sheave bolt) 3.
Page 116: Secondary Sheave
POWR SECONDARY SHEAVE SECONDARY SHEAVE 64 Nm (6.4 mSkg, 46 ftSlb) Order Job name/Part name Q’ty Remarks Secondary sheave removal Remove the parts in the order listed below. Left side cover Refer to “PRIMARY SHEAVE AND V-belt V-BELT”. Washer and bolt –...
Page 117 POWR SECONDARY SHEAVE 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Secondary sheave disassembly Remove the parts in the order listed below. Spring seat Secondary sheave spring Fixed sheave...
Page 118: Disassembly
POWR SECONDARY SHEAVE DISASSEMBLY WARNING S Use extreme CAUTION when disassem- bling the secondary sheave since serious injury can occur due to the sudden release of spring tension. Use the sheave com- pressor to contain the spring tension be- fore removing the nuts (spring seat). S Do not attempt this procedure unless you have the proper tools and understand the instructions thoroughly.
Page 119: Assembly
POWR SECONDARY SHEAVE 5. Measure: S Ramp shoe thickness a Out of specification ! Replace the ramp shoe. Wear limit: 1.0 mm (0.04 in) ASSEMBLY 1. Install: S Stopper S Sliding sheave Screw (stopper): 7 Nm (0.7 mSkg, 5.1 ftSlb) 2.
Page 120 POWR SECONDARY SHEAVE Installation steps: S Hold the spring seat 1 and turn the fixed sheave 2 counterclockwise to the specified angle a . NOTE: The holes in the spring seat should align with the bolts on the sliding sheave. a = (sheave hole number + spring seat hole number) Twist angle:...
Page 121: Installation
S Install new shims of the proper thickness and reassemble the secondary sheave. S Measure the secondary sheave clearance again. Repeat these steps until the clearance is within specification. NOTE: Yamaha recommends keeping the original shims. Shims: Part number Thickness 90201-061H1 0.5 mm (0.02 in) 90201-06037 1.0 mm (0.04 in)
Page 122: Drive Chain Housing
POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 123: Inspection
POWR DRIVE CHAIN HOUSING INSPECTION 1. Inspect: S Drive chain housing 1 S Drive chain housing cover 2 Cracks/damage ! Replace. S Oil seals (drive chain housing) Wear/damage ! Replace. S Bearings (drive chain housing and cover) 3 Pitting/damage ! Replace. S Bearing (chain tensioner) 4 Pitting/damage ! Replace the bearing and the inner race holder as a set.
Page 124 POWR DRIVE CHAIN HOUSING 3. Measure: S 14 link section a of the drive chain Using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b . Out of specification ! Replace the drive chain.
Page 125: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the fol- lowing. A Make sure that the bearing seals face towards the drive chain as shown. B Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps.
Page 126: With Reverse Model
POWR DRIVE CHAIN HOUSING WITH REVERSE MODEL 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 127 POWR DRIVE CHAIN HOUSING 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 128: Inspection
POWR DRIVE CHAIN HOUSING INSPECTION 1. Inspect: S Drive chain housing 1 S Drive chain housing cover 2 Cracks/damage ! Replace. S Shift fork 3 Pitting/wear/damage ! Replace. S Oil seals (drive chain housing) Wear/damage ! Replace. S Bearings (drive chain housing and cover) 4 Pitting/damage ! Replace.
Page 129: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the fol- lowing. A Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. B Make sure that the bearing seals face towards the drive chain as shown.
Page 130 POWR DRIVE CHAIN HOUSING 4. Install: S Shift rod 1 5. Adjust: S Shift rod length a Adjustment steps: S Move the shift lever to the “FWD.” position. S Loosen the locknuts 2 . S Turn the shift rod 1 so that shift rod free play is 0 mm (in direction where a can be short- ened appropriately) and then turn back the shift rod 1/4 turns.
Page 131: Secondaryshaft
POWR SECONDARYSHAFT SECONDARYSHAFT Order Job name/Part name Q’ty Remarks Secondaryshaft removal Remove the parts in the order listed below. Secondary sheave Refer to “SECONDARY SHEAVE”. Drive chain housing Refer to “DRIVE CHAIN HOUSING”. Circlip Secondaryshaft Bearing For installation, reverse the removal procedure.
Page 132: Inspection
POWR SECONDARYSHAFT INSPECTION 1. Inspect: S Secondaryshaft 1 Scratches (excessive)/damage ! Replace. S Splines 2 Wear/damage ! Replace the secondary- shaft. S Bearing contact surface 3 Scratches/wear/damage ! Replace the secondaryshaft. 2. Inspect: S Bearing 1 Pitting/damage ! Replace. 3. Measure: S Brake disc thickness a Out of specification ! Replace.
Page 133: Secondaryshaft And Drive Chain Housing Installation
POWR SECONDARYSHAFT SECONDARYSHAFT AND DRIVE CHAIN HOUSING INSTALLATION 1. Install: S Secondaryshaft S Drive chain housing Installation steps: S Install the secondaryshaft. S Install the drive chain housing 1 . S Tighten the bolts. Bolt (drive chain housing): 48 Nm (4.8 mSkg, 35 ftSlb) S Install the drive chain, drive sprocket and driven sprocket.
Page 134: Brake
POWR BRAKE BRAKE 6 Nm (0.6 mSkg, 4.3 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring Brake pad Brake caliper assembly For installation, reverse the removal procedure.
Page 135: Brake Pad Replacement
POWR BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: S Do not disassemble components unless absolutely necessary. S Do not use solvents on internal brake com- ponents. S Do not use contaminated brake fluid for cleaning. Use only clean brake fluid. S Do not allow brake fluid to contact the eyes, otherwise eye injury may occur.
Page 136 POWR BRAKE 2. Install: S Brake pads S Pad spring Installation steps: S Connect a suitable hose 1 tightly to the cali- per bleed screw 2 . Put the other end of this hose into an open container. S Loosen the caliper bleed screw and push the pistons into the caliper with your finger.
Page 137 POWR BRAKE 30 Nm (3.0 mSkg, 22 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) Order Job name/Part name Q’ty Remarks Brake caliper and parking brake Remove the parts in the order listed below. removal Brake fluid Drain.
Page 138: Brake Caliper Disassembly
POWR BRAKE BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: S Pistons S Piston oil seals 1 Removal steps: S Using a wood of piece 2 , lock the right pis- ton.
Page 139: Brake Caliper Assembly
POWR BRAKE 1. Inspect: S Caliper piston 1 Scratches/rust/wear ! Replace the caliper assembly. S Caliper cylinder 2 Wear/scratches ! Replace the caliper as- sembly. S Caliper body 3 Cracks/damage ! Replace. S Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and dust seals whenever a caliper is disassembled.
Page 140 POWR BRAKE 10 Nm (1.0 mSkg, 7.2 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job name/Part name Q’ty Remarks Brake master cylinder removal Remove the parts in the order listed below. Brake fluid Drain. Parking brake cable Brake switch Brake lever Parking brake lever Union bolt...
Page 141: Inspection
POWR BRAKE INSPECTION 1. Inspect: S Master cylinder 1 Wear/scratches ! Replace the master cyl- inder assembly. S Master cylinder body 2 Cracks/damage ! Replace. S Oil delivery passage (master cylinder body) Blow out with compressed air. 2. Inspect: S Master cylinder kit 1 Scratches/wear/damage ! Replace as a set.
Page 142: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION RX10, RX10S, RX10R, RX10RS 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen.
Page 143 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 mSkg, 2.9 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 144 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Suspension wheel Collar Wheel bracket Circlip Suspension wheel Collar...
Page 145 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear shock absorber Bushing Collar Pull rod Collar Bushing Guide wheel Control rod assembly Bushing Bushing...
Page 146 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear pivot arm Bushing Shaft Shaft Rear pivot arm bracket...
Page 147: Rx10M, Rx10Ms
POWR SLIDE RAIL SUSPENSION RX10M, RX10MS 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Left side cover Refer to “PRIMARY SHEAVE AND DRIVE VELT”.
Page 148 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 mSkg, 2.9 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 149 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Suspension wheel Collar Wheel bracket Front pivot arm bracket Circlip Suspension wheel...
Page 150 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear shock absorber Bushing Collar Pull rod Collar Bushing Guide wheel Control rod assembly Bushing Bushing...
Page 151 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear pivot arm Bushing Collar Collar Rear pivot arm bracket...
Page 152: Inspection
POWR SLIDE RAIL SUSPENSION INSPECTION 1. Inspect: S Suspension wheel S Guide wheel Cracks/damage ! Replace. S Wheel bearing Wheel turns roughly ! Replace. 2. Inspect: S Stopper band 1 Frayed/damage ! Replace. S Pull rod 2 Bends/damage ! Replace. S Shock absorber 3 Oil leaks/damage ! Replace.
Page 153: Assembly
POWR SLIDE RAIL SUSPENSION ASSEMBLY 1. Install: S Stopper band 1 NOTE: S For RX10, RX10S, RX10R, RX10RS: Install the stopper band with a toward the hook and b toward the front suspension bracket. S For RX10M, RX10MS: Install the stopper band with a toward the hook and b toward the shaft.
Page 154 POWR SLIDE RAIL SUSPENSION Control rod parts number Control rod 1 Length mm (in) Length mm (in) Length mm (in) RX10, RX10S, 301.0 (11.85) 155.5 (6.12) 2.5P 3 = 7.5 RX10R, RX10RS (0 098P (0.098P 3 = 0 295) 3 = 0.295) RX10M, RX10MS 257.5 (10.14) 165.0 (6.50)
Page 155: Front Axle And Track
POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK 9 Nm (0.9 mSkg, 6.5 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job name/Part name Q’ty Remarks Front axle and track removal Remove the parts in the order listed below. Drive chain housing Refer to “DRIVE CHAIN HOUSING”.
Page 156: Inspection
POWR FRONT AXLE AND TRACK INSPECTION 1. Inspect: S Track 1 S Slide metal 2 Wear/cracks/damage ! Replace. 2. Inspect: S Sprocket wheel 1 Wear/break/damage ! Replace. S Front axle 2 Bends/scratches (excessive)/damage ! Re- place. INSTALLATION 1. Install: S Sprocket wheels S Guide wheels NOTE: S When pressing the sprocket wheels onto the...
Page 157 POWR FRONT AXLE AND TRACK 2. Place the track in the chassis. NOTE: For track with a direction of rotation mark a : Install the track with the mark pointing in the direction of track rotation. A RX10, RX10S, RX10R, RX10RS B RX10M, RX10MS 4-51...
Page 158: Chapter 5. Engine
SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK Order Job name/Part name Q’ty Remarks Seat and fuel tank removal Remove the parts in the order listed below. Rear cover Muffler end pipe Muffler side cover Tail/brake light cover Seat Fuel tank cover Side cover Fuel tank...
Page 159: Exhaust Pipe And Muffler
EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER 20 Nm (2.0 mSkg, 14 ftSlb) 25 Nm (2.5 mSkg, 18 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 11 Nm (1.1 mSkg, 8 ftSlb) Order Job name/Part name Q’ty Remarks Exhaust pipe and muffler removal Remove the parts in the order listed below.
Page 160: Installation
EXHAUST PIPE AND MUFFLER INSTALLATION 1. Install: S Muffler 1 2. Install: S Exhaust pipe 1 NOTE: Hang the exhaust pipe to the frame a . 3. Tighten: S Exhaust pipe bolts 1 Bolt (band): 9 Nm (0.9 mSkg, 7 ftSlb) 4.
Page 161: Magneto And Starter
ENGINE ASSEMBLY ENGINE ASSEMBLY 7 Nm (0.7 mSkg, 5.1 ftSlb) 65 Nm (6.5mSkg, 47 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job name/Part name Q’ty Remarks Engine assembly removal Remove the parts in the order listed below. Intake silencer Refer to “CARBURETORS”...
Page 162: Inspection
ENGINE ASSEMBLY INSPECTION 1. Inspect: S Engine mounting adjust bolts Cracks/damage ! Replace. INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routing. 1. Install: S Engine mounting adjust bolts S Engine S Engine mounting bolts and nuts NOTE:...
Page 163 CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) Order Job name/Part name Q’ty Remarks Cylinder head cover removal Remove the parts in the order listed below. Coolant Drain. Coolant hose and pipe Refer to “HEAT EXCHANGER”...
Page 164 CAMSHAFTS CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job name/Part name Q’ty Remarks Camshaft removal Remove the parts in the order listed below. Oil tank Refer to “A.C.
Page 165 CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job name/Part name Q’ty Remarks Intake camshaft Exhaust camshaft For installation, reverse the removal procedure.
Page 166: Removal
CAMSHAFTS REMOVAL 1. Remove: S Timing plug 2. Align: S “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) NOTE: S Turn the crankshaft clockwise. S When piston #4 is at TDC on the compression stroke, align the “I”...
Page 167 CAMSHAFTS 7. Remove: S Timing chain guide (exhaust side) 1 S Camshaft caps S Dowel pins CAUTION: To prevent damage to the cylinder head, camshafts or camshafts caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 8.
Page 168: Inspection
CAMSHAFTS INSPECTION 1. Inspect: S Camshaft lobes Blue discoloration/pitting/scratches ! Re- place the camshaft. 2. Measure: S Camshaft lobe dimensions a and b Out of specification ! Replace the cam- shaft. Camshaft dimensions: Intake: <Limit>: a 32.40 mm (1.2756 in) b 24.85 mm (0.9783 in) Exhaust: <Limit>: a 32.85 mm (1.2933 in)
Page 169 CAMSHAFTS Measurement steps: S Install the camshaft into the cylinder head (without the dowel pins and camshaft caps).  S Position a strip of Plastigauge 1 onto the camshaft journal. S Install the dowel pins and camshaft caps. NOTE: S Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
Page 170 CAMSHAFTS 8. Inspect: S Timing chain tensioner Cracks/damage ! Replace. Inspection steps: S While lightly pressing the timing chain tension- er rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . S Remove the screwdriver and slowly release the timing chain tensioner rod.
Page 171: Installation
CAMSHAFTS INSTALLATION 1. Install: S Exhaust camshaft 1 S Intake camshaft 2 NOTE: Install the camshafts with the punch mark a facing up. 2. Install: S Dowel pins S Intake camshaft caps S Exhaust camshaft caps NOTE: Make sure that the punch marks a on the cam- shafts are aligned with the arrow marks b on the camshaft caps.
Page 172 CAMSHAFTS S Place the timing chain onto both camshaft sprockets and then install the camshaft sprockets onto the camshafts. NOTE: When installing the camshaft sprockets, start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the ex- haust side.
Page 173 CAMSHAFTS S Tighten the timing chain tensioner bolts 3 to the specified torque. Bolt (timing chain tensioner): 10 Nm (1.0 mSkg, 7.2 ftSlb) S Remove the screwdriver, make sure that the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. Bolt (cap): 6 Nm (0.6 mSkg, 4.3 ftSlb) S Turn the crankshaft...
Page 174 CYLINDER HEAD CYLINDER HEAD 20 Nm (2.0 mSkg, 14 ftSlb) + 121_ 20 Nm (2.0 mSkg, 14 ftSlb) + 105_ 20 Nm (2.0 mSkg, 14 ftSlb) + 140_ 12 Nm (1.2 mSkg, 8.7 ftSlb) 25 Nm (2.5 mSkg, 18 ftSlb) Order Job name/Part name Q’ty...
Page 175 CYLINDER HEAD REMOVAL 1. Remove: S Cylinder head nuts 1 S Cylinder head cap nut 2 S Cylinder head bolts 3 NOTE: S Loosen the nuts in the proper sequence as shown. S Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
Page 176 CYLINDER HEAD INSPECTION 1. Eliminate: S Carbon deposits (from the combustion chambers) Use the rounded scraper. NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: S Spark plug threads S Valve seats 2. Inspect: S Cylinder head Damage/scratches ! Replace.
Page 177 CYLINDER HEAD INSTALLATION 1. Install: S Gasket (cylinder head) S Dowel pins 2 S Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 2. Tighten: S Cylinder head nuts 1 X S Cylinder head bolts NOTE: S First, tighten the nuts 1 X to approximate- ly 20 Nm (2.0 mSkg, 15 ftSlb) with a torque wrench.
Page 178 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job name/Part name Q’ty Remarks Valves and valve springs removal Remove the parts in the order listed below. Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve retainer Intake valve spring Intake valve stem seal...
Page 179 VALVES AND VALVE SPRINGS Order Job name/Part name Q’ty Remarks Exhaust valve spring Exhaust valve stem seal Exhaust valve spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure. 5-22...
Page 180 VALVES AND VALVE SPRINGS REMOVAL NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Remove: S Valve lifter 1 S Valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place.
Page 181: Inspection
VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment Intake valve 90890-04114, YM-4114 Exhaust valve 90890-04108, YM-4108 4. Remove: S Valve retainer 1 S Valve spring 2 S Stem seal 3 S Valve spring seat 4 S Valve 5 NOTE: Identify the position of each part very carefully...
Page 182 VALVES AND VALVE SPRINGS Replacement steps: S Remove the valve guide with a valve guide remover 1 . S Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . S After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem-valve-guide clearance.
Page 183 VALVES AND VALVE SPRINGS 6. Measure: S Valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide. S If the valve is removed or replaced, always re- place the oil seal. Valve stem runout: 0.01 mm (0.0004 in) 7.
Page 184 VALVES AND VALVE SPRINGS Lapping steps: S Apply a coarse lapping compound a to the valve face. CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. S Apply molybdenum disulfide oil onto the valve stem.
Page 185 VALVE AND VALVE SPRINGS 12. Measure: S Compressed spring force a Out of specification ! Replace the valve spring. b Installed length Compressed spring force: Intake 82 X 96 N at 34.5 mm (8.2 X 9.6 kg at 34.5 mm, 18.1 X 21.2 lb at 1.36 in) Exhaust 110 X 126 N at 35.0 mm...
Page 186: Installation
VALVES AND VALVE SPRINGS INSTALLATION 1. Deburr: S Valve stem end (with an oil stone) 2. Lubricate: S Valve stem 1 S Valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: S Valve 1 S Lower spring seat 2 S Oil seal 3 S Valve spring 4...
Page 187 VALVES AND VALVE SPRINGS 4. Install: S Valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor: 90890-04019, YM-04019 Attachment: Intake valve 90890-04114, YM-4114 Exhaust valve 90890-04108, YM-4108 5.
Page 188 A.C. MAGNETO AND STARTER CLUTCH A.C. MAGNETO AND STARTER CLUTCH A.C. MAGNETO ROTOR COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 19 Nm (1.9 mSkg, 14 ftSlb) Order Job name/Part name Q’ty Remarks A.C. magneto rotor cover removal Remove the parts in the order listed below.
Page 189 A.C. MAGNETO AND STARTER CLUTCH A.C. MAGNETO ROTOR AND STARTER CLUTCH 130 Nm (13.0 mSkg, 94 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job name/Part name Q’ty Remarks A.C. magneto rotor and starter clutch Remove the parts in the order listed below. removal A.C.
Page 190: Removal
A.C. MAGNETO AND STARTER CLUTCH REMOVAL 1. Remove: S A.C. magneto rotor bolt S Washer NOTE: S While holding the A.C. magneto rotor 1 with the sheave holder 2 , loosen the magneto ro- tor bolt. S Do not allow the sheave holder to touch the projection on the A.C.
Page 191 A.C. MAGNETO AND STARTER CLUTCH 3. Remove: S Starter clutch NOTE: S While holding the magneto rotor with the sheave holder, remove the starter clutch bolt S Do not allow the sheave holder to touch the projection on the magneto rotor. Sheave holder 90890-01701, YS-01880 4.
Page 192: Installation
A.C. MAGNETO AND STARTER CLUTCH INSTALLATION 1. Install: S Starter clutch NOTE: S While holding the magneto rotor with the sheave holder, tighten the starter clutch bolt. S Do not allow the sheave holder to touch the projection on the magneto rotor. Sheave holder 90890-01701, YS-01880-A 2.
Page 193 A.C. MAGNETO AND STARTER CLUTCH 5. Apply: S Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505  Quick gasket ACC-1100-15-01 5-36...
Page 194: Oil Pan And Oil Pump
OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job name/Part name Q’ty Remarks Oil pan and oil pump removal Remove the parts in the order listed below. Engine Refer to “ENGINE ASSEMBLY”.
Page 195 OIL PAN AND OIL PUMP Order Job name/Part name Q’ty Remarks Oil pump disassembly Disassemble the parts in the order listed below. Oil pump cover 1 Oil pump inner rotor 1 Oil pump outer rotor 1 Oil pump cover 2 Oil pump inner rotor 2 Oil pump outer rotor 2 Oil pump shaft...
Page 196: Removal
OIL PAN AND OIL PUMP REMOVAL 1. Remove: S Pipe 1 S Oil pan 2 S Oil pump NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 5-39...
Page 197: Inspection
OIL PAN AND OIL PUMP INSPECTION 1. Inspection: S Oil pump housing 1 S Oil pump cover 2 Cracks/damage/wear ! Replace the de- fective part(-s). 2. Measure: S Inner-rotor-to-outer-rotor-tip clearance a (between inner rotor 1 and outer rotor 2 ) S Outer-rotor-to-oil-pump-housing clearance (between outer rotor 2 and pump housing Out of specifications ! Replace oil pump as-...
Page 198: Installation
OIL PAN AND OIL PUMP INSTALLATION 1. Lubricate: S Inner rotor S Outer rotor S Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S Pin 1 S Inner rotor 2 S Outer rotor 3 S Housing 4 NOTE: When installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a on the...
Page 199: Crankcase
CRANKCASE CRANKCASE CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) E Tighten these bolts first. F Tighten these bolts second. Order Job name/Part name Q’ty Remarks Crankcase removal...
Page 200 CRANKCASE CONNECTING RODS AND PISTONS 20 Nm (2.0 mSkg, 14 ftSlb) + 120_ Order Job name/Part name Q’ty Remarks Connecting rods and pistons Remove the parts in the order listed below. removal Connecting rod cap Big end bearing Piston pin clip Piston pin Piston Connecting rod...
Page 201 CRANKCASE CRANKSHAFT AND COUNTER SHAFT 75 Nm (7.5 mSkg, 54 ftSlb) A This bolt has a left-hand thread. Order Job name/Part name Q’ty Remarks Crankshaft and counter shaft Remove the parts in the order listed below. removal Crankshaft Crankshaft journal bearing Drive gear Lock plate Counter shaft assembly...
Page 202: Removal
CRANKCASE REMOVAL 1. Remove: S Crankcase bolts NOTE: S Place the engine upside down. S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).
Page 203 CRANKCASE 5. Remove: S Piston pin clips 1 S Piston pin 2 S Piston 3 S Connecting rod 4 CAUTION: Do not use a hammer to drive the piston pin out. NOTE: S For reference during installation, put identifi- cation marks on the piston crown. S Before removing the piston pin, deburr the pis- ton pin clip’s groove and the piston’s pin bore area.
Page 204: Inspection
CRANKCASE INSPECTION 1. Inspect: S Piston wall and cylinder wall Vertical scratches ! Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: S Piston-to-cylinder clearance Measurement steps: 1st step: S Measure cylinder bore “C” with the cylinder bore gauge 1 .
Page 205 CRANKCASE 2nd step: S Measure piston skirt diameter “P” with the micrometer. a 5 mm (0.20 in) from the bottom edge of the piston. Piston size (standard) (P): 73.955 X 73.970 mm (2.9116 X 2.9122 in) S If out of specification, replace the piston and piston rings as a set.
Page 206 CRANKCASE 4. Install: S Piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the pis- ton crown. a 5 mm (0.20 in) 5. Measure: S End gap (piston rings) Out of specification ! Replace the piston rings as a set.
Page 207 CRANKCASE 8. Measure: S Piston pin bore inside diameter Out of specification ! Replace the piston. Piston pin bore inside diameter: 17.002 X 17.013 mm (0.6694 X 0.6698 in) 9. Calculate: S Piston pin to piston pin bore clearance Out of specification ! Replace the piston pin and piston as a set.
Page 208 CRANKCASE 11. Inspect: S Crankshaft journal surfaces S Crankshaft pin surfaces S Bearing surfaces Scratches/wear ! Replace the crankshaft. 12. Measure: S Crankshaft-journal-to-crankshaft-journal- bearing clearance Out of specification ! Replace the crank- shaft journal bearings. Crankshaft-journal-to-crankshaft- journal-bearing clearance: 0.004 X 0.028 mm (0.0002 X 0.0011 in) Measurement steps: CAUTION:...
Page 209 CRANKCASE S Install the crankshaft journal lower bearings 1 into the lower crankcase and assemble the crankcase halves. NOTE: S Align the projections a of the crankshaft jour- nal lower bearings with the notches b in the crankcase. S Do not move the crankshaft until the clearance measurement has been completed.
Page 210 CRANKCASE 13. Select: S Crankshaft journal bearings (J1 X J5) NOTE: S The numbers A stamped into the crankshaft web and the numbers B stamped into the low- er crankcase are used to determine the re- placement crankshaft journal bearing sizes. S “J1 X J5”...
Page 211 CRANKCASE Measurement steps: CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear- ance and prevent engine damage, the big end bearings must be installed in their origi- nal positions. S Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods.
Page 212 CRANKCASE S Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. S Clean the connecting rod bolts and nuts. S Tighten the connecting rod nuts. S Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3 .
Page 213 CRANKCASE 15. Select: S Big end bearings (P NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. S “P1” X “P4” refer to the bearings shown in the crankshaft illustration.
Page 214 CRANKCASE 17. Inspect: S Bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement ! Replace. 18. Inspect: S Oil seals Damage/wear ! Replace. 19. Inspect: S Primary drive gear 1 S Oil pump driven gear 2 Cracks/damage/wear ! Replace the de- fective part(-s).
Page 215: Installation
CRANKCASE INSTALLATION 1. Install: S Crankshaft journal bearing 1 (into the upper crankcase) NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the crankcase. S Be sure to install each crankshaft journal up- per bearing in its original place.
Page 216 CRANKCASE 5. Lubricate: S Piston S Piston rings S Cylinder S Crankshaft pins S Big end bearings (with the recommended lubricant) Recommended lubricant Engine oil 6. Offset: S Piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander...
Page 217 CRANKCASE 8. Align: S Bolt heads (with the connecting rod caps) 9. Tighten: S Connecting rod nuts Nut (connecting rod): 20 Nm (2.0 mSkg, 14 ftSlb)+120_ S Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method.
Page 218 Recommended lubricant Engine oil 11. Apply: S Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505, ACC-1100-15-01 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings.
Page 219 CRANKCASE 14. Install: S Crankcase bolts NOTE: S Lubricate the bolt threads with engine oil. S Tighten the bolts in increasing numerical or- der. S Install washers on bolts 1 X Crankcase bolt Bolt 1 X 1st: 15 Nm (1.5 mSkg, 11 ftSlb) 2nd: 15 Nm (1.5 mSkg, 11 ftSlb) + 45 X 50_...
Page 220 COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAPTER 2. Primary sheave assembly Refer to “PRIMARY SHEAVE AND DRIVE V-VELT”...
Page 221 COOL HEAT EXCHANGER 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Coolant pipe 2 Coolant hose 7 Coolant hose 8 Thermostat assembly Coolant hose 9 Coolant hose 10 Oil cooler outlet hose Oil cooler Oil cooler inlet hose Pipe 3 Water pump hose Carburetor heater hose...
Page 222: Heat Exchanger
COOL HEAT EXCHANGER INSPECTION 1. Inspect: S Coolant hoses S Heat exchangers S Oil cooler S Coolant pipes Cracks/damage ! Replace. 2. Measure: S Filler cap opening pressure Cap opens with a pressure below the speci- fied pressure ! Replace. Filler cap opening pressure: 95 X 125 kPa (0.95 X 1.25 kg/cm...
Page 223: Installation
COOL HEAT EXCHANGER INSTALLATION 1. Install: S Heat exchangers Use the rivet gun. 2. Install: S O-ring S Oil cooler S Lock washer S Bolt (oil cooler bolt) Bolt (oil cooler): 35 Nm (3.5 mSkg, 25 ftSlb) NOTE: S Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with a thin coat of engine oil.
Page 224: Thermostat
COOL THERMOSTAT THERMOSTAT 10 Nm (1.0 mSkg, 7.2 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job name/Part name Q’ty Remarks Thermostat disassembly Disassemble the parts in the order listed below. Thermostat housing cover Thermostat Thermostat housing Water temperature sensor For assembly, reverse the disassembly procedure.
Page 225 COOL THERMOSTAT INSPECTION 1. Inspect: S Thermostat Does not open at 71 X 85_C (160 X 185_F) ! Replace. Inspection steps: S Suspend the thermostat in a container filled with water. S Slowly heat the water. Place a thermometer in the water. S While stirring the water, observe the thermo- stat and thermometer’s indicated tempera- ture.
Page 226: Installation
COOL THERMOSTAT INSTALLATION 1. Install: S Thermostat (into the thermostat housing) NOTE: Install the thermostat with its breather hole a aligned with the this place b on the thermostat housing. 2. Install: S Thermostat cover S Bolts (thermostat housing) Bolt (thermostat housing): 10 Nm (1.0 mSkg, 7.2 ftSlb) 3.
Page 227: Water Pump
COOL WATER PUMP WATER PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job name/Part name Q’ty Remarks Water pump disassembly Disassembly the parts in the order listed below. Oil pan Refer to “OIL PAN AND OIL PUMP”. Water pump cover Plate Circlip Impeller shaft...
Page 228: Disassembly
COOL WATER PUMP DISASSEMBLY 1. Remove: S Impeller S Water pump seal 1 NOTE: Remove the water pump seal 1 from the inside of the water pump housing 2 . 2. Remove: S Bearing 1 S Oil seal 2 NOTE: Remove the bearing 1 and oil seal 2 from the inside of the water pump housing 3 .
Page 229: Inspection
COOL WATER PUMP INSPECTION 1. Inspect: S Water pump housing cover 1 S Water pump housing 2 S Impeller 3 S Rubber damper 4 S Rubber damper holder 5 S Water pump seal S Oil seal Cracks/damage/wear ! Replace. 2. Inspect: S Bearing Rough movement ! Replace.
Page 230 S Install the water pump seal 1 with the water pump seal installers 4 5 . S Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3 . Water pump seal installer: 90890-04078, YM-33221...
Page 231: Chapter 7. Carburetion
CARB CARBURETORS CARBURETION CARBURETORS 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job name/Part name Q’ty Remarks Carburetors removal Remove the parts in the order listed below. Intake silencer Fuel pump Carburetor switch (T.O.R.S.) lead Disconnect. Starter cable Throttle position sensor coupler Disconnect.
Page 232 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Carburetor separation Remove the parts in the order listed below. Carburetor heater harness Carburetor heating hose Starter plunger link Connecting bolt Spacer Fuel inlet pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Carburetor For installation, reverse the removal...
Page 233 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Carburetor disassembly Disassemble the parts in the order listed below. NOTE: The following procedure applies to all of the carburetors. Starter plunger Pilot air jet Vacuum chamber cover Piston valve spring Piston valve Jet needle holder Jet needle kit Pilot screw...
Page 234 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet Carburetor switch (T.O.R.S.) Carburetor heater Starter jet For assembly, reverse the disassembly procedure.
Page 235: Inspection
CARB CARBURETORS INSPECTION 1.Inspect: S Carburetor body S Float chamber S Jet housing Cracks/damage ! Replace. 2. Inspect: S Fuel passages Obstruction ! Clean. NOTE: S Use a petroleum based solvent for cleaning. S Blow out all passage and jets with compressed air.
Page 236 CARB CARBURETORS 8. Inspect: S Piston valve 1 Damage/scratches/wear ! Replace. S Rubber diaphragm 2 Cracks/tears ! Replace. 9. Inspect: S Vacuum chamber cover 1 S Piston valve spring 2 S Jet needle holder 3 Cracks/damage ! Replace. 10. Inspect: S Jet needle kit 1 S Starter jet 2 S Main jet 3...
Page 237: Assembly
CARB CARBURETORS ASSEMBLY NOTE: S Before assembling the carburetors, wash all of the parts in a petroleum based solvent. S Always use a new gasket and O-rings. 1. Install: S Jet needle kit S Needle jet S Pilot jet S Main jet 2.
Page 238: Installation
CARB CARBURETORS INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routing. 1. Adjust: S Carburetor synchronization Refer to “SYNCHRONIZING THE CARBU- RETORS” in CHAPTER 2. 2. Adjust: S Engine idling speed Engine idle speed: 1,350 ±...
Page 239: Fuel Lebel Adjustment
CARB CARBURETORS FUEL LEVEL ADJUSTMENT 1. Measure: S Fuel level a Out of specification ! Adjust. Fuel level (below the line on the float chamber): 3.0 X 4.0 mm (0.118 X 0.157 in) Measurement steps: S Install the fuel level gauge 1 to the fuel drain pipe 2 .
Page 240: Throttle Position Sensor
CARB CARBURETORS THROTTLE POSITION SENSOR (T.P.S.) INSPECTION AND ADJUSTMENT NOTE: Before adjusting the throttle position sensor, properly adjust the idle speed. 1. Inspect: S Throttle position sensor. Inspection steps: S Disconnect throttle position sensor coupler. S Connect the pocket tester (Ω 1k) to the throttle position sensor coupler.
Page 241 CARB CARBURETORS 2. Adjust: S Throttle position sensor position Adjustment steps: S Disconnect the throttle position sensor cou- pler. S Connect the test coupler to the throttle position sensor. S Connect three dry cells (1.5 V 3 pcs.) in se- ries to the test coupler.
Page 242: Fuel Pump
CARB FUEL PUMP INSPECTION 1. Inspect: S Fuel hose 1 S Vacuum hose 2 Clogs/damage ! Replace. 2. Inspect: S Fuel pump operation. Inspection steps: S Connect the Mity vac 1 to the vacuum hose Mity vac: 90890-06756, YB-35956 S Place a container 3 under the end of the fuel hoses 4 .
Page 243: Chapter 8. Electrical
ELEC SWITCH INSPECTION ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: 90890-03112, YU-03112 NOTE: S Set the pocket tester to “0” before starting a test.
Page 244: Ignition System
ELEC IGNITION SYSTEM...
Page 245: Circuit Diagram
ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery Engine stop switch Throttle switch Carburetor switch CDI unit ignition coil Spark plug Fuse (IGNITION)
Page 246: Troubleshooting
ELEC IGNITION SYSTEM TROUBLESHOOTING NO SPARK OR WEAK SPARK. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 247: A.c. Magneto
ELEC IGNITION SYSTEM A.C. MAGNETO 1. Disconnect: S A.C. magneto coupler 1 2. Connect: S Pocket tester (to the A.C. magneto coupler) 3. Measure: S Stator coil resistance b /pickup coil resis- tance a Out of specification ! Replace. Pickup coil resistance: (Gray –...
Page 248: Ignition Spark Gap
ELEC IGNITION SYSTEM IGNITION SPARK GAP 1. Remove: S Ignition coil 2. Measure: S Ignition spark gap Out of specification ! Replace the ignition coil Measurement steps: S Disconnect the ignition coil 2 from the spark plug. S Connect the dinamic spark tester 1 . S Set the main switch to “ON”.
Page 249: Throttle Override System (T.o.r.s.)
ELEC IGNITION SYSTEM THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should mal- function during operation, T.O.R.S. will operate when the throttle lever is released. T.O.R.S. is designed to interrupt the ignition and keep the engine revolutions between 2,800 and 3,000 r/min if the carburetor fails to return to idle when the lever is released.
Page 250: Handlebar Switch (Right)
ELEC IGNITION SYSTEM HANDLEBAR SWITCH (RIGHT) Engine stop switch and throttle switch 1. Disconnect: S Handlebar switch (right) coupler 1 2. Connect: S Pocket tester 3. Inspect: S Engine stop switch continuity Faulty ! Replace the handlebar switch (right). Switch position Continuity RUN (pulled out) OFF (pushed in)
Page 251: Main Switch
ELEC IGNITION SYSTEM MAIN SWITCH 1. Disconnect: S Main switch coupler 1 2. Connect: S Pocket tester 3. Inspect: S Main switch continuity Faulty ! Replace. Switch position Continuity Color code Switch position Br/W START Continuity MAIN RELAY 1. Inspect: S Main relay 1 Inspection steps: S Disconnect the main relay from the coupler.
Page 252: Electrical Starting System
ELEC ELECTRICAL STARTING SYSTEM 8-10...
Page 253: Troubleshooting
ELEC ELECTRICAL STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. WARNING Before starter motor operation, push the engine stop switch to “OFF”. 1. Connect: S Starter relay terminals (battery side and starter motor side) Check the battery and connectors. Refer to “BATTERY INSPECTION” in CHAP- TER 2.
Page 254: Main Switch
ELEC ELECTRICAL STARTING SYSTEM FAULTY Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the main switch. Replace the main switch. Correct the connection. MAIN SWITCH 1.
Page 255: Starter Motor
ELEC ELECTRICAL STARTING SYSTEM STARTER MOTOR 27 Nm (2.7 mSkg, 20 ftSlb) Order Job name/Part name Q’ty Remarks Starter motor disassembly Disassemble the parts in the order listed below. Starter motor removal Refer to “ENGINE REMOVAL” in CHAPTER 5. Rear bracket Bearing Starter motor yoke O-ring...
Page 256 ELEC ELECTRICAL STARTING SYSTEM Inspection 1. Inspect: S Commutator (outer surface) Dirty ! Clean with #600 grit sandpaper 1 . Hold the armature in a vise 2 and copper or aluminium plate 3 . CAUTION: Lightly grip the armature with a vise. 2.
Page 257 ELEC ELECTRICAL STARTING SYSTEM 5. Measure: S Brush length a Out of specification ! Replace the starter motor. Brush wear limit: 5 mm (0.20 in) 6. Measure: S Brush spring pressure Fatigue/out of specification ! Replace as a set. Brush spring pressure: 7.36 X 11.04 N (736 X 1,104 g, 26.0 X 38.9 oz) Assembly...
Page 258: Charging System
ELEC CHARGING SYSTEM 8-16...
Page 259: Troubleshooting
ELEC CHARGING SYSTEM TROUBLESHOOTING BATTERY IS NOT CHARGED. 1. Connect: S Pocket tester (to the battery terminals) OUT OF SPECIFICATIONS 2. Measure: S Battery voltage S Check the battery. Battery voltage: S Replace and/or charge the battery. more than 12 V at 20_C (68_F) Refer to “BATTERY INSPECTION”...
Page 260: Battery
ELEC CHARGING SYSTEM BATTERY Inspection 1. Inspect: S Battery condition Refer to “BATTERY INSPECTION” in CHAPTER 2. Battery Storage The battery should be stored if the vehicle is not going to be used for a long period. 1. Remove: S Battery WARNING When removing the battery, disconnect the negative lead first.
Page 261: Lighting System
ELEC LIGHTING SYSTEM 8-19...
Page 262: Circuit Diagram
ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery CDI unit Tail / brake light Fuse (HEADLIGHT) Fuse (SIGNAL) Fuse (IGNITION) Headlight beam switch Headlight relay Headlight Meter light Hi beam indicator light 8-20...
Page 263: Troubleshooting
ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT AND/OR METER LIGHT DO NOT COME ON. Check the bulb(s). NO CONTINUITY Replace the bulb(s). Check the main fuse, ignition fuse and headlight fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or headlight fuse.
Page 264 ELEC LIGHTING SYSTEM TAIL LIGHT DOES NOT COME ON. Check the tail/brake light bulb(s). NO CONTINUITY Replace the tail/brake light bulb(s). Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 265: Bulb(S)
ELEC LIGHTING SYSTEM BULB(S) 1. Remove: S Headlight bulb a S Tail/brake light bulb b S Meter light bulb c 2. Connect: S Pocket tester (to the bulb terminals) WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot.
Page 266 ELEC LIGHTING SYSTEM HEADLIGHT RELAY 1. Inspect: S Headlight relay (black coupler) 1 Inspection steps: S Disconnect the headlight relay from the cou- pler. S Connect the pocket tester (Ω 1) and battery (12 V) to the headlight relay terminals as shown.
Page 267: Signal System
ELEC SIGNAL SYSTEM 8-25...
Page 268: Circuit Diagram
ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery CDI unit Water temperature sensor Back buzzer Gear position switch Brake light switch Tail / brake light Fuse (SIGNAL) Fuse (IGNITION) Water temperature indicator light Multi-function meter Warning light Oil level switch...
Page 269: Troubleshooting
ELEC SIGNAL SYSTEM TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. Check the tail/brake light bulb(s). Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the tail/brake light bulbs. Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 270 ELEC SIGNAL SYSTEM WATER TEMPERATURE INDICATOR LIGHT DOES NOT COME ON. Check the water temperature indicator light bulb(s). Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb(s). Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 271 ELEC SIGNAL SYSTEM FUEL METER AND/OR WARNING LIGHT DO NOT OPERATE. Check the warning light bulb. Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb. Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 272 ELEC SIGNAL SYSTEM ENGINE OIL INDICATOR LIGHT AND/OR WARNING LIGHT DO NOT COME ON. Check the warning light bulb. Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb. Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 273 ELEC SIGNAL SYSTEM SPEEDOMETER DO NOT OPERATE. Check the speedometer unit. Refer to “SPEEDOMETER UNIT INSPECTION” in CHAPTER 2. FAULTY Replace the speedometer unit. Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse.
Page 274 ELEC SIGNAL SYSTEM BACK BUZZER DOES NOT SOUND. (RX10R, RX10RS) Check the main fuse, ignition fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse and/or signal fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 275: Brake Light Switch
ELEC SIGNAL SYSTEM BRAKE LIGHT SWITCH 1. Disconnect: S Brake light switch coupler 1 2. Inspect: S Brake light switch continuity Faulty ! Replace. Switch position Continuity Brake lever operates Brake lever does not operate GEAR POSITION SWITCH (RX10R, RX10RS) 1.
Page 276: Water Temperature Sensor
ELEC SIGNAL SYSTEM WATER TEMPERATURE SENSOR 1. Disconnect the water temperature sensor coupler 1 and remove the water tempera- ture sensor. CAUTION: Handle the water temperature sensor with special care. Never subject it to shock or al- low it to be dropped. If it is dropped, it must be replaced.
Page 277: Engine Oil Level Switch
ELEC SIGNAL SYSTEM ENGINE OIL LEVEL SWITCH 1. Remove: S Oil level gauge 1 2. Connect: S Pocket tester (to the oil level switch coupler) 3. Inspect: S Oil level switch continuity Faulty ! Replace. Switch Good position condition condition Down position Up position f : Continuity...
Page 278: Speed Sensor
ELEC SIGNAL SYSTEM SPEED SENSOR 1. Inspect: S Speed sensor Inspection steps: S Connect the pocket tester (DC 20 V) to the speed sensor coupler 1 (wire harness side) as shown. Positive tester probe ! White Negative tester probe ! Black/Green Positive battery terminal ! Blue/Yellow Negative battery terminal ! Black/Green S Elevate the track and slowly rotate it.
Page 279: Grip Warmer System
ELEC GRIP WARMER SYSTEM 8-37...
Page 280: Circuit Diagram
ELEC GRIP WARMER SYSTEM GRIP WARMER SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery Grip warmer Thumb warmer CDI unit Grip warmer switch Thumb warmer switch Fuse (SIGNAL) Fuse (IGNITION) Multi-function meter 8-38...
Page 281: Troubleshooting
ELEC GRIP WARMER SYSTEM TROUBLESHOOTING GRIP WARMER AND THUMB WARMER DO NOT OPERATE. Check the main fuse and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 282: Grip And Thumb Warmer Coil
ELEC GRIP WARMER SYSTEM GRIP AND THUMB WARMER COIL 1. Disconnect: S Grip warmer leads 1 S Thumb warmer coupler 2 2. Connect: S Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads) 3. Inspect: S Grip warmer 1 continuity S Thumb warmer 2 continuity No continuity ! Replace both grips together or separately and/or the handlebar switch.
Page 283: Grip Warmer Switch
ELEC GRIP WARMER SYSTEM GRIP WARMER SWITCH 1. Disconnect: S Grip warmer switch coupler 1 2. Connect: S Pocket tester (to the switch coupler) 3. Inspect: S Grip warmer switch continuity Switch is operated. Faulty ! Replace the handlebar switch (left).
Page 284: Carburetor Heater System
ELEC CARBURETOR HEATER SYSTEM 8-42...
Page 285: Circuit Diagram
ELEC CARBURETOR HEATER SYSTEM CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Main switch Main relay Fuse (MAIN) Battery Carburetor heater relay Carburetor heater CDI unit Water temperature sensor Fuse (SIGNAL) Fuse (CARBURETOR HEATER) Fuse (IGNITION) 8-43...
Page 286: Troubleshooting
ELEC CARBURETOR HEATER SYSTEM TROUBLESHOOTING CARBURETOR HEATER DO NOT OPERATE. Check the main fuse, signal fuse, carburetor heater fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or signal fuse, and/or carburetor heater fuse and/or ignition fuse.
Page 287: Carburetor Heater Relay
ELEC CARBRETER HEATER SYSTEM CARBURETOR HEATER RELAY 1. Inspect: S Carburetor heater relay 1 Inspection steps: S Disconnect the carburetor heater relay from the coupler. S Connect the pocket tester (Ω 1) and battery (12 V) to the carburetor heater relay terminals as shown.
Page 288: Self-Diagnosis
ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS This model features a self-diagnosing system for following displays. 1. Fuel meter, fuel level warning indicator 1 and the warning light 4 2. Coolant temperature warning light 2 and the warning light 4 3. Self-diagnosis warning indicator 3 and the warning light 4 NOTE: The oil level warning indicator and the warning light come on when the engine oil level is low.
Page 289: Coolant Temperature Warning Light And The Warning Light
ELEC SELF-DIAGNOSIS 2. COOLANT TEMPERATURE WARNING LIGHT AND THE WARNING LIGHT The coolant temperature warning light and the warning light faults are displayed as follows S Thermo sensor Item Thermo sensor Condition Disconnected Short-circuit 3. SELF-DIAGNOSIS WARNING INDICATOR AND THE WARNING LIGHT The self-diagnosis warning indicator and the warning light faults are displayed as follows S Throttle position sensor (T.P.S.) S Variable resistor (grip and thumb warmer)
Page 290 ELEC ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS Item Grip warmer Condition Short-circuit Item Thumb warmer switch Condition Disconnected Item Thumb warmer Condition Short-circuit Item Voltage Condition Wrong Warning light ON Warning light OFF s Time (second) 8-48...
Page 291: Chapter 9. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Model code number: 8FA1 (RX10 for U.S.A/Canada) 8EU1 (RX10S for U.S.A/Canada) 8ER1 (RX10R for U.S.A/Canada) 8EW1 (RX10RS for U.S.A/Canada) 8EP1 (RX10M for U.S.A/Canada) 8EV1 (RX10MS for U.S.A/Canada) 8FA2 (RX10 for Europe) 8ER2 (RX10R for Europe) 8EW2 (RX10RS for Europe)
Page 292 SPEC GENERAL SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Oil filter: Oil filter type Cartridge (paper) Drive chain housing oil: Type Gear oil API “GL-3” SAE#75 or #80 Capacity 0.25 L (8.8 lmp oz, 8.5 US oz) Coolant: Capacity 4.7 L (4.1 lmp qt, 5.0 US qt) Fuel: Type...
Page 293 SPEC GENERAL SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Track: Track type Internal drive type Track width 381 mm (15.0 in) Length on ground 752 mm (29.6 in) (RX10, RX10S, RX10R, RX10RS) 1,071 mm (42.2 in) (RX10M, RX10MS) 25 X 30 mm (0.98 X 1.18 in) Track deflection mm/ 100 N (10 kg, 22 lb) Brake:...
Page 294: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Cylinder head: 13.45 X 14.00 cm (0.82 X 0.85 cu. in) Volume (with spark plug) <Warpage limit> 0.1 mm (0.004 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating 74.000 X 74.010 mm (2.9134 X 2.9138 in)
Page 295 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Valve dimensions: Valve head diameter A 22.9 X 23.1 mm (0.9016 X 0.9094 in) Intake 24.4 X 24.6 mm (0.9606 X 0.9685 in) Exhaust Head Diameter Valve face width B 1.76 X 2.90 mm (0.0693 X 0.1142 in) Intake 1.76 X 2.90 mm (0.0693 X 0.1142 in)
Page 296 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Valve spring: Free length Intake 38.90 mm (1.53 in) Exhaust 40.67 mm (1.60 in) Installed length (valve closed) Intake 34.50 mm (1.36 in) Exhaust 35.00 mm (1.38 in) Compressed spring force (installed) 82 X 96 N (8.2 X 9.6 kg, 18.1 X 21.2 lb) Intake...
Page 297 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Piston pin: 16.991 X 17.000 mm (0.6689 X 0.6693 in) Piston pin outside diameter 51.4 X 51.5 mm (2.0236 X 2.0276 in) Piston pin length 0.002 X 0.022 mm (0.00008 X 0.0009 in) Piston pin to piston pin bore clearance <Limit>...
Page 298 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Carburetor: Type/Quantity BSR37/4 Manufacturer MIKUNI I.D. mark 8FA100 Main jet (M.J) #135 Main air jet (M.A.J) #120 Jet needle (J.N) Ab-3 Needle jet (N.J) Pilot jet (P.J) #17.5 Pilot air jet (P.A.J.1) (P.A.J.2) #125...
Page 299: Power Train
SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Transmission: Type V-belt automatic 3.8 X 1.0 : 1 Range of ratio 3,600 ± 200 r/min (3,400 X 3,800 r/min) Engagement speed r/min (RX10, RX10S, RX10R, RX10RS) 4,200 ± 200 r/min (4,000 X 4,400 r/min) (RX10M, RX10MS) 10,250 ±...
Page 300 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Secondary sheave spring: Part number 90508-60012 (RX10, RX10S, RX10R, RX10RS) 90508-60007 (RX10M, RX10MS) Color code PINK (RX10, RX10S, RX10R, RX10RS) White (RX10M, RX10MS) Outside diameter 69.5 mm (2.736 in) Wire diameter 6 mm (0.236 in) Hole position Sheave side-spring side (twist angle)
Page 301 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Slide rail suspension (Rear suspension): Center travel 221 mm (8.70 in) (RX10, RX10S, RX10R, RX10RS) 188 mm (7.40 in) (RX10M, RX10MS) Rear travel 298 mm (11.73 in) (RX10, RX10S, RX10R, RX10RS) 237 mm (9.33 in) (RX10M, RX10MS) Suspension spring rate Front...
Page 302 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Slide runner: Thickness 17.8 mm (0.70 in) Wear limit 10 mm (0.39 in) Track sprocket wheel: Material High molecular weight polyethylene Number of teeth 9 T (RX10, RX10S, RX10R, RX10RS) 8 T (RX10M, RX10MS) Rear guide wheel: Material...
Page 303: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Frame: Frame material Aluminum Seat height 738 mm (29.1 in) Luggage box location Front Steering: Lock-to-lock angle (left) 30.0_ (R ski) 34.7_ (L ski) (right) 34.7_ (R ski) 30.0_ (L ski) Ski alignment Toe-out 0 X 15 mm (0 X 0.59 in)
Page 304: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5_ at 1,450 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T54973 /MITSUBISHI 0.16 X 0.22 Ω at 20_C (68_F) Primary coil resistance 5.0 X 6.8 kΩ...
Page 305 SPEC MAINTENANCE SPECIFICATIONS Model RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Starter relay: Model/Manufacturer MS5F-441/JIDECO Amperage rating 180 A 4.2 X 4.6 Ω at 20_C (68_F) Coil resistance T.P.S. (throttle position sensor): Model/Manufacturer TS67/02-1C/MIKUNI 4 X 6 KΩ at 20_C (68_F) Resistance (Blue –...
Page 306: High Altitude Settings
SPEC HIGH ALTITUDE SETTINGS HIGH ALTITUDE SETTINGS RX10, RX10S, RX10R, RX10RS Tempera- –40_C –20_C 16_C ture (–40_F) Idling speed (r/min) (–4_F) (32_F) (60_F) Altitude 0 X 200 m #140 #137.5 #135 (0 X 670 ft) 1350 200 X 1000 m #137.5 #135 #132.5...
Page 307: Tightening Torque
SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Spark plug Cylinder head nut (M10 1.25) 20 + 121_ 2.0 + 121_ 14 + 121_ Cylinder head nut (M10 1.25) 20 + 105_ 2.0 + 105_...
Page 308 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Fuel pump Fuel pump stay NOTE: 1. First, tighten the bolt to approximately 15 Nm (1.5 mSkg, 11 ftSlb) with a torque wrench, then loosen the bolt completely.
Page 309: Power Train
SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Primary sheave (1st) Tighten the bolt in two (2nd) stages. See NOTE. Spider and sliding sheave 20.0 Left-hand thread.  Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave...
Page 310 SPEC TIGHTENING TORQUE Tightening torque Parts be tightened Parts be tightened Remarks Remarks mSkg ftSlb  Wheel bracket shaft and sliding frame Apply LOCTITE Set bolt (front axle) Speed sensor Gear unit (speed sensor) NOTE: Tightening steps: 1. Tighten the bolt to a torque at 155 Nm (15.5 mSkg, 112 ftSlb). 2.
Page 311: Chassis
SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Handlebar holder Steering column Upper Lower Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod...
Page 312: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (nut) (bolt) (bolt) This chart specifies torque for standard fasteners mSkg ftSlb with standard I.S.O. pitch threads. Torque speci- 10 mm 6 mm fications for special components or assemblies 12 mm 8 mm are included in the applicable sections of this...
Page 313: Cable Routing
SPEC CABLE ROUTING 9-23...
Page 314 SPEC CABLE ROUTING 1 To the headlight and meter as- sembly Battery negative lead Battery positive lead Oil level switch lead coupler Oil level switch Carburetor switch lead connec- Coolant temperature sensor lead coupler To the brake caliper To the heat exchanger Main switch Joint connector Tail/ brake light lead coupler...
Page 315 SPEC CABLE ROUTING 9-25...
Page 316 SPEC CABLE ROUTING Connect the battery negative lead to the starter motor mount- ing bolt Voltage regulator Relay Back buzzer (RX10R, RX10RS) Bolt Battery negative lead Clamp the vacuum hose to the coolant hose Clamp the ignition coil lead to the frame Route the fuel hose under the clamp...
Page 317 SPEC CABLE ROUTING 9-27...
Page 318 SPEC CABLE ROUTING 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securety fit in the rubber cover) 9-28...
Page 319 SPEC CABLE ROUTING 9-29...
Page 320 SPEC CABLE ROUTING 1 Do not clamp the throttle cable Throttle cable Handlebar holder All leads and cables except brake hose and parking brake cable Clamp the tail / brake light lead, headlight beam switch lead and grip warmer lead Parking brake cable Left handlebar switch Brake hose and parking brake...
Page 321 SPEC CABLE ROUTING 9-31...
Page 322 SPEC CABLE ROUTING Right handlebar switch Clamp the wire harness only Clamp the fuel sender head and speed sensor lead Less than 50 mm (2.0 in) Clamp the wire harness Route the carburetor air vent hose under the fuel hose Push into the end of clamp be- tween frame and fuel tank Breather tank...
Page 323 SPEC CABLE ROUTING 9-33...
Page 324 SPEC CABLE ROUTING Coolant reservoir tank Reservoir tank hose Parking brake cable Brake hose Clamp the hose at the white paint position. Point the clamp position to the front outside Clamp the battery positive lead Headlight lead Tighten the frame ground and voltage regulator upper bolt to- gether Engine oil tank hose...
Page 325 SPEC CABLE ROUTING 9-35...
Page 326 SPEC CABLE ROUTING 1 Fuel pump Coolant reservoir tank Point the pawl of clip to the up- ward Clamp the fuel tank breather and speed sensor lead. Thigh- ten the frame cross member and frame together Wire harness clamp Rivets Speed sensor Point the pawl of clip to the downward...
Page 327 SPEC CABLE ROUTING 9-37...
Page 328 SPEC CABLE ROUTING 1 CDI unit Battery negative lead Starter motor Position the negative lead on the engine at 45_ Battery positive lead CDI unit bracket Battery band Battery cover To the carburetor Equip it with the frame cross member Wire harness holder Battery bracket Battery seat...
Page 329 1 A.C. magneto 2 Rectifier / regulator 3 Main switch 4 Main relay 5 Fuse (MAIN) 6 Starter relay 7 Starter motor 8 Battery 9 Engine stop switch 10 Throttle switch 11 Carburetor switch 12 Carburetor heater relay 13 Carburetor heater 14 Grip warmer 15 Thumb warmer 16 CDI unit...
Page 330 01. 05 PRINTED ON RECYCLED PAPER...
Page 332 (LIT-12618-02-28) ing or repairing the snowmobile. NOTICE CAUTION: This manual was written by the Yamaha Motor A CAUTION indicates special precautions that Company primarily for use by Yamaha dealers must be taken to avoid damage to the snowmo- and their qualified mechanics. It is not possible bile.
Page 333 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. POWR 1 General information CHAS 2 Periodic inspections and adjustments 3 Chassis 4 Power train 5 Engine COOL 6 Cooling system...
Page 334 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTIONS AND INSP ADJUSTMENTS CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 335 CHAPTER 1. INSTALLATION ....GENERAL INFORMATION CHAPTER 5. SPECIAL TOOLS ..... . ENGINE FOR TUNE UP .
Page 336: Special Tools
SPECIAL TOOLS SPECIAL TOOLS INFO INFO SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent dam- age that can be caused by the use of improper tools or improvised techniques.
Page 337: Chapter 2. Periodic Inspection And Adjustment
Drive track and idler Check deflection, and for wear and damage. wheels *Adjust / replace if necessary. Check for wear and damage. Slide runners Slide runners *Replace if necessary. * It is recommended that these items be serviced by a Yamaha dealer.
Page 338 Tool kit and recommended Check for proper placement. equipment * It is recommended that these items be servised by a Yamaha dealer. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required.
Page 339: Power Train
INSP PARKING BRAKE ADJUSTMENT POWER TRAIN PARKING BRAKE ADJUSTMENT 1. Measure: S Parking brake cable distance a Out of specification ! Adjust. Parking brake cable distance: 43.5 X 46.5 mm (1.713 X 1.831 in) 2. Adjust: S Parking brake cable Adjustment steps: S Loosen the locknut 1 S Turn the adjuster 2 in or out until the specified...
Page 340: Chassis
INSP LUBRICATION CHASSIS LUBRICATION Brake lever, throttle lever and throttle cable 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables. Recommended lubricant: ESSO Beacon 325 Grease WARNING Apply a dab of grease onto only the end of the cables.
Page 341: Tuning
INSP CLUTCH TUNING G Green P Pink W White CLUTCH S Silver Y Yellow High altitude X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft)
Page 342 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the de- sired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the en- gine speed at which the machine first begins to move from a complete stop.
Page 343: Gear Selection
INSP GEAR SELECTION 1 Chain and sprocket part number Parts name Teeth & links Parts no. Standard 20 teeth 8FA-17682-00 21 teeth 8FA-17682-10 Drive sprocket 22 teeth 8FA-17682-20 23 teeth 8FA-17682-30 RXW10J, RXW10SJ 24 teeth 8FA-17682-40 38 teeth 8FB-47587-80 RXW10J, RXW10SJ Driven sprocket 39 teeth 8FB-47587-90...
Page 344 INSP GEAR SELECTION 5 Torque cam (secondary spring seat) Identification mark Effects Part no. Cam angle Identification mark Standard Quicker upshifting RXW10J, 8FA-17604-00 51-43_ 8BVFA during acceleration RXW10SJ 8BV-17604-71 8BV71 8BV-17604-51 8BV51 8BV-17604-31 8BV31 Quicker 8BV-17604-11 8BV11 backshifting backshifting 8BV-17604-91 8BV91 under load...
Page 345 INSP GEAR SELECTION 6 Primary spring Spring identification color code Spring rate color Preload color Spring rate Wire Outside Free Preload Color No. of Standard Parts No. N / mm gauge diameter length N (kg) coils (kg / mm) mm (in) mm (in) mm (in) 90501-551L3...
Page 346 INSP GEAR SELECTION 7 Clutch weight Weight g (oz) Parts no. without bush Shape & ID mark Standard and rivets 35.32 8CH-17605-10 (1.247) 38.09 8CR-17605-10 (1.345) 34.26 8DG-17605-00 (1.209) 37.77 8DJ-17605-00 (1.333) 42.09 8DN-17605-20 (1.486) 39.00 8EK-17605-00 (1.376) 63.8 8FA-17605-00 (2.25)
Page 347 INSP GEAR SELECTION 7 Clutch weight Weight g (oz) Parts no. without bush Shape & ID mark Standard and rivets 39.76 8DN-17605-10 (1.40) 63.8 RXW10J, 8FA-17605-10 (2.25) RXW10SJ...
Page 348 INSP GEAR SELECTION 8 Weight rivets Length Weight Parts No. Material Standard Effects mm (in) g (oz) Increased 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) IN: RXW10J, RXW10SJ Force 3.6 (0.127) 90269-06006 Steel 17.2 (0.677) OUT: RXW10J, RXW10SJ with hole 90261-06019 Steel 13.3 (0.524) 3.1 (0.109)
Page 349: Front Suspension
INSP FRONT SUSPENSION/REAR SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: S Spring preload Adjustment steps: S Turn the spring seat 1 in or out. Spring seat Standard Shorter z ! Longer distance Harder z ! Softer Preload Min. Max. Length 248 mm 258 mm 258 mm...
Page 350: Rear Suspension
INSP REAR SUSPENSION Adjustment steps: S Loosen the locknut 1 . S Turn the adjusting nut 2 in or out to adjust the stopper band tension. 15 ± 0.5 mm (0.59 ± 0.02 in) Adjuster thread Maximum: 35 mm (1.37 in) length Minimum: 10 mm (0.40 in) Effects...
Page 351 INSP REAR SUSPENSION Control rod 1. Check S Control rod bolt a Bolt (control rod bolt): 32 Nm (3.2 mSkg, 23 ftSlb) 2. Adjust: S Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: S Loosen the lock nut 1 .
Page 352: Chapter 3. Chassis
CHAS STEERING CHASSIS STEERING INSTALLATION 1. Install: S Relay arms 1 S Bushings S Washers 2 Bolt (relay arm): 67 Nm (6.7 mSkg, 49 ftSlb) S Clips 3 2. Install: S Idler arm 4 S Bushings S Washers S Relay rod 5 Nut (idler arm): 35 Nm (3.5 mSkg, 25 ftSlb) Nut (relay rod):...
Page 353 CHAS STEERING 5. Install: S Tie rods 1 NOTE: S Make sure that the indentation a on the tie rod faces out. S The threads on both rod ends must be the same length. CAUTION: Always use new cotter pins. Locknut (rod end): 25 Nm (2.5 mSkg, 18 ftSlb) ...
Page 354 CHAS STEERING 7. Adjust: S Handlebar Adjustment steps: S Temporarily install the handlebar. S Install the steering linkage alignment plate Steering linkage alignment plate 90890-01487, YS-01487 S Loosen the locknuts (steering shaft) 1 . S Turn the steering shaft 2 clockwise or coun- terclockwise and then secure the handle bar in the straight position.
Page 355 CHAS STEERING 9. Install: S Handlebar CAUTION: S Be sure the projection on the handlebar is not installed into the area a shown. S Be sure the side of the holder with the small gap b faces forward. b = 0 mm (0 in) S First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.
Page 356: Front Suspension
CHAS FRONT SUSPENSION FRONT SUSPENSION 45 Nm (4.5 mSkg, 33 ftSlb) 37 Nm (3.7 mSkg, 27 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 65 Nm (6.5 mSkg, 47 ftSlb) 34 Nm (3.4 mSkg, 25 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 357 CHAS FRONT SUSPENSION 45 Nm (4.5 mSkg, 33 ftSlb) 37 Nm (3.7 mSkg, 27 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 65 Nm (6.5 mSkg, 47 ftSlb) 34 Nm (3.4 mSkg, 25 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order...
Page 358: Chapter 4. Power Train
POWR SECONDARYSHAFT POWER TRAIN SECONDARYSHAFT Order Job name/Part name Q’ty Remarks Secondary shaft removal Remove the parts in the order listed below. Secondary sheave Refer to “SECONDARY SHEAVE”. Drive chain housing Refer to “DRIVE CHAIN HOUSING”. Collar nut Collar Circlip Secondary shaft Bearing For installation, reverse the removal...
Page 359: Removal
POWR POWR SECONDARYSHAFT SECONDARYSHAFT REMOVAL 1. Remove: S Drive chain housing parts Refer to “DRIVE CHAIN HOUSING WITH REVERSE MODEL” in CHAPTER 4 S Secondary sheave assembly Refer to “SECONDARY SHEAVE” in CHAP- TER 4 2. Install: S Secondary shaft slide & holder 2 A Outside B Inside NOTE:...
Page 360: Inspection
POWR SECONDARYSHAFT INSPECTION 1. Inspect: S Secondary shaft 1 Scratches (excessive)/damage ! Replace. S Splines 2 Wear/damage ! Replace the secondary shaft. S Bearing contact surface 3 Scratches/wear/damage ! Replace the secondary shaft. 2. Inspect: S Bearing 1 Pitting/damage ! Replace. NOTE: When install the bearing 1 , larger side of the in- ner race 2 is outside of the frame.
Page 361: Installation
POWR SECONDARYSHAFT INSTALLATION 1. Install S Drive chain housing parts Refer to “DRIVE CHAIN HOUSING WITH REVERSE MODEL” in CHAPTER 4. 2. Install: S Bearing collar nut 1 S Secondary shaft 2 A Engine side B Secondary clutch side 3. Install: S Drive gear socket 3 Drive gear socket 90890–01490, YU–01490...
Page 362 POWR SECONDARYSHAFT 7. Install: S Secondary sheave mounting bolt 7 NOTE: S Use the secondary sheave mounting bolt 7 and washer which tighten the secondary clutch. 8. Tighten: S Secondary sheave mounting bolt 7 Secondary sheave mounting bolt 30 NSm (3.0 mSkg, 22 ftSlb) 9.
Page 363: Brake
POWR BRAKE BRAKE 30 Nm (3.0 mSkg, 22 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) Order Job name/Part name Q’ty Remarks Brake caliper and parking brake Remove the parts in the order listed below. removal Brake fluid Drain.
Page 364: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Left side cover Refer to “PRIMARY SHEAVE AND DRIVE VELT”.
Page 365 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 mSkg, 2.9 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...
Page 366 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Suspension wheel Collar Wheel bracket Circlip Suspension wheel Collar...
Page 367 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear shock absorber Collar Bushing Pull rod Collar Bushing Collar Suspension wheel Control rod Bushing...
Page 368 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear pivot arm Bushing Shaft Shaft Rear pivot arm bracket...
Page 369: Installation
POWR SLIDE RAIL SUSPENSION INSTALLATION Control rod parts number Control rod 1 Length mm (in) Length mm (in) Length mm (in) 2.5P 3 = 7.5 RXW10J, RXW10SJ 303.5(11.95) 160.0(6.30) (0.098P 3 = 0.295) Washer plate parts number Control rod 1 Control rod 2 Washer plate thickness mm (in) parts number...
Page 370: Chapter 5. Engine
ENGINE ASSEMBLY ENGINE ENGINE ASSEMBLY INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routing. 1. Install: S Engine mounting adjust bolts S Engine S Engine mounting bolts and nuts NOTE: S Use the pivot shaft wrench to tighten the en- gine mounting adjust bolts.
Page 371 ENGINE ASSEMBLY 2. Fill: S Coolant Refer to “COOLING SYSTEM” in CHAPTER 3. Fill: S Engine oil Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 2.
Page 372: Carburetors
CARB CARBURETORS CARBURETORS Order Job name/Part name Q’ty Remarks Carburetor separation Remove the parts in the order listed below. Carburetor heater harness Carburetor heating hose Starter plunger link Connecting bolt Spacer Fuel inlet pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Carburetor...
Page 373 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Carburetor disassembly Disassemble the parts in the order listed below. Starter plunger NOTE: Pilot air jet The following procedure applies to all of Vacuum chamber cover the carburetors. Piston valve spring Piston valve Jet needle holder Jet needle kit Pilot screw...
Page 374 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet Carburetor switch (T.O.R.S.) Carburetor heater Starter jet For assembly, reverse the disassembly procedure.
Page 375: Chapter 9. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model RXW10J, RXW10SJ Model code number: 8FG1 (for U.S.A./Canada) 8FH1 (for U.S.A./Canada) 8FG2 (for Europe) 8FH2 (for Europe) Dimensions: Overall length 3,000 mm (118.1 in) Overall width 1,210 mm (47.6 in) Overall height 1,190 mm (46.9 in) Weight: Dry weight 264 kg (581 lb)
Page 376 SPEC GENERAL SPECIFICATIONS Model RXW10J, RXW10SJ Carburetors: BSR37 4 Type/Quantity Manufacture MIKUNI Spark plug: Type CR9E Manufacture 0.7 X 0.8 mm (0.028 X 0.031 in) Primary reduction: Primary reduction system Spur gear Primary reduction ratio 1.19 (37/31) Transmission: Primary reduction system V-Belt 3.8 : 1 X 1 : 1 Primary reduction ratio...
Page 377: Camshafts
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model RXW10J, RXW10SJ Cylinder head: 13.45 X 14.00 cm (0.82 X 0.85 cu. in) Volume (with spark plug) <Warpage limit> 0.1 mm (0.004 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating 74.000 X 74.010 mm (2.9134 X 2.9138 in) Bore size <Taper limit>...
Page 378 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Valve dimensions: Valve head diameter A 22.9 X 23.1 mm (0.9016 X 0.9094 in) Intake 24.4 X 24.6 mm (0.9606 X 0.9685 in) Exhaust Head Diameter Valve face width B 1.76 X 2.90 mm (0.0693 X 0.1142 in) Intake 1.76 X 2.90 mm (0.0693 X 0.1142 in) Exhaust...
Page 379 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Valve spring: Free length Intake 38.90 mm (1.53 in) Exhaust 40.67 mm (1.60 in) Installed length (valve closed) Intake 34.50 mm (1.36 in) Exhaust 35.00 mm (1.38 in) Compressed spring force (installed) 82 X 96 N (8.2 X 9.6 kg, 18.1 X 21.2 lb) Intake 110 X 126 N Exhaust...
Page 380 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Piston pin: 16.991 X 17.000 mm (0.6689 X 0.6693 in) Piston pin outside diameter 51.4 X 51.5 mm (2.0236 X 2.0276 in) Piston pin length 0.002 X 0.022 mm (0.00008 X 0.0009 in) Piston pin to piston pin bore clearance <Limit>...
Page 381 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Carburetor: Type/Quantity BSR37/4 Manufacturer MIKUNI I.D. mark 8FA101 Main jet (M.J) #135 Main air jet (M.A.J) #120 Jet needle (J.N) 5DHP50 - 53 - 3 Needle jet (N.J) Pilot jet (P.J) #17.5 Pilot air jet (P.A.J.1) #140 Pilot outlet...
Page 382: Power Train
SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model RXW10J, RXW10SJ Transmission: Type V-belt automatic 3.8 X 1.0 : 1 Range of ratio 3,600 ± 200 r/min (3,400 X 3,800 r/min) Engagement speed r/min 10,250 ± 250 r/min (10,000 X 10,500 r/min) Shift r/min 268.5 ±...
Page 383 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Secondary sheave spring: Part number 90508-60007 Color code White Outside diameter 69.5 mm (2.736 in) Wire diameter 6 mm (0.236 in) Hole position Sheave side-spring side (twist angle) 3-3 (60_) Spring rate 13.45 N/mm (1.372 kg/mm, 76.84 lb/in) Number of coils 5.19 Free length...
Page 384 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Suspension setting position: 15 ± 0.5 mm (0.59 ± 0.02 in) Hook setting length *(Standard) (Maximum) 35 mm (1.37 in) (Minimum) 10 mm (0.40 in) Full rate adjusting position ** Shock absorber: Damping force Center Extension 910 N/0.3 m/s (93 kg/0.3 m/s, 204 lb/0.3 m/s)
Page 385: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model RXW10J, RXW10SJ Frame: Frame material Aluminum Seat height 680 mm (26.8 in) Luggage box location Front Steering: Lock-to-lock angle (left) 30.0_ (R ski) 34.7_ (L ski) (right) 34.7_ (R ski) 30.0_ (L ski) Ski alignment Toe-out 0 X 15 mm (0 X 0.59 in) Toe-out size...
Page 386: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model RXW10J, RXW10SJ Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5_ at 1,350 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T54973 /MITSUBISHI 0.16 X 0.22 Ω at 20_C (68_F) Primary coil resistance 5.0 X 6.8 kΩ at 20_C (68_F) Secondary coil resistance Charging system: Type...
Page 387 SPEC MAINTENANCE SPECIFICATIONS Model RXW10J, RXW10SJ Starter relay: Model/Manufacturer MS5F-441 /JIDECO Amperage rating 180 A 4.2 X 4.6 Ω at 20_C (68_F) Coil resistance T.P.S. (throttle position sensor): Model/Manufacturer TS67/02-1C/MIKUNI 4 X 6 KΩ at 20_C (68_F) Resistance (Blue – Black) 0 X 4 KΩ...
Page 388: High Altitude Settings
SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS Tempera- –40_C –20_C 16_C ture (–40_F) (–4_F) (32_F) (60_F) Idling speed (r/min) Altitude 0 X 200 m #140 #137.5 #135 (0 X 670 ft) 1350 200 X 1000 m #137.5 #135 #132.5 1350 (X 3300 ft) 1000 X 2000 m #135 #132.5...
Page 389: Tightening Torque
SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Spark plug 20 + 121_ 2.0 + 121_ 14 + 121_ Cylinder head nut (M10 1.25) Cylinder head nut (M10 1.25) 20 + 105_ 2.0 + 105_...
Page 390 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Fuel pump Fuel pump stay NOTE: 1. First, tighten the bolt to approximately 15 Nm (1.5 mSkg, 11 ftSlb) with a torque wrench, then loosen the bolt completely.
Page 391: Power Train
SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Primary sheave (1st) Tighten the bolt in two (2nd) stages. See NOTE. Spider and sliding sheave 20.0 Left-hand thread.  Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave...
Page 392 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb  Wheel bracket shaft and sliding frame Apply LOCTITE Set bolt (front axle) Speed sensor Gear unit (speed sensor) Bearing nut NOTE: Tightening steps: 1.
Page 393: Chassis
SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Handlebar holder Steering column (Upper) Steering column (Lower) Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod...
Page 394: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (nut) (bolt) (bolt) This chart specifies torque for standard fasteners mSkg ftSlb with standard I.S.O. pitch threads. Torque speci- 10 mm 6 mm fications for special components or assemblies 12 mm 8 mm are included in the applicable sections of this...
Page 395: Cable Routing
SPEC CABLE ROUTING...
Page 396 SPEC CABLE ROUTING CABLE ROUTING To the headlight and meter as- sembly Clamp the lead at the position of white tape. Battery positive lead Battery negative lead Main harness Negative lead connector Carburetor heater lead coupler Oil level switch lead coupler Oil level switch Starter motor positive lead (un- der the battery bracket)
Page 397 SPEC CABLE ROUTING...
Page 398 SPEC CABLE ROUTING Brake hose Fuel sender lead coupler Set the coupler in the rear space of the instrument panel Clamp the ignition coil lead un- der the fuel hose. Clamp the fuel hose. There should be no slack of leads.
Page 399 SPEC CABLE ROUTING...
Page 400 SPEC CABLE ROUTING 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Clamp 1 Clamp Meter coupler (Securely fit in the rubber cover)
Page 401 SPEC CABLE ROUTING...
Page 402 SPEC CABLE ROUTING 1 Right handlebar switch Clamp the main harness, main switch and harness. Clamp the grip warmer lead and the right handlebar switch lead. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Ex- cept for brake hose and parking brake cable.) Clamp the tail / brake light lead,...
Page 403 SPEC CABLE ROUTING...
Page 404 SPEC CABLE ROUTING Carburetor air vent hose To the parking brake. To the brake caliper Brake hose Clamp the wire harness and fuel tank breather hose from the top. Less than 50 mm (2.0 in). Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side.
Page 405 SPEC CABLE ROUTING...
Page 406 SPEC CABLE ROUTING Headlight wire harness Tighten the frame ground and voltage regulator upper bolt to- gether. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through be- tween engine and heat ex- changer.
Page 407 SPEC CABLE ROUTING...
Page 408 SPEC CABLE ROUTING 1 Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the up- ward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross mem- ber and frame. Wire harness clamp Rivets Speed sensor Nylon nuts...
Page 409 SPEC CABLE ROUTING...
Page 410 SPEC CABLE ROUTING 1 Starter motor Battery positive lead CDI unit Battery negative lead Air box drain hose Battery band Battery cover 0 X 5 mm (0 X 0.20 in) Wire harness Plate cover Clip it to the frame cross mem- To the carburetor.
Page 411 1 A.C. magneto 2 Rectifier / regulator 3 Main switch 4 Main relay 5 Fuse (MAIN) 6 Starter relay 7 Starter motor 8 Battery 9 Engine stop switch 10 Throttle switch 11 Carburetor switch 12 Carburetor heater relay 13 Carburetor heater 14 Grip warmer 15 Thumb warmer 16 CDI unit...
Page 413 WIRING DIAGRAM RXW10J, RXW10SJ - L/R G/B Sb Y/B G Y/G Lg/B Lg/B R/B G/R - W/R - B/L Y/L L/R Lg/W G G/R - Br/Y Y/B Lg/B Y/G B/W B - - - - - - - W/G - - B/Y Y/W W/Y L Lg/L L/R Br/W Lg Y/R Sb Br/W B/R B/W - Y W Gy O SUB-WIRE SUB-WIRE SUB-WIRE...
Page 414 SUPPLEMENTARY SERVICE MANUAL LIT-12618-02-39...
Page 415 A CAUTION indicates special precautions that must be taken to avoid damage to the snowmo- bile. NOTICE This manual was written by the Yamaha Motor NOTE: Company primarily for use by Yamaha dealers A NOTE provides key information that can and their qualified mechanics.
Page 416 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. POWR 1 General information CHAS 2 Periodic inspections and adjustments 3 Chassis 4 Power train 5 Engine COOL 6 Cooling system...
Page 417 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTIONS AND INSP ADJUSTMENTS CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 418 CHAPTER 2. INSPECTION ..... PERIODIC INSPECTIONS FRONT AXLE AND TRACK ... . AND ADJUSTMENTS INSTALLATION .
Page 419: Periodic Inspections
BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION/ INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) PERIODIC INSPECTIONS AND ADJUSTMENTS POWER TRAIN BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Inspect: S Brake pad wear a Wear indicator 1 nearly contacts the brake disc ! Replace as a set. Wear limit: 7.5 mm (0.30 in) BRAKE HOSE INSPECTION...
Page 420 INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) a. Slowly apply the brake lever several times. b. Pull the lever in, then hold the lever in posi- tion. c. Loosen the bleed screws and allow the brake lever to travel towards its limit. d.
Page 421: Track Tension Adjustment
TRACK TENSION ADJUSTMENT/ INSP SLIDE RUNNER INSPECTION TRACK TENSION ADJUSTMENT Shifted Shifted Track alignment to right to left Left adjuster Turn out Turn in Right adjuster Turn in Turn out 8 Slide runner 9 Track Track metal Forward A RX10K, RX10RK, RX10RSK B RX10MK, RX10MSK c.
Page 422: Lubrication
INSP LUBRICATION LUBRICATION Brake lever, throttle lever and throttle cable 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables. Recommended lubricant: ESSO Beacon 325 Grease WARNING Apply a dab of grease onto only the end of the cables.
Page 423: Clutch
INSP CLUTCH CLUTCH G Green P Pink High altitude S Silver Y Yellow Specifications Model: RX10K, RX10RK, RX10RSK X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft)
Page 424 INSP CLUTCH S Silver O Orange W White P Pink Specifications Model: RX10MK, RX10MSK X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft) (X 2,500 ft)
Page 425: Gear Selection
INSP GEAR SELECTION GEAR SELECTION 1 Chain and sprocket part number Parts name Teeth & links Parts no. Standard 19 teeth 8FA-17682-90 20 teeth 8FA-17682-00 21 teeth 8FA-17682-10 RX10MK, RX10MSK Drive sprocket Drive sprocket 22 teeth 8FA-17682-20 23 teeth 8FA-17682-30 RXW10K, RXW10SK 24 teeth 8FA-17682-40...
Page 426 INSP GEAR SELECTION 5 Torque cam (secondary spring seat) Identification mark Effects Part no. Cam angle Identification mark Standard RX10K, RX10RK, Quicker upshifting RX10RSK, during acceleration 8FA-17604-00 51-43_ 8BVFA RXW10K, RXW10SK 8BV-17604-71 8BV71 RX10MK, 8BV-17604-51 8BV51 RX10MSK 8BV-17604-31 8BV31 Quicker Quicker 8BV-17604-11 8BV11...
Page 427 INSP GEAR SELECTION 6 Primary spring Spring identification color code Spring rate color Preload color Spring rate Wire Outside Free Preload Color No. of Standard Parts No. N / mm gauge diameter length N (kg) coils (kg / mm) mm (in) mm (in) mm (in) 90501-551L3...
Page 428 INSP GEAR SELECTION 7 Clutch weight Weight g (oz) Parts no. without bush Shape & ID mark Standard and rivets 45.41 8BU-17605-20 RX10MK, RX10MSK (1.60) 34.26 8DG-17605-00 (1.209) 37.77 8DJ-17605-00 (1.333) 39.76 8DN-17605-10 (1.40) 39.00 8EK-17605-00 (1.376) 54.6 8ES-17605-00 (1.93) RX10K, RX10RK, 63.8 8FA-17605-10...
Page 429 INSP GEAR SELECTION 8 Weight rivets Length Weight Parts No. Material Standard Effects mm (in) g (oz) Increased 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) IN: RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK Force 3.6 (0.127) 90269-06006 Steel 17.2 (0.677) OUT: RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK with hole 90261-06019 Steel...
Page 430: Front Suspension
INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: S Spring preload Adjustment steps: S Loosen the lock nut 1 S Turn the spring seat 2 in or out. RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK Spring seat Standard Shorter z ! Longer distance Harder z ! Softer...
Page 431: Rear Suspension
INSP REAR SUSPENSION REAR SUSPENSION Stopper band 1. Adjust: S Stopper band tension CAUTION: Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. (RX10MK, RX10MSK) NOTE: This adjustment affects the handling character- istics of the machine. Adjustment steps: S Loosen the stopper band nut 1 .
Page 432 INSP REAR SUSPENSION Spring preload (RX10K, RX10RK, RX10RSK) 1. Adjust: S Spring preload Adjustment step: WARNING This shock absorber contains highly pres- surized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assem- bly to flames or high heat, which could cause it to explode.
Page 433 INSP REAR SUSPENSION Spring preload (RX10MK, RX10MSK) 1. Adjust: S Spring preload Adjustment steps: S Turn the adjusting ring 1 to the proper posi- tion. Spring adjuster position Softer z ! Harder Preload Front Standard S Turn the adjusting hook 2 to the proper posi- tion.
Page 434 INSP REAR SUSPENSION Control rod (RX10MK, RX10MSK) 1. Adjust: S Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: S Loosen the lock nut 1 . S Turn the adjusting nut 2 in or out to adjust the control rod stroke.
Page 435: Chapter 3. Chassis
CHAS STEERING CHASSIS STEERING RX10MK, RX10MSK 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11ftSlb) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Thumb warmer lead coupler Disconnect.
Page 436 CHAS STEERING 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11ftSlb) Order Job name/Part name Q’ty Remarks Master cylinder assembly NOTE: Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” in CHAPTER 9, to check the Handlebar cable, lead and hose routings.
Page 437: Ski
CHAS RX10K, RX10RK, RX10RSK 19 Nm (1.9 mSkg, 14 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Ski removal...
Page 438: Rx10Mk, Rx10Msk
CHAS RX10MK, RX10MSK 19 Nm (1.9 mSkg, 14 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below.
Page 439: Chapter 4. Power Train
POWR DRIVE CHAIN HOUSING POWER TRAIN DRIVE CHAIN HOUSING RX10K, RX10MK, RX10MSK 16 Nm (1.6 mSkg, 12 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 440: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the fol- lowing. A Make sure that the bearing seals face towards the drive chain as shown. B Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps.
Page 441: With Reverse Model Rx10Rk, Rx10Rsk
POWR DRIVE CHAIN HOUSING WITH REVERSE MODEL RX10RK, RX10RSK 16 Nm (1.6 mSkg, 12 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 442 POWR DRIVE CHAIN HOUSING 16 Nm (1.6 mSkg, 12 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job name/Part name Q’ty...
Page 443: Installation
POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the fol- lowing. A Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. B Make sure that the bearing seals face towards the drive chain as shown.
Page 444 POWR DRIVE CHAIN HOUSING 4. Install: S Shift rod 1 5. Adjust: S Shift rod length a Adjustment steps: S Move the shift lever to the “FWD.” position. S Loosen the locknuts 2 . S Turn the shift rod 1 so that shift rod free play is 0 mm (in direction where a can be short- ened appropriately) and then turn back the shift rod 1/4 turns.
Page 445: Brake
POWR BRAKE BRAKE 6 Nm (0.6 mSkg, 4.3 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring Brake pad Brake caliper assembly For installation, reverse the removal procedure.
Page 446: Brake Pad Replacement
POWR BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: S Do not disassemble components unless absolutely necessary. S Do not use solvents on internal brake com- ponents. S Do not use contaminated brake fluid for cleaning. Use only clean brake fluid. S Do not allow brake fluid to contact the eyes, otherwise eye injury may occur.
Page 447 POWR BRAKE 2. Install: S Brake pads S Pad spring Installation steps: S Connect a suitable hose 1 tightly to the cali- per bleed screw 2 . Put the other end of this hose into an open container. S Loosen the caliper bleed screw and push the pistons into the caliper with your finger.
Page 448 POWR BRAKE 30 Nm (3.0 mSkg, 22 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) Order Job name/Part name Q’ty Remarks Brake caliper and parking brake Remove the parts in the order listed below. removal Brake fluid Drain.
Page 449: Brake Caliper Disassembly
POWR BRAKE BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: S Pistons S Piston oil seals 1 Removal steps: S Using a piece of wood 2 , lock the right pis- ton.
Page 450: Brake Caliper Assembly
POWR BRAKE 1. Inspect: S Caliper piston 1 Scratches/rust/wear ! Replace the caliper assembly. S Caliper cylinder 2 Wear/scratches ! Replace the caliper as- sembly. S Caliper body 3 Cracks/damage ! Replace. S Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and dust seals whenever a caliper is disassembled.
Page 451: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION RX10K, RX10RK, RX10RSK 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen.
Page 452 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below. Shock absorber adjuster assembly Stopper band Shaft Rubber collar Shock absorber Spacer Collar Oil seal Bearing Control rod assembly Spacer Collar Oil seal...
Page 453 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Front pivot arm Bushing Collar Sliding runner Suspension wheel Suspension wheel bracket Shaft Collar Front pivot arm bracket Bushing Collar Shaft Rear pivot arm Circlip Guide wheel Bushing Shaft Rear pivot arm bracket...
Page 454 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Guide wheel Collar Tension adjuster Rear axle shaft For assembly, reverse the disassembly procedure.
Page 455: Rx10Mk, Rx10Msk
POWR SLIDE RAIL SUSPENSION RX10MK, RX10MSK 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Slide rail suspension Collar For installation, reverse the removal procedure.
Page 456 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below. Stopper band Shaft Rubber collar Front shock absorber Collar Bushing Front pivot arm Shaft Bushing Collar Suspension wheel assembly Shaft Suspension bracket Bushing...
Page 457 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Suspension wheel Hook assembly Rear shock absorber Collar Reay rod Collar Bushing Shaft Collar Bushing Braket Collar Guide wheel Spacer Rear spring Shaft Bushing Rear pivot arm protector Rear pivot arm...
Page 458 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Circlip Hook Control rod assembly Shaft Pivot shaft Suspension wheel Suspension bracket Guide wheel Rear axle shaft Collar Tension adjuster For assembly, reverse the disassenbly procedure.
Page 459: Inspection
POWR SLIDE RAIL SUSPENSION INSPECTION 1. Inspect: S Suspension wheel S Guide wheel Cracks/damage ! Replace. S Wheel bearing Wheel turns roughly ! Replace. 2. Inspect: S Stopper band 1 Frayed/damage ! Replace. S Relay rod 2 (RX10MK, RX10MSK) Bends/damage ! Replace. S Shock absorber 3 Oil leaks/damage ! Replace.
Page 460 POWR SLIDE RAIL SUSPENSION Control rod parts number A RX10K, RX10RK, RX10RSK B RX10MK, RX10MSK Control rod 1 Length mm (in) Length mm (in) Length mm (in) RX10K, RX10RK, 292.3 (11.51) 150.5 (5.93) – RX10RSK 2.5P 2 = 5 RX10MK, RX10MSK 228.8 (9.01) 198.7 (7.82) (0.098P...
Page 461: Front Axle And Track Installation
POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK INSTALLATION 1. Install: S Sprocket wheels S Guide wheels NOTE: S When pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel. S Position each sprocket wheel on the axle as shown in the illustration.
Page 462: Chapter 5. Engine
SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK Order Job name/Part name Q’ty Remarks Seat and fuel tank removal Remove the parts in the order listed below. Muffler end pipe Rear cover Muffler side cover Tail/brake light cover Seat Fuel tank cover Side cover Fuel tank...
Page 463: Exhaust Pipe And Muffler
EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER 20 Nm (2.0 mSkg, 14 ftSlb) 25 Nm (2.5 mSkg, 18 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 11 Nm (1.1 mSkg, 8 ftSlb) Order Job name/Part name Q’ty Remarks Exhaust pipe and muffler removal Remove the parts in the order listed below.
Page 464: Heat Exchanger Rx10Mk, Rx10Msk
COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER RX10MK, RX10MSK 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAPTER 2. Primary sheave assembly Refer to “PRIMARY SHEAVE AND DRIVE V-VELT”...
Page 465 COOL HEAT EXCHANGER 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Coolant pipe 1 Coolant pipe 2 Coolant hose 7 Coolant hose 8 Thermostat assembly Coolant hose 9 Coolant hose 10 Oil cooler outlet hose Oil cooler Oil cooler inlet hose Pipe 3 Water pump hose...
Page 466 COOL HEAT EXCHANGER 35 Nm (3.5 mSkg, 25 ftSlb) Order Job name/Part name Q’ty Remarks Coolant hose 11 Coolant hose 12 For installation, reverse the removal procedure.
Page 467: Chapter 9. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Model code number: 8FU1 (RX10K for U.S.A/Canada) 8FV1 (RX10RK for U.S.A/Canada) 8FY1 (RX10RSK for U.S.A/Canada) 8FX1 (RXW10K for U.S.A/Canada) 8GB1 (RXW10SK for U.S.A/Canada) 8FW1 (RX10MK for U.S.A/Canada) 8GA1 (RX10MSK, for U.S.A/Canada) Dimensions: Overall length...
Page 468 SPEC GENERAL SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Engine oil: Type API SE, SF, SG or highter SAE0W-30 Oil capacity Periodic oil change 2.8 L (2.5 lmp qt, 3.0 US qt) With oil filter replacement 3.0 L (2.6 lmp qt, 3.2 US qt) Total amount 3.8 L (3.3 lmp qt, 4.0 US qt) Oil filter:...
Page 469 SPEC GENERAL SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Suspension: Front suspension type Independent double wishbone suspension Rear suspension type Slide rail suspension Track: Track type Internal drive type Track width 381 mm (15.0 in) Length on ground 768 mm (30.2 in) (RX10K, RX10RK, RX10RSK) 944 mm (37.2 in) (RXW10K, RXW10SK) 1,068 mm (42.0 in) (RX10MK, RX10MSK)
Page 470: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Cylinder head: 13.45 X 14.05 cm (0.82 X 0.86 cu. in) Volume (with spark plug) <Warpage limit> 0.1 mm (0.004 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating...
Page 471 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Valve dimensions: Valve head diameter A 22.9 X 23.1 mm (0.9016 X 0.9094 in) Intake 24.4 X 24.6 mm (0.9606 X 0.9685 in) Exhaust Head Diameter Valve face width B 1.76 X 2.90 mm (0.0693 X 0.1142 in) Intake 1.76 X 2.90 mm (0.0693 X 0.1142 in)
Page 472 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Valve spring: Free length Intake 38.90 mm (1.53 in) Exhaust 40.67 mm (1.60 in) Installed length (valve closed) Intake 34.50 mm (1.36 in) Exhaust 35.00 mm (1.38 in) Compressed spring force (installed) 82 X 96 N (8.2 X 9.6 kg, 18.1 X 21.2 lb) Intake...
Page 473 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Piston pin: 16.991 X 17.000 mm (0.6689 X 0.6693 in) Piston pin outside diameter 51.4 X 51.5 mm (2.0236 X 2.0276 in) Piston pin length 0.002 X 0.022 mm (0.00008 X 0.0009 in) Piston pin to piston pin bore clearance <Limit>...
Page 474 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Carburetor: Type/Quantity BSR37/4 Manufacturer MIKUNI I.D. mark 8FA102 Main jet (M.J) #135 Main air jet (M.A.J) #120 Jet needle (J.N) 5DHP50-53-3 Needle jet (N.J) Pilot jet (P.J) #17.5 Pilot air jet (P.A.J.) #140 Pilot outlet...
Page 475: Power Train
SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Transmission: Type V-belt automatic 3.8 X 1.0 : 1 Range of ratio 3,600 ± 200 r/min (3,400 X 3,800 r/min) (RX10K, RX10RK, Engagement speed r/min RX10RSK, RXW10K, RXW10SK) 4,200 ±...
Page 476 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Rivet: Outer Part number 90269-06006 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) Material Steel (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) Size 17.2 mm (0.677 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) Quantity 3 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK,...
Page 477 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Drive chain: Type Borg Warner Automotive 23RH303-70ASM Number of links Secondary reduction ratio 38/23 (1.65) (RXW10K, RXW10SK) 38/24 (1.58) (RX10K, RX10RK, RX10RSK) 40/21 (1.90) (RX10MK, RX10MSK) Track: Part number 8FA-47110-00 (RX10K, RX10RK, RX10RSK) 8FG-47110-00 (RXW10K, RXW10SK) 8EP-47110-00 (RX10MK, RX10MSK)
Page 478 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Suspension setting position: 25 ± 0.5 mm (0.98 ± 0.02 in) (RX10K, RX10RK, Hook setting length (Standard) RX10RSK) 15 ± 0.5 mm (0.59 ± 0.02 in) (RXW10K, RXW10SK) 10 ± 0.5 mm (0.39 ± 0.02 in) (RX10MK, RX10MSK) (Maximum) 35 mm (1.37 in) (RXW10K, RXW10SK) (Minimum)
Page 479: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Frame: Frame material Aluminum Seat height 720 mm (28.3 in) Luggage box location Front Steering: Lock-to-lock angle (left) 30.0_ (R ski) 34.7_ (L ski) (right) 34.7_ (R ski) 30.0_ (L ski) Ski alignment Toe-out 0 X 15 mm (0 X 0.59 in)
Page 480: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5_ at 1,450 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T54975 /MITSUBISHI 0.16 X 0.22 Ω at 20_C (68_F) Primary coil resistance 5.0 X 6.8 kΩ...
Page 481 SPEC MAINTENANCE SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, Model RXW10SK, RX10MK, RX10MSK Starter relay: Model/Manufacturer MS5F-421/JIDECO Amperage rating 180 A 4.2 X 4.6 Ω at 20_C (68_F) Coil resistance T.P.S. (throttle position sensor): Model/Manufacturer TS67/02-1C/MIKUNI 4 X 6 kΩ at 20_C (68_F) Resistance (Blue –...
Page 482: High Altitude Settings
SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK Tempera- –40_C –20_C 16_C ture (–40_F) (–4_F) (32_F) (60_F) Idling speed (r/min) Altitude 0 X 200 m #140 #137.5 #135 (0 X 670 ft) 1350 200 X 1000 m #137.5 #135 #132.5...
Page 483: Tightening Torque
SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Spark plug 20 + 121_ 2.0 + 121_ 14 + 121_ Cylinder head nut (M10 1.25) Cylinder head nut (M10 1.25) 20 + 105_ 2.0 + 105_...
Page 484 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Fuel pump Fuel pump stay NOTE: 1. First, tighten the bolt to approximately 15 Nm (1.5 mSkg, 11 ftSlb) with a torque wrench, then loosen the bolt completely.
Page 485: Power Train
SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Primary sheave (1st) 12.0 Tighten the bolts in two (2nd) stages. See NOTE. Spider and sliding sheave 20.0 Left-hand thread.  Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave)
Page 486 SPEC TIGHTENING TORQUE Tightening torque Parts be tightened Parts be tightened Remarks Remarks mSkg ftSlb (RXW10K, RXW10SK) Stopper band Hook and front pivot arm (RXW10K, RXW10SK)  Wheel bracket and sliding frame Apply LOCTITE  Bracket bolt (front) Apply LOCTITE ...
Page 487: Chassis
SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Handlebar holder Steering column Upper Lower Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod...
Page 488: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (nut) (bolt) (bolt) This chart specifies torque for standard fasteners mSkg ftSlb with standard I.S.O. pitch threads. Torque speci- 10 mm 6 mm fications for special components or assemblies 12 mm 8 mm are included in the applicable sections of this...
Page 489: Cable Routing
SPEC CABLE ROUTING...
Page 490 SPEC CABLE ROUTING CABLE ROUTING FOR RX10K, RX10MK, RX10MSK To the headlight and meter as- sembly Clamp the lead at the position of white tape. Clamp the wire harness and A.C.magneto lead. Battery negative lead Battery positive lead Main harness Negative lead connector Carburetor heater lead coupler Oil level switch lead coupler...
Page 491 SPEC CABLE ROUTING...
Page 492 SPEC CABLE ROUTING Route the starter cable above the left handlebar switch lead. Brake hose Fuel sender lead coupler Clamp the ignition coil lead un- der the fuel hose. Clamp the fuel hose. Route the coolant hose be- tween the upper vacuum hose and lower vacuum hose.
Page 493 SPEC CABLE ROUTING...
Page 494 SPEC CABLE ROUTING 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securely fit in the rubber cover) Put the boots of the meter cou- pler in the boss root on the side of the meter.
Page 495 SPEC CABLE ROUTING...
Page 496 SPEC CABLE ROUTING 1 Clamp the grip warmer lead and the right handlebar switch lead. Clamp the main harness, main switch and harness. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Ex- cept for brake hose and parking brake cable.) Pass the brake hose and the parking brake cable through...
Page 497 SPEC CABLE ROUTING...
Page 498 SPEC CABLE ROUTING Carburetor air vent hose To the parking brake. To the brake caliper Brake hose Clamp the wire harness and fuel tank breather hose from the top. Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side.
Page 499 SPEC CABLE ROUTING...
Page 500 SPEC CABLE ROUTING Headlight wire harness Tighten the frame ground and voltage regulator upper bolt to- gether. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through be- tween engine and heat ex- changer.
Page 501 SPEC CABLE ROUTING...
Page 502 SPEC CABLE ROUTING 1 Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the up- ward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross mem- ber and frame. Wire harness clamp Rivets Speed sensor Nylon nuts...
Page 503 SPEC CABLE ROUTING...
Page 504 SPEC CABLE ROUTING 1 Battery positive lead CDI unit Battery negative lead Air box drain hose Starter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat CDI unit bracket Latch Battery band Battery cover...
Page 505 SPEC CABLE ROUTING...
Page 506 SPEC CABLE ROUTING FOR RX10RK, RX10RSK, RXW10K, RXW10SK To the headlight and meter as- sembly Clamp the lead at the position of white tape. Clamp the wire harness and A.C.magneto lead. Battery positivee lead Battery negative lead Main harness Negative lead connector Carburetor heater lead coupler Oil level switch lead coupler Oil level switch...
Page 507 SPEC CABLE ROUTING...
Page 508 SPEC CABLE ROUTING Route the starter cable above the left handlebar switch lead. Brake hose Fuel sender lead coupler Clamp the ignition coil lead un- der the fuel hose. Clamp the fuel hose. Route the coolant hose be- tween the upper vacuum hose and lower vacuum hose.
Page 509 SPEC CABLE ROUTING...
Page 510 SPEC CABLE ROUTING 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securely fit in the rubber cover) Put the boots of the meter cou- pler in the boss root on the side of the meter.
Page 511 SPEC CABLE ROUTING...
Page 512 SPEC CABLE ROUTING 1 Clamp the grip warmer lead and the right handlebar switch lead. Clamp the main harness, main switch and harness. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Ex- cept for brake hose and parking brake cable.) Pass the brake hose and the parking brake cable through...
Page 513 SPEC CABLE ROUTING...
Page 514 SPEC CABLE ROUTING Carburetor air vent hose To the parking brake. To the brake caliper Brake hose Clamp the wire harness and fuel tank breather hose from the top. Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side.
Page 515 SPEC CABLE ROUTING...
Page 516 SPEC CABLE ROUTING Headlight wire harness Tighten the frame ground and voltage regulator upper bolt to- gether. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through be- tween engine and heat ex- changer.
Page 517 SPEC CABLE ROUTING...
Page 518 SPEC CABLE ROUTING 1 Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the up- ward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross mem- ber and frame. Wire harness clamp Rivets Speed sensor Nylon nuts...
Page 519 SPEC CABLE ROUTING...
Page 520 SPEC CABLE ROUTING 1 Battery negative lead CDI unit Battery positive lead Air box drain hose Starter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat CDI unit bracket Latch Battery band Battery cover...
Page 521 WIRING DIAGRAM - L/R G/B Sb Y/B G Y/G Lg/B Lg/B R/B G/R - W/R - B/L Y/L L/R Lg/W G G/R - Br/Y Y/B Lg/B Y/G B/W B - - - - - - - W/G - - B/Y Y/W W/Y L Lg/L L/R Br/W Lg Y/R Sb Br/W B/R B/W - Y W Gy O SUB-WIRE SUB-WIRE SUB-WIRE...
Page 522 1 A.C. magneto 2 Rectifier / regulator 3 Main switch 4 Main relay 5 Fuse (MAIN) 6 Starter relay 7 Starter motor 8 Battery 9 Engine stop switch 10 Throttle switch 11 Carburetor switch 12 Carburetor heater relay 13 Carburetor heater 14 Grip warmer 15 Thumb warmer 16 CDI unit...
Page 523 05. 11 PRINTED ON RECYCLED PAPER...
Page 524 SUPPLEMENTARY SERVICE MANUAL RX10RTL/RX10RL RX10RTRL/RX10GTL RXW10L/RX10ML LIT-12618-02-44 8FS-28197-10...
Page 525 NOTE: A NOTE provides key information that can NOTICE make procedures easier or clearer. This manual was written by the Yamaha Motor MANUAL FORMAT Company primarily for use by Yamaha dealers All of the procedures in this manual are orga- and their qualified mechanics.
Page 526 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols are designed as thumb tabs to indicate the chapter’s number and content. General information Periodic inspections and adjustments Chassis Power train Engine Cooling system Fuel injection system Electrical Specifications Illustrated symbols are used to iden- tify the specifications which appear.
Page 527 INDEX 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 528 CHAPTER 1. CHAPTER 4. GENERAL INFORMATION POWER TRAIN SPECIAL TOOLS ..........1 PRIMARY SHEAVE AND DRIVE V-BELT.. 37 FOR FUEL INJECTION SERVICE....1 SLIDE RAIL SUSPENSION ......39 RX10GTL..........39 CHAPTER 2. RXW10L ..........43 PERIODIC INSPECTION RX10ML..........47 AND ADJUSTMENT CHAPTER 5. INTRODUCTION..........2 ENGINE PERIODIC MAINTENANCE CHART FOR...
Page 529 CHAPTER 8. ENGINE ..........129 POWER TRAIN ........131 ELECTRICAL CHASSIS ..........133 IGNITION SYSTEM ........93 GENERAL TORQUE SPECIFICATIONS ..134 CIRCUIT DIAGRAM ....... 93 THROTTLE OVERRIDE SYSTEM DEFINITION OF UNITS ......134 (T.O.R.S.) ..........95 HANDLEBAR SWITCH (RIGHT) .... 96 CABLE ROUTING ........135 MAIN SWITCH........
Page 530: General Information
SPECIAL TOOLS INFO GENERAL INFORMATION 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 531: Periodic Maintenance Chart For The Emission Control System
INTRODUCTION/PERIODIC MAINTENANCE INSP CHART FOR THE EMISSION CONTROL SYSTEM PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced.
Page 532 INSP GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART Every Initial Pre-opera- 1 month or Seasonally Item Remarks tion check 800 km or 4,000 km (Daily) (500 mi) (2,500 mi) (40 hr) (200 hr) Check oil level. Engine oil Replace.
Page 533 INSP GENERAL MAINTENANCE AND LUBRICATION CHART Every Initial Pre-opera- 1 month or Seasonally Item Remarks tion check 800 km or 4,000 km (Daily) (500 mi) (2,500 mi) (40 hr) (200 hr) Check engagement and shift speed. Whenever operating elevation is Adjust if necessary.
Page 534 INSP FUEL LINE INSPECTION/COOLING SYSTEM FUEL LINE INSPECTION 1. Remove: • Top cover Refer to “COWLINGS” in CHAPTER 3. 2. Remove: • Intake silencer Refer to “FUEL INJECTION” in CHAPTER 7. 3. Inspect: • Fuel hoses • Fuel delivery hoses Cracks/damage →...
Page 535 INSP COOLING SYSTEM 5. Remove: • Side cover (right) • Side under cover (right) Refer to “COWLINGS” in CHAPTER 3. 6. Place an open container under the coolant hose. 7. Disconnect: • Coolant hose 8. Drain the coolant. NOTE: NOTE: Lift up the tail of the machine to drain the cool- ant.
Page 536 INSP COOLING SYSTEM 12.Connect: • Coolant hoses 13.Install: • Rear cover Bolt (rear cover): 3 Nm (0.3 m•kg, 2.2 ft•lb) 14.Install: • Coolant hose 15.Install: • Side under cover (right) Refer to “COWLINGS” in CHAPTER 3. 16.Install: • Intake silencer Refer to “FUEL INJECTION”...
Page 537 INSP COOLING SYSTEM 18.Bleed the air from the cooling system. 19.Inspect: • Cooling system Decrease of pressure (leaks) → Repair as required. Inspection steps: • Attach the cooling system tester adapter to the coolant filler Cooling system tester: 90890-01325, YU-24460-01 Adapter: 90890-01352, YU-24460-01 •...
Page 538 INSP COOLING SYSTEM Air bleeding steps: • Lift up the tail of the machine. • Remove the bleed bolt on the heat exchanger. • While slowly adding coolant to the coolant filler, drain the coolant until no more air bub- bles appear.
Page 539 INSP SYNCHRONIZING THE THROTTLE BODIES SYNCHRONIZING THE THROTTLE BODIES NOTE: NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Place the machine on a level surface. 2.
Page 540 INSP SYNCHRONIZING THE THROTTLE BODIES 7. Adjust: • throttle body synchronization a. With throttle body #1 as standard, adjust throttle bodies #2, #3, and #4 using the air screws , #2 , #3 , #4 NOTE: NOTE: • After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
Page 541 INSP ENGINE IDLE SPEED ADJUSTMENT ENGINE IDLE SPEED ADJUSTMENT NOTE: NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes.
Page 542 INSP THROTTLE CABLE FREE PLAY ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: NOTE: • Before adjusting the throttle cable free play, the engine idle speed should be adjusted. • Adjust the throttle cable free play while the cable is in the cable guide. 1.
Page 543 INSP SHEAVE OFFSET ADJUSTMENT POWER TRAIN SHEAVE OFFSET ADJUSTMENT 1. Measure: • Sheave offset Use the sheave gauge. Out of specification → Adjust. Sheave offset: 13.5 ~ 16.5 mm (0.53 ~ 0.65 in) Sheave gauge: YS-42421-1 NOTE: NOTE: Push the secondary sheave toward the inside of vehicle frame first and measure the sheave offset.
Page 544 INSP SHEAVE OFFSET ADJUSTMENT/LUBRICATION LUBRICATION 3. Measure: • Secondary sheave freeplay (clearance) Use a feeler gauge. Out of specification → Adjust. Secondary sheave free play (clearance): 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) 4. Adjust: • Secondary sheave freeplay (clearance) Adjustment steps: •...
Page 545 INSP LUBRICATION Applay grease Applay grease (Both sides) Applay grease (Bpth sides) Front Rear (RX10RTL, RX10RL, RX10RTRL, RX10GTL) Rear (RXW10L) Rear (RX10ML) (Both sides)
Page 546 INSP CLUTCH CLUTCH Blue P Pink S Silver High altitude W White Y Yellow Specifications Model: RX10RTL, RX10RL, RX10RTRL, RX10GTL – 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m Elevation (–...
Page 547 INSP CLUTCH Blue P Pink S Silver W White Y Yellow Specifications Model: RXW10L – 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)
Page 548 INSP CLUTCH Blue P Pink S Silver W White Y Yellow Specifications Model: RX10ML – 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)
Page 549 INSP GEAR SELECTION GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions. If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions exist, decrease the ratio.
Page 550 INSP GEAR SELECTION Chain and sprocket part number Parts name Teeth & links Parts no. Standard 18 teeth 8FA-17682-80 19 teeth 8FA-17682-90 20 teeth 8FA-17682-00 RX10ML 21 teeth 8FA-17682-10 Drive sprocket 22 teeth 8FA-17682-20 23 teeth 8FA-17682-30 RXW10L RX10RTL, RX10RL, RX10RTRL, 24 teeth 8FA-17682-40 RX10GTL...
Page 551 INSP GEAR SELECTION Secondary sheave spring Spring rate Preload Wire Free Outside No. of Part no. N•mm/rad N/mm (kg / mm) Color gauge length diameter Standard coils (kg•mm/rad) (lb/in) mm (in) mm (in) mm (in) 90508-500B1 6003 (613) 6.2 (0.63), 35.28 Brown 5.0 (0.196) 5.19...
Page 552 INSP GEAR SELECTION Primary spring Spring identification color code Spring rate color Preload color Spring rate Wire Outside Free Preload No. of Parts No. N/mm Color gauge diameter length Standard N (kg) coils (kg/mm) mm (in) mm (in) mm (in) 90501-551L3 19.6 (2.00) 294 (30)
Page 553 INSP GEAR SELECTION Clutch weight Weight g (oz) Parts no. without bush Shape & ID mark Standard and rivets 8BU-17605-20 45.41 (1.60) 8CH-17605-10 35.32 (1.247) 8DG-17605-00 34.26 (1.209) 8DJ-17605-00 37.77 (1.333) 8DN-17605-10 39.76 (1.40) 8ES-17605-00 54.6 (1.93) 8FA-17605-10 63.8 (2.25)
Page 554 INSP GEAR SELECTION Weight g (oz) Parts no. without bush Shape & ID mark Standard and rivets RX10RTL, RX10RL, 8FP-17605-00 67.81 (2.392) RX10RTRL, RX10GTL, RXW10L 8FS-17605-00 65.52 (2.311) RX10ML Weight rivets Length Weight Parts No. Material Standard Effects mm (in) g (oz) IN: RX10RTL, RX10RL, RX10RTRL, RX10GTL, Increased...
Page 555 INSP GEAR SELECTION Rollers I.D. 9 mm (0.354 in) Roller with Outside Bushing Identification bushing part diameter Standard Effects type (P/N) mark (Width) number mm (in) Grooved & Machined VESPEL Increased TP-8549 force RX10RTL, RX10RL, 8FG-17624-00 14.5 (0.57) RX10RTRL, RX10GTL, RXW10L (1.46 mm) 90386-09001 Grooved...
Page 556 INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: • Spring preload Adjustment steps: • Loosen the locknut • Adjust the spring preload by turning the spring seat RX10RTL, RX10RL, RX10RTRL, RXW10L Standard Spring seat Shorter ← → Longer distance Harder ←...
Page 557 INSP REAR SUSPENSION REAR SUSPENSION Spring preload (RX10GTL) 1. Adjust: • Spring preload Adjustment step: • Loosen the locknut • Adjust the spring preload by turning the spring seat Front Standard Spring seat Shorter ← → Longer distance Harder ← →...
Page 558 INSP REAR SUSPENSION • Press the electric suspension/grip warmer adjustment switch in direction (Maximum: 16 push) Adjustment switch pushed direction Display Adjustment 9 10 11 12 13 14 15 16 switch Damping Softer ← → Harder force • This display scale is set in 2-level for one graduation.
Page 559 CHAS COWLINGS CHASSIS COWLINGS Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Shroud Side cover (left and right) Side under cover (left and right) Top cover Headlight assembly Headlight stay Intake silencer For installation, reverse the removal procedure.
Page 560 CHAS STEERING STEERING RX10RTL, RX10RL, RX10RTRL, RXW10L RX10RL, RXW10L 10 Nm (1.0 m•kg, 7.2 ft•lb) 15 Nm (1.5 m•kg, 11 ft•lb) Order Job/Part Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Top cover Refer to “COWLINGS”. Handlebar cover Cable guide (front) Grip warmer lead coupler...
Page 561 CHAS STEERING RX10RL, RXW10L 10 Nm (1.0 m•kg, 7.2 ft•lb) 15 Nm (1.5 m•kg, 11 ft•lb) Order Job/Part Q’ty Remarks Master cylinder assembly NOTE: NOTE: Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” to check the cable, lead and Handlebar hose routings.
Page 562 CHAS STEERING RX10GTL 10 Nm (1.0 m•kg, 7.2 ft•lb) 15 Nm (1.5 m•kg, 11 ft•lb) Order Job/Part Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Top cover Refer to “COWLINGS”. Cable guide (front) Grip warmer lead coupler Disconnect.
Page 563 CHAS STEERING 10 Nm (1.0 m•kg, 7.2 ft•lb) 15 Nm (1.5 m•kg, 11 ft•lb) Order Job/Part Q’ty Remarks Master cylinder assembly NOTE: NOTE: Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” to check the cable, lead and Handlebar hose routings.
Page 564 CHAS STEERING RX10ML 10 Nm (1.0 m•kg, 7.2 ft•lb) 15 Nm (1.5 m•kg, 11 ft•lb) Order Job/Part Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Top cover Remove to “COWLINGS”. Cable guide (front) Grip warmer lead coupler Disconnect.
Page 565 CHAS STEERING 10 Nm (1.0 m•kg, 7.2 ft•lb) 15 Nm (1.5 m•kg, 11 ft•lb) Order Job/Part Q’ty Remarks Master cylinder assembly NOTE: NOTE: Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” to check the cable, lead and Handlebar hose routings.
Page 566 POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT 120 Nm (12 m•kg, 85 ft•lb) 60 Nm (6.0 m•kg, 43 ft•lb) Order Job/Part Q’ty Remarks Primary sheave removal Remove the parts in the order listed below. Left side cover Refer to “COWLINGS”...
Page 567 POWR PRIMARY SHEAVE AND DRIVE V-BELT 6 Nm (0.6 m•kg, 4.3 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 200 Nm (20.0 m•kg, 145 ft•lb) Clean the threads. Apply LOCTITE648 AS illustrated in And then tighten the spider. (The spider must 16 mm (0.63 in) be turned counterclockwise to be tightened.) 30 mm (1.18 in)
Page 568 POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION RX10GTL 60 Nm (6.0 m•kg, 43 ft•lb) 84 Nm (8.4 m•kg, 61 ft•lb) Order Job/Part Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen.
Page 569 POWR SLIDE RAIL SUSPENSION Order Job/Part Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below. Stopper band Shaft Rubber collar Electric suspension sub-wire lead Shock absorber Collar Control rod assembly Spacer Collar Oil seal Bearing...
Page 570 POWR SLIDE RAIL SUSPENSION Order Job/Part Q’ty Remarks Front pivot arm Bushing Collar Sliding runner Suspension wheel Suspension wheel bracket Shaft Collar Front pivot arm bracket Bushing Collar Shaft Rear pivot arm Guide wheel Bushing Shaft Rear pivot arm bracket...
Page 571 POWR SLIDE RAIL SUSPENSION Order Job/Part Q’ty Remarks Guide wheel Collar Tension adjuster Rear axle shaft For assembly, reverse the disassembly procedure.
Page 572 POWR SLIDE RAIL SUSPENSION RXW10L 72 Nm (7.2 m•kg, 52 ft•lb) 84 Nm (8.4 m•kg, 61 ft•lb) Order Job/Part Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Collar Shaft Guide wheel...
Page 573 POWR SLIDE RAIL SUSPENSION Order Job/Part Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below. Shock absorber adjuster assembly Stopper band Shaft Rubber collar Shock absorber Spacer Collar Oil seal Bearing Control rod assembly Spacer Collar Oil seal Bearing...
Page 574 POWR SLIDE RAIL SUSPENSION Order Job/Part Q’ty Remarks Front pivot arm Bushing Collar Sliding runner Protector Suspension wheel Suspension wheel bracket Shaft Collar Front pivot arm bracket Bushing Collar Shaft Rear pivot arm Bushing Shaft Rear pivot arm bracket Slider...
Page 575 POWR SLIDE RAIL SUSPENSION Order Job/Part Q’ty Remarks Guide wheel Collar Tension adjuster Rear axle shaft For assembly, reverse the disassembly procedure.
Page 576 POWR SLIDE RAIL SUSPENSION RX10ML 72 Nm (7.2 m•kg, 52 ft•lb) Order Job/Part Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Slide rail suspension Collar For installation, reverse the removal procedure.
Page 577 POWR SLIDE RAIL SUSPENSION Order Job/Part Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below. Stopper band Shaft Rubber collar Front shock absorber Collar Bushing Front pivot arm Shaft Bushing Collar Suspension wheel assembly Shaft Shaft Suspension bracket Bushing...
Page 578 POWR SLIDE RAIL SUSPENSION Order Job/Part Q’ty Remarks Suspension wheel Hook assembly Rear shock absorber Collar Relay rod Collar Bushing Shaft Collar Bushing Bracket Collar Guide wheel Spacer Rear spring Shaft Bushing Rear pivot arm protector Rear pivot arm...
Page 579 POWR SLIDE RAIL SUSPENSION Order Job/Part Q’ty Remarks Circlip Hook Control rod assembly Shaft Pivot shaft Suspension wheel Suspension bracket Shaft Guide wheel Rear axle shaft Collar Tension adjuster For assembly, reverse the disassenbly procedure.
Page 580 POWR SLIDE RAIL SUSPENSION Control rod parts number RX10RTL, RX10RL, RX10RTRL, RX10GTL, RX10ML RXW10L Control rod 1 Length mm (in) Length mm (in) Length mm (in) RX10RTL, RX10RL, RX10RTRL, 277.3 (10.92) 150.5 (5.93) – RX10GTL, RXW10L 2.5P × 2 = 5 RX10ML 236.3 (9.30) 200.7 (7.90)
Page 581 SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK Order Job/Part Q’ty Remarks Seat and fuel tank removal Remove the parts in the order listed below. Muffler end pipe Tail/brake light cover Muffler side cover Seat Fuel tank cap Fuel tank cover Side cover Fuel tank For installation, reverse the removal...
Page 582 EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER 20 Nm (2.0 m•kg, 14 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 16 Nm (1.6 m•kg, 12 ft•lb) 11 Nm (1.1 m•kg, 8 ft•lb) Order Job/Part Q’ty Remarks Exhaust pipe and muffler removal Remove the parts in the order listed below.
Page 583 COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER 35 Nm (3.5 m•kg, 25 ft•lb) Order Job/Part Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAPTER 2. Primary sheave assembly Refer to “PRIMARY SHEAVE AND DRIVE V-VELT”...
Page 584 COOL HEAT EXCHANGER 35 Nm (3.5 m•kg, 25 ft•lb) Order Job/Part Q’ty Remarks Heat exchanger (front) Coolant hose 6 Water pump assembly Throttle body heater hose Coolant hose 7 Coolant pipe 1 Coolant hose 8 Coolant pipe 2 Coolant hose 9 Water jacket joint Coolant hose 10 Thermostat assembly...
Page 585 COOL HEAT EXCHANGER 35 Nm (3.5 m•kg, 25 ft•lb) Order Job/Part Q’ty Remarks Pipe 3 Water pump hose O-ring Coolant hose 13 Coolant hose 14 For installation, reverse the removal procedure.
Page 586 COOL...
Page 587 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM Ignition coil Engine trouble warn- Intake temperature Intake silencer Spark plug ing light sensor Crankshaft position Fuel tank Cylinder identification Atmospheric pressure sensor Fuel pump sensor sensor Oil level switch Grip warmer adjust- Fuel delivery hose Pressure regulator ment down side switch...
Page 588 FUEL INJECTION SYSTEM WIRING DIAGRAM Br B B Lg...
Page 589 FUEL INJECTION SYSTEM Crankshaft position sensor Main switch Fuse (MAIN) Fuse (FUEL INJECTION SYSTEM) Battery Engine stop switch Oil pressure switvh E.C.U. Ignition coil #1 Ignition coil #2 Ignition coil #3 Ignition coil #4 Spark plug Fuel injection system relay Injector #1 Injector #2 Injector #3...
Page 590 FUEL INJECTION SYSTEM EAS00899 ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 591 FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
Page 592 FUEL INJECTION SYSTEM Fault Able/unable Able/unable Item Symptom Fail-safe action Code No. to start to drive Error in writing the An error is detected while – amount of CO reading or writing on EEPROM Able Able adjustment on EEPROM (CO adjustment value). Vehicle system power Power supply to the FI system is Grip warmer output is OFF.
Page 593 FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light flash. *Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light does not come The engine trouble warning light flash.
Page 594 FUEL INJECTION SYSTEM EAS00905 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.
Page 595 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 trip LCD. • Actuator operation Set the grip warmer adjustment down side switch to “ON”...
Page 596 FUEL INJECTION SYSTEM Diagnostic fault code table Fault Diagnostic Symptom Probable cause of malfunction Code No. code No normal signals are received from • Open or short circuit in wiring sub lead. the cylinder identification sensor. • Open or short circuit in wiring harness. •...
Page 597 FUEL INJECTION SYSTEM Fault Diagnostic Symptom Probable cause of malfunction Code No. code No normal signals are received from • Open or short circuit in wiring harness. the speed sensor. • Defective speed sensor. • Malfunction in vehicle speed sensor detected unit. •...
Page 598 FUEL INJECTION SYSTEM Diagnostic mode table Switch the meter display from the regular mode to the diagnosis mode. To switch the display, refer to “DIAGNOSTIC MODE”. NOTE: • 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 599 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Suspension for the The following connection judgment result is transmitted to the – adjustment of meter. When the connection judgment is “Connected”: H’00 damping force When the connection judgment is “Not connected”: H’F0 The following item is performed only when the connection judgment is “Connected”.
Page 600 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Fuel injection system After the engine stop switch has been turned from OFF to ON, it Check the fuel injection system relay actuates the fuel injection system relay five times every second relay operating sound 5 times and illuminates the engine trouble warning light (the light is OFF with the engine stop switch ON.
Page 601 FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the order. When the check and maintenance of malfunctioned part is completed, restore the meter display according to the “Restore method”.
Page 602 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No. – – Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Installed condition of sensor Check the installed area for looseness or pinching.
Page 603 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor – open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that...
Page 604 FUEL INJECTION SYSTEM Intake air pressure sensor – hose system malfunction (clogged or detached Fault code No. Symptom hose). Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Intake air pressure sensor hose Repair or replace the sensor hose.
Page 605 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Used diagnostic code No. 01 (throttle position sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method When detecting fault code No.15. Refer to “Fault code No.15”. Reinstated by starting the Installed condition of throttle position...
Page 606 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected from the intake temperature sensor. Used diagnostic code No. 05 (intake temperature sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that...
Page 607 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code No. 02 (atmospheric pressure sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that...
Page 608 FUEL INJECTION SYSTEM Fault code No. Symptom Oil pressure dropped. Used diagnostic code No. – – Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Oil pressure dropped Keep the snow mobile horizontal and then measure the oil pressure after the sufficient warm-up, and check that the value is 25 kpa or more.
Page 609 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil (#3). Used diagnostic code No. 32 (ignition coil #3) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that...
Page 610 FUEL INJECTION SYSTEM Fault code No. Symptom 1 No normal signals are received from the speed sensor. Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of speed sensor If there is a malfunction, repair it and connect it...
Page 611 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that...
Page 612 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEP-ROM (CO adjustment value). Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Malfunction in ECU Execute diagnostic code 60 Reinstated by...
Page 613 FUEL INJECTION SYSTEM Fault code No. Symptom Grip warmer-short circuit detected. Used diagnostic code No. 26 Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Short circuit in wiring harness. Repair or replace if there is an short circuit. Reinstated by Between switch coupler and ECU coupler turning the main...
Page 614 FUEL INJECTION SYSTEM Er-1 Symptom No signal are received from the ECU. Er-2 Symptom No signal are received from the ECU within the specified duration. Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Er-4 Symptom Non-registered data has been received from the meter. Used diagnostic code No.
Page 615 FUEL INJECTION SYSTEM OIL PRESSURE SWITCH 1. Disconnect: • Oil pressure switch coupler 2. Connect: • Pocket tester (to the switch coupler) 3. Inspect: • Oil pressure switch continuity Switch is operated. Faulty → Replace the oil pressure switch. Main switch Continuity position...
Page 616 THROTTLE BODIES THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed below. Intake silencer Refer to “COWLINGS” in CHAPTER 3. Headlight stay Refer to “COWLINGS” in CHAPTER 3. Sub wire harness coupler Disconnect.
Page 617 THROTTLE BODIES EAS00910 INJECTORS Order Job/Part Q’ty Remarks Removing the injectors Remove the parts in the order listed. Throttle position sensor coupler Disconnect. Intake air pressure sensor coupler Disconnect. Cylinder #4-injector coupler Cylinder #3-injector coupler Cylinder #2-injector coupler Cylinder #1-injector coupler Sub wire harness Negative pressure hose Intake air pressure sensor...
Page 618 THROTTLE BODIES EAS00911 CAUTION: The throttle bodies should not be disas- sembled. EAS00912 CHECKING THE INJECTORS 1. Check: • injectors Damage → Replace. EAS00913 CHECKING THE THROTTLE BODIES 1. Check: • throttle bodies Cracks/damage → Replace the throttle bodies as a set. 2.
Page 619 THROTTLE BODIES CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • fuel pump operation Refer to “SEAT AND FUEL TANK” in CHAPTER 5. a. Remove the seat and fuel tank. Refer to “SEAT AND FUEL TANK” in CHAPTER 5. b.
Page 620 THROTTLE BODIES EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor a. Disconnect the throttle position sensor cou- pler. b.
Page 621 THROTTLE BODIES f. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly → Replace the throttle position sensor. The slot is worn or broken → Replace the throttle position sensor.
Page 622 ELEC IGNITION SYSTEM ELECTRICAL IGNITION SYSTEM CIRCUIT DIAGRAM Br B B Lg...
Page 623 ELEC IGNITION SYSTEM A.C. magneto Rectifier/regulator Main switch Load relay Fuse (MAIN) Battery Engine stop switch Throttle switch Ignition coil #1 Ignition coil #2 Ignition coil #3 Ignition coil #4 Spark plug Fuse (IGNITION)
Page 624 ELEC IGNITION SYSTEM THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should mal- function during operation, T.O.R.S. will operate when the throttle lever is released. T.O.R.S. is designed to interrupt the fuel injec- tion and keep the engine revolutions between 2,800 and 3,000 r/min if the throttle body fails to return to idle when the lever is released.
Page 625 ELEC IGNITION SYSTEM HANDLEBAR SWITCH (RIGHT) Engine stop switch and throttle switch 1. Disconnect: • Engine stop switch coupler • Throttle switch coupler 2. Connect: • Pocket tester 3. Inspect: • Engine stop switch continuity Faulty → Replace the handlebar switch (right).
Page 626 ELEC IGNITION SYSTEM MAIN SWITCH 1. Disconnect: • Main switch coupler 2. Connect: • Pocket tester 3. Inspect: • Main switch continuity Faulty → Replace. Switch position Continuity Switch Color code position Br/W START Continuity LOAD RELAY 1. Inspect: • Load relay Inspection steps: •...
Page 627 ELEC ELECTRICAL STARTING SYSTEM ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM...
Page 628 ELEC ELECTRICAL STARTING SYSTEM MAIN SWITCH 1. Disconnect: • Main switch coupler 2. Connect: • Pocket tester 3. Inspect: • Main switch continuity Faulty → Replace. Switch position Continuity Switch Color code position Br/W START Continuity...
Page 629 ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM...
Page 630 ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM Br B B Lg...
Page 631 ELEC LIGHTING SYSTEM HEADLIGHT BEAM SWITCH 1. Disconnect: • Headlight beam switch coupler 2. Connect: • Pocket tester (to the headlight beam switch coupler) 3. Inspect: • Headlight beam switch continuity Faulty → Replace. Switch position Continuity HEADLIGHT RELAY 1. Inspect: •...
Page 632 ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM Br B B Lg...
Page 633 ELEC SIGNAL SYSTEM A.C. magneto Rectifier/regulator Main switch Load relay Fuse (MAIN) Battery E.C.U. Speed sensor Water temperature sensor Back buzzer Gear position switch Brake light switch Tail/brake light Fuse (SIGNAL) Fuse (IGNITION) Multi-function meter Warning light Water temperature indicator light Oil level switch Fuel sender...
Page 634 ELEC SIGNAL SYSTEM ENGINE OIL LEVEL SWITCH 1. Remove: • Oil level gauge 2. Connect: • Pocket tester (to the oil level switch coupler) 3. Inspect: • Oil level switch continuity Faulty → Replace. Good Switch position condition condition × ×...
Page 635 ELEC GRIP WARMER SYSTEM GRIP WARMER SYSTEM CIRCUIT DIAGRAM Br B B Lg...
Page 636 ELEC GRIP WARMER SYSTEM GRIP AND THUMB WARMER COIL 1. Disconnect: • Grip warmer leads • Thumb warmer coupler 2. Connect: • Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads) 3. Inspect: • Grip warmer continuity •...
Page 637 ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM B Lg...
Page 638 ELEC COOLING SYSTEM TROUBLESHOOTING RADIATOR FAN MOTOR AND RADIATOR FAN MOTOR RELAY Check the main fuse and radiator fan motor fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or radiator fan FAULTY motor fuse. Check the battery. Refer to “BATTERY INSPECTION”...
Page 639 ELEC COOLING SYSTEM RADIATOR FAN MOTOR 1. Disconnect: • Radiator fan motor coupler 2. Connect: • Battery 3. Inspect: • Radiator fan motor Positive battery terminal → Blue Negative battery terminal → Black Does not move → Replace the radiator fan motor.
Page 640 SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Model code number: 8FP1 (RX10RTL for U.S.A/Canada) 8FR1 (RX10RL for U.S.A/Canada) 8FR3 (RX10RTRL for U.S.A/Canada) 8GD1 (RX10GTL for U.S.A/Canada) 8FT1 (RXW10L for U.S.A/Canada) 8FS1 (RX10ML for U.S.A/Canada) Dimensions: Overall length 2,805 mm (110.4 in) (RX10RTL, RX10RL, RX10RTRL,...
Page 641 SPEC GENERAL SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Engine oil: Type API SE, SF, SG or higher SAE0W-30 Oil capacity Periodic oil change 2.8 L (2.5 Imp qt, 3.0 US qt) With oil filter replacement 3.0 L (2.6 Imp qt, 3.2 US qt) Total amount 3.8 L (3.3 Imp qt, 4.0 US qt) Oil filter:...
Page 642 SPEC GENERAL SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Suspension: Front suspension type Independent double wishbone suspension Rear suspension type Slide rail suspension Track: Track type Internal drive type Track width 381 mm (15.0 in) Length on ground 768 mm (30.2 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 959 mm (37.8 in) (RXW10L) 1,201 mm (47.3 in) (RX10ML)
Page 643 SPEC...
Page 644 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Cylinder head: Volume (with spark plug) 13.45 ~ 14.05 cm (0.82 ~ 0.86 cu. in) <Warpage limit> 0.1 mm (0.04 in) * Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating...
Page 645 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Valve dimensions: Valve head diameter A Intake 22.9 ~ 23.1 mm (0.9016 ~ 0.9094 in) Exhaust 24.4 ~ 24.6 mm (0.9606 ~ 0.9685 in) Head Diameter Valve face width B Intake 1.76 ~ 2.90 mm (0.0693 ~ 0.1142 in) Exhaust...
Page 646 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Valve spring: Free length Intake 43.59 mm (1.72 in) Exhaust 40.62 mm (1.60 in) Installed length (valve closed) Intake 34.50 mm (1.36 in) Exhaust 35.00 mm (1.38 in) Compressed spring force (installed) Intake 126 ~ 146 N (12.8 ~ 14.9 kg, 28.3 ~ 32.8 lb) Exhaust...
Page 647 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Piston ring: Sectional sketch Top ring Ring type Barrel Dimensions (B × T) 0.90 × 2.75 mm (0.035 × 0.108 in) 2nd ring Ring type Taper Dimensions (B × T) 0.8 × 2.8 mm (0.031 × 0.110 in) Oil ring Dimensions (B ×...
Page 648 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Oil pump: Oil pump type Trochoidal Inner-rotor-to-outer-rotor-tip clearance 0.00 ~ 0.12 mm (0.000 ~ 0.005 in) Outer-rotor-to-oil-pump-housing 0.09 ~ 0.15 mm (0.004 ~ 0.006 in) clearance Max. impeller shaft tilt 0.15 mm (0.0059 in) <Limit>...
Page 649 SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Primary sheave spring: Part number 90501-582L1 (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 90501-581L5 (RX10ML) Color code Yellow – Silver – Yellow (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) Yellow – Pink – Yellow (RX10ML) Diameter 59.5 mm (2.34 in) Wire diameter...
Page 650 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Rivet: Outer Part number 90261-06033 (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 90266-06002 (RX10ML) Material Steel Size 17.2 mm (0.677 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 13.3 mm (0.524 in) with hole (RX10ML) Quantity Hole quantity Center...
Page 651 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Secondary sheave spring: Part number 90508-60012 (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 90508-60007 (RXW10L, RX10ML) Color code PINK (RX10RTL, RX10RL, RX10RTRL, RX10GTL) White (RXW10L, RX10ML) Outside diameter 69.5 mm (2.736 in) Wire diameter 6 mm (0.236 in) Hole position Sheave side-spring side (twist angle) 2-6 (80°) (RX10RTL, RX10RL, RX10RTRL, RX10GTL)
Page 652 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Track: Part number 8FA-47110-00 (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 8FG-47110-00 (RXW10L) 8FS-47110-00 (RX10ML) Width 381 mm (15.0 in) Length 3,072 mm (120.9 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 3,456 mm (136.1 in) (RXW10L) 4,115 mm (162.0 in) (RX10ML) Pitch 64 mm (2.52 in) (RX10RTL, RX10RL, RX10RTRL,...
Page 653 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Shock absorber: Damping force Extension 1,950 N/0.3 m/s (198.71 kg/0.3 m/s, 438 lb/0.3 m/s) (RX10RTL, RX10RL, RX10RTRL) 1,069 ~ 1,167 N/0.3 m/s (108.93 ~ 118.92 kg/0.3 m/s, 240 ~ 262 lb/0.3 m/s) (RX10GTL) 1,830 N/0.3 m/s (186.48 kg/0.3 m/s, 411 lb/0.3 m/s) (RXW10L) Compression...
Page 654 SPEC MAINTENANCE SPECIFICATIONS CHASSIS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Frame: Frame material Aluminum Seat height 765 mm (30.1 in) (RX10RTL, RX10RL, RX10RTRL, RXW10L, RX10ML) 770 mm (30.3 in) (RX10GTL) Luggage box location Rear Steering: Lock-to-lock angle (left) 29.0° (R ski) 34.5° (L ski) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 30.1°...
Page 655 SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5° at 1,500 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T567/MITSUBISHI 1.19 ~ 1.61 Ω at 20°C (68°F) Primary coil resistance Secondary coil resistance 8.5 ~ 11.5 kΩ...
Page 656 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Starter relay: Model/Manufacturer 2768081-A/JIDECO Amperage rating 180 A 4.2 ~ 4.6 Ω at 20°C (68°F) Coil resistance T.P.S. (throttle position sensor): Model/Manufacturer TS62/146/MIKUNI Resistance 4 ~ 6 kΩ at 20°C (68°F) (Blue –...
Page 657 SPEC MAINTENANCE SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, Model RXW10L, RX10ML Circuit breaker: Type Fuse Amperage for individual circuit 40 A × 1 Main fuse 10 A × 1 Fuel injection system fuse 20 A × 1 Headlight fuse 10 A × 1 Signal fuse 20 A ×...
Page 658 SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m•kg ft•lb Spark plug Cylinder head nut (M10 × 1.25) × 2 20 + 121° 2.0 + 121° 14 + 121° Cylinder head nut (M10 × 1.25) × 6 20 + 105°...
Page 659 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m•kg ft•lb Crankcase (M9 × 1.5) (1st) See NOTE. (2nd) 15 + 65 ~ 70° 1.5 + 65 ~ 70° 11 + 65 ~ 70° Crankcase (M6 × 1.0) Countershaft cover A.C.
Page 660 SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Remarks m•kg ft•lb Primary sheave (1st) 12.0 Tighten the bolts in two (2nd) stages. See NOTE. Spider and sliding sheave 20.0 145 Left-hand thread. ® Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave Stopper (secondary sheave)
Page 661 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m•kg ft•lb (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) Shockabsorber adjuster assembly and frame (RX10RTL, RX10RL, RX10RTRL, RXW10L) Front pivot arm and frame Front pivot arm and shockabsorber Front pivot arm and stopper band Shaft and stopper band Sliding runner and sliding frame Suspension wheel and sliding frame...
Page 662 SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Remarks m•kg ft•lb Handlebar holder Steering joint cover Steering column Upper Lower Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod...
Page 663 GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (bolt) This chart specifies torque for standard fasten- m•kg ft•lb 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 664 SPEC CABLE ROUTING CABLE ROUTING...
Page 665 SPEC CABLE ROUTING CABLE ROUTING Clamp the A.C. magneto lead and wire harness ground lead. Clamp the wire harness and A.C. magnet lead to the raised portion of the battery bracket. Battery positive lead Main fuse Main harness Battery negative lead Flange bolt Clamp the wire harness to the steering gate clamp.
Page 666 SPEC CABLE ROUTING...
Page 667 SPEC CABLE ROUTING Place damper locating between the fuel tank and sheet. To the tail/brake light. Sub-wire harness Brake hose Fuel sender lead cover Auxiliary DC jack coupler Headlight lead coupler To the meter assembly. Clamp the headlight lead. Rout the headlight stay. Align the hole of dia.
Page 668 SPEC CABLE ROUTING...
Page 669 SPEC CABLE ROUTING Right handlebar switch Tube lead Handlebar holder (Route the wire harness, parking brake cable, throttle cable.) Parking brake cable Left handlebar switch Pass all the wire harness, brake hose, brake cable and throttle cable through it. Arrange the line of cables and hoses as shown in the illustra- tion and they should not lap over each other.
Page 670 SPEC CABLE ROUTING...
Page 671 SPEC CABLE ROUTING Route the fuel tank breather hose along the steering gate. Clamp the compression spring section of the fuel tank breather hose. Compression spring Point the clip position to the upward. Insert the fuel tank breather hose until it contacts the projec- tion.
Page 672 SPEC CABLE ROUTING...
Page 673 SPEC CABLE ROUTING Route the fuel tank breather hose behind the steering gate. Wire harness Bracket When the gear position switch lead is equipped with reverse, route it to the reverse gear. If it is not equipped with reverse, insert it to the inner side. Fuse box Coolant reservoir tank Clamp...
Page 674 SPEC CABLE ROUTING...
Page 675 SPEC CABLE ROUTING Fit it to the rear suspension lead. (Other types are attached with plugs.) (RX10GTL) Clamp the wire harness and radi- ator fan motor lead. (RX10RTL, RX10RL, RX10RTRL, RXW10L, RX10ML) Clamp the wire harness, radiator fan motor lead and electronic rear suspension lead.
Page 676 SPEC CABLE ROUTING...
Page 677 SPEC CABLE ROUTING Coolant recovery tank Coolant reservoir tank 10 ~ 30 mm (0.4 ~ 1.2 in) 20 ~ 40 mm (0.8 ~ 1.6 in) Clamp the fuel pipe and sub- wire lead. Pass the fuel tank breather hose between the relay harness and the speed sensor harness.
Page 678 SPEC CABLE ROUTING...
Page 679 SPEC CABLE ROUTING Tail/brake light lead coupler (Place the tail/brake light lead coupler leads so that they are not caught between the seat bottom and tail light bracket.) Tail/brake light lead coupler (RX10ML) Clamp (RX10ML) Tail/brake light lead (RX10ML) Tail/brake light lead cover...
Page 680 WIRING DIAGRAM 2006 RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML (8FP-0F001-00) Gy/R O R/W Gy/R Gy/R G O/G R/L R/B G/B L/B Gy/R Y R/W G G L/R L/R G G L/R R/L B Y/L Br/Y O/B L B/L Y R/B B Ch HEADLIGHT SUB-WIRE HEADLIGHT SUB-WIRE HEADLIGHT SUB-WIRE...
Page 681 A.C. magneto Rectifier/regulator Main switch Load relay Fuse (MAIN) Fuse (FUEL INJECTION SYSTEM) Starter relay Starter motor Battery Diode Engine stop switch Throttle switch Grip warmer Thumb warmer Oil presser switch Fuse (ELECTRONIC CONTROL SUSPENSION) (RX10GTL) Electronic control suspension sole- noid (RX10GTL) E.C.U.
Page 682 COLOR CODE B ..Black Br ..Brown Ch ..Chocolate G ..Green Gy ..Gray L ..Blue Lg .
Page 683 2005. 06 PRINTED ON RECYCLED PAPER...

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Yamaha RX10H Service Manual

Index 1 Gen Info

Chapter 1. General Information

Chapter 3. Chassis

Chapter 4. Power Train

Chapter 5. Engine

Chapter 6

Chapter 7. Carburetion

Chapter 8. Electrical

Chapter 9. Specifications

Section 2

Chapter 2. Periodic Inspection and Adjustment

Section 3

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha RX10H