Read this manual carefully

before operating this vehicle.

OPERATOR’S MANUAL
SR10RDF
SR10RSF
SR10RLF
SR10LDF
SR10LSF
SR10LLF
SR10SDF
SR10XSF
SR10XLF
SR10M53F
SR10M53SF
SR10M62SF
SR10M62LF

LIT-12628-03-22 8JR-F8199-71
 Table of Contents
Foreword ............................................................ 2 Varying Altitude Operation............................... 16
General Information ......................................3-12 Lubrication.................................................. 17-18
Snowmobile Identification.................................. 3 Chain Case...................................................... 17
Control Locations .............................................. 3 Rear Suspension ............................................. 18
Gasoline-Oil....................................................... 4 Maintenance ............................................... 19-40
Engine Break-In................................................. 4 Periodic Maintenance Checklist....................... 19
Drive Belt Break-In ............................................ 4 Fuel System..................................................... 20
Cold Drive-Away Function ................................. 5 Checking Engine Oil Level............................... 21
Speedometer/Tachometer/Digital Gauge .......... 5 Changing Engine Oil/Filter............................... 21
Diagnostic Codes .............................................. 6 Coolant Level................................................... 22
Handlebar Tilt (SR10M Models) ........................ 7 Spark Plugs ..................................................... 23
Handlebar Tilt (SR10 Models) ........................... 7 Checking/Adjusting Valve Clearance............... 23
Exhaust System ................................................ 8 Battery ............................................................. 23
Air-Intake Silencer ............................................. 8 Fuses............................................................... 25
Cooling System ................................................. 8 Brake System .................................................. 26
Battery ............................................................... 8 Burnishing Brake Pads .................................... 29
Jump-Starting .................................................... 8 Chain Tension.................................................. 29
Drive Clutch and Driven Clutch ......................... 9 Drive Belt ......................................................... 29
Drive Clutch/Driven Clutch Alignment ............. 10 Track Tension................................................... 31
Fuel Pump ....................................................... 10 Track Alignment ............................................... 32
Shock Absorbers (Rebuildable Gas) ............... 10 Suspension...................................................... 33
Track/Track Studs ............................................ 10 Lights ............................................................... 36
Paddle Track (SR10M, XL Models).................. 11 Ski Wear Bars.................................................. 37
Reverse Operation .......................................... 11 Adjusting Ski Stance........................................ 38
Access Panel/Hood ......................................... 12 Rail Wear Strips............................................... 39
Removable Seat .............................................. 12 Performance Tips ....................................... 41-42
Towing ............................................................. 12 Preparation for Storage ....................................43
Operating Instructions .................................13-16 Preparation after Storage .................................44
Starting and Stopping Engine ......................... 13 Snowmobile Safety Rules.................................45
Braking ............................................................ 14 Consumer Information ......................................46
Emergency Stopping ....................................... 15
Throttle/Ignition Monitor Switch ....................... 15
 Reference Information
Write the appropriate information for your Yamaha Snowmobile in the spaces
below.
Always use these numbers when referring to your snowmobile.
Model: _________________________________________________
Date of Purchase: ________________________________________
Vehicle Identification Number: _______________________________
Engine Serial Number: _____________________________________
Your Yamaha Dealer: _____________________________________
Address: _______________________________________________
Phone: _________________________________________________

! WARNING
A snowmobile is a very high performance vehicle. Because it does accelerate
rapidly and is capable of very high speeds, it should not be operated by a nov-
ice or an inexperienced operator. Never accelerate rapidly or drive at high speed
beyond the limits of visibility or without being totally familiar with the terrain
and what lies in front of you. Obey speed limits and never operate at speeds
that do not allow adequate maneuvering and stopping distances. Read and
study the entire Operator’s Manual and Safety Handbook. Failure to follow this
warning could result in personal injury to yourself or others.

Personal Injury
• To avoid injury to yourself and others, NEVER operate the snowmobile without
first reading and understanding this manual and the Snowmobile Safety Hand-
book; then follow the instructions and heed the warnings given.
• USE COMMON SENSE.
• DON’T DRINK and DRIVE.
• STAY IN CONTROL at ALL TIMES.
• TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at
excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it is
too late to warn of the consequences of snowmobile misuse. Such conduct
endangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR-
SELF AND OTHERS.

Parts and Accessories

When in need of replacement parts, oil, or accessories for your Yamaha Snowmo-
bile, be sure to only use GENUINE YAMAHA PARTS, OIL, AND ACCESSO-
RIES. Only genuine Yamaha parts, oil, and accessories are engineered to meet the
standards and requirements of your Yamaha Snowmobile. For a complete list of
accessories, refer to the current Yamaha Accessory Catalog. To aid in service and
maintenance procedures on these snowmobiles, an Illustrated Parts Manual and a
Service Manual are available through your local Yamaha Snowmobile dealer.

1
 Foreword
Congratulations! You have chosen a quality Yamaha Snowmobile designed and
assembled to give dependable service. Be sure, as the owner/operator of a Yamaha
Snowmobile, to become thoroughly familiar with its basic operation, maintenance,
and off-season storage procedures. Read this manual and the accompanying Snow-
mobile Safety Handbook before operating the snowmobile to learn safe and proper
use of your new Yamaha Snowmobile. Always operate the snowmobile within your
level of skill and current terrain conditions.
The Operator’s Manual, Snowmobile Safety Handbook, and Snowmobile Decals
display the words Warning, Caution, and Note to emphasize important information.
The symbol ! WARNING identifies personal safety-related information. Be
sure to follow the directive because it deals with the possibility of serious personal
injury or even death. A CAUTION identifies unsafe practices which may result
in snowmobile-related damage. Follow the directive because it deals with the possi-
bility of damaging part or parts of the snowmobile. The symbol  NOTE: identi-
fies supplementary information worthy of particular attention.
This manual covers operator-related maintenance, operating instructions, and off-
season storage instructions. If major repair or service is ever required, contact an
authorized Yamaha Snowmobile dealer for professional service.
At the time of publication, all information and illustrations were technically cor-
rect. Some illustrations used in this manual are used for clarity purposes only and
are not designed to depict actual conditions. Because Yamaha constantly refines
and improves its products, no retroactive obligation is incurred.
This Operator’s Manual should be considered a permanent part of the snowmobile
and must remain with the snowmobile at the time of resale. If the snowmobile
changes ownership more than once, contact Yamaha, Service Department, P.O. Box
6555, Cypress, CA 90630, for proper registration information. This manual was
prepared by the Product Service and Warranty Department of Yamaha.
Every Yamaha Snowmobile meets or exceeds the standards of the Snowmobile
Safety and Certification Committee and displays the SSCC decal. Yamaha endorses
and encourages the safe use of all snowmobiles. Always wear a helmet and eye pro-
tection. Drive with caution, observe all state and local regulations, and respect the
rights of others. ISMA members like Yamaha do their part to improve trails, spon-
sor events, and generally support the sport of snowmobiling. As a member of the
National Snowmobile Foundation, Yamaha promotes snowmobiling through edu-
cation, charity, and research programs.
© 2014 Yamaha

2
 General Information
Snowmobile These numbers are required by the dealer
Identification to complete warranty claims properly. No
The snowmobile has two important iden- warranty will be allowed by Yamaha Inc.
tification numbers. The Vehicle Identifi- if the engine serial number or VIN is
cation Number (VIN) is stamped into the removed or mutilated in any way.
tunnel near the right-side footrest and on Always provide the snowmobile name,
a decal beneath the seat. The decal also VIN, and ESN when contacting an autho-
displays pertinent production informa- rized Yamaha Snowmobile dealer for
tion. The Engine Serial Number (ESN) is parts, service, accessories, or warranty. If
stamped into the crankcase of the engine. the complete engine must be replaced,
ask the dealer to notify Yamaha for cor-
rect registration information.
Control Locations
Shown are the typical control locations
for Yamaha snowmobiles. Location of a
specific control will vary according to
model.

0726-383

SR10 Models

0748-273

SR10M, XL Models

0748-274

3
Gasoline-Oil Engine Break-In
Recommended Gasoline The engine (when new or rebuilt) requires
a short break-in period before the engine is
The recommended gasoline to use in subjected to heavy load conditions.
these snowmobiles is 87 octane regular
unleaded. In many areas, oxygenates are This engine does not require any pre-
added to the gasoline. Oxygenated gaso- mixed fuel during the break-in period.
lines containing up to 10% ethanol are There is never a more important period in
acceptable gasolines. the life of the engine than the first 500
When using ethanol blended gasoline, it is km (300 miles).
not necessary to add a gasoline antifreeze Since the engine is brand new, do not put
since ethanol will prevent the accumula- an excessive load on it for the first 500
tion of moisture in the fuel system. km (300 miles). The various parts in the
Recommended Engine Oil engine wear and polish themselves to the
correct operating clearances. During this
The recommended oil to use is Semi- period, prolonged full throttle operation
Synthetic Yamalube 0W-30 oil. or any condition that might result in
engine overheating must be avoided.
CAUTION
Operating your snowmobile for the first
Any oil used in place of the recom- time: Start the engine and let it idle for 15
mended oil could cause serious minutes.
engine damage
0-160 km (0–100 miles): Avoid pro-
After 800 km (500 miles) of operating, longed operation above 6000 RPM.
the engine oil must changed and the oil
filter replaced. The engine oil should be 160-500 km (100–300 miles): Avoid pro-
changed every 4000 km (2500 miles) longed operation above 8000 RPM.
before prolonged storage and the oil filter 500 km (300 miles) and beyond: The
should be changed every 20,000 km snowmobile can now be operated nor-
(12,500 miles). mally.
Filling Gas Tank  NOTE: After 800 km (500 miles) of
Since gasoline expands as its temperature operation, the engine oil must be
increases, the gas tank must be filled to changed and the oil filter replaced. If
its rated capacity only. Expansion room any engine trouble should occur dur-
must be maintained in the tank particu- ing the engine break-in period,
larly if the tank is filled with cold gaso- immediately have a Yamaha dealer
line and then moved to a warm area. check the snowmobile.
Also, if the snowmobile is to remain on a Drive Belt Break-In
trailer after filling the gas tank, the bed of
Drive belts require a break-in period of
the trailer must be maintained level to approximately 40 km (25 miles). Drive the
prevent gasoline from draining out snowmobile for 40 km (25 miles) at 3/4
through the gas tank vent hose. throttle or less. By revving the engine up
and down (but not exceeding 100 km/h [60
! WARNING mph]), the exposed cord on the side of a
Always fill the gas tank in a well-venti- new belt will be worn down. This will
lated area. Never add gasoline to the allow the drive belt to gain its optimum
snowmobile gas tank near any open flexibility and will extend drive belt life.
flames or with the engine running. DO  NOTE: Before starting the snowmo-
NOT SMOKE while filling the gas tank.
Do not sit on the snowmobile without bile in extremely cold temperatures,
first installing the gas tank cap. the drive belt should be removed and
warmed up to room temperature.
Once the drive belt is at room temper-
ature, install the drive belt.

4
 If the coolant temperature rises too far
CAUTION above proper operating temperature, the
indicator will flash a warning (alert) and
Never run the engine with the drive the engine will “surge” to alert the opera-
belt removed. Excessive revving of tor. If the coolant temperature rises to a
the engine could result in serious critical point above proper operating tem-
engine damage and drive clutch fail- perature, the indicator will cease flashing
ure.
and will remain constantly illuminated.
Cold Drive-Away  NOTE: If the indicator is constantly
Function on, the engine will shut off if vehicle
There is a “cold drive-away” function speed is reduced to 1.5 km-h (0.9
incorporated within the engine. MPH) or slower.
 NOTE: When cold-starting the CAUTION
engine, the coolant temperature
warning icon will illuminate and the If the indicator is illuminated, stop the
LOW TEMP display on the readout engine immediately and allow it to cool
screen will begin to flash. With the down. If unable to either determine or
engine in this temperature range, the remedy the problem, take the snowmo-
RPM “limit” of the engine will be bile to an authorized Yamaha Snowmo-
below drive system engagement bile dealer for service. If not under
speed. As the engine warms, the warranty, this service is at the discretion
coolant temperature warning icon and expense of the snowmobile owner.
will begin to flash, the TEMP display
will continue to flash, and the RPM B. High Beam Indicator
“limit” of the engine will increase The indicator is on whenever the high
allowing the snowmobile to move beam mode is selected by the headlight
without full-throttle operation. When switch.
the engine reaches proper operating
temperature, the coolant tempera- C. Oil Pressure Indicator
ture warning icon and the LOW
TEMP display will go out. The indicator relates to engine oil pres-
sure, not the oil level; however, if the oil
Speedometer/ level is low, it may affect oil pressure. If
Tachometer/Digital oil pressure is lost, check the oil level
Gauge (see page 21).
If the indicator does not go out or if the
engine does not start, take the snowmo-
bile to an authorized Yamaha Snowmo-
bile dealer. If not under warranty, this
service is at the discretion and expense of
the snowmobile owner.
D. Low Fuel Indicator
The indicator illuminates whenever the
gas in the gas tank is low.
CWI-050A
E. Coolant Temperature/
A. Coolant Temperature Battery Voltage/Intake Air
Indicator Temperature
The indicator and LOW TEMP display This bar display shows coolant tempera-
will cease to flash when the engine ture, battery voltage, and intake air tem-
reaches proper operating temperature. perature. Press the Lower Left Button to
change which parameter is being dis-
played. Press and hold the Lower Left
Button to see the actual values associated
with the mode selected.

5
F. Fuel Level Display H. Engine Hour Meter/
This display shows the approximate Odometer/Trip Meter/
amount of gas remaining in the gas tank. Clock
This display shows engine hours, odome-
G. RPM/Speed/Clock/ ter, trip meter, or clock. Press the Lower
Altimeter Right Button to change which parameter
Press the Upper Left Button to cycle the is being displayed. The Engine Hour
left screen between RPM and speed. Meter and Odometer cannot be reset. To
reset the trip meter, select the Trip Meter;
 NOTE: When RPM is displayed on then press and hold the Lower Right But-
the left screen, the right screen will ton until the trip meter display reads 0.
display speed, clock, or altimeter.
When speed is displayed on the left  NOTE: The clock can only be dis-
screen, the right screen will display played in this position if it is not
RPM, clock, or altimeter. already being displayed in the main
right screen. To set the clock when
Press the Upper Right Button to cycle the the clock is in this position, press
right screen between speed, RPM, clock, and hold the Lower Right Button;
and altimeter. then use the procedure found in G.
Press and hold the Upper Button on the Diagnostic Codes
speed-side of the gauge to shift the gauge
between standard (MPH/miles/fahren- Diagnostic codes are activated by the
heit) and metric (km/h/kilometers/cel- ECM and may be displayed on the read-
sius) modes. out screen for a number of reasons.
Press and hold the Upper Button on the If a code is displayed while the engine is
RPM-side of the gauge to view maxi- running, the ECM is receiving input that
mum RPM. This value is reset each time is outside of its established parameters. If
the ignition key is turned off. a code has been activated, take the snow-
mobile to an authorized Yamaha Snow-
With the clock mode selected by pressing mobile dealer for service. If not under
the Upper Right Button, press and hold warranty, this service is at the discretion
the Upper Right Button to set the clock. and expense of the snowmobile owner.
The option of selecting the 12-hour or
24-hour clock is available; press the Refer to the following chart for diagnos-
either Left Button to alternate between tic codes.
the two modes. Next, press the Lower Code Trouble
Right Button to set the clock. Press either P0031 O2 Heater Control Circuit Low
Left Button to set the hours; then press P0032 O2 Heater Control Circuit High
the Lower Right Button to set the min-
utes. Press either Left Button to set the P0107 Manifold absolute pressure circuit low
minutes. When the proper time has been P0108 Manifold absolute pressure circuit high
set, press the Lower Right Button to P0112 Intake air temp sensor circuit low
return to the main gauge display. P0113 Intake air temp sensor circuit high
P0115 Engine coolant temp sensor 1 circuit
With the altimeter mode selected by P0117 Engine coolant temp sensor 1 circuit
pressing the Upper Right Button, press low
and hold the Upper Right Button to set P0118 Engine coolant temp sensor 1 circuit
the current altitude by using either Left high
Button. When the proper altitude has P0120 Throttle position sensor circuit
been set, press the Lower Right Button to P0122 Throttle position sensor circuit low
return to the main gauge display. P0123 Throttle position sensor circuit high
P0130 O2 sensor circuit
P0131 O2 sensor circuit low
P0132 O2 sensor circuit high
P0171 System too lean
P0172 System too rich

6
Code Trouble 2. Tighten the four cap screws evenly
P0201 Injector circuit/open - cylinder 1 to 15 ft-lb.
P0202 Injector circuit/open - cylinder 2
P0203 Injector circuit/open - cylinder 3 ! WARNING
P0217 Engine coolant over temp condition Tighten the cap screws according to
P0261 Cylinder 1 injector circuit low specifications to prevent unexpected
P0264 Cylinder 2 injector circuit low
“movement” of the handlebar during
operation over rough terrain. DO NOT
P0267 Cylinder 3 injector circuit low position handlebar so steering (maxi-
P0508 Idle air control system circuit low mum right/left turning capabilities) or
P0509 Idle air control system circuit high throttle and brake controls are affected.
P0511 Idle air control circuit
P0522 Engine oil pressure sensor circuit low
Handlebar Tilt (SR10
P0523 Engine oil pressure sensor circuit high
Models)
P0562 System voltage low The handlebar can be adjusted to the
P0563 System voltage high
operator’s preference. To adjust the han-
dlebar, use the following procedure:
P0780 Shift Error
P1315 Crankshaft Position out of sync 1. Remove the handlebar cover; then
P1338 Crankshaft spike detected loosen the eight cap screws securing
P1339 Crankshaft tooth not detected the handlebar caps to the riser and the
P1685 Main relay open circuit riser to the steering post.
P1686 Main relay circuit low
P1688 Reverse relay open circuit
P1689 Reverse relay circuit low
P1691 Forward relay open circuit
P1692 Forward relay circuit low
P1694 Headlight relay open circuit
P1695 Headlight relay circuit low
P2228 Barometric pressure sensor A circuit
low
P2229 Barometric pressure sensor A circuit
high 0747-828

P2300 Ignition coil A primary control circuit low 2. Adjust the handlebar to operator’s
P2303 Ignition coil B primary control circuit low desired position, tighten the cap
P2306 Ignition coil C primary control circuit low screws evenly to 2.0 kg-m (15 ft-lb),
U0155 Lost communication with the ECM
and check steering for maximum
right/left turning capabilities.
Handlebar Tilt (SR10M
Models) CAUTION
1. Loosen the four cap screws and tilt Do not rotate the handlebar to a posi-
the handlebar to the desired position. tion that allows air to enter the brake
system.

! WARNING
Tighten cap screws according to
specifications to prevent unexpected
“movement” of the handlebar during
operation over rough terrain. DO NOT
position the handlebar so steering
(maximum right/left turning capabili-
ties) or throttle and brake controls
are affected.
0747-617

7
Exhaust System Battery
The exhaust system is designed to reduce It is extremely important that the battery
noise and to improve the total perfor- be maintained at full charge at all times
mance of the engine. If any exhaust sys- and that the battery connections be clean
tem component is removed from the and tight. If charging the battery becomes
engine and the engine is run, severe necessary, refer to Battery sub-section in
engine damage will result. the Maintenance section.
Air-Intake Silencer CAUTION
Used in conjunction with the fuel intake
system is a specially designed air-intake Always turn the ignition switch key to
silencer. The purpose of the silencer is to the OFF position when the snowmo-
bile is not being used. Leaving the
quiet the intake of fresh air. Since the fuel ignition switch in the ON position will
intake system is calibrated with the air- result in discharging the battery and
intake silencer in place, the engine must possible damage to the battery.
never be run with the silencer removed.
Performance will not be improved if the Jump-Starting
air-intake silencer is removed. In con-
trast, severe engine damage will occur.  NOTE: Yamaha does not recom-
mend jump-starting a snowmobile
CAUTION with a dead battery but rather to
remove the battery, service it, and
These snowmobiles are not designed correctly charge it; however, in an
to be operated in dusty conditions. emergency, it may be necessary to
Operating the snowmobile in dusty jump-start a snowmobile. If so, use
conditions will result in severe the following procedure to carefully
engine damage. and safely complete this procedure.
Cooling System
! WARNING
These snowmobiles are equipped with a
closed liquid cooling system for engine Improper handling or connecting of a
cooling. The cooling system should be battery may result in severe injury
inspected daily for leakage and damage. including acid burns, electrical burns,
Also, the coolant level should be checked or blindness as a result of an explo-
sion. Always remove rings and
daily. If leakage or damage is detected, watches. Any time service is per-
take the snowmobile to an authorized formed on a battery, the following
Yamaha Snowmobile dealer for service. must be observed: keep sparks, open
If not under warranty, this service is at flame, cigarettes, or any other flame
the discretion and expense of the snow- away. Always wear safety glasses.
mobile owner. Protect skin and clothing when han-
dling a battery. When servicing a bat-
When filling the cooling system, use an tery in an enclosed space, keep the
ethylene glycol-based coolant/water mix- area well-ventilated.
ture which will satisfy the coldest antici-
pated weather conditions of your area in  NOTE: To access the battery, the
accordance with the coolant manufac- seat must be removed.
turer’s recommendations.
1. For the snowmobile to be jump-
 NOTE: If operating on ice or hard- started, slide any terminal boots away.
packed snow conditions, it is recom-
mended that Ice Scratchers be 2. Inspect the battery for any signs of
installed to reduce wear strip wear electrolyte leaks, loose terminals, or
and engine overheating. bulging sides. Leaking or bulging
battery cases may indicate a frozen
For checking/filling cooling system, refer or shorted battery.
to Coolant Level sub-section in the Main-
tenance section.

8
 ! WARNING
If any of these conditions exist, DO
NOT attempt to jump-start, boost, or
charge the battery. An explosion
could occur causing serious injury.
3. Inspect the snowmobile to be used for
jump-starting to determine if voltage
and ground polarity are compatible.
The vehicle must have a 12-volt DC, 0744-527
negative ground electrical system.  NOTE: Some jumper cables may be
the same color but the clamps or ends
CAUTION will be color-coded red and black.
Always make sure the electrical sys- 7. Attach one clamp of the negative
tems are of the same voltage and jumper cable (black) to the negative
ground polarity prior to connecting (-) terminal (3) of the good battery
jumper cables. If not, severe electri- (B); then attach the other clamp of
cal damage may occur.
the negative (black) jumper cable (4)
4. Move the vehicle to be used for the to an unpainted metal surface (A) on
jump-start close enough to ensure the engine or frame well away from
the jumper cables easily reach; then the dead battery and fuel system
set and lock the brakes, shut off all components.
electrical accessories, and turn the
ignition switch OFF. ! WARNING
 NOTE: Make sure all switches on Never make the final connection to a
the snowmobile to be jump-started battery as a spark could ignite hydrogen
are turned OFF. gases causing an explosion of the bat-
tery resulting in acid burns or blindness.
5. Disconnect all external accessories
such as cell phones, GPS units, and 8. Stand well away from the dead bat-
radios on both vehicles. tery and start the vehicle with the
good battery. Allow the vehicle to
CAUTION run for several minutes applying
some charge to the dead battery.
Failure to disconnect electronic acces-
sories during jump-starting may cause 9. Start the snowmobile with the dead
system damage due to power spikes. battery and allow it to run for several
minutes before disconnecting the
6. Attach one clamp of the positive jumper cables.
(red) cable to the positive (+) termi-
nal (1) of the dead battery (C) being 10. Remove the jumper cables in oppo-
careful not to touch any metal with site order of hook-up (4, 3, 2, 1). Be
the other clamp; then attach the careful not to short cables against
other clamp of the positive (red) bare metal.
cable to the positive (+) terminal (2)  NOTE: Have the battery and elec-
of the good battery (B). trical system checked prior to oper-
ating the snowmobile again.
Drive Clutch and Driven
Clutch
The drive clutch and driven clutch do not
require lubrication; therefore, no special
maintenance is required by the snowmo-
bile owner except for periodical cleaning.

9
However, the drive clutch and driven Shock Absorbers
clutch should be disassembled, cleaned, (Rebuildable Gas)
and inspected by an authorized Yamaha Each shock absorber should be visibly
Snowmobile dealer after every 4000 km checked weekly for fluid leakage, cracks or
(2500 miles) or seasonally, whichever breaks in the body/reservoir, or a bent shaft.
occurs first. This service is at the discre-
If any one of these conditions is detected,
tion and expense of the snowmobile replacement or service is necessary. Take the
owner. snowmobile to an authorized Yamaha
When operating the snowmobile at high Snowmobile dealer for this service. If not
altitudes, it may be necessary to change under warranty, this service is at the discre-
certain component parts of the drive tion and expense of the snowmobile owner.
clutch and/or the driven clutch. See an  NOTE: When the snowmobile is
authorized Yamaha Snowmobile dealer operated in extremely cold weather
for further information. (-23° C/-10° F or colder), a small
amount of leakage may be present.
CAUTION Unless the leakage is excessive,
replacement is not necessary.
DO NOT attempt to service the drive
clutch and driven clutch. The drive  NOTE: The frequency of servicing
clutch and driven clutch must be ser- rebuildable shock absorbers will
viced by an authorized Yamaha Snow- vary according to the types of condi-
mobile dealer only. tions and terrain the snowmobile has
Drive Clutch/Driven been subjected to. If riding quality
deteriorates (or seems to be deterio-
Clutch Alignment rating), take the snowmobile to an
The alignment between the drive clutch authorized Yamaha Snowmobile
and driven clutch is set at the factory. dealer for shock absorber evaluation
Normally, no adjustment is necessary as and/or servicing. This service is at
long as neither the drive clutch nor the the discretion and expense of the
driven clutch is removed or disassem- snowmobile owner.
bled. However, if premature drive belt
wear is experienced or if the drive belt Track/Track Studs
turns over, the drive clutch/driven clutch Accelerated wear strip and track clip
alignment must be checked. Take the wear caused by operating on ice or hard-
snowmobile to an authorized Yamaha packed snow conditions is NOT covered
Snowmobile dealer for this service. If not under Yamaha warranty policy.
under warranty, this service is at the dis-  NOTE: If regularly operating on ice
cretion and expense of the snowmobile or hard-packed snow conditions,
owner. Performance Wear Strips may be
Fuel Pump installed at the expense of the snow-
mobile owner.
The fuel pump is designed to provide
adequate amount of gas to the injectors In general, track life will be shortened
at all throttle settings. If a fuel delivery when studs are installed. Drilling stud
problem is suspected, take the snowmo- holes into the drive track will cut the
bile to an authorized Yamaha Snowmo- internal fibers weakening the track.
bile dealer. If not under warranty, this Avoid spinning the drive track. Studs
service is at the discretion and expense of may catch on an object and pull out of the
the snowmobile owner. track leaving tears and damage around
the already weakened area. To minimize
possible damage, consult your stud man-
ufacturer for installation and stud pattern
recommendations. Yamaha does not rec-
ommend studding a track.

10
Paddle Track (SR10M, 1. Always warm up the engine for 2-3
XL Models) minutes prior to shifting into reverse.
These models are equipped with a Power 2. With the engine at idle (under 2500
Claw style track which is specially RPM) and the snowmobile at a com-
designed for use in powder snow riding plete stop, press and release the
conditions. When the Power Claw track is reverse switch button.
operated in hard-packed snow conditions,
it will run slightly slower than a standard  NOTE: The snowmobile must be at
track and it will accelerate wear strip wear. a complete stop and the engine run-
To decrease the amount of wear strip wear, ning under 2500 RPM before the sys-
slower speeds must be maintained when tem will allow shifting.
operating on hard-packed trails. Acceler- 3. When reverse is engaged, a reverse
ated wear strip wear caused by operating a icon will illuminate on the deluxe
Power Claw track on hard-packed snow digital gauge and a reverse alarm
conditions is NOT covered under Yamaha will sound.
warranty policy.
 NOTE: If operating on ice or hard- CAUTION
packed snow conditions, it is recom- Never shift into reverse while the
mended that Ice Scratchers be snowmobile is moving forward as it is
installed to reduce wear strip wear hard on the drive system.
and engine overheating.
Operating in Reverse
Reverse Operation
The electrical reverse function offers the ! WARNING
operator the convenience of being able to Use caution and minimal speed when
back up the snowmobile rather than hav- operating the snowmobile in reverse.
ing to turn the snowmobile around by Be sure the button is in the desired
hand. This feature, under most situations, position.
should not be used to free a stuck snow-
mobile as it will tend to dig the skis 1. When shifting into reverse, always
deeper into the snow. Always use mini- wait for the reverse icon to illumi-
mal speed when operating in reverse and nate and the reverse alarm to sound
come to a complete stop before shifting before backing up.
from either forward to reverse or reverse  NOTE: The reverse function is can-
to forward. celled whenever the engine is shut off.
Shifting Into Reverse 2. After shifting from reverse to for-
ward (or from forward to reverse),
apply the throttle slowly and evenly
to allow the driven pulley to engage
properly.

CAUTION
After reversing in deep powder snow
conditions, make sure the snowflap
does not become “caught up” in the
track. Track and/or snowflap damage
741-438A may occur.
 NOTE: Correct drive belt tension
(deflection) is important for the CAUTION
reverse function to operate properly. If the snowmobile is equipped with
If the belt is too tight, difficulty in ice scratchers, the scratchers must
engaging reverse will be experi- be disengaged or component dam-
enced. age will occur.

11
Access Panel/Hood Removable Seat
To remove the access panel and hood, use To remove the seat, remove the torx-head
the following procedure: screw from the underside of the seat; then
lift on the back of the seat and move it up
1. Remove the hairpin clip from the pin and rearward to remove it.
located at the front of the access
panel. Remove the thumb screw
securing the front left access panel CAUTION
to the front facia. Move the panel up Prior to removing the seat, lift the
and off the pin; then swing the panel rear of the seat and disconnect the
all the way out and unhinge the seat heater harness connector.
panel from the lower console.
2. Remove the torx-head screws secur-
ing the hood (located on the underside
of the hood above the front tube of the
upper A-arm); then remove the torx-
head screws from the top-side of the
hood securing the hood to the upper
console and the torx-head screws
from under the nosepiece of the hood.

0747-739
To install the seat, route the front tab on
the seat through the seat-base hold-down
bracket; then install the seat and secure
using the torx-head screw.

0747-830
3. Remove the intake panel below the
gauge; then locate the hood harness
connector (located in front of the
speedometer) and unplug the con-
nector; then move the hood slightly
forward and remove the hood. SNO-273
To install the access panel and hood, use  NOTE: Prior to lowering and secur-
the following procedure: ing the seat, connect the seat heater
1. Position the hood onto the snowmo- harness connector.
bile and connect the hood harness Towing
connector making sure the harness
does not become pinched. If the snowmobile is to be towed by
another snowmobile, do not tow using
2. Secure the hood with torx-head the loops in the skis. The tow rope should
screws and tighten securely. be attached to the spindles.
3. Install the access panel onto the
lower console; then close the access
panel and secure with the hairpin
clip. Install the intake panel.

12
 Operating Instructions
Starting and Stopping 3. If the brake fluid is below the high
Engine brake fluid mark, add Yamaha
It is imperative that the brake system be approved DOT 4 brake fluid until
checked for wear and proper operation the fluid is at the recommended
and that all safety checks found in the level. Install and secure the reservoir
accompanying Snowmobile Safety cover. Do not allow moisture to con-
Handbook be performed before attempt- taminate the brake system.
ing to start the engine. After the engine
has been started, check the headlights CAUTION
(high and low beam), taillight, and brake- Brake fluid is highly corrosive. Do not
light to be sure they are working properly spill brake fluid on any surface of the
and adjusted correctly. Make sure all snowmobile.
lights are clean to provide maximum illu-
mination. The headlight and taillight ! WARNING
must be clean and must be illuminated Do not overfill the brake fluid reser-
whenever the engine is running. voir. Overfilling the reservoir may
1. Test the operation of the brake sys- cause the brake system to hydrauli-
cally lock. Use only Yamaha
tem by compressing the brake lever. approved brake fluid.
The brake lever must feel firm when
compressed; then while holding the ! WARNING
brake lever in the compressed posi-
tion, measure the distance between Do not start the engine if the brake sys-
the brake lever and the handlebar. tem is not functioning properly. Service
The distance must be greater than the brake system or have it properly
repaired prior to operating the snow-
2.54 cm (1 in.). mobile. Serious personal injury or even
death may occur if the brake system is
not operating properly.
4. Test the throttle control lever by
completely compressing and releas-
ing it several times. The lever
MUST return to the idle position
quickly and completely.

CAUTION
0745-816
Always check the coolant level before
starting the engine.
2. With the brake fluid reservoir in a
level position and the cover 5. Move the emergency stop switch to
removed, check the fluid level. The the UP or RUN position.
brake fluid level must be at the high 6. Insert key into ignition switch; then
brake fluid mark in the reservoir. rotate key to the RUN position.
 NOTE: Rotate the key to the START
position; then when the engine starts,
release the key.

CAUTION
Do not continuously run the starter
for more than 5 seconds at a time.

0745-817

13
 NOTE: When the engine starts, This cool-down period will vary
allow it to warm up properly. Idle the depending upon the ambient air tem-
engine several minutes until the perature and the temperature of the
engine has reached normal operating brake fluid. If loss of brakes has
temperature. Do not idle the engine occurred because of high fluid temper-
for excessively long periods of time. atures, do not operate the snowmobile
7. There is a “cold drive-away” function until the cool-down period has expired
incorporated within the engine. This and brake lever firmness has returned.
function is active until the engine
reaches operating temperature. ! WARNING
Excessive, repetitive use of the
8. Flooding — If the engine does not hydraulic brake for high speed stops
start but seems ready to start, engage will cause overheating of the brake
the brake lever lock; then compress fluid and premature brake pad wear
the throttle control lever fully and try which will result in an unexpected
to start the engine. When the engine loss of brakes.
starts, release the throttle control lever
immediately. After the warm-up, 2. Be sure to maintain the brake fluid at
release the brake lever lock. the proper level and take care not to
get any moisture in the system as
9. To shut off the engine, turn the igni- moisture in the brake fluid lowers the
tion key to the OFF position or push boiling point. If the brake fluid is ever
the emergency stop switch to the boiled (by high speed stops or repeti-
DOWN position. tive use) or if moisture is allowed to
enter the system, it must be changed.
CAUTION Never substitute or mix different types
Always turn the ignition switch key to or grades of brake fluid.
the OFF position when the snowmobile
is not being used. Leaving the ignition ! WARNING
switch in the ON position will result in Use only Yamaha approved DOT 4
discharging the battery and possible brake fluid. Never substitute or mix
damage to the battery. different types or grades of brake
Braking fluid. Brake loss can result. Check
brake fluid level and pad wear before
The following items are items that the each use. Brake loss can result in
operator must be familiar with when severe injury or even death.
operating this snowmobile and its
hydraulic brake system. Important addi- 3. Never ride the brake. Even main-
tional information on the proper mainte- taining minimal pressure on the
nance of the brake system is found in the brake lever will cause the brake pads
Maintenance section. to drag on the disc and may overheat
the brake fluid.
1. Use the brakes wisely. Each time the
brakes are applied in all hydraulic 4. The brake lever lock is not a parking
brake systems (including automotive brake and should not be applied for
applications), heat is transferred to the periods exceeding 5 minutes.
brake fluid. The amount of heat trans- NEVER OPERATE THE SNOW-
ferred during high speed stops and/or MOBILE WITH THE BRAKE
repetitive use may be high enough to LEVER LOCK ENGAGED.
boil the brake fluid and cause the
brakes to either fade or may cause an
unexpected loss of brakes. If this
occurs, the brake fluid requires a cool-
down period before the brakes will
again function properly.

14
 ! WARNING ! WARNING
The brake lever lock is not a parking If any malfunction of the throttle sys-
brake and should not be applied for tem occurs (such as freezing in fluffy
periods exceeding 5 minutes. The snow) and the monitor switch does
brake lever lock maintains the brake not shut off the engine, press down
lever in the compressed position and on the emergency stop switch IMME-
maintains pressure against the brake DIATELY to stop the engine. DO NOT
disc; however, after a period of time, start the engine until the malfunction
the pressure applied to the brake disc in the throttle system has been
may relax below the amount required located and corrected.
to hold the snowmobile stationary.
If the snowmobile engine stops abruptly
5. Pumping the brake lever is permissi- when the throttle control lever is released
ble; however, if pumping the brake and the activation of the monitor switch
lever more than twice is necessary to is suspected, use the following proce-
obtain the necessary stopping power, dure:
immediately take the snowmobile to
an authorized Yamaha Snowmobile 1. Rotate the ignition key to the OFF
dealer for service. If not under war- position.
ranty, this service is at the discretion 2. Remove ice and snow from the
and expense of the snowmobile throttle system and wait 5-10 min-
owner. utes for the engine heat to thaw ice
6. When new brake pads are installed, from the throttle system.
a “burnishing” process is required. 3. Test the throttle control lever by
Emergency Stopping compressing and releasing it several
times. The lever MUST return to the
There are several methods of stopping or idle position quickly and completely.
slowing the snowmobile under a variety
of situations. Identified in the following  NOTE: If the throttle control lever
chart are the ways a snowmobile may be operates properly and the engine
brought to a stop and the effectiveness does not start, compress the throttle
under normal conditions. lever slightly (approximately 1/8
throttle) and try starting the engine.
Item Function If the engine now starts and stops
Emergency Stop interrupts ignition circuit when the throttle lever is released,
Switch take the snowmobile to an autho-
Throttle/Ignition interrupts ignition circuit rized Yamaha Snowmobile dealer for
Monitor Switch service. If not under warranty, this
Ignition Switch interrupts ignition circuit service is at the discretion and
expense of the snowmobile owner.
Brake slows the drive system
Throttle/Ignition ! WARNING
Monitor Switch If the throttle control lever does not
The throttle control is equipped with a work properly, DO NOT ATTEMPT TO
monitor switch for safety purposes which START THE ENGINE.
will stop the engine when a loss of return
spring force occurs. If ice forms in the 4. If the throttle control lever operates
throttle system or if there is some other properly, rotate the ignition key to
malfunction of the throttle system result- the RUN position and go through
ing in a loss of return spring force, the normal starting procedures.
monitor switch will stop the engine when
the throttle control lever is released.

15
 NOTE: If the throttle control lever  NOTE: The monitor switch is now
operates properly and the engine bypassed. All other ignition/electrical
does not start, a malfunctioning moni- features (ignition switch, emergency
tor switch may be the problem. Take stop switch, headlight, taillight, and
the snowmobile to an authorized brakelight) will operate properly.
Yamaha Snowmobile dealer for ser-
vice. If not under warranty, this ser- Varying Altitude
vice is at the discretion and expense Operation
of the snowmobile owner. However, if Operating a snowmobile at varying alti-
a dire emergency exists wherein the tudes requires changes in performance
engine must be started, disconnect components. These changes affect drive
the throttle monitor switch located in train components. Have a Yamaha dealer
the right-side handlebar control. perform altitude-related service.
 NOTE: If disconnection of the throt-  NOTE: Just as important as cali-
tle monitor switch is needed to start brating the snowmobile for higher alti-
the engine, take the snowmobile to an tudes is recalibrating the snowmobile
authorized Yamaha Snowmobile when going to lower altitudes.
dealer for service as soon as possi-
ble. If not under warranty, this service  NOTE: Drive train changes can be
is at the discretion and expense of the made by the snowmobile owner if
snowmobile owner. qualified to do so. If the owner does
not feel qualified, take the snowmo-
! WARNING bile to an authorized Yamaha Snow-
mobile dealer for this service. This
Under no circumstances should dis- service is at the discretion and
connection of the throttle control wir-
ing harness be used as a substitute expense of the snowmobile owner.
for the monitor switch during normal
operation of the snowmobile. Per-
sonal injury and damage could occur
if the throttle system malfunctions or
if the operator is unable to stop the
engine in an emergency. If the snow-
mobile must be operated with a dis-
connected throttle control wiring
harness, EXTREME CAUTION MUST
BE TAKEN. NEVER EXCEED 10 MPH
WITH THE THROTTLE CONTROL
WIRING HARNESS DISCONNECTED.

16
 Lubrication
Chain Case
Checking Lubricant Level
 NOTE: The snowmobile must be
on a level surface for this procedure.
1. Check the lubricant level in the
chain case by using the sight glass.

0748-259

CAUTION
When installing the shift actuator,
rotate the actuator back and forth to
properly align it with the extension
gear. Failure to do so could cause
component damage.
0746-115 3. Start the engine and verify proper
 NOTE: The correct level is when reverse and forward operation by shift-
the lubricant is at least halfway up in ing in and out of reverse three times.
the sight glass.  NOTE: If excessive build-up of
 NOTE: Adding lubricant can be moisture or discolored oil is
done by the snowmobile owner if detected in the chain case, it may be
qualified to do so. If the owner does necessary to replace the lube.
not feel qualified, take the snowmo- Replacing Lubricant
bile to an authorized Yamaha Snow-
mobile dealer for this service. This  NOTE: Replacing the lubricant can
service is at the discretion and be done by the snowmobile owner if
expense of the snowmobile owner. qualified to do so. If the owner does
not feel qualified, take the snowmo-
2. If the lubricant level is low, remove bile to an authorized Yamaha Snow-
the three screws securing the shift mobile dealer for this service. This
actuator to the chain case, discon- service is at the discretion and
nect the actuator wiring harness, and expense of the snowmobile owner.
remove the actuator w/extension,
detent, and spring; then add appro- To replace the lubricant, use the follow-
priate amount of Synthetic Chain ing procedure:
Lube through the shift actuator  NOTE: The side panels, hood, and
opening. When the lubricant is half- exhaust resonator must be removed
way up the sight glass, install the for this procedure.
shift actuator w/extension, detent,
and spring and connect the actuator 1. Place a drain pan under the chain
wiring harness. Tighten screws to case; then loosen the eleven screws
0.4 kg-m (36 in.-lb). securing the chain case cover/oil tank
assembly to the chain case housing
starting with the bottom screws first.
 NOTE: It is critical that the snow-
mobile is on a level surface to
ensure the lubricant drains properly
and completely.
 NOTE: Inspect the chain case
cover seal for nicks or damage.

17
 2. When the lubricant has completely  NOTE: Make sure the reverse sen-
drained from the case and the chain sor wire is routed up so the wires do
case is cleaned of old oil, install the not become pinched between the
chain case cover. Tighten the cap actuator and the case.
screws to 1.2 kg-m (105 in.-lb).
CAUTION
CAUTION When installing the shift actuator,
Before installing the chain case screws, rotate the actuator back and forth to
be sure to clean the holes using com- properly align it with the extension
pressed air completely of debris or gear. Failure to do so could cause
damage to the chain case may occur. component damage.
4. Install and secure the exhaust reso-
nator.
5. Start the engine and verify proper
reverse and forward operation by
shifting in and out of reverse three
times.

CAUTION
The correct lubricant to use in the
XM092 chain case is Synthetic Chain Lube.
3. Remove the three screws securing Any substitute may cause serious
the shift actuator to the chain case, damage to the drive system.
disconnect the actuator wiring har- Rear Suspension
ness, and remove the actuator w/
extension, detent, and spring. Pour This procedure should be done every 40
the recommended chain lubricant operating hours.
through the shift actuator opening  NOTE: Yamaha recommends that
until the lubricant is at least halfway All-Temp Grease be used for this
up in the sight glass; then install the procedure.
shift actuator w/extension, detent,
and spring and connect the actuator 1. Using Handlebar Stand or Steering
wiring harness. Post Stand or a suitable substitute,
lay the snowmobile on its left side.
2. Lubricate all grease fittings with all-
temperature grease.

18
 Maintenance
Periodic Maintenance Checklist
Item Interval Page Remarks
Brake System Daily 26 Check for binding, leakage, and proper operation;
lever firmness, travel, caliper, disc, and pads
Cooling System - Liquid Daily 8,22 Check for leakage, damage, obstructions, coolant
level
Engine Oil - Initial 800 km (500 Mi) 21 Change oil
Engine Oil - After Initial 4000 km 21 Change oil
(2500 Mi)
Engine Oil Filter - Initial 800 km (500 Mi) 21 Change filter
Engine Oil Filter - After Initial 20000 km 21 Change filter
(12500 Mi)
Battery Daily 8,23 Check for proper charge and tight connections
Stop Switch Daily — Check for proper operation
Hoses Daily — Check for damage, leakage, and wear
Headlight & Taillight/Brakelight Daily 36-36 Check for proper operation and cleanliness
Steering System Daily — Check for proper operation, tightness of bolts, and
binding
Throttle Control System Daily 15 Check for binding, sticking, proper operation, throt-
tle cable tension, and wear
Drive Belt Daily 29 Check for wear, cracks, and fraying
Monthly Check length and width dimensions
Ski Wear Bars Daily 37 Check for wear and damage
Electrical Wiring Weekly — Check for wear, damage, and tight connections
Exhaust System Weekly 8 Check for damage, leakage, and obstructions
Nuts, Bolts, Fasteners Weekly — Check tightness
Shock Absorbers Weekly 10,33 Check for fluid leakage and damage and air pres-
sure (Fox Air Shocks)
Spark Plugs 4000 km 23 Check center electrode insulator color, carbon,
(2500 Mi)/ and gap
Seasonal
Valve Clearance 40000 km 23 Check/adjust
(25000 Mi)
Crankcase Breather System Seasonal — Check breather hose for cracks or damage and
replace as necessary
Suspension Weekly 33 Check for damage, loose components, and proper
adjustment
Track Tension/Alignment Weekly 31,32 Check/adjust as necessary
Wear Strips Weekly 39 Check for wear and damage
Wires & Cables Weekly — Check for wear, damage, and fraying
Fuel System - Tank, Pump, Weekly — Check for damage, wear, obstructions, and leak-
In-Line Filter, & Vent Hose age
Fuel Filter 8000 km — Replace
(5000 Mi)/
2 years
Chain Case Daily 17 Check lube level and for leakage
Chain Case - Lubricant Seasonal 17 Replace
Drive Chain Tension - Initial 500 km (300 Mi) 29 Check tension and adjust as necessary
Drive Chain Tension - After 800 km (500 Mi) 29 Check tension and adjust as necessary
Initial
Heat Exchangers Monthly — Check for wear, leakage, and damage
Drive Clutch/Driven Clutch 4500 km 9,10 Check for damage, binding, and wear/remove
(2500 Mi)/ drive belt, clean drive clutch/driven clutch
Seasonal
Rear Suspension Monthly 18 Grease

19
The longevity and safety of the snowmo-  NOTE: The fuel filter is located
bile can be increased by making periodic below the upper console and to the
checks of the items in the preceding right of the steering support. To
checklist. access the filter, the access panels
and hood need to be removed.
If, at any time, abnormal noises, vibra-
tions, or improper working conditions of 1. Remove the hose clamps and dis-
any component of this snowmobile are card; then slowly remove the fuel
detected, DO NOT OPERATE THE hoses from the fuel filter. Dispose of
SNOWMOBILE. Take the snowmobile the excess fuel from the filter prop-
to an authorized Yamaha Snowmobile erly.
dealer for inspection and adjustment or 2. Inspect the fuel hoses thoroughly for
repair. If not under warranty, this service any signs of cracking, cuts, or wear
is at the discretion and expense of the points.
snowmobile owner.
3. Place the new hose clamps on the
The snowmobile should be taken to an fuel hoses; then with the fuel pump
authorized Yamaha Snowmobile dealer at inlet and outlet noted, connect the
the end of each snowmobiling season for fuel hoses to the fuel filter. Secure
general inspection and for off-season with the hose clamps.
storage servicing. This inspection and
servicing is at the expense of the snow-
mobile owner. CAUTION
Make sure the fuel filter is properly
Fuel System seated into the holder.
! WARNING
Whenever any maintenance or
inspection is made on the fuel sys-
tem in which there may be fuel leak-
age, there should be no welding,
smoking, open flames, etc., in the
area.
In-Line Fuel Filter
Yamaha recommends that the in-line fuel
filter be replaced every 8000 km (5000 XM184A
miles). The filter must be clean to allow
the fuel hose to transmit the amount of  NOTE: After completing the
gasoline required. changing of the fuel filter and the
engine is started for the first time,
If the in-line fuel filter is obstructed, gas- inspect the filter area for any signs
oline flow will be restricted; therefore, of leaks.
the filter must be replaced. To remove
and install the in-line fuel filter, use the Gasoline Additives
following procedure: Fuel de-icer can be used for all models.
Yamaha Fuel Stabilizer should also be
! WARNING added to the last tank of gasoline before
Since the fuel supply hose may be storage.
under pressure, always wear safety Fuel Pickup Valves
glasses; then remove the hose slowly
to release the pressure. Place an If ever there is a restricted fuel flow and a
absorbent towel around the connec- pickup valve is suspected, take the snow-
tion to absorb the fuel. mobile to an authorized Yamaha Snowmo-
bile dealer for this service. If not under
 NOTE: Before removing the fuel fil- warranty, this service is at the discretion
ter, take note that the filter is direc- and expense of the snowmobile owner.
tional and the arrow should be
directed towards the engine.

20
 CAUTION
Care must be taken not to over-fill the
tank with oil.
Changing Engine Oil/
Filter
! WARNING
0747-833 Engine oil is extremely hot immedi-
ately after the engine is turned off.
Checking Engine Oil Burning could occur if oil contacts
Level skin or clothing.
 NOTE: The engine must be at  NOTE: Recycle or properly dis-
operating temperature before check- pose of the used engine oil.
ing the oil level or an incorrect oil
level will result.  NOTE: The access panels and
hood must be removed for this pro-
CAUTION cedure.
If the engine and oil are not at operat- 1. Park the snowmobile on a level sur-
ing temperature, the oil will not be face; then start the engine and let it
visible in the sight glass. Tip the idle and warm up until the fan on the
snowmobile to the right at a 45° radiator turns on, or if the snowmo-
angle; then check to see if oil is pres- bile was operated, allow the engine
ent in the sight glass. to idle for approximately 30 sec-
1. Park the snowmobile on a level sur- onds. Shut the engine off.
face; start the engine and let it idle and 2. Remove the torx-head screws and
warm up until the fan on the radiator the rear access plate from beneath
turns on, or if the snowmobile was the snowmobile.
operated, allow the engine to idle for
approximately 30 seconds. 3. Place a drain pan beneath the engine oil
drain screw; then remove the screw and
2. Shut the engine off; then remove the allow the oil to drain completely.
right-side access panel and verify oil
is visible at least halfway up in the
sight glass.

XM125A
4. Using Oil Filter Wrench, loosen (but
do not remove) the oil filter and allow
SNO-244A
the oil to drain from the filter into the
3. If oil is not visible halfway up in the drain pan; then remove the filter.
sight glass, add recommended
engine oil until oil is visible half- 5. Apply a light coat of fresh engine oil
way up the sight glass. to the seal of the new oil filter.

21
 6. Install the new oil filter by turning the  NOTE: If the warning icon does not
oil filter by hand until the seal has con- go out, shut the engine off immedi-
tacted the oil filter mounting surface; ately and repeat step 11; then place
then tighten the oil filter to 1.7 kg-m the ignition switch to the ON posi-
(12 ft-lb). tion and repeat step 12. If the warn-
ing icon does not go out, take the
7. Install the engine oil drain screw snowmobile to an authorized
with a new gasket. Tighten the screw Yamaha Snowmobile dealer for ser-
to 1.0 kg-m (7.2 ft-lb). vice. If not under warranty, this ser-
8. Remove the four torx-head screws vice is at the discretion and expense
of the snowmobile owner.
securing the right-side footrest to the
tunnel and the support; then with a 13. Shut the engine off; then add oil to
drain pan in position, remove the the oil tank until oil is visible half-
drain plug from the oil tank. way up in the sight glass.
 NOTE: If the oil and engine are not
at operating temperature, the oil
level may read too low. Always make
sure the engine is at operating tem-
perature before checking the oil.
14. Install the access plate and torx-head
screws beneath the snowmobile; then
install the hood and access panels.
Coolant Level
746-121A
 NOTE: Use a good quality, ethyl-
 NOTE: To aid in draining the oil ene glycol-based, automotive-type
from the tank, position a funnel coolant.
between the tank and the opening of
the tunnel running board. ! WARNING
9. After the oil has drained completely, Always check the coolant level with
install the drain plug with a new O- the engine cold.
ring and tighten to 2.2 kg-m (16 ft-lb).
Locate the filler neck located above the
10. Pour the recommended engine oil resonator; then remove the coolant cap
into the oil tank. from the filler neck. Verify that the coolant
11. Without starting the engine, place is at the bottom of the tab in the filler neck.
the handlebar emergency stop
switch to the RUN position and the
ignition switch to the ON position.
The Oil Pressure Warning Icon
should illuminate.
 NOTE: If the warning icon does not
illuminate, take the snowmobile to an
authorized Yamaha Snowmobile dealer
for service. If not under warranty, this
service is at the discretion and
expense of the snowmobile owner. 0747-547

12. If the warning icon illuminates Locate the coolant tank above the drive
(from step 11), start the engine. The clutch; then remove the plug from the
warning icon should go out within coolant tank. Add coolant to the full level
five seconds. If it does, proceed to on the tank. Install the plug.
step 13.

22
 Checking/Adjusting
Valve Clearance
After 40,000 km (25,000 miles), valve
clearance should be checked and adjusted
as necessary.
 NOTE: Take the snowmobile to an
authorized Yamaha Snowmobile
dealer for inspection and service.
This service is at the discretion and
0747-766 expense of the snowmobile owner.

CAUTION CAUTION
If the coolant is below the neck and if It is critical that the checking/adjust-
coolant has been added, immediately ing valve clearance be done at the
inspect for leakage and/or damage. If recommended intervals or severe
leakage or damage is detected, take engine damage may occur.
the snowmobile to an authorized
Yamaha Snowmobile dealer for ser- Battery
vice. If not under warranty, this ser-
These sealed batteries after being in ser-
vice is at the discretion and expense
of the snowmobile owner. vice require regular cleaning and charg-
ing in order to deliver peak performance
Spark Plugs and maximum service life. The following
 NOTE: Always use the recom- procedure is recommended for cleaning
mended spark plugs in the engine. and maintaining sealed batteries. Always
See the appropriate specifications read and follow instructions provided
sheet for correct spark plug gap. with battery chargers and battery prod-
ucts.
CAUTION  NOTE: Battery maintenance may
If adjusting spark plug gap is neces- be done by the snowmobile owner if
sary, do not use the center electrode qualified to do so. If the owner does
as a leverage point. Damage to the not feel qualified, take the snowmo-
plug may occur. bile to an authorized Yamaha Snow-
mobile dealer for this service. This
1. Disconnect the main harness from the service is at the discretion and
ignition coils; then remove the ignition expense of the snowmobile owner.
coils from the cylinder head cover.
2. Remove the three spark plugs.
! WARNING
Improper handling or connecting of a
 NOTE: Prior to installing the spark battery may result in severe injury
plugs, check the gap between the including acid burns, electrical burns,
electrode and ground strap. The or blindness as a result of an explo-
clearance should be 0.7-0.8 mm sion. Always remove rings and
(0.028-0.031 in.). watches. Any time service is per-
formed on a battery, the following
3. Install new spark plugs. Tighten to must be observed: keep sparks, open
1.3 kg-m (9.4 ft-lb). flame, cigarettes, or any other flame
4. Install the ignition coils onto the cyl- away. Always wear safety glasses.
inder head cover making sure they Protect skin and clothing when han-
dling a battery. When servicing a bat-
are fully seated. Connect the main tery in an enclosed space, keep the
harness to the ignition coils. area well-ventilated.
5. Install the hood and access panels.

23
 ! WARNING  NOTE: If battery posts or cable
ends have a build-up of white/green
Battery posts, terminals, and related powder residue, apply water and
accessories contain lead and lead baking soda to neutralize acid; then
compounds, chemicals known to the flush off with warm soapy water.
state of California to cause cancer
and reproductive harm. Wash hands
after handling.
CAUTION
1. Remove the torx-head screw from Do not remove seal strip on a sealed
battery.
the rear underside of the seat; then
remove the seat. ! WARNING
CAUTION Battery acid is harmful if it contacts
eyes, skin, or clothing. Care must be
Make sure to disconnect the seat taken whenever handling a battery.
heater harness connector prior to
removing the seat. 5. Using a multimeter, test the battery
voltage. The meter must read no less
2. Remove the negative battery cable than 12.5 DC Volts for a fully
and ground wire; then remove the charged battery.
positive cable.
 NOTE: At this point if the meter
 NOTE: For installing purposes reads as specified, the battery may
prior to removing the battery, note be returned to service (see step 9).
the routing and securing locations of
the cables and harness wires. 6. If the meter reads less than specified
voltage, charge the battery using the
3. Remove the two screws and lock following guidelines.
nuts securing the battery bracket/
solenoid to the seat-base; then move A. When using an automatic battery
the bracket up and out of the way charger, always follow the char-
and remove the battery. ger manufacturer’s instructions.
B. When using a constant-current
battery charger, use the follow-
ing Battery Charging Chart.

CAUTION
Never exceed the standard charging
rate.
! WARNING
0747-528
An overheated battery could explode
causing severe injury or death.
! WARNING Always monitor charging times and
charge rates carefully. Stop charging
Avoid spillage and contact with skin, if the battery becomes very warm to
eyes, and clothing. the touch. Allow it to cool before
resuming charging.
CAUTION
Do not charge the battery while it is in
the snowmobile with the battery ter-
minals connected.
4. Thoroughly wash the battery with soap
and water; then using a wire brush,
clean the battery posts and cable ends
removing all corrosive buildup.
Replace damaged cables or cable ends.

24
 Battery Charging Chart 11. Secure the main black negative
(Constant-Current Charger) cable and the small black negative
cable to the battery using a cap
Battery Charge Time screw, lock washer, and a flat
Voltage Charge Required (at 1.5-
(DC)
State
2.0 Amps) washer. Tighten securely.
12.5 (mini-
mum)
100% None CAUTION
Connecting cables in reverse (posi-
12.2-12.4 75%-99% 3-6 hours tive to negative and negative to posi-
12.0-12.2 50%-74% 5-11 hours tive) can cause serious damage to
the electrical system.
11.0-11.9 25%-49% 13 hours (minimum)
11.5 or less 0-24%
 NOTE: Assure the harness wires and
20 hours (minimum)
cables are routed properly as noted
 NOTE: If the battery voltage is 11.5 during removing battery procedure.
DC Volts or less, some chargers may
“cut off” and fail to charge. If this
occurs, connect a fully charged
booster battery in parallel (positive
to positive and negative to negative)
for a short period of time with the
charger connected. After 10-15 min-
utes, disconnect the booster battery
leaving the charger connected and
the charger should continue to
charge. If the charger “cuts off,”
replace the battery. XM167A

7. After charging the battery for the 12. Install the battery bracket/solenoid
specified time, remove the battery and tighten the two screws and lock
charger and allow the battery to sit nuts to 1.2 kg-m (105 in.-lb); then
for 1-2 hours. install the seat and secure with the
torx-head screw. Tighten securely.
8. Connect the multimeter and test the
battery voltage. The meter should  NOTE: Prior to lowering and secur-
read no less than 12.5 DC Volts. If ing the seat, connect the seat heater
the voltage is as specified, the bat- harness connector.
tery is ready for service. Fuses
 NOTE: If voltage in step 8 is below Fuses protect the snowmobile electrical
specifications, charge the battery an
additional 1-5 hours; then retest. The system from overloading. If electrical
battery is ready for service. parts in the snowmobile are not working,
the system may have been overloaded and
9. Place the battery into position in the caused a blown fuse. Before repairing or
snowmobile; then coat the battery replacing any electrical part, check the
posts and cable ends with a light appropriate fuses. If a fuse blows (opens a
coat of multi-purpose grease. circuit), all the parts of the snowmobile
that use that circuit will not work.
CAUTION Once which fuse to check has been deter-
Before installing the battery, make mined, perform the following steps:
sure the ignition switch is in the OFF
position. 1. Locate the fuse block and remove
the fuse block cover.
10. Secure the red positive cable to the
positive terminal on the battery  NOTE: The fuse block is behind
using a cap screw, lock washer, and the coolant overflow bottle.
a flat washer. Tighten securely.

25
 ! WARNING
DO NOT operate the snowmobile
when the brake lever lock is engaged
or when any component in the brake
system is damaged, worn, or
adjusted improperly. If the snowmo-
bile is operated and the brake system
is not functioning properly, severe
personal injury could result.
XM124A

 NOTE: There are spare fuses Checking/Adding Brake

beneath the fuse block cover. Fluid
2. Remove the suspected fuse. 1. With the brake fluid reservoir in a
level position and the cover
 NOTE: Fuse function descriptions removed, check the fluid level. The
are next to the fuse contacts in the brake fluid level must be at the high
fuse block. brake fluid mark in the reservoir.
3. Look through the clear side of the
fuse to see if the element inside is
burned or separated. If it is, the fuse is
blown and should be replaced with a
fuse of the correct amperage rating.

! WARNING
Always replace a fuse with one hav-
ing the same specified amperage rat-
ing. Using a fuse with a higher rating
can cause severe wire damage and 745-817A
could start a fire. 2. If the brake fluid is below the high
brake fluid mark, add Yamaha
4. Install the fuse block cover and close approved DOT 4 brake fluid until
the access panel. the fluid is at the recommended
Even after replacing a fuse, it may con- level. Install and secure the reservoir
tinue to blow if the cause of the overload cover. Do not allow moisture to con-
is not determined. If the fuse continues to taminate the brake system.
blow, take the snowmobile to an autho-
rized Yamaha Snowmobile dealer for ser- CAUTION
vice. If not under warranty, this service is Brake fluid is highly corrosive. Do not
at the discretion and expense of the spill brake fluid on any surface of the
snowmobile owner. snowmobile.
Brake System ! WARNING
Yamaha recommends that the brake sys-
tem (brake lever, fluid reservoir, hose, Do not overfill the brake fluid reser-
voir. Overfilling the reservoir may
caliper, pads, and brake disc) be checked cause the brake system to hydrauli-
daily for fluid leakage, wear, or damage cally lock. Use only Yamaha approved
and for proper operation. Also, the brake DOT 4 brake fluid. Never substitute or
fluid level must be checked every time mix different types or grades of brake
before starting the engine. fluid. Brake loss can result. Brake
loss can result in severe injury or
even death.

26
Changing Brake Fluid Bleeding Brake System
The brake fluid must be changed on a If the brake lever feels spongy when
regular basis and whenever the brake applied, the brake system may need to be
fluid has been overheated or contami- bled. To bleed the brake, use the follow-
nated. The brake fluid should be changed ing procedure:
every 1600 km (1000 miles) or at the end
of the snowmobiling season, whichever  NOTE: The brake system may be
occurs first. Take the snowmobile to an bled by the snowmobile owner if
qualified to do so. If the owner does
authorized Yamaha Snowmobile dealer not feel qualified, take the snowmo-
for this service. This service is at the dis- bile to an authorized Yamaha Snow-
cretion and expense of the snowmobile mobile dealer for this service. This
owner. service is at the discretion and
Checking Brake Lever expense of the snowmobile owner.
Travel 1. Remove the reservoir cover and (if
Before each use, check the brake lever necessary) fill the reservoir to the
travel using the following procedure: high brake fluid mark with Yamaha
approved DOT 4 brake fluid.
1. Compress the brake lever fully.
 NOTE: Do not pump the brake CAUTION
lever as it will produce an inaccurate Brake fluid is highly corrosive. Do not
reading. spill brake fluid on any surface of the
snowmobile.
2. Measure the distance between the
brake lever and the handlebar. The ! WARNING
distance must be greater than 2.54
cm (1 in.). Use only Yamaha approved DOT 4
brake fluid. Any substitute may result
in a loss of brakes.
2. Slide a piece of flexible tubing over
the ball of the bleeder valve and
direct the other end into a container.

0745-816
3. If the resultant distance is less than
specified, take the snowmobile to an
authorized Yamaha Snowmobile
dealer for service. If not under war-
ranty, this service is at the discretion XM145A
and expense of the snowmobile owner. 3. Slowly compress the brake lever
until maximum pressure is attained;
! WARNING then hold the lever in the com-
Do not operate the snowmobile if the pressed position to maintain pres-
compressed distance between the sure. Open the bleeder valve to
brake lever and the handlebar is less release the fluid and air. When the
than 2.54 cm (1 in.). Brake loss may fluid stops, close the bleeder valve;
occur. Brake loss can result in severe then release the brake lever.
personal injury.
4. Repeat step 3 until the brake fluid
flows free of air bubbles.

27
 NOTE: It may be necessary to refill 4. Carefully move the shield out of the
the reservoir during the bleeding way; then remove the hairpin clip
process. Never allow the brake fluid securing the brake pads to the cali-
to go below the low brake fluid mark per assembly.
in the reservoir.
5. Using a pair of pliers, pull the outer
5. When the brake fluid is free of all air brake pad out of the caliper assembly.
and the brake lever feels firm when
compressed, fill the reservoir to the
high brake fluid mark; then install and
secure the cover. Remove the tube
from the bleeder valve.
Checking/Changing Brake
Pads
The condition of the brake pads must be
checked daily and changed if worn or
damaged. To check and change the brake PC013
pads, use the following procedure:
 NOTE: Changing one pad at a time
 NOTE: The brake pads may be will prevent one piston from pushing
changed by the snowmobile owner if out the other piston from the caliper.
qualified to do so. If the owner does
not feel qualified, take the snowmo- 6. Measure the thickness of the brake pad.
bile to an authorized Yamaha Snow- The brake pad thickness must be greater
mobile dealer for this service. This than 5.0 mm (0.20 in.). If the brake pad
service is at the discretion and thickness is less than specified, replace-
expense of the snowmobile owner. ment of both pads is necessary.
 NOTE: When installing new brake
pads, always install them as a set.
Never install just one pad or use
brake pads which have been used in
another snowmobile.
1. Remove the brake fluid reservoir
cover; then remove most of the
brake fluid from the reservoir. Install
the cover.
PC011A
CAUTION 7. Using a flat-blade tool, slowly and
Brake fluid is highly corrosive. Do not carefully push the piston into the
spill brake fluid on any surface of the caliper.
snowmobile.
8. Position the outer brake pad into the
 NOTE: The above procedure will caliper; then install the hair-pin clip
allow room for the fluid from the cali- into the caliper assembly.
per when the pistons are pushed
into the caliper for installing new 9. Repeat steps 5-8 for the inner pad; then
brake pads. Replacing the cover will secure the pad with the hairpin clip.
prevent fluid spillage. 10. Remove the reservoir cover and
2. Open the left-side access panel. remove the remaining fluid; then fill
the reservoir with fresh fluid and
3. Remove the torx-head screws secur- install the cover.
ing the brake shield to the belt guard
mount; then remove the cap screws 11. Pump the brake lever to ensure cor-
securing the brake shield to the rect positioning of the brake pads
brake caliper. and proper brake lever travel; then
release.

28
 NOTE: If brake lever travel is not Chain Tension
within specification, bleed the brake 1. Remove the shroud, right-side cover,
system. and exhaust assembly.
12. Remove the reservoir cover and fill 2. Loosen the jam nut.
the reservoir (if necessary) to the
proper level with fresh brake fluid; 3. Turn the chain tension adjustment
then install the cover. bolt clockwise until it is finger tight;
then loosen it 1 1/2 turns.
13. Secure the brake shield, the driven
clutch (tightened to 20 ft-lb), and the
rear belt guard; then close and
secure the left-side access panel.
 NOTE: When new brake pads are
installed, a “burnishing” process is
required (see Burnishing Brake Pads
sub-section).
Burnishing Brake Pads
After changing brake pads, the new brake
pads must be burnished to achieve full
braking effectiveness. Braking distance
will be extended until brake pads are
properly burnished. 0747-831
To properly burnish the brakes, use fol- 4. While holding the bolt with a
lowing procedure: wrench, tighten the jam nut to 2.5
1. Choose an area sufficiently large to kg-m (18 ft-lb).
safely accelerate to 50-65 km/h (30- 5. Install the exhaust assembly with a
40 mph) and to brake to a stop. new gasket.
 NOTE: This procedure can also be 6. Install the right-side cover and the
accomplished using a shielded jack shroud.
stand.
 NOTE: Check that the harness is
2. Accelerate to 50-65 km/h (30-40 installed correctly.
mph); then compress brake lever to
decelerate to a stop. Drive Belt
 NOTE: Lightly apply the brake lever Thedrive
drive belt transfers power from the
clutch to the driven clutch. If the
to come to an easy stop; do not over-
apply brakes or “lock up” the track. belt is worn, cracked, or stretched, maxi-
mum power will not be transmitted and
3. Repeat procedure 10-15 times allow- the belt could also fail and therefore must
ing some cooling between stops. be replaced. Periodic checks (at least
once a month under normal usage) of two
 NOTE: Do not repeat too soon or drive belt specifications are essential.
too aggressively as to get the brake
disc “red hot.” 1. Measure the outside circumference of
the drive belt. The belt should be
! WARNING within 1118-1126 mm (44.0-44.3 in.).
Do not attempt sudden stops or put 2. Measure the outside width of the drive
yourself into a situation where a sud- belt. The belt should be at least 34.5
den stop will be required until the mm (1.36 in.) on a new belt or 32.5
brake pads are properly burnished. mm (1.28 in.) on a broken in belt.
 NOTE: This procedure stabilizes 3. Check the belt for cracking, fraying, etc.
the pad material and extends the life
of the pads. If any of the specifications or conditions
are unsatisfactory, replace the drive belt.

29
 NOTE: Drive belts should be pur-
chased from an authorized Yamaha
Snowmobile dealer, as Yamaha drive
belts are made to exact specifica-
tions and of quality material. Belts
made by other manufacturers may
not be of the same specifications or
quality and, therefore, usage could
result in poor performance and pre-
mature belt failure.
SNO-336
 NOTE: Before starting the snowmo-
bile in extremely cold temperatures, Installing Drive Belt
the drive belt should be removed and  NOTE: Before installing the drive
warmed up to room temperature. belt, use a suitable cleaning solvent
Once the drive belt is at room temper- to thoroughly clean the sheaves.
ature, install the drive belt.
1. Open the left-side access panel.
Also, new drive belts have a break-in
period of approximately 40 km (25 miles). 2. Rotate the driven clutch sliding
After installing a new drive belt, drive the sheave clockwise (1); then push
snowmobile for 40 km (25 miles) at 3/4 towards the engine (2) so it will sep-
throttle or less. By revving the engine up arate from the fixed sheave.
and down (but not exceeding 97 km/h [60 3. Install the drive belt (3) between the
mph]), the exposed cord on the side of a sheaves.
new belt will be worn down. This allows
the drive belt to gain its optimum flexibil-
ity and will extend drive belt life.

CAUTION
Never run the engine with the drive
belt removed. Excessive revving of the
engine could result in serious engine
damage and drive clutch failure.
Removing Drive Belt
SNO-326
 NOTE: Changing a drive belt can be
done by the snowmobile owner if qual-
ified to do so. If the owner does not
feel qualified, take the snowmobile to
an authorized Yamaha Snowmobile
dealer for this service. This service is
at the discretion and expense of the
snowmobile owner.
1. Place the snowmobile on a level sur-
face and engage the brake lever SNO-327
lock. 4. Install the left-side access panel.
2. Open the left-side access panel and
remove the belt guard assembly. ! WARNING
3. Rotate the driven clutch sliding Never operate the snowmobile without
sheave clockwise (1); then push the access panel secured in place.
towards the engine (2) so it will sep-
arate from the fixed sheave.
4. Remove the drive belt by pulling it
up and over the fixed sheave.

30
Track Tension
Track tension is directly related to the
overall performance of the snowmobile.
If the track is too loose, it may slap
against the tunnel causing wear or it may
“ratchet” on the track drive sprockets. If
extremely loose, the idler wheels may
climb over the track lugs forcing the
track against the tunnel causing the track
to “lock.” Yamaha recommends that the
track tension be checked daily during the 746-788A

first 500 km (300 miles) of operation and  NOTE: Measurement is from the
once a week thereafter and adjusted bottom of the wear strip at the point
according to need. The track will stretch of the shock pad on the slide rail.
and take a “set” during break-in. Track
deflection must be maintained within the  NOTE: Only tighten track until the
recommended range. track does not ratchet. Too tight of a
track will cause the rear suspension
to not work properly.
! WARNING
Track tension must be properly main- Adjusting Track Tension
tained. Personal injury could result if  NOTE: To ensure proper track ten-
a track is allowed to become exces- sion adjustment, perform all adjust-
sively loose. ments on both sides of the
Checking Track Tension snowmobile.
1. Loosen the idler wheel axle cap
! WARNING screws.
DO NOT attempt to check or adjust
track tension with engine running.
Turn ignition key to the OFF position.
Personal injury could result from
contact with a rotating track.
1. Remove excess ice and snow buildup
from the track, track drive sprockets,
and the inside of the skid frame.
2. Elevate the snowmobile on a
shielded safety stand high enough to
use a spring scale. 0745-811
2. If the deflection (distance between
3. At the mid-point of the track (on the the bottom of the wear strip and the
bottom side), hook a spring scale inside surface of the track clip)
around a track clip; then pull down exceeds specifications, tighten the
on the scale to the recommended adjusting bolts to take up excessive
pressure (see chart). Measure the slack in the track.
deflection (distance) between the
bottom of the wear strip and the 3. If the distance between the bottom of
inside surface of the track clip. Mea- the wear strip and the inside surface
surement should be 50 mm (2.0 in.). of the track clip is less than specified,
loosen the adjusting bolts to increase
Track Pressure the slack in the track.
3277 mm (129 in.) 9.1 kg (20 lb)
3480 mm (137 in.) 11.3 kg (25 lb) CAUTION
3581 mm (141 in.) 5.4-6.8 kg (12-15 lb) Always maintain track tension within
3886 mm (153 in.) 5.4-6.8 kg (12-15 lb)
recommended specification.
4114 mm (162 in.) 5.4-6.8 kg (12-15 lb) 4. Check track alignment.

31
 5. After proper track tension is
obtained, tighten the idler wheel ! WARNING
axle cap screws to 4.7 kg-m (34 ft- DO NOT stand behind the snowmo-
lb); then tighten the adjusting bolts bile or near the rotating track. NEVER
securely against the axle. run the track at high speed when the
track is suspended.
 NOTE: Since track tension and
track alignment are interrelated, 3. Start the engine and accelerate
always check both even if only one slightly. Use only enough throttle to
adjustment seems necessary. turn the track several revolutions.
SHUT ENGINE OFF.
! WARNING  NOTE: Allow the track to coast to a
Always make sure the adjusting bolts stop. DO NOT apply the brake
are snug against the axle and the because it could produce an inaccu-
idler wheel cap screws are tightened rate alignment condition.
to specifications. Failure to do so
could cause the track to become 4. When the track stops rotating, check
extremely loose and, under some the relationship of the rear idler
operating conditions, allow the idler wheels and the inner track drive lugs.
wheels to climb over the track lugs If the rear idler wheels are centered
forcing the track against the tunnel between the inner track drive lugs, no
causing the track to “lock.” If a track adjustment is necessary.
“locks” during operation, severe per-
sonal injury could result.
Track Alignment
Proper track alignment is obtained when
the rear idler wheels are equal distance
from the inner track drive lugs. Excessive
wear to the idler wheels, drive lugs, and
track will occur if the track is improperly
aligned. Yamaha recommends that the
track alignment be checked once a week
0745-809
or whenever the track tension is adjusted.
5. If the idler wheels are not centered
Checking Track Alignment between the inner track drive lugs,
an adjustment is necessary.
! WARNING
Adjusting Track Alignment
Make sure the ignition key is in the
OFF position and the track is not 1. On the side of the track which has the
rotating before checking or adjusting inner track drive lugs closer to the rear
track alignment. Personal injury idler wheel, loosen the idler wheel
could result if contact is made with a axle cap screw; then rotate the adjust-
rotating track. ing bolt clockwise 1 to 1 1/2 turns.
1. Remove excess ice and snow buildup
from the track, track drive sprockets,
and the inside of the skid frame.
2. Position the tips of the skis against a
wall; then using a shielded safety
stand, raise the rear of the snowmo-
bile off the floor making sure the
track is free to rotate.

! WARNING 0745-811
The tips of the skis must be positioned
against a wall or similar object.

32
 2. Check track alignment and continue
adjustment until proper alignment is ! WARNING
obtained.
Read and understand the following
 NOTE: Make sure correct track information before handling shock
tension is maintained after adjust- absorbers that contain highly pres-
ing track alignment. surized nitrogen gas.
• Do not tamper with tor attempt to
3. After proper track adjustments are open the cylinder assemblies.
obtained and the adjusting bolts are • Do not subject the shock absorb-
snug against the axle housings, ers to an open flame or other high
tighten the idler wheel axle cap heat source. This may cause the
screws to 4.7 kg-m (34 ft-lb). unit to explode due to excessive
gas pressure.
! WARNING • Do not deform or damage the cyl-
Always make sure the adjusting bolts inders in any way. Cylinder dam-
are snug against the axle and the age will result in poor damping
idler wheel cap screws are tightened performance.
to specifications. Failure to do so • Do not dispose of a damaged or
could cause the track to become
extremely loose and, under some worn out shock absorber your-
operating conditions, allow the idler self. Take the shock absorber to a
wheels to climb over the track lugs Yamaha dealer for any service.
forcing the track against the tunnel
causing the track to “lock.” If a track  NOTE: On SD, XL, XS, ML, and MS
“locks” during operation, severe per- models with a rear arm float shock,
sonal injury could result. this adjustment is achieved by
increasingly or decreasing the air
4. Field test the track under actual con- pressure in the rear arm air shock
ditions. absorber.
5. After the field test, check the align- Adjusting Front (Ski)
ment of the track. If additional adjust- Shock Springs
ment is necessary, repeat Adjusting
Track Alignment procedure. The front (ski) shock springs are individu-
ally adjustable for the terrain conditions and
Suspension driving style of the operator. The spring
The suspension should be adjusted for adjuster nut has been set at the factory so the
the operational needs and riding prefer- correct amount of threads are exposed
ence of the operator. between the adjuster nut and the threaded
shock body as an initial setting. Additional
The front shock springs determine the ski pressure can be obtained by tightening
amount of ski pressure and the reaction the spring tension; ski pressure can be
of the front suspension to rough terrain. decreased by relaxing spring tension.
The amount of ski pressure can also be
changed by adjusting the length of the  NOTE: Equal adjustments should
skid frame front arm limiter straps. be maintained on both sides of the
snowmobile.
On standard models, the rear arm shock
absorber spring influences the load carry- Front (ski) shock spring pre-load adjust-
ing capability of the snowmobile and ment is accomplished by loosening the
should be adjusted for the weight and rid- adjuster nut locking collar (B) from the
ing preference of the operator. adjuster nut (A) and using the Spring
Adjuster Tool from the tool kit, rotating
the adjuster nut in whichever direction is
desired. Tighten the locking collar
against the adjuster nut.

33
  NOTE: Care should be taken to
have equal pressure in the front (ski)
shocks before operating the snow-
mobile.
To increase or decrease air pressure, use
the following procedure.
 NOTE: When adjusting air pres-
sure, all weight must be removed
0745-159 from the suspension, and the shock
absorbers must be fully extended.
Adjusting Fox Air Shocks
1. Remove the air valve cap from the
 NOTE: It is recommended to moni- shock.
tor the air pressure in the air shocks
once every month. 2. Thread the valve of Shock Absorber
Air Pump onto the shock air valve
 NOTE: Adjusting air shocks may approximately six rotations.
be done by the snowmobile owner if
qualified to do so. If the owner does  NOTE: As the pump is being attached
not feel qualified, take the snowmo- to the shock, the hose will fill with air.
bile to an authorized Yamaha Snow- This will result in a lower gauge pres-
mobile dealer for this service. This sure of 0.14-0.35 kg/cm2 (2-5 psi).
service is at the discretion and
expense of the snowmobile owner. 3. To decrease air pressure in the
shock, press the black bleed valve
The air shocks are individually adjustable button half way down and hold until
for the terrain conditions and driving style desired pressure is attained.
of the operator. The shocks are preset at the
factory (see chart) as an initial setting;  NOTE: Pressing the button fully
however, it is possible to “fine tune” the down and releasing it will allow only
shocks to match the operator’s weight, rid- a small amount of air to escape
ing style, and terrain conditions. (micro-adjust).
 NOTE: Adding air pressure will 4. To increase air pressure in the shock,
increase the air spring force; reduc- pump until desired pressure is attained.
ing air pressure will decrease air 5. Remove the pump valve from the
spring force. shock air valve.
Checking and adjusting air pressure must  NOTE: As the pump valve is being
be done at riding temperature (outside). removed from the shock, the sound
Also, it is advisable to check air pressure of air loss is from the pump hose,
when the outside temperature varies not from the shock.
more than 25°.
6. Install the air valve cap onto the
Initial Setting Chart shock.
Front Shock Rear Arm
Model
(Ski) Shock Adjusting Skid Frame
SR10XL/XS 2 2 Front Arm
6.3 kg/cm 10.2-10.6 kg/cm
(90 psi) (145-150 psi) The skid frame front arm shock spring ten-
SR10RS, LL/ 5.3 kg/cm2 N/A sion and the limiter straps are adjustable.
LS (75 psi) However, Yamaha recommends that the
SR10M53S, 6.3 kg/cm2 10.2-10.6 kg/cm2 shock spring be maintained at the factory pre-
M62S/L (90 psi) (145-150 psi) set of 3.2-6.4 mm (1/8-1/4 in.) preload. Tight-
SR10RL,ML 5.62 kg/cm2 10.2-10.6 kg/cm2 ening the skid frame front arm shock spring
(80 psi) (Main (145-150 psi) - may cause improper balance and may ruin
Chamber) ML only the handling features of the snowmobile.
14.06 kg/cm2
(200psi) (EVOL
Chamber)

34
The length adjustment of the front arm Rear spring pre-load adjustment is accom-
limiter straps determines the weight distri- plished by rotating the adjusting cams.
bution between the front of the skid frame Position 3 provides the stiffest ride, and
and the skis. Tightening the limiter strap position 1 is for the light driver or slow-
(shortening the strap) will pull up on the speed trail riding. Position 2 is for the
front of the skid frame and will increase ski average operator under normal conditions.
pressure. Loosening the limiter strap Always rotate the cam from the lighter
(lengthening the strap) lowers the front of position to the heavier position.
the skid frame and decreases ski pressure.
When customizing the amount of ski CAUTION
pressure, be sure to adjust both straps Never force the adjustment cams
equally and do not over-adjust the limiter from the low position to the high
straps to adversely affect steering and position. Cam damage may occur.
operator control of the snowmobile.
Some experimentation may be required
until the proper adjustment for the opera-
tor’s individual style is obtained.
 NOTE: If the limiter straps are
adjusted, it is highly recommended
that at least a minimum of 3.2 mm
(1/8 in.) preload on the shock spring
be maintained.

! WARNING 741-450A

Do not adjust the front arm limiter To rotate an adjusting cam, use the spark
straps to a point at which steering plug wrench from the tool kit. Rotate the
and operator control of the snowmo- wrench until the cam is in the desired
bile are adversely affected. position. To stiffen the ride, rotate the cam
so as to raise the spring end. Make the
Adjusting Rear Spring Pre- appropriate adjustment on the other cam.
Load (SR10R Models,
Adjusting Skid Frame Rear
SR10L Models)
Arm Shock Spring
Proper adjustment of rear spring pre-load (SR10M Models)
is necessary to get the most desirable
ride. The chart is designed to help in set- Proper adjustment of rear arm shock
ting up rear spring pre-load; however, absorber spring pre-load is necessary to
riding style is the single greatest factor in get the most desirable ride.
determining rear spring requirements. The rear arm shock spring is adjustable
for the terrain conditions and driving
Rider Weight (lb) Cam Position
style and weight of the operator. The
Up to 80 kg (180 lb) 1 spring adjuster nut has been set at the fac-
80 kg (180 lb) - 110 kg (240 lb) 2 tory so the correct amount of threads are
Over 110 kg (240 lb) 3 exposed between the adjuster nut and the
 NOTE: These cam position set- threaded shock body as an initial setting.
tings are suggestions only. Personal Rear spring pre-load adjustment is
riding style will greatly influence accomplished by loosening the adjuster
cam position settings. Spend time to nut locking collar (B) from the adjuster
determine setting preferences. nut (A) and using the Spring Adjuster
Tool from the tool kit, rotating the
adjuster nut in whichever direction is
desired. Tighten the locking collar
against the adjuster nut.

35
 1. Disconnect the headlight harness
connector from the bulb; then
remove the rubber grommet from
the headlight housing.
2. Rotate the bulb retainer counter-
clockwise until it unlocks from the
housing; then remove the bulb.

0745-159

Lights
For the correct headlight bulb and/or tail-
light/brakelight LED, see the appropriate
specifications sheet.
Removing and Installing
Taillight/Brakelight
0747-832
These models are equipped with an LED
taillight/brakelight. If the LED fails, it 3. Install the bulb and retainer; then
must be replaced. To remove and install rotate the retainer clockwise until it
the LED, use the following procedure. properly locks in place.
4. Install the rubber grommet; then
connect the headlight harness con-
nector to the bulb.
5. Check headlight aim.

! WARNING
Do not operate the snowmobile
unless headlight beam is adjusted
properly. An incorrectly adjusted
beam will not provide the operator
746-097B
the optimum amount of light.
1. Disconnect the taillight harness con-
nector. Adjusting Headlight Aim
2. Remove the two torx-head screws The headlight can be adjusted for vertical
securing the taillight to the bracket. aim of the HIGH/LOW beam. The geo-
metric center of HIGH beam zone is to be
3. Connect the taillight harness connec- used for vertical aiming.
tor; then secure the taillight to the
bracket with the two torx-head screws. 1. Position the snowmobile on a level
floor so the headlight is approxi-
Removing/Installing mately 8 m (25 ft) from an aiming
Headlight Bulb surface (wall or similar surface).
 NOTE: The bulb portion of headlight  NOTE: There should be an “aver-
is fragile. HANDLE WITH CARE. When age” operating load on the snowmo-
replacing the headlight bulb, the bulb bile when adjusting headlight aim.
assembly must first be removed from
the housing. Do not touch the glass 2. Measure the distance from the floor
portion of the bulb. If the glass is to midpoint of the headlight.
touched, it must be cleaned with a dry 3. Using the measurement obtained in
cloth before installing.
step 2, make a horizontal mark on
the aiming surface.

36
4. Make a vertical mark which inter- Ski Wear Bars
sects the horizontal mark on the aim- The ski wear bar is a replaceable bar
ing surface directly in front of the attached to the underside of the ski. The
headlight. purpose of the wear bar is to assist in turn-
5. Engage the brake lever lock and start ing the snowmobile, to minimize ski wear,
the engine. Move the headlight dim- and to maintain good steering control. If
mer switch to the HIGH beam posi- the snowmobile is operated primarily in
tion. DO NOT USE LOW BEAM. deep snow, ski wear bar wear will be mini-
mal; however, if the snowmobile is oper-
6. Observe the headlight beam aim. ated on terrain where the snow cover is
Proper aim is when the most intense minimal, the ski wear bar will wear faster.
beam is centered on the vertical mark To maintain positive steering characteris-
50 mm (2 in.) below the horizontal tics, Yamaha recommends that the ski wear
mark on the aiming surface. bars be checked before each use and
replaced if worn beyond 1/2 of the original
diameter. Ski wear bars are available from
an authorized Yamaha Snowmobile dealer.

! WARNING
Operating the snowmobile with
excessively worn ski wear bars may
result in a loss of steering control.
Removing (Single)
0747-834 1. Using Front End Lift, elevate the
7. Adjust the headlight using the adjust- front of the snowmobile.
ing screw on the backside of the head- 2. Remove the lock nuts securing the
light using a 4 mm swivel socket and wear bar to the ski.
long extension until correct aim is
obtained. Shut the engine off; then
disengage the brake lever lock.

0747-825
3. Remove the wear bar from the ski.
0746-807 Installing (Single)
1. Move the wear bar into position on
the bottom of the ski.
2. Align the wear bar studs with the
holes in the ski; then install the lock
nuts. Tighten to 2.0 kg-m (15 ft-lb).
Removing (Dual)
1. Using Front End Lift, elevate the
front of the snowmobile.

37
 2. Remove the lock nuts, washers, and
spacers securing the wear bars to the
ski.
3. Remove the wear bars from the ski.
 NOTE: When the wear bars are
removed, measure the thickness of
both wear bars to see if they are
within the wear limit of 6.0 mm (0.24
in. (A and B). Replace as necessary.
SNO-441A
2. Tighten the nuts evenly to 2.0 kg-m
(15 ft-lb).
Adjusting Ski Stance
 NOTE: Local laws and/or regula-
tions as to maximum width of the ski
stance on these snowmobiles may
be applicable. Always comply with
the maximum width laws and/or reg-
ulations when adjusting ski stance.
SNO-441A

 NOTE: Measure the thickness of  NOTE: Ski stance can be increased/

the ski where the front and rear of decreased by 25 mm (1.0 in.).
the wear bar contacts the ski to see Single Wear Bar
if it is within the wear limit of 13 mm
(0.51 in.) (A) and 8 mm (0.31 in.) (B). 1. Place the front of the snowmobile on
Replace as necessary. a support stand.
2. Remove the cotter pin; then remove
the slotted nut and cap screw secur-
ing the ski assembly to the spindle.
Remove the ski. Account for the
rubber damper, inserts, and washers.
3. To increase ski stance, place ski
stance spacer to the outside of the
spindle and adjust the damper.

SNO-442A

Installing (Dual)
1. Position the wear bar with the car-
bide (A) on the inside of ski and
loosely secure using the existing
spacer, washer, and nut; then posi-
tion the wear bar without the carbide
(B) on the outside of the ski and
loosely secure using the existing 0747-827
spacer, washer, and nut. 4. To decrease ski stance, place ski
stance spacer to the inside of the
spindle and adjust the damper.

38
 5. Apply an all-temperature grease to the
non-threaded portion of the cap
screw; then slide the cap screw
through the ski accounting for the rub-
ber damper, inserts, and washers.
 NOTE: Install the cap screw so the
slotted nut will be located to the
inside of the ski.
6. Apply Yamabond Red Threadlocker
0747-826 to the threads of the cap screw; then
5. Apply an all-temperature grease to the tighten the nut to 6.2 kg-m (45 ft-lb).
non-threaded portion of the cap
screw; then slide the cap screw 7. Place the cotter pin into the ski cap
through the ski accounting for the rub- screw and spread the pin.
ber damper, inserts, and washers. 8. Repeat procedure for the other ski.
 NOTE: Install the cap screw so the Rail Wear Strips
slotted nut will be located to the Yamaha recommends that the wear strips
inside of the ski. be checked weekly and replaced as nec-
6. Apply Yamabond Red Threadlocker essary. Measure the wear strips at 254
to the threads of the cap screw; then mm (10 in.) intervals. Wear strips must
tighten the nut to 6.2 kg-m (45 ft-lb). be 10.7 mm (0.42 in.) thick or thicker.
7. Place the cotter pin into the ski cap
screw and spread the pin.
8. Repeat procedure for the other ski.
Dual Wear Bar
1. Place the front of the snowmobile on
a support stand.
2. Remove the cotter pin; then remove
the slotted nut and cap screw secur-
ing the ski assembly to the spindle. 0745-807

Remove the ski. Account for the If wear strip measurements are less than
rubber damper, inserts, and washers. specified, replacement of both wear strips
is necessary to prevent premature track
3. To increase ski stance, place ski clip wear and possible track damage.
stance spacer to the outside of the Take the snowmobile to an authorized
spindle and adjust the damper. Yamaha Snowmobile dealer for this ser-
4. To decrease ski stance, place ski vice. This service is at the discretion and
stance spacer to the inside of the expense of the snowmobile owner.
spindle and adjust the damper. Each time a new set of wear strips are
installed, they should be tempered. Tem-
per the wear strips by driving the snow-
mobile for approximately a mile on a
hard pack trail; then immediately drive
into deep snow and allow the wear strips
to cool. Repeat the procedure (warming
up the wear strips; then cooling them
down) two or three times.

SNO-443

39
 NOTE: The rail wear strips will  NOTE: Two Wheel Kit and Four
wear rapidly if the snowmobile is Wheel Kit are available to reduce
operated on terrain on which the wear strip wear.
snow cover is minimal. Loose snow
is required to cool and lubricate the  NOTE: If operating on ice or hard-
wear strips and prevent accelerated packed snow conditions, it is recom-
wear. mended that Ice Scratchers be
installed to reduce wear strip wear
and engine overheating.

40
 Performance Tips
Operating a high performance snowmo- 3. Adjust the position by removing or
bile requires a special attention that is not adding a spacer on each adjusting bolt.
required by a low performance snowmo-
bile. Often, a minor adjustment will CAUTION
result in a large increase in performance. As the belt wears, adjustment may be
This section is intended to highlight necessary. To ensure proper clutch
minor conditions that adversely affect performance, the belt position should
performance and the adjustments needed be adjusted by adding a spacer (2) on
to correct them. Be sure, however, to each adjusting bolt (1) whenever the
thoroughly read and understand this belt position reaches 1.5 mm (0.05
entire manual especially the section on in.) below the edge of the sheaves.
spark plugs, track tension and alignment,
and suspension.
DRIVE BELT POSITION
Drive belt length, condition, and position are
all important for peak performance. To
check and adjust drive belt, remove the belt
guard; then use the following procedure.
 NOTE: Removing/adding shim
washers may be done by the snow-
mobile owner if qualified to do so. If
the owner does not feel qualified, SNO-338
take the snowmobile to an autho-
rized Yamaha Snowmobile dealer for Belt Position Adjustment
this service. This service is at the More than 1.5 mm (0.06 in.) Remove a
discretion and expense of the snow- above the edge spacer
mobile owner. 1.5 mm (0.06 in.) above the No adjustment
edge to 0.5 mm (0.02 in.) necessary
1. Turn the engine off; then open the below the edge
left access panel. More than 0.5 mm (0.02 in.) Add a spacer
below the edge
2. Make sure the drive belt is posi-
tioned from 1.5 mm (0.06 in.) above Spacer Part Numbers:
the edge of the driven clutch sheaves
to 0.5 mm (0.02 in.) below the edge. 90201-061H1: 0.5 mm (0.02 in.)
90201-06037: 1.0 mm (0.04 in.)
4. Close the access panel.
DRIVE CLUTCH AND
DRIVEN CLUTCH
Keeping the drive clutch and driven
clutch clean should be the primary con-
sideration of the operator. The drive
clutch and driven clutch can be cleaned
of any drive belt accumulation using
SNO-337
compressed air. The sheaves can be
! WARNING cleaned using a clean cloth and parts-
cleaning solvent.
If the belt is not positioned correctly,
the clutch engagement speed will be
changed. The snowmobile may move
unexpectedly when the engine is
started.

41
DRIVE CLUTCH/DRIVEN 4. If offset adjustment needs to be
CLUTCH OFFSET made, remove the driven clutch and
add shims (p/n 8JP-RA449-00: 2
If premature drive belt wear is experienced mm, 8JP-RA448-00: 1 mm) to
or if the drive belt turns over, offset must be increase the offset or remove shims
checked. Also, offset must be checked when- to decrease the offset.
ever either the drive clutch or driven clutch is
serviced. 5. Once the correct offset is reached,
install driven clutch and tighten cap
Checking Offset screw to 6.4 kg-m (46 ft-lb).
1. Remove the left-side access panel;  NOTE: When adjusting the driven
then move the console up and out of clutch, the clutch free play (clear-
the way. ance) should be adjusted.
2. Remove the drive belt. 6. Using a feeler gauge, measure the
 NOTE: Use a straightedge that is clutch free play (clearance). Free
approximately 470 mm (18.5 in.) play (a) should be within 1.0-2.0
long, 20 mm (0.79 in.) wide, and 4 mm (0.04-0.08 in.). If adjustment
mm (0.16 in.) thick. needs to be made proceed to step 7.
3. Place the straightedge along the
back side of the drive clutch; then
measure the offset (a) between the
driven clutch and the straightedge.
Sheave offset must be within 13.0-
16.0 mm (0.51-0.63 in.). If adjust-
ment is needed, proceed to step 4.

SNO-325
7. Remove the driven clutch cap screw
and washer; then add shims (p/n
8JP-RA447-00: 2 mm, 8JP-RA446-
00: 1 mm, 8JP-RA433-00: 0.5 mm).
8. Install the driven clutch cap screw
SNO-324 and washer. Tighten to 6.4 kg-m (46
 NOTE: The straightedge must ft-lb).
extend beyond the front edge of the GASOLINE
drive clutch.
For optimum performance, use 87 octane
(minimum) gasoline.

42
 Preparation for Storage
Prior to storing the snowmobile, it must be 11. Tighten all nuts, bolts, and cap
properly serviced to prevent corrosion and screws making sure all nuts, bolts,
component deterioration. An authorized and cap screws are tightened
Yamaha Snowmobile dealer should per- securely. Make sure all rivets hold-
form this service; however, the owner/oper- ing the components together are
ator can perform this service if desired. This tight. Replace all loose rivets.
service is at the discretion and expense of
the snowmobile owner. To prepare the 12. Clean and polish the hood, console,
snowmobile for storage, Yamaha recom- and chassis. DO NOT USE SOL-
mends the following procedure: VENTS. THE PROPELLANT
WILL DAMAGE THE FINISH.
1. Clean the seat cushion with a damp
cloth and a Vinyl Protectant.  NOTE: Disconnect the battery cables
making sure to disconnect the negative
2. Clean the snowmobile thoroughly cable first; then clean the battery posts
by hosing dirt, oil, grass, and other and cables. Charge the battery.
foreign matter from the skid frame,
tunnel, hood, and belly pan. Allow CAUTION
the snowmobile to dry thoroughly. Sealed batteries require charging if
DO NOT get water into any part of left for extended non-start periods.
the engine. Yamaha recommends trickle charging
3. Change the engine oil. once a month. Follow the manufac-
turer’s instructions and cautions.
4. Plug the exhaust system outlet with
a clean cloth. 13. If possible, store the snowmobile
indoors. Raise the track off the floor
5. Fill the gas tank to its rated capacity; by blocking up the back end making
then add Yamaha Fuel Stabilizer to sure the snowmobile is secure.
the gas tank following directions on Loosen the track adjusting bolts to
the container for the stabilizer/gaso- reduce track tension. Cover the
line ratio. Tighten the gas tank cap snowmobile with a machine cover or
securely. a heavy tarpaulin to protect it from
6. With the snowmobile level, check dirt and dust.
the lubricant level in the chain case. 14. If the snowmobile must be stored out-
If low, add chain lube through the doors, position the snowmobile out of
fill plug hole. direct sunlight; then block the entire
7. Remove the drive belt from the drive snowmobile off the ground making
clutch/driven clutch. Lay the belt on sure the snowmobile is secure. Loosen
a flat surface or slide it into a card- the track adjusting bolts to reduce
board sleeve to prevent warping or track tension. Cover with a machine
distortion during storage. cover or a heavy tarpaulin to protect it
from dirt, dust, and rain.
8. Clean and inspect the drive clutch
and driven clutch. CAUTION
9. Apply light oil to the upper steering Avoid storing in direct sunlight and
post bushing and shafts of the shock using a plastic cover as moisture
absorbers. may collect on the snowmobile caus-
ing corrosion.
10. Lubricate the rear suspension with
all-temperature grease.

43
 Preparation after Storage
Taking the snowmobile out of storage 5. Tighten all nuts, bolts, and cap
and correctly preparing it for another sea- screws making sure all nuts, bolts,
son will assure many miles and hours of and cap screws are tightened
trouble-free snowmobiling. Yamaha rec- securely.
ommends the following procedure:
6. If not done during preparation for
1. Clean the snowmobile thoroughly. storage, lubricate the rear suspen-
Polish the exterior of the snowmobile. sion with all-temperature grease.
2. Clean the engine. Remove the cloth 7. Check the coolant level and all cool-
from the exhaust system. Check ant hoses and connections for deteri-
exhaust system and air-intake oration or cracks. Add properly
silencer for obstructions. mixed coolant as necessary.
3. Inspect all control wires and cables 8. Charge the battery until fully
for signs of wear or fraying. Replace charged; then connect the battery
if necessary. Use cable ties or tape to cables making sure to connect the
route wires and cables away from positive cable first. Test the electric
hot or rotating parts. start system.
4. Inspect the drive belt for cracks and 9. Inspect the entire brake system, all
tears. Check belt specifications. controls, headlight, taillight, brake-
Replace if damaged or worn. Install light, ski wear bars, and headlight
the drive belt. aim; adjust or replace as necessary.
 NOTE: If the old belt is worn but in 10. Adjust the track to the proper tension
reasonable condition, retain it with and alignment.
the snowmobile as a spare in case of
emergency.

44
Snowmobile Safety Rules

45
 Consumer Information
Yamaha Snowmobile 4. Installation of parts or accessories
Limited Warranty that are not qualitatively equivalent
Yamaha Motor Corporation, U.S.A. and to genuine Yamaha parts.
Yamaha Motor Canada Ltd. (“Yamaha”) 5. Abnormal strain, neglect, or abuse.
hereby warrant that new Yamaha snow-
mobiles will be free from defects in 6. Lack of proper maintenance.
material and workmanship for the period 7. Accident or collision damage.
of time stated herein, subject to certain
stated limitations. 8. Modification to original parts.
WARRANTY PERIOD SPECIFIC EXCLUSIONS from this
warranty shall include parts replaced due
All new Yamaha snowmobiles purchased to normal wear or routine maintenance
from an authorized Yamaha dealer in the including oil, spark plugs, clutch drive
customer’s country of residence (United belts, slide runners, and tracks.
States or Canada) and registered with
Yamaha shall be warranted against THE CUSTOMER’S RESPONSI-
defects in material and workmanship, BILITY under this warranty shall be to:
subject to the exclusions stated herein, 1. Operate and maintain the snowmo-
for the following stated period of time: bile as specified in the appropriate
All Yamaha snowmobiles shall be war- Owner’s Manual. It is recommended
ranted for a term of one (1) year from the that the customer keep records to
date of purchase, plus a special early-sea- show proof of proper maintenance
son extension (if applicable). All Yamaha and off-season storage having been
snowmobile clutch components are war- performed.
ranted against normal wear for a period 2. Give notice to an authorized Yamaha
of three (3) months, or 1250 miles (2000 snowmobile dealer of any and all
km), whichever comes first. All Yamaha apparent defects within ten (10) days
snowmobile batteries are warranted for a after discovery, and make the
period of thirty (30) days from the date of machine available at that time for
purchase. inspection and repairs at such
DURING THE PERIOD OF WAR- dealer’s place of business.
RANTY any authorized Yamaha snowmo- EMISSION CONTROL
bile dealer shall, free of charge, repair or SYSTEM WARRANTY
replace, at Yamaha’s option, any part (U.S.A. ONLY)
adjudged defective by Yamaha due to faulty
workmanship or material from the factory. Yamaha also warrants to the ultimate pur-
Parts used in warranty repairs will be war- chaser and each subsequent purchaser of
ranted for the balance of the snowmobile’s each applicable model Yamaha snowmo-
warranty period. All parts replaced under bile covered by this warranty that the
warranty become the property of Yamaha. vehicle is designed, built, and equipped
so as to conform at the time of sale with
GENERAL EXCLUSIONS from this all U.S. emissions standards applicable at
warranty shall include any failures to the the time of manufacture and that it is free
machine caused by: from defects in materials and workman-
1. Lack of proper setup and/or pre- ship which would cause it not to meet
delivery service by an authorized these standards within the period listed
Yamaha dealer. immediately below. Failures other than
those resulting from defects in material
2. Competition, racing, or non-Yamaha or workmanship which arise solely as a
authorized rental use. result of owner abuse and/or lack of
3. Operation on surfaces other than proper maintenance are not covered by
snow or ice. this warranty.

46
All Models All new Yamaha snowmobiles purchased
between May 1 and November 30 will
Thirty (30) months from the original pur- have the warranty extended to November
chase date. 30 of the following year.
WARRANTY TRANSFER: To trans-
fer any remaining warranty from the WARRANTY
original purchaser to any subsequent pur- QUESTIONS AND
chaser, it is imperative that the machine ANSWERS
be inspected and registered for warranty Q. What costs are my responsibility
by an authorized Yamaha snowmobile during the warranty period?
dealer in the country of residence of the A. The customer’s responsibility
original purchaser. In order for this war- includes all costs of normal mainte-
ranty to remain in effect, this inspection nance services, non-warranty repairs,
and registration must take place within accident and collision damages, as
ten (10) days after ownership transfer. well as oil, spark plugs, clutch drive
YAMAHA MAKES NO OTHER belts, and slide runners.
WARRANTY OF ANY KIND, Q. What are some examples of “abnor-
EXPRESSED OR IMPLIED. ALL mal” strain, neglect, or abuse?
IMPLIED WARRANTIES OF MER-
CHANTABILITY AND FITNESS A. These terms are general and over-
FOR A PARTICULAR PURPOSE lap each other in areas. Specific
WHICH EXCEED THE OBLIGA- examples include: Running the
TIONS AND TIME LIMITS machine out of oil, hitting an object
STATED IN THIS WARRANTY submerged under snow, operation
ARE HEREBY DISCLAIMED BY on surfaces other than snow or ice,
YAMAHA AND EXCLUDED FROM operating the machine with a bro-
THIS WARRANTY. SOME STATES/ ken or damaged part which causes
PROVINCES DO NOT ALLOW another part to fail, and so on. If
LIMITATIONS ON HOW LONG AN you have any specific questions on
IMPLIED WARRANTY LASTS, SO operation or maintenance, please
THE ABOVE LIMITATIONS MAY contact your dealer for advice.
NOT APPLY TO YOU. ALSO Q. May I perform any or all of the rec-
EXCLUDED FROM THIS WAR- ommended maintenance shown in
RANTY ARE ANY INCIDENTAL the Owner’s Manual instead of hav-
OR CONSEQUENTIAL DAMAGES ing the dealer do them?
INCLUDING LOSS OF USE. SOME
STATES/PROVINCES DO NOT A. Yes, if you are a qualified snowmo-
bile mechanic and follow the proce-
ALLOW THE EXCLUSION OR dures specified in the Owner’s and
LIMITATION OF INCIDENTAL OR Service Manual. We do recommend,
CONSEQUENTIAL DAMAGES, SO however, that items requiring spe-
THE ABOVE EXCLUSION MAY cial tools or equipment be done by a
NOT APPLY TO YOU. Yamaha snowmobile dealer.
THIS WARRANTY GIVES YOU Q. Will the warranty be void or can-
SPECIFIC LEGAL RIGHTS, AND celed if I do not operate or maintain
YOU MAY ALSO HAVE OTHER my new Yamaha exactly as speci-
RIGHTS WHICH VARY FROM fied in the Owner’s Manual?
STATE TO STATE/PROVINCE TO
PROVINCE. A. No. The warranty on a new Yamaha
cannot be “voided” or “canceled.”
SPECIAL EARLY-SEASON However, if a particular failure is
WARRANTY EXTENSION caused by operation or maintenance
A special warranty extension is available other than as shown in the Owner’s
for all new Yamaha snowmobiles pur- Manual, that failure may not be
chased between May 1 and November 30. covered under warranty.

47
 Q. Under what conditions is the clutch U.S.A. CUSTOMERS:
not covered by warranty?
YAMAHA MOTOR CORPORATION,
A. Clutches as well as clutch compo- U.S.A.
nents wear with use. Normal wear is CUSTOMER RELATIONS DEPART-
not covered under warranty such ser- MENT
vice is the customer’s responsibility. P.O. Box 6555
Abnormal wear is, however, cov- Cypress, California 90630
ered for one (1) year from the date of
purchase. Your Yamaha snowmobile CANADIAN CUSTOMERS:
dealer possesses criteria as to what YAMAHA MOTOR CANADA LTD.
constitutes abnormal wear. CUSTOMER RELATIONS DEPART-
Q. What responsibility does my dealer MENT
have under this warranty? 480 GORDON BAKER RD
Toronto, Ontario M2H 3B4
A. Each Yamaha snowmobile dealer is
expected to: When contacting Yamaha, be sure to
include the model, serial number, names,
1. Completely set up every new dates, and receipts.
machine before sale.
CHANGE OF ADDRESS
2. Explain the operation, mainte- The federal government requires each
nance, and warranty require- manufacturer of a motor vehicle to main-
ments to your satisfaction at the tain a complete, up-to-date list of all first
time of sale, and upon your purchasers against the possibility of a
request at any later date. safety related defect and recall. This list
3. In addition, each Yamaha snow- is compiled from the purchase registra-
mobile dealer is held responsible tions sent to Yamaha by the selling dealer
for his setup, service and war- at the time of your purchase. If you
ranty repair work. should move after you have purchased
your new snowmobile, please advise
Q. Whom should I contact if I have fur- Yamaha of your new address by sending
ther questions about this warranty? a subsequent owner’s card listing your
A. Your Yamaha snowmobile dealer snowmobile model name, engine serial
has the information and experience number, dealer number (or dealer’s
necessary to answer almost any name) as it is shown on your warranty
questions about this warranty. If theregistration identification, your name and
dealer is not able to do so, he is new mailing address. Mail to:
expected to contact Yamaha, for U.S.A. CUSTOMERS:
clarification or assistance.
YAMAHA MOTOR CORPORATION,
CUSTOMER SERVICE U.S.A.
If your machine requires warranty ser- CUSTOMER RELATIONS DEPART-
vice, you must take it to any authorized MENT
Yamaha snowmobile dealer within the P.O. Box 6555
continental United States or Canada. Be Cypress, California 90630
sure to bring your warranty identification CANADIAN CUSTOMERS:
card or other valid proof of the original
date of purchase. If a question or problem YAMAHA MOTOR CANADA LTD.
arises regarding warranty, first contact CUSTOMER RELATIONS DEPART-
the owner of the dealership. Since all MENT
warranty matters are handled at the 480 GORDON BAKER RD
dealer level, this person is in the best Toronto, Ontario M2H 3B4
position to help you. If you are still not
satisfied and require additional assis- This will ensure that Yamaha has an up-
tance, please write: to-date registration record in accordance
with federal law.

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YAMAHA EXTENDED
SERVICE (Y.E.S.) FOR
U.S.A. CUSTOMERS

49
YAMAHA PROTECTION • With Yamaha Protection Plus,
PLUS (YPP) FOR Yamaha is ready to step in to make
CANADIAN any needed repairs (excluding those
CUSTOMERS repairs due to normal wear or aging)
using genuine parts and factory
No one else offers you the superior engi- authorized service for the full dura-
neering, style and performance you enjoy tion of your coverage.
with your Yamaha. And no one else stands
behind its product the way Yamaha does— For further information, contact your
with the industry’s best warranty coverage dealer. For a dealer near you, visit our
and best extended warranty plan: Yamaha web site: www.yamaha-motor.ca
Protection Plus. Yamaha Protection Plus
gives you the option to extend your factory
warranty by 12, 24 months, depending on For your best ownership experience,
your product and requirements. Combine think Genuine Yamaha!
that with Yamaha’s unsurpassed reputation Genuine Yamaha Parts – Genuine
for reliability, and you’ve got the peace of Yamaha replacement parts are the exact
mind you deserve. same parts as the ones originally
• While other plans can confuse you equipped on your vehicle, providing you
with deductibles, parts coverage and with the performance and durability you
claim paperwork hassles, our fac- have come to expect. Why settle for
tory-backed Yamaha Protection Plus aftermarket parts that may not provide
gives you bullet-proof protection full confidence and satisfaction?
from the unexpected. And it’s as Genuine Yamaha Accessories –
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Yamaha factory warranty. our high standards for quality and perfor-
• Yamaha Protection Plus will be mance. Buy with confidence, knowing
there, whether your repair expense your Genuine Yamaha Accessories will
is a few dollars or a few thousand. fit right and perform right – right out of
• Under the Yamaha Protection Plus the box.
program, Yamaha picks up the entire
Yamalube – Take care of your Yamaha
cost of parts and labour to repair
with legendary Yamalube oils, lubricants,
every applicable mechanical defect.
and care products. They’re formulated
• Yamaha’s computerized warranty sys- and approved by the toughest judges we
tem is updated as soon as you buy know: the Yamaha engineering teams
coverage, so Yamaha Protection Plus that know your Yamaha from the inside
takes over automatically—and imme- out.
diately—when your factory warranty
expires. You can even get Yamaha Genuine Yamaha Service Manuals –
Protection Plus coverage on many Get the same factory manual for your
pre-owned Yamaha models. vehicle that the technicians at your autho-
• Your Yamaha Protection Plus war- rized Yamaha dealer use. Service manu-
ranty is transferable, increasing the als are available through your Yamaha
value of your Yamaha if you decide dealer or you can order them directly
to sell or trade it in. through yamahapubs.com (for US con-
• Since we already know your sumers only).
Yamaha, you don’t have to fill out Genuine Yamaha products are available
claim forms. Your Yamaha Protection only from your Yamaha dealer.
Plus coverage information is avail-
able to every authorized Yamaha Find out more at:
dealer nationwide. For US consumers, please visit yamaha-
• You can purchase years of our motor.com
Yamaha Protection Plus coverage
for a fraction of what a single major For Canadian consumers, please visit
repair could cost you.
yamaha-motor.ca

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