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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.
CORPORATION, U.S.A. Drive guard ........5-12 SNOWMOBILE LIMITED Carburetor coolant shut-off lever ...5-12 WARRANTY ........1-1 Louvers..........5-13 V-belt holders ........5-13 Storage areas ........5-13 YAMAHA EXTENDED SERVICE (Y.E.S.) ..........1-4 PRE-OPERATION CHECKS....6-1 Fuel ..........6-1 LOCATION OF THE IMPORTANT Engine oil.........6-2 LABELS..........2-1 Engine oil level ........6-3 Coolant ..........6-4...
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Ice or icy surface ......7-5 STORAGE ........10-1 Hard-packed snow......7-6 Operation on surfaces other than SPECIFICATIONS......11-1 snow or ice ........7-6 Dimensions........11-1 Maximizing drive track life ....7-7 Engine ...........11-1 Strap ..........7-8 Chassis..........11-2 Driving ..........7-9 Electric...........11-3 Stopping the engine.......7-10 Transporting ........7-11 WIRING DIAGRAM ......12-1 PERIODIC MAINTENANCE ....8-1 Periodic maintenance chart for the emission control system ....8-1...
WARRANTY PERIOD: WARRANTY TRANSFER: To transfer any remain- 1. All Yamaha snowmobiles shall be warranted for a ing warranty from the original purchaser to any subse- term of one (1) year from the date of purchase, plus quent purchaser, it is imperative that the machine be a special early-season extension (if applicable).
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Post Office Box 6555 specified in the Owner’s Manual? Cypress, California 90630 A. No. The warranty on a new Yamaha cannot be “voided” or “canceled.” However, if a particular failure is caused by operation or maintenance other than as shown in the Owner’s Manual, that failure may not be...
If the dealer is not able to do so, he is expected to contact Yamaha Motor If you should move after you have purchased your new Corporation, U.S.A., for clarification or assistance.
ESU00070 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. 8DM-77761-E0 8FN-77761-E0...
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4AA-22259-60 CAUTION ATTENTION Severe engine damage Des dommages graves risquent de survenir par can result from oil loss if suite de fuites d’huile résultant d’un mauvais crankcase breather hoses branchement des tuyaux de reniflard du carter. are not installed correctly. Après l’entretien de la batterie ou après la Inspect hoses and clamps dépose de l’épurateur d’air, assurez-...
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. Handle fuel with care; it is HIGHLY FLAMMABLE. Never add fuel when the engine is running or hot. Allow the engine to cool for several minutes after running. Use an approved fuel container. Fill the fuel tank outdoors with extreme care. Never remove the fuel cap indoors.
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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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C Side mirror D Tail/brake lights E Snow flap F Brake lever G Parking brake lever H Grip warmer adjustment switch I Headlight beam switch J Strap K Engine stop switch L Thumb warmer adjustment switch M Throttle lever N Shift lever O Shroud latch P Main switch Q Auxiliary DC jack...
ESU00013 C ONTROL FUNCTIONS ESU00362 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. 3 “START” The starting circuit is switched on.
ESU00201 Starter lever (choke) Use the starter lever (choke) when starting and warming up a cold engine. 1 Starter lever (choke) 2 When starting a cold engine. 3 Warming up 4 When the engine is warm. NOTE: Refer the “Starting the engine” section for proper opera- tion.
ESU04151 Throttle override system (T.O.R.S.) If the carburetor or throttle cable should malfunction dur- ing operation, the T.O.R.S. will operate when the throttle lever is released. The T.O.R.S. is designed to interrupt the ignition and keep the engine speed between 2,800 and 3,000 r/min if the carburetor fails to return to idle when the lever is released.
ESU04160 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 fuel meter (which shows the fuel remaining in the...
ESU03824 Fuel meter and grip/thumb warmer level indicator 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. Fuel meter As the fuel level decreases in the fuel tank, the segments disappear until the level goes down to the last segment...
The fuel level warning indicator 1, warning light 2, and all segments of the fuel meter 3 warn the rider of the above problems by flashing continuously. When this occurs, have a Yamaha dealer inspect the snowmobile as soon as possible. ESU00377...
If the self-diagnosis warning indicator, warning light, and an error code flash after the engine has been restarted, note the error code, and then have a Yamaha dealer inspect the snowmobile as soon as possible.
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...
ESU00039 Headlight beam switch Push the headlight beam switch to change the headlight beam to high or low. 1 Headlight beam switch 2 Push 3 High beam 4 Low beam ESU04301 Auxiliary DC jack The auxiliary DC jack is located in the front panel and can be used for accessories.
ESU04290 Passenger grip warmer switch The passenger grip warmer switch controls the electri- cally heated passenger grips. 1 Passenger grip warmer switch 2 Off 3 “HI” High 4 “LO” Low ESU00481 Shroud latches To open the shroud, unhook the shroud latches, and then slowly raise the shroud forward until it stops.
ESU00521 Drive guard The drive guard is designed to cover the V-belt clutch and V-belt in case parts break or come loose. WARNING Make sure that the drive guard is tightened securely before operating the snowmobile. Never run the engine with the V-belt or drive guard removed.
5 °C (41.5 °F) or higher, the steel plates can be removed as needed by removing the screws. Before removing the steel plates, consult a Yamaha dealer. 1 Steel plate 2 Screws ESU00053...
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CAUTION : Do not place sharp items in the storage compart- ment. Fuel could leak if the fuel tank is damaged. The bottom of the storage compartment may be hot during or immediately after operating the snowmobile. It can cause burns if it becomes extremely hot.
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To remove the passenger seat and backrest 1. Open the rider seat. (See “Storage compartment” for details.) 2. Remove the passenger seat bolts, slide the passen- ger seat and backrest slightly rearward, and then lift them straight up to remove them. 3.
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.
5% of ethanol can be used, although richer jetting may be required to prevent engine dam- age. 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.
ESU03441 Engine oil level The engine oil level should be checked before each use. CAUTION : Do not run the engine with too much or not enough oil in the oil tank. Oil could flow into the air filter case and the engine could be damaged.
6. Insert the oil level gauge/dipstick into the oil filler hole, and then tighten it securely. 7. Connect the oil level gauge coupler. ESU04900 Coolant Check the coolant level in the coolant reservoir when the engine is cold. If the coolant level is below the “LOW” mark, remove the coolant reservoir cap and add soft water until it reaches the “FULL”...
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 8-23–8-25 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. ESU01050 Lights Check the lights.
ESU03502 Air filter Always check that there is no snow under the air filter element frame. 1. Unhook the air filter case cover fasteners and the latch. 2. Remove the air filter case cover. 3. Lift up the air filter element frame and check the air filter element.
ESU00345 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 ESU00366 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.
CAUTION : After 800 km (500 mi) of operation, the engine oil must be changed and the oil filter cartridge replaced. If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the snowmobile.
totally familiar with the snowmobile’s han- ESU01272 Riding your snowmobile dling and performance characteristics. Set the parking brake and follow the Getting to know your snowmobile instructions on pages 7-1–7-2 to start the A snowmobile is a rider active vehicle, and 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.
ESU02450 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.
ESU04360 Driving WARNING Be sure to read the “SAFETY INFORMATION” and “Riding your snowmobile” sections carefully before operating the snowmobile. NOTE: Make sure that the engine is warmed up enough before riding. 1. To select the desired operating position, pull the shift lever out, slide it to “FWD”...
2. Release the parking brake by moving the parking brake lever to the right. 3. Press the throttle lever slowly to move the snowmo- bile. 4. Turn the handlebar in the desired direction. 5. Squeeze the brake lever to stop the snowmobile. 6.
ESU00367 Transporting When transporting your snowmobile on a trailer or in a truck, observe the following recommendations to help protect it from damage: Make sure that the fuel level in the fuel tank is lower than the bottom of the carburetors. Otherwise, the vibration and bumps from the road surface could make it possible for fuel to flow through the carbure- tors into the cylinders.
(if applicable). WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you. PROPER PERIODIC MAINTENANCE OF YOUR SNOWMOBILE IS IMPORTANT IN ORDER TO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL.
Adjust the jets. (elevation/temperature) is changed. Check for leakage. ∗ Exhaust system Tighten or replace gasket if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer. ESU04980 General maintenance and lubrication chart CD-32E Every Initial...
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∗ Adjust toe-out if necessary. Check for damage. Strap ∗ Replace if necessary. Check operation. 6-9, Lights Replace bulbs if necessary. 8-28–8-29 Check condition. ∗ Battery 8-30–8-31 Charge 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. 6-11 mended equipment ∗ It is recommended that these items be serviced by a Yamaha dealer. NOTE: Brake system: After disassembling the master cylinder or caliper cylinder, always change the brake fluid. Regularly check the brake fluid level and add fluid if necessary.
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. ESU03681 Checking the spark plugs The spark plug is an important engine component and is easy to inspect.
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Spark plugs are produced in several different thread lengths. The thread length or reach is the distance from the spark plug gasket seat to the end of the threaded portion. If the reach is too long, overheating and engine damage may result. If the reach is too short, spark plug fouling and poor performance may result.
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. 1. Start the engine and warm it up.
The carburetors are an important part of the engine and its emission control system, which require very sophisti- cated adjustment. Therefore, carburetor adjustments should be left to a Yamaha dealer, who has the neces- sary professional knowledge and experience. ESU01571...
The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the peri- odic maintenance chart. ESU04201...
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7. Remove the oil filter cartridge 9 with an oil filter wrench. NOTE: An oil filter wrench is available at a Yamaha dealer. 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
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If oil is leaking or the oil level warning indicator comes on when the engine is running, immediately turn the engine off and have a Yamaha dealer check the snowmobile. Continuing to operate the engine under such conditions could cause severe engine damage.
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. 1 Radiator cap CAUTION :...
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3. Fill the coolant reservoir with coolant until it reaches the “FULL” mark. 4. Install the coolant reservoir cap. Check for any cool- ant leakage. NOTE: If you find any leaks, consult a Yamaha dealer. 8-13...
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. Remove the dipstick and check that the oil is between the maximum and minimum level marks. If the oil is below the minimum level mark, add sufficient oil to raise it to the maximum level mark. 2 Maximum level mark 3 Minimum level mark Drive chain oil: GL-3 75W or 80W...
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) ESU00352 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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ESU03042 Adjusting the ski spring preload The spring preload can be adjusted by turning the spring preload adjuster 1. CD-10E Spring adjuster position 2 Hard Soft 3 Preload Standard CAUTION : The left and right ski spring preload must be set to the same setting.
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Preload Soft Hard É Standard (rear) WARNING Be sure to have a Yamaha dealer make this adjust- ment. This shock absorber contains highly pressurized nitrogen gas. It could explode by improper handling, causing injury, or property damage. Do not tamper with or attempt to open the shock absorber.
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Adjusting the rear suspension full rate The total suspension spring rate and damping character- istics can be adjusted by changing the installed position of the shock absorber. WARNING Be sure to have a Yamaha dealer make this adjust- ment. CD-07E Installation position Spring rate and...
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. ESU03543 Adjusting the handlebar 1.
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3. Move the handlebar up or down to adjust the handle- bar height to the desired position. CAUTION : Make sure that the projection on the handlebar is not installed into the area a shown. 4. Tighten the handlebar bolts and install the handlebar cover.
Apply a dab of grease onto the cable end only. Do not grease the throttle cable because it could become frozen, which could cause loss of control. 2 Front suspension 3 Rear suspension WARNING Be sure to have a Yamaha dealer lubricate the front and rear suspensions. 8-27...
ESU02082 Replacing a headlight bulb 1. Lift up the shroud. 2. Disconnect the headlight coupler. 3. Remove the bulb holder cover. 4. Unhook the bulb holder by pushing it in, then upward. 1 Bulb holder cover 2 Bulb holder 5. Remove the bulb. WARNING Keep flammable products and your hands away from the hot bulb until it has cooled down.
ESU04920 Adjusting the headlight beams 1. Lift up the shroud. 2. Remove the locking pin from a headlight beam adjuster. 3. Turn the headlight beam adjuster in or out to adjust the headlight beams. 1 Locking pin 2 Headlight beam adjuster Headlight beam movement: a Down and to the left b Up and to the right...
To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the snowmobile is equipped with electrical accessories.
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9. Install the air filter case by reversing the removal steps. CAUTION : Be sure to connect the breather hoses securely when installing the air filter case. NOTE: If the fuse immediately blows again, ask a Yamaha dealer to inspect the snowmobile. 8-31...
Worn or damaged piston and cylinder No fuel in tank ... Supply fuel..Ask a Yamaha dealer to inspect. Clogged fuel line ... Clean fuel line. Clogged carburetor ... Clean carbure- B. Starting the engine with a dis- tor.
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2. Open the shroud. 5. Connect the other end of the red (+) jumper cable to the positive (+) terminal of the booster battery. 6. Connect the black (-) jumper cable to the negative (-) terminal of the booster battery. 7.
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4. Improper fuel flow ... See A.1 above. NOTE: 5. Incorrect V-belt clutch settings for alti- Make sure that both the red (+) lead and tude or conditions ... Ask a Yamaha the black (-) lead are seated securely in the dealer to inspect. lead holders.
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J. Engine does not upshift or down- shift properly or engages harshly 1. Worn or damaged V-belt ... Replace the V-belt or ask a Yamaha dealer to inspect. 2. Incorrect V-belt clutch settings for alti- tude or conditions ... Ask a Yamaha dealer to inspect.
In areas where oxygenated fuel (gaso- WARNING hol) is used, completely drain the fuel Never smoke around the battery system. Consult a Yamaha dealer if further while it is being charged. Sparks information is needed. may ignite the hydrogen gas created by the battery.
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Do not charge the battery quickly. that you have your snowmobile checked Charge the battery for 10 hours at and tuned by a Yamaha dealer. The dealer 1.8 amperes. has the experience and training to help you get the maximum performance and use out 7.
ESU00232 Electric CS-04E VK10 Ignition system Spark plug Type · R · CR8E (NGK) 0.7–0.8 mm (0.028–0.031 in) Battery Capacity YTX20L-BS 12 V 18 A·h Maximum charge rate 1.8 Amperes/hr for 10 hrs Bulb × Quantity 12 V, 60/55 W × 2 Headlight Bulb ×...
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