1991 yamaha viking vk 540 series snowmobile service repair manual

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ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols Q) to ® are designed as 'thumb tabs to indicate the chapter's number and content.

Q)General information

® Periodic inspection and adjustment @Engine @Cooling system CIDCarburetion CID Power train (j)Chassis Electrical ®Appendices

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ICHASIJ IIELECI iiil Illustrated symbols QW to @ are used to identify the specifications appearing.

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QWFilling fluid @Lubricant @Tightening @Wear limit, clearance @ Engine speed

@n,V,A

Illustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point. @Apply locking agent (LOCTITE@) @Apply engine oil @ Apply gear oil @Apply molybdenum disulfide oil Apply wheel bearing grease Apply low-temperature lithium-soap base grease @ Apply molybdenum disulfide grease

® ®

INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL

CARBURETION

POWER TRAIN ~

.....rtIIIJ.!IS

CHASSIS

ELECTRICAL

APPENDICES

iiii ELEC ~,

CHAPTER 1.

GENERAL INFORMATION MACHINE IDENTifiCATION ..................................... 1-' FRAME SERIAL NUMBER .................................... '-1 ENGINE SERIAL NUMBER .................................... 1-1 STORAGE .................................................... 1-2 PRE-SEASON PREPARATION .................................... '-2 IMPORTANT INfORMATION ..................................... 1-3 NO FLAME SOURCES ........................................ 1-3 WASHING AND CLEANING ................................... 1-3 RIGHT TOOLS .............................................. '-3 MAKING IT NEAT ........................................... 1-3 TIGHTENING TORQUE ...................................... 1-3 ALL REPLACEMENT PARTS .................................. 1-4 GASKETS, Of L SEALS, AND O-RINGS .......................... 1-4 LOCK WASHERS/PLATES AND COTTER PINS .................... 1-4 BEARINGS AND OIL SEALS .................................. 1-4 Cl RCLIPS .................................................. 1-5 SPECIAL TOOLS ...............................................

FOR TUNE UP ..............................................

FOR ENGINE SERVICE ......................................

FOR POWE R TRAI N SERVICE .................................

FOR ELECTRICAL SERVICE ..................................

1-5 1-5 1-6 1-6 1-7

SPECIAL TOOLS CROSS REFERENCE LIST ......................... 1-9

D

IM'j:~I~IMACHINE

IDENTIFICATION

GENERAL INFORMATION MACHINE IDENTI FICATION FRAME SERIAL NUMBER The frame serial number ill is located on the right-hand side of the frame (just below the front of the seat).

ENGINE SERIAL NUMBER The engine serial number ill, is located on thp right-hand side of the crankcase.

NOTE: __________________________ The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.

Starting Serial Number: For (OK, N, NL, S, SF): 83R-000101 For (CON): 84R-000101 NOTE: _________________________ Designs and specifications are subject to change without notice.

1-1

STORAGE/PRE-SEASON PREPARATION

I~l:~I­

STORAGE If a snowmobile will not be used for several months, it should be stored in a proper place so that both the engine and the track are not damaged .

• Completely drain the fuel tank, and disconnect the fuel line from the carburetor .

• With the engine running at idle, squirt oil into the carburetor until the engine dies. This will distribute oil evenly throughout the engine, and protect it against rust.

• Disassemble the suspension, clean and grease all parts, and reassemble the suspension.

• Lightly coat all shafts and axles with grease.

• Oil all fittings and cable controls with a lightly oiled cloth.

• Loosen the track.

• Block the chassis so that the track is off the floor .

• Protect the snowmobile with a covering.

PRE-SEASON PREPARATION Perform the predelivery service as described in the predelivery check list before operating any snowmobile that has been stored for several months. (Refer to CHAPTER 2. "PERIODIC MAINTENANCE TABLE", page 2-1.)

1-2

IMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign material before removal and disassembly.

While cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc., from high pressure water splashes.

2. Use proper tools and cleaning equipment.

Refer to "SPECIAL TOOLS".

3. When disassembling the machine, keep mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.

4. During the machines disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

5. Keep away from fire.

6. Be sure to keep to tightening torque specifications. When tightening bolts, nuts, and screws, start with a larger-diameter one and from an inner-positioned one to an outerpositioned one in a criss-cross pattern.

'-3

IMPORTANT INFORMATION

I~1f=~1-

ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.

2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates CD and cotter pins must be replaced when they are removed.

Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

300-000

300-002

BEARINGS AND OIL SEALS 1. Install the bearing(s) CD and oil seal(s) CV with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seallip(s). Oil the bearings liberally when installing.

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

300-003

1-"

I~~~I.I

si

SPECIAL TOOLS Cl RC LI PS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one -use. R.eplace distorted circlips. When installing a circlip <D , make sure that the sharp edged corner <ID is positioned opposite to the thrust @ it receives. See the sectional view.

300-001

@Shaft

SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.

FOR TUNE UP 1. Sheave Gauge PIN YS-91047 This gauge is used for sheave distance and offset adjustment.

2. Dial Gauge PIN YU-03097 This gauge is used for ignition timing adjustment.

3. Dial Gauge Stand Set PIN YU-01256 These tools are uSed for ignition timing adjustment.

1-5

SPECIAL TOOLS

IMIf=~I-

FOR ENGINE SERVICE 1. Universal Rotor Holder PIN YU-01235 This tool is used to hold starter pulley and COl magneto.

2. Piston Pin Puller PIN YU-01304 This tool is used to remove piston pin.

3. Rotor Puller PIN YU-33270 This tool is used to remove COl magneto.

FOR POWER TRAIN SERVICE 1. Primary Sheave Holder PIN YS-01880 This tool is used to hold primary sheave.

2. Primary Sheave Puller PIN YS-01882-A This tool is used for removing primary sheave.

1-6

SPECIAL TOOLS 3. Sheave Compressor PIN YS-28891 This tool is used for disassembling and assembling sheave.

4. Clutch Spider Separator PIN YS-28890-A These tools are used for disassembling and assembling primary sheave.

5. Clutch Separator Adapter PIN Y5-34480 This tool is used for disassembling and assembling primary sheave.

6. Track Clip Installer PIN Y5-91045 This tool is used for installing the track clip.

FOR ELECTRICAL SERVICE 1. Pocket Tester PIN Y U-03112 This instrument is necessary for checking the electrical components.

1-7

SPECIAL TOOLS 2. Electro Tester PIN Y U-33260 This instrument is invaluable for checking the electrical system.

1-8

SPECIAL TOOLS CROSS REFERENCE LIST SPECIAL TOOLS CROSS REFERENCE LIST SPECIAL TOOL NAME

PART NUMBER

PART NUMBER

FOR TUNE UP

-

1.

Sheave Gauge

YS-91 047

2.

Dial Gauge

YU-03097

90890-03097

3.

Dial Gauge Stand Set

YU-01256

90890-01256

FOR ENGINE SERVICE

1.

Universal Rotor Holder

YU-01235

90890-01235

2.

Piston Pin Puller

YU-01304

90890-01304

3.

Rotor Puller

YU-33270

-

FOR POWER TRAIN SERVICE 1.

Primary Sheave Holder

YS-01880

90890-01701

2.

Primary Sheave Puller

YS-01882-A

90890-01898

3.

Sheave Compressor

YS-28891

90890-01712

4.

Clutch Spider Separator

YS-28890-A

90890-01711

5.

Clutch Separator Adapter

YS-34480

6.

Track Clip Installer

YS-91 045

TLS90-91 045

-

FOR ELECTRICAL SERVICE 1.

Pocket Tester

YU-03112

90890-03112

2.

Electra Tester

YU-33260

90890-03021

1-9

CHAPTER 2.

PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-1 PERIODIC MAINTENANCE TABLE ............................... 2-1 LUBRICATION INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-3 SHROUD COVERS AND SEAT ........... , .......................

SHROUD OPENING .. " ...... " .. " ., .. " ...................

SHROUD .................................................

SEAT ........ , .. " ............... , .......................

HANDLEBAR COVER .......................................

WIND SHIELD SPEEDOMETER AND HEADLIGHT ...............

COVERS ..................................................

2-4 2-4 2-4 2-4 2-5 2-6 2-7

ENGINE .................... ; .............................. " 2-9 ENGINE OIL LEVEL INSPECTION ............................. 2-9 FUEL LINE INSPECTION .................................... 2-10 ENGINE OIL LINE INSPECTION .............................. 2-10 ENGINE IDLE SPEED ADJUSTMENT ........ , ................. 2-10 THROTTLE CABLE FREE PLAY ADJUSTMENT ... , ............. 2-11 STARTER CABLE ADJUSTMENT ... , ......................... 2-12 OIL PUMP CABLE FREE PLAY ADJUSTMENT ................... 2-12 OIL PUMP STROKE ADJUSTMENT ............................ 2-13 OIL PUMP AIR BLEEDING ................................... 2-18 OIL FILTER INSPECTION ................................... 2-19 FUEL FILTER INSPECTION .................................. 2-20 FUEL PUMP OPERATION CHECK ............................. 2-20 COOLING FAN BELT INSPECTION ............................ 2-22 COOLING FAN BELT TENSION ADJUSTMENT .................. 2-23 POWER TRAIN ........... ',' .................................. 2-25 DRIVE V-BELTINSPECTION ..................... , ........... 2-25 SHEAVE DISTANCE AND OFFSET ADJUSTMENT ............... 2-27 DRIVE CHAIN HOUSING OIL LEVEL INSPECTION ..... , ......... 2-30 DRIVE CHAIN HOUSING OIL REPLACEMENT ...... , ... , ....... 2-31 DRIVE CHAIN SLACK ADJUSTMENT ................ , ......... 2-32 BRAKE PAD INSPECTION ................................... 2-34 BRAKE ADJUSTMENT ...................................... 2-34 TRACK TENSION ADJUSTMENT.............................. 2-36 HINGED EXTENSION ADJUSTMENT .......................... 2-38

....

CHASSIS.....................................................

SKI ADJUSTMENT .........................................

BRAKE CABLE END LUBRICATION ...........................

SLlDER RUNNER INSPECTION ...............................

2-39 2-39 2-40 2-41

ELECTRICAL.................................................

SPARK PLUG INSPECTION .............. , . '" .............. , IGNITION TIMING ADJUSTMENT ......................... , ...

HEADLIGHT BULB REPLACEMENT ...........................

HEADLIGHT BEAM ADJUSTMENT ............................

TAIL/BRAKE LIGHT REPLACEMENT..........................

METER LIGHT REPLACEMENT ...............................

2-41 2-41 2-42 2-44 2-45 2-46 2-46

TUNING . ....................................................

CARBURETOR TUNING .....................................

CLUTCH TUNING .................. , .......................

SLIDE RAIL SUSPENSION TUNING ... , .......................

HIGH ALTITUDE TUNING ........... , .......................

2-47 2-47 2-55 2-57 2-59

INTRODUCTION/PERIODIC MAINTENANCE TABLE

PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments.

These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE TABLE Every Check point

20 hrs. or 400 km (250 mi)

40 hrs. or 80 hrs. or 800 km 1,600 km (500 mi) (1,000 mU

When Seasonally necessary

ENGINE: Tightness of bolts and nuts Bends, cracks and wear Abnormal noise Loose connection and breaks of fuel and pulse pipes Loose connection and breaks of oil pipes Loose connection and breaks of oil delivery pipe

0 0 0 0 0 0

0 0 0 0 0 0 0

0

Manual rope starter system CARBURETOR: •

Operation of starter jet

•

Mixing adjuster (pilot screw)

•

Idling speed adjustment

0 0 0 0

Operation and adjustment of oil pump Ignition timing

0

Engine compression Cylinder head/exhaust pipe decarbonization Fan belt tension, damage Spark plug condition, gap and cleaning

0 0

Tightening of the cylinder head**

0 0 0 0 0 0 0 0 0 0

DRIVE: Tightness of bolts and nuts Wear on slide runners

0 0 0

Primary drive system V-belt

0 0 0 0 0 0 0 0 0 0 0 0 0

Secondary drive system Sheave distance Sheave offset Brake pad wear Brake operation and adjustment Guide wheel rubber Wear of drive track wheel sprocket Drive track adjustment Breaks in drive track Bends in front and rear axles Checking of lock washers Drive chain adjustment Drive chain oil level 2-1

0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

PERIODIC MAINTENANCE TABLE Every Check point

20 hrs. or 400 km (250 mi)

40 hrs. or 80 hrs. or 800 km 1,600 km (500 mi) (1,000 mi)

When Seasonally necessary

BODY: Tightness of bolts and nuts Bends and cracks Welded/riveted, joints

0 0 0 0

Ski adjustment Ski runner wear

0 0 0 0 0 0 0 0 0 0 0

0 0

Breaks in fuel tank Cleaning of fuel tank Fuel filter

0 0

Loose connection and breaks in fuel pipe Breaks in oil tank Oil filter ELECTRICAL:

0

Wear, breakage of wire covering Breaks in high-tension cord

0

Voltage regulator working voltage Operation of engine stop switch Operation of throttle override system Headlight Taillight Brake light

** Retighten every

0 0 0 0 0

.

0 0 0 0 0 0 0 0

10 hours from the first use.

2-2

Ir8f IQI

LUBRICATION INTERVALS

LUBRICATION INTERVALS Every Check point

20 hrs. or 400 km (250 mi)

40 hrs. or 80 hrs. or 800 km 1,600 km (500 mi) (1,000 mi)

When Seasonally necessary

Oil/Grease Brand name

ENGINE:

0 0 0

Starter case

0 0

Oil pump control box Pump drive cover

0

Oil in the oil tank

Aeroshell grease #7 A or Esso Beacon 325 grease YAMALUBE 2-cycle oil

DRIVE: Primary sheave weight and roller pins

0

0

Molybdenum disulfide snowmobile grease

Secondary shaft and sliding sheave

0

0

Molybdenum disulfide snowmobile grease

Front axle housing

0

0

Shaft 1 and shaft 2 (Slide rail) Drive chain oil replacement

0 Initial

0

Light all-purpose grease

0

0

Gear oil API GL-3 SAE #75 or #80

Steering column lower bearing

0

0

Light all-purpose grease

Steering column upper bearing

0

0

Motor oil

Ski retaining pin

0 0 0 0

0 0 0 0

Brake wire and stopper and brake lever

0

0

0

BODY:

Steering links Ski column Ski wear plate

2-3

Light all-purpose grease Light all-purpose grease Esso Beacon 325 grease

lA NOSJP I~ I I ----------------------------------------------------SHROUD OPENING/SHROUD/SEAT

~

SHROUD COVERS AND SEAT

SHROUD OPENING When the engine requires a check or service, the shroud can be opened forward.

1. Unhook: - Shroud latches CD Right and left of the shroud.

2. Should be slowly raised until shroud stops.

SHROUD Removal 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Disconnect: - Headlight lead CD - Meter light leads ® -Speedometer cable ®

3. Unhook: -Stop wire CD 4. Remove: -Shroud ®

Installation Reverse the removal procedure.

Note the following points.

1. Install: -Shroud Nuts (Shroud hinger): 5 Nm (0.5 m· kg, 3.6 ft·lb)

SEAT Removal 1. Unhook: - Seat latches

CD

2-4

Ir&r Ifit I

HANDLEBAR COVER 2. Remove: -Seat hinge pins

CD

3. Remove: -Seat CD

Installation Reverse the removal procedure.

1. Install: -Seat

HANDLEBAR COVER

Removal 1. Remove: - Handlebar covers (Front CD and rear

Installation 1. Install: - Handlebar covers (Front and rear)

2-5

CV )

WIND SHIELD, SPEEDOMETER AND HEADLIGHT WIND SHIELD, SPEEDOMETER AND HEADLIGHT Removal 1. Remove: .Windshield

CD

2. Open the shroud.

3. Disconnect: • Speedometer cable CD • Meter light leads CV

4. Remove: • Front cowl CD • Headlight adjuster handle CV • Meter panel @

5. Disconnect: • Headlight lead

CD

2-6

Ir8fl§ll_co_V_ER_S______________________ 6. Remove: • Headlight

CD

Installation Reverse the removal procedure.

Note the following points.

1. Install: -Headlight • Front cowl

Nuts (Front cowl): 5 Nm (0.5 m' kg, 3.6 ft·lb)

2. Install: • Meter panel

Nuts: fo-iiiiiOIIo....

2 Nm (0.2 m' kg, 1.4 ft·lb) Screw: 2 Nm (0.2 m·kg, 1.4 ft·lb)

3. Install: et Windshield

I~

Screw: 2 Nm (0.2 m·kg, 1.4 ft·tb)

COVERS

Removal 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Remove: • Side covers (Left CD and right CV )

2-7

COVERS 3. Remove: • Main switch holding nut CD ."STARTER" lever holding nut CID • Tether switch holding nut @

4. Remove: • Handlebar cover (Lower)

5. Remove: • Drive select lever boots

CD

CD

6. Open the seat.

7. Remove: • Fuel level indicator hose CD .Oillevel indicator hose CID • Center cover @

2-8

llEVEl INSPECTION Installation Reverse the removal procedure.

Note the following points.

1. Install: • Center cover .Oillevei indicator hose CD • Fuel level indicator hose CV

NOTE: _ _ _ _ _ _ _ _ _ _ _ _ _....

When installing the oil and fuel level indicator hoses, be sure to secure the hoses using the white guide plates in proper positions.

ENGINE ENGINE Oil lEVEL INSPECTION 1. Place the machine on a level place.

2. Inspect: "Engine oil level Oil level low -? Add sufficient oil.

CD "F" (Full) level mark CV "E" (Empty) level mark 3. Open the shroud.

Refer to the "SHROUD OPENING" section.

4. Add the engine oil until the oil level reaches "F" level mark. ~

•U CD

Recommended oil: Y AMAlUBE "2" or equivalent

Oil tank cap

Always use the same type of engine oil; mixing oils may result in a hurmful chemical reaction and lead to poor performance.

2-9

FUEL LINE INSPECTION/ENGINE 01 L LINE INSPECTIONI ENGINE IDLE SPEED ADJUSTMENT FUEL LINE INSPECTION 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Inspect: ~ Fuel hose Crack/Damage -+ Replace.

ENGINE OIL LINE INSPECTION 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. inspect: @ Engine oil hose Crack/Damage -+ Replace.

ENGINE iDLE SPEED ADJUSTMENT 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Adjust: @Pilot screw

CD

Pilot screw adjustment steps: @Turn in the both pilot screw until they are lightly seated.

Ii Turn out the both piiot screw to specification.

Pilot Screw: 1-1/4 turns out 3. Start the engine and let it warm up.

4. Adjust: • Engine idle speed

Adjustment steps: • Turn the throttle stop screw CD in or out until the specified engine speed is obtained.

2-10

I JP IMl·1 -------------------------------------------------lANDS.

~

THROTTLE CABLE FREE PLAY ADJUSTMENT Turn in

Idle speed becomes higher.

Turn out

Idle speed becomes lower.

C1

Engine Idle Speed: 1,100 '" 1,200 r/min

NOTE: After adjusting the engine idle speed, the throttle cable free play should be adjusted.

THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: _________________ Before adjusting the throttle cable free play, the engine idle speed should be adjusted.

1. Measure: • Throttle cable free play ® Out of specification ~ Adjust.

Throttle Cable Free Play: 1.0 '" 2.0 mm (0.04 '" 0.08 in) 2. Open the shroud.

Refer to the "SHROUq OPENING" section.

3. Adjust: • Throttle cable free play Free play adjustment steps: • Open the shroud.

Refer to the "SHROUD OPENING" section.

• Loosen the locknut CD .

• Turn the adjuster CV in or out until the specified free play is obtained.

Turn in

Free play is increased.

Turn out

Free play is decreased.

• Tighten the locknut.

4. Close the shroud.

2-11

STARTER CABLE ADJUSTMENT/ OIL PUMP CABLE FREE PLAY ADJUSTMENT STARTER CABLE ADJUSTMENT 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Remove: • Rubber cap CD

3. Pull the outer tube of starter cable upward.

4. Measure: • Starter cable free play ® Out of specification -+ Adjust.

FreePlay®: 0.5'" 1.5 mm (0.02'" 0.06 in)

~H---+®

5. Adjust: • Starter cable free play Free play adjustment steps: • Loosen the locknut CD .

• Turn the adjuster <ID in or out until the specified free play is obtained.

Turn in

Free play is increased.

Turn out

Free play is decreased.

.Tighten the locknut and install the rubber cap.

6. Close the shroud.

OIL PUMP CABLE FREE PLAY ADJUSTMENT NOTE: ___________________________ Before adjusting the oil pump cable free play, the throttle cable free play should be adjusted.

1. Open the shroud.

Refer to the "SHROUD section.

OPENING" 2-12

I IANDSJPlel_~~~~~~~~_ 11' _

_~ _ OIL PUMP STROKE ADJUSTMENT

2_ Pull: .Oil pump outer cable 3. Measure: • Oil pump cable free play ® Out of specification -+ Adjust.

Free Play:

24 - 26 mm (0.94 - 1.02 in)

4. Adjust: • Oil pump cable free play Free play adjustment steps: • Loosen the locknut CD .

• Turn the adjuster ® in or out until the specified free play is obtained.

Turn in

Free play is increased.

Turn out

Free play is decreased.

• Tighten the locknut and install the rubber cap.

5. Close the shroud.

OIL PUMP STROKE ADJUSTMENT 1. Open the shroud.

2. Remove: • Drive V -belt guard

CD

3. Loosen: • Locknut CD (Oil pump cable) .Adjuster ® (Oil pump cable) 4. Remove: .Oil pump cable ®

2-13

OIL PUMP STROKE ADJUSTMENT 5. Disconnect: • Oil hoses CD .Oil delivery hoses

®

NOTE: _ _ _ _ _ _ _ _ _- - Plug the oil hoses and oil delivery hoses so that oil does not run out.

6. Remove: .Oil pump assembly

CD

7. Remove: .Oil pump driven gear housing CD Place a rug under the oil pump assembly.

8. Disconnect: .Oil hoses ®

9. Remove: • Oil pump cover CD 10. Wipe off the grease from the plunger top.

2-14

IlANOSJP IMl··1 --------------------------------------------------------~

.®~ ® @

OIL PUMP STROKE ADJUSTMENT

11. Measure: -Minimum pump stroke ® Out of specification ~ Adjust.

Minimum Pump Stroke: 0.20'" 0.25 mm (O.OOS'" 0.010 in) Minimum pump stroke measurement steps: - Turn the pump worm gear CD with your fingers, until the plunger top ® is at its maximum distance from the pump body mating surface @ of the pump cover.

- Using a Feeler Gauge, measure the minimum pump stroke ® between the adjusting plate @ and the raised boss <ID on the adjusting pulley.

-If minimum pump stroke is not within the specjfied limits, perform the adjustment steps.

12. Measure: - Maximum pump stroke@ Out of specification ~ Adjust.

Maximum Pump Stroke: 1.65'" 1.S7 mm (0.065'" 0.074 in)

Maximum pump stroke measurement steps: - Pull the oil pump cable CD out of its sheather as far as it will go. The cable must be held in this taut position when measuring the maximum pump stroke.

NOTE: _________________________ It may be helpful to securely warp duct tape ® around the cable where it enters the sheath.

- Turn the pump worm gear @ with your fingers, until the plunger top @ is at its maximum distance from the pump body <ID. - Using a Feeler Gauge, measure the maximum pump stroke @ .

-If maximum pump stroke is not within the specified limits, perform the adjustment steps.

2-15

01 L PUMP STROKE ADJUSTM ENT 13. Adjust: .Oil pump stroke Adjustment steps: • Remove the locknut CD , spring washer ® and adjusting plate @ .

• Adjust the pump stroke by adding or removing a shim.

(4)'Shims

Add shim

Pump stroke is increased.

Remove shim Pump stroke is decreased.

• Reinstall the adjusting plate, spring washer and locknut.

I®

Locknut: 7 Nm (0.7 m·kg, 5.1 ft'lb)

• Recheck the minimum and maximum pump stroke.

If out of specification limits, perform the above steps again.

14. Apply: • Lithium soap base grease To out side of pump pulley.

15. Install: • Oil pump cover CD NOTE: _ _ _ _ _ _ _ _ _ _ __ Apply the Yamabond No. 5® (ACC-ll001-3100) to the mating surface of the oil pump cover.

2-16

pump driven gear

6

,

i:

CD

pump

. ! I1stai!: @

III

hoses

@

pump, oil hose and oH

bleed.

to section.

IL

AIR B

23. Adjust: '" Oil pump cable free

Free Play: 24 ~ 26 mm (0.94 - 1.02 in) Refer to the "OIL PUMP CABLE. FREE PLAY ADJUSTMENT" section.

24. Close the shroud.

2-17

OIL PUMP AIR BLEEDING OIL PUMP AIR BLEEDING The oil pump and delivery line must be bled on the following occasions: .Any portion of the oil system has beendisconnected .

• The machine has been turned on its side .

• Whenever the oil tank has been run empty .

• During predelivery.

1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Disconnect: .Oil delivery hoses CD

3. Fill: .Oil tank

CD

~ Recommended Oil: Yamalube "2" or equivalent

'u

4. Place a rug under the oil pump assembly.

5. Put Yamalube "2" or equivalent into the oil delivery hoses for complete air bleeding.

Then, connect them with the oil pump.

6. Remove: • Bleed screw CD 7. Inspect: • Gasket (B leed screw) Damage ~ Replace.

2-18

OIL FILTER INSPECTION 8. Keep the oil running out until air bubbles disappear.

9. Install: • Gasket (Bleed screw) • Bleed screw 10. Close the shroud.

OIL FILTER INSPECTION 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Remove: • Drive V-belt guard CD

3. Remove: • Oil filter CD NOTE: _ _ _ _ _ _ _ _ _ _ __ Plug the oil hoses so that the oil will not run out of the oil tank and oil pump.

4. Inspect: • Oil filter CD Contamination ~ Replace.

Recommended Replacement Interval: Every season

5. Install: .Oil filter 6. Install: • Drive V-belt guard 7. Close the shroud.

2-19

FUEL FILTER INSPECTION/FUEL PUMP OPERATION CHECK FUEL FILTER INSPECTION 1. Remove the center cover.

Refer to the "COVE RS" section.

2. Remove: -Springs CD

3. Remove: -Cap CD - Fuel filter

CV

4. Inspect: - Fuel filter CD Contamination -+- Replace.

Recommended Replacement Interval: Every season .

5. Install: - Fuel filter -Cap -Springs - Center cover

FUEL PUMP OPERATION CHECK 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Remove: -Oil tank CD

2·20

I IANDSJPlel_~~~~~~~~_ _

_ ~ _ FUEL PUMP OPERATION CHECK

3. Disconnect: • Fuel hoses CD • Pu Iser hose CV

4. Remove: • Fuel pump

CD

5. Inspection: • Fuel hoses CD • Pu lser hose CV Clog/Damage -+ Replace.

6. Check: • Fuel pump operation Fuel pump operation checking steps: • Connect a hand-operated vacuum pump (such as Mighty - Vac®) to the pulser hose

CD. • When operating a hand-operated vacuum pump, fuel flows out of the fuel hose CV and@.

• If fuel does not flow out, replace the fuel pump.

2-21

1"'1 1 -------------------------------------------------

NOSJP _~ _ COOLING FAN BELT INSPECTION _lA 7. Install: • Fuel pump 8. Connect: • Fuel hoses • Pulser hose 9. Install: .Oil tank 10. Close the shroud.

COOLING FAN BELT INSPECTION 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Remove: • Seal rubber stay (Air duct) CD • Recoil starter assembly CID • Cooling fan cover ®

3. Remove: • Starter pu lIey CD

NOTE: ___________________________ Attach the Universal Rotor Holder (YU-01235) CID to hold the starter pulley.

• Fan belt drive pulley • Fan belt @

®

4. Remove: • Fan belt driven pulley

CD

5. Inspect: • Fan belt Wear/Crank/Damage -+- Replace.

2-22

COOLING FAN BELT TENSION ADJUSTMENT 6. Install: • Fan belt driven pulley Nut (Driven Pulley): 43 Nm (4.3 m- kg, 31 ft·lb)

7. Install: • Fan belt • Fan belt drive pulley • Starter pu lIey • Cooling fan cover • Recoil starter assembly • Seal rubber stay (Air duct) 8. Close the shroud.

COOLING FAN BELT TENSION ADJUSTMENT 1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Remove: • Seal rubber stay (Air duct) CD • Cooling fan cover CV

3. Measure: • Fan belt deflection ® Pushed at belt center by a force of 4 - 6 kg(8.8-13.2Ib).

Out of specification -+- Adjust.

Fan Belt Deflection ®: 8 mm (0.31 in)!

4 - 6 kg (8.8 - 13.2Ib) 4. Adjust: • Fan belt deflection Fan belt deflection adjustment steps: • Remove the recoil starter assembly and drive pulley.

Refer to the "COOLING FAN BELT INSPECTION" section.

2-23

COOLING FAN BELT TENSION ADJUSTMENT

I~gr I~ I

• Remove the pulley (Outer half) and shim(s).

• There are usually two shims, one of 0.5 mm (0.02 in) thickness CD and the other of 1.0 mm (0.04 in) thickness CV , between the pulley halves. Check the number of the shims and their thicknesses.

• Select the suitable shim(s) using the following chart.

NOTE: 2

Install the removed shim(s) on the outside of the pulley. Do not dispose of the removed shim(s).

Shim requirement!

Place one 1.0 mm (0.04 in) shim between the pulley halves.

~ After securing the driven pulley nut, check the belt tension .

~ 18 mm (0.31 in) ~

I

•

I~

8 mm (0.31 in) or more

Proper belt tension is attained.

"Iq

,.

Change the "Shim requirement" to (1) and then (2), and repeat the same procedure.

(1) Place one 0.5 mm (0.02 in) shim between the pulley halves.

(2) Remove both shims between the pulley halves.

5. Install: • Fan belt driven pulley Refer to the "COOLING INSPECTION" section.

6. Close the shroud.

FAN

BELT

2-24

I

lA NOSJP

I~ I--------------------------------------------------------~

DRIVE V-BELT INSPECTION

POWER TRAIN

DRIVE V-BELT INSPECTION

1. Open the shroud.

Refer to the "SHROUD OPENING" section.

2. Remove: • Drive V-belt guard CD • Drive V-belt CID Drive V-belt removal steps: • Turn the secondary sliding sheave <V clockwise and push it towards the engine .

• While holding the secondary sliding sheave in this compressed position, remove the drive V -belt CID from the secondary sheave .

• Then, remove the drive V -belt from the primary sheave.

3. Inspect: • Drive V-belt Crack/Wear/Damage -7 Replace.

Oil or grease adhered to the V-belt -7 Check the primary and secondary sheaves.

4. Inspect: • Primary sheave • Secondary sheave Oil or grease adhered to the primary and secondary sheaves -7 Remove the oil or grease using a rug soaked in lacquer thinner or solvent.

2-25

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