SIDEWINDER €® YAMAHA “s PIN BKG-FE197-70-E0 Gs (LIT-12618-03-39)A @ This manual is divided into sections. The sections cover specific snowmobile components or stems and, in addition to the standard service procédures, includes assembling, disassembling, and inspecting instructions. When using this man- ual as a guide, the techniciaifghould use discretion a8 to how much disassembly i needed to corect fay given condition. _¢. The service technician should Bégome familiar with the operation and construction of the componentépr systems by e om oF arefully studying the complete maiual, This will assist the service fechnician in becoming more aware vith -edures, Such effici i efficient ‘sith servicing procedures. Such effi a: helps build consumer confidence but also saves time and labor {Al Yarnaha publications and snowmobile decals display the words WaminCaution, and Note to emphasize important infomation. The symbol A. WANING igentifics personal safety-related information. Be sure to fallow the direc- tive Decatise it deals with the possibilty of severe personal injury or even death, ACGAUTHON identifies unsafe prac- ticos whickmay result in snowmebile-related damage. Follow the directive boeyse it deals with the possibility of ‘damaging part parts ofthe snowmebile, The symbol NOTE: identifies supplementary information worthy of partie- Ularaitentio. ¢ AL the time of publication, all information, photographs, and illustrations were technically" carrect, Some photographs and lostations weds manna ar sed for clanty proses only ad area designed agp ata codons Because Yamaha constanily refines and improves is products, no retroactive obligation is ineur All materials and specificaiofigre subject to change without notice a Keep this manual accessible in thé area fr reference ©2017 by Yamaha Motor Corporation, US.A Satiaey 2017 ‘All Rights reserved. Any reprinting or unauthorized use without the written expressly prohibited. USA. is RNSpecial Toois. ‘Snowinobile Kdentifcation Recommended Gascline and Oi Engine Breakeln Drive Belt Breat Genuine Parts... Varying Atude Operation Preparaiion For Siorage%, Preparation After Storage” ‘Alter Break-In Checkup/Cheskist Engine Specifcatons Etecinical Specitcations “m_Drivo Syetom Speotications “Track Specincations Torgye Conversions ‘oique’Specitcatons Steering and Body vevrsnsvsnnnnnsnn Steering F Ski (ual Westar. ‘Sk (Single Weer Ban Wear Bar (Singo} Wear Bar (Dual) non Spindle no 5 Spindle (6-1 MTX), Steering Te Rod Ski Alignment. "2 AeA “deksms (B-1X, M-TX}. Ki Shock Absorber Sua Bar. Front Seat Assen) Seat Cushioh Tetons Ase Rear Bumper Wincshisi/Consolesaaigt Adjusting Heedight Air. Engine Removing Instaling SeCENG one “Troubleshooting Engine Engine-Related Items, Wiates Purp Pressute Testing Engine. CChecking’Gompression Changing Engine Outer Cooling System Senematc Heat Exchanger. Air Slencer. Yon “TABLE OF CONTENTS 1 rutecne etre os 1 Fuel Systems: : 68 2 Fuel System unas 8 2 Individual Compontnis 62 2 SelfDiagnastic SystemiCades 70 2 Tette Body Assembly. 71 2 Fuel Injection System wn. 3 2, Troubleshooting % Ps, Thrtte Cable 5%, Fuel Pump 3 “Ges Tank $ Ee al Systeme 8 ‘S/S. I : 7 Thrtteostton Sensor 403 3 Elecircal Resistance Tests 108 9 Voltage Regulator Tess. 405 ‘esting Fue Gauge Sender .ssvsvsnvvvnneonens103 Emorgoney Sop Swtch 405 Starr Relay Soro 105 Fuse 108 Igniton Switch vo 906 Starior Motor. s. 108 ‘Troubleshooting Electric Sart ey 108 Magneto... ow 03 14 Brakecht Switch 109 light Dimmer Switch 110 Testing Handlebar Warmer Elemen's 110 Testing Thumb Warmer Element... 140 Testing Handleber Warmer/Thumb Warmer Switch... 110 Testing Seat eater Switch tt “esting Speedometer Sensor mt Testing Geer Postion Sich it Testing Shit Switch. 112 Testing Shik Actuator. 112 Drive Train/Tracl/Brake Systoms 413 Drive Bett Me 19 Primary Sheave % 118 23° Secondary Sheave nnn Synon cai? “24%, Primary Sheavelstaionary Shoa 118 2$®prve Train 119 27 ‘Dye Sprockets 125 31 Tack TOMBION sass ssssnsressnonnnsnvannnnen 12 55 Track Alignment. 127 ST Brake System (Hydraulic) 128 Brake Laveritfasior Cylincor Assombly 133 Trovbleshootng TACK on na 13 Troubleshooting Higrauic Brake Syston 135 “rowesootng Primary Sheve/Secocary Seve. 138 Susponsion. ‘Suspension Setup Basie, 137 Servicing Suspension ww... 2. 441 Wiring Harnesses 1532, General Information MINOTE: Whenever a part is worn excessively, cracked, ‘or damaged in any way, replacement isnecessery. Description "ey Yamana pia] KAU a Fuel Pressure Tester TORILEMLESIILEMA [cat Ange Driver 00.03173 ’ INosel es wunmeter rag 03174 _YO-ATS2 Fuel Pressure Adeptor fpeaso.03176 vuort76 it, Dagrosties Too! YT 2) OURS i >, NaWve Spring Compressor 390.04019_|YM04010 NOTE: Some illustrations and photographs used in Sam" Sr5 Cones posroouoie Narouore ts mere re, ued olay Purposes nV and gona rr festa tse 4, * Nave Capping Too! fp090-04701 _|YM-AB996 % - Nave Guide Remover (45mm) 0Bs0-0F1 76 YM-04116- Special Tools Ne Guide ir Csmnt paeo ori? Nori? ° Te as Ge Peat (etn) pono. 15- aT. ‘A number of special tools must be availabie4o the techni- _ Mesranieal Sea rater fposs0.0015e7 vw0Sar Gian when sericing snowmobile a ison in Gomes Son SF _RIBON , Fame rat Spe Crier ——prsootnrot ror? NOTE: Special tools are available from the Yamaha Ser- [Rear Spring Installer fpoas0-11110_|YS-17770 vice Pats Department or KBL Tool Supply Compam, sc cp saan sor VST Description Yamaha pm KEL pa}; Palo lor Wheel Unseds“balow)_POBOO=1T117_VS.ATHT7 —_— 2, Farinas Boneiie ene [ere reronse bores stooe (umes | Stoner BAIT Baie vStiTs Foe ee ee ee Fe rserion toot (1.257 fso000:11 120 vS-11120 Fats Pease josconroes fcsuanor] FR Pee sorter Ya iat Pesos Taiaoor ——[posoviess_fcsonet | [ASAIECPH TT postoriae sree [reavy Duly Puler BRO Use| (-oAdewwe ate (1259) fposgo.11128__¥s-11129 ft Wren pontsaraso fcovaco | LESS oso: ed" es-re8 [er kek na Ja uss saoree | [EPuersot Stee isc Sse Pros pasones,Verc—| Smenne re emo e-age Fina Gut oder Bacon soa] Pt ___ i Koc Scr St oseosi7it Vsqensoc | (SATE TonaH posse _feree [iit fsonrrer_NestasC] Fosiraren bran posto Sis Bae Repersior Aetepter fpoaso-o1740 [8-94 [Fuel Hose Clamp Tool fooag0.11135 [95-7061 Ewart Boscovs Years © Some, ey ese banTiss best [ar carpe Lassoaioar Hees] Attra bemotrar pena [a Srctonar oss fstaes Tak rea ash —— post TEST [bial Incicator ja0sso-os097_fyU-Aea26 {ainigha Bond 1215 390 85505 rays Tr Bossom fucosnec | pre Gue am, “> 90890-11110 “90390-11111 90890-11117 90890-11126. YS-11110 Yeagitt YS-11117 YS-11126 "e 90980-11149 90890-11135 90890-11138 90890-11130 YS-11149 35-1061 11 YS-11130@. & Snowmobile Identification Ts ‘The Yamaha Snowmobile has 1wo itfiporcant identifica tion numbers. The Vehiele Identification:Number (VIN) is stamped into the tunnel near the right-side footrest or fon top of the tunnel. The decal also display®; pertinent production information. The Engine Serial "Sumber (ESN) is stamped into the crankcase ofthe engine. These aumbers are required to complet waranty claims pr, cerly. No warranty willbe allowed by Yamaha if the engine“ sefial number or VIN is moved or mutilated in any way. Recommendé Gasoline and CAUTION “=, ‘Do not use white gas or gasoline containing methanol. Only ‘Yamaha approved gasoline additives should be Used. CAUTION %, [Any oll used In place of the recommended oll ray’ (cause serious damat RECOMMENDED GASOLINE “The recommended gesolifto use is 91 octane premium unleaded (PON for North America) or 95 octane pre- miu unleaded (RON for EurGpe). In many areas, oxy- ‘genates are acided to the gasoline 4)xygenaied gasolines ‘containing up © 10% ethanol are scout ‘gasolines. When using ethanol blended gasoline, ifi®,not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system. RECOMMENDED OIL Pg ‘The recommended vil to use is Semi-Synthetie Yana, LUBE OW30 iL ©, CAUTION Ay ell used in place of the recommended oll could cause serious engine damages; °MNOTE: Before starting the sn Operating your snowmobile for thet time: Star the engine and let tile for 3 minutes. 0160 km (0-100 miles Avoid ron eneraion teow eOD0 RPM 3 above 8090 RPM. 500 km (300 miles) and beyond: now be operated normally MNOTE: After 800 km (500 miles) of operation, the %, ‘engine oll must be changedand the ol filter replaced. “% “ff any engine trouble should ogcur during the engine reakcin period, immediately haye a Yamaha dealer check the snowmobile. Drive Belt Break-In Drive belts require a break-in period of 40 km (25 Miles). Drive the snowmobile for 40 km (25 miles) at 3/4 throttle or less, By revving the engine up and down (but nét,, exceeding 100 krw/h (60 mph]), the exposed cord on the side of a new belt will be worn down, This will allow the drive belt to gain its optimum flexibility and will extend, dive belt life 4 smobile in extremely cold temperatures, the drive belfshould be removed and warmed up to room temperature. Once the drive belt ie at room tomporature, install thé rive belt. ‘Never run the engine with the drive bolt removed. Exco: [sive revving of the engine could result in serious engine| {damage and primary sheave failure. Genuine Parts » When replacement of parts is névessary, use only genuine “Yamaha parts. They are recisigimade to ensure high quality and correct fit ‘The engine oil and filter should be, changed every 4000 km 2360 miles) before prolonged stoidge and the oil fier should be changed every 20,000 km (12 Engine Break-In *, 6, “The engine (when new or rebuilt) requires a short bre pesiod before the engine is subjected to heey load ‘conditions, This engine does not ?oguire any premixed fuel during * the break-in period. ‘There is never a more importint period in the life of the nie tan the fs 30 km (20 mile Sins te engine i ‘brand new, do not pur sm excessive lal on it forthe first S00 km 300 miles). The various pars in the-engine wear and pol ish themselves to the comect operating clearances. During this poriod. prolonged fll throttle operation'Sy any condition ‘that might result in engine overheating musi be@yoied 2 Varying Altitude Operation Sarying Altitude “peration Operating 2 snowmobile at varying altitudes require?pecal- ibration of drive system components. Following are basie altitude theories for clutching: engine, suspension, and track, CLUTCHING ‘The clutch may require tuning’depending upon where the ® ‘snowmobile will be operated and the desired handling characteristics. The clutch can be feed by changing the engagement and shifting speeds. % Clutch engagement speed is defined as thé-engine speed at which the snowmobile first begins to ffigye from a complete stop. on%, % "ey y Shifting”¢peed is defined as the engine speed reached ‘when the shexymobile has traveled 800 m (2,500 f) after being started a full-throttle from a dead stop. Normally, when «snowmobile reaches shifting speed, the snowmobile speed infreases but the engine speed remains nearly constant. Under tinfavorable conditions (wet snow, iy snow, hills, or rough terrain), however, engine speed ray decrease ater the shifting speed has been reached. 1 Engine speed . Goea bo conan °c: Shitina speed D. Ohtch E. Stating, position“, F. Distance, traveled Bm — IF Goon ‘LUTCr Xe, jh Altitude Tuning®, } % Atmospheric pressure decreases afd. engine output. ‘becomes low at high altitude cic aeree of this, Mesos tnt gh alte laine pms oF ecreas® and unable to maximize the engine output power, Tosmaximize the engine output, tuning for increasing latch engagement speed and shifting speed is, necessary. This'serting is called high altitude tuning. The following changssare usualy performed in high alttud= 1B “s + To increase the clutefeengegement and shifting speed changing toa larger spritig.constant or using lighter \weighs and rivets (decreasing primary sheave thrust) + Increasing the reduction rato dane crven peaidrive ger (increasing the deving pertSinance) Fn) w =o By z TURBOCHARGING % Turbocliging is one method of compensating for loss of sir density that works extremely well when applied to four-eyele intel combustion engines. "8 ‘CLUTCH Exhaust gases aréidirected through the turbocharger tur- bine wheel which is“ttached to the compressor through cominion shaft, As the exhaust gases spin the turbine, the fompressor is spun al very high RPM. Inlet si is drawn ine he compressor compressed, and owe 1 the take manifold of the engine. Intake pressure, therefore, 8 iaintained at the optimum levels altitude or temperax ture increases. ee ‘The turbocharger ourput must be regiflated to maintain the optimum manifold pressure throughout the designed operating range. This is accomplished by regulating the Volume Gfexhaust gases passing through the tuzbine by controlling’, diverter valve (Waste gate) at the turbo. charger turbii inlet At lower altitudes/temperatares, excessive exhaust gases are diverted past the turbine and into the exhaust Gownsiream of the turbocharger thus Timiting the compressag output to maintain correct mani- fold pressure. Ye, [As altitude inereases, the manifold pressure is held con- stant by diverting Tess exhaust past the turbine, thus increesing compressor speed. This will continue until the ‘waste-gate is completely closed at hich time manifold pressure will star fo decrease much the same as a nor mally aspirated engine. "e ‘The waste gate is controlled by a. spri ivaiaphragm echanisit that is connected to the intake manifold by an airline, A méchanical linkage connects the diaphrigm to the waste gate éanttol arm. " Air isheated by fniétion and compression through the tur- tbocharger and air density i lost by heating the ar; there- fore, an after-cooker is ifistaled between the turbocharger compressor and the intake manifold, This is an sitto-air aflercooler that uses outside sy directed through a radiow torlype cooler to cool the compressed air prior 10 enter- ing the intake manifold, ‘ SUSPENSION te ‘nil ing versus powder snow riding {sus combina- tion riding will all require different suspension setings The differettsiding styles of the individual opetiton, the ‘varying snow Copditions, and the type of terrain are all factors thal alfet the persion at high aktade Tal nding versus powder stow rif vtsus combination riding will all require different suspentign settings. ‘The nonnal seting for fortski suspension is as litle spring re-load tension ss possible for powder snow ring allowing the skis to float across the snow;with the least amount of resistance. Trail riding will reguiré:-more spring tension to carry the varying load more effectively, Many diferent set tings and sping tensions to consider existyhen adjusting for siding style and snow conditions. "e ‘The rear uspension has a numberof spring settings tha pro- duce different riding characteristics. *"y, handling when either on a tail or in powder snow. A strong “a, Sptng setting on tis shock will cause the stowmobile to tend "opto “dig” more when riding in the power snow rather than “climbing up ontop ofthe snow. But it will work more efec- set ening oa tal A sor pinging low the fant ofthe rea suspension wo collapse much quicker and change the angle of the track to the stow. A more gradaal angle will endo raise the snowmobile up on the snow rather than digging Tato it. Many possible vefigbles and adjustments to the rear saypen sion exist dependingon snow conditions, riding style,-and iypeotterain. These adjustments can be made to individuat,. ize the snowmobile to the viding style ofthe operator, ‘As snow cover and riding conditions change, several differ », ent adjustments can be made to change the ride and handling “>, characteristics for operator preference. Located on the front esuspension arm are limiter straps. They limit the amount of “fallout” the front arm can have. These straps may be adjiqted in'or out dc to conditions and riding style. The more fhe straps are brought up, the more steering power the pert as duet the amount of ki pressure Another adjétment that can be made on the rear suspension is the fiont antiyshock spring tension, As tral condi change, the springpre-load may be used to decrease. the chance ofthe front ond “bottoming out”. With a stiffer spring pre-load, the ride ofthe Snowmobile will improve on the trai, deep powder snow, the stiffer spring pre-load will cause the front-end to “dig” and possibly take longer for it to plane off. "a, Several different-rae springs are available for different riding “a, styles and terrain conditions 1c Sandard models, the front shock springs are also indi= ‘idutlly adjustable forthe terrain conditions snd driving style of the Spgrator. The spring adjuster has been set atthe factory 0 the cofmeet amount of threads are exposed between the spring adjuster and the sbock housing as an initial setting Additional ski pressure can be obiained by tightening the spring tension; ski, pressure can be decreased by relaxing spa cin, Sie wi fc pin ats ce ae operator choice'and snow conditions. 2 AA limit exists as to how far you can pre-load the springs before “voll bind” takes effect where the wire on the spring actually rans into itself and causes binding, Equal adjust %a_ ments should be maintained on both sides ofthe snowmobile “On models with air shocks, they are individually adjustable forthe terrain conditions and driving style of the operato ‘The Shacks are presct at the factory {sce chart) as en init setting: however, i is possible to “Fine tune” the shocks to match the @perator’s weight, riding style, and terrain condi- fox TRACK %,, e Carefully matching the riding requirements tothe typeof track will ensure the maximum use of all available engin2®, power Lug helght end tack durorcter are the two main Eoncems when selecting a track for various riding styles “The front arm spring and shock will also affect the ride and “4Jracks exis with hug heights from 31.75 - 75 mm (1.25 -3.0 ‘ft J0 accommodate various snow conditions. Generally, the deeper the snow. the taller the lug. It must be noted thet the SSealliga of ey doop ua tack ny eos top ond peed and provioje premature Wear stip Wear in marginal snow conditions. 9, ct gsurement of how hard a rubber is. The lugs on most tracks range between 60 and 80 durometer. On the durometer seaig, the higher the number, the harder the lugs. For riding in deep powder snow, a softer durom= eter track works best. Thé,softer rubber allows the track to “give” a little and pack the snow creating lift rather than digging its way straight day. When hill-climbing, the harder lug of an 80 durometer track works the best dive to penetrating the hard snow creating more bite Sang tracks come with a dual durometer rating, such as a rack:with a 80/60 durometer rating. The lugs on this track are 80% 80 durometer rubber, and the top 20% is made of the softer 60 durometer rubber. This track is designed to be 2 good allgund track for riding mesily in deep powder snow but can climb the occasional hard show hill a Preparation For Storage %, Prior to storing the snowmobile, it must be properly ser- ‘iced to prevent corrosion and éomnponent deterioration but will fet the pecformance in the deep powder snow. In”, %2,1. Clean the seat cushion with a damp cloth and a Vinyl *e, Protectant. 2 "Clean the snowmobile thoroughly by hosing din, oil, same, and other forcign matter from the skid frame, {unnd) Hood, and belly pan, Allow the snowmabils to dry thoroughly. DO NOT get water into any part ofthe engine 3. Change the efgine ol. 4, Plug the exhaust Sem outlet with a clean cloth 5. Fill the gas tank Wis rated capacitys then add vel Stabilize 40 the gis tank following 18 on the container for the stabilizer/gasoline ratio. Tighten the gas tank cap securely. “6, With the snowmobile level, check the lubricant level “cin the chain ease. If low, add chain lube through the “fll plug hole. 7. Reritove the drive belt from the primary sheave'soe- ‘ondary sheave, Lay the belt on a flat surface or slide itinto a eardboard sleeve to prevent warping or dis- tortion during storage. 8 Glan and inspect the primary sheave and secondary 9. Apply light oil to the fpper steering post bushing and lias of the shock absorbers, 10. Lubricate the rear suspension with all-temperature , Brease “a, Tighten all nuts, bolts, and cap screws making sure “all nuts, bos, and cap screws are tightened securely. ure all rivets holding the components together are tight, Replace all loose rivets.12. Clean and pilish the hood, console, and chassis, DO NOT USE SOLVENTS. THE PROPELLANT WILL DAMAGE THE FINISH. NOTE: Disconnect thibattery cables making sure Bjacomosttne segutvessble rts on seen the battery posts and cables. Charge ‘the battery, CAUTION ‘Sealed batteries require charging if let for extended nor start periods. Yamaha recommends trickle charging once a month, Follow the manufacturer's instructions and cautions 13. If possible, store the snowmobile indoors. Raise the track off the floor by blocking up the back end’ mak= ing sure the snowmebile is secure. Loosen the track adjusting bolty.to reduce track tension. Cover the snowmobile withia machine cover or a heavy tarpau- lin w protect i Horire and dus 14. If the snowmobile must-be stored outdoors, position the snowmobile out of citest sunlight; then block the entire soowmobile off the wound making sure the Stowmobile is secure. Loosen the track adjusting bolts to reduce track tension, Cover witha machine cover ct a heavy tarpaulin to protec it from dit, dust, and rain, CAUTION in direct sunlight and using a plastié cover as tnd) golacton the nowncblo causing Spseion| ————————————————— Preparation After Storage “Taking the snowmobile eit of storage and corcetly pee paring it for another season ‘ill assure many miles and Roum of weubleres:snownubiing, Yamaha tecom= mends the following procedure: %y 1 Clean the snownobiethoroghifRptish th oxtin Sie oar 2. Clean the engine, Remove the cloth frorifthe exhaust syste, Check exhaust system and air-intake silencer tor obsttuctions. % 3. Inspect all Goptrol wires and cables for signs of wear or fraying. Replat if nccessary. Use cable tics or tape 10 route Wires and Cables away’ from hot or rotating pats 4. trspst the dive belbefor cracks and tears. Check bet spevifiations. Replace if damaged or wor, Install Redvers SPs samme AINOTE: I tho old bette worn but in reasonable con- dition, retaln win the snowmoble as a spare In case Stan emergency e ‘5. Tighten all nuts, bolts, and cap screw.making sure all uts, bolts, and cap screws ae tigheed securely 6. [fnot dene during preparation for storage, litbrieate the rear sspension vith all-empetaure urease. 7. Check the coolant féxgl and all coolant hoses and connections for deterioration or eracks. Add properly ‘mixed coolant as necessary, 8 Charge the battery until fully’eharged: then connect the battery cables making sure to connect the posi- tive eabie firs. Test he eGctie ativystem 9. Inspect the entire brake system, all céintrols, head- Tight, tailighe brakelight ski wear bas and heae= light aim; adjst or replace as necessary, 10, Adjust the wack the prope tension an alg After Bri Checkup/ © ch eckup/ Kk! Certain areas require adjustment“afier the break-in period in ender i obtain peak performance andnclud the following DRIVE. BELT POSITION — Drvbelt eng, cond tion, and position are all important for peak performance. After the break-in period, drive belt defleetign should be checked according to the instructions given ié:the Drive ‘Train/Track/Brake Systems section of this manta. PRIMARY SHEAVE/SECONDARY SHEAVE OFF- SET — Iftpremiture drive belt wear is experienced oF if the drive belt turns°over, offset must be checked. Also,” offset must be whenever either the primary sheave or secondary sheiyp is servis TRACK TENSION AND ALIGNMENT — A certain amount of stretch occurs on all racks during the first 800 km (500 miles). The track must’be inspected/adjusted after the first 80 to 160 km (50 to 110-miles) to the speci- fications given in the Track Specifications sub-section of this section and periodically thereaiter. If. these, adjust- iments aren’t performed, the track may “égsail” which leads to track and slide rail damage. Along with these major areas, other areas shouihl be checked and adjusted, Below isa list of items to check after the break-in period, The recommended mileage for thi, inspection is betwee’460 and 500 km (100 and 300 miles). (0 Chesk drive belt positon primary sheavelsecondary sheave ‘offer "ee Aus tack tension and amet ‘Check thot cable tension Dy Chicek engine idle Check coolant evel (check chaincasehbrican level Check engine oil level ( Chesk lihts¢hihvTow boom, brakeight) 1 chesk safety switch operation Chest cage sampertnent bx any rubbing coméoens ‘Check stering hardware for tightness % (Dy Check ski fame and 4-arm mounting hardvare for zh (Dy Chesk brake fevsr ravel and adjustment Ty Gresse all britEngine Specifications Sr) | MoCo NUTS Displacement faves feampresstn Rao 01 Bore x Stoke 9566 Finn GISXBAT ening Sy Ligue Spark Pin NGX) lonse % Spare Pivyap 71-070 m0 OB DIATT Psion Sent finae Creaance Piston Pin Diarmata Piston Pin Bore Oi Piston Pinto Piston Pir Bore Clearance (Cenvactng Fog Smal ENG Diametee icrentsnat PComecirg Ha} Era Gearsncs re ED (Cennacting rx Big End Disior (0360061 mi (G00T%9.0024) i0.900-20.085 nm (0.82669, 8236) 1.90421 015 rm (00205-0.02747) (0980005 mm (00003-0 0008) 1.05 21.027 (0.6260 0.02787) 0300048 mm (G0TZ-00019) ‘oo Ova (TTAB STA Piston ring Ecap (appara mnieasa3iey {Bn en98 mm (oone 919} Pisce Top) F030:965 rm (00012 coRE femove Ceara faze dts mn Oto 8 wee} [ (633 10400 148g (0018-0 085 Fis Danemr 357596 [9107-3400 [Rom om botam eee) "s. ? (camLobe Hoon Ile SoM TIT (earobe Height era) [750 93950 ne (15R571.927) {cartons wah ie) 350-25 03011m (952%:9. 9652) icamLane Wh (pu) ft 960.25 050 mm (09323-59652) (arta Jura Oar 4628.47 (096509 £635) [Camshaft Journal Clearanés, 028-0 062 mm (0.0071-0.0024") (eank Pin ieneter Sor. 976 38 0m (14961149697) (Cranishan Runout (max) — 7 (eranishal Vain Bearing Clawaned (canisnaivod Beaing Clearance Waive Stem Diarsor (rake) Waive Ste ire (Exhauel) ‘Sm (0012) (027.0045 een (00017-00078) 090008 mmm (00012-00019) (75.4 90 mn (01760-01677) 4803475 mn (01755-0-17627) Waive Guide isi Crater (rake) 4500-4812 mmm (0.1772-.17767 Waive Guide inside ameter (Exhaur 4.800-45(Biyn (0.1778-0.1776) Wvave Guaerstem Garance(mate)_[0 0100037 rfnga.000t-0.0015) Vaive GuiseStem Charanes (Exhaust 025: 052 rm (9010-0 0020°) Waive Face Wig (reat) [ave Faco Wath exhaust) WALVE TRING (bai) 9-1 10m {O0HTDOET 99-1 10mm (000500497 ine Oper (STOO) Teese jrtko Clesoa (A500) “©, 15.0 eosteoe [Sevaust Open (BEDS) 2 degrees jExraust Clesed (TDC) (5.0 eogreos Waive Overep 7,8 seareos ——_ Electrical Specifications = Tesi Connections | a) ‘Component hemectone Tr oeaen ene ae ae re Eesenay puter gy — pet errs Grate on Sebi om lr — a Fate Repusurreone?ape es oe ves —femnd —ferer Mime otto eat a snip for Sage ogo fra SAN Sen * Soe page 73 for tot procsdiy Hamess plugged in The main harness connectors must be unplugged (except con primary eoil and regulatot/zectifie tests) and tested by pressing the starter button. MNOTE: Lighting coil output is Unregulated voltage. /\ WARNING Most voltages generated by the ignition system are sut- licient to interrupt pacemakers! All technicians, espe- jally those using pacemekers, must avoid contact with) lll electrical connections when pressing the starter but. iton or after the éngine has been started. |125" Tack sAicAL SAions, lsaiats, Drive System ~*~, Specifications ~~, coer) 4000-8509") 1809-2600 (6000-8809) ‘2400-3000 (6000-10000 Primary ‘Cluten Spring err cory aLRo0 Coens Cremeans Roller coed an) 145 re rae eT metto yeutow | stim] ‘ Protadt 8 am Pree CoC es up.00| 8750 ey Tian) 100 un en | 197,14" oh Ne ack sie1osos7| Swanxstt ‘007 2001) 0-140, 2000-4500 6) 14000-8500 1809-2600 (6000-8609) “SF 2400-3000m, (taa0« 10000 Gadd “Gad oe aLR00 “hyeLiow Mga tose Prog 30 2uP-00| 8750 3100 a) a | a 159 15 task 00 Bevin 00-1400 2000-800 8) "200-2000m 1909-2000 (6000-8509) 2400-3000 (6000-10000) Gad Red ‘Gad Sigh gurion.s7 | 4000-6800) | 4 SOREy aLr00 yeLtow 12 tre “ 36° Preoad 60 1P.00| 9750 3100 uavase 2 Sivont 22001) 00-1400 12005-48098) “00-2000 | Sswrsoets}4000-6800 #) | “in00-2000m ie000-8500 8) coded ‘Gas 0K 2400-000 600010000 te, 38 182" 30" Tack Swe 2200 1) 00-1400 2000-609) “200-2000 | «4000-6500 8) 1800-2000 6000-8809 8) 400-2000 00016000 cod ned ‘Gus some excoo ye.tow 121 au axce 160" 35 hack Swroines Europe aon, 2200) "Fgo0- 400m, (00-4600 | r2t552000m | «4000-6500 8) 1800-2600 6000-8809) ‘2400-2009 | e000" 000] white & White kg 223K) yeuow |, 2ttiginey| 8, PronWEIGHT RIVETS cn Cd A O02e GOSS feel Ti72mm| nag |ireresse FOE {3066-06005 | Stes winheie [172 mm| 3.69 (Conasienss steely [133-mm|_3.60 (0 ona61.06019 | steal [13 mm| 3.19 iE b0296-06002 | Sieal wen hole “a3 mm] Zag FF onoei-c6015 | Steel [1A mm| 2.410 (@-bo261-c6028 | Auminum —|10>pm| case [Decrease Fo (CLUTCH ROLLERS *s ror eee oFa-t7e24-00 cree Groove eFG.17626-10 aF¢.17624.20| 156 mm sF817620-0| 10.0 om Machined 96 6.17604-40 [6.5 mm [Dncrenee Force CHAIN CASE’;COMPONENTS oy ed 20 BRANT) Pera Teeth TOP GEAR, oo BRCETEOAO} Ter ba fake Ercan] 2 BKC-RAWEr-o} 21 BKC E7eDA-10|_49_[eIP-G7587 DRIVE SYSTEM INFLUENCE ‘Complnenis of the V-belt transmission hing a direct impact onthe shifiing function are deseribod below. ‘0 aKC-PAMUT: 1} 2338 Part Element Impact on the shifting function Aer Will ng ead att Se (reese ce oe Cee tt as ngage special wr cpt ‘ig seg as MGoass he hing ead flo stony inreasos the atch ergagement ope Singers tazone cope hater. ree Ingthe sorng reacton fre) Shami onal decreas iting cane cs [iso slant decreases tno cutch enbanoment spat Ehiting lend o become somewhat eer (ecteas: jnptne sorng eacion too) ‘Shape and weight determine, te Sze ol momert ‘ggbout the cont oft woght wiaton whon the Breve i urnng Phheavie’ weit decreases me cur engagement rafting sBeea.sriting tas to became some ina ease Inaasing te sheeve must Ugur woh irereases he cach engagement ena Brin sou, Siting ras 0 Focgne sonnet Sone rae an oh Feroor (Becrasing te sheave thrust) CTE rm 8 s RP Racal Fina oftmes acute cscs Esta -Lersecy eae Sieeas Sacto sia festa alee ens beens er eres eRe since angioma I dant cp ch ae beeen caret cs So ona figs ams ema sate pat aang hi oor eacen Jatioles stim decreases he reed ard omeri moecd aeaane he spay reacion Fires ES face Re PRR ng co k a ae i fantom ©, furnincioaeas tho shoave thrustto mabe ack ening ,peusaeteeseer eg renee sores eta eae ae Prt ge ort gh Exar asses aan ea 3 fue shave ag siang sheave) carb sested by ine numberof sins used jus the Ceerance when the V-belt weer deterio- fates ara ball wsth bates smaiee isms she rae economy sheave la hig essa scary chemo claranca han the Vet with is eat tro th Bot on tho premary she uch ongagoment oncou i amy Track Specifications paround dam: legor ane oe wr on Tam | TSAR BES Z In oF es 2 Tog | Sm BEI Tao | am BESZ mn oF ‘ns 2 Sign sam “Heer a pn Baia STAR wes ZR ar” Ge, Be ve eg) Asam BET IRR en” | 38 prea Tor | — 57 SR BESrZ mn Bs 2a 2 Fieqm | 75 00m BEI HHOTE: Tho track toncior#on all modle should be at 9.1 kg (20 Ib). ‘y ‘y % % Se Torque Conversions Secured to, —————ee Bac Case Cover 7h. Od n=) ° Brake Caper ass Meas] a ERRGAR EERE Tepe RR ene] es ae ae preset 2 fas | 2 (tess Cpor Hoving jada Caper Povena] 3a | 25] _Bs irakoine ager Sef as es akan estar Gfcar [ae [35 Bae capa ioe Cover [3 fen, STEERING/FRONT SUSPENSION Bx nde 35 Sk Heabar a) Ba Bara & [oe fain.) S Fase xaunerBear—post 7, ——Tav fo] 5 Isteaing Stppor juning def 11 | + pein [tein Pest oeing Stop Sagat se | 52] a3 ‘Stern Te Rad Steingamm 0. 27 | 28 | 29 Eteorng Te Rod Boing Pest “pao | 40] 95 [Steoxng Post Cap Five Bose ras] a fom fe Red ong Pet ziae| 2 ne a [28] 2 be oa inde Be waa [tering Spo par ¥ ‘Steina Stor Unperconsoe [35 [steer Arm rosa 1 Iiarm (Upper MTR) ——_ohassis 2 cae (Upp0e ass ai Iarm (Cowen Tassb Fon) | 68 » fearnttoee ass Rig) ——[ Pear (FTTH) pine [or fee | a5 arm (UTX) Seindle arfaa [3s [Shock Absorber RL) Arm Spe [aa [ae [Sock Absorber (@TRLIX) (Chassis a [aa [Shade Absorber TX) Ackem aefaa [ae [Shock Atsorber (HTX) hess 3 ze [sway ar Lin Armia Bar Unk | a1 | 33] 98 [Snap 6a Noung Bache iz REAR SUSPENSION wear Sb Ret os Ini Can Rel ° Ind Cepia Cap Wheel Pa a iar. a | ficartog eae Bal = a ‘necificati Fara Ret zr Torque Specifications [Ra Support Bail 27 a Feat 3 NOTE: Torque specifications have the following tok [ose rm ide i "har [28 [29 erances: "e ior rm OORT Fear fr ‘mos i0 t ear sncor army Fron: armiaiar ara | ar"[a2 | 30 Frent sheet (crx) Fron em sa o {inter Sap Fei Sopra 31 [osx 6 rent ar unr are Pas Fear arm ilo Arm sees 102 aa Rear tear wre Reariderwreel—[-9 [0s Boi B, Secured to Far Shock Link EX — Front armiderarm—[at[ aa] 39], a = Baran TA Peet srpezp se], Fina saa al =e fergie era hal ca Primary Sheave Cover —“peusbia Shave | %, Reupe Be al 5S % Prmensremconr pontesmens [ue iel ie |S Eigeaneingr uma Larter as : ee ee ete] [erie no m7 [ar [owe [Secondary Shoave rie a woe [ae] earsneckrnrn) Front Afar Ay Esomens ee te Rear Sek Link (Front rr Ar rove 9 | 2820] 17 + wiGreen Lostie #009 ** wBlue Lote (hain Casa (Cap Saw) —forassis {Shain ase CorcHead — [assis Sciowy 416 (hain Case Cor an Cae ebe eSteering and Body ‘This section has been organized into sub-sectionSor ser- vicing steering and body components; however, some components may vary from model to model. The tectni- cian should use discretion and sound judgment whet % removing and installing components Steering Post REMOVING *, TW ramoe he sess pe and he igs the following procedure: % 1. Rowe the two quarter wins to the verti position: then pull the top of the side panel out and upand off the skid plate, 2. Disconnect the hood harness on the left-side of the 2 hood then loosen the two quarter turns securing thet % front ofthe hood, Pull the hood forward and remove -, the hood. 3. Remove the push rivets securing the right-side steet- ing boot to the chassis, This.allows access to the two nuts securing the bottom of tte steering post 10 soe 4, Remove the mut (A) securing the bortom sahe exist ing stering post to the steering stop bracket, then ng te (3 ecg hei eo assembly to the steering post. Discard both nts, 5, Remove the cap screws and handlebar caps securing’ the handlebar to the top of the handlebar riser, then remove the two torx-head screws and nuts securing the top of steering post to the chassis. Account for both steering post blocks and a retaining plate “4, Carefully remove the steering post from the snow “mobile < ‘sure to align the steering post ball joint aligament tab with the steering stop bracket. Tighten tp, 59 Nam (6 kgsan, 43 lb). a4 Storing Pest Ball Joint = Steering Stop Bracket —_ ey, SHORT 2 secu the tie rod assembly to the steering post using ew MIO nut Be sure to align the te rod bal joine alignment tab with the steering post. Tighten toa N-s a ke m, 35 fsb SHORT side, steering boot to the chassis using the exisfing push me's. wT 4, Secure the top OF the stecring pest to the steering support using the &xisting retaining plate, steering post blocks, and nuts’Make sure the throttle cable is Positioned between the steering post blocks. Tighten to TL Nem (1.1 kgm, 8 x B03 5. Insall the Hapdlebar riser onto the top of the steering post and secifte using the cxisting cap screws and caps, Tighten evenly to 21 Nem (2 kg-m, 15.5 Feb), 6, Position the hood Gio the snowmobile and connect the hood harness confegtor and seeure the two front quarter tums, a 7. Install the access panel into'the skid plate; then close the access panel and secure Wwith the two quarter turns, Su —— Ski (Dual Wear Bar) MNOTE: Local, laws and/or regulations as to maxi- mum width of the ski stance may be applicable. ‘Always comply with the maximum width laws and/or regulations when adjusting ski stance. REMOVING “ey 1. Blevate the front of the siteyymobile and secure on a support stand oe 2. Remove and discard the cottr fi then remove the nut and eap setew securing the ski te the spindle. SINOTE: Noto the orientation of the deme for instal lation purposes. 3. Removélthe ski. Account for the rubber dam} washers. %, INSPECTING... 1, Inspect the ski formes or deterioration 2, Inspect the ski for sbndial bends or cracks 3. Inspect the wear ber for wear 4 Inspect all hardware and the“Spindle bushings fer ‘wear and damage. uy 5, Inspect the nubher damper for damagepr wear INSTALLING My 1 Blevathetiontorthe snowmobile, 2. Apply all ature grease to the shaft portion of ie cap screw fd the new spindle axle 3. Install the spindle“axle and spacer into the spindle; then position the ski'damper into the bottom of the ski making sure the damper is properly positioned forthe desired ski stance. 1"7 NOTE: Local laws andlor regulations as to max mum width of the ski stance may be applicabl Always comply with the maximum width laws andlor regulations when adjusting ski stance: 4, Slide the cap screw through the ski accounting for the rubber damper. sy, NOTE: Install the cap screw so the slotted nut wil be Iocatedto the inside ofthe SKI. %, Spacer — Spindle le ——~ ores 5. Install the lock mat; thon tighten the lock nut to 4.8 ke-m, om 35 feb). e 6, Place the cotter pin isfy the ski cap serew and spread the pin. Repeat for oppdsixe Ski (Single Wear Bar) AINOTE: Loco! lowe andor regulations‘ to max mum width of the ski stance may be applicable. ‘Always comply with the maximum width twa onder 2. Slide a washer onto the cap screw? hen apply all temperature grease to the shaft portién of the eap serew and the new spindle axle. Ge 3. Testa th spindle ale and spaces into the ingles then position the ski damper into the bottom of she 2B malig sa the ape" ecpery postion forthe desired ski stance 4, With the cap serew hole of he ski centered with the .,. spindle axle, slide the eap serew with washer through “eye cuse ofthe ski and spndlseembis NOTE: Install the cap screw so the‘lock nut will be located to the inside of the ski and the Gotter pin slot inthe cap screw wil be horizrtal with thes 5. sal the remaining washer and fck nuts theighten the lock nut to 48 N-m (48 kg-m, 35 fb), NOTE: Assure the cotter pin slot in the cap screw is’. still horizontal with the ski. regulations when adjusting ski stance. e %, ov %, 6 Install the cotter pin from the backside ofthe ski cap REMOVING %,,” serew and spread the pin. Repeat for opposite side. 1. Blevate the front ofthe snowmobile and secure on a), c suppor stands = 2. Remove and discard thegiter pin: then remove the autand cap ste scoring the shite the spn NOTE: Note the orientation ofthe. damper for instal lation purposes. os 3. Remove the ski, Account for the rabber damper, anle, spacers and washers. INSPECTING 1. Inspect the ski for eracks or deterioration. 2: Ineo thes forghnomal Bends or eck, 5. Inspect the wear bar Fer weer, 4 Ingpoot all hardware andhe spindle bushings for wear and damage. Se 5 Inspet the rubber damper for eimage or wea. INSTALLING %, 1. Elevate the front of the snowmobile, 12 ~ Wear Bar (Single) The ski wear bar is a replacenble bar atfached to the underside of the ski. Ifthe snowmobile is operated pri- marily in deep snow, ski wear bar wear will be fninimals however, i the snowmobile is operated on terrain where the snow cover is minimal, the ski Wear bar will Wear faster. Yamaha recommends that the ski wear bars replaced if wom to 6.35 mm (0.25 in.) or less. REMOVING 1. Using Front End Lif, elevate the font ofthe snow mobile, “a Remove the ok ats and wh Mar tothe skis then remove the wl securing the wearPosition the wea“bar up and into the ski and secure using ‘tte nuts. Tighten to 14.3-234 Nem three washers and (124-203 in.-Ib). & ROGIER Wear Bar. (Dual) 2, ‘The ski wear bar is a replaceable“gr attached to the underside of the ski. Ifthe snowmobile is operated pri- mail in deep snow, ski wear ar wear ile minimal however, if the snowmobile is operated on tesrain where tie snow cover is minimal, the ski wear bar vill wear faster. Yoriaha recommends that the ski wear bars be replaced if worn to 6.35 mm (0.25 in) oF less. REMOVING», 1. Using Front End, elevate the front of the snow mobile ¢ 8 2. Remove the lock mats, washers, and spacers securing 3. Remove the wear brs om gk. MINOTE: When the weer bars are rémoved, measure the thickness of both wear bars to see if they are within the wear limit of 6.0 mm (0.24 in.) Replace as necessary. % MINOTE: Measure the thickness of the ski where the front and rear of the wear bar contacts the ski to 908 it itis within the wear limit of 13 mm (0.51 in.) (A) and 8 mm (0.31 in} (B). Replace as nocossary. &, hue Waster "7 2. Tighten the nuts evenly to #9 N-m (2.0 ke-m, 15 fie by 3, 5 om 1, Position ihe: front of the snowmobile on a sil stand; then remove the ski 2, Remove the cap’gcrew and lock nut securing the shock absorber to the spindle 3, Remove the lock nut searing the tie rod to the spin~ dle arm, Account for the washer on the top side. 13‘, & ey 2 4, Refagye the two lock nuts securing the spindle to the upper‘and lower A-arms; then using a rubber mallet, remove the arms from the spindle. 5. Remove the Spindle INSPECTING 1, Inspect the spindle féexcessive wear, cracks, bends, or imperfections." 2. Inspect the A-arm boshings and sudo area for wear 43, Inspect ihe ski spindle axte at-bearings for wear, ® damage, or loose fit. Replace the bearings as a set NOTE: Replacing the ski belt bushings is dificult. The oxieting bushings will be damaged during removal. Be-careful, however, not to damage the spin- dle when removing the bushings. Press the new bushings into the spindle. 2 INSTALLING “7 1. Place the shock absor Secure with the cap se into position on the spindle and lock mut, Tighten to 44 Nem (4.5 kgm, 32 f-1b)-for RTX and LTX mod- els. Tighten to 52 Nem (3.3 koem, 24 ft-lb) tor MTX ©, and XTX models. % 2 pstall the upper and lower A-arms into the spindle; ‘hen remove the snowmobile from the suppor stand. Secure with new lock nuts. Tighten to 61 N-m (6.2 kgem4§ feb) NOTE: The Weight of the snowmobile will allow the ball joints to séat into the spindle before tightening the nuts. “s * 3. Place the tie rod with, washer into position on the spindle arm. Secure with a new lock nut. Tighien to 44 N-m (4.5 kg-m, 32 f-tbp, 4 4, Install the ski "a % '5,,Tum the handlebar fully to the right and then to the “ft to verify the steering moves freely ee Spindle (B-TX, M-TX) 1. Position the fronfof the snowmobile on a safety stand; then remove thg ski bo “ %, “bp, % ny 2. Remove théeap screw and lock nut securing the shock absorber the spindle. 3. Remove the lock rift securing the tie rox to the spin- die arm. Account for the washer on the top side. 4. Remove the machine soréw and t-nut securing the Upper Arm ball onc totnSopindl 5. Remove two lock mut securing he spindle 10 the Tower A at, thn ung nsber tal reeves lower arm from the spindle. %, 7 INSPECTING % 1 neh apie oexcesive wear rekon orinpetetons 2, Inspect the A-émn bushings and ale area for weat. 3. Inspect the ski spifidle axle and bearings for wear, nage, or lose Tit Replace the bearings aba set NOTE: Replacing the ski bolt bushings is dificult. The existing bushings will be damaged during romoval. Bo careful, however, notte damage the spin- die when removing the bushings. Press the new bushings into the spindle. %, INSTALLING 1, Place thérshock absorber into position, Secui® with the cap sere and new lock nuts. Tighten to 32 Nem G3 kg-m, 248-1), 2. Insall the lower Aparm into the spindle and loosely secure using & new fogk nut 3. Secure the upper A-arfinpall joint to the spine using the existing machine'Secew ond ti-aut. Tighica the machine serew f0 32 N-I3.3 kam, 28 Fb) Remove the snowmobile front ahe support stand Tighten the lower A-arm nut to 6FsN-m (6.2 ke-m, 45 fi-lb), Ba SNOTE!The weight of the snowmobile wilfallow the ball joints to soat into the spindle before tightening the nuts. ~ 4, Place the tie fod. with washer into position on the spindle arm. Seduise with a new lock nut. Tighten to 44 Nem (4.5 kgm, 32 fb). 5. Install the ski ‘,6. Tum the banclebar fully to the right afid-then to the left to verify the steering moves freely. Steering Tie Rod NOTE: To access the steering arm, the steering tie rods must be removed. REMOVING “J, Remove both machine screwscand nyloe nuts secur ‘ing the scoring te od ends to thy steering arm, Dis ‘card both nuts. "5, 2. Remove the nyloc nuts securing the Steering tie rod ends to the spindle arms. Account for @e washers and discard both nuts ro ROTe 3. Slide the steering tie rod out of the steering hodtand out ofthe snowmobile e 4, Remove the screw and lock nut securing the steerin tie tod end to the steering arm. Discard the nut % %, Y ny 5, Remove the lock nut securing the steering tie ré¢:to the steering post. Diseard the nut, %, nt if the technician's objective is to, 1g arm, the reinforcement bracket, will need to be removed by drilling out the appropri ate rivets. “46, Remove all torx-head screws securing the front skid. ate to the chassis; then remove the cap screw and ‘i securing the stecring arm to the chassis. Account fortwo washers and two bushings, @. INSPECTING s joints for damaged threads oF Wear. 2. Inspect the tie rod for damage, unusual bendsi*r INSTALLING 1. Secure steering arm into position and secure using. the existing cap screw, flat washers, and new mul. Tighten to 1’ Nem (1-1 kgsm, So n1b) 1. Inspect the%s, % ay y 2, Placé'the steering tie rad into position on the steering 2 new nyloe nut. Tighten to 48 N- %, ‘SHOR MINOTE: Make sue the tie rod tab is fully seated into the steering post and threads of the ball joint are above the nut when tightened correctly 3. Place the tie rod end infiposition on the steering tie rod bracket. Secure with «mew nyloc nut. Tighten to 28 Nem (2.8 ky-m, 20 f-lb). %, Nos A, Slige the steering ce rod throug the steering boct and into the snormobil; then piaesthe steering fie ‘ed into the spindle arm with the végsher. Secure with, a new nyloc nut. Tighten to 44 N-m (4.5 kg-m, seb) SRO 5. Secure the steering tie tod to the stesting tie rod bracket with the screw and new nyloe nut Tighten to 28'Nim (2.8 fag, 20 Ub). 16 *, Machine Serews-z = lw [os Ski Alignment CHECKING “ MNOTE: Track tension and alignment must be prop- erly adjusted prior to checking or adjusting ski aligh ment. Ski alignment must be performed on a fiat, lovel surface. Ski too-out must fall within the range of 1,586.35 mm (1/16-1/4 in). %, 1, Rais@he front end of snowmobile just high enough Spars conven too eS 2. Tam the Fapdlebar to the straight-ahead position. Visually inspebs the handlebar for being centered and inthe straight-ahad position, 3. With the handlebatin the straight head position, Secure the handlebar prevent the alignment front Becoming. disturbed dufing the remainder of the Sligument procedure, NOTE: Track tension and alighinent must be prop- erly adjusted prior to placing the straightedge against the outside edge cfthetack. a 4, Place a long straightedge against the outéige edge of the tfagk 30 it ios near the inside edge of the left-side sks, NOTE: The straightedge should be long enough to extend from the back of the track to the front of the ski. ‘, &, 5, Measure the disianésfiom the straightedge to the left-side ski wear bar bolts in two Plazes approx, mately 18-20 em (7-8 in, vi front of the spindle and 18-20 em (7-8 in.) behind ‘the spindle. Record the measurements ten forthe lefeside_ VERIFYING “4, 9.1. With the handlebar in the straght-ahead position, “2 verify ski alignment by measuring across from the “outside edge ofthe lef-sde weut bac bolls Yo the out lle edge of the right-side wear bar bolts (without Usii e staghiedge) in two places: approsimateh TR-2H eta (Tak i) infront ofthe spindle and 18-2 cm (7-8 behind the spindle 2. The measuréient from in front of the spindle to the outer edge of tg wear bar bolts (without wsing the Strsightedge) muctnot exceed the rear measurement, bby more than 159-6°35 mm (1/ 16-14 in.) toe-out, > Guan “ay 6, Place the straightedge against the outside edge of the’. < "% track so it lies near the inside edge of the right-side Ti % wi g/\s 7. Measure the distance from the straightedge to the 2 .¢ (Gaze right sid ski wear bar bolts in two places: 18.20 em © §8 [rocsresed ‘s (7-8 in) in fron’ of the spindle and 18-20 em (7-8 in.) g@ a3 behind the spindle. Record the measurements takea $ 0°30 ORR: fg the right sd »2 \ F The measurement from the font nd rear ser Bar oe bolts to the straightedge can be equal (ski parallel to TAA, the track), but the: front measurement must never-be o, less (ski toed-in) or poor handing will be experienced, o ny, The fron weer bar belt measurement tothe straight. [remensurement ken n onto e spigio must never, ledge must not exceed the measurement from tha rear, e eve en the mace e at ta ‘ wear bar bolt to the straightedge (kt toeceout) must) “20 Tana Wit pera eos oos of snow fall within the range of 1.56-6.35 mm (1/16-1/4 in.) Sy emolarud jewel parsenal itary 8 [ski alignment is not as specified, adjust che al ment of the ski(s) not parallel to the straightedge. EE ADJUSTING 2, NOTE: The following procedure can be used to clus te afonment of ether sr the snows nd aor wing Sibi suppor ag MINOTE: The push rivets securing the steer will nave to be removed in order to adjust the inner te rod onds. 2, Remove the torx-headl Sbrews securing the front skid "ra plate to the chassis; then remove the front skid plate. 1. Secure the steering tie rod in the centered position 3. Remove the eit push rive’s securing the steering 2. Loosen both spindle tie rod jam nuts on the same boot to the chassis; then slide the boot away from the side as the ski to be aligned, snowmobile, °c, 3. Using a wrench on the spindle tie rod “flats” rotate 4. Remove the ski shock. the spindle tie rod until recommended specification jsattained. 5. Reméye the two lock nuts securing the spindle tothe Ber ung sue amallet, remove the arms 4, Apply blue Loctite #243 to each jam nut thread area; thetiaighten the jam nuts against the spindle tie rod MNOTE: Repeat this procedure on each side (it nec- essary) until Ski too-out is within specification. Neglecting to lock the tie rod by tightening the jam, inuts may cause loss of snowmobile control and poss ©. % ble personal injury. 76. Remove the cap screw and lock nut securing the sway bar link to the lower arm, Diseard the nut b. ‘SROTE 7. Remove the two cap screws and nyloc nuts securing the lower arm to the chassis; then slide the boot from the anm and remove the a "g ‘SoRemove the two cap serews and lock nuts securing theupper arm to the chassis. Discard the nuts. INSPECTING 1. Inspect ihe grm welded areas for cracks or any signs ofdeterioriticn 2 2. npc the bsitngs and axles for wear or damages, ing. 4. Inspect mounting location of the chassis for eracks or wear, ANSTALLING Toplace the upper arm into position on the chassis and sare with the cap screws and new nyloc nuts, Tee 032. Nim G2 kg-m, 33 Mb). 2. Slide thejower arm ino the boot then place the arm %, ito. positign on the chaxsis. Secure with the cap Serevts and new nyloe nuts and tighten to 75 Nem Gah ee a and 65 N-m (6.6 ke-mns 45 “iby Gen). %, “6.” cap serew and new nyloe nut, Tighten to 32N-m 3.3 3, Inepect the arm tubing for signs of twisting or bend e ‘svo226A 3. Secure the sway bar link to the lower arm with the ©, kes, 23 feb). ¢ ¢ "% 07 4 Segue the A-arms to the spindle. 5. Insaflibe ski shock absorber. 6, Place the? front skid plat with the torechead screws. (0 position; then secure REMOVING 1. Elevate the front of the snowmobile and secure using -.," asuitable support stand, %, move the push rivets securing the steering boot to the sss; then side the boot away from the snowmobik. “s. % OTe 3. Resse the tonchead serews securing the fat ski piateto the chassis; then remove the front ski plate%, %e, % “ay 4, Remove the ski shock absorber. 4,4, Inspect mounting Ineation of the chassis for cracks or 5. Remove the lock nut, machine serew, and ui-nut | SS securing the spindle fo the A-arms; then using arub- 1NSTALLING ber mallet, remove the lower A-acm from the spin- dle. Discard the lock nut. %, Romove the two cap screws and nyloe auts securing “dhe lower arm to the chassis; then slide the boot from thegam and remove the arm, 7. Remove the two cap screws an! look nuts the uppeFarm to the chassis. Discard the mits, T oS o aly ot oe ; 4 ag, INSPECTING: 1. Inspect the arm welded areas for cracks or any si of deterioration 2. Inspect the bearings and axles for wear or damage, 3. Inspect the arm tubing for signs of twisting or bend- ng. 1. Place the upper arm into position on the chassis and seciue with the cap screws, axles, and new lock nuts. Tighten to 2 Nem (3.3 kgm, 23 lb) 2, Slide the lawer arm into the book then place the arma into positionon the chassis. Secure with the cap serews and net, nyloc nuts and tighten to 75 Nan (7.6 kg-m, 55 EE) (Iront) and 65 N-m (6.6 ke-me, 43) fi-lb (rear) % PomER 3, Secure the A-arms to thé spindle using one new lock nut and one new ti aut. Tighten to the lock nut securing the lower A-arm 10 32 Nem (3 kg-m, 45 ficlb) and the tore serew and tri-nut securing the upper Avarm 0 32 N-m G3.3 kg-m, 23 flb, 4, Irigiall the ski shock absorber and secure using the elt cap ste anne Tock nuts. igen 32 N-m (3:3 ke-m, 24 fib). 5, Insall the eering boot and secure using the existing pusherivet lace the front skid plate into postion; {hen secure wih the tora-head screws Ski Shock Absorber REMOVING Position the front of the snowmobile on a safety “stand taking al pressure off the skis 2. Rémove the cap screws securing the shock absorber to the, chassis and spindle; then remove the shock absorbey, Account Fo all mounting hardwate % 19NOTE: Note the number of tfieads exposed btrgen the spring adjuetor and sheet fouing for Installing purposes. io 3. Inspec the links, bushings, bushing rea hardware for damage or wear, es INSTALLING %, 3. Using the Shock Spring Removal Tool, retfove the \ spring fom the shock body by compressia.the — fractettinon mata the sway bur tte snowing, spring; then remove the spring retainer ftom the bile Secure wih the tonchedd screws and tighten to Of the spring. Ingpect the shock absorber by quick bile, Secure hth ton be compressing and extending the shock plunger while firmly holding the shock bod. Resistance must be, 2. Secure the sway bar links tothe sway bar and lower felt in both directions. “2, CLEANING AND INSPECTING “) Acarm with the cap serews and new nyloc nuts °ATighten to 32 N-m (3.3 kg-m, 23 fb) Insy ect the shock absorber 5 gal area for signs of exeessive oil kakage en, 8 2, Inspect the shock absorber mouriing eyelet, bush Ingieand sieve for wero mage Inspect the threaded shock sleeve for “amaze or wear. Clean the sleeve and apply a light‘coat of grease to the threads before installing, INSTALLING 1. Using the shock spring tool, place the spring on the © shock absorber and secure with the retainer, 2. Adjust the retainer nut (spring adjuster) (if applica- ble) until the specified=amount of threads are ;posed between the spring adjuster and the shock °c, housing (noted in removing) ‘san initial setting, 3 Install the bushings, sleeves, anY’spacers into each stock end; then place the shock abfagber into past tion and secure with the cap screws and lock nuts Tighten the lock nuts to 44 Nem (4.5 kg-4, 32 ft-lb) for RTX and LTX models. Tighten w 32 Nem G3 gem, 24 fi-ib) for MTX and XTX models Sway Bar REMOVING 1. Remove the nyloc nuts aif,cap screws securing the sway bar link to the lower A-arm and the sway bar. wio7e Y Remove the tonc-head sorews s@ouring the sway bar ‘mounting brackets; then pull the stay bar out oF the srowmobile INSPECTING 1 Inspect the sway bar for eny signs of isin fatigue, or wear 2. Inspect the sway bar arms for cracks or damage. 20 REMOVING/INSTALLING Front Bumper »,, 1, Remove both access panels and the hood, Remove the eight torx screws and washers securing the front fascia and bumper to the chassis; then remove the front center fascia, 3. Remove the PDM from the PDM bracket, remove the front bumper assembly then ‘AQsing a punch and a hummer, remove the center of the existing huck rivets securing the PDM bracket to the bumper 5. Using &1/d-in. dil bit, dill out the four yck rivets,ames vn 6. Secure the PDM brackebto the botiom side of new Front Bumper using the four-huck rivets 7. Position the fioat bumper asseiibly over the front of the snowmobile and align with the previous mount- ing locations 5, 8 Secure the bumper to the intercooler asSembly using, the existing four or screws Tighten secu, 9. Install the PDM into the PDM bracket; then position the front fascia and secure using the existing eres and washers. Tighten securely. 10. Install dhe hood avi-both access panels Seat Assembly &, ‘To remove the seat, remove the torx-head serew from the underside of the seat; then lift on the bu@k of the seat and. ‘move itup and rearward to removeit. “s, CAUTION ‘On models with seat heaters prior to removing the lift the rear of the seat and disconnect the seat h haress connector. MNOTE: On models with seat né or to lowering and securing the seat, connect the séat heater har- ness connector. o, Seat Cushion REMOVING 1, Remove the seat assembly. 2. Using a sharp tool, pry gut all staples securing the Seat covert the pksis set ase 3, From beneath the seat foun egmove the seat wire ftom the two elas foops thetsemove the cover from the seat basoand set foam = INSTALLING %, 1. Position the cover over the seat foam and seat base; thea pull the two elastic loops through the slots in the seat foam and secure with the seat wire. Check to make sure itis positioned stright. Fold the rear edge of the cushion down and around ” sheplsicbae Usingasiplegunando3Smn (4% in.) staples, staple the rear Map of the cushion to the 9, plastic base in the same areas as the original staples “ap, ‘were located, Position sails 25.4 mm (1 in.) apa % “3, Fold the sides of the cushion“down ground the bot- tom edge of the plastic seat base Position the staples inthe same area asthe orignal apes were located NOTE: Note the cushion fit. If any ‘wrinkles are noted, remove by pulling the cushion material in the appropriate direction before securing with staples. 4. Fold the front cushion material back and onthe Plast Seat ise, Check for wrinkles and Scat wih, Staples and two Seren. ‘5, Install the seat assembly. To install the seat, soit the front tab on the seat through", the scat-base hold dows bracket then install the seat and secure using the torx sd 1. Remove the two torx-head screws Securing the t Hight tothe taillight support then diseoanest the tal- ight hamess connector.all skid frame assembly using two existing %, smachine screws. Tighten socuroly. REMOVING SNOWFLAP 1. Drill yt the rivets oF remove the four screws, wash es, and nts securing the snowlap to the tunnel and to the rear bumper: 2. Remove the say flap, INSTALLING SNOWFLAP Add the appropriate rivets'gr reuse the screws, wasters, and nts to-secure the snowy to the tunnel and to the tear bumper ty Windshield/Console/ Headlight REMOVING 1, Remove both access panels and the hood, 2, Remove the sikeyerews securing the windshield the console; then Fémove the windshield 3. Remove the sx crew yecuring tbe console 0998 tg 2. Connect the taillight hamess connector, then secure %. the taillight to the taillight support with the two tors- ©, head screws, Tighten to 6 N-m (0.6 kg-m, 48 in.-Ib). Rear Bumper/Snowflap REMOVING BUMPER 1. Remove“and retain only the two machine screws securing the'bear of the skid frame assembly. 2, Place cardboarr a suitable substitute on the fRoge to protect the snowmobile from being scratched: them installa suitable stind into the lower holes in the handlebar riser (from the left-side) and tip the stow- mobile onto its left side. 3. Swing the skid frame assembly away from the chas- sis; then using 2 4.76 mm (3/10-in,) drill bit, remove » all'rivets securing the left-side of the bumper; then “sepeat for opposite side. 4, Refove and retain the two machine screws and nuts secuitag the front of the existing bumper to the chas- sis. 5. Remove the'pwo rivets securing the snovflap to the bumper Remove the bumper 4, Disconnect the gaug: eléetrcal accessory wires, and INSTALLING BUMPER +, Reigate awe a 1. Align the holes inthe bumper with the existing holes ©, 5 Remove the three serews securing the headlight to in the tunnel; then using new rivets, secure rear, smpet to the tunel; then secure the snow! "1, the hood; then disconnect the headlight connector, bumper to the tunnel; then secure the snowflsp to the o Remove the headlal rear bumper using new rivets 42. Sccure the front of the bumper to the chassis using, % “the existing machine screws and nuts. Tighten ‘Securely. 22INSTALLING 1. Position the headlight anto the hoods then secure the headlight using the existing serews. Connect the headlight conneetor 2. Engage the side console tabs onthe headlight assem bly: then place the front of the console over the head Hight asserably and press dowa until itspaps in place 3. Secure the console to the headlight aiid, the hood using the existing screws. Tighten securely. , 4. Conncct ig gauge; then connect the electrical Sony ies he ignition switch 5. With the winddhigld in position, secure the wind” Shstto the Tt ing the si stews Then Searls e 6. Insta the hood and bottigzess panels, Adjusting Headlight Aim of the beam ‘The headlight can be adjusted for verity HIGH/LOW beam. The geometric center of H zone is to be used for vertical aiming 1. Poxiton the sowmabile ofa eve or so the head ight is approximately 7.62 m(25 fi) from an aiming surface (Wall oF sit surf NOTE: There should be an “averages “aperating load ‘on the snowmobile when edjusting he ight an. Measure the distance from the floor to midpoint of the headlight. %, Using the measurement obtained in step 2, makiva horizontal mark on the siming surface. Make a vertical Shark intersecting the horizontal ark on the aiming surface directly in font of the headlight. in Engaue the brake lev iGek and start the engine. elect the. headlight dimmer: switch HIGH beam positon DO NOFUSE LOW BEAM. Observe the headlight beam aim. Pifjper aim is when the most intense beam is centered én, the vertical ‘mark $0.8 mm (2 in.) below the horizonial mark on the aiming surface. % Adjust the headlight using the adjusting screw do the backside of the headlight using a4 mm swivel socket and long extension until correc: aim is obtained. Shite, the engine off: then disengage the brake lever lock.—— Engine ———ern'—"'"“———_ This engine sub-sction has Bien organized to show a progression for the removing/instfiling of the engine. For consistency purposes, this sub-sectiéa shows a complete ‘and thorough progression; however, forgfficiency it may be preferable to remove only those components needing, to be addressed. Also, some components niy.vary from mode! to model. ‘The technician should use disctesion and sound judgifent. fe Removing NOTE: White removing jhe engine, note all cable tie locations. ny, 1. Remove both acvess panéi, then loasen the two quarter tums securing the hood Diseonnect the hood haraess and pull the hood Tora and off of the snowmobile 2, Remove the seat then remove the gas Bap and retan- ing mt irom the nck of the gas tank. Remove the Clan serews securing the Console, Remove ihe com sles % urea > 3, Remove the’gas tank assembly. 4. Remove the ea from the secondary sheave ry sheave (along with the drive belt) off the drivenrshaft. Account for alignment washers and sheave a ‘5. Remove the cap screw and jyasher securing the pri- mary sheave to the crankshaft, 6. Using Primary Sheave Pulley‘tighten the pull: Remove the primary sheave. NOTE: If the primary sheave will fot rolea sharply stike the head of the puller. Repect this unt the sheave releases. Me, 7. Remove te'sorx-head screws and both access pistes from beneath the snowmobile. 8. Place a drain per igncath the engine oil dain sews then remove the sCrew and allow the oll to drain completely, After the oilas drained, install the érain plug and tighten to 10 N-ia(1 kg-m, 7.2 fb). %, 24 9. Remove the four torx-he.serews securing the ight- side footrest to the tunnel aiid the support; then with 8 drain pan in position, remo the dain plug fom the oil nk. oil Drain Plug ae NOTE: To aid in draining tho ol from. position a funnel between the tank an of the tunnel running board. 10 reservoir, ‘opening 10. After the oi! has drained completely, install dedrain lug with a new O-ring and tighten to 22 N-mv42.2 Ken 16 feb). LL Using a suitablé’yacuum from the coolant files ned Imp, remove the coolant, ‘andthe reservoir tank 12. Remoxe the five seeds and washers sceuring the turbo heat shield tothe turbg. Kemove the shield 13. Remove the cap screws and:washers securing the heat shield to the manifold.wees 14, Apply a small amount Uf penetrating lubricant to the threads of the 1wo clampthreads; then remove the two nuts securing the exhatist pipe clamps. Remove the clamps and the pipe. 15, Remove the six torx screws securing the resonator to the turbo; then remove the spring seturring the reso- nator, Remove the resonator and account for a was- ket NOTE: A long 150 ball head torx bit (p/n "g0890- 11148/YS-11148) will be needed to remove the torx 16, Remove the seréws and washers securing the exhaust hheat shield to the tunnel Mies? 17, Remove the hose clamps securfig hoses to the turbo, intake manifold, intercooler, and, the air bypass valve, Remove both hoses, SNORE 18. Remove the steering post assembly: then temove the ‘two cap screws and nuts securing the vapot. tank to the right-side suppor. 19, Remove the cap screws securing the front sparstp the chassis; then remove the cap serews and nuts Securing the right-side support to the chassis. Remove the steering support as an assembly. 20. Remove the screws sectiting the air silencer to the clutch guard; then disconneet the hose from the top Of the engi te gate hose, Remove the airsilencer assembly, 25Remové/the two cap serows and spacers securing the intake maififold and throuile body 1o the engine; then remove the thee clamps seeuring the intake boots to the throtile body; Remoye the intake manifold. 22, Remove the clamp” securing the intake duct to the PTO.side of the turbo: 23. Remove the hose clamp Seuring the coolant hose to the vapor tank; then remove'the hase clamp securing the coolant hese from the bottom of the turbo. Wares 24, Remove the clamp securing the oil retym hose to the crankcase; then remove the oil deliveryhose to the cylingler using the existing banjo bolt ard new wash- eis. Tighten to 10 N-m (1-0 kg-m, 7.2 ft-lb) 26 25, Remove the two ca@-serews and nuts securing the fiont of the right-side chassis support to the chassis. Remove the turbo and support assembly 26, Remove the three screws aid ene nut securing the clutch guard; then remove the sCrews and nuts secur ing the left-side chassis support. Rotate the support up to gain access to the rear engine ep serev. 27, Remove all six cap serews and nuts sGeuring the front engine bracket; then remove the ‘bracket. Remove the cap sere’ and nut securing the ground Wire to the engine.‘swoses 7 % 28. Remove the cap serew and nut securing the.rear of the engine tothe chassis ( 20. Remove the clamp securing the MAG-side costagt fiwe (0 te coline, en Uigcomnest Ue ol prose, Switch and theo pressure sensor 30. With all hoses and wires disconnected from the zngine, move ihe engine forward and out the Tight site of he chases "81, Remove the throttle body assembly once the engine iistenoved “%, Installing ~*, SINOTE: Before installing the engine, be sure the starter motor and cables are Inetalled and the engine. % NOTE: It the thermostat-to-heat exchanger coolant, hoe was romoved, mako sure it Ie properly touted “>. and installed onto the heat exchanger. Tighten o4N- (0.8 gem, 35 in-lb). 1. Position the front engine bracket with the front > te mounts then loosely seeure using the existing cap screws and new nuts 2. Gaqoflly lower the engine into the chassis aligning the'tgar engine mounts with the chassis mounts; then loosely, secure using the existing cap screw and a a ee 3. Loosely segive the fromt engine mounting bideket to the chassis sig the existing cap screws and new nuts; then loosely secure the ground cable to. the engine using the cxisting cap serew and a new nut%, a 4. Tighiéa the rear engine cap screw and nut to 126 N- sm (12.8%Rg-m, 03 fb). 5. Tighten the tap screws (A and B) to 34 N-m (3.5 ke- m, 25 ft-lb). iten cap screws (C) to 88 N-m (8.9 kg-m, 65 ftlb) Tighten cap screw (D) to 41 N-m. (42 Kem, 30 feb} 6. Conc eo esse and he presse conmeet te gree 7. Connect the coolant hose frofi.ghe heat exchanger (@ the water pump and secure using the existing hose , clamp. Tighten to 4 N-m (oct kg 3 nb) MNOTE: All wires, cables, and hoses must be installed. on the inside of the coolant hose and the PTO-side’bracket. %,, CAUTION Make sure the top’slamp Is routed like the image below, ‘so the clamp does not come in contact with the primary, isheave. “y 28 MNOTE: Route the positive and negative battery ablos up and ovor the ongino mounte. 8 Install the throttle Boxy eg ihe strane Sas Tighten to 3 N-m (03 . ane 9, Install the throttle body coolant-hoses to the engine and the water pump. Secure Using the existing clamps. %e, 10. Install the intake manifold assembly oni@ the throitle body assembly and secure using the existriy clamps. Tighten to 24 Nem (0.24 kg-m, 20 inlb). ©, 1. Secure the fingnifold bracket to the engine using’the seigws and spacers, Tighten to 19 N-m fb). 12, Position the right-sid@:zear spar with the chain case assembly; then’ instalP-the existing cap screws: through the chain case and the spac. 13. With the turbo installed onto the MAG-side mount- ing bracket; secure the assembly the chassis using the existing serews and nuts, Tighieg to 27 N-m 2.8 kkgom, 20 fitb).Yuri6s 14, Connect the lower coolant hose on the backside of the turbo to the oil@poler, Secure using the existing hhose clamp. Tighten €@,3.5 N-m (0.35 kg-m, 35 in Ib, Maniee 15. Secure the cil retum hose to the crankcase using the existing clamp; then seeure the oil delivery hose to the eylinder using the existing banjo bolt and new washers. Tighten to 10 Nem (10 kg- 7-2 ft-lb). MNOTE: Make sure the distance (A) between the oll delivery hose and the turbo is 3.0 mm (0.12 in... 16, Install the front two spars to the @hassis and loosely secure using the existing cap serews,and nuts; then position the steering support over all fur spars and loosely secure ising the exiting cap serews and ‘nuts. Tighten all cap serews to 34 Nem (3.5-he-m, 25 fbb). ° ,"ey 17. Secure the ‘aor tan assembly to the nightie rear Spar ding ing cap serews and nuts; then SBaneel fe coolant Heke ts te bo iting sod tank breathigr Tine to the ait intake tube. Tighten the hose clamps ty 4 Nem (0.4 kgm, 35 i 18, Install steering pobthrough the intake manifold and into postion. Secure to te steering stop bracket with fnew MIO hat, Be suo co align the steering post Dall fein alignment tab, with the steering stop Bracket Tighten to 58 Neng ken 8 ib) Steering Pest Bal Joint Steering Stop Bracket — wOR 49. Secure the iro assembly tte staring post using “o,anew MIO nul. Be sure to aligithe tie rod Dall nt alignment tab with the steerinig post. Tighten y48 Nem (4.9 kgom, 35 ft-lb), %, %, SHORT 20. Seéuse the right-side steering boot to the chassis, using th existing push ress. 21. Secure tH@0p of the steering post 0 the steering support using, the existing retaining plate and nuts ‘making sure the jhrottle cable is routed between the staring bushings? gwen 10 11 Nem (Lt ke, 96 30 % 22, Insall the titake duct to the turbo and secure using the existing clin. Tighten the hose clamps to 4 N-m (04 ken. mA 23, Install the air silenes#onto the air duct; then install the hoses from the ait bypass valve and the hose from the top of the engine into the air silencer. Sccure the silencer using Tighten securely. 24, Install the intake manifold assemblyonto the throttle body and secure using the existing clamps. Tighten WA Nm (024 keem, LTD). 25, Usingahe long (PTO-side) andthe shor (MAG-side) spacers, secure the intake manifold assembly to the rane hana cannes thea wD 26. Inval the hoses ek intercooler, trbo intake man- Hold, and air bypasS-valve using the existing clamps. Tighten io 1N-m Ot ks me in27. Trgtall the exhaust heat shield onto the tunnel and seeore using the serews and washers. c securely. 28. Position’the exhaust gasket between the turbo and the resonator: then using the long T'50 ball head tors bit, secure the’ resonator to the turbo using the exist- ing screws. Tighten the screws to 12 N-m (1.2 kg 9 fi-Ih) then to 24 Nem (2.4 kg-m, [8 f-lb) in a criss. cross pattern, (OTE: Apply a small ammount of anti-selze to the threads of the screws. 29. Install the exhaust pipe onto’ the exhaust manifold and the turbo and secure using néw clamps. Tighten 108.5 Nem (0.85 kg-m, 6.1 ft-lb) 30. [fall the exhaust heat shield to the exhaust pipe uusing:the eaisting cap serews and washers. Tighten securely, Yess 31. Install thie,turbo heat shield and secure using the existing capyscrews and washers. Tighten securely, 32, Install the gas tink assembly and connect the battery; then install the cOgsole making sure to connect the reverse alarm and heated seat switch, 33, Install the primary shea¥, drive belt snd the second- ary sheave. 34, Install the seat and secure usinghe screw MNOTE: On models with soat hoaiérs, connect the seat heater harness connector. 35. Instill she hood and both access panels. Servicing This engine sub-sectidn bas been organized to show a progression for servicing-of the engine. For consistency purposes, this sub-section’ shows a complete and thor- ugh progression; however, foreficiency it may be pref- erable to disassemble only thos8components needing to be addressed. Also, some compofienis may vary from modal to model. Th? technician should yse discretion and sound judgment Disassembling |. With the engine secured to a suitable engine stand, move the ignition coils from the cylinder head ‘cover; then reimdfee the spark plugs. 2, Remove the four Allef.-head serews securing the ey! indor head caver to thévcylinder head; then remove the cover. Account for thé gasket. 3t‘snore 3. Remove both plastic plugs (A&B) from the MAG: HNOTE: The engine cylinders are numbered #1, #2, ‘aft #3 from the PTO to the MAG. apis OVW ORR 4*Obtain top-dead-center (TDC) by rotating the erank- shat (clockwise) until the mark (A) on the magneto rotor is aligned with the pointer on the magneto cover (B) and the #8 piston Isat TDC “y MOTE: TOC on the compression stroke can be foundsihan the camchat tobse or eyinaer #9 (MAG side) are {umed away from each other. NOTE: At thi point if the technician's objective isto service the valves, proceed to Servicing Components ‘Valves in this Subssection. 5. Remove the twoeap screws securing the starter rotor assembly to typ crankease: thew remove the Sanerimowr ows securing the MAG note the location of 6. Remove the Allen-head % cover to the crankcase tal “%,, Thread the MAG cover removal cap serew into the “aiming mark hole, then carefully pull the MAG cover fm the crankease. Account far two dowel pins and agit WARNING ‘cover be sure to keep hands away] [When removing: the case. irom being pinched between the cover‘yuzoe ‘yu20s 9. Remove the cap serew securing the flywheel to the crankshaft. Account far the washer. 40, Using Flywheel Puller, remove the flywieel from the cgrankshafl. Account for the key in the erankshafl, usar 1. Remove the four cap serews securing the output shaft assembly to tho crankeass; then thread the pri- ‘mary sheave bol into the end of the crankshaft and pill the output shaft assembly from the engine YMO08 12, Remo¢e, the Allen-head screws securing the water pump assembly to the crankease; then remove the assembly. Aecount for two dowel pins and two gas- kets, ROT 13. Remove the five Align-head serews securing the oil cooler assembly to the eagine. Remove the assembly. SHOTS 14, Remove the two Allen-héad screws securing the cchain tensioner to the eylinder assembly. Remove the tensioner and gasket. 1Saemove the cap screws securing the exhaust cam shaft cap (A), intake camshaft cap (B), and the cam haf), Atcount for the dowel pins that may stil Beedheguel io ne camshalt caps% %, Y ny NOTE: To prevent damage to the:-cylinder head, camshafts, or camshaft caps, loosen’the camshaft ap, sorews In stages and in a eri pattern Working from the outside in 19, Remove the four cap screws securing the rett-engine mounting brackets to the crankease, Remove, the brackets , 16. Remove the exhaust and intake camshafis from the engine %, bs comeEn EEL “> ‘wiz (El : nie Lit 20. Tip the engine upside down: then remove the cap’, Kt bs screws securing the oil pan to the crankcase. Using a © comet (| Se anunetarume sar gomiees, Cone“, 4, Separates. Account for the oil pan gasket and two dowel pins. 17. Remove the eight cap screws (#3-10) and two Allen- head screws (Hand #2). Remove the head and account for the gasket and dowel pins. MOTE: Loosen the cap screws in the proper sequence ao shown, Lassen coch cop acrew 72.3 a tum ata time, After all of the cap screws are fully loosened, remove them. Yo sKO7H lote the location of the different-length cap screws for assembling purposes. CAUTION ~~, [DO NOT drive any tool between the halves to seperate] ithe crankease. Damage to the sealing st wil result. 18, Remove the cap screws securing the tinting ch: tension guides to the engine; then remove the guide in 21, Remove the two cap screws securing the oil pur ‘ ehatn guide, Remove ie exp sere securing the off riven gear (A) to the oil pump using the Sprocket holding tool (Bi) ten remove the oil pump chain end timing chain fromm the eransha 3422, Remove the five cap screws securing the oil pump to "Ze, the erankease, Account for two dowel pins. yascz0, Loosen the cap screws in decreasing numerical order of the embossed numbers on the crankcase, Loosen each bolt I/4 of a tum at a time. Afterall screws are loosened, remove the screws, Remove the lower “erankcase hall. 2. *, &s, "s ‘BROT p on one side of the crankcase with a soft p only on reinforced portions cf the anoTt hammer. ‘erankcase, not on the crankcase mating surfaces. Work slowly ang carefully and make sure that the crankcase halves:separate evenly. 2 24, Remove the cap Screws securing the comecing 15 caps (A) to the connecting rods, Account for the ®,, bearings eg 26. 6. ‘SHO Pe NOTE: Because the connecting rods and connect- ing rod caps aro unique, noto the 11D. marks and Koop all associated parts together for assembling pul poss 2 25. Remove the dapkshaft and piston assemblies from the crankcase, oy Pistons can be Seam 9p side onl Remove the piston pin clips; then remove the piston pin. SHOTS Before removing the piston pin, de-burr the pn clip groove and the piston in bore area. i fag are de-burred and the piston pin is ot", sae 27,Straighten the locking tabs securing the cap screws securingite balancer shah then teinove both cap serews anid hoth balancer weights NOTE: To remoie the cap screws (C), place a small piece of wood (B) between the balancer weight (C) and the crankcase, “7 28, Remove the snap ring sé ager; then remove the gea {spacer and a bearing Servicing Components Thoroughly clean all non-ele¢trical components in parts- cleaning solvent; then remove aby carbon buildup from ie cylinder head and piston dome” Visually inspect all engine componentifor weer or dam- age. CHECKING CAMSHAFT LOBES [seating sur 1. Measure the intae camshaft lobe heights (A): 33.750-33.850_ mm %(1.3287-1.3327-in.).. : 33.680 mm 1.3248%in., 2. Measure the intake base citéle diameter (B): 24.950- 25.050 mm (0,9823-0,9862-in2,limit>: 24.850 mm 019862-in te 3. Measure the exhaust camshaft lobe, heights (A) 38.780-38 860 mm (1287-1 3427-in)

: 33.650 mm 1.3248%in. oy 4, Measure=the exhaust base circle diameige, (B): 24.950-25:050_ mm. (0.9823-0.9862-in.).

: 24.830 mm 09783+n,‘SNOT CHECKING CAMSHAFT RUNOUT 1.“Measure the camshaft runout: 0.030 mm (0.0012- in} Replace if necessary. i %, o % SHOTS (CHECKING CAMSHAFT JOURNAL-TO- cAP %e, Measure the camshaft joumal-to-camshafl cap us following procedure Clearance 0028-0. (0.0011-0,0024-in.) . |. Install the camshaft into the eylinder heat without the &, dowel pins and the camshaft caps installed, os %,_ 2. Position a stip of a pieve of Plastigauge® (A) onto °o~* the camshaft joumal; then install the dowel pins and * the camshaft caps 1 KOE YEO) VQ kD ee % fe, 3. Tighten the camshaft caps cap screws in stages and _,, in a crisscross pattern working from the inner caps outward. Tighten to 7.2 f-1b. NCTE: Do not tum the camshat when moasuring the camshaft journal-to-camshaft cap clearance with the Plastigauges. 4, Remove tiécamshaf caps and measure the width of CHECKING DIAMETER Pe 1. Measure the camshaft jougnal diameter (A): 24.459- 24.472 mm (0,9630-0,9635-in,). Replace if neces- ©-2. If the camshaft is within specification, the cylinder head and camshafts might need to be replaced as a be CHECKING CAM CHAIN/SPROCKET%, ‘NOTE 2. If the camshaft is within specification, the eylinder head and camshafts might need to be Teplaced as a %e If the cam chain or cam sprockets are damaied or wear is should be in found, the eam chain and cam sprockets replaced as a set VALVES ny 53. Using an appropriate thickness gauge, 'mensure and feootd the ake und exit rlve clone ofthe vlinder that is on dhe ‘compression ‘sok. then fatate the engine 360° and measure and reed the valve clearance ofthe other eylinde. Valve clearing Inust be within spect z old) Tetons 015-022 Hm (0.C050 0.0087 In) Eohaust 027-0225 mm (00085-0088) 15-25" oor ® } % ° 8 * e If any valve 1s discolored of. pitted or if the seating surface is worn, the valve must, be replaced. Do not attempt to grind a valve or severe engine damage may It'valves, valve guides, oF valve seats requite servicing or replacement, Yamaha’ recommends the cofippnents be taken to a qualified machine shop for servicing. 1. Install the primary sheave; then using Pritnary 2. Rotate the engine until the camshaft lobe of the valve being measured is di 38 “MNOTE: At this point if valvehappet clearances are within specitications, servicing 1s complete. If any valv@ftappet clearance is not within. specifications, complete step 15 of Disassembling before proceed" ing to step 4. "on, MINOTE: Make a note of the position of each valve liter and valve pad so that they ean be reinstalled in their original place. % spceification clearance, note the threc-digit number oon the surface of the existing shim: then refer to the Appropriate Tappet Shim Selection Table (Exhaust or Intake) inthis sub-section and use this procedure: A. Find the Measured Tappet Clearance (from step 3) inthe lefside vertical coluiag ofthe table. HbFind the Present Shim Size (thige-digit-aumber) at the top-side horizontal column the table. . Match the clearance in the vertical catumn with the present shim size to obtain the recomended replacement shim, Mag 5. After verifying proper valvetappt clara, nsf the timing’ inspection Plug to the magneto case anc tighten securely. MNOTE: At this time, remove the items used to close off the intake ports of the cylinder head.ss J o wausye pag ozs aus nus? fea uns wens ww 86° 4° eouesee9 yedde eS ards ‘uuinjoo yejwozvoy u 22s Uys WwaSEIG YM UURN|Co feDHJ8A U! eoUeHLy e ria s (usnwHxa) Davi NOWOSTaS'N IHS LaddvL ef : a 8 GauNOSH aR SNTaY NTSONMAVNO ROR s wee [oe [eee [ee we [ore [owe] owe [we | oe [| oe | we [ ce | we [we [we [ee] we Loe [we ere [ore [ereG'e| oe [ove [ore | ore [ore | ore Gigal we [we | ws [ove [wre | ore flrs [oe [or |r ose |ore| ore | sce fee | sex | see sie | ore | oe | ove | sre fore | see | or | sxe | ace | sve | ore | sre | oe | 9 | oz | 22 | oe fons ae | oe | oe |e | ee | sex on | cir | ow | oe | om | oe eee | oe | oe | cur | oc | cme Jom jo | se |e | me oor | ot se > eo Fo oe eo& posn ca oi ezitluns oz ys luoned rade é é vos Poe Poe ¢ we é vise epoypien ens neon qn vunro renin gsSiee vr = ‘Sevan heseid ocean = ‘p02 eubue aj unye cucnnp essetemareh | Soo sig oso MoM on fwe we a oa [wae a ole se z_pinr we [we wee ve | we |e [a | oe [re ‘G38INDSE INNS WOY ONZONVEYS'O 0315035 < wee [me omy ee [oe | me] ove | ove | ore | are fre | we | we [oom] we] me we we sez [we [aie Low [we [we we Loe [we [a we Lo | we bowel we [oe oe g"ny CONNECTING ROD BIG END BEARING a NOTE: Do not interchange the big end bearings and connecting rods. To obtain the correct cranksheft- Pin-to-big-end-bearing clearance and prevent engine ‘damage, the big end bearings must be installed in thelr original positions. % 1. Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods, 2. Install the bigsend upper heating into the connect red and the big end lower bearing ino the connecting’, rod cap. hy NOTE: Align the projéetions on the big end bear ings with the notches in the connecting rod and con necting rod cap. “O % ‘SRO 4 Puta pee of Pasizauser €Q) oa the canta pin; then install the connecting rod halves. NOTE: Do not move the connecting’ rod or crank: shaft until the clearance measurement hasbeen com- ploted. Apply molybdenum disulfide oll onto the bolt, threads, and seats. %, 4. Make sure that the “Y” mark (A) oa the connect rod faces towards the right side (AC magneto ro side) ofthe crankshaft 5. Make sure that the @haracters (B) on both the con- necting rod and connecting rod cap are aligned. Fe 6 6. Tighten the connecting rod eap se*eiys: then remove the connecting rod and big end bearings. Measure the compressed Plastigauge® width “(A) on the crankshaft pin 2 NOTE: The numbers (A) stamped into the cranke, shaft web and the numbers on the connecting rods, are used to determine the replacement big end bear- ing sizes. °.%e, wa For example, if the connecting rod “P1" and the crank- foram comet go Pam oe ‘then the bearing size for “P1” is: Bearing size for “P1": ase a chaatacee eed (Gress) BIG END BEARING COLOR CODE 7 Bue 2 Black 3,3 Brown % Green 5 Yelow € Pink A % NOTE: Do not put the Plastigauge@ over the il hole in * the crankshaft journal. “efosal the crankshaft joumal lower bearings into the ver erankease and assemble the crankcase halves. mNOTE!| meesuter ot move the crankshaft until the clearance nthas been completed. % 5. Tighten the“eap serews in the order of the embossed numbers on the, crankease; then remove the lower crankcase and thécrankshaft jourral lower bearings. 3 6 (6, Measure the compréssed Plastigauge®) width on each, cankshatjoumal %, (CRANKSHAFT JOURNAL BEARING ~ MINOTE: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaftjournal-o- ‘erankshaitjournal-bearing clearance and prevent ngine damage, the crankshaft journal bearings must ‘be installed in their original positions. L ‘Clean the crankshaft joural bearings, crankshaft jour- nal and bearing portions of the crankcase. Place the uppef erankcuse upside down ona bench. 2 Install theoumal bearings into the upper engine case. MNOTE: Make sue the tabs of the bearings are properly seated to the notchiés inthe upperengine case. 3. Putapiece of Plastigauget on each crankshaft journal Ee Nn %, 7. If the clearance is out of specification, select replace- ‘ment crankshaft journal bearings. MNOTE: The numbers stamped into the crankshaft web ithe numbers stamped into the lower crankcase are us determine the replacement crankshaft journal izes. bear %,‘sNo-e7 ‘sno NOTE: “1 - JA” refer to the bearings shown in the crankshaft web and lower crankcase illustration. If “Jt - 44” are'the same, use the same size for all of the bear- ings. faye crankcase “JI” and crankshaft web “1” respectively, the beating size for“)1” is: J1 (erankcase) ~FPgrankshatt web) + 2=6— 1+ ‘CRANKSHAFT JOURNAL BEARING COLOR CODE "ey PISTON. ASSEMBLY NOTE: Whenever a pidion, rings, or pin are out of tolerance, they must be replaced. Cleaning/Inspecting Piston 1. Using a non-metallic carbon, removal tool, remove S any carbon buildup from the dome ef the piston. 2. Tfispect the piston for eracks in the pista pin, dome, and kit areas ad 3, Inspect the piston for seizure marks or scuffing. JOTE: If seizuse marks or scuffing is detected, the piston must be replaced c perimiler of each pision for signs of “ilowhy. "Excessive “lowby” indicates ‘wom piston rings or an oyt-ofround cylinder. Removing iston Rings z Black 1. Starting with the top ring, slide‘gne end of the ring. 3 a Bra 6 out of the ring groove. Se mw ea on 2. Remove each ring by working it towardthe dome of 4 Grsen {hg pon nhc ting iat of hegre é Pink 7 led m8 White °6 7, 0 NOTE: I the existing rings will not be replaced with few ones, note the location of cach ring for proper installation. When installing naw rings, install as a complete set onl"y, “a, “4 Measuring = ‘6, if Bere (6) [so000-a0 O10 mm G.IEOS IS ND “;,{Installed) [Taper i (7) 0.050 mm (0.0020 i.) (Out of Rout (0.050 rm (.00207n.) “Place each piston ring in the wear portion of the cyl- Sader Use the piston fo postion cath rig squarely in they. MINOTE: Remove any carbon; then clean the top of the cylinder'bore ‘before inserting the piston rings. 2. Using a feel gouge, measure cach piston-ring end gap, Acceptablé zing end gap must be within the fol- Towing specifications. 8. ston Ring/Groove Clearance NOTE: Before checking, piston grooves must be clean, dry, and free of carbon. Fit new piston ring into piston groove and measure clear- ‘between, ring and ringland by using feeler ni“must be within the following specifica tions. If clearancsis out of specification, replace piston. fraing Joan. obes mm (OonTe-0 RBI) Ring 70002-0055 mm (0.6008 00022.) |, oy ‘woes Measuring Piston Skirt/Cylinder Clearance “a. Measure the cylinder bore using a gauge by taking side~ © -to-side and front-to-back measurements of the cylinder. ‘Then, find the average ofthe measurements 44 string (pss) —] *) ne Ring “0.70.080 mm (0.928.0.061 m) [on Finas .1C035 mm 00040.010 7) SRO: ravimum of DY 06 ain of DY fB2 = mavimam of or ann of1 63 GS —maxrun ofS, 58 oBE ENOTE: If out of specification, replace the crankcase ‘and the piston and piston tings as a sot. Measuring Piston Skirt Diameter “4. Measure the piston skirt deter (A) with « 7, micrometer. Be sure to measure 10.0 mm (0.39 in.) om tnsboitom sue of tie paton (8) 2 Fig ski diameter must be within 79.95-79.96 min (G.1476-3.1480 in.) BOTA Measuring, Piston Pin Bore Diameter NOTE: It may be nedessary to use Piston Pin Puller toremove the piston pins, 1. Insert_an inside dial indigator into the piston-pin bore, Take two measurements fo ensure accuracy. 5,2. Piston pin bore must be withisi221.004-21.015 mm %, (0.8264-0.8266 in.) 6,ny %e, Exhaust OQ ‘SH0-2948 “Measuring Piston Pin Diameter Incorrect Installation of the piston rings will reeult in Mibagure the piston pin diameter at each end ond in the cence eucnat trust be within 2090-20995 mm [engine damage. (0.8264-0 8266 in.) If measurement is not within specifi 1AF cations, thepiston pin must be replaced, CRANKSHAFT RUNOUT % 1. Support the crankhafl using a set of V Blocks; use a dial indicator to readhsrankshaf nou. NOTE: The contact pointof the dial indicator should i bo on sithor sido of the oil“port holo of the contor , ¢fankshaft journal and to the outside of the oll port “> hole on the MAG and PTO end of the crankshaft. mst Rotate the crankshaft slowly. % aw 3. The,reading must be 0.03 mm (0.0012 in.) or exank- Ss} shaft repairing/replacing will be necessary. MEASURING CRANKSHAFT MAIN/ ROD JOURNALS (Bearing Surfaces) “, -. . 1, Using a micrometer, measure each main and con- ‘Piston Rings necting rod bearing jéumal from along its length and *y 90° from the first rieaSgrement, Measurement aust 1. Install the pistoisings according to the illustration be within 3697697 WOO mma Class Te1dSO7) below. Stagger the‘end gaps of the upper and lower diameter for the crankshaft fain journal and 37.976. thin oil rings until tidy. are on directly opposite sides © 33.900 mm (1.4951-1.4961") diameter for connect ofthe piston. e >, ing rod journal e 2° any journal is badly damaged or has wear that is. (ak within specifications, the crankshaft must be replaced. “Assembling MNOTE: Yamaha réegmmends that new gaskets, seals, and O-rings be installed whenever assembling the engine. “he NOTE: For assembling purposes, use oll-issolv- ble molybdenum disulfide grease as engine-assem- % SNO20A “S MNOTE: Bo sure to install the piston rings so that the 1’Mnsiall the balancer driven gear (A); then install the “, manutacturer marks (A) face up. balancer shaft (B) making sure to face the punch a otteth sth ' sao mma) on the alaneer driven gear inward, Align otate the rings until the ring end gaps are 120° from tl jon (D) on the balancer shaft with the slat ne another. «) Fnleataner ven shat 6, 6, 45on > Snook 5, Sette the balancer weights (C) using a small piece *, 2, Install the water pump drive gear (A) by aligning the oF woéd (B). Tighten cap serewe to 34 Nom Cs ke “punch mark (B) on the water pump gear with the m, se hay then bend the locking washer over te ter spline (C) on the balancer shaft end. cap serew Gh) % , sHOatS 3. Install the right balancer weight (A) onto the shaft; then ital the washer, Tock washers, and sebure using the existing cap screws making sure (0 ali sl ligt ape king Se ali spline (©) oma shat en. e WSSss/ rs BOTTA 6. Apply engine il onto the piston pin. Make sure the “Y" mark (A) Gip the connecting rod faces to the mae Ae comes 5a eso Oe 2, SNO-S7A pointing up. e 4 Install the left"bglancer weight (A) onto the shaft; then install the Washers, lock washers, and secure using the existing Cap screws making Sure to align the shaft with the shorter the punch mark (B) ® spline (C) on the shaft ¢I the piston pin clips so the clip ends are 3 mm ) (C) of more from the eutout in the piston, ‘Make sue the oil ring end gaps are on cireetly oppo- site sides’ of the piston and the compression ring end ‘90 from one ancther. gaps are 8 With the psn i lubricate each piston and cylinder witi-engine oi: then with the pune fhe ings installed, lubricate each piston marks on the top of the pistons directed towards the exhaust side of the engine, install the piston assem- bli int the cylinder usig Ring Compressor and ‘sNo2a7 °, i % 9. Rotate the engine to the upside.down position for ©, installing the erankshaft My 10. ‘With the proper bearings selected, install the half bearings into the upper engine case: then lubricate the bearing faces liberally with engine-assembling sgrease Taking care not to get any grease between the engine casa,and bearing IINOTE: Make sue tho tabeof th bearings aro prop- Sryanaed tothe Hotchoe ne per anne cee SRO LL, Install the “aptput shaft onto the crankcase making sure to align the shallow groove (A) with the low spline (B) of the-granksha. % 13. Align the ole A) he erin ep) on grankshafl the upper crankease; then install t \ NOTE: Make su ‘connect- ing rods’face towards the right side (MAG side) of the crankshaft. Make sure the projection (B) face towards tho right sidé (IMAG sido) of the crankshaft. a7SNS “ey, 13, Seitahe comecting rods to the crankshaft then install he connecting rod caps, new cap serews, and new nuts.-Fighten only until snug at this time. 14, Altemately, tighten each of the connecting rod cap serew eveniy fa [4 ft-lbs then put a mark (A) on the onnecting od Gap serew. Tighten dhe connecting rod cap screw further to reach the specified angle (115-125°), %, 115-125° = 0 NOTE: Rotate the crankshaft one revolution to ver- iiyfeemovements 15. Using Yamaha Bond Sealiit No. 1215, apply alight film of sealant ont the sealing surfaces of the upper and lower enginecases, 7 wy *, NOTE: Do not ‘allow any sealant to come into con- tact with the oil galley or crankshaft journal bearings. Do not apply sealant to within 2-3 mm (0.08-0.12 in} ofthe crankshaft journal bearings. 16: Isle oer tot per engine ca ipa awe cokes 1 pers 17. Install the cap screws into te Bioper locations in the crankcase; then with the torque pattem shown as num bere onthe eas, tighten the cap serevs aly until sug. % *%, 2 @ 9 OR pee © $eStoi¢ o ast ‘two Bat eo ald oa wole 82.8? | Be! ‘alow ee 5 aroma ncTEsjubenta cap ecrows 18 thasdfapd wash ers with engine oil, Lubricate bolts 9-15 and 19-24 threads and-mating surtace with engine oi Apoly Yamaha Bond Sealant No. 1216 to the threads of cap screws 16-18,“ 18, Tighten crankeasdgap serows 1-8 to 15 N-m (1.5 ka- mm IL flo) then Tapsen and Fesghien to 13 Na IS kgem, 1 feb) 6, 19. Tighten the cap screws 154 an additional 95°-100°; then tighten cap serews 5-8 aaxadditional 75°-80°Y %® *y, y “4 MINOTE: If a cap screw is tightened more than the “<_, specified angle, do not looson the bolt and thon ro- ©, tighten It. Instead, replace the bolt with a new one >and perform the procedure again MINOTE: Do not use a torque wrench to tighten the bolt tp the specified angle. 3 ky-m, 17 fib) and cap screws 13-24 to 12 Nom (ea kam, 8.7 Pb) JOTE: Install the oll pump driven gear with the stamped mark “4XV" facing towards the oil pump % MINOTE: After the ‘tightening sequence, rotate the Crankshaft one revolution to verity tree movement. aa 21, Plave the dowel pins in place; then position the oi ump assembly nthe cankcase al secre using the existing cap serews. Tighten to 12 Nem (1.2 kg msn te * . 1¢ oil pump chain guide with the existing ‘montng Jgeations and secure using the existing ea serews. Tighten to 9.8 N-m (1.0 kg-m, 7.2 ft-lb) 24, With « new Gasket and the existing dowel pins ia asi ei pan st the se fength exp screws Us pattem shown, tighten the serews to 10 N-m/41.0 kg-m, 86 in.-Ib). ‘yito208 MINQTE: At this time, install the timing chain around the orankshart as it must go on before the oll pump chain 2. Posto, coil pump chain around the crankshaft: then instafl-the oil pump driven gear and secure using R03 *y plug was removed, always Install new plug washer and reservoir O-ring. 'MNOTE: At this time, rotate the engine to the upright position. the existing cap sctew. Tighten to 15 Nem (1.3 ke-m, Titty ~, MINOTE: Ifthe oil pan dt 25, Séeyre the rear mounting brackets to the engine case making sure (ne martes on te rages Gh the numbefs,on the case. Tighten to 24 N-m 2.4 kg-m, 18 felb). 7 498NO-307 MINOTE: Prior to%installing the cam chain tensioner, assure the chain is properly seated to the gear on the crankshaft. ae 26. Install the chain guides cap screws (threads coat id secure using the existing with blue Loctite #243) ‘iBhteno 1) Nem (LO kgrhe $6 in) NOTE: Clean the tapered portiofof the crankshatt and the fywh 5, 27. With the key installed into the tsi install the Rywgel onto the crankshaft aligning witht key on theetsastan uni sully seeds % > 28. Lubricate the flywheel cap serew and washer with oil; then while holding the flywheel with the sheave holder fighten the cap screw to 130 Nem (13, kgm, 94 ft-lb). %, 29. Apply Yamaha Bond’Sealant No, 1215 to the stator grommet; then place the grommet into the crankcase groove. , 50 i, 530, Install the magneto c6ver and secure using the exist- ing Allen-hea serows, Tighten fo 12 Nom (12 kgm, 87 fel) CD MNOTE: Apply blue Loctite #243:t0 head screws which should be ins angle mark on the cover. Tighten to 1 8.7 telb). 51. Position a new cylinder head gasket onto the crank case; then position the existing dowel pins into the ccrankease, ” 32, Route the ting chain through the cylinder hed assembly and plage the head onto the crankease. 33. Lubricate the cap sBrews 3-10; then secure the ey!- Farin acer Wipe ganic cake ten to 25 the black Allen- xd next to the tri- Nem (12 kgm, ing cap serews. Tighten to.25 N-m (2.4 Ib); then loosen the cap screws and te-tis Nem 2.4 kg-m, 18 f-Ib) 34, Tighten the cylinder head bolts fisher to reach the specified angle 175°-185° in the proper tightening, Sequence as shown, Do not use a toriue wrench for175 ~ 185° = NO ., 35. Tighten the Allen-head screws #1 and #2 to [\N-m 40, Install the existing dowel pins into the cylinder head; "4, (123 keer, 87 feb). % into the head. ‘TDC on the compression stroke, align the 36. Position the intake and exhaust camshaft assemblies, 37, Tum the crankshaft clockwise, When piston #3 is at ark =, (A)on the magneto rotor with the Sationary pointer ’o, (B) on the magneto cover. Install the timing chain conto both camshaft sprockeis. the intake camshaN ani Make sure the matks (Dy en the timing chain ets are parallel with the edge of the cylinder ead. Location (E} is eylinder #3 cam location, il the cars withthe ole (C) in cylinder #8 (cai facing vp). When installing the fiming chain, es re a8 tight 48 possible on the iia side rock %, thon awl the nek and ext call saps, 6, patter ee ‘Tighten the camshaft cap serews to 10 Nem (1.0 1m, 86 in -Ib) in two stages and in a erisseras ‘working from the inner cops out. rk refers to the intake camshaft E” mark refers to the exhaust camshaft ap: bolting towards ine MAG side ot the engine. Wake Sure the holes (8) in the camshaft are aligned with the marks (C)on the camshaft caps. Lubricate the camshaft cap screws with engine oil. Tho [camshaft cap screws must be tightened evenly or dam lage to the cylinder head, camehaft caps, and camshatts| jwill result. Do not turn the crankshaft when installing) ithe camshaft to avoid damage or improper valve timing. 49. Slowly insert the timing chain tensioner rod (A) into the timing chain tensioner housing while squeé timing chain tensioner clip (B) until the clip is i the'grpove, % %, “2, st, 41, Insert the timing cffain tensioner rod little by little so that the eirclip (A) is seated into the groove (B), te sNOmDEA o™ NOTE: Insert the timing chain little so that the circlip (A) comes into the groove in the rod (B). Check that the mark.(C) on chain tensioner housing is ‘chain tensioner clip (D) and that the timing chain ten- sloner rod Is locked in position. ROSITA tensioner rod little by timing iming igned with the aby 43. Apply Yamaha Bond Seal: 10. 1215 onto OE TE aa %, 44, Apply Yamaha Bond Sealant No. 1215,onto t surfaces of the © (B). Tighten the cyl ‘cross pattern to 12 hain tensioner assembly and seéure using Allen-head screws. fghten to F2,Nem ey, tall the timing chain tensioner, with the “L" mark is protruding ” the timing chain tensioner. ithe timing chain tensioner NOTE: Bo sur’ jasket 50 Its sect rom the lower left ‘The arrow mark (A) oF SHESIOR park plugs. Tighten to 13 Nem (13 ke-fty, 4 46, Install the ignition 6s over the spark plugs making sure they are fully seated! and aligned with the marks 6n the cylinder headey Assembly Schematic Apply Lithium Grease 14gnem 15 kgm site = Fp, 72 ft-lb fs RY Gow RS ta vyonace 17.1 583