Yamaha VK10W Supplementary Service Manual
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Yamaha VK10W Supplementary Service Manual

Yamaha VK10W Supplementary Service Manual

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SUPPLEMENTARY SERVICE MANUAL
VK10W
LIT-12618-02-57
8GS-28197-10

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Summary of Contents for Yamaha VK10W

  • Page 1 SUPPLEMENTARY SERVICE MANUAL VK10W LIT-12618-02-57 8GS-28197-10...
  • Page 2 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the VK10W. For complete information, on service procedures, it is necessary to use this Supple- mentary Service Manual together with following manual: RS90K, RS90RK, RSG90K, RS90MK, RST90K, RST90TFK SERVICE MANUAL:...

  • Page 3: How To Use This Manual

    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: Chassis

    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. 1 General information 2 Periodic inspection and adjustment POWR 3 Chassis CHAS 4 Power train 5 Engine 6 Cooling system 7 Carburetion...
  • Page 5 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTION AND INSP ADJUSTMENT CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB – ELECTRICAL ELEC SPECIFICATIONS SPEC...

  • Page 6: Table Of Contents

    GENERAL INFORMATION ENGINE SPECIAL TOOLS ..........1 CAMSHAFTS............. 38 FOR ELECTRICAL SERVICE ......1 INSTALLATION..........38 PERIODIC INSPECTION AND CARBURETION ADJUSTMENT CARBURETORS ..........43 THROTTLE POSITION SENSOR (T.P.S.) INTRODUCTION...........2 INSPECTION AND ADJUSTMENT ..... 44 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM....2 ELECTRICAL GENERAL MAINTENANCE AND LUBRICATION CHART........3...

  • Page 7: 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 improvised techniques. NOTE: •...

  • Page 8: Periodic Inspection And Adjustment

    INTRODUCTION/PERIODIC MAINTENANCE CHART FOR INSP THE EMISSION CONTROL SYSTEM PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer ser- vice life.

  • Page 9: General Maintenance And Lubrication Chart

    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 10 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) Steering column bearing Lubricate with specified grease. Ski and front suspension Lubricate with specified grease.

  • Page 11: Power Train

    INSP DRIVE V-BELT POWER TRAIN DRIVE V-BELT WARNING When installing the new V-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to –0.5 mm (–0.02 in) below the edge a. If the V-belt is not positioned correctly, the clutch engagement speed will be changed.
  • Page 12 INSP DRIVE V-BELT 2. Adjust the position of the V-belt by removing or adding a spacer 1 on each adjusting bolt 2. V-belt position Adjustment More than 1.5 mm (0.06 in) above the Remove a spacer edge From 1.5 mm (0.06 in) above the edge to Not necessary –0.5 mm (–0.02 in)

  • Page 13: Brake Pad Inspection

    DRIVE V-BELT/BRAKE PAD INSPECTION/ INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 6. Measure: • Drive V-belt circumference a Out of specification → Replace. V-belt circumference: 1,132 ~ 1,138 mm (44.6 ~ 44.8 in) BRAKE PAD INSPECTION 1. Apply the brake lever. 2.

  • Page 14: Drive Chain

    AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP DRIVE CHAIN i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the fluid. j. Tighten the bleed screws. Bleed screw: 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours.
  • Page 15 INSP DRIVE CHAIN Checking steps: • Remove the rubber cap 1. • Check the oil level through the check window 2 located on the drive chain housing. • If the oil is below the minimum level mark a, remove the dipstick 3 and add sufficient oil to the maximum level mark b.
  • Page 16 INSP DRIVE CHAIN Oil replacement Oil replacement steps: • Place the oil pan under the drain hole. • Remove the oil drain bolt (along with the gas- ket) 1 and drain the oil. CAUTION: Be sure to remove any oil from the heat protec- tor.

  • Page 17: Tuning

    INSP CLUTCH TUNING CLUTCH L Blue P Pink High altitude W White Y Yellow Specifications ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È 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 18: Gear Selection

    INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the machine first begins to move from a complete stop.
  • Page 19 INSP GEAR SELECTION 1 Chain and sprocket part number È Parts name É Teeth & links Ê Parts no. Ë Standard 19 teeth 8FA-17682-90 20 teeth 8FA-17682-00 21 teeth 8FA-17682-10 Ì Drive sprocket 22 teeth 8FA-17682-20 23 teeth 8FA-17682-30 24 teeth 8FA-17682-40 38 teeth 8FB-47587-80...
  • Page 20 INSP GEAR SELECTION 4 Secondary spring twist angle È Seat É Sheave 10° 40° 70° 100° 20° 50° 80° 110° 30° 60° 90° 120° 5 Torque cam (secondary spring seat) É Effects Ê Part no. Ë Cam angle Ì Identification mark Í...
  • Page 21 INSP GEAR SELECTION 6 Primary spring Ì Spring rate Ð Outside Í Preload Ï Wire gauge Ò Free length Ë Parts No. Î Color Ñ No. of coils Ó Standard N/mm diameter N (kg) mm (in) mm (in) (kg/mm) mm (in) 90501-550A2 19.6 (2.00) 196 (20)
  • Page 22 INSP GEAR SELECTION 7 Clutch weight É Weight g (oz) È Parts No. Ê Shape & ID mark Ë Standard without bush and rivets 8BU-17605-20 45.41 (1.603) 8CH-17605-10 35.32 (1.246) 8DG-17605-00 34.26 (1.208) 8DJ-17605-00 37.77 (1.332) 8DN-17605-10 39.76 (1.402) 8ES-17605-00 54.63 (1.928) 8FA-17605-10 63.81 (2.251)
  • Page 23 INSP GEAR SELECTION 8 Weight rivets Ê Length Ë Weight È Parts No. É Material Ì Standard Í Effects mm (in) g (oz) √ (OUT) Î Increased force 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) 90261-06034 Steel 13.9 (0.547) 3.6 (0.127) √...

  • Page 24: 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 • Carburetors • Spark plugs Adjust the main jet size according to the chart Test the main jet Adjust the size of the main jet Not OK...

  • Page 25: Power Train

    POWR SHIFT LEVER POWER TRAIN SHIFT LEVER È: kg, 7.2 ft 10 Nm (1.0 m • • É: É 23 Nm (2.3 m kg, 17 ft • • É È É Q’ty Remarks Order Job name/Part name Shift lever assembly removal Remove the parts in the order listed below.
  • Page 26 POWR SHIFT LEVER È: kg, 17 ft 23 Nm (2.3 m • • É: 59 Nm (5.9 m kg, 43 ft • • È È É Q’ty Remarks Order Job name/Part name Shift lever disassembly Remove the parts in the order listed below. Shift lever stay Circlip Bearing...

  • Page 27: Installation

    POWR SHIFT LEVER INSTALLATION 1. Install: • Shift lever 1 • Shift lever stopper 2 • Shift guide 3 • Shift lever pin 4 • Spring Installation steps: • Install the shift lever 1 onto the shift lever stop- per 2. •...

  • Page 28: Drive Chain Housing

    POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING Ï: È: Ì: kg, 4.3 ft kg, 13 ft kg, 31 ft 6 Nm (0.6 m 18 Nm (1.8 m 43 Nm (4.3 m • • • • • • Ð: É: Í: kg, 7.2 ft kg, 14 ft 55 Nm (5.5 m...
  • Page 29 POWR DRIVE CHAIN HOUSING È: Ì: Ï: kg, 4.3 ft kg, 13 ft kg, 31 ft 6 Nm (0.6 m 18 Nm (1.8 m 43 Nm (4.3 m • • • • • • Ð: É: Í: kg, 7.2 ft kg, 14 ft kg, 40 ft 10 Nm (1.0 m...
  • Page 30 POWR DRIVE CHAIN HOUSING È: Ì: Ï: kg, 4.3 ft kg, 13 ft kg, 31 ft 6 Nm (0.6 m 18 Nm (1.8 m 43 Nm (4.3 m • • • • • • Ð: É: Í: kg, 7.2 ft kg, 14 ft kg, 40 ft 10 Nm (1.0 m...

  • Page 31: Removal

    POWR DRIVE CHAIN HOUSING REMOVAL 1. Remove: • Driven gear 1 NOTE: While holding the front axle assembly with spanner wrench 2, loosen the reverse driven gear bolt. INSPECTION 1. Inspect: • Drive chain housing • Drive chain housing cover Cracks/damage →...
  • Page 32 POWR DRIVE CHAIN HOUSING 2. Inspect: • Drive sprocket • Driven sprocket • Driven gear • Reverse drive gear • Counter gear • Low pinion gear • Low wheel gear • Low drive gear • Journal • Chain tensioner Pitting/wear/damage → Replace. •...

  • Page 33: Installation

    POWR DRIVE CHAIN HOUSING 5. Measure: • Brake disc thickness a Measure the brake disc thickness 1 ~ 3 mm (0.04 ~ 0.12 in) from the edge of the brake disc. Out of specification → Replace. Minimum thickness: 3.5 mm (0.14 in) INSTALLATION 1.
  • Page 34 POWR DRIVE CHAIN HOUSING Ó 0 ~ 1 mm (0 ~ 0.039 in) 3. Install: • Shift rod lock washer 1 NOTE: Bend a lock washer tab along a flat side of the bolt. 4. Adjust: • Shift rod length a Adjustment steps: •...

  • Page 35: Secondary Shaft

    POWR SECONDARY SHAFT SECONDARY SHAFT SECONDARY SHAFT AND DRIVE CHAIN HOUSING INSTALLATION 1. Install: • Secondary shaft È • Drive chain housing Installation steps: • Install the secondary shaft. • Tighten the bolt. Secondary shaft bolt: 30 Nm (3.0 m · kg, 22 ft · lb) •...
  • Page 36 POWR SECONDARY SHAFT 2. Measure: • Brake disc clearance a Out of the specification → Adjust. Brake disc clearance: 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) 3. Adjust: • Brake disc clearance Adjustment steps: • Remove the circlip 8. •...

  • Page 37: Brake

    POWR BRAKE BRAKE È: kg, 4.3 ft 6 Nm (0.6 m • • É: kg, 13 ft 18 Nm (1.8 m • • Ê: kg, 35 ft 48 Nm (4.8 m • • È Ê È É Q’ty Remarks Order Job name/Part name Brake pad removal Remove the parts in the order listed below.

  • Page 38: Brake Pad Replacement

    POWR BRAKE CAUTION: Disc brake components rarely require disas- sembly. DO NOT: • Do not disassemble components unless absolutely necessary. • Do not use solvents on internal brake compo- nents. • Do not use contaminated brake fluid for cleaning. • Use only clean brake fluid. •...
  • Page 39 POWR BRAKE 2. Install: • Brake pads • Pad spring Installation steps: • Connect a suitable hoses 1 tightly to the cali- per bleed screws 2. Put the other end of this hose into an open container. • Loosen the caliper bleed screws and push the pistons into the caliper with your finger.
  • Page 40 POWR BRAKE Q’ty Remarks Order Job name/Part name Brake caliper and parking brake Remove the parts in the order listed below. removal Brake fluid Drain. Brake hose Brake caliper assembly Parking brake cable Spring Parking brake assembly Collar For installation, reverse the removal proce- dure.
  • Page 41 POWR BRAKE È: 6 Nm (0.6 m kg, 4.3 ft • • É: 18 Nm (1.8 m kg, 13 ft • • È È É Q’ty Remarks Order Job name/Part name Brake caliper disassembly Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring...

  • Page 42: 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: • Pistons • Piston seals 1 Removal steps: • Using a wood of piece 2, lock the right piston. •...

  • Page 43: Front Axle And Track

    POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK 103.5 mm 121.5 mm 121.5 mm 103.5 mm (4.07 in) (4.78 in) (4.78 in) (4.07 in) INSTALLATION 1. Install: • Sprocket wheels • Guide wheels NOTE: • When pressing the sprocket wheels onto the front 32.5 mm 42 mm 58.5 mm...

  • Page 44: Engine

    CAMSHAFTS ENGINE CAMSHAFTS INSTALLATION 1. Install: • Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2 (with the special tool 3) Rotor holding tool: 90890-01235, YU-01235 • Camshaft sprocket bolts Camshaft sprocket bolt: 24 Nm (2.4 m · kg, 17 ft · lb) NOTE: Make sure that the holes a in the cylinder #3 cam and marks b and c on the camshaft sprockets are...
  • Page 45 CAMSHAFTS 2. Install: • Exhaust camshaft 1 • Intake camshaft 2 (with the camshaft sprockets) Installation steps: • Turn the crankshaft clockwise. • When piston #3 is at TDC on the compression stroke, align the “I” mark a on the A.C. mag- neto rotor with the stationary pointer b on the A.C.
  • Page 46 CAMSHAFTS 3. Install: • Dowel pins • Intake camshaft caps • Exhaust camshaft caps NOTE: • The “I” mark refers to the intake camshaft caps and the “E” mark refers to the exhaust camshaft cap. • Install the camshaft caps with the arrow mark a pointing towards the right side of the engine.
  • Page 47 CAMSHAFTS 5. Install: • Timing chain tensioner Installation steps: • While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clock- wise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise.
  • Page 48 ® • Apply Sealant (Quick Gasket ) or Yamaha bond No. 1215 2 onto the mating surfaces of the cylin- der head cover gasket and cylinder head. • Tighten the cylinder head cover bolts stages and...

  • Page 49: Carburetion

    CARB CARBURETORS CARBURETION CARBURETORS Q’ty Remarks Order Job name/Part name Carburetor separation Remove the parts in the order listed below. Sub-wire harness 3 Carburetor heating hose Fuel delivery hose Float chamber air vent hose Vacuum hose Spring Starter plunger link Connecting bolt Throttle position sensor Carburetor...

  • Page 50: Throttle Position Sensor (T

    CARB CARBURETORS THROTTLE POSITION SENSOR (T.P.S.) INSPECTION AND ADJUSTMENT NOTE: Before adjusting the throttle position sensor, prop- erly adjust the idle speed. 1. Inspect: • Throttle position sensor Inspection steps: • Disconnect the throttle position sensor coupler. • Connect the pocket tester (Ω × 1k) to the throt- tle position sensor coupler.
  • Page 51 CARB CARBURETORS 2. Adjust: • Throttle position sensor angle Adjustment steps: • Disconnect the throttle position sensor coupler. • Connect the test coupler to the throttle position sensor. • Connect three dry cells (1.5 V × 3 pcs.) in series to the test coupler.

  • Page 52: Electrical

    – ELEC SIGNAL SYSTEM ELECTRICAL...

  • Page 53: Circuit Diagram

    – ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 2 A.C. magneto 3 Rectifier/regulator 4 Main switch 5 Load control relay 6 Main fuse 9 Battery I Ignitor unit M Coolant temperature sensor P Frame ground T DC back buzzer U Gear position switch relay V Gear position switch W Brake light switch X Tail/brake light...

  • Page 54: Troubleshooting

    – ELEC SIGNAL SYSTEM TROUBLESHOOTING BACK BUZZER DOES NOT SOUND. Check the signal fuse. FAULTY Replace the signal fuse. Check the battery. OUT OF SPECIFICATION Replace and/or charge the battery. Check the stator coil. OUT OF SPECIFICATION Replace the stator coil assembly. Check the main switch.

  • Page 55: Gear Position Switch

    – ELEC SIGNAL SYSTEM GEAR POSITION SWITCH 1. Check: • Gear position switch 1 continuity Faulty → Replace. – Shift lever position Continuity DRIVE (D) or LOW (L) REVERSE GEAR POSITION SWITCH RELAY 1. Inspect: • Gear position switch relay 1 Inspection steps: •...

  • Page 56: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model VK10W Model code number: 8GS1 (USA/Canada) 8GS2 (Europe) Dimensions: Overall length 3,270 mm (128.7 in) Overall width 1,200 mm (47.2 in) Overall height 1,380 mm (54.3 in) Weight: Dry weight 360 kg (794 lb)
  • Page 57 SPEC GENERAL SPECIFICATIONS Model VK10W Spark plug: Type NGK R CR8E Manufacture 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Transmission: Primary reduction system V-Belt Primary reduction ratio 3.8 ~ 1 : 1 Clutch type Automatic centrifugal engagement Secondary reduction system...

  • Page 58: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model VK10W Cylinder head: Volume (with spark plug) 22.82 ~ 23.62 cm (1.39 ~ 1.44 cu.in) <Warpage limit> 0.10 mm (0.0039 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating Bore size 79.000 ~ 79.010 mm (3.1102 ~ 3.1106 in)
  • Page 59 SPEC MAINTENANCE SPECIFICATIONS Model VK10W Valves, valve seats, valve guides: Valve clearance (cold) Intake 0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) Exhaust 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Valve dimensions Valve head diameter A Intake 29.9 ~ 30.1 mm (1.1771 ~ 1.1850 in) Exhaust 25.9 ~ 26.1 mm (1.0197 ~ 1.0276 in)
  • Page 60 SPEC MAINTENANCE SPECIFICATIONS Model VK10W Valve spring: Free length Intake 39.73 mm (1.56 in) <Limit> 37.74 mm (1.48 in) Exhaust 39.73 mm (1.56 in) <Limit> 37.74 mm (1.48 in) Installed length (valve closed) Intake 33.0 mm (1.30 in) Exhaust 33.0 mm (1.30 in)
  • Page 61 SPEC MAINTENANCE SPECIFICATIONS Model VK10W Piston ring: Sectional sketch Top ring Ring type Barrel Dimensions (B × T) 1.00 × 2.80 mm (0.039 × 0.110 in) 2nd ring Ring type Taper Dimensions (B × T) 1.00 × 2.90 mm (0.039 × 0.114 in) Oil ring Dimensions (B ×...

  • Page 62: Cooling System

    SPEC MAINTENANCE SPECIFICATIONS Model VK10W Carburetor: Type/Quantity CVK40/3 Manufacturer KEIHIN I.D. mark 8ES1 02 Main jet (M.J) #148 Main air jet (M.A.J) Jet needle (J.N) N425-BSJ00 Needle jet (N.J) W9554-26538#6 Pilot jet (P.J) Pilot air jet (P.A.J) #120 Pilot outlet (P.O)

  • Page 63: Power Train

    SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model VK10W Transmission: Type V-belt automatic Range of ratio 3.8 ~ 1.0 : 1 Engagement speed r/min 2,200 ~ 2,600 r/min Shift r/min 8,250 ~ 8,750 r/min Sheave distance 267 ~ 270 mm (10.51 ~ 10.63 in) Sheave offset 13.5 ~ 16.5 mm (0.53 ~ 0.65 in)
  • Page 64 SPEC MAINTENANCE SPECIFICATIONS Model VK10W Hole position Sheave side-spring side (twist angle) 3-3 (60°) Spring rate 12.3 N/mm (1.25 kg/mm, 70.23 lb/in) Number of coils 5.53 Free length 75 mm (2.95 in) Torque cam angle 39° Drive chain: Type Borg Warner Automotive 23RH303-68ASM...
  • Page 65 SPEC MAINTENANCE SPECIFICATIONS Model VK10W Shock absorber: Damping force Front Extension 540 N/0.3 m/s (55.1 kg/0.3 m/s, 121.4 lb/0.3 m/s) Compression 1,130 N/0.3 m/s (115.2 kg/0.3 m/s, 254.0 lb/0.3 m/s) Rear Extension 2,530 N/0.3 m/s (258.0 kg/0.3 m/s, 568.7 lb/0.3 m/s) Compression 690 N/0.3 m/s (70.4 kg/0.3 m/s, 155.1 lb/0.3 m/s)

  • Page 66: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model VK10W Frame: Frame material Monocoque (Aluminum & Steel) Seat height 716 mm (28.2 in) Luggage box location Under seat Steering: Lock-to-lock angle (left) 29.7° (R ski) 34.4° (L ski) (right) 34.4° (R ski) 29.7° (L ski)

  • Page 67: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model VK10W Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5° at 1,400 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T558/MITSUBISHI Ignition spark gap 6.0 mm (0.24 in) 1.19 ~ 1.61 Ω at 20 °C (68 °F)
  • Page 68 SPEC MAINTENANCE SPECIFICATIONS Model VK10W T.P.S. (throttle position sensor): Manufacturer KEIHIN Resistance 4 ~ 6 kΩ at 20 °C (68 °F) (Blue – Black) 0 ~ 4 kΩ at 20 °C (68 °F) (Yellow – Black) Oil level switch: Model/Manufacturer...
  • Page 69 SPEC MAINTENANCE SPECIFICATIONS Model VK10W Speed sensor: Model/Manufacture 8EK/NIPPON SEIKI Carburetor heater: Model/Manufacture 5FU/NIPPON THERMOSTAT Wattage 30 W 6 ~ 10 Ω at 20 °C (68 °F) Resistance...

  • Page 70: High Altitude Settings

    SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS Temperature –30 °C –10 °C 10 °C (–22 °F) (–14 °F) (50 °F) Altitude Idling speed (r/min) 0 ~ 200 m #150 #148 #148 1,400 (0 ~ 700 ft) 200 ~ 1,500 m #148 #148 #145 1,400...
  • Page 71 SPEC MAINTENANCE SPECIFICATIONS...

  • Page 72: Tightening Torque

    SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m · kg ft · lb Spark plug Cylinder head bolt (M10 × 1.25) See NOTE. Cylinder head bolt Camshaft cap and cylinder head Apply the engine oil. Cylinder head cover Camshaft and camshaft sprocket Timing chain tensioner...
  • Page 73 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Primary sheave drive shaft assembly bolt Connecting rod and cap See NOTE. Balancer ® Balancer shaft bearing retainer Apply LOCTITE A.C. magneto rotor Apply the engine oil. A.C.

  • Page 74: Power Train

    SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Remarks m · kg ft · lb Primary sheave See NOTE. Spider and sliding sheave Left-hand thread. ® Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) ®...
  • Page 75 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb ® Shaft and sliding frame Apply LOCTITE Shock absorber and front pivot arm Shock absorber and front suspension bracket ® Front pivot arm and sliding frame Apply LOCTITE ®...

  • Page 76: Chassis

    SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Remarks m · kg ft · lb Handlebar holder Steering column 1 (front) Steering column 1 (rear upper) Steering column 1 (rear lower) Steering column 2 (upper) Steering column 2 (lower) Steering column 2 and steering shaft ®...

  • Page 77: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (bolt) This chart specifies torque for standard fasteners m · kg ft · lb with standard I.S.O. pitch threads. Torque specifi- 10 mm 6 mm cations for special components or assemblies are 12 mm 8 mm included in the applicable sections of this book.

  • Page 78: Cable Routing

    SPEC CABLE ROUTING...
  • Page 79 SPEC CABLE ROUTING CABLE ROUTING 1 Positive battery lead 2 Negative battery lead 3 Pass the wire harness (two leads) through the hole in the cover. 4 Wire harness 5 A.C. magneto lead 6 Negative battery lead coupler 7 Positive starter motor lead 8 Fasten the A.C.
  • Page 80 SPEC CABLE ROUTING...
  • Page 81 SPEC CABLE ROUTING Z Starter cable [ Brake hose \ Fuel sender lead coupler ] Fasten the ignition coil lead to the frame cross member with the plastic band, making sure to fas- ten the lead under the fuel hoses and to face the end of the band rearward.
  • Page 82 SPEC CABLE ROUTING...
  • Page 83 SPEC CABLE ROUTING x Pass the carburetor heater lead under the positive starter motor lead. y Be sure to install the positive bat- tery lead terminal so that it is fac- ing rearward.
  • Page 84 SPEC CABLE ROUTING...
  • Page 85 SPEC CABLE ROUTING 1 Headlight sub-wire harness 2 Fasten the headlight sub-wire harness at the white tape with the holder on the shroud. 3 Fasten the headlight sub-wire harness with the holder. 4 Shroud stopper 5 Pass the headlight sub-wire har- ness inside of the shroud stop- per.
  • Page 86 SPEC CABLE ROUTING...
  • Page 87 SPEC CABLE ROUTING 1 Right handlebar switch 2 Handlebar holder 3 Throttle cable 4 Pass all of the leads and cables through the guide, except the parking brake cable. Do not pass the brake hose through the guide. 5 Fasten the wire harness with the plastic band.
  • Page 88 SPEC CABLE ROUTING...
  • Page 89 SPEC CABLE ROUTING Y Pass the wire harness, brake hose, and parking brake cable through the guide. Do not pass the throttle cable and starter cable through the guide. Z Place the end of the plastic band between the frame cross mem- ber and the fuel tank.
  • Page 90 SPEC CABLE ROUTING...
  • Page 91 SPEC CABLE ROUTING 1 Headlight sub-wire harness 2 Oil tank outlet hose 3 Starter motor positive lead 4 Pass the starter motor positive lead behind the engine. 5 Gear position switch lead 6 To the tail/brake light 7 Route the wire harness to the front of the frame cross member bolts, making sure that the har- ness is not on the bolts.
  • Page 92 SPEC CABLE ROUTING...
  • Page 93 SPEC CABLE ROUTING 1 Fuel pumps 2 Face the ends of each clamp outward. 3 Fuel hoses 4 Coolant reservoir 5 Fasten the fuel tank breather hose, speed sensor lead and relay leads with the holder. Secure the frame cross member and the holder to the frame with the nut and bolt.
  • Page 94 SPEC CABLE ROUTING...
  • Page 95 SPEC CABLE ROUTING 1 To the starter motor 2 Starter motor positive lead 3 Negative battery lead 4 Positive battery lead 5 Ignitor unit 6 Ignitor unit bracket 7 Air filter case latch 8 Battery band 9 Battery cover 0 To the carburetor A Wire harness B Battery bracket...
  • Page 96 SPEC CABLE ROUTING...
  • Page 97 SPEC CABLE ROUTING 1 Forward 2 Wire harness 3 Battery bracket 4 To the air filter case 5 A.C. magneto lead 6 Route the crankcase breather hose inside of the wire harness, and then over the starter motor positive lead, and under the bat- tery bracket.
  • Page 98 SPEC CABLE ROUTING...
  • Page 99 SPEC CABLE ROUTING 1 Fasten the passenger grip warmer lead with the plastic band, making sure that the end of the band is on top of the pipe and facing rearward. The plastic band should not be visible when the passenger seat is installed. 2 Route the passenger grip warmer lead along the groove in the storage compartment.
  • Page 100 WIRING DIAGRAM VK10W 2007 8GS-0F001-00 1 Pickup coil COLOR CODE 2 A.C. magneto B ..... Black 3 Rectifier/regulator Br .... Brown 4 Main switch Dg ... Dark green 5 Load control relay G ..... Green 6 Main fuse Gy ... Gray 7 Starter relay L....
  • Page 102 YAMAHA MOTOR CO., LTD. PRINTED IN U.S.A. 2006.07 CR...
  • Page 103 WIRING DIAGRAM VK10W 2007 8GS-0F001-00 (BLACK) B/Y G/B G L/Y (BLACK) (BLACK) R/W B/W Br/B Br/R Lg Br/Y Y/R G R/L G/Y L Y/B Br/L B HEADLIGHT HEADLIGHT TAIL/BRAKE LIGHT SUB-WIRE (BLACK) WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS...

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