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Record the frame number, engine number (Primary ID), and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer. 1 The frame number is the seventeen-digit number stamped on the frame of the snowmobile. (See fig.
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ESU00011 I NTRODUCTION Congratulations on your purchase of a Yamaha snowmo- bile. This model is the result of Yamaha’s vast experience in the production of fine sporting and touring snowmo- biles. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
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PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE SNOWMO- BILE. NOTE: Yamaha continually seeks advancements in product design and quality. Therefore, while this manual con- tains the most current product information available at the time of printing, there may be minor discrepan- cies between your snowmobile and this manual.
YAMAHA MOTOR Storage compartment ....5-14 CORPORATION, U.S.A. SNOWMOBILE LIMITED PRE-OPERATION CHECKS....6-1 WARRANTY ........1-1 Fuel ..........6-1 Engine oil.........6-2 YAMAHA EXTENDED SERVICE Coolant ..........6-2 (Y.E.S.) ..........1-4 Throttle lever ........6-3 Recoil starter ........6-3 Throttle override system LOCATION OF THE (T.O.R.S.) ........6-3 IMPORTANT LABELS .......2-1 Brake ..........6-4...
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Checking the spark plug ....8-4 Adjusting the engine idling speed..8-5 Adjusting the throttle cable ....8-6 Adjusting the oil pump cable....8-6 Adjusting the carburetors....8-7 Yamaha Power Valve System (Y.P.V.S.).........8-9 Adjusting the high altitude settings ..........8-10 Cooling system ......8-11 Replacing the V-belt ......8-13...
ESU04050 L OCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operat- ing this snowmobile. NOTE: Maintain or replace safety and instruction labels, as nec- essary. 8EK-77761-E0 4AA-22259-60...
1. Read the Owner’s Manual and all labels before oper- ating this snowmobile. Become familiar with all of the operating controls and their function. Consult a Yamaha dealer about any control or function you do not understand. 2. This snowmobile was not manufactured for use on public streets, roads, or highways.
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7. Do not allow anyone to stand behind the snowmobile when starting, inspecting, or adjusting the snowmo- bile. A broken track, track fittings, or debris thrown by the track could be dangerous to the operator or bystanders. 8. Handle fuel with care; it is HIGHLY FLAMMABLE. Never add fuel when the engine is running or hot.
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Fuel may leak out from the fuel breather hose. 2. Modifications made to the snowmobile not approved by Yamaha, or the removal of original equipment may render your snowmobile unsafe for use that may cause severe personal injury. Modifications may also make the snowmobile illegal to use.
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0 Storage compartment A Tail/brake light B Snow flap C Brake lever D Parking brake lever E Grip warmer adjustment switch F Headlight beam switch G Strap H Engine stop switch I Thumb warmer adjustment switch J Throttle lever K Starter handle L Shroud latch M Main switch N Starter lever...
ESU00013 C ONTROL FUNCTIONS ESU00170 Main switch The main switch controls the following items. 1 “OFF” The ignition circuit is switched off. The key can be removed only in this position. 2 “ON” The ignition circuit is switched on. The engine can be started. NOTE: The headlight, meter lights, and taillight will come on after the engine starts.
ESU00022 Throttle lever Once the engine is running cleanly, squeezing a the throt- tle lever 1 will increase the engine speed and cause engagement of the drive system. Regulate the speed of the snowmobile by varying the throttle position. Because the throttle is spring-loaded, the snowmobile will deceler- ate, and the engine will return to idle when it is released b.
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CA-01E Mode Idling/ Running Trouble starting Item Throttle switch Carburetor switch T.O.R.S. Engine will operate È Idling/starting É Running Ê Trouble 1 Carburetor switch 2 Throttle switch 3 Throttle cable 4 Throttle valve a On b Off...
ESU03810 Speedometer unit The speedometer unit is equipped with the following: a digital speedometer (which shows riding speed) an odometer (which shows the total distance trav- eled) a tripmeter (which shows the distance traveled since it was last set to zero) warning indicators (which show self-diagnosis, cool- ant temperature, fuel level, and oil level warnings) a “D.C.S.”...
ESU03630 High beam indicator light The high beam indicator light 1 comes on when the high beams of the headlights are switched on. (See page 5-12 for headlight beam switch operation.) ESU03821 Fuel meter and grip/thumb warmer level indica- The fuel meter and grip/thumb warmer level indicator have eight segments 1 which show the amount of fuel remaining in the fuel tank, the grip warmer level, or the thumb warmer level.
(See the table below for warning indicator, warning light and fuel meter segment flash pattern.) When this occurs, have a Yamaha dealer inspect the snowmobile as soon as possible. CA-08E Warning indicator, warning light, and fuel meter segments of the fuel meter flash pattern ·...
(See the table below for warning indicator and warning light flash pattern.) When this occurs, have a Yamaha dealer inspect the snowmobile as soon as possible. CA-09E Warning indicator and warning light flash pattern ·...
The self-diagnosis warning indicator 1 and warning light 2 warn the rider of the above problems by flashing continuously. If necessary, ask a Yamaha dealer for fur- ther details. (See page 5-9 for warning indicator and warning light flash patterns.)
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CA-15E Self-diagnosis warning indicator and warning light flash patterns Warning indicator and warning · · · light flash continuously in this 0.75 s pattern. 0.25 s Warning indicator and warning · · · light flash continuously in this 0.25 s pattern.
If the carburetor settings are not appropriate for the operating conditions, detonations may occur. If the “D.C.S.” indicator light flashes continuously, it is recommended to consult a Yamaha dealer. CA-16E “D.C.S.” indicator light flash patterns Light flashes continuously in this ·...
ESU00031 Engine stop switch The engine stop switch 1 is used to stop the engine in an emergency. Simply push 2 the stop switch to stop the engine. To start the engine, pull 3 the stop switch and proceed with starting the engine. (See page 7-1 for more details.) During the first few rides, practice using the stop switch so that you can react quickly in an emergency.
ESU00035 Parking brake lever When parking the snowmobile or starting the engine, apply the parking brake by moving the brake lever 1 to the left. To release the parking brake, move the parking brake lever 1 to the right. È To apply the parking brake É...
ESU00481 Shroud latches To open the shroud, unhook the shroud latches, and then slowly raise the shroud forward until it stops. When clos- ing the shroud, slowly lower it to its home position, and then hook the shroud latches. 1 Shroud latch 2 Shroud CAUTION : Make sure that all cables and wires are in place when...
ESU00053 V-belt holders Keep a spare V-belt for emergency use by placing it into the V-belt holders provided. CAUTION : Make sure that the V-belt is installed securely in the holders. ESU00056 Spark plug holders Keep spare spark plugs for emergency use by placing them into the spark plug holders provided.
ESU00072 P RE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the snowmobile is used. WARNING The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair.
Consult a Yamaha dealer. Gasohol contain- ing methanol is not recommended. Make sure that snow or ice does not enter the fuel tank when refueling. Do not use alcohol deicers or water absorbing additives with oxygenated fuel. The fuel tank should be filled with straight gaso- line as specified.
The T.O.R.S. will operate and the engine should run between 2,800 and 3,000 r/min. WARNING If the engine does not run between 2,800 and 3,000 r/min, stop the engine by turning the main switch to the “OFF” position and consult a Yamaha dealer.
Do not operate the snowmobile if you find any problems in the brake system. You could lose braking ability, which could lead to an accident. Ask a Yamaha dealer to inspect and repair the brake system. CAUTION : Make sure that the brake lever end does not project out over the handlebar end.
Apply the brake for a few minutes. Check to see if any brake fluid leaks out from the brake hose joints or the master cylinder. WARNING If brake fluid leakage is found, ask a Yamaha dealer for immediate repairs. CAUTION : Brake fluid may deteriorate painted surfaces or plas- tic parts.
ESU00097 Drive track Check the drive track for deflection, wear, or damage. Adjust or replace if necessary. (See pages 8-22–8-24 for more details.) WARNING Do not operate the snowmobile if you find damage to the drive track, or if it has been maladjusted. Drive track damage or failure could result in loss of brak- ing ability and snowmobile control, which could cause an accident.
Check the handlebar for excessive free play: 1. Push the handlebar up and down and back and forth. 2. Turn the handlebar slightly to the right and left. If excessive free play is noticed, consult a Yamaha dealer. ESU00105 Lights Check the lights.
The air filter element can be removed when the ambi- ent temperature is 5 °C (41.5 °F) or higher. Before removing the air filter element, consult a Yamaha dealer. ESU00110 Fittings and fasteners Check the tightness of the fittings and fasteners.
ESU01111 Tool kit and recommended equipment It is good practice to carry the tool kit, spare parts, and other necessary equipment with you while riding the snowmobile so that minor repairs can be done if neces- sary. The following should be carried at all times: Tool kit Flashlight Roll of plastic tape...
ESU00112 O PERATION ESU01170 Starting the engine WARNING Be sure to check the “SAFETY INFORMATION” section carefully before starting the engine. Make sure that the parking brake is applied. NOTE: Make sure that the engine stop switch is in the on posi- tion.
ESU01240 Emergency engine starting If the recoil starter system should fail, take the emer- gency starter rope and the screwdriver handle out of the tool kit and proceed as follows. NOTE: The emergency starter rope and a screwdriver handle are supplied in the tool kit at the factory. 1.
Also avoid lugging the engine, such as laborious opera- tion in wet snow. If any abnormal condition is noticed, such as excessive vibration or noise, consult a Yamaha dealer. NOTE: To ensure proper engine break-in, use a 50:1 gasoline/oil mixture when filling the fuel tank of a new snowmobile for the first time.
totally familiar with the snowmobile’s han- ESU01272 Riding your snowmobile dling and performance characteristics. Getting to know your snowmobile Set the parking brake and follow the A snowmobile is a rider active vehicle, and instructions on page 7-1 to start the your riding position and your balance are engine.
Turning Riding uphill For most snow surfaces, “body English” is You should practice first on gentle slopes. the key to turning. Try more difficult climbs only after you have As you approach a curve, slow down and developed your skill. As you approach a begin to turn the handlebar in the desired hill, accelerate before you start the climb, direction.
Riding downhill downhill leg on the seat and the foot of your uphill leg on the running board. This position will make it easier for you to shift your body weight as needed. Snow and ice are slippery, so be prepared for the possibility that your snowmobile could begin to slip sideways on the slope.
Hard-packed snow WARNING It can be more difficult to negotiate on Drive track damage or failure could hard-packed snow as both the skis and result in loss of braking ability and drive track do not have as much traction as snowmobile control, which could cause when the snowmobile is operated on fresh an accident.
Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible dam- age, consult your stud manufacturer for installation and stud pattern recommendations. Yamaha does not recommend track studding.
ESU00245 Strap The strap 1 should be used only by experienced opera- tors to assist them when traverse (side-hill) riding. WARNING Improper use of the strap on the handlebar can result in severe injury or death. Use the strap only as an operator grip point when needed to shift weight uphill to maintain balance during traverse (side-hill) riding.
ESU01360 Stopping the engine Turn the main switch to the “OFF” position to stop the engine. 1 “OFF” WARNING Push down the engine stop switch to stop the engine in an emergency. Make sure that the key is removed from the main switch whenever the operator leaves the snow- mobile, to prevent accidental starting.
Engine stop switch 5-11 ∗ Repair if necessary. Throttle override Check operation. 5-2–5-3, ∗ Repair if necessary. system (T.O.R.S.) Check operation. Throttle lever 5-2, 6-3 ∗ Repair if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer.
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∗ Replace if necessary. Check operation. Steering system ∗ Adjust toe-out if necessary. Check for damage. Strap ∗ Replace if necessary. Check operation. Lights 6-7, 8-26 Replace bulbs if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer.
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Tool kit and recom- Check for proper placement. mended equipment ∗ It is recommended that these items be serviced by a Yamaha dealer. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid.
NOTE: If you do not have a torque wrench available during a service operation requiring one, take your snowmobile to a Yamaha dealer to check the torque settings and adjust them if necessary. ESU01442 Checking the spark plug The spark plug is an important engine component and is easy to inspect.
20 Nm (2.0 m·kgf, 14 ft·lb) ESU03701 Adjusting the engine idling speed CAUTION : Be sure to have a Yamaha dealer make this adjustment. Make sure that the throttle lever moves smoothly. Make sure that the carburetor is synchronized first.
ESU01472 Adjusting the throttle cable CAUTION : Be sure to adjust the engine idle speed first. 1. Loosen the locknut. 2. Turn the adjuster in or out until the proper throttle lever free play is achieved. Throttle lever free play a: 1.0–2.0 mm (0.04–0.08 in) 1 Locknut 2 Adjuster...
Under some operating conditions, the carburetor settings may have to be changed due to air temperature changes, elevation changes, use of oxygenated fuels (gasohol), etc. These settings should be made by a Yamaha dealer. CAUTION : The drive chain gears and V-belt clutch should be adjusted when operating at altitudes above 900 m (3,000 ft).
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Adjusting a jet needle Adjust the jet needle by changing its clip position accord- ing to the setting chart which is available at a Yamaha dealer. Standard jet needle clip 1 position: 3rd groove from upper end CD-03E Clip position...
Yamaha Power Valve System (Y.P.V.S.) The Y.P .V.S. is a vital part of the engine and requires very sophisticated adjustment. Adjustment should be left to a Yamaha dealer who has the professional knowledge, specialized data and equip- ment to do so properly.
If you plan to operate your snowmobile at an altitude different from the area where you bought it, be sure to consult a Yamaha dealer. They can tell you if there are any changes necessary for the altitude where you plan to ride.
The cooling system must be bled of air if the coolant reservoir becomes empty, if air can be seen in the cooling system, or if there is a cooling system leak. Consult a Yamaha dealer. CAUTION : Operating the engine with an improperly bled cool- ing system can cause overheating and severe engine damage.
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3. Fill the coolant reservoir with coolant until it reaches the “COLD LEVEL” mark. 4. Install the coolant reservoir cap. Check for any cool- ant leakage. NOTE: If you find any leaks, consult a Yamaha dealer. 8-12...
Adjust the V-belt position by removing or adding a spacer 1 on each adjusting bolt. Have a Yamaha dealer make this adjustment. CAUTION : As the V-belt wears, adjustment may be necessary. To ensure proper clutch performance, the V-belt...
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3. Pull 3 the V-belt up over the secondary fixed sheave. 4. Remove the V-belt from the secondary sheave assembly and primary sheave assembly. 5. Put the new V-belt back on the secondary sheave assembly only. Do not force the V-belt between the sheaves;...
8. Install the V-belt over the primary sheave assembly. 9. Rotate the secondary sliding sheave clockwise 6 and push 7 it so that it separates from the secondary fixed sheave. 10. Install the V-belt 8 between the secondary sliding and secondary fixed sheaves. 11.
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3. Pull up the dipstick and check that the oil is between the upper and lower levels. If not, add oil to the upper level. 2 Upper level 3 Lower level Drive chain oil: GL-3 75W or 80W È For models without reverse transmissions (SXV70M) É...
ESU00174 Checking the brake pads Check the brake pads for wear. If the brake pads reach the wear limit, ask a Yamaha dealer to replace them. 1 Brake pad wear indicator Wear limit a: 1.5 mm (0.06 in) ESU00179 Checking the parking brake pads Check the parking brake pads for wear by measuring the thickness of the pads.
Water will significantly lower the boiling point of the fluid and may result in vapor lock. If the brake fluid level goes down, consult a Yamaha dealer. CAUTION : Brake fluid may deteriorate painted surfaces or plas- tic parts.
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Do not deform or damage the shock absorber in any way. Do not dispose of a worn or damaged shock absorber by yourself. Take the unit to a Yamaha dealer. 8-19...
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The spring preload can be adjusted by turning the spring preload adjuster 3 on the front and rear shock absorb- ers. WARNING Be sure to have a Yamaha dealer make this adjust- ment. CD-13E Spring adjuster position Preload...
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ESU04221 Adjusting the control rods The weight transfer can be adjusted by turning the con- trol rod adjusting nut 1. 1. Loosen the locknut 2 while holding the control rod adjusting nut. 2. Turn the adjusting nut in direction a to increase weight transfer or direction b to decrease weight transfer.
ESU03532 Adjusting the drive track WARNING A broken track, track fittings or debris thrown by the drive track could be dangerous to an operator or bystanders. Observe the following precautions: Do not allow anyone to stand behind the snow- mobile when the engine is running. When the rear of the snowmobile is raised to allow the drive track to spin, a suitable stand must be used to support the rear of the snowmo-...
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Adjusting the drive track WARNING Be sure to have a Yamaha dealer make this adjustment. Support the snowmobile securely on a suitable stand before working underneath the snowmo- bile. Operate the engine in a well-ventilated area. 1. Lift the rear of the snowmobile onto a suitable stand to raise the drive track off the ground.
2. Check the following for ski alignment: a. Skis are facing forward. b. Ski toe-out (1 – 2) is within specification. Ski toe-out (1 – 2): 0–15 mm (0–0.59 in) 3. If the alignment is not correct, consult a Yamaha dealer. 8-24...
ESU02760 Lubrication Lubricate the following points. Lubricant: Low-temperature grease 1 Throttle cable end WARNING Apply a dab of grease onto the cable end only. Do not grease the brake or throttle cable themselves because they could become frozen, which could cause loss of control.
ESU02081 Replacing a headlight bulb 1. Lift up the shroud. 2. Disconnect the headlight connector. 3. Remove the bulb holder cover. 4. Remove the bulb holder by depressing and turning it counterclockwise. 1 Bulb holder cover 5. Remove the bulb. WARNING Keep flammable products or your hands away from the hot bulb until it cools down.
Spark plugs are dirty with carbon or are wet ... Remove carbon or wipe the spark plugs dry; replace if necessary. Faulty ignition system ... Ask a Yamaha dealer to inspect. T.O.R.S. system malfunction ... Discon- nect the carburetor switch connectors...
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2. Incorrect V-belt clutch offset ... Ask a times with the ignition off to expel Yamaha dealer to inspect. excess fuel. Ask a Yamaha dealer to 3. Loose or broken engine mount ... Ask a inspect. Yamaha dealer to inspect.
In areas where oxygenated fuel (gaso- hol) is used, completely drain the fuel 8. Storage system. Ask a Yamaha dealer if further Store the snowmobile in a dry, well-venti- information is needed. lated place out of direct sunlight. Put a fab- ric cover over the snowmobile, preferably 4.
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For peak performance, it is recommended that you have your snowmobile checked and tuned by a Yamaha dealer. They have the experience and training to help you get the maximum performance and use of your Yamaha snowmobile.