sr10 viper owners 8jrf819970e0

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Read this manual carefullybefore operating this vehicle.

OPERATOR'S MANUAL

SR10RE

SR10RSE

SR10LE

SR10LSE

SR10XSE

LIT-12628-03-16 8JR-F8199-70


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Table of ContentsForeword ............................................................2General Information ......................................3-12Snowmobile Identification.................................. 3Control Locations .............................................. 3Gasoline-Oil....................................................... 3Engine Break-In.................................................4Drive Belt Break-In ............................................4Cold Drive-Away Function.................................4Speedometer/Tachometer/Digital Gauge ..........5Diagnostic Codes ..............................................6Handlebar Tilt....................................................7Exhaust System ................................................7

Air-Intake Silencer .............................................7Cooling System ................................................. 7Battery ...............................................................8Jump-Starting....................................................8Drive Clutch and Driven Clutch ......................... 9Drive Clutch/Driven Clutch Alignment ...............9Fuel Pump.........................................................9Shock Absorbers (Rebuildable Gas) ...............10Track/Track Studs ............................................10Reverse Operation ..........................................10

Access Panel/Hood.........................................11Removable Seat .............................................. 11Towing .............................................................12

Operating Instructions .................................13-16Starting and Stopping Engine ......................... 13Braking ............................................................14Emergency Stopping .......................................15Throttle/Ignition Monitor Switch.......................15Varying Altitude Operation...............................16

Lubrication. ................................................. 17-18Chain Case......................................................17Rear Suspension.............................................18

Maintenance............................................... 19-38Periodic Maintenance Checklist.......................19Fuel System.....................................................20Checking Engine Oil Level...............................21Changing Engine Oil/Filter...............................21Coolant Level...................................................22Spark Plugs .....................................................23Checking/Adjusting Valve Clearance...............23Battery .............................................................23Fuses...............................................................25Brake System..................................................26Burnishing Brake Pads ....................................29Chain Tension..................................................29Drive Belt .........................................................29Track Tension...................................................31Track Alignment...............................................32Suspension......................................................33Lights ...............................................................35Ski Wear Bars..................................................37

Adjusting Ski Stance........................................37Rail Wear Strips...............................................38Performance Tips ....................................... 39-40Preparation for Storage ....................................41Preparation after Storage.. ...............................42Snowmobile Safety Rules.................................43Consumer Information......................................44


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Reference InformationWrite the appropriate information for your Yamaha Snowmobile in the spacesbelow.

Always use these numbers when referring to your snowmobile.

Model: _________________________________________________

Date of Purchase: ________________________________________

Vehicle Identification Number: _______________________________

Engine Serial Number: _____________________________________

Your Yamaha Dealer: _____________________________________

Address: _______________________________________________

Phone: _________________________________________________

! WARNINGA snowmobile is a very high performance vehicle. Because it does acceleraterapidly 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 terrainand what lies in front of you. Obey speed limits and never operate at speedsthat do not allow adequate maneuvering and stopping distances. Read andstudy the entire Operators Manual and Safety Handbook. Failure to follow thiswarning 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. DONT 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, dont wait until it is

too late to warn of the consequences of snowmobile misuse. Such conductendangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR-SELF AND OTHERS.

Parts and AccessoriesWhen 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 thestandards and requirements of your Yamaha Snowmobile. For a complete list ofaccessories, refer to the current Yamaha Accessory Catalog. To aid in service andmaintenance procedures on these snowmobiles, an Illustrated Parts Manual and aService Manual are available through your local Yamaha Snowmobile dealer.


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ForewordCongratulations! You have chosen a quality Yamaha Snowmobile designed andassembled 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 properuse of your new Yamaha Snowmobile. Always operate the snowmobile within yourlevel of skill and current terrain conditions.

The Operators Manual, Snowmobile Safety Handbook, and Snowmobile Decalsdisplay the words Warning, Caution, and Note to emphasize important information.The symbol ! WARNING identifies personal safety-related information. Besure to follow the directive because it deals with the possibility of serious personalinjury or even death. A CAUTION identifies unsafe practices which may resultin 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 anauthorized 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 andare not designed to depict actual conditions. Because Yamaha constantly refinesand improves its products, no retroactive obligation is incurred.

This Operators Manual should be considered a permanent part of the snowmobileand must remain with the snowmobile at the time of resale. If the snowmobilechanges ownership more than once, contact Yamaha, Service Department, P.O. Box6555, Cypress, CA 90630, for proper registration information. This manual wasprepared by the Product Service and Warranty Department of Yamaha.

Every Yamaha Snowmobile meets or exceeds the standards of the SnowmobileSafety and Certification Committee and displays the SSCC decal. Yamaha endorsesand 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 therights 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 theNational Snowmobile Foundation, Yamaha promotes snowmobiling through edu-cation, charity, and research programs.

2013 Yamaha


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General InformationSnowmobileIdentificationThe snowmobile has two important iden-tification numbers. The Vehicle Identifi-cation Number (VIN) is stamped into thetunnel near the right-side footrest and ona decal beneath the seat. The decal alsodisplays pertinent production informa-tion. The Engine Serial Number (ESN) isstamped into the crankcase of the engine.

0726-383

These numbers are required by the dealerto complete warranty claims properly. No

warranty will be allowed by Yamaha Inc.if the engine serial number or VIN isremoved or mutilated in any way.

Always provide the snowmobile name,VIN, and ESN when contacting an autho-rized Yamaha Snowmobile dealer for

parts, service, accessories, or warranty. Ifthe complete engine must be replaced,ask the dealer to notify Yamaha for cor-rect registration information.

Control LocationsShown are the typical control locationsfor Yamaha snowmobiles. Location of aspecific control will vary according tomodel.

0747-829

Gasoline-OilRecommended Gasoline

The recommended gasoline to use inthese snowmobiles is 87 octane regularunleaded. In many areas, oxygenates areadded to the gasoline. Oxygenated gaso-lines containing up to 10% ethanol areacceptable gasolines.

When using ethanol blended gasoline, it isnot necessary to add a gasoline antifreezesince ethanol will prevent the accumula-tion of moisture in the fuel system.

Recommended Engine OilThe recommended oil to use is Semi-Synthetic Yamalube OW-30 oil.

The engine oil should be changed every4000 km (2500 miles) before prolongedstorage and the oil filter should bechanged every 20,000 km (12,500 miles).

Filling Gas Tank

Since gasoline expands as its temperatureincreases, the gas tank must be filled to

its rated capacity only. Expansion roommust be maintained in the tank particu-larly if the tank is filled with cold gaso-line and then moved to a warm area.

CAUTIONAny oil used in place of the recom-mended oil could cause seriousengine damage


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Also, if the snowmobile is to remain on atrailer after filling the gas tank, the bed ofthe trailer must be maintained level to

prevent gasoline from draining out

through the gas tank vent hose.

Engine Break-InThe engine (when new or rebuilt)requires a short break-in period beforethe engine is subjected to heavy load con-ditions.

This engine does not require any pre-mixed fuel during the break-in period.

There is never a more important period inthe life of the engine than the first 500km (300 miles).

Since the engine is brand new, do not putan excessive load on it for the first 500km (300 miles). The various parts in theengine wear and polish themselves to thecorrect operating clearances. During this

period, prolonged full throttle operationor any condition that might result inengine overheating must be avoided.

Operating your snowmobile for the first

time: Start the engine and let it idle for 15minutes.

0-160 km (0100 miles): Avoid pro-longed operation above 6000 RPM.

160-500 km (100300 miles): Avoid pro-longed operation above 8000 RPM.

500 km (300 miles) and beyond: Thesnowmobile can now be operated nor-mally.

NOTE: After 800 km (500 miles) ofoperation, the engine oil must bechanged and the oil filter replaced. Ifany engine trouble should occur dur-ing the engine break-in period,

immediately have a Yamaha dealercheck the snowmobile.

Drive Belt Break-InDrive belts require a break-in period ofapproximately 40 km (25 miles). Drivethe snowmobile for 40 km (25 miles) at3/4 throttle or less. By revving the engineup and down (but not exceeding 100 km/h [60 mph]), the exposed cord on the sideof a new belt will be worn down. Thiswill allow the drive belt to gain its opti-mum flexibility and will extend drive beltlife.

NOTE: Before starting the snowmo-bile in extremely cold temperatures,the drive belt should be removed andwarmed up to room temperature.Once the drive belt is at room temper-ature, install the drive belt.

Cold Drive-AwayFunctionThere is a cold drive-away functionincorporated within the engine.

NOTE: When cold-starting theengine, the coolant temperaturewarning icon will illuminate and theLOW TEMP display on the readoutscreen will begin to flash. With theengine in this temperature range, theRPM limit of the engine will bebelow drive system engagementspeed. As the engine warms, thecoolant temperature warning iconwill begin to flash, the TEMP displaywill continue to flash, and the RPMlimit of the engine will increaseallowing the snowmobile to movewithout full-throttle operation. Whenthe engine reaches proper operatingtemperature, the coolant tempera-ture warning icon and the LOWTEMP display will go out.

! WARNINGAlways fill the gas tank in a well-venti-lated area. Never add gasoline to thesnowmobile gas tank near any openflames or with the engine running. DONOT SMOKE while filling the gas tank.Do not sit on the snowmobile withoutfirst installing the gas tank cap.

CAUTIONNever run the engine with the drivebelt removed. Excessive revving ofthe engine could result in seriousengine damage and drive clutch fail-ure.


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Speedometer/Tachometer/DigitalGauge

CWI-050A

A. Coolant TemperatureIndicator

The indicator and LOW TEMP displaywill cease to flash when the engine

reaches proper operating temperature.If the coolant temperature rises too farabove proper operating temperature, theindicator will flash a warning (alert) andthe engine will surge to alert the opera-tor. If the coolant temperature rises to acritical point above proper operating tem-

perature, the indicator will cease flashingand will remain constantly illuminated.

NOTE: If the indicator is constantlyon, the engine will shut off if vehiclespeed is reduced to 1.5 km-h (0.9MPH) or slower.

B. High Beam Indicator

The indicator is on whenever the highbeam mode is selected by the headlightswitch.

C. Oil Pressure Indicator

The indicator relates to engine oil pres-

sure, not the oil level; however, if the oillevel is low, it may affect oil pressure. Ifoil pressure is lost, check the oil level(see page 21).

If the indicator does not go out or if theengine 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 ofthe snowmobile owner.

D. Low Fuel Indicator

The indicator illuminates whenever thegas in the gas tank is low.

E. Coolant Temperature/Battery Voltage/Intake AirTemperature

This bar display shows coolant tempera-ture, battery voltage, intake air tempera-ture, and on the 6000, exhausttemperature. Press the Lower Left Buttonto change which parameter is being dis-

played. Press and hold the Lower LeftButton to see the actual values associatedwith the mode selected.

F. Fuel Level Display

This display shows the approximateamount of gas remaining in the gas tank.

G. RPM/Speed/Clock/Altimeter

Press the Upper Left Button to cycle theleft screen between RPM and speed.

NOTE: When RPM is displayed onthe left screen, the right screen willdisplay speed, clock, or altimeter.When speed is displayed on the left

screen, the right screen will displayRPM, clock, or altimeter.

Press the Upper Right Button to cycle theright screen between speed, RPM, clock,and altimeter.

Press and hold the Upper Button on thespeed-side of the gauge to shift the gauge

between standard (MPH/miles/fahren-heit) and metric (km/h/kilometers/cel-sius) modes.

Press and hold the Upper Button on theRPM-side of the gauge to view maxi-mum RPM. This value is reset each timethe ignition key is turned off.

CAUTIONIf the indicator is illuminated, stop theengine immediately and allow it to cooldown. If unable to either determine orremedy the problem, take the snowmo-bile to an authorized Yamaha Snowmo-bile dealer for service. If not underwarranty, this service is at the discretionand expense of the snowmobile owner.


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With the clock mode selected by pressingthe Upper Right Button, press and holdthe Upper Right Button to set the clock.The option of selecting the 12-hour or

24-hour clock is available; press theeither Left Button to alternate betweenthe two modes. Next, press the LowerRight Button to set the clock. Press eitherLeft Button to set the hours; then pressthe Lower Right Button to set the min-utes. Press either Left Button to set theminutes. When the proper time has beenset, press the Lower Right Button toreturn to the main gauge display.

With the altimeter mode selected bypressing the Upper Right Button, pressand hold the Upper Right Button to setthe current altitude by using either LeftButton. When the proper altitude has

been set, press the Lower Right Button toreturn to the main gauge display.

H. Engine Hour Meter/Odometer/Trip Meter/ClockThis display shows engine hours, odome-ter, trip meter, or clock. Press the LowerRight Button to change which parameteris being displayed. The Engine HourMeter and Odometer cannot be reset. Toreset the trip meter, select the Trip Meter;then press and hold the Lower Right But-ton until the trip meter display reads 0.

NOTE: The clock can only be dis-played in this position if it is not

already being displayed in the mainright screen. To set the clock whenthe clock is in this position, pressand hold the Lower Right Button;then use the procedure found in G.

Diagnostic CodesDiagnostic codes are activated by theECM and may be displayed on the read-out screen for a number of reasons.

If a code is displayed while the engine isrunning, the ECM is receiving input thatis outside of its established parameters. Ifa code has been activated, take the snow-mobile to an authorized Yamaha Snow-mobile dealer for service. If not under

warranty, this service is at the discretionand expense of the snowmobile owner.

Refer to the following chart for diagnos-tic codes.

Code Trouble

P0031 O2 Heater Control Circuit LowP0032 O2 Heater Control Circuit High

P0107 Manifold absolute pressure circuit low

P0108 Manifold absolute pressure circuit high

P0112 Intake air temp sensor circuit low

P0113 Intake air temp sensor circuit high

P0115 Engine coolant temp sensor 1 circuit

P0117 Engine coolant temp sensor 1 circuitlow

P0118 Engine coolant temp sensor 1 circuithigh

P0120 Throttle position sensor circuit

P0122 Throttle position sensor circuit low

P0123 Throttle position sensor circuit high

P0130 O2 sensor circuit

P0131 O2 sensor circuit lowP0132 O2 sensor circuit high

P0171 System too lean

P0172 System too rich

P0201 Injector circuit/open - cylinder 1



P0217 Engine coolant over temp condition

P0261 Cylinder 1 injector circuit low



P0508 Idle air control system circuit low

P0509 Idle air control system circuit high

P0511 Idle air control circuit

P0522 Engine oil pressure sensor circuit low

P0523 Engine oil pressure sensor circuit high

P0562 System voltage low

P0563 System voltage high

P0780Shift Error

P1315 Crankshaft Position out of sync

P1338 Crankshaft spike detected

P1339 Crankshaft tooth not detected

P1685 Main relay open circuit

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 lowP2228 Barometric pressure sensor A circuit

low

P2229 Barometric pressure sensor A circuithigh


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Handlebar TiltThe handlebar can be adjusted to theoperators preference. To adjust the han-dlebar, use the following procedure:

1. Remove the handlebar cover; thenloosen the eight cap screws securingthe handlebar caps to the riser and theriser to the steering post.

0747-828

2. Adjust the handlebar to operatorsdesired position, tighten the capscrews evenly to 2.0 kg-m (15 ft-lb),and check steering for maximum

right/left turning capabilities.

Exhaust SystemThe exhaust system is designed to reducenoise and to improve the total perfor-mance of the engine. If any exhaust sys-tem component is removed from theengine and the engine is run, severeengine damage will result.

Air-Intake SilencerUsed in conjunction with the fuel intakesystem is a specially designed air-intakesilencer. The purpose of the silencer is toquiet the intake of fresh air. Since the fuelintake system is calibrated with the air-intake silencer in place, the engine mustnever be run with the silencer removed.Performance will not be improved if theair-intake silencer is removed. In con-trast, severe engine damage will occur.

Cooling SystemThese snowmobiles are equipped with aclosed liquid cooling system for enginecooling. The cooling system should beinspected daily for leakage and damage.Also, the coolant level should be checkeddaily. If leakage or damage is detected,take the snowmobile to an authorizedYamaha Snowmobile dealer for service.

If not under warranty, this service is atthe discretion and expense of the snow-mobile owner.

When filling the cooling system, use anethylene glycol-based coolant/water mix-ture which will satisfy the coldest antici-

pated weather conditions of your area inaccordance with the coolant manufac-turers recommendations.

NOTE: If operating on ice or hard-packed snow conditions, it is recom-mended that Ice Scratchers beinstalled to reduce wear strip wearand engine overheating.

For checking/filling cooling system, referto Coolant Level sub-section in the Main-tenance section.

P2300 Ignition coil A primary control circuitlow

P2303 Ignition coil B primary control circuit

lowP2306 Ignition coil C primary control circuit

low

U0155Lost communication with the ECM

CAUTIONDo not rotate the handlebar to a posi-tion that allows air to enter the brakesystem.

! WARNINGTighten cap screws according tospecifications to prevent unexpectedmovement of the handlebar duringoperation over rough terrain. DO NOTposition the handlebar so steering(maximum right/left turning capabili-ties) or throttle and brake controlsare affected.

Code Trouble

CAUTIONThese snowmobiles are not designedto be operated in dusty conditions.Operating the snowmobile in dustyconditions will result in severeengine damage.


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BatteryIt is extremely important that the battery

be maintained at full charge at all timesand that the battery connections be cleanand tight. If charging the battery becomesnecessary, refer to Battery sub-section inthe Maintenance section.

Jump-Starting

NOTE: Yamaha does not recom-mend jump-starting a snowmobile

with a dead battery but rather toremove the battery, service it, andcorrectly charge it; however, in anemergency, it may be necessary to

jump-start a snowmobile. If so, usethe following procedure to carefullyand safely complete this procedure.

NOTE: To access the battery, theseat must be removed.

1. For the snowmobile to be jump-started, slide any terminal boots away.

2. Inspect the battery for any signs ofelectrolyte leaks, loose terminals, or

bulging sides. Leaking or bulgingbattery cases may indicate a frozen

or shorted battery.

3. Inspect the snowmobile to be used forjump-starting to determine if voltageand ground polarity are compatible.The vehicle must have a 12-volt DC,negative ground electrical system.

4. Move the vehicle to be used for thejump-start close enough to ensurethe jumper cables easily reach; thenset and lock the brakes, shut off allelectrical accessories, and turn theignition switch OFF.

NOTE: Make sure all switches onthe snowmobile to be jump-startedare turned OFF.

5. Disconnect all external accessoriessuch as cell phones, GPS units, andradios on both vehicles.

6. Attach one clamp of the positive(red) cable to the positive (+) termi-nal (1) of the dead battery (C) beingcareful not to touch any metal withthe other clamp; then attach theother clamp of the positive (red)cable to the positive (+) terminal (2)of the good battery (B).

CAUTIONAlways turn the ignition switch key tothe OFF position when the snowmo-bile is not being used. Leaving theignition switch in the ON position willresult in discharging the battery andpossible damage to the battery.

! WARNINGImproper handling or connecting of abattery may result in severe injuryincluding acid burns, electrical burns,or blindness as a result of an explo-sion. Always remove rings andwatches. Any time service is per-formed on a battery, the followingmust be observed: keep sparks, openflame, cigarettes, or any other flameaway. Always wear safety glasses.Protect skin and clothing when han-dling a battery. When servicing a bat-tery in an enclosed space, keep thearea well-ventilated.

! WARNINGIf any of these conditions exist, DO

NOT attempt to jump-start, boost, orcharge the battery. An explosioncould occur causing serious injury.

CAUTIONAlways make sure the electrical sys-tems are of the same voltage andground polarity prior to connectingjumper cables. If not, severe electri-cal damage may occur.

CAUTIONFailure to disconnect electronic acces-sories during jump-starting may causesystem damage due to power spikes.


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0744-527

NOTE: Some jumper cables may bethe same color but the clamps or endswill be color-coded red and black.

7. Attach one clamp of the negativejumper cable (black) to the negative(-) terminal (3) of the good battery(B); then attach the other clamp ofthe negative (black) jumper cable (4)

to an unpainted metal surface (A) onthe engine or frame well away fromthe dead battery and fuel systemcomponents.

8. Stand well away from the dead bat-tery and start the vehicle with thegood battery. Allow the vehicle torun for several minutes applyingsome charge to the dead battery.

9. Start the snowmobile with the deadbattery and allow it to run for severalminutes before disconnecting the

jumper cables.

10. Remove the jumper cables in oppo-site order of hook-up (4, 3, 2, 1). Becareful not to short cables against

bare metal.

NOTE: Have the battery and elec-trical system checked prior to oper-ating the snowmobile again.

Drive Clutch and DrivenClutchThe drive clutch and driven clutch do not

require lubrication; therefore, no specialmaintenance is required by the snowmo-

bile owner except for periodical cleaning.

However, the drive clutch and drivenclutch should be disassembled, cleaned,and inspected by an authorized YamahaSnowmobile dealer after every 4000 km

(2500 miles) or seasonally, whicheveroccurs first. This service is at the discretionand expense of the snowmobile owner.

When operating the snowmobile at highaltitudes, it may be necessary to changecertain component parts of the driveclutch and/or the driven clutch. See anauthorized Yamaha Snowmobile dealerfor further information.

Drive Clutch/DrivenClutch AlignmentThe alignment between the drive clutchand driven clutch is set at the factory.

Normally, no adjustment is necessary aslong as neither the drive clutch nor thedriven clutch is removed or disassem-

bled. However, if premature drive beltwear is experienced or if the drive beltturns over, the drive clutch/driven clutchalignment must be checked. Take thesnowmobile to an authorized YamahaSnowmobile dealer for this service. If notunder warranty, this service is at the dis-cretion and expense of the snowmobileowner.

Fuel PumpThe fuel pump is designed to provideadequate amount of gas to the injectorsat all throttle settings. If a fuel delivery

problem is suspected, take the snowmo-bile to an authorized Yamaha Snowmo-bile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

! WARNINGNever make the final connection to abattery as a spark could ignite hydrogengases causing an explosion of the bat-tery resulting in acid burns or blindness.

CAUTIONDO NOT attempt to service the driveclutch and driven clutch. The driveclutch and driven clutch must be ser-viced by an authorized Yamaha Snow-mobile dealer only.


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Operating in Reverse

1. When shifting into reverse, alwayswait for the reverse icon to illumi-nate and the reverse alarm to sound

before backing up.

NOTE: The reverse function is can-celled whenever the engine is shut off.

2. After shifting from reverse to for-ward (or from forward to reverse),apply the throttle slowly and evenlyto allow the driven pulley to engage

properly.

Access Panel/HoodTo remove the access panel and hood, use

the following procedure:

0747-830

1. Remove the hairpin clip from the pinlocated at the front of the access

panel. Move the panel up and off the

pin; then swing the panel all the wayout and unhinge the panel from thelower console.

2. Remove the torx-head screws secur-ing the hood (located on the undersideof the hood above the front tube of theupper A-arm); then remove the torx-

head screws from the top-side of thehood securing the hood to the upperconsole and the torx-head screwsfrom under the nosepiece of the hood.

3. Remove the intake panel below thegauge; then locate the hood harnessconnector (located in front of thespeedometer) and unplug the con-nector; then move the hood slightlyforward and remove the hood.

To install the access panel and hood, usethe following procedure:

1. Position the hood onto the snowmo-bile and connect the hood harness

connector making sure the harnessdoes not become pinched.

2. Secure the hood with torx-headscrews and tighten securely.

3. Install the access panel onto thelower console; then close the access

panel and secure with the hairpinclip. Install the intake panel.

Removable SeatTo remove the seat, remove the torx-headscrew from the underside of the seat; thenlift on the back of the seat and move it upand rearward to remove it.

0747-739

To install the seat, route the front tab onthe seat through the seat-base hold-downbracket; then install the seat and secureusing the torx-head screw.

! WARNING

Use caution and minimal speed whenoperating the snowmobile in reverse.Be sure the button is in the desiredposition.

CAUTIONAfter reversing in deep powder snowconditions, make sure the snowflapdoes not become caught up in thetrack. Track and/or snowflap damagemay occur.

CAUTIONIf the snowmobile is equipped withice scratchers, the scratchers mustbe disengaged or component dam-age will occur.

CAUTIONPrior to removing the seat, lift therear of the seat and disconnect theseat heater harness connector.


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SNO-273

NOTE: Prior to lowering and secur-ing the seat, connect the seat heaterharness connector.

TowingIf the snowmobile is to be towed byanother snowmobile, do not tow usingthe loops in the skis. The tow rope should

be attached to the spindles.


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Operating InstructionsStarting and StoppingEngineIt is imperative that the brake system bechecked for wear and proper operationand that all safety checks found in theaccompanying Snowmobile SafetyHandbook be performed before attempt-ing to start the engine. After the enginehas been started, check the headlights(high and low beam), taillight, and brake-light to be sure they are working properlyand adjusted correctly. Make sure alllights are clean to provide maximum illu-mination. The headlight and taillightmust be clean and must be illuminatedwhenever the engine is running.

1. Test the operation of the brake sys-

tem by compressing the brake lever.The brake lever must feel firm whencompressed; then while holding the

brake lever in the compressed posi-tion, measure the distance betweenthe brake lever and the handlebar.The distance must be greater than2.54 cm (1 in.).

0745-816

2. With the brake fluid reservoir in alevel position and the coverremoved, check the fluid level. The

brake fluid level must be at the highbrake fluid mark in the reservoir.

0745-817

3. If the brake fluid is below the highbrake fluid mark, add Yamaha

approved DOT 4 brake fluid untilthe fluid is at the recommendedlevel. Install and secure the reservoircover. Do not allow moisture to con-taminate the brake system.

4. Test the throttle control lever bycompletely compressing and releas-ing it several times. The leverMUST return to the idle positionquickly and completely.

5. Move the emergency stop switch tothe UP or RUN position.

6. Insert key into ignition switch; thenrotate key to the RUN position.

NOTE: Rotate the key to the STARTposition; then when the engine starts,release the key.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

! WARNINGDo not overfill the brake fluid reser-voir. Overfilling the reservoir maycause the brake system to hydrauli-cally lock. Use only Yamaha

approved brake fluid.

! WARNINGDo not start the engine if the brake sys-tem is not functioning properly. Servicethe brake system or have it properlyrepaired prior to operating the snow-mobile. Serious personal injury or evendeath may occur if the brake system isnot operating properly.

CAUTIONAlways check the coolant level beforestarting the engine.

CAUTIONDo not continuously run the starter

for more than 5 seconds at a time.


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NOTE: When the engine starts,allow it to warm up properly. Idle theengine several minutes until theengine has reached normal operating

temperature. Do not idle the enginefor excessively long periods of time.

7. There is a cold drive-away functionincorporated within the engine. Thisfunction is active until the enginereaches operating temperature.

8. Flooding If the engine does notstart but seems ready to start, engagethe brake lever lock; then compressthe throttle control lever fully and tryto start the engine. When the enginestarts, release the throttle control leverimmediately. After the warm-up,release the brake lever lock.

9. To shut off the engine, turn the igni-tion key to the OFF position or pushthe emergency stop switch to theDOWN position.

BrakingThe following items are items that theoperator must be familiar with whenoperating this snowmobile and itshydraulic brake system. Important addi-tional information on the proper mainte-nance of the brake system is found in theMaintenance section.

1. Use the brakes wisely. Each time thebrakes are applied in all hydraulicbrake systems (including automotiveapplications), heat is transferred to the

brake fluid. The amount of heat trans-ferred during high speed stops and/orrepetitive use may be high enough to

boil the brake fluid and cause thebrakes to either fade or may cause anunexpected loss of brakes. If thisoccurs, the brake fluid requires a cool-

down period before the brakes willagain function properly.

This cool-down period will varydepending upon the ambient air tem-perature and the temperature of thebrake fluid. If loss of brakes has

occurred because of high fluid temper-atures, do not operate the snowmobileuntil the cool-down period has expiredand brake lever firmness has returned.

2. Be sure to maintain the brake fluid atthe proper level and take care not toget any moisture in the system as

moisture in the brake fluid lowers theboiling point. If the brake fluid is everboiled (by high speed stops or repeti-tive use) or if moisture is allowed toenter the system, it must be changed.Never substitute or mix different typesor grades of brake fluid.

3. Never ride the brake. Even main-taining minimal pressure on the

brake lever will cause the brake padsto drag on the disc and may overheatthe brake fluid.

4. The brake lever lock is not a parkingbrake and should not be applied forperiods exceeding 5 minutes.NEVER OPERATE THE SNOW-MOBILE WITH THE BRAKELEVER LOCK ENGAGED.

CAUTIONAlways turn the ignition switch key tothe OFF position when the snowmobileis not being used. Leaving the ignitionswitch in the ON position will result indischarging the battery and possibledamage to the battery.

! WARNINGExcessive, repetitive use of thehydraulic brake for high speed stopswill cause overheating of the brakefluid and premature brake pad wearwhich will result in an unexpectedloss of brakes.

! WARNINGUse only Yamaha approved DOT 4brake fluid. Never substitute or mixdifferent types or grades of brakefluid. Brake loss can result. Checkbrake fluid level and pad wear beforeeach use. Brake loss can result insevere injury or even death.


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5. Pumping the brake lever is permissi-ble; however, if pumping the brakelever more than twice is necessary toobtain the necessary stopping power,immediately take the snowmobile toan authorized Yamaha Snowmobiledealer for service. If not under war-

ranty, this service is at the discretionand expense of the snowmobileowner.

6. When new brake pads are installed,a burnishing process is required.

Emergency StoppingThere are several methods of stopping orslowing the snowmobile under a varietyof situations. Identified in the followingchart are the ways a snowmobile may be

brought to a stop and the effectivenessunder normal conditions.

Throttle/IgnitionMonitor SwitchThe throttle control is equipped with amonitor switch for safety purposes whichwill stop the engine when a loss of returnspring force occurs. If ice forms in thethrottle system or if there is some othermalfunction of the throttle system result-ing in a loss of return spring force, themonitor switch will stop the engine when

the throttle control lever is released.

If the snowmobile engine stops abruptlywhen the throttle control lever is releasedand the activation of the monitor switchis suspected, use the following proce-dure:

1. Rotate the ignition key to the OFFposition.

2. Remove ice and snow from thethrottle system and wait 5-10 min-utes for the engine heat to thaw icefrom the throttle system.

3. Test the throttle control lever bycompressing and releasing it severaltimes. The lever MUST return to theidle position quickly and completely.

NOTE: If the throttle control leveroperates properly and the enginedoes not start, compress the throttlelever slightly (approximately 1/8throttle) and try starting the engine.If the engine now starts and stopswhen the throttle lever is released,

take the snowmobile to an autho-rized Yamaha Snowmobile dealer forservice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.

4. If the throttle control lever operatesproperly, rotate the ignition key tothe RUN position and go throughnormal starting procedures.

! WARNINGThe brake lever lock is not a parking

brake and should not be applied forperiods exceeding 5 minutes. Thebrake lever lock maintains the brakelever in the compressed position andmaintains pressure against the brakedisc; however, after a period of time,the pressure applied to the brake discmay relax below the amount requiredto hold the snowmobile stationary.

Item Function

Emergency Stop

Switch

interrupts ignition circuit

Throttle/IgnitionMonitor Switch

interrupts ignition circuit

Ignition Switch interrupts ignition circuit

Brake slows the drive system

! WARNINGIf any malfunction of the throttle sys-

tem occurs (such as freezing in fluffysnow) and the monitor switch doesnot shut off the engine, press downon the emergency stop switch IMME-DIATELY to stop the engine. DO NOTstart the engine until the malfunctionin the throttle system has beenlocated and corrected.

! WARNINGIf the throttle control lever does notwork properly, DO NOT ATTEMPT TOSTART THE ENGINE.


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NOTE: If the throttle control leveroperates properly and the enginedoes not start, a malfunctioning moni-tor switch may be the problem. Take

the snowmobile to an authorizedYamaha Snowmobile dealer for ser-vice. If not under warranty, this ser-vice is at the discretion and expenseof the snowmobile owner. However, ifa dire emergency exists wherein theengine must be started, disconnectthe throttle monitor switch located inthe right-side handlebar control.

NOTE: If disconnection of the throt-tle monitor switch is needed to startthe engine, take the snowmobile to anauthorized Yamaha Snowmobiledealer for service as soon as possi-ble. If not under warranty, this serviceis at the discretion and expense of the

snowmobile owner.

NOTE: The monitor switch is nowbypassed. All other ignition/electricalfeatures (ignition switch, emergencystop switch, headlight, taillight, and

brakelight) will operate properly.

Varying AltitudeOperationOperating a snowmobile at varying alti-tudes requires changes in performancecomponents. These changes affect drivetrain components. Have a Yamaha dealer

perform altitude-related service.

NOTE: Just as important as cali-brating the snowmobile for higher alti-tudes is recalibrating the snowmobilewhen going to lower altitudes.

NOTE: Drive train changes can bemade by the snowmobile owner if

qualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Yamaha Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

! WARNINGUnder no circumstances should dis-connection of the throttle control wir-ing harness be used as a substitutefor the monitor switch during normaloperation of the snowmobile. Per-sonal injury and damage could occurif the throttle system malfunctions orif the operator is unable to stop theengine in an emergency. If the snow-mobile must be operated with a dis-connected throttle control wiringharness, EXTREME CAUTION MUSTBE TAKEN. NEVER EXCEED 10 MPHWITH THE THROTTLE CONTROL

WIRING HARNESS DISCONNECTED.


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LubricationChain CaseChecking Lubricant Level

NOTE: The snowmobile must beon a level surface for this procedure.

1. Check the lubricant level in thechain case by using the sight glass.

0746-115

NOTE: The correct level is whenthe lubricant is at least halfway up inthe sight glass.

NOTE: Adding lubricant can bedone by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Yamaha Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

2. If the lubricant level is low, removethe three screws securing the shiftactuator to the chain case, discon-

nect the actuator wiring harness, andremove the actuator w/extension;then add appropriate amount of Syn-thetic Chain Lube through the shiftactuator opening. When the lubri-cant is halfway up the sight glass,install the shift actuator w/extensionand connect the actuator wiring har-ness. Tighten screws to 0.4 kg-m (36in.-lb).

0746-804

3. Start the engine and verify properreverse and forward operation by shift-ing in and out of reverse three times.

NOTE: If excessive build-up ofmoisture or discolored oil isdetected in the chain case, it may benecessary to replace the lube.

Replacing Lubricant

NOTE: Replacing the lubricant canbe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Yamaha Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

To replace the lubricant, use the follow-ing procedure:

NOTE: The side panels, hood, andexhaust resonator must be removedfor this procedure.

1. Place a drain pan under the chaincase; then loosen the eleven screwssecuring the chain case cover/oil tankassembly to the chain case housingstarting with the bottom screws first.

NOTE: It is critical that the snow-mobile is on a level surface to

ensure the lubricant drains properlyand completely.

NOTE: Inspect the chain casecover seal for nicks or damage.

CAUTIONWhen installing the shift actuator,rotate the actuator back and forth toproperly align it with the extensiongear. Failure to do so could causecomponent damage.


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2. When the lubricant has completelydrained from the case and the chaincase is cleaned of old oil, install thechain case cover. Tighten the cap

screws to 1.2 kg-m (105 in.-lb).

XM092

3. Remove the three screws securingthe shift actuator to the chain case,disconnect the actuator wiring har-ness, and remove the actuator w/extension. Pour the recommendedchain lubricant through the shiftactuator opening until the lubricantis at least halfway up in the sightglass; then install the shift actuatorw/extension and connect the actua-tor wiring harness.

NOTE: Make sure the reverse sen-sor wire is routed up so the wires donot become pinched between theactuator and the case.

4. Install and secure the exhaust reso-nator.

5. Start the engine and verify properreverse and forward operation byshifting in and out of reverse threetimes.

Rear SuspensionThis procedure should be done every 40operating hours.

NOTE: Yamaha recommends thatAll-Temp Grease be used for thisprocedure.

1. Using Handlebar Stand or SteeringPost Stand or a suitable substitute,lay the snowmobile on its left side.

2. Lubricate all grease fittings with all-temperature grease.

CAUTIONBefore installing the chain case screws,be sure to clean the holes using com-pressed air completely of debris ordamage to the chain case may occur.

CAUTIONWhen installing the shift actuator,rotate the actuator back and forth toproperly align it with the extensiongear. Failure to do so could causecomponent damage.

CAUTIONThe correct lubricant to use in thechain case is Synthetic Chain Lube.Any substitute may cause seriousdamage to the drive system.


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MaintenancePeriodic 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 7,22 Check for leakage, damage, obstructions, coolantlevel

Oil-Injection System Daily Check for leakage, damage, and injection/engineoil level

Engine Oil - Initial 800 km (500 Mi) 21 Change oil

Engine Oil - After Initial 4000 km(2500 Mi)

21 Change oil

Engine Oil Filter - Init ial 500 km (300 Mi) 21 Change filter

Engine Oil Filter - After Initial 20000 km(12500 Mi)

21 Change fil ter

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 & Tail light/Brakelight Daily 35-36 Check for proper operation and cleanliness

Steering System Daily Check for proper operation, tightness of bolts, andbinding

Throttle Control System Daily 15 Check for binding, sticking, proper operation, throt-tle cable tension, and wear

Drive Belt DailyMonthly

29 Check for wear, cracks, and frayingCheck 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 7 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(2500 Mi)/Seasonal

23 Check center electrode insulator color, carbon,and gap

Valve Clearance 40000 km(25000 Mi)

23 Check/adjust

Crankcase Breather System Seasonal Check breather hose for cracks or damage and

replace as necessarySuspension Weekly 33 Check for damage, loose components, and proper

adjustment

Track Tension/Alignment Weekly 31,32 Check/adjust as necessary

Wear Strips Weekly 38 Check for wear and damage

Wires & Cables Weekly Check for wear, damage, and fraying

Fuel System - Tank, Pump,In-Line Filter, & Vent Hose

Weekly Check for damage, wear, obstructions, and leak-age

Fuel Filter 5000 Mi/2 years

Replace

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 - AfterInitial

800 km (500 Mi) 29 Check tension and adjust as necessary

Heat Exchangers Monthly Check for wear, leakage, and damage

Dr ive Clutch/Driven Clutch 4500 km

(2500 Mi)/Seasonal

9,9 Check for damage, binding, and wear/remove

drive belt, clean drive clutch/driven clutch

Rear Suspension Monthly 18 Grease


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The longevity and safety of the snowmo-bile can be increased by making periodicchecks of the items in the precedingchecklist.

If, at any time, abnormal noises, vibra-tions, or improper working conditions ofany component of this snowmobile aredetected, DO NOT OPERATE THESNOWMOBILE. Take the snowmobileto an authorized Yamaha Snowmobiledealer for inspection and adjustment orrepair. If not under warranty, this serviceis at the discretion and expense of thesnowmobile owner.

The snowmobile should be taken to anauthorized Yamaha Snowmobile dealer atthe end of each snowmobiling season forgeneral inspection and for off-seasonstorage servicing. This inspection and

servicing is at the expense of the snow-mobile owner.

Fuel System

In-Line Fuel Filter

Yamaha recommends that the in-line fuelfilter be replaced every 8000 km (5000miles). The filter must be clean to allowthe fuel hose to transmit the amount ofgasoline required.

If the in-line fuel filter is obstructed, gas-oline flow will be restricted; therefore,the filter must be replaced. To removeand install the in-line fuel filter, use thefollowing procedure:

NOTE: Before removing the fuel fil-ter, take note that the filter is direc-tional and the arrow should bedirected towards the engine.

NOTE: The fuel filter is locatedbelow the upper console and to theright of the steering support. Toaccess the filter, the access panels

and hood need to be removed.

1. Remove the hose clamps and dis-card; then slowly remove the fuelhoses from the fuel filter. Dispose ofthe excess fuel from the filter prop-erly.

2. Inspect the fuel hoses thoroughly forany signs of cracking, cuts, or wear

points.

3. Place the new hose clamps on thefuel hoses; then with the fuel pumpinlet and outlet noted, connect thefuel hoses to the fuel filter. Securewith the hose clamps.

XM184A

NOTE: After completing thechanging of the fuel filter and theengine is started for the first time,inspect the filter area for any signsof leaks.

Gasoline Additives

Fuel de-icer can be used for all models.Yamaha Fuel Stabilizer should also beadded to the last tank of gasoline beforestorage.

Fuel Pickup Valves

If ever there is a restricted fuel flow and apickup valve is suspected, take the snow-mobile to an authorized Yamaha Snowmo-

bile dealer for this service. If not underwarranty, this service is at the discretionand expense of the snowmobile owner.

! WARNINGWhenever any maintenance orinspection 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 thearea.

! WARNINGSince the fuel supply hose may beunder pressure, always wear safetyglasses; then remove the hose slowlyto release the pressure. Place anabsorbent towel around the connec-tion to absorb the fuel.

CAUTIONMake sure the fuel filter is properlyseated into the holder.


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0747-833

Checking Engine OilLevelNOTE: The engine must be atoperating temperature before check-ing the oil level or an incorrect oillevel will result.

1. Park the snowmobile on a level sur-face; start the engine and let it idle andwarm up until the fan on the radiatorturns on, or if the snowmobile wasoperated, allow the engine to idle forapproximately 30 seconds.

2. Shut the engine off; then remove theright-side access panel and verify oilis visible at least halfway up in the

sight glass.

SNO-244A

3. If oil is not visible halfway up in thesight glass, add recommendedengine oil until oil is visible half-way up the sight glass.

Changing Engine Oil/Filter

NOTE: Recycle or properly dis-pose of the used engine oil.

NOTE: The access panels andhood must be removed for this pro-cedure.

1. Park the snowmobile on a level sur-face; then start the engine and let itidle and warm up until the fan on theradiator turns on, or if the snowmo-

bile was operated, allow the engineto idle for approximately 30 sec-onds. Shut the engine off.

2. Remove the torx-head screws andthe rear access plate from beneaththe snowmobile.

3. Place a drain pan beneath the engine oildrain screw; then remove the screw andallow the oil to drain completely.

XM125A

4. Using Oil Filter Wrench, loosen (butdo not remove) the oil filter and allowthe oil to drain from the filter into thedrain pan; then remove the filter.

5. Apply a light coat of fresh engine oilto the seal of the new oil filter.

CAUTION

If the engine and oil are not at operat-ing temperature, the oil will not bevisible in the sight glass. Tip thesnowmobile to the right at a 45angle; then check to see if oil is pres-ent in the sight glass.

CAUTIONCare must be taken not to over-fill the

tank with oil.

! WARNINGEngine oil is extremely hot immedi-ately after the engine is turned off.Burning could occur if oil contactsskin or clothing.


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6. Install the new oil filter by turning theoil filter by hand until the seal has con-tacted the oil filter mounting surface;then tighten the oil filter to 1.7 kg-m

(12 ft-lb).

7. Install the engine oil drain screwwith a new gasket. Tighten the screwto 1.0 kg-m (7.2 ft-lb).

8. Remove the four torx-head screwssecuring the right-side footrest to thetunnel and the support; then with adrain pan in position, remove thedrain plug from the oil tank.

746-121A

NOTE: To aid in draining the oilfrom the tank, position a funnelbetween the tank and the opening ofthe tunnel running board.

9. After the oil has drained completely,install the drain plug with a new O-ring and tighten to 2.2 kg-m (16 ft-lb).

10. Pour the recommended engine oilinto the oil tank.

11. Without starting the engine, placethe handlebar emergency stopswitch to the RUN position and theignition switch to the ON position.The Oil Pressure Warning Iconshould illuminate.

NOTE: If the warning icon does notilluminate, take the snowmobile to anauthorized Yamaha Snowmobile dealerfor service. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.

12. If the warning icon illuminates(from step 11), start the engine. Thewarning icon should go out within

five seconds. If it does, proceed tostep 13.

NOTE: If the warning icon does notgo out, shut the engine off immedi-ately and repeat step 11; then placethe ignition switch to the ON posi-

tion and repeat step 12. If the warn-ing icon does not go out, take thesnowmobile to an authorized

Yamaha Snowmobile dealer for ser-vice. If not under warranty, this ser-vice is at the discretion and expenseof the snowmobile owner.

13. Shut the engine off; then add oil tothe oil tank until oil is visible half-way up in the sight glass.

NOTE: If the oil and engine are notat operating temperature, the oillevel may read too low. Always makesure the engine is at operating tem-perature before checking the oil.

14. Install the access plate and torx-headscrews beneath the snowmobile; theninstall the hood and access panels.

Coolant LevelNOTE: Use a good quality, ethyl-ene glycol-based, automotive-typecoolant.

Locate the filler neck located above theresonator; then remove the coolant capfrom the filler neck. Verify that the coolant

is at the bottom of the tab in the filler neck.

0747-547

Locate the coolant tank above the driveclutch; then remove the plug from thecoolant tank. Add coolant to the full level

on the tank. Install the plug.

! WARNINGAlways check the coolant level withthe engine cold.


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0747-766

Spark PlugsNOTE: Always use the recom-mended spark plugs in the engine.See the appropriate specificationssheet for correct spark plug gap.

1. Disconnect the main harness from theignition coils; then remove the ignitioncoils from the cylinder head cover.

2. Remove the three spark plugs.

NOTE: Prior to installing the sparkplugs, check the gap between theelectrode and ground strap. Theclearance should be 0.7-0.8 mm(0.028-0.031 in.).

3. Install new spark plugs. Tighten to1.3 kg-m (9.4 ft-lb).

4. Install the ignition coils onto the cyl-inder head cover making sure theyare fully seated. Connect the mainharness to the ignition coils.

5. Install the hood and access panels.

Checking/AdjustingValve ClearanceAfter 40,000 km (25,000 miles), valve

clearance should be checked and adjustedas necessary.

NOTE: Take the snowmobile to anauthorized Yamaha Snowmobiledealer for inspection and service.This service is at the discretion andexpense of the snowmobile owner.

BatteryThese sealed batteries after being in ser-

vice require regular cleaning and charg-ing in order to deliver peak performanceand maximum service life. The following

procedure is recommended for cleaningand maintaining sealed batteries. Alwaysread and follow instructions providedwith battery chargers and battery prod-ucts.

NOTE: Battery maintenance maybe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Yamaha Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

CAUTIONIf the coolant is below the neck and ifcoolant has been added, immediatelyinspect for leakage and/or damage. Ifleakage or damage is detected, takethe snowmobile to an authorizedYamaha Snowmobile dealer for ser-vice. If not under warranty, this ser-

vice is at the discretion and expenseof the snowmobile owner.

CAUTIONIf adjusting spark plug gap is neces-sary, do not use the center electrodeas a leverage point. Damage to theplug may occur.

CAUTIONIt is critical that the checking/adjust-ing valve clearance be done at therecommended intervals or severeengine damage may occur.

! WARNINGImproper handling or connecting of abattery may result in severe injuryincluding acid burns, electrical burns,or blindness as a result of an explo-sion. Always remove rings andwatches. Any time service is per-formed on a battery, the followingmust be observed: keep sparks, openflame, cigarettes, or any other flameaway. Always wear safety glasses.Protect skin and clothing when han-dling a battery. When servicing a bat-tery in an enclosed space, keep thearea well-ventilated.


26/52


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NOTE: If the battery voltage is 11.5DC Volts or less, some chargers maycut off and fail to charge. If thisoccurs, connect a fully chargedbooster battery in parallel (positiveto positive and negative to negative)

for a short period of time with thecharger connected. After 10-15 min-utes, disconnect the booster batteryleaving the charger connected andthe charger should continue tocharge. If the charger cuts off,replace the battery.

7. After charging the battery for thespecified time, remove the batterycharger and allow the battery to sitfor 1-2 hours.

8. Connect the multimeter and test thebattery voltage. The meter shouldread no less than 12.5 DC Volts. Ifthe voltage is as specified, the bat-tery is ready for service.

NOTE: If voltage in step 8 is belowspecifications, charge the battery anadditional 1-5 hours; then retest. Thebattery is ready for service.

9. Place the battery into position in thesnowmobile; then coat the battery

posts and cable ends with a lightcoat of multi-purpose grease.

10. Secure the red positive cable to thepositive terminal on the batteryusing a cap screw, lock washer, anda flat washer. Tighten securely.

11. Secure the main black negativecable and the small black negativecable to the battery using a capscrew, lock washer, and a flat

washer. Tighten securely.

NOTE: Assure the harness wires andcables are routed properly as notedduring removing battery procedure.

XM167A

12. Install the battery bracket/solenoidand tighten the two screws and locknuts to 1.2 kg-m (105 in.-lb); theninstall the seat and secure with thetorx-head screw. Tighten securely.

NOTE: Prior to lowering and secur-ing the seat, connect the seat heaterharness connector.

FusesFuses protect the snowmobile electricalsystem from overloading. If electricalparts in the snowmobile are not working,the system may have been overloaded andcaused a blown fuse. Before repairing orreplacing any electrical part, check theappropriate fuses. If a fuse blows (opens acircuit), all the parts of the snowmobilethat use that circuit will not work.

Once which fuse to check has been deter-mined, perform the following steps:

1. Locate the fuse block and removethe fuse block cover.

NOTE: The fuse block is behindthe coolant overflow bottle.

Battery Charging Chart(Constant-Current Charger)

Battery

Voltage(DC)

Charge

State

Charge Time

Required (at 1.5-2.0 Amps)

12.5 (mini-mum)

100% None

12.2-12.4 75%-99% 3-6 hours

12.0-12.2 50%-74% 5-11 hours

11.0-11.9 25%-49% 13 hours (minimum)

11.5 or less 0-24% 20 hours (minimum)

CAUTIONBefore installing the battery, makesure the ignition switch is in the OFFposition.

CAUTIONConnecting cables in reverse (posi-tive to negative and negative to posi-tive) can cause serious damage tothe electrical system.


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XM124A

NOTE: There are spare fusesbeneath the fuse block cover.

2. Remove the suspected fuse.

NOTE: Fuse function descriptionsare next to the fuse contacts in thefuse block.

3. Look through the clear side of the

fuse to see if the element inside isburned or separated. If it is, the fuse isblown and should be replaced with afuse of the correct amperage rating.

4. Install the fuse block cover and closethe access panel.

Even after replacing a fuse, it may con-tinue to blow if the cause of the overloadis not determined. If the fuse continues to

blow, take the snowmobile to an autho-rized Yamaha Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner.

Brake SystemYamaha recommends that the brake sys-tem (brake lever, fluid reservoir, hose,caliper, pads, and brake disc) be checkeddaily for fluid leakage, wear, or damageand for proper operation. Also, the brakefluid level must be checked every time

before starting the engine.

Checking/Adding BrakeFluid

1. With the brake fluid reservoir in alevel position and the coverremoved, check the fluid level. The

brake fluid level must be at the highbrake fluid mark in the reservoir.

745-817A

2. If the brake fluid is below the highbrake fluid mark, add Yamahaapproved DOT 4 brake fluid untilthe fluid is at the recommendedlevel. Install and secure the reservoircover. Do not allow moisture to con-taminate the brake system.

! WARNINGAlways replace a fuse with one hav-ing the same specified amperage rat-ing. Using a fuse with a higher ratingcan cause severe wire damage andcould start a fire.

! WARNINGDO NOT operate the snowmobile

when the brake lever lock is engagedor when any component in the brakesystem is damaged, worn, oradjusted improperly. If the snowmo-bile is operated and the brake systemis not functioning properly, severepersonal injury could result.


! WARNINGDo not overfill the brake fluid reser-voir. Overfilling the reservoir maycause the brake system to hydrauli-cally lock. Use only Yamaha approvedDOT 4 brake fluid. Never substitute ormix different types or grades of brakefluid. Brake loss can result. Brakeloss can result in severe injury or

even death.


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Changing Brake Fluid

The brake fluid must be changed on aregular basis and whenever the brake

fluid has been overheated or contami-nated. The brake fluid should be changedevery 1600 km (1000 miles) or at the endof the snowmobiling season, whicheveroccurs first. Take the snowmobile to anauthorized Yamaha Snowmobile dealerfor this service. This service is at the dis-cretion and expense of the snowmobileowner.

Checking Brake LeverTravel

Before each use, check the brake levertravel using the following procedure:

1. Compress the brake lever fully.

NOTE: Do not pump the brakelever as it will produce an inaccuratereading.

2. Measure the distance between thebrake lever and the handlebar. Thedistance must be greater than 2.54cm (1 in.).

0745-816

3. If the resultant distance is less thanspecified, take the snowmobile to anauthorized Yamaha Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

Bleeding Brake System

If the brake lever feels spongy whenapplied, the brake system may need to be

bled. To bleed the brake, use the follow-ing procedure:

NOTE: The brake system may bebled by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Yamaha Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

1. Remove the reservoir cover and (ifnecessary) fill the reservoir to thehigh brake fluid mark with Yamahaapproved DOT 4 brake fluid.

2. Slide a piece of flexible tubing overthe ball of the bleeder valve anddirect the other end into a container.

XM145A

3. Slowly compress the brake leveruntil maximum pressure is attained;then hold the lever in the com-

pressed position to maintain pres-sure. Open the bleeder valve torelease the fluid and air. When thefluid stops, close the bleeder valve;then release the brake lever.

4. Repeat step 3 until the brake fluidflows free of air bubbles.

! WARNINGDo not operate the snowmobile if thecompressed distance between thebrake lever and the handlebar is lessthan 2.54 cm (1 in.). Brake loss mayoccur. Brake loss can result in severe

personal injury.


! WARNINGUse only Yamaha approved DOT 4brake fluid. Any substitute may resultin a loss of brakes.


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NOTE: It may be necessary to refillthe reservoir during the bleedingprocess. Never allow the brake fluidto go below the low brake fluid mark

in the reservoir.

5. When the brake fluid is free of all airand the brake lever feels firm whencompressed, fill the reservoir to thehigh brake fluid mark; then install andsecure the cover. Remove the tubefrom the bleeder valve.

Checking/Changing BrakePads

The condition of the brake pads must bechecked daily and changed if worn ordamaged. To check and change the brake

pads, use the following procedure:

NOTE: The brake pads may be

changed by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Yamaha Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

NOTE: When installing new brakepads, always install them as a set.Never install just one pad or usebrake pads which have been used inanother snowmobile.

1. Remove the brake fluid reservoircover; then remove most of the

brake fluid from the reservoir. Install

the cover.

NOTE: The above procedure willallow room for the fluid from the cali-per when the pistons are pushedinto the caliper for installing newbrake pads. Replacing the cover willprevent fluid spillage.

2. Open the left-side access panel.

3. Remove the torx-head screws secur-

ing the brake shield to the belt guardmount; then remove the cap screwssecuring the brake shield to the

brake caliper.

4. Carefully move the shield out of theway; then remove the hairpin clipsecuring the brake pads to the cali-

per assembly.

5. Using a pair of pliers, pull the outerbrake pad out of the caliper assembly.

PC013

NOTE: Changing one pad at a timewill prevent one piston from pushingout the other piston from the caliper.

6. Measure the thickness of the brake pad.The brake pad thickness must be greaterthan 5.0 mm (0.20 in.). If the brake padthickness is less than specified, replace-ment of both pads is necessary.

PC011A

7. Using a flat-blade tool, slowly andcarefully push the piston into thecaliper.

8. Position the outer brake pad into thecaliper; then install the hair-pin clipinto the caliper assembly.

9. Repeat steps 5-8 for the inner pad; thensecure the pad with the hairpin clip.

10. Remove the reservoir cover andremove the remaining fluid; then fillthe reservoir with fresh fluid andinstall the cover.

11. Pump the brake lever to ensure cor-rect positioning of the brake padsand proper brake lever travel; thenrelease.



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NOTE: If brake lever travel is notwithin specification, bleed the brakesystem.

12. Remove the reservoir cover and fillthe reservoir (if necessary) to theproper level with fresh brake fluid;then install the cover.

13. Secure the brake shield, the drivenclutch (tightened to 20 ft-lb), and therear belt guard; then close andsecure the left-side access panel.

NOTE: When new brake pads areinstalled, a burnishing process isrequired (see Burnishing Brake Padssub-section).

Burnishing Brake PadsAfter changing brake pads, the new brake

pads must be burnished to achieve fullbraking effectiveness. Braking distancewill be extended until brake pads are

properly burnished.

To properly burnish the brakes, use fol-lowing procedure:

1. Choose an area sufficiently large tosafely accelerate to 50-65 km/h (30-40 mph) and to brake to a stop.

NOTE: This procedure can also beaccomplished using a shielded jackstand.

2. Accelerate to 50-65 km/h (30-40mph); then compress brake lever to

decelerate to a stop.NOTE: Lightly apply the brake leverto come to an easy stop; do not over-apply brakes or lock up the track.

3. Repeat procedure 10-15 times allow-ing some cooling between stops.

NOTE: Do not repeat too soon ortoo aggressively as to get the brakedisc red hot.

NOTE: This procedure stabilizesthe pad material and extends the lifeof the pads.

Chain Tension1. Remove the shroud, right-side cover,

and exhaust assembly.

2. Loosen the jam nut.3. Turn the chain tension adjustment

bolt clockwise until it is finger tight;then loosen it 1/4 turn.

0747-831

4. While holding the bolt with awrench, tighten the jam nut to 2.5kg-m (18 ft-lb).

5. Install the exhaust assembly with anew gasket.

6. Install the right-side cover and theshroud.

NOTE: Check that the harness isinstalled correctly.

Drive BeltThe drive belt transfers power from thedrive clutch to the driven clutch. If the

belt is worn, cracked, or stretched, maxi-mum power will not be transmitted andthe belt could also fail and therefore must

be replaced. Periodic checks (at leastonce a month under normal usage) of twodrive belt specifications are essential.

1. Measure the outside circumference ofthe drive belt. The belt should bewithin 1118-1126 mm (44.0-44.3 in.).

2. Measure the outside width of the drivebelt. The belt should be at least 34.5mm (1.36 in.) on a new belt or 32.5

mm (1.28 in.) on a broken in belt.3. Check the belt for cracking, fraying, etc.

If any of the specifications or conditionsare unsatisfactory, replace the drive belt.

! WARNINGDo not attempt sudden stops or putyourself into a situation where a sud-den stop will be required until thebrake pads are properly burnished.


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NOTE: Drive belts should be pur-chased from an authorized YamahaSnowmobile dealer, as Yamaha drivebelts are made to exact specifica-

tions and of quality material. Beltsmade by other manufacturers maynot be of the same specifications orquality and, therefore, usage couldresult in poor performance and pre-mature belt failure.

NOTE: Before starting the snowmo-bile in extremely cold temperatures,the drive belt should be removed andwarmed up to room temperature.Once the drive belt is at room temper-ature, install the drive belt.

Also, new drive belts have a break-inperiod of approximately 40 km (25 miles).After installing a new drive belt, drive the

snowmobile for 40 km (25 miles) at 3/4throttle or less. By revving the engine upand down (but not exceeding 97 km/h [60mph]), the exposed cord on the side of anew belt will be worn down. This allowsthe drive belt to gain its optimum flexibil-ity and will extend drive belt life.

Removing Drive Belt

NOTE: Changing a drive belt can be

done by the snowmobile owner if qual-ified to do so. If the owner does notfeel qualified, take the snowmobile toan authorized Yamaha Snowmobiledealer for this service. This service isat the discretion and expense of thesnowmobile owner.

1. Place the snowmobile on a level sur-face and engage the brake leverlock.

2. Open the left-side access panel andremove the belt guard assembly.

3. Rotate the driven clutch slidingsheave clockwise (1); then pushtowards the engine (2) so it will sep-

arate from the fixed sheave.

4. Remove the drive belt by pulling itup and over the fixed sheave.

SNO-336

Installing Drive Belt

NOTE: Before installing the drivebelt, use a suitable cleaning solventto thoroughly clean the sheaves.

1. Open the left-side access panel.

2. Rotate the driven clutch slidingsheave clockwise (1); then push

towards the engine (2) so it will sep-arate from the fixed sheave.

3. Install the drive belt (3) between thesheaves.

SNO-326

SNO-327

4. Install the left-side access panel.

CAUTIONNever run the engine with the drivebelt removed. Excessive revving of theengine could result in serious enginedamage and drive clutch failure.

! WARNINGNever operate the snowmobile withoutthe access panel secured in place.


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Track TensionTrack tension is directly related to theoverall performance of the snowmobile.If the track is too loose, it may slapagainst the tunnel causing wear or it mayratchet on the track drive sprockets. Ifextremely loose, the idler wheels mayclimb over the track lugs forcing thetrack against the tunnel causing the trackto lock. Yamaha recommends that thetrack tension be checked daily during thefirst 500 km (300 miles) of operation andonce a week thereafter and adjustedaccording to need. The track will stretchand take a set during break-in. Trackdeflection must be maintained within therecommended range.

Checking Track Tension

1. Remove excess ice and snow buildupfrom the track, track drive sprockets,and the inside of the skid frame.

2. Elevate the snowmobile on ashielded safety stand high enough touse a spring scale.

3. At the mid-point of the track (on thebottom side), hook a spring scalearound a track clip; then pull downon the scale to the recommended

pressure (see chart). Measure thedeflection (distance) between the

bottom of the wear strip and theinside surface of the track clip. Mea-surement should be 50 mm (2.0 in.).

746-788A

NOTE: Measurement is from thebottom of the wear strip at the pointof the shock pad on the slide rail.

NOTE: Only tighten track until thetrack does not ratchet. Too tight of atrack will cause the rear suspensionto not work properly.

Adjusting Track Tension

NOTE: To ensure proper track ten-sion adjustment, perform all adjust-ments on both sides of thesnowmobile.

1. Loosen the idler wheel axle capscrews.

0745-811

2. If the deflection (distance betweenthe bottom of the wear strip and theinside surface of the track clip)exceeds specifications, tighten theadjusting bolts to take up excessiveslack in the track.

3. If the distance between the bottom ofthe wear strip and the inside surfaceof the track clip is less than specified,loosen the adjusting bolts to increasethe slack in the track.

4. Check track alignment.

! WARNING

Track tension must be properly main-tained. Personal injury could result ifa track is allowed to become exces-sively loose.

! WARNINGDO NOT attempt to check or adjusttrack tension with engine running.Turn ignition key to the OFF position.Personal injury could result fromcontact with a rotating track.

Track Pressure

3277 mm (129 in.) 9.1 kg (20 lb)

3480 mm (137 in.) 11.3 kg (25 lb)3581 mm (141 in.) 5.4-6.8 kg (12-15 lb) CAUTIONAlways maintain track tension within

recommended specification.


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5. After proper track tension isobtained, tighten the idler wheelaxle cap screws to 4.7 kg-m (34 ft-lb); then tighten the adjusting bolts

securely against the axle.

NOTE: Since track tension andtrack alignment are interrelated,always check both even if only oneadjustment seems necessary.

Track AlignmentProper track alignment is obtained whenthe rear idler wheels are equal distancefrom the inner track drive lugs. Excessivewear to the idler wheels, drive lugs, andtrack will occur if the track is improperlyaligned. Yamaha recommends that thetrack alignment be checked once a weekor whenever the track tension is adjusted.

Checking Track Alignment

1. Remove excess ice and snow buildupfrom the track, track drive sprockets,and the inside of the skid frame.

2. Position the tips of the skis against awall; then using a shielded safetystand, raise the rear of the snowmo-

bile off the floor making sure thetrack is free to rotate.

3. Start the engine and accelerateslightly. Use only enough throttle toturn the track several revolutions.SHUT ENGINE OFF.

NOTE: Allow the track to coast to astop. DO NOT apply the brakebecause it could produce an inaccu-rate alignment condition.

4. When the track stops rotating, checkthe relationship of the rear idlerwheels and the inner track drive lugs.If the rear idler wheels are centeredbetween the inner track drive lugs, noadjustment is necessary.

0745-809

5. If the idler wheels are not centeredbetween the inner track drive lugs,an adjustment is necessary.

Adjusting Track Alignment1. On the side of the track which has the

inner track drive lugs closer to the rearidler wheel, loosen the idler wheelaxle cap screw; then rotate the adjust-ing bolt clockwise 1 to 1 1/2 turns.

0745-811

! WARNINGAlways make sure the adjusting boltsare snug against the axle and theidler wheel cap screws are tightenedto specifications. Failure to do socould cause the track to becomeextremely loose and, under someoperating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to lock. If a tracklocks during operation, severe per-sonal injury could result.

! WARNINGMake sure the ignition key is in theOFF position and the track is notrotating before checking or adjustingtrack alignment. Personal injurycould result if contact is made with arotating track.

! WARNINGThe tips of the skis must be positionedagainst a wall or similar object.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVER

run the track at high speed when thetrack is suspended.


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2. Check track alignment and continueadjustment until proper alignment isobtained.

NOTE: Make sure correct tracktension is maintained after adjust-

ing track alignment.

3. After proper track adjustments areobtained and the adjusting bolts aresnug against the axle housings,tighten the idler wheel axle capscrews to 4.7 kg-m (34 ft-lb).

4. Field test the track under actual con-ditions.

5. After the field test, check the align-ment of the track. If additional adjust-ment is necessary, repeat AdjustingTrack Alignment procedure.

SuspensionThe suspension should be adjusted for

the operational needs and riding prefer-ence of the operator.

The front shock springs determine theamount of ski pressure and the reactionof the front suspension to rough terrain.The amount of ski pressure can also bechanged by adjusting the length of theskid frame front arm limiter straps.

On standard models, the rear arm shockabsorber spring influences the load carry-ing capability of the snowmobile andshould be adjusted for the weight and rid-ing preference of the operator.

NOTE: On SE models with a reararm float shock, this adjustment isachieved by increasingly or decreas-ing the air pressure in the rear armair shock absorber.

Adjusting Front (Ski)Shock Springs

The front (ski) shock springs are individu-ally adjustable for the terrain conditions anddriving style of the operator. The springadjuster nut has been set at the factory so thecorrect amount of threads are exposedbetween the adjuster nut and the threadedshock body as an initial setting. Additionalski pressure can be obtained by tighteningthe spring tension; ski pressure can bedecreased by relaxing spring tension.

NOTE: Equal adjustments shouldbe maintained on both sides of thesnowmobile.

Front (ski) shock spring pre-load adjust-ment is accomplished by loosening theadjuster nut locking collar (B) from theadjuster nut (A) and using the SpringAdjuster Tool from the tool kit, rotatingthe adjuster nut in whichever direction isdesired. Tighten the locking collar

against the adjuster nut.

! WARNINGAlways make sure the adjusting boltsare snug against the axle and theidler wheel cap screws are tightenedto specifications. Failure to do socould cause the track to becomeextremely loose and, under some

operating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to lock. If a tracklocks during operation, severe per-sonal injury could result.

! WARNINGRead and understand the following

information before handling shockabsorbers that contain highly pres-surized nitrogen gas.

Do not tamper with tor attempt toopen the cylinder assemblies.

Do not subject the shock absorb-ers to an open flame or other highheat source. This may cause theunit to explode due to excessivegas pressure.

Do not deform or damage the cyl-inders in any way. Cylinder dam-age will result in poor dampingperformance.

Do not dispose of a damaged orworn out shock absorber your-

self. Take the shock absorber to aYamaha dealer for any service.


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0745-159

Adjusting Fox Air Shocks

NOTE: It is recommended to moni-tor the air pressure in the air shocksonce every month.

NOTE: Adjusting air shocks maybe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-

bile to an authorized Yamaha Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

The air shocks are individually adjustablefor the terrain conditions and driving styleof the operator. The shocks are preset at thefactory (see chart) as an initial setting;however, it is possible to fine tune theshocks to match the operators weight, rid-ing style, and terrain conditions.

NOTE: Adding air pressure willincrease the air spring force; reduc-ing air pressure will decrease airspring force.

Checking and adjusting air pressure mustbe done at riding temperature (outside).Also, it is advisable to check air pressurewhen the outside temperature variesmore than 25.

NOTE: Care should be taken tohave equal pressure in the front (ski)shocks before operating the snow-mobile.

To increase or decrease air pressure, usethe following procedure.

NOTE: When adjusting air pres-sure, all weight must be removedfrom the suspension, and the shockabsorbers must be fully extended.

1. Remove the air valve cap from theshock.

2. Thread the valve of Sho

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