Yamaha Apex/Attak Service Manual 2006-2013
This manual is comprised of a base manual for the 2003-2004 Yamaha RX-1 snowmobile, plus additional supplement manuals for the updates made to that model, along with updates to make it relevant to the 2006-2013 Yamaha Apex and Attak models. Yamaha service manuals tend to utilize this build-on-earlier models method when new models are similar to the old models they are replacing. Use the links below or the bookmarks to the left to get to the manual that covers your model.
2003-2004 Yamaha RX-1 models base manual
2004 Yamaha RX Warrior models supplement manual
2005 Yamaha RX-1/RX Warrior models supplement manual
2006 Yamaha Apex/Attak models supplement manual
2007-2010 Yamaha Apex/Attak models supplement manual
2011-2013 Yamaha Apex models supplement manual
Pgs. 332
Use Genuine
YAMAHA Parts And Accessories
For a list of Genuine YAMAHA Parts Go to www.yamaha-motor.com/sport/parts/home.aspx
LIT-12618-RX-03 YAMAHA MOTOR CORPORATION, U.S.A. PRINTED IN U.S.A. BY CRESTEC USA
Service Manual
*LIT12618RX03*
APEX / SE / XTX 2011-2012
PROTECT YOUR INVESTMENT
.6875
Fo. 7
APEX SE / XTX 2011-2012 Service Manual
LIT-12618-RX-03
SERVICE MANUAL
NOTICE
HOW TO USE THIS MANUAL
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understanding of the mechanical concepts and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to this model may render it unfit and/or unsafe to use. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
Particularly important information is distinguished in this manual by the following notations:
~ The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snowmobile.
A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile. NOTE: A NOTE provides key information that can make procedures easier or clearer. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g., • Bearings Pitting/damage -+ Replace.
RX1 OH/RX1 OSH RX1 OMH/RX1 OMSH RX1 ORH/RX1 ORSH SERVICE MANUAL Š 2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, June 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. PIN.LIT-12618-02-28
EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.
ILLUSTRATED SYMBOLS (Refer to the illustration)
@
@
ICHASI ~ II,.....--p~:'C1D1
Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content.
CD General information
® Periodic inspections and adjustments @Chassis
@ Power train @ Engine
® Cooling system (l)
@
ICARSI " II~~L-EC"'---Iu-:I
(l) Carburetion @ Electrical
® Specifications
®
Illustrated symbols @ to @ are used to identify the specifications which appear.
@ Filling fluid @ Lubricant @ Tightening @ Wear limit, clearance (j3) Engine speed
® Special tool @Q,V,A
@
@
1
@
1
@
@
~ @
1m!
1
~
~
Illustrated symbols@ to@ in the exploded diagram indicate grade of lubricant and location of lubrication point.
~
~ @
~
@ @ @ @ @ @ @ @ @
Apply locking agent (LOCTITE®) Apply Yamabond No.S® 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 Use new one
INDEX GENERAL INFORMATION
~ GEN INFO
PERIODIC INSPECTIONS AND ADJUSTMENTS CHASSIS POWER TRAIN
CHAS
crD POWR TR
ENGINE COOLING SYSTEM CARBURETION ELECTRICAL
CARB
ELEC
g--
SPECIFICATIONS
SPEC
~
CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY ALL REPLACEMENT PARTS GASKETS, OIL SEALS, AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS LOCTITE® SPECIAL TOOLS FOR TUNE UP FOR ENGINE SERVICE FOR POWER TRAIN SERViCE FOR CARBURETION SERVICE FOR ELECTRICAL SERVICE
1-1 1-1 1-1 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-3 1-4 1-4 1-5 1-7 1-8 1-8
CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION
2-1
PERIODIC MAINTENANCE TABLE ..... 2-1 ENGINE SPARK PLUGS FUEL LINE INSPECTION COOLING SYSTEM VALVE CLEARANCE ADJUSTMENT CARBURETOR SYNCHRONIZATION ENGINE IDLE SPEED ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK COMPRESSION PRESSURE MEASUREMENT
2-3 2-3 2-4 2-4 2-9 2-14 2-16 2-17 2-18 2-18
ENGINE OIL LEVEL INSPECTION. . . . . . . . . . . . . . . . . . .. ENGINE OIL REPLACEMENT ..... CRANKCASE BREATHER HOSE INSPECTION. . . . . . . . . . . . . . . . . . .. CABURETOR JOINTS INSPECTION. . . . . . . . . . . . . . . . . . .. EXHAUST SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . ..
2-20 2-22 2-24 2-24 2-25
POWER TRAIN . . . . . . . . . . . . . . . . . . . .. SHEAVE OFFSET ADJUSTMENT DRIVE V-BELT ENGAGEMENT SPEED CHECK. .. PARKING BRAKE ADJUSTMENT.. BRAKE LEVER ADJUSTMENT . . .. BRAKE FLUID LEVEL INSPECTION BRAKE PAD INSPECTION . . . . . . .. BRAKE HOSE INSPECTION AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) . . . . . . . . . . . . . . .. DRIVE CHAIN TRACK TENSION ADJUSTMENT.. SLIDE RUNNER INSPECTION .... MAXIMIZING DRIVE TRACK LIFE .
2-26
CHASSIS SKI/SKI RUNNER STEERING SYSTEM . . . . . . . . . . . .. LUBRICATION
2-39 2-39 2-40 2-41
ELECTRICAL HEADLIGHT BEAM ADJUSTMENT BATTERY INSPECTION FUSE INSPECTION. . . . . . . . . . . . .. SPEEDOMETER UNIT INSPECTION
2-43
TUNING CARBURETOR TUNING CLUTCH . . . . . . . . . . . . . . . . . . . . . . .. GEAR SELECTION HIGH ALTITUDE TUNING FRONT SUSPENSION REAR SUSPENSION. . . . . . . . . . . ..
2-52 2-52 2-59 2-61 2-67 2-68 2-69
2-26 2-27 2-29 2-30 2-30 2-31 2-32 2-32 2-32 2-34 2-36 2-37 2-38
2-43 2-44 2-50 2-51
CHAPTER 3. CHASSIS STEERING INSPECTION INSTALLATION SKI
3-1 3-7 3-8
INSPECTION INSTALLATION
3-11 3-12 3-12
FRONT SUSPENSION HANDLING NOTES INSPECTION INSTALLATION
3-13 3-15 3-15 3-16
SLIDE RAIL SUSPENSION RX10, RX10S, RX10R, RX10RS RX10M, RX10MS INSPECTION. . . . . . . . . . . . . . . . . . .. ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . ..
4-32 4-33 4-33 4-35 4-35 4-35 4-36 4-36 4-41 4-46 4-47 4-47
FRONT AXLE AND TRACK . . . . . . . . .. 4-49 INSPECTION. . . . . . . . . . . . . . . . . . .. 4-50 INSTALLATION . . . . . . . . . . . . . . . . .. 4-50
CHAPTER 4. POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION
BRAKE CALIPER INSPECTION AND REPAIR BRAKE CALIPER ASSEMBLY. . . .. BRAKE CALIPER INSTALLATION . INSPECTION. . . . . . . . . . . . . . . . . . .. BRAKE MASTER CYLINDER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . ..
4-1 4-3 4-3 4-5 4-7 4-9
SECONDARY SHEAVE DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION
4-10 4-12 4-12 4-13 4-15
DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL INSPECTION INSTALLATION WITH REVERSE MODEL . . . . . . . .. INSPECTION. . . . . . . . . . . . . . . . . . .. INSTALLATION . . . . . . . . . . . . . . . . ..
4-16 4-16 4-17 4-19 4-20 4-22 4-23
SECONDARYSHAFT . . . . . . . . . . . . . . .. 4-25 INSPECTION. . . . . . . . . . . . . . . . . . .. 4-26 SECONDARYSHAFT AND DRIVE CHAIN HOUSING INSTALLATION. 4-27 BRAKE 4-28 BRAKE PAD REPLACEMENT . . . .. 4-29 BRAKE CALIPER DISASSEMBLY .. 4-32
CHAPTER 5. ENGINE SEAT AND FUEL TANK
5-1
EXHAUST PIPE AND MUFFLER INSTALLATION
5-2 5-3
ENGINE ASSEMBLy INSPECTION INSTALLATION
5-4 5-5 5-5
CAMSHAFTS REMOVAL INSPECTION INSTALLATION
5-6 5-9 5-11 5-14
CYLINDER HEAD REMOVAL INSPECTION INSTALLATION . . . . . . . . . . . . . . . . ..
5-17 5-18 5-19 5-20
VALVES AND VALVE SPRINGS REMOVAL INSPECTION. . . . . . . . . . . . . . . . . . .. INSTALLATION . . . . . . . . . . . . . . . . ..
5-21 5-23 5-24 5-29
A.C. MAGNETO AND STARTER CLUTCH 5-31 REMOVAL 5-33 INSTALLATION .. . . . . . . . . . . . . . . .. 5-35 OIL PAN AND OIL PUMP REMOVAL INSPECTION. . . . . . . . . . . . . . . . . . .. INSTALLATION .. . . . . . . . . . . . . . . ..
5-37 5-39 5-40 5-41
CRANKCASE REMOVAL INSPECTION INSTALLATION .. . . . . . . . . . . . . . . ..
5-42 5-45 5-47 5-58
CHAPTER 6. COOLING SYSTEM HEAT EXCHANGER INSPECTION INSTALLATION
6-1 6-3 6-4
THERMOSTAT INSPECTOIN INSTALLATION
6-5 6-6 6-7
WATER PUMP DISASSEMBLY INSPECTION ASSEMBLY
6-8 6-9 6-10 6-10
CHAPTER 7. CARBURETION CARBURETORS INSPECTION ASSEMBLY INSTALLATION FUEL LEBEL ADJUSTMENT THROTTLE POSITION SENSOR (T.P.S.) INSPECTION AND ADJUSTMENT
7-1 7-5 7-7 7-8 7-9
7-10
FUEL PUMP INSPECTION INSTALLATION
7-12 7-12 7-12
CHAPTER 8. ELECTRICAL SWITCH INSPECTION 8-1 SWITCH INSPECTION 8-1 INSPECTING A SWITCH SHOWN IN THE MANUAL 8-1 IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING A.C. MAGNETO SPARK PLUG IGNITION SPARK GAP IGNITION COIL THROTTLE OVERRIDE SYSTEM (T.O.R.S.) HANDLEBAR SWITCH (RIGHT) CARBURETOR SWiTCH MAIN SWiTCH MAIN RELAy
8-2 8-2 8-4 8-5 8-5 8-6 8-6 8-7 8-8 8-8 8-9 8-9
ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING MAIN SWITCH STARTER MOTOR
8-10 8-10 8-11 8-12 8-13
CHARGING SySTEM CIRCUIT DIAGRAM TROUBLESHOOTING BATTERy STATOR COIL
8-16 8-16 8-17 8-18 8-18
LIGHTING SYSTEM . . . . . . . . . . . . . . . .. CIRCUIT DIAGRAM TROUBLESHOOTING BULB(S) HEADLIGHT BEAM SWITCH . . . . .. HEADLIGHT RELAY
8-19 8-19 8-21 8-23 8-23 8-24
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . .. CIRCUIT DIAGRAM TROUBLESHOOTING. . . . . . . . . . .. BRAKE LIGHT SWITCH GEAR POSITION SWITCH (RX10R, RX10RS) BACK BUZZER (RX10R, RX10RS) WATER TEMPERATURE SENSOR ENGINE OIL LEVEL SWITCH FUEL SENDER. . . . . . . . . . . . . . . . .. SPEED SENSOR
8-25 8-25 8-27 8-33 8-33 8-33 8-34 8-35 8-35 8-36
GRIP WARMER SYSTEM. . . . . . . . . . .. CIRCUIT DIAGRAM TROUBLESHOOTING. . . . . . . . . . .. GRIP AND THUMB WARMER COIL THUMB WARMER SWITCH. . . . . .. GRIP WARMER SWITCH
8-37 8-37 8-39
CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING. . . . . . . . . . .. CARBURETOR HEATER RELAY .. CARBURETOR HEATER
8-42 8-42 8-44 8-45 8-45
SELF-DIAGNOSIS FUEL METER, FUEL LEVEL WARNING INDICATOR AND THE WARNING LIIGHT COOLANT TEMPERATURE WARNING LIGHT AND THE WARNING LIGHT SELF-DIAGNOSIS WARNING INDICATOR AND THE WARNING LIGHT
8-46
8-40 8-40 8-41
8-46
8-47
8-47
CHAPTER 9. SPECIFICATIONS GENERAL SPECiFiCATIONS
9-1
MAINTENANCE SPECIFICATIONS ENGINE POWER TRAIN CHASSIS ELECTRICAL HIGH ALTITUDE SETTINGS
9-4 9-4 9-9 9-13 9-14 9-16
TIGHTENING TORQUE ENGINE POWER TRAIN CHASSIS
9-17 9-17 9-19 9-21
GENERAL TORQUE SPECIFICATIONS
9-22
DEFINITION OF UNITS . . . . . . . . . . . . .. 9-22 CABLE ROUTING
9-23
MACHINE IDENTIFICATION
II~~~ I~I
GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number CD is located on the right-hand side of the frame Oust below the front of the seat). ENGINE SERIAL NUMBER The engine serial number CD is located on the left-hand side of the crankcase. NOTE: - - - - - - - - - - - - - - - - - - Designs and specifications are subject to change without notice.
1-1
IMPORTANT INFORMATION
II~~~ I~I
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. SCH1030
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 parts that have been "mated" through normal wear. Mated parts must be reused or replaced as an assembly.
4. During disassembly of the machine, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help ensure that all parts are reinstalled correctly.
5. Keep all parts away from any source of fire.
6. Be sure to keep to the tightening torque specifications. When tightening bolts, nuts, and screws, start with those that have larger diameters, and proceed from the inside to the outside in a crisscross pattern.
ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments.
1-2
U
IMPORTANT INFORMATION
II~~~ I~I
GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surlaces, 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 All lock washers/plates CD and cotter pins must be replaced if 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.
BEARINGS AND OIL SEALS Install the bearings CD and oil seals ® with their manufacturer's marks or numbers facing outwards. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil the bearings liberally when installing.
Do not use compressed air to spin the bearings dry. This causes damage to the surface of the bearings.
SCH1120
CIRCLIPS All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing a circlip CD, make sure that the sharp edged corner ® is positioned opposite to the thrust ® it receives. See the sectionalview.
@
Shaft
LOCTITE ® After installing fasteners that have LOCTITE ® applied, wait 24 hours before using the machine. This will give the LOCTITE ® time to dry properly.
1-3
SPECIAL TOOLS
II~~~ I~I
SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques.
NOTE: - - - - - - - - - - - - - - - - - - - - Be sure to use the correct part number when ordering the tool, since the part number may differ according to country.
FOR TUNE UP • Sheave gauge PIN: YS-42421-1 (15 mm offset) (for U.S.A./Canada) This gauge is used to measure the sheave distance and for offset adjustment. ·Dial gauge PIN: YU-03097 (for U.S.A./Canada) 90890-03097 (for Europe) This gauge is used for run out measurement.
• Fuel level gauge PIN: YM-01312-A (for U.S.A./Canada) 90890-01312 (for Europe) This gauge is used to measure the fuel level in the float chamber.
• Carburetor angle driver: PIN: 90890-03173 (for Europe) This tool is used to adjust the pilot screw when synchronizing the caburetor.
• Angle gauge: Use goods on the market. This tool is used to tightening the torque.
1-4
SPECIAL TOOLS FOR ENGINE SERVICE • Piston pin puller PIN: YU-01304 (for U.S.A./Canada) 90890-01304 (for Europe) This tool is used to remove the piston pin. • Rotor holding puller, attachment PIN: YU-33270 (for U.S.A./Canada) 90890-01362 (for Europe) PIN: YM-33282 90890-04089 This tool is used to remove the magneto rotor. • Cooling system tester, adapter PIN: YU-24460-01 (for U.S.A./Canada) 90890-01325 (for Europe) PIN: YU-33984 (for U.S.A./Canada) 90890-01352 (for Europe) This tester is used for checking the cooling system. • Oil filter wrench PIN: YU-38411 (for U.S.A./Canada) 90890-01426 (for Europe) This tool is needed to loosen or tighten the oil filter cartridge.
• Carburetor synchronizer PIN: YU-8030 (for U.S.A./Canada) 90890-03094 (for Europe) This guide is used to synchronize the carburetors.
• Compression gauge set PIN: YU-33223 (compression gage) (for U.S.A./Canada) 90890-03081 (for Europe) PIN: YU-33223-3 (adapter) (for U.S.A./Canada) (for Europe) 90890-04136 (for Europe) These tools are used to measure engine compression. • Valve spring compressor set, quick release, attachment PIN: YM-04019 (valve spring compresser) (for U.S.A./Canada) 90890-04019 (for Europe) PIN: YM-41 08, YM-4114 (attachment) (for U.S.A./Canada) 90890-04108, 90890-04114 (for Europe) These tools are used-to remove or install the valve assemblies. • 40 and 50 mm bearing driver. Water pump seal installer. PIN: YM-4058 (40 and 50 mm bearing driver) (for U.S.A./Canada) 90890-04058 (for Europe) PIN: YM-33221 (water pump seal installer) (for U.S.A./Canada) 90890-04078 (for Europe) These tools are used to install the water pump seal. 1-5
SPECIAL TOOLS • Valve guide remover (04, 04.5) PIN: YM-04111 (04) (for U.S.A./Canada) 90890-04111 (for Europe) PIN: YM-4116 (04.5) (for U.S.A./Canada) 90890-04116 (for Europe) These tools are used to remove or install the valve guides. • Valve guide installer (04, 04.5) PIN: YM-04112 (04) (for U.S.A./Canada) 90890-04112 (for Europe) PIN: YM-4117 (04.5) (for U.S.A./Canada) 90890-04117 (for Europe) These tools are used to install the valve guides. • Valve guide reamer (04, 04.5) PIN: YM-04113 (04) (for U.S.A./Canada) 90890-04113 (for Europe) PIN: YM-4118 (04.5) (for U.S.A./Canada) 90890-04118 (for Europe) These tools are used to rebore the new valve guides. • Valve lapper PIN: 90890-04101 (for Europe) This tools is needed to remove and install the valve lifter.
• Piston ring compresser PIN: YM-8037 (for U.S.A./Canada) 90890-05158 (for Europe) This tool is used to compress the piston rings when installing the piston into the cylinder. • Dynamic spark tester PIN: YM-34487 (for U.S.A./Canada) 90890-06754 (for Europe) This tool is used to check the ignition system component.
• Quick gasket ® PIN: ACC-11 00-15-01 (for U.S.A./Canada) 90890-85505 (for Europe) This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces.)
1-6
SPECIAL TOOLS FOR POWER TRAIN SERVICE • Primary sheave holder PIN: YS-01880 (for U.S.A./Canada) 90890-01701 (for Europe) This tool is used to hold the primary sheave. • Primary sheave puller (18 mm) PIN: YS-01881-1 CD, YS-01882-1 ® (for U.S.A./Canada) 90890-01898 (for Europe) This tool is used for removing the primary sheave.
• Clutch spider separator PIN: YS-28890-B (for U.S.A./Canada) 90890-01711 (for Europe) This tool is used when disassembling and assembling the primary sheave. • Clutch separator adapter PIN: YS-34480 (for U.S.A./Canada) 90890-01740 (for Europe) This tool is used when disassembling and assembling the primary sheave. • YXR clutch bushing jig kit PIN: YS-39752 (for U.S.A./Canada) This tool is used for removal and installation of primary clutch weight and roller bushings.
• Clutch bushing press PIN: YS-42424 (for U.S.A./Canada) This tool is used for removing and installing the post bushings (primary sheave cap bush, sliding sheave bush and torque cam bush).
• Track clip installer PIN: YS-91045-A (for U.S.A./Canada) 90890-01721 (for Europe) This tool is used for installing the track clip.
1-7
SPECIAL TOOLS FOR CARBURETION SERVICE - Mity vac PIN: YB-35956 (for U.S.A./Canada) 90890-06756 (for Europe) This tool is used to check the fuel pump.
FOR ELECTRICAL SERVICE - Pocket tester PIN: YU-03112 (for U.S.A./Canada) 90890-03112 (for Europe) This instrument is necessary for checking the electrical components. - Electro tester PIN: YU-33260-A (for U.S.A./Canada) 90890-03021 (for Europe) This instrument is invaluable for checking the electrical system.
- Speedometer unit test coupler. PIN: YS-45686 (for U.S.A./Canada) 8EK-82507-09 (For Europe) This tool is used for checking the speedometer unit.
-Inductive self-powered tachometer PIN: YU-8036-B (for U.S.A./Canada) 90793-80009 (for Europe) This tool is used to check engine speed.
1-8
IANDSJP I
INTRODUCTION/PERIODIC MAINTENANCE TABLE
-------------------------------
I
(O~ ~
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE
Item
Remarks
Spark plugs
Check condition. Adjust gap and clean. Replace if necessary.
Valves
Check valve clearance. Adjust clearance when engine is cold.
Engine oil
Engine oil filter cartridge
Check oil level. Replace.
• •
Check fuel level.
Fuel filter Fuel line
Check fuel hose for cracks or damage. Replace if necessary. Check coolant level. Air bleed the cooling system if necessary. Check the throttle lever operation.
• •
• •
•
Every 20,000 km (12,000 mi)
• • •
Whenever operating condition (elevation/temperature) is changed.
Adjust the jets.
• • •
Engine stop switch
Check operation. Repai r if necessary.
Throttle override system (T.O.R.S.)
Check operation. Repai r if necessary.
Th rottle lever
Check operation. Repai r if necessary.
Exhaust system
Check for leakage. Tighten or replace gasket if necessary.
Drive guard
Check for cracks, bends or damage. Replace if necessary.
V-belt
Check for wear and damage. Replace if necessary.
Drive track and idler wheels
Check deflection, and for wear and damage. Adjust/ replace if necessary.
Slide runners
Seasonally or 3,200 km (2,000 mi) (160 hr)
Every 40,000 km (25,000 mi)
Replace.
Check condition. Replace if necessary.
Carburetor
Every
•
Fuel
Engine coolant
Preoperation check (Daily)
Initial 1 month or 800 km (500 mi) (40 hr)
Check for wear and damage. Replace if necessary.
2-1
• • • •
•
•
I
PERIODIC MAINTENANCE TABLE
Item
Remarks
Check operation and fluid leakage. Brake and parking brake
Adjust free play and/or replace pads if necessary. Repair brake fluid.
Disc brake installation
Drive chain oil Drive chain Skis and ski runners
Steering system Lights
Preoperation check (Daily)
ADJ Initial 1 month or 800 km (500 mi) (40 hr)
•
Check for slight free play. Lubricate shaft with specified grease as required.
Every 1,600 km (1,000 mi)
•
Check oil level. Replace. Check deflection. Adjust if necessary.
Every Seasonally or 3,200 km (2,000 mi) (160 hr)
•
See note.
•
Initial at 500 km (300 mi) and every 800 km (500 mi) thereafter.
Check for wear and damage. Repai r if necessary. Check operation. Adjust toe-out if necessary. Check operation. Replace bulbs if necessary.
• • •
Check engagement and shift speed.
• • •
Whenever operating elevation is changed.
Adjust if necessary. Primary and secondary clutches
INSP
Inspect sheaves for wear/damage. Inspect weights/ rollers and bushings for wear-for primary. Inspect ramp shoes/bushings for wear-for secondary. Replace if necessary. Lubricate with specified grease.
Steering column bearing
Lubricate with specified grease.
Ski and front suspension
Lubricate with specified grease.
Suspension component
Lubricate with specified grease.
Parking brake cable end and lever end/throttle cable end
Lubricate with specified grease. Check cable damage. Replace if necessary.
Shroud latches
Make sure that the shroud latches and hooked.
Fittings and fasteners
Check tightness. Replace if necessary.
Tool kit and recommended equipment
Check for proper placement.
• • •
• • • • • • •
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required. 2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3. Replace the brake hoses every four years, or if cracked or damaged.
2-2
SPARK PLUGS
INSP ADJ
ENGINE SPARK PLUGS 1. Remove: • Spark plug caps • Spark plugs 2. Inspect: • Electrodes CD Damage/wear -+ Replace the spark plug. • Insulator color ® 3. Measure: • Spark plug gap ® Out of specification -+ Regap. Use a wire thickness gauge.
SCH2010
Spark plug gap: 0.7 -- 0.8 mm (0.028 -- 0.031 in)
If necessary, clean the spark plugs with a spark plug cleaner. Standard spark plug: CR9E (NGK) Before installing a spark plug, clean the gasket surface and spark plug surface.
SCH2020
4. Install: • Spark plugs ,
~~
Spark plug: 13 Nm (1.3 mekg, 9.4 ftelb)
NOTE: - - - - - - - - - - - Finger-tighten ® the spark plug before torquing @ it to specification.
SCH2030
2-3
FUEL LINE INSPECTION/COOLING SYSTEM
INSP ADJ
FUEL LINE INSPECTION 1. Remove: -Intake silencer Refer to "CARBURETORS" in CHAPTER 7. 2. Inspect: - Fuel hoses CD - Fuel delivery hoses ® Cracks/damage -+ Replace. 3. Install: -Intake silencer Refer to "CARBURETORS" in CHAPTER 7.
COOLING SYSTEM Coolant replacement NOTE: - - - - - - - - - - - - - The coolant should be changed at least every season. 1. Place the machine on a level surface. 2. Remove: -Intake silencer Refer to "CARBURETORS" in CHAPTER 7. 3. Remove: - Coolant filler cap CD
~ ---------Do not remove the coolant filler cap CD when the engine is hot. Pressurized scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, place a thick rag or a towel over the coolant filler cap. Slowly turn the cap counterclockwise until it stop. This allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise to remove it.
2-4
COOLING SYSTEM
IANOSJP I (O~ ~
I
---------------------------4. Place an open container under the coolant I
hose. 5. Disconnect: - Coolant hose CD 6. Drain the coolant. NOTE: - - - - - - - - - - - - Lift up the tail of the machine to drain the coolant.
7. Remove: - Rear cover CD
8. Disconnect: - Coolant hoses CD 9. Drain the coolant. NOTE: - - - - - - - - - - - - - Lift up the front of the machine to drain the coolant completely.
m!mmmmI ---------Coolant is poisonous. It is harmful or fatal if swallowed. -If coolant is swallowed, induce vomiting immediately and get immediate medical attention. -If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. -If coolant splashes on your skin or clothes, quickly wash it away with soap and water.
10. Connect: - Coolant hoses 11. Install: - Rear cover CD
Bolt (rear cover): 3 Nm (0.3 m-kg, 2.2 ft-Ib)
2-5
COOLING SYSTEM
INSP ADJ
12. Install: • Coolant hose CD
13. Install: • Intake silencer Refer to "CARBURETORS" in CHAPTER 7. 14. Fill: • Cooling system
Recommended coolant: High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors Coolant mixing ratio (coolant:water) 3:2 (600/0:40%) Total amount: 4.7 L (4.14 Imp qt, 4.97 US qt)
• Hard water or salt water is harmful to engine parts. If soft water is not available, use boiled or distilled water. • Do not use water containing impurities or oil. 15. Bleed the air from the cooling system. 16. Inspect: • Cooling system Decrease of pressure (leaks) -+ Repair as required.
2-6
COOLING SYSTEM
--------------------------Inspection steps:
I
IANOSJP I (O~ ~
- Attach the cooling system testerCD and adapter ® to the coolant filler ®. Cooling system tester: 90890-01325, YU-24460-01 Adapter: 90890-01352, YU-24460-01 -Apply 100 kPa (1.0 kg/cm 2 , 14 psi). - Measure the pressure with the gauge. Air bleeding 1. Remove: - Rear cover CD 2. Bleed air from the cooling system.
Air bleeding steps: - Lift up the tail of the machine. - Remove the bleed bolt CD on the heat exchanger. - While slowly adding coolant to the coolant filler, drain the coolant until no more air bubbles appear. - Tighten the bleed bolt CD. ,
~~
Bleed bolt: 13 Nm (1.3 m-kg, 9.4 ft-Ib)
- Add coolant to the coolant cold level ®. -Install the coolant filler cap. Apply and lock the parking brake. Start the engine and run it at approximately 2,500 ~ 3,000 r/min until the coolant circulates (approximately 3 ~ 5 minutes). The rear heat exchanger will be warm to the touch.
2-7
I
COOLING SYSTEM
INSP ADJ
ffmmIIm1 ---------To avoid severe injury or death: • Make sure the machine is securely supported with a suitable stand. • Do not exceed 3,000 r/min. Drive line damage and excessive V-belt wear could occur, or the machine could unexpectedly move forward if the clutch engages. • Operate the engine only in a well-ventilated area. • Remove the coolant filler cap and bleed the cooling system again, as described above. No air bubbles -+ OK. • Add coolant to the specified level. • Pour coolant into the coolant reservoir CD until the coolant level reaches the "COLD LEVEL" level mark ®. 3. Install: • Rear cover
2-8
VALVE CLEARANCE ADJUSTMENT
IANOSJP I (O~ ~
I
---------------------------VALVE CLEARANCE ADJUSTMENT I
NOTE: - - - - - - - - - - - - - • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Drain: • Coolant 2. Remove: • Cylinder head cover Refer to "CYLINDER HEAD" in CHAPTER 5. • Timing plug 3. Measure: • Valve clearance Out of specification --+ Adjust. Valve clearance (cold) Intake valve 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) Exhaust valve 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in)
Checking steps: • Turn the crankshaft clockwise. • When piston #4 is at TDC on the compression stroke, align the TDC mark ® on the A.C. magneto rotor with the mark @ on the A.C. magneto cover. • Turn the crankshaft clockwise. NOTE: - - - - - - - - - - - - - TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. • Measure the valve clearance with a thickness gauge CD.
2-9
VALVE CLEARANCE ADJUSTMENT
IANOSJP I (O~ ~
I
---------------------------NOTE: - - - - - - - - - - - - - I
• If the valve clearance is incorrect, record the measured reading. • Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #1 -+ #2 -+ #4 -+ #3
[A] Front For each cylinder, starting with cylinder #1 at TDC, turn the crankshaft clockwise as specified in the following table.
[BJ Degrees that the crankshaft is turned clockwise ~ Cylinder
[Q] Combustion cycle #1
#4
#3
> 1--1-----+-1-11-----+-1-----II
ffi] " " , - - I_
#2
0
0
180
0
360
0
540
0
720
0
#2 Cylinder
180 0
#4 Cylinder
360 0
#3 Cylinder
540 0
_
#1
~
#2 #3 #4
4. Remove: • Intake camshaft • Exhaust camshaft NOTE: - - - - - - - - - - - - - • Refer to "CAMSHAFTS" in CHAPTER 5. • When removing the timing chain and camshafts, fasten a wire to the timing chain to retrieve it if it falls into the crankcase.
5. Adjust: • Valve clearance Adjustment steps: • Remove the valve lifter CD and the valve pad ® with a valve lapper ®.
11171102
2-10
VALVE CLEARANCE ADJUSTMENT
IANOSJP I (O~ ~
I
---------------------------NOTE: - - - - - - - - - - - - - I
- Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. - Make a note of the position of each valve lifter CD and valve pad ÂŽ so that they can be installed in the correct place. 11172202
-
'"'""----------------......
Select the proper valve pad from the following table. Valve pad thickness range
Available valve pads
1.20 -Nos. 2.40 mm 120 -- 240 (0.047 -0.095 in)
25 thicknesses in 0.05 mm (0.0020 in) increments
NOTE: - - - - - - - - - - - - - - The thickness ÂŽ of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. - Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original.
a
-Round off the original valve pad number according to the following table. 11171001
Last digit
Rounded value
o or 2
0
5
5
8
10
EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 -Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: - - - - - - - - - - - The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect.
2-11
INSP
VALVE CLLEARANCE ADJUSTMENT
ADJ
VALVE PAD SELECTION TABLE INTAKE Measured clearance ~
0.00 0.03 0.08 0.11 exa 0.21
~ ~ ~
~ ~
120 125 130 135 0.02 120 0.07 120 125 0.10 120 125 130 0.20 0.22 125 130 135 140
140 125 130 135
145 130 135 140
155 140 145 150
145 150
160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.32 0.37 0.42 0.47 0.52 0.57 0.62 0.67 0.72 0.77 0.82 0.87 0.92 0.97 1.02 1.07 1.12 1.17 1.22 1.27 1.32 1.37
155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
--+
0.28 0.33 0.38 0.43 0.48 0.53 0.58 0.63 0.68 0.73 0.78 0.83 0.88 0.93 0.98 1.03 1.08 1.13 1.18 1.23 1.28 1.33
~ ~ ~ ~
~ ~
~ ~ ~
~ ~ ~
~ ~ ~
~ ~
~ ~ ~
~ ~
135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
120 125 130 135 140 145 120 120 125 120 125 130 120 125 130 135 120 125 130 135 140
150 125 130 135 140 145
INSTALLED PAD NUMBER 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 Specification 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 175 180 185 190 195 200 205 210 215 220 225 230 235 240 180 185 190 195 200 205 210 215 220 225 230 235 240 185 190 195 200 205 210 215 220 225 230 235 240 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 235 240 EXAMPLE: 240 VALVE CLEARANCE: 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) Installed is 150 Measured clearance is 0.25 mm (0.0098 in) Replace 150 pad with 160 pad
EXHAUST Measured clearance ~
exa --+
0.00 0.03 0.08 0.13 0.18 0.21 0.26 0.36 0.41 0.46 0.51 0.56 0.61 0.66 0.71 0.76 0.81 0.86 0.91 0.96 1.01 1.06 1.11 1.16 1.21 1.26 1.31 1.36 1.41
~ ~
~ ~ ~
~
~ ~ ~
~ ~ ~
~ ~ ~
~ ~ ~
~ ~
~ ~ ~
~ ~ ~ ~ ~
155 130 135 140 145 150
INSTALLED PAD NUMBER 160 165 170 180 185 190 135 140 145 155 160 165 140 145 150 160 165 170 145 150 155 165 170 175 150 155 160 170 175 180 155 160 165 175 180 185
0.02 0.07 0.12 0.17 0.20 ,... 0.25 0.30 125 130 135 140 145 150 155 160 165 170 175 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45
135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
175 180 185 190 195 200 205 210 215 220 225 230 235 240
180 185 190 195 200 205 210 215 220 225 230 235 240
185 190 195 200 205 210 215 220 225 230 235 240
....
190 195 200 205 210 215 220 225 230 235 240
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
195 170 175 180 185 190
200 175 180 185 190 195
205 180 185 190 195 200
210 185 190 195 200 205
215 190 195 200 205 210
220 195 200 205 210 215
225 200 205 210 215 220
230 205 210 215 220 225
235 210 215 220 225 230
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240 230 235 240 235 240 240
EXAMPLE: VALVE CLEARANCE: 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Installed is 175 Measured clearance is 0.35 mm (0.0138 in) Replace 175 pad with 185 pad
2-12
240 215 220 225 230 235
VALVE CLEARANCE ADJUSTMENT
IANOSJP I (O~ ~
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----------------------------Install the new valve pad CD and the valve lifter I
ÂŽ.
NOTE: - - - - - - - - - - - - - - Apply molybdenum disulfide oil to the valve pad and the valve lifter. - The valve lifter must turn smoothly when rotated by hand. -Install the valve lifter and the valve pad in the correct place. -Install the exhaust and intake camshafts, timing chain and camshaft caps. Camshaft cap bolt 10 Nm (1.0 m-kg, 7.2 ft-Ib) NOTE: - - - - - - - - - - - - - - Refer to "CAMSHAFTS" in CHAPTER 4. - Lubricate the camshaft caps, camshaft lobes and camshaft journals. - First, install the exhaust camshaft. - Align the camshaft marks with the camshaft cap marks. - Rotate the crankshaft clockwise several turns to seat the parts. - Measure the valve clearance again. -If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 6. Install: - Cylinder head cover Refer to "CAMSHAFTS" in CHAPTER 5. 7. Install: - All removed parts NOTE: - - - - - - - - - - - - - For installation, reverse the removal procedure. Note the following points.
2-13
CARBURETOR SYNCHRONIZATION
IANOSJP I (O~ ~
I
--------------------------CARBURETOR SYNCHRONIZATION I
NOTE: - - - - - - - - - - - - Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Remove: • Vacuum cap 2. Install: • Carburetor synchronizer CD • Engine tachometer (near the spark plug) Carburetor synchronizer 90890-03094, YU-8030 Engine tachometer 90793-80009, YU-8036-B 3. Start the engine and let it warm up for several minutes. 4. Inspect: • Engine idle speed Out of specification -+ Adjust. Refer to "ENGINE IDLE SPEED ADJUSTMENT". Engine idle speed: 1,350 ± 100 r/min (1,250 --- 1,450 r/min) 5. Adjust: • Carburetor synchronization
Adjustment steps: • Synchronize carburetor #2 to carburetor #3 by turning the synchronizing screw CD in either direction until both gauges read the same.
2-14
CARBURETOR SYNCHRONIZATION
IANOSJP I (O~ ~
I
---------------------------NOTE: - - - - - - - - - - - - - I
After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. • Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw ® in either direction until both gauges read the same. • Synchronize carburetor #2 to carburetor #1 by turning the synchronizing screw ® in either direction until both gauges read the same. Vacuum pressure at engine idling speed 35 kPa (0.35 kglcm 2 , 4.98 psi) NOTE: - - - - - - - - - - - - - The difference in vacuum pressure between two carburetors should not exceed 1.33 kPa (0.01 kg/cm 2 , 0.19 psi). 6. Measure: • Engine idle speed Out of specification --+ Adjust. 7. Adjust: • Throttle cable free play Refer to "THROTTLE CABLE FREE PLAY ADJUSTMENT".
2-15
ENGINE IDLE SPEED ADJUSTMENT
IANOSJP I (O~ ~
I
--------------------------ENGINE IDLE SPEED ADJUSTMENT I
NOTE: - - - - - - - - - - - - - Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Install: • Engine tachometer (near the spark plug) . '.
Engine tachometer 90793-80009, YU-8036-B
3. Measure: • Engine idle speed Out of specification
-+
Adjust.
Engine idle speed: 1,350 ± 100 r/min (1,250 -- 1,450 r/min) 4. Adjust: • Engine idle speed
• Turn the throttle stop screweD in or out until the specified engine idle speed is obtained. Turning in -+ Idle speed is increased. Turning out -+ Idle speed is decreased. NOTE: - - - - - - - - - - - - - After adjusting the engine idle speed, the throttle cable free play should be adjusted.
2-16
THROTTLE CABLE FREE PLAY ADJUSTMENT
IANOSJP I (O~ ~
I
--------------------------THROTTLE CABLE FREE PLAY I
ADJUSTMENT NOTE: - - - - - - - - - - - - • Before adjusting the throttle cable free play, the engine idle speed should be adjusted. • Adjust the throttle cable free play while the cable is in the cable guide.
1. Measure: • Throttle cable free play ® Out of specification --+ Adjust. Throttle cable free play: 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) 2. Adjust: • Throttle cable free play
Adjustment steps: .LoosenthelocknutGD. • Turn the adjusting nut® in or out until the specified free play is obtained. Turning in --+ Free play is increased. Turning out --+ Free play is decreased. • Tighten the locknut. NOTE: - - - - - - - - - - - After adjusting the free play, turn the handlebar to right and left, and make sure that the engine idling does not run faster.
2-17
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECKI COMPRESSION PRESSURE MEASUREMENT
II~~~ I (O~
~
I
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK
ffmmIIm1 ---------When checking T.O.R.S.: - Be sure the parking brake is applied. - Be sure the throttle lever moves smoothly. - Do not run the engine up to the clutch engagement speed. Otherwise, the machine could start moving forward unexpectedly, which could cause an accident.
1. Start the engine. 2. Hold the pivot point of the throttle lever away from the throttle switch by putting yourthumb (above) and forefinger (below) between the throttle lever pivot CD and stop switch housing@. While holding as described above, press the throttle lever @ gradually. The T.O.R.S. will operate and the engine should run between 2,800 and 3,000 r/min.
ffmmIIm1 ---------If the engine does not run between 2,800 and 3,000 r/min, stop the engine by turning the main switch to the "OFF" position and check the electrical system. COMPRESSION PRESSURE MEASUREMENT NOTE: - - - - - - - - - - - Insufficient compression pressure will result in a loss of performance. 1. Measure: - Valve clearance Out of specification --+ Adjust. Refer to "VALVE CLEARANCE ADJUSTMENT". 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Remove: -Spark plug
2-18
COMPRESSION PRESSURE MEASUREMENT
INSP ADJ
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders.
4. Install: • Compression gauge CD
Compression gauge set 90890-03081, YU-33223 Compression gauge adapter 90890-04136, YU-33223-3 5. Measure: • Compression pressure Above the maximum pressure --+ Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure --+ Squirt a few drops of oil into the affected cylinder and measure again. Refer to the following table.
Compression pressure (with oil applied into cylinder) Reading
Diagnosis
Higher than without oil
Piston ring(-s) wear or damage --+ Repair.
Same as without oil
Piston, valves, cylinder head gasket or piston possibly defective --+ Repair. Compression pressure (at sea level)
Compression pressure (at sea level): Standard: 1,450 kPa (14.5 kglcm 2 , 206 psi) at 400 r/min Minimum: 1,260 kPa (12.6 kg/cm 2 , 179 psi) at 400 r/min Maximum: 1,620 kPa (16.2 kg/cm 2 , 230 psi) at 400 r/min
2-19
COMPRESSION PRESSURE MEASUREMENTI ENGINE OIL LEVEL INSPECTION
II~~~ I (O~
~
I
Measurement steps: -Turn the main switch to "ON". - With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.
~ ---------To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: - - - - - - - - - - - - - The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm 2 , 14.2 psi) 6. Install: -Spark plug
,
~~
Spark plug: 13 Nm (1.3 mekg, 9.4 ftelb)
ENGINE OIL LEVEL INSPECTION 1. Inspect: - Engine oil level
Do not run the engine with too much or not enough oil in the oil tank. Oil could flow into the intake silencer and the engine could be damaged. Inspection steps: - Place the snowmobile on a level surface and apply the parking brake. - Start the engine, warm it up for 10 ~ 15 minutes, and then turn off. - Disconnect the oil level gauge coupler.
Disconnect the oil level gauge coupler before removing the oil level gauge. Otherwise the lead can twist and become severed. - Remove the oil level gauge, wipe it clean, insert it back into the filler hole (without screwing it in), and then remove it again to check the oil level.
2-20
ENGINE OIL LEVEL INSPECTION
IANOSJP I (O~ ~
I
---------------------------• The engine oil level should be between the I
minimum level mark ® and maximum level mark@. Below the minimum level mark -+ Add the recommended engine oil to the proper level.
rFl-J~
w
~
When adding the engine oil, be careful not to fill above the maximum level mark and minimum level mark on the oil level gauge. Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard API SE, SF, SG or higher SAE 5W-30
Do not allow foreign materials to enter the crankcase. NOTE: - - - - - - - - - - - - Before checking the engine oil level, wait a few minutes until the oil has settled.
SAE -40°
-20°
0°
20°
I
I,
I,
I,
: I I I I I I I I
..
-40°
I
I I I I I I I I
-29°
I
I
API
NOTE: - - - - - - - - - - - - - Before checking the engine oil level, wait a few minutes until the oil has settled.
40° 60° F
I, I
I I I I I
I I I I I
I I I I I I I I
-18°
_7°
4°
SAE 5W-30
• Start the engine, warm it up for several minutes, and then turn it off. • Check the engine oil level again.
I
.: I I I I I I I I
SE,SF,SG or higher
16°C
• Use only 4-stroke engine oil. ·In order to prevent starter clutch slippage, do not mix any chemical additives. Do not use oils with a diesel specification of "CD" or oils of a higher quality than specified. In addition, do not use oils labeled "ENERGY CONSERVING II" or higher.
2-21
ENGINE OIL REPLACEMENT
IANOSJP I (O~ ~
I
--------------------------ENGINE OIL REPLACEMENT I
_Q_~
Q_____!\r-\- - - _
1. Start the engine, warm up for several minutes, and then turn it off. 2. Place a containers under the engine oil drain bolt and oil tank. 3. Remove: • Bottom panel • Right side cover • Oil level gauge coupler ·Oillevel gauge/dipstick • Cylinder head cap • Oil pan drain bolt CD • Oil tank drain bolt ®
4. Drain: • Engine oil (completely from the oil pan and oil tank) 5. If the oil filter cartridge is also to be replaced, perform the following procedure.
Replacement steps: a) Remove air box b) Remove battery c) Remove battery bracket d) Then remove oil filter • Remove the oil filter cartridge CD with an oil filter wrench ®. NOTE: - - - - - - - - - - - - When remove the oil filter cartridge, turn the handlebar to the left.
Oil filter wrench: 90890-01426, YU-38411
2-22
ENGINE OIL REPLACEMENT
IANOSJP I (O~ ~
I
--------------------------- Apply a thin coat of engine oil onto the a-ring I
CD of the new oil filter cartridge.
CD
Make sure that the O-ring CD is positioned correctly in the groove of the oil filter cartridge. 11730302
-
~--------------~
Tighten the new oil filter cartridge to specification wnh an oil fi~er wrench.
'.#7
~~
Oil filter cartridge: 17 Nm (1.7 mekg, 12 ftelb)
6. Install: - Drain bolts (along with the new gaskets)
Drain bolt (oil 16 Nm (1.6 Drain bolt (oil 30 Nm (3.0
tank): m-kg, 12 ft-Ib) pan): m-kg, 22 ft-Ib)
7. Fill: -Engine oil (with the specified amount of the recomended engine oil) Add 2.0 L (1.8 Imp qt, 2.1 US qt) of the recommended engine oil to the oil tank, and then install and tighten the oil level gauge/dipstick and the cylinder head cap.
Quantity Total amount 3.8 L (3.3 Imp qt, 4.0 US qt) Periodic oil change 2.8 L (2.5 Imp qt, 3.0 US qt) With oil filter replacement 3.0 L (2.6 Imp qt, 3.2 US qt) 8. Inspect: - Engine and oil tank (for engine oil leaks) 9. Inspect: - Engine oil level Refer to "ENGINE OIL INSPECTION".
2-23
ENGINE OIL REPLACEMENT/CRANKCASE BREATHER HOSE INSPECTION/CARBURETOR JOINTS INSPECTION
INSP ADJ
10. Inspect: - Engine oil pressure Inspection steps: - Slightly loosen the oil gallery bolt CD. - Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. - Check the engine oil passages, the oil filter and the oil pump for damage or leakage. -Start the engine after solving the problem(-s) and check the engine oil pressure again. Tighten the oil gallery bolt to specification. Oil gallery bolt 10 Nm (1.0 m-kg, 7.2 ft-Ib)
CRANKCASE BREATHER HOSE INSPECTION 1. Inspect: - Crankcase breather hose CD Cranks/damage --+ Replace. Loosen connection --+ Connect properly.
Make sure that the crankcase breather hose is routed correctly.
CARBURETOR JOINTS INSPECTION 1. Remove: - Silencer assembly 2. Inspect: - Carburetor joints CD Refer to "CARBURETORS" in CHAPTER 6.
2-24
(O~
__ _ _ _ IIANOSJP I ~ I EXHAUST SYSTEM INSPECTION _ ____ EXHAUST SYSTEM INSPECTION 1. Remove: • Seat • Exhaust system • Refer to "EXHAUST PIPE AND MUFFLER" in CHAPTER 5. 2. Inspect: • Exhaust joint CD • Tightening torque
2
6
'.J7 "
Bolt (exhaust joint): 25 Nm (2.5 m-kg, 18 ft-Ib)
• Muffler® • Tightening torque
,
~~
Bolt (muffler): 16 Nm (1.6 m-kg, 12 ft-Ib)
• Exhaust pipe ® • Tightening torque
,
~~
Bolt (exhaust pipe): 25 Nm (2.5 m-kg, 18 ft-Ib)
• Muffler band @ • Tightening torque
,
~~
Bolt (muffler band): 20 Nm (2.0 m-kg, 14 ft-Ib)
• Exhaust pipe band ® • Tightening torque
'.J7
~~
Bolt (exhaust pipe band): 9 Nm (O.9 m-kg, 6.5 ft-Ib)
Cracks/damage --+ Replace. • Gaskets@ • Gaskets (J) ·Gasket@ Exhaust gas leaks--+Replace.
2-25
SHEAVE OFFSET ADJUSTMENT
--------------------------POWER TRAIN
I
IANOSJP I (O~ ~
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SHEAVE OFFSET ADJUSTMENT 1. Measure: • Sheave offset ® Use the sheave gauge. Out of specification -+ Adjust. Sheave offset: 15 ± 1.5 mm (0.59 ± 0.06 in) (13.5 ~ 16.5 mm (0.53 ~ 0.65 in»
~l_S_h_e_a_V_e_g_a_u_g_e_: ~ YS-42421-1
__
NOTE: - - - - - - - - - - - - Push the secondary sheave toward the inside of vehicle frame first and measure the sheave offset.
2. Adjust: • Sheave offset Adjustment steps: • Apply the brake to lock the secondary sheave. • Remove the bolt (Secondary sheave) CD, washer ® and secondary sheave ®. • Adjust the sheave offset by adding or removing shim(s) @. Adding shim -+ Offset is increased. Removing shim -+ Offset is decreased. Shim size Part Number
Thickness
90201-25526
2.0 mm (0.08 in)
• Install the secondary sheave, bolt (secondary sheave) and washer.
'.#7
~~
Bolt (secondary sheave): 64 Nm (6.4 m-kg, 46 ftelb)
• Recheck the sheave offset. If out of specification, repeat the above steps. NOTE: - - - - - - - - - - - - When adjusting the sheave offset, the secondary sheave free play (clearance) should be adjusted.
2-26
SHEAVE OFFSET ADJUSTMENT/DRIVE V-BELT
--------------------------3. Measure:
I
IANOSJP I (O~ ~
I
• Secondary sheave freeplay (clearance) @ Use a feeler gauge. Out of specification -+ Adjust.
Secondary sheave free play (clearance): 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) SCH2400
4. Adjust: • Secondary sheave freeplay (clearance)
Adjustment steps: • Apply the brake to lock the secondary sheave. • Remove the bolt CD and washer ®. • Adjust the secondary sheave freeplay (clearance) by adding or removing a shim(s) @. SCH2410
Shim size Part number
Thickness
90201-222FO
0.5 mm (0.02 in)
90201-225A4
1.0 mm (0.04 in)
DRIVE V-BELT
m!mmmmI ---------When installing the new V-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to -0.5 mm (-0.02 in) below the edge @. If the V-belt is not positioned correctly, the clutch engagement speed will be changed. The machine may move unexpectedly when the engine is started. Adjust the V-belt position by removing or adding a spacer CD on each adjusting bolt
®.
As the V-belt wears, adjustment may be necessary. To ensure proper clutch performance, the V-belt position should be adjusted by adding a spacer on each adjusting bolt when the V-belt position reaches 1.5 mm (0.06 in) below the edge.
SCH2420
2-27
DRIVE V-BELT
---------------------------
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IANOSJP I (O~ ~
I
New belt width: 34.5 mm (1.36 in) Belt wear limit width: 32.5 mm (1.28 in) 1. Measure: - V-belt position ÂŽ
NOTE: - - - - - - - - - - - - Install the new V-belt onto the secondary sheave only. Do not force the V-belt between the sheaves; the sliding and fixed sheaves must touch each other. Standard V-belt height: -0.5 ~ 1.5 mm (-0.02 ~ 0.06 in)
SCH2430
2. Adjust the position of the V-belt by removing or adding a spacerG) on each adjusting bolt
(2). V-belt position
SCH2440
Adjustment
More than 1.5 mm (0.06 in) above the edge
Remove a spacer
From 1.5 mm (0.06 in) above the edge to -0.5 mm (-0.02 in) below the edge
Not necessary (It is correct.)
More than -0.5 mm (-0.02 in) below the edge
Add spacer
Part number
Thickness
90201-061 H1
0.5 mm (0.02 in)
90201-06037
1.0 mm (0.04 in)
3. Tighten: - Adjusting bolt (2)
Adjusting bolt: 10 Nm (1.0 m-kg, 7.2 ft-Ib)
2-28
DRIVE V-BELT/ENGAGEMENT SPEED CHECK
INSP ADJ
4. Inspect: • Drive V-belt Cracks/damage/wear -+ Replace. Oil or grease on the V-belt -+ Check the primary and secondary sheaves.
5. Inspect: • Primary sheave • Secondary sheave Oil or grease on the primary and secondary sheaves -+ Use a rag soaked in lacquer thinner or solvent to remove the oil or grease. Check the primary and secondary sheaves.
SCH2460
6. Measure: • Drive V-belt circumference ® Out of specification -+ Replace.
®
V-belt circumference: 1,129 -- 1,137 mm (44.4 -- 44.8 in)
SCH2470
ENGAGEMENT SPEED CHECK 1. Place the machine on a level surface of hardpacked snow. 2. Inspect: • Clutch engagement speed Inspection steps: • Start the engine, and open the throttle lever gradually. • Check the engine speed when the machine starts moving forward. Out of specification -+ Adjust the primary sheave. Engagement speed: 3,600 ± 200 r/min (RX10, RX10S, RX10R, RX10RS) 4,200 ± 200 r/min (RX10M, RX10MS)
2-29
PARKING BRAKE ADJUSTMENTI BRAKE LEVER ADJUSTMENT
II~~~ I (O~
~
I
PARKING BRAKE ADJUSTMENT 1. Measure: eParking brake cable distance ® Out of specification -+ Adjust. Parking brake cable distance: 43.5 -- 46.5 mm (1.713 -- 1.831 in)
2. Adjust: eParking brake cable
Adjustment steps: eLoosenthelocknutGD eTurn the adjuster(g) in or out until the specified distance ® is obtained. Turning in -+ Distance ® is increased. Turning out -+ Distance ® is decreased. eTighten the locknut. 3. Measure: eBrake pad clearance @ Out of specification -+ Adjust.
Brake pad clearance: 1.5 -- 2.0 mm (0.059 -- 0.079 in)
4. Adjust: eBrake pad clearance
Adjustment steps: eLoosenthelocknutGD eTurn the adjuster(g) in or out to until the specified clearance between the brake pad ® and brake disc @ is obtained. eTighten the locknut.
BRAKE LEVER ADJUSTMENT 1. Adjust: eBrake lever position (distance from the grip to the brake lever)
2-30
BRAKE LEVER ADJUSTMENTI BRAKE FLUID LEVEL INSPECTION
INSP ADJ
Adjustment steps: .LoosenthelocknutGD. • While lightly pushing the brake lever in direction @, turn the adjusting bolt ® by fingers to set the brake lever to the desired position. • Tighten the locknut securely after adjusting. ,
~~
Locknut: 6 Nm (0.6 mekg, 4.3 ftelb)
BRAKE FLUID LEVEL INSPECTION 1. Place the machine on a level surface. 2. Check: • Fluid level Fluid level is underthe "LOWER" levelline@ --+ Fill to the proper level.
Recommended brake fluid: DOT 4 NOTE: - - - - - - - - - - - - - For a correct reading of the brake fluid level, make sure that the top of the handlebar brake master cylinder reservoir is horizontal.
Brake fluid may corrode painted surfaces or plastic parts. Always clean up spilled fluid immediately.
~ ---------• Use only the designated brake fluid. Other fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of fluid. Mixing fluids may result in a harmful chemical reaction leading to poor brake performance. • When refilling, be careful that water does not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the fluid and may cause vapor lock.
2-31
BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
II~~~ I (O~
~
I
BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Inspect: • Brake pad wear @ Wear indicator CD nearly contacts the brake disc --+ Replace as a set.
I~ ®
®
Wear limit: 7.5 mm (0.30 In)
SCH2530
BRAKE HOSE INSPECTION 1. Inspect: • Brake hose Cracks/damage/wear --+ Replace. 2. Check: • Fluid leakage Apply the brake lever several times. Fluid leakage --+ Replace the defective parts.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
ffmmIIm1 ---------Bleed the brake system in the following cases: • The system has been disassembled. • A brake hose is loosened or removed. • The brake fluid has been very low. • Brake operation is faulty. If the brake system is not properly bled a loss of braking performance may occur.
1. Bleed: • Brake system Air bleeding steps: • Fill the brake master cylinder reservoir with the proper brake fluid. • Install the diaphragm. Be careful not to spill any fluid or allow the brake master cylinder reservoir to overflow. • Connect clear plastic hoses CD tightly to the brake caliper bleed screws ®. • Place the other ends of the hoses in a container.
2-32
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
IANOSJP I (O~ ~
I
--------------------------a. Slowly apply the brake lever several times. I
b. Pull the lever in, then hold the lever in position. c. Loosen the bleed screws and allow the brake lever to travel towards its limit. d. Tighten the bleed screws when the brake lever limit has been reached, then release the lever. - Repeat steps (a) to (d) until all of the air bubbles have disappeared from the fluid. - Tighten the bleed screws.
Bleed screw: 6 Nm (0.6 m-kg, 4.3 ft-Ib) NOTE: - - - - - - - - - - - - - If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. - Add brake fluid to the proper level. Refer to "BRAKE FLUID LEVEL INSPECTION".
~ ---------After bleeding the brake system, check the brake operation.
2-33
DRIVE CHAIN
INSP ADJ
DRIVE CHAIN Oil level inspection
ffmmIIm1 ---------The engine and muffler will be very hot after the engine has run. Avoid touching a hot engine and muffler while they are still hot with any part of your body or clothing during inspection or repair. 1. Place the machine on a level surface. 2. Check: ·Oillevel
Checking steps: • Remove the dipstick CD and wipe it off with a clean rag. Reinsert the dipstick.
There is a magnet attached to the end of the dipstick. It is used to remove any metal particles that may accumulate in the drive chain housing. Be sure to: • Pull the dipstick out slowly and gently so the metal particles do not fall off the magnet back into the drive chain housing. • Wipe off the magnet before reinserting the dipstick into the drive chain housing.
A
• Remove the dipstick and check that the oil is between the upper ® and lower © levels. If not, add oil to the upper level.
B
[A] For models without reverse transmissions (RX10, RX10S, RX10M, RX10MS)
[6] For models with reverse transmissions (RX10R, RX10RS)
2-34
DRIVE CHAIN
---------------------------
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IANOSJP I (O~ ~
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Recommended oil: Gear oil API "GL-3" SAE #75 or #80
Make sure that no foreign material enters the gear case. SCH2570
- Reinsert the dipstick ÂŽ.
Oil replacement Oil replacement steps: - Place the oil pan under the drain hole. - Remove the oil drain bolt CD and drain the oil.
Be sure to remove any oil from the heat protector. -Install the oil drain bolt CD.
Oil drain bolt: 16 Nm (1.6 m-kg, 12 ft-Ib) Recommended oil: Gear oil API "GL-3" SAE #75 or #80 Oil capacity: 0.25 L (8.8 Imp OZ, 8.5 US oz) Chain slack adjustment 1. Adjust: - Drive chain slack Adjustment steps: -Loosen the locknut CD. - Turn the adjusting bolt tight. - Tighten the locknut.
2-35
ÂŽ
in until it is finger
TRACK TENSION ADJUSTMENT
IANOSJP I (O~ ~
I
---------------------------TRACK TENSION ADJUSTMENT I
~
----------
A broken track or track fittings, and debris thrown by the track could be dangerous to an operator or by standers. Observe the following precautions. • Do not allow anyone to stand behind the machine when the engine is running. • When the rear of the machine is raised to allow the track to spin, a suitable stand must be used to support the rear of the machine. Never allow anyone to hold the rear of the machine off the ground to allow the track to spin. Never allow anyone near a rotating track. • Inspect the condition of the track frequently. Replace the track if it is damaged to a level where the fabric reinforcement material is visible.
1. Lift the rear of the machine onto a suitable stand to raise the track off the ground. 2. Measure: • Track deflection ® Using a spring scale CD, pull down on the center of the track with 100 N (10 kg, 221b) of force. Out of specification --+ Adjust. Track deflection: 25 --- 30 mm (0.98 --- 1.18 in) 3. Adjust: • Track deflection
Adjustment steps: • Place the machine onto a suitable stand to raise the track off of the ground. • Loosen the rear axle nut CD. a. Start the engine and rotate the track once or twice. Stop the engine. b. Check the track alignment with the slide runner ®. If the alignment is incorrect, turn the left and right adjusters to adjust.
SCH2630
2 SCH2640
2-36
TRACK TENSION ADJUSTMENTI SLIDE RUNNER INSPECTION A
Track alignment
@ Left adjuster @ Right adjuster
INSP ADJ [IDShifted to right
[ZJShifted to left
Turn out
Turn in
Turn in
Turn out
@ Slide runner ® Track @ Track metal @ Gap @ Forward [A] RX10, RX10S, RX10R, RX10RS [al RX10M, RX10MS c. Adjust the track deflection until the specified amount is obtained.
Track deflection
6
More than Less than specified specified
@ Left adjuster
Turn in
Turn out
@ Right adjuster
Turn in
Turn out
The adjusters should be turned an equal amount.
7
• Recheck the alignment and deflection. If necessary, repeat steps (a) to (c) until the specified amount is obtained. • Tighten the rear axle nut. ,
I
~
~~
Nut (rear axle): 75 Nm (7.5 mekg, 54 ftelb)
SLIDE RUNNER INSPECTION 1. Inspect: • Slide runner CD Cracks/damage/wear -+ Replace. 2. Measure: • Slide runner thickness @ Out of specification -+ Replace.
JI
Slide runner wear limit: 10 mm (0.39 in)
SCH2680
2-37
MAXIMIZING DRIVE TRACK LIFE
IANOSJP I (O~ ~
I
----------------------------MAXIMIZING DRIVE TRACK LIFE I
Recommendations Track tension During initial break-in, the new drive track will tend to stretch quickly as the track settles. Be sure to correct the track tension and alignment frequently. (See pages 2-36 --- 2-37 for adjustment procedures.) A loose track can slip (ratchet), derail or catch on suspension parts causing severe damage. Do not overtighten the drive track, otherwise it may increase the friction between the track and the slide runners, resulting in the rapid wear of both components. Also, this may put an excessive load on the suspension components, resulting in component failure. Marginal snow The drive track and the slide runners are lubricated and cooled by snow and water. To prevent the drive track and slide runners from overheating, avoid sustained high-speed usage in areas such as icy trails, frozen lakes and rivers that have minimal snow coverage. An overheated track will be weakened internally, which may cause failure or damage. Off-trail riding Avoid off-trail riding until there is sufficient snow coverage. It generally takes several feet of snow to provide a good overall base to properly cover debris, such as rocks, logs, etc. If snow coverage is not sufficient, stay on trails to avoid impact damage to the drive track. Studded track In general, track life will be shortened when studs are installed. Drilling stud holes into the drive track will cut the internal fibers, which weakens the track. Avoid spinning the drive track. Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible damage, consult your stud manufacturer for installation and stud pattern recommendations. Yamaha does not recommend track studding.
2-38
SKI/SKI RUNNER
INSP ADJ
CHASSIS SKI/SKI RUNNER 1. Inspect: ·Ski • Ski runner Damage/wear -+ Replace. • Ski runner thickness @ • Plastic ski thickness @ Out of specification -+ Replace.
Ski runner wear limit: 8 mm (0.31 in) Plastic ski wear limit: 24 mm (0.95 in) ( c:::::::
To avoid scratching, wearing and damaging the plastic skis, be careful when loading and unloading the snowmobile and avoid riding in areas with little or no snow and on surfaces with sharp edges such as concrete, curbs, etc.
2-39
STEERING SYSTEM
STEERING SYSTEM Free play check 1. Check: • Steering system free play Move the handlebar up and down and back and forth. Turn the handlebar slightly to the right and left. Excessive free play -+ Check that the handlebar, tie rod ends and relay rod ends are installed securely in position. If free play still exists, check the steering bearing, front suspension links and ski mounting area for wear. Replace if necessary.
SCH2710
1+-------1
a
1-----+,1
~----(
C
I------+-...-
INSP ADJ
Toe-out adjustment 1. Place the machine on a level surface. 2. Check: • Ski toe-out (@ - ©) • Ski stance @ Point the skis forward. Out of specification -+ Adjust. Ski toe-out: o -- 15 mm (0 -- 0.59 in) Ski stance (center to center): RX10, RX10S, RX10R, RX10RS 1,068 mm (42.0 in) RX10M, RX10MS 980 mm (38.6 in)
I
SCH2715
2-40
STEERING SYSTEM/LUBRICATION
INSP ADJ
3. Adjust: e Ski toe-out
Adjustment steps: e Loosen the locknuts (tie-rod) CD. e Turn the tie rods 速 in or out until the specified toe-out is obtained. e Tighten the locknuts (tie-rod) CD. Locknut (rod end): 25 Nm (2.5 mekg, 18 ftelb) LOCTITE速
After tightening the inside and outside ball joint locknuts CD, make sure the tie rod 速 can be rotated freely through the ball joint travel. If not, loosen the locknut CD and reposition the ball joint so that the tie rod 速 can be rotated freely. Tighten the locknuts to specification.
c
[A] Left side [B] Right side [Q] Inside
LUBRICATION Brake lever, throttle lever and throttle cable end 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables. ~
l
Recommended lubricant: ESSO Beacon 325 Grease
m!mmmmI ---------Apply a dab of grease onto only the end of the cables. Do not grease the throttle cables. They could freeze and cause a loss of control.
2-41
LUBRICATION
IANOSJP I (O~ ~
-------------------------Front and rear suspension A I
1. Use a grease gun to inject grease into the nipples CD. Recommended lubricant: Esso Beacon 325 Grease or Aeroshell Grease #7A
[A] Front [aJ Rear (RX1 0, RX10S, RX10R, RX10RS) [Q] Rear (RX1 OM, RX10MS) A
B
SCH2755
c
---
2-42
--------
SCH2760
I
HEADLIGHT BEAM ADJUSTMENT
--------------------------ELECTRICAL
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HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Place the machine in front of a wall at the recommended distance @. Refer to the table below. 3. Measure the distance CED from the floor to the center of the headlight and place a mark on the wall at that height. 4. With a person sitting on the machine, apply the parking brake, start the engine and let it idle. 5. Switch on the headlight's high beam and check the height of the projected beam on the wall. The projection should be at the position marked in step 3 or 1/2° lower (set range
@
SCH2765
@).
@ @
3.0 m (10 1t)
7.6 m (25 1t)
26 mm (1.0 in)
66 mm (2.6 in)
@: Distance
@: Set range
6. Adjust: • Headlight beam (vertically) Vertical adjustment Higher Turn the adjusting screw clockwise. Lower Turn the adjusting screw counterclockwise.
--------~
-
o
/
2-43
CD CD
BATTERY INSPECTION
INSP ADJ
EAS00178
BATTERY INSPECTION
ffmIJDIm1 ---------Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). • DO NOT SMOKE when charging or handling batteries. • KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. First aid in case of bodily contact: External • SKIN - Wash with water. • EYES - Flush with water for 15 minutes and get immediate medical attention. Internal • Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.
18350701
• This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. • Charging time, charging amperage and charging voltage for a MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.
2-44
BATTERY INSPECTION
IANOSJP I (O~ ~
I
-----------------------------NOTE: - - - - - - - - - - - - - I
Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Disconnect: • Battery leads (from the battery terminals)
First, disconnect the negative lead CD, then the positive lead ®. 2. Remove: • Battery 3. Inspect: • Battery charge
Inspection steps: • Connect a pocket tester to the battery terminals.
Volt meter
Tester positive lead
battery positive terminal Tester negative lead -+ battery negative terminal -+
18350601
_
NOTE: - - - - - - - - - - - - • The charge state of a MF battery can be checked by measuring its open-circuit voltage (Le., the voltage when the positive terminal is disconnected) . • No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
Relationship between the open-circuit voltage and the chargiJ"lg time at 20°C
13.0
G-
.s 12.5 Q)
(5
~ 12.0 ~
I
~
I I
.~ 11.5 ~
o
I
L -
---+---+-'_ _ I I
~I-----I
5
6.5 10 Charging time (hours) These values vary with the temperature, the condition of the battery plates, and the electrolyte level.
• Check the charge of the battery, as shown in the charts and the following example. Example • Open-circuit voltage = 12.0 V • Charging time = 6.5 hours • Charge of the battery = 20 ~ 30%
2-45
BATTERY INSPECTION
4. Charge: • battery (refer to the appropriate charging method illustration)
Charging ~ 18
-----------
Ambient temperature 2
~ 17
.E! 16
\ \
(5
;: 15 "~ 14 "<;> 13
~ o
"-
~ ----------
---
12 11
Do not quick charge a battery.
10
~
o
10
20
30
4
50 60 Time (minutes) Check the open-circuit voltage.
40
14 13 t--------1~ ~--r---~-~---f
Q)
0>
~
12
t---+---+---~~~-----l
11
t---t---t---t------t-r-----i
>
"5 ~
~
~
o
INSP ADJ
• Make sure that the battery vent is free of obstructions. • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. ·If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. • When charging a battery, be sure to remove it from the motorcycle. (If charging has to be done with the battery mounted on the motorcycle, disconnect the negative lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. • Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
Ambient temperature 20°C
I
10 t----+----+----+-----!--+-:I,---------4 I I
I
100
75
50
30 2520
0
Charging condition of the battery (%)
2-46
INSP ADJ
BATTERY INSPECTION Charging method using a variable voltage charger
-"""1 \'
Charger
L+--_ _
O â&#x20AC;˘
Measure the open-circuit voltage prior to charging.
AMP meter
I~I A
t Connect a charged and AMP meter to the battery and start charging. 18350101
YES ,.....----------i
Make sure that the current is higher than the standard charging current written on the battery.
NOTE:-------Voltage should be measured 30 minutes after the machine is stopped.
NOTE:-------Set the charging voltage at 16 - 17 V. (If the setting is lower, charging will be insufficient. If too high, the battery will be over-charged.)
NO 1---------,
By turning the charging voltage adjust dial, set the charging voltage at 20 -- 24 V. Adjust the voltage so that the current is at the standard charging level.
Monitor the amperage for Y ES _ _ _----I3 -- 5 minutes to check if the standard charging current is reached.
14--_ _
NO
Set the time according to the charging time suitable for the open-circuit voltage. Refer to "Battery condition checking steps".
If the current does not exceed the standard charging current after 5 minutes, replace the battery.
If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.
2-47
BATTERY INSPECTION
INSP ADJ
Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging.
NOTE:--------Voltage should be measured 30 minutes after the machine is stopped.
Connect a charger and AMP meter to the battery and start charging.
YES ---------1
Make sure that the current is higher than the standard charging current written on the battery.
Charge the battery until the battery's charging voltage is 15 V.
NO 1----------.,
This type of battery charger cannot charge the MF battery. A variable voltage charger is recommended.
NOTE:--------Set the charging time at 20 hours (maximum).
Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. 18350102
2-48
BATTERY INSPECTION
INSP ADJ
5. Install: • Battery
6. Connect: • Battery leads (to the battery terminals)
First, connect the positive lead CD, then the negative lead ®. 7. Check: • Battery terminals Dirt --+ Clean with a wire brush. Loose connection --+ Connect properly. 8. Lubricate: • Battery terminals
Recommended lubricant Dielectric grease
2-49
FUSE INSPECTION
--------------------------FUSE INSPECTION
I
IANOSJP I (O~ ~
I
The following procedure applies to all of the fuses.
To avoid a short circuit, always set the main switch to "OFF" when checking or replacing a fuse.
1. Inspect: - Continuity Inspection steps: - Connect the pocket tester to the fuse and check the continuity. NOTE: - - - - - - - - - - - - - Set the pocket tester selector to "Q x 1".
Pocket tester: 90890-03112, YU-03112 - If the pocket tester indicates "00", replace the fuse. 2. Replace: -Blown fuse Replacing steps: - Set the main switch to "OFF". -Install a new fuse of the correct amperage. - Set the main switch to "ON" and verify if the electrical circuit is operational. -If the fuse immediately blows again, check the electrical circuit. Item
Amperage
Q'ty
Main fuse
30A
1
"HEAD" fuse
20A
1
"SIGNAL" fuse
10A
1
10A
1
20A
1
Reserve fuse
20A 10A
1 1
(J) Reserve fuse
30A
1
CD ® ®
@ "IGNITION" fuse
@ "CARBURETOR HEATER" fuse
®
2-50
FUSE INSPECTION/SPEEDOMETER UNIT INSPECTION
INSP ADJ
~ ---------Never use a fuse with an amperage other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting, ignition, grip warmer, signal and meter systems to malfunction and could possibly cause a fire.
SPEEDOMETER UNIT INSPECTION 1. Inspect: - Speedometer unit Inspection steps: - Remove the speedometer coupler CD and headlight coupler ÂŽ. - Connect the speedometer unit test coupler @ to the speedometer coupler and headlight coupler. - Connect the speedometer unit test coupler leads as follows. Speedometer unit test coupler lead (red) @ --+ Battery (+) terminal Speedometer unit test coupler lead (black) @ --+ Battery (-) terminal . '.
Speedometer unit test coupler: 8EK-82507-09, YS-45686
- Check that the light and LCD in the speedometer light up. -If the light does not light up. --+ Check the bulbs. Refer to "BULB(S)" in CHAPTER 8. -If the LCD is not indicated. --+ Replace the speedometer unit.
2-51
INSP ADJ
CARBURETOR TUNING
TUNING CARBURETOR TUNING The carburetors are set at the factory to run at temperatures of ooe ,---2o oe (32°F '---4°F) at sea level. If the machine is to be operated under conditions other than those specified above, the carburetors must be properly adjusted. Special care should be taken in carburetor setting so that the pistons will not be damaged or will not seize.
Before performing the carburetor tuning, make sure that the following items are set to specification. • Engine idle speed • Throttle cable free play • Carburetor synchronization • Starter cable free play Carburetor tuning data 1. Standard specifications
[A] Type
BSR37
[B] Manufacturer [Q] 1.0. Mark
MIKUNI 8FA100
[Q] Main jet (M.J.)
#135
[EJ Pilot jet (P.J.)
#17.5
[EJ Pilot screw (P.S.) Approx 2 turns out
2-52
[G] Float height
11 ,-- 15 mm (0.43 ,-- 0.59 in)
[H] Idle speed
1,350 ± 100 r/min (1,250 ,-- 1,450 r/min)
CARBURETOR TUNING
IANOSJP I (O~ ~
I
---------------------------Mid-range and high speed tuning I
Adjustments are normally not required, but may sometimes be necessary, depending on temperatures, altitude or both. Mid-range speed and high speed tuning (from 1/4 to full-throttle) can be done by adjusting the main jet.
Never run the engine without the air intake silencer installed. Severe engine damage may result. 1. Start the engine and operate the machine under normal conditions to make sure that the engine operates smoothly. Stop the engine. 2. Remove: â&#x20AC;˘ Spark plugs
3. Check: â&#x20AC;˘ Spark plug insulator CD color A medium to light tan color indicates normal conditions. Distinctly different color --+ Replace the main jet. 4. The main jet should be adjusted on the basis of the "Main jet selection chart". NOTE: - - - - - - - - - - - - - By checking the condition of the spark plugs, it is easy to get some idea of the condition of the engine. This may diagnose potential problems before engine damage occurs.
High altitude tuning Use the chart in CHAPTER 9 to select main jets according to variations in elevation and temperature. NOTE: - - - - - - - - - - - - - These jetting specifications are subject to change. Consult the latest technical information from Yamaha to be sure you have the most up-todate jetting specifications.
CD Clip ÂŽ Jet needle @ Pilot screw @ Main jet 2-53
INSP
CARBURETOR TUNING
ADJ
Guide for carburetion
[A] Piston valve opening [B] Mid-range speed tuning [Q] High speed turning [Q] Fully opened
1/2--...t1lliW=l-~*-M~-~---HH---1rltfttb:::::::=-t-'II-r
-_1.....-- 1/4--..l.JJ~~~~::------~~---=r---tt~~----r1---r1 1/8--J...b~:"""+--~~--~7==-f~q----~ITI [EJ Closed ~--~~~~!!!!!!!!!!!!!!!~~~~~~--rPt::::::::::::~/-T,
[E] Low speed tuning CD(2)@@@
[Q] Closed
1/8
1/4
1/2
[A] Piston valve opening
2-54
3/4
[EJ Fully opened
CARBURETOR TUNING
----------------------------® Standard main jet
I
IANOSJP I (O~ ~
@ Main jet whose diameter is 10
%
I
smaller than
standard
© Main jet whose diameter is 10
%
larger than stan-
dard
1/2
3/4
[Q] Fully opened
[BJ Piston valve opening
® No. ® position @ No. CD position
© No. ® position
1/8
1/2
3/4
[Q] Fully opened
[BJ Piston valve opening
[AJ Clip
If the air silencer box is removed from the carburetors, the change in pressure in the intake will create a lean mixture that may cause severe engine damage. The air silencer box has no effect on performance characteristics and must be secured to the carburetors during carburetor tuning and adjustment. Also, it must always be in place when the engine is operated. Regularly clean the silencer and keep it free from obstructions.
[BJ Jet needle 2-55
CARBURETOR TUNING
---------------------------Low-speed tuning
I
IANOSJP I (O~ ~
I
The carburetors are built so that low speed tuning can be done by adjusting the pilot mixture screw CD and throttle stop screw ®.
Never run the engine without the air intake silencer installed. Severe engine damage may result. 1. Tighten the pilot mixture screw until it is lightly seated and then back it out the specified number of turns. Pilot screw CD: Approx 2 turns out
NOTE: - - - - - - - - - - - - - Number of return rotation of pilot screw may vary depending on each cylinder. Make sure to rotate the screw backward after listing its present number of return rotation on each cylinder. Pilot mixture screw effects: Turn in
~
Leaner Mixture
(
STD setting
----7
Turn out
Richer ) Mixture
2. Set the engine idle speed by turning the throttle stop screw ® in (to increase engine speed) or out (to decrease engine speed).
Engine idle speed: 1,350 ± 100 r/min (1,250 -- 1,450 r/min) 3. If low-speed performance is still poor at higher elevations under extreme conditions, the standard pilot jets may need to be replaced. In this way, the proper air/fuel mixture is obtained.
NOTE: - - - - - - - - - - - - - In this case, use a larger numbered pilot jet to enrich the air/fuel mixture. Standard pilot jet: #17.5
2-56
CARBURETOR TUNING
INSP
ADJ
Main jet selection chart Spark plug color
Diagnosis
Remedy
Light tan or gray
Carburetors are tuned properly.
Dry black or fluffy deposits
Mixture is too rich.
Replace the main jet with the next smaller size.
White or light gray
Mixture is too lean.
Replace the main jet with the next larger size.
White or gray insulator with small black or grayish brown spots and electrodes having a bluish-burnt appearance
Mixture is too lean. The piston is damaged or seized.
Replace the piston and spark plug. Tune the carburetors again. Begin with lowspeed tuning.
Melted electrodes and possibly a blistered insulator Metallic deposits on insulator
Mixture is too lean. The spark plug melted.
Check the piston for holes or seizure. Check the cooling system, gasoline octane rating and ignition timing. After replacing the spark plug with a colder type, tune the carburetors again. Begin with low-speed tuning.
Troubleshooting
Trouble Hard starting
Poor idling: • Poor performance at low speeds • Poor acceleration • Slow response to throttle • Engine tends to stall
Diagnosis
Adjustment
Insufficient fuel
Add gasoline.
Excessive use of the starter or choke
Return the starter lever to its seated position so that the starter valve is fully closed.
Fuel passage is clogged or frozen
• Check and, if necessary, clean the fuel tank air vent, the fuel filter and all of the fuel passages. • Check and, if necessary, clean the carburetor air vents, fuel passages and the float valve. • Clean the float chamber of any ice or water.
Overflow
Adjust the fuel level.
Improper idling speed adjustment
Adjust the engine idle speed. Refer to "Low speed tuning".
Damaged pilot screw
Replace the pilot screw.
Clogged bypass hole
Clean the bypass hole.
Clogged or loose pilot jet
• Remove the pilot jet, clean it with compressed air and then install it. • Make sure that the pilot jet is fully tightened.
Air leaking into the carburetor joint
Retighten the clamp screws on the carburetor joints.
Defective starter valve seat
Clean or replace the starter valve seat.
Overflow
Adjust the fuel level. 2-57
CARBURETOR TUNING Trouble
Diagnosis
INSP
ADJ
Adjustment
Poor performance at mid-range speeds: • Momentary slow response to the throttle • Poor acceleration
Clogged or loose pilot jet
• Remove the pilot jet, clean it with compressed air, and then install it. • Make sure that the pilot jet is fully tightened.
Lean mixture
Overhaul the carburetors.
Poor performance at normal speeds: • Excessive fuel consumption • Poor acceleration
Clogged air vent
Remove the air vent hose and clean it.
Clogged or loose main jet
• Remove the main jet, clean it with compressed air, and then install it. • Make sure that the main jet is fully tightened.
Overflow
Check and, if necessary, clean the float and float valve.
Starter valve is left open
Return the starter lever to its seated position so that the starter valve is fully closed.
Clogged air vent
Remove and clean the air vent.
Clogged or loose main air jet
• Remove the main jet, clean it with compressed air, and then install it. • Make sure that the main jet is fully tightened.
Clogged fuel line
Clean or replace the fuel line.
Dirty fuel tank
Clean the fuel tank.
Air leaks into the fuel line
Tighten or replace the fuel line joint.
Low fuel pump performance
Repair or replace the fuel pump.
Clogged fuel filter
Replace the fuel filter.
Clogged intake
Remove any obstructions (e.g., ice).
Lean mixture
Clean and adjust the carburetors.
Dirty carburetors
Clean the carburetors.
Dirty or clogged fuel line
Clean or replace the fuel line.
Clogged air vent
Clean the air vent.
Clogged float valve
• Disassemble and clean the float valve. • Do not scratch the valve seat.
Scratched or unevenly worn float valve or valve seat
• Clean or replace the float valve and valve seat. • The valve seat and body must be replaced as a set
Broken float
Replace the float.
Incorrect float level
Check and, if necessary, replace the following parts: • Float tang • Float (entire assembly) • Arm pin
Poor performance at high speeds: • Power loss • Poor acceleration
Abnormal combustion: • Backfiring
Overflow: • Poor idling • Poor performance at low, mid-range, and high speeds • Excessive fuel consumption • Hard starting • Power loss • Poor acceleration
2-58
INSP
CLUTCH CLUTCH High altitude
ADJ
G Green
P Pink
S Silver
Y Yellow
Specifications Model: RX10, RX10S, RX10R, RX10RS 800m 2,500 ft)
600 ~ 1,400 m (2,000 ~ 4,500 ft)
1,200 ~ 2,000 m (4,000 ~ 6,500 ft)
1,800 ~ 2,600 m (6,000 ~ 8,500 ft)
2,400 ~ 3,000 m (8,000 ~ 10,000 ft)
1,350 ± 100 r/min
+-
+-
+-
+-
3,600 ± 200 r 1min
+-
+-
+-
+-
+-
+-
+-
+-
~
[A]
Elevation
[6]
Engine idle speed
[Q] [Q] [:EJ [E] [G]
Engagement r 1min Shift r/min
10,250 ± 250 r 1min
[8]
rn
(~
Main jet
[ill
Pilot jet*1
Refer to "HIGH ALTITUDE SETTINGS" in "MAINTENANCE SPECIFICATIONS".
Pilot screw Secondary reduction ratio (number of links)
38/24 (70 L)
+-
38/23 (70 L)
38/22 (68 L)
+-
Primary sheave spring
90501-582L1
+-
90501-582L2
90501-602L3
+-
Color
y-S-y
+-
G-S-G
P-S-P
+-
Free length
87.4 mm (3.44 in)
+-
85.1 m (3.35 in)
+-
Preload
343 N (35 kg, 771b)
+-
[M]
Spring rate
24.5 N/mm (2.50 kg/mm, 140lb/in)
+-
[NJ [Q]
Wire diameter
5.8 mm (0.228 in)
+-
+-
Outside diameter
60 mm (2.36 in)
+-
+-
+-
+-
[EJ
Weight (ID)
8FA-17605-00 (8FAOO)
+-
+-
+-
+-
[Q]
~eight rivet
[8]
Weight bushing
Duralon
+-
+-
+-
+-
[S] [I] [Q]
Roller outer dia.
15.0 mm (0.59 in)
+-
+-
+-
+-
Roller bushing
Duralon
+-
+-
+-
+-
Pri. clutch shim
None
+-
+-
+-
+-
90508-60012
+-
+-
+-
+-
P
+-
+-
+-
+-
Free length
75 mm (2.95 in)
+-
+-
+-
+-
[y]
Preload rate
60° (3-3) 1211 kgemm/rad
+-
+-
+-
+-
[ZJ
Wire diameter
6.0 mm (0.236 in)
+-
+-
+-
+-
~ Outside diameter
69.5 mm (2.736 in)
+-
+-
+-
+-
[liJ [Q]
Sec. torque cam angle
51 -43°
+-
+-
+-
+-
Sec. clutch shim
1.0 mm (0.04 in)
+-
+-
+-
+-
[JJ [K]
CD
+-
27 N/mm (2.75 kg/mm, 154lb/in)
+-
+-
29.4 Nm (3.00 kg/mm, 168lb/in)
+-
6.0 mm (0.236 in)
+-
OUT
Steel 17.2 with-hole
Steel 13.3
Steel 13.3 with-hole
Aluminum 13.3 with-hole
None
IN
Steel 17.2
Steel 13.3
Steel 13.3 with-hole
Steel 13.3 with-hole
None
M Secondary sheave spring Iw Color [Xl
+-
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - *1: Number of return rotation of pilot screw may vary depending on each cylinder.
Make sure to rotate the screw backward after listing its present number of return rotation on each cylinder.
2-59
INSP ADJ
CLUTCH S Silver W White
o I Orange
I
Specifications Model: RX10M, RX10MS -- 800 m (-- 2,500 ft)
600 -- 1,400 m
1,200 -- 2,000 m
1,800 -- 2,600 m
2,400 -- 3,000 m
(2,000 -- 4,500 ft)
(4,000 -- 6,500 ft)
(6,000 -- 8,500 ft)
(8,000 -- 10,000 ft)
Engine idle speed
1,350 ± 100 r/min
+-
+-
+-
+-
Engagement r/min
4,200 ± 200 r/min
+-
+-
+-
+-
Shift r/min
10,250±250 r/min
+-
+-
+-
+-
[A]
Elevation
[BJ [Q] [Q] [EJ [E]
Main jet
[ill Refer to "HIGH ALTITUDE SETTINGS" in "MAINTENANCE SPECIFICATIONS".
Pilot jet*1
~ Pilot screw
[8]
Secondary reduction ratio (number of links)
40/23 (70 L)
+-
[ ] Primary sheave spring
90501-624L8
+-
+-
+-
+-
Q] [K]
O-S-O
+-
+-
+-
+-
84.2 mm(3.32 in)
+-
+-
+-
+-
343 N (35 kg, 771b)
+-
+-
+-
+-
+-
+-
+-
+-
Color Free length
[ ] Preload
40/22 (70 L)
40/21 (70 L)
+-
31.9 N/mm
[M]
(3.25 kg/mm,
Spring rate
182Ib/in)
[NJ [Q]
Wire diameter
6.2 mm (0.244 in)
+-
+-
+-
+-
Outside diameter
60 mm (2.36 in)
+-
+-
+-
+-
[EJ
Weight (ID)
+-
+-
+-
+-
8FA-17605-00 (8FAOO) OUT
[Q]
Weight rivet IN
[8] [S] [I] [Q] [SZ]
Steel 17.2 with-hole Steel 17.2
Steel 13.3
Aluminum
with-hole
13.3 with-hole
Steel 13.3
Aluminum
Aluminum
with-hole
13.3 with-hole
13.3 with hole
Steel 13.3
None None
Weight bushing
Duralon
+-
+-
+-
+-
Roller outer dia.
16.5 mm (0.65 in)
+-
+-
+-
+-
Roller bushing
Duralon
+-
+-
+-
+-
Pri. clutch shim
None
+-
+-
+-
+-
Secondary sheave spring
90508-60007
+-
+-
+-
+-
+-
+-
+-
+-
+-
+-
+-
+-
+-
+-
+-
+-
~ Color
W
[X]
Free length
75 mm (2.95 in)
[y]
Preload rate
[ZJ [ill [li] @]
Wire diameter
6 mm (0.236 in)
+-
+-
+-
+-
Outside diameter
69.5 mm (2.736 in)
+-
+-
+-
+-
Sec. torque cam angle
45°
+-
+-
+-
+-
Sec. clutch shim
1.0 mm (0.04 in)
+-
+-
+-
+-
70° (1-6) 1290 kgemm/rad
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - *1: Number of return rotation of pilot screw may vary depending on each cylinder.
Make sure to rotate the screw backward after listing its present number of return rotation on each cylinder.
2-60
CLUTCH/GEAR SELECTION
IANOSJP I (O~ ~
I
----------------------------The clutch may require tuning depending upon I
where the machine will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the machine first begins to move from a complete stop. Clutch shifting speed is defined as the engine speed reached when the machine has travelled 800 m (2,500 ft) after being started at fullthrottle from a dead stop. Normally, when a machine reaches shifting speed, the vehicle speed increases but the engine speed remains nearly constant. Under unfavorable conditions (wet snow, icy snow, hills, or rough terrain), however, engine speed may decrease after the shifting speed has been reached.
o
t
[9----. -----
t
I
(400m)
~ SCH2845
[A] Engine speed ~ Good condition
[Q Clutch shifting speed
[Q] Clutch engagement speed [E] Starting position [E] Distance travelled 800 m (2,500 ft)
GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions. If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions exist, decrease the ratio. Gear ratio chart The drive and driven gears and the chains shown in the gear ratio chart are available as options. The figures containing a decimal point represent the drive/driven gear ratios, while the bottom numbers designate the number of links in the chain.
2-61
INSP
GEAR SELECTION
ADJ
CD Chain and sprocket part number [A] Parts name
[BJ Teeth & links
[Q] Parts no.
20 teeth
8FA-17682-00
21 teeth
8FA-17682-10
22 teeth
8FA-17682-20
23 teeth
8FA-17682-30
24 teeth
8FA-17682-40
37 teeth
8DW-47587-70
38 teeth
8DW-47587-80
RX10, RX10S
38 teeth
8FB-47587-80
RX10R, RX10RS
39 teeth
8DW-47587-90
39 teeth
8FB-47587-90
40 teeth
8DW-47587-00
68 links
94890-09068
70 links
94890-09070
[EJ Drive sprocket
[EJ Driven sprocket
~ Chain
[Q] Standard RX10M, RX10MS
RX10, RX10S, RX10R, RX10RS
RX10M, RX10MS RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
® Gear ratio [A] Drive gear 20 teeth
21 teeth
22 teeth
23 teeth
24 teeth
1.76 68 links
1.68 68 links
1.61 68 links
1.54 70 links
[BJ Driven gear
/
37 teeth 38 teeth
1.90 68 links
1.81 68 links
1.73 68 links
1.65 70 links
1.58 70 links
39 teeth
1.95 68 links
1.86 68 links
1.77 70 links
1.70 70 links
1.63 70 links
40 teeth
2.00 68 links
1.91 70 links
1.82 70 links
1.74 70 links
1.67 70 links
® Secondary sheave spring [A]
[6] Spring rate Part no.
[Q]Preload N/mm (kg/mm) (Ib/in)
N-mm/rad (kg-mm / rad)
[Q]
Color
[f]Wire gauge mm(in)
[E]
No. of coils
[8]
~Free
Outside diameter mm(in)
length mm(in)
[]Standard
90508-500B1
6003 (613)
6.2 (0.63), 35.28
Brown
5.0 (0.196)
5.19
75 (2.95)
69.5 (2.736)
90508-536A9
7147 (729)
7.3 (0.74), 41.44
Red
5.3 (0.209)
5.53
75 (2.95)
69.5 (2.736)
90508-556A2
8314 (848)
8.5 (0.87),48.72
Green
5.5 (0.217)
5.53
75 (2.95)
69.5 (2.736)
90508-556A7
9460 (965)
10.21 (1.04),58.24
Silver
5.5 (0.217)
4.86
75 (2.95)
69.5 (2.736)
90508-60012
11876 (1211)
12.32 (1.256), 70.34
Pink
6.0 (0.236)
5.53
75 (2.95)
69.5 (2.736)
RX10, RX10S, RX10R,RX10RS
90508-60007
12654 (1290)
13.45 (1 .372) 76.84
White
6.0 (0.236)
5.19
75 (2.95)
69.5 (2.736)
RX10M, RX10MS
@ Secondary spring twist angle
Ii Sheave
S~t
0
3
6
9
1
10°
40°
70°
100°
2
20°
50°
80°
110°
3
30°
60°
90°
120°
[A]
2-62
IANOSJP I (O~ ~
GEAR SELECTION
-------------------------@ Torque cam (secondary spring seat)
I
[A] Identification mark
[aJ Effects ~
Quicker upshifting during acceleration
[Q] Part no.
[Q] Cam angle [EJ Identification mark
8FA-17604-00
51-43°
8BVFA
8BV-17604-71
47°
8BV71
8BV-17604-51
45°
8BV51
8BV-17604-31
43°
8BV31
[8] Quicker
8BV-17604-11
41°
8BV11
backshifting under load
8BV-17604-91
39°
8BV91
~~
~,
2-63
[EJ Standard RX10, RX10S, RX10R, RX10RS
RX10M, RX10MS
I
INSP
GEAR SELECTION
ADJ
® Primary spring [A] Spring identification color code
[6] Spring rate color [Q] Preload color'
[E] [Q]
Parts No.
Spring rate N/mm (kg/mm)
[E]
[BJ
IT]
Q]
[K]
Preload N (kg)
Wire gauge mm(in)
Outside diameter mm(in)
No. of coils
Free length mm(in)
~ Color
90501-551 L3
19.6 (2.00)
294 (30)
Blue-Pink-Blue
5.5 (0.216)
60 (2.36)
4.91
88.4 (3.48)
90501-551 L9
19.6 (2.00)
343 (35)
Blue-Silver-Blue
5.5 (0.216)
60 (2.36)
4.91
90.9 (3.58)
90501-552L5
19.6 (2.00)
392 (40)
Blue-Green-Blue
5.5 (0.216)
60 (2.36)
4.91
93.4 (3.68)
90501-581 L5
24.5 (2.50)
294 (30)
Yellow-Pink-Yellow
5.8 (0.228)
60 (2.36)
4.92
85.4 (3.36)
90501-581 L6
27 (2.75)
294 (30)
Green-Pink-Green
5.8 (0.228)
60 (2.36)
4.66
84.3 (3.32)
90501-582L1
24.5 (2.50)
343 (35)
Yellow-Silver-Yellow
5.8 (0.228)
60 (2.36)
4.92
87.4 (3.44)
90501-582L2
27 (2.75)
343 (35)
Green-Silver-Green
5.8 (0.228)
60 (2.36)
4.66
86.1 (3.39)
90501-582L6
22.1 (2.25)
392 (40)
White-Green-White
5.8 (0.228)
60 (2.36)
5.25
91.2 (3.59)
90501-582L7
24.5 (2.50)
392 (40)
Yellow-G reen-Yellow
5.8 (0.228)
60 (2.36)
4.92
89.4 (3.52)
90501-583LO
19.6 (2.00)
441 (45)
Blue-White-Blue
5.8 (0.228)
60 (2.36)
5.65
95.9 (3.78)
90501-583L1
22.1 (2.25)
441 (45)
White-White-White
5.8 (0.228)
60 (2.36)
5.25
93.4 (3.68)
90501-583L4
22.1 (2.25)
343 (35)
White-Silver-White
5.8 (0.228)
60 (2.36)
5.25
89.0 (3.50)
90501-583L5
22.1 (2.25)
294 (30)
White-Pink-White
5.8 (0.228)
60 (2.36)
5.25
86.7 (3.41)
90501-601 L7
29.4 (3.00)
294 (30)
Pink-Pink-Pink
6.0 (0.236)
60 (2.36)
4.82
83.4 (3.28)
90501-601 L8
31.9 (3.25)
294 (30)
Orange-Pink-Orange
6.0 (0.236)
60 (2.36)
4.60
82.6 (3.25)
90501-602L3
29.4 (3.00)
343 (35)
Pink-Silver-Pink
6.0 (0.236)
60 (2.36)
4.82
85.1 (3.35)
90501-602L8
27.0 (2.75)
392 (40)
Green-G reen-Green
6.0 (0.236)
60 (2.36)
5.08
87.9 (3.46)
90501-602L9
29.4 (3.00)
392 (40)
Pink-Green-Pink
6.0 (0.236)
60 (2.36)
4.82
86.7 (3.41)
90501-603L2
24.5 (2.50)
441 (45)
Yellow-White-Yellow
6.0 (0.236)
60 (2.36)
5.39
91.4 (3.60)
90501-603L3
27.0 (2.75)
441 (45)
Green-White-Green
6.0 (0.236)
60 (2.36)
5.08
89.8 (3.54)
90501-624L8
31.9 (3.25)
343 (35)
Orange-Silver-Orange
6.2 (0.244)
60 (2.36)
5.00
84.2 (3.32)
2-64
[]Standard
RX10, RX10S, RX10R, RX10RS
RX10M, RX10MS
GEAR SELECTION
----------------------(J) Clutch weight [AJ Parts no.
~
Weight g (oz) without bush and rivets
8CH-17605-10
35.32 (1.247)
8CR-17605-10
38.09 (1.345)
8DG-17605-00
34.26 (1.209)
8DJ-17605-00
37.77 (1.333)
8DN-17605-20
42.09 (1.486)
8EK-17605-00
39.00 (1.376)
8FA-17605-00
69.43 (2.449)
[Q] Shape & ID mark
I
IANOSJP I (O~ ~ [Q] Standard
OOE>as
RX10, RX10S, RX10M, RX10MS, RX10R, RX10RS
2-65
I
GEAR SELECTION
INSP
ADJ
® Weight rivets [A]
[EJ
[E]
Material
[Q]
90261-06033
Steel
17.2 (0.677)
4.5 (0.159)
IN: RX10, RX10S, RX10R, RX10RS
90269-06006
Steel
17.2 (0.677)
3.6 (0.127) with hole
OUT: RX10, RX10S, RX10R, RX10RS
90261-06034
Steel
13.9 (0.548)
3.6 (0.127)
90261 -06019
Steel
13.3 (0.524)
3.1 (0.109)
90261 -06017
Steel
11 .3 (0.445)
2.7 (0.095)
90266-06002
Steel
13.3 (0.524)
2.4 (0.085) with hole
90261 -06015
Steel
10.3 (0.406)
2.4 (0.085)
90261-06028
Aluminum
10.3 (0.406)
0.8 (0.028)
90266-06001
Aluminum
13.3 (0.524)
0.8 (0.028) with hole
Parts No.
[6]
Length mm(in)
[Q]
Weight g (oz)
None
Standard
Effects
~ Increased Force ~~
~,
[8]
Decreased Force
RX10M, RX10MS
® Rollers I.D. 9 mm (0.354 in)
[A]
Roller with bushing part number
8CR-17624-00
[6]
Outside diameter mm(in) 14.5 (0.57)
[Q]
[Q]
Bushing type (PIN) Duralon
~
Identification mark (Width)
[EJ
Standard
[E]
Grooved & Machined
•
[l]
15.0 (0.59)
Increased force j~
II
90380-09245 8CR-17624-10
Effects
(14.6 mm)
[8]
Duralon
Grooved
RX10, RX10S, RX10R, RX10RS
90380-09245 8CR-17624-20
15.6 (0.61)
8CR-17624-30
16.0 (0.63)
(14.6 mm)
Duralon
[ ] No Mark
90380-09245 Duralon
(14.6 mm)
[JJ
Grooved & Grooved
90380-09245 8CR-17624-40
16.5 (0.65)
Duralon
(14.6 mm)
[KJ
Machined ~,
RX10M, RX10MS
90380-09245
(14.6 mm)
2-66
[M]
Decreased force
(O~
_ __ _ IIANOSJP I ~ I ALTITUDE TUNING _ _ _ _ _ _HIGH HIGH ALTITUDE TUNING To attain the best pertormance in high altitude conditions, carefully tune the snowmobile as outlined below.
Check STD settings â&#x20AC;˘ Carburetors â&#x20AC;˘ Spark plugs
Adjust the main jet size according to the chart
Test the main jet (performance & plug color)
-
Not OK ----
Adjust the size of the main jet
I OK
Re-test OK
OK -
Check to see if the gearing is too high or low
Adjust the engine idle speed by turning the stop screw of carburetor.
Not OK
Not OK
I
I
OK
Adjust the engine idle speed by turning the stop screw of carburetor.
Not OK
OK
Decide if the problem is with the pilot jet and adjust accordingly
Check the engagement speed and shift performance
I Not OK
OK
I
I
Not OK
High altitude tuning OK OK
Not OK
Not OK
Adjust the secondary clutch as required
2-67
OK
INSP ADJ
FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: â&#x20AC;˘ Spring preload
Adjustment steps: â&#x20AC;˘ Turn the spring seat CD in or out. RX10, RX10S, RX10R, RX10RS Spring seat distance
Shorter
Standard
Preload
Harder
+--
-+
+--
Longer
-+
Min. Length@
Softer Max.
250mm (9.84 in)
258mm 260mm (10.16 in) (10.24 in)
RX10M, RX10MS Spring seat distance
Shorter
Standard
Preload
Harder
+--
-+
+--
-+
Min. Length@
213mm (8.39 in)
Longer Softer Max.
223mm (8.78 in)
226mm (8.90 in)
Be sure that the left and right spring preloads are the same.
~ ---------This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could cause it to explode.
2-68
REAR SUSPENSION
INSP ADJ
REAR SUSPENSION Stopper band 1. Adjust: eStopper band tension
Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. NOTE: - - - - - - - - - - - - This adjustment affects the handling characteristics of the machine. Adjustment steps: eLoosenthelocknutGD. eTurn the adjusting nut ® in or out to adjust the stopper band tension. Adjuster thread length ®
RX10, RX10S, RX10R, RX10RS: 25 ± 0.5 mm (0.98 ± 0.02 in) RX10M, RX10MS: 10 ± 0.5 mm (0.39 ± 0.02 in) Longer Shorter (Maximum) (Minimum)
Effects
More weight on skis; Less weight transfer
Less weight on skis; More weight transfer
eTighten the locknut.
,
~~
Locknut: 16 Nm (1.6 m-kg, 12 ft-Ib)
[A] RX10, RX10S, RX10R, RX10RS [B] RX10M, RX10MS
2-69
REAR SUSPENSION
IANOSJP I (O~ ~
I
--------------------------Spring preload (RX10, RX10S, RX10R, A I
RX10RS) 1. Adjust: • Spring preload
®
Adjustment step: • Turn the spring seat CD in or out. Front [A] SCH2910
Spring seat distance
Standard Shorter +--+ Longer
Preload
Harder +--
-+ Softer
Min. Length®
Max.
180mm (7.09 in)
190mm (7.48 in)
190mm (7.48 in)
ffmmIImI ---------This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could cause it to explode.
B
• Turn the adjusting ring tion.
CD to the proper posi-
4
o o
S
6
7
Spring adjuster position
1
Preload
Softer +--
[al Rear Standard
2-70
2
3
4
5
6
7
-+ Harder
4
REAR SUSPENSION
IANOSJP I (O~ ~
I
---------------------------Spring preload (RX10M, RX10MS) I
1. Adjust: • Spring preload Adjustment steps: • Turn the adjusting ring tion.
B
CD to the proper posi-
Spring adjuster position
1
Preload
Softer
2
3 +--
[A] Front Standard
S
6
Harder
--+
3
Spring adjuster position
1
Preload
Softer
2
3
4
5
+--
[aJ Rear Standard
4
o o
5
4
--+
6
7
Harder
4
7
Rear suspension full rate 1. Adjust: • Full rate adjuster
----
-- ----",.y::.--
Adjustment steps: Installation position Spring rate and damping Standard
A
B
C
Soft
Medium
Hard
B
NOTE: - - - - - - - - - - - Be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile. • Loosen the nut CD 1/2 or 3/4 turns, while holding the adjusting bolt ® securely with a wrench so it does not move.
t
Never allow the adjusting bolt while loosening the nut.
2-71
®
to move
REAR SUSPENSION
IANOSJP I (O~ ~
I
--------------------------- Turn the adjusting boltÂŽ to the desired posiI
tion.
2
Be sure the adjusting bolt ends are set at the same position on each side. - While holding the adjusting bolt securely, tighten the nut CD.
Nut (shock absorber): 49 Nm (4.9 m-kg, 35 ft-Ib)
Never allow the adjusting bolt to move while tightening the nut. - This model has a "Easy adjust" system for the Full rate adjuster. The bolt has teeth on it. So when the bolt is turned, it rides up and down the bracket. NOTE: - - - - - - - - - - - - - - The nut has to be loosen first, while the bolt is held in place with a wrench. - Then the bolt can be turned to adjust the shock position up or down. -If the bolt is turned with the nut tight, it is possible to strip the teeth off the bolt.
2-72
INSP ADJ
REAR SUSPENSION Control rod 1. Adjust: e Control rod stroke ®
Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: e Loosen the lock nut CD. e Turn the adjusting nut ® in or out to adjust the control rod stroke. Adjusting position
1
3
2
Increase +weight transfer
Effect Standard
4
-.+Decrease pitching
3
~ ---------Never adjust the control rods beyond the maximum range indicated on the rods with red paint@. e
,
r - -IT -
~ ~
o-----../h\
I I
II II
:
::
I
II
I
II
While holding the adjusting bolt securely, tighten the locknut CD.
~~
Locknut: 25 Nm (2.5 mekg, 18 ftelb)
Rear suspension position (RX10M, RX10MS) 1. Adjust: e Rear suspension position
-
I I:- -
NOTE: - - - - - - - - - - - - - Select the rear suspension position according to the snow conditions: ® standard; @ deep new snow.
_______________ r -
SCH2935
Bolt (slide rail suspension): 72 Nm (7.2 mekg, 52 ftelb)
2-73
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~
CHASSIS STEERING RX10, RX10S, RX10R, RX10RS
!AI : I
10 Nm (1.0 mekg, 7.2 ttelb)
[B] :
15 Nm (1.5 mekg, 11 ttelb)
I
2
Order
Q'ty
Job name/Part name
Handlebar removal 1
2 3 4 5 6 7
8 9 10 11 12
Remarks Remove the parts in the order listed below.
1
Handlebar cover Plastic band Thumb warmer lead coupler Thumb warmer switch lead coupler Engine stop switch coupler Brake switch coupler Headlight beam switch coupler Grip warmer lead coupler Grip warmer switch lead coupler Throttle cable holder Throttle cable Brake lever holder
2 1 1 1 1 1
4 1 1 1 1
3-1
Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I [BJ : I [AJ :
I~
10 Nm (1.0 m.kg, 7.2 tt.lb)
15 Nm (1.5 m.kg, 11 tt.lb)
2
Order
13 14 15 16 17
Job name/Part name
Q'ty
Remarks
1
NOTE: After installing all parts, refer to "CABLE ROUTING" in CHAPTER 9, to check the cable, lead and hose routings.
Master cylinder assembly Handlebar holder (upper) Cable holder Handlebar Handlebar holder (lower)
2
1 1 1
For installation, reverse the removal procedure.
3-2
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~
RX10M, RX10MS
I [BJ : I [A] :
10 Nm (1.0 m-kg, 7.2 tt-Ib) 15 Nm (1.5 m-kg, 11 tt-Ib)
2
Order 1 2
3 4 5 6 7
8 9 10 11 12
Job name/Part name
Q'ty
Handlebar removal Handlebar cover Plastic band Thumb warmer lead coupler Thumb warmer switch lead coupler Engine stop switch coupler Brake switch coupler Headlight beam switch coupler Grip warmer lead coupler Grip warmer switch lead coupler Throttle cable holder Throttle cable Brake lever holder
Remarks Remove the parts in the order listed below.
1
3 1 1 1 1 1
4 1 1 1 1
3-3
Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I [BJ : I [AJ :
I~
10 Nm (1.0 m-kg, 7.2 tt-Ib) 15 Nm (1.5 m-kg, 11ft-lb)
2
Order
13 14 15 16 17
Job name/Part name
Q'ty
Remarks
1
NOTE: After installing all parts, refer to "CABLE ROUTING" in CHAPTER 9, to check the cable, lead and hose routings.
Master cylinder assembly Handlebar holder (upper) Cable holder Handlebar Handlebar holder (lower)
2
1 1 1
For installation, reverse the removal procedure.
3-4
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
1
5
~~ ~ ---l~
7
F
6
~
~ v
I
/~
AJ
V
8 9 10 11 12 13 14 15 16
7
&.
~rJ
~;~
4
~ ~3 mil 13
~,~~_ ~~ _ ~B
~
1 2 3 4 5 6 7
~
8 7
15~~3m11
~ ~ <}12
Order
~
9
15
II
---t :
~
8
~1\1l~ ~3m11 V\~ ~ __ '--
17
<}12~Y A
0~~"
6
7
1
~
,
1~~'~
>\)~)
~
F
I~
/~)
I~------_
[AJ : 25 Nm (2.5 m.kg, 18 tt.lb) [BJ : 1==3=5=N=m=(3=.5=m=.=k=g,=2=5=tt.=lb=)= [Q :
I===========~ 30 Nm (3.0 m.kg, 22 ft·lb)
I [E] : I [Q] :
35 Nm (3.5 m.kg, 25 tt.lb)
=========~
CD ESSO beacon 325 grease or
67 Nm (6.7 m.kg, 49 tt.lb)
rp .I=========~
Aeroshell grease #7A
LCJ •
Job name/Part name
Q'ty
Steering column and tie rod removal Handlebar Clip Relay rod Cotter pin Steering shaft Steering column 1 Lock plate Bearing Bearing holder Plate Collar Steering column 2 Tie rod Idler arm Relay arm Bushing Washer 3-5
~_2_3_N_m_(2_3_m_._kg__,_1_7_tt._lb_)_
Remarks Remove the parts in the order listed below.
6 1 7 1 1 3 6 6 4 6 1 2 1 2 4 2
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
1
~ ~ "_~
6 , /
~\~
5
~
-\J{
ImI
~~~~
6 8
~1~~ ~~
1/-\~ 4~:
_
~
,
1
8~~,(7
j
F
~
@~
10 7
,,~9
X
/
(I
16~ ~
A
15
~
/AJ
~3 ImI
/"--L')
~
--. : CD ESSO beacon 325 grease or Aeroshell grease #7A
Order
17 18 19
Job name/Part name
~V
~7
~1 ~----8 ~
7
8
31m1
C
13
V12~~~ _ ~ .~~~-----rnJ V
~
~~
~;~
4
15
~
7 11
~"~
.~~ 1J9 ~ t\~~31m1 0~~~~'~ ~31m1 A12~~ ~~~ V A
I~
Q'ty
[A] : 1r=:::;:25~N=m::::::::(2=.5=m=ek=9=,1=8=ft=e1b=)====1
I [Q] : I [QJ : I [E] : I [E] : I [HJ :
35 Nm (3.5 m.kg, 25 tt.lb) 30 Nm (3.0 m.kg, 22 tt.lb) 35 Nm (3.5 m.kg, 25 tt.lb) 67 Nm (6.7 m.kg, 49 tt.lb) 23 Nm (23 m.kg, 17 tt.lb)
Remarks
4 2 2
Washer Collar Clip
For installation, reverse the removal procedure.
3-6
I I I I I
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I
INSPECTION 1. Inspect: -Handlebar CD (RX10, RX10S, RX10R, RX10RS) -Handlebar® (RX10M, RX10MS) - Steering column ® Bends/cracks/damage -+ Replace.
,
p1r---------LQ3-4,~ 1
I~
m!mmDIm1 ----------
SCH3040
Do not attempt to straighten a bent column. This may dangerously weaken the column. 2. Inspect: - Bearings (steering column) CD -Collars® Wear/damage -+ Replace. - Steering column ® (bearing contact surfaces) Scratches/wear/damage -+ Replace.
SCH3050
3. Inspect: - Relay rod CD -Tie rod ® Bends/cracks/damage
-+
Replace.
m!mmDIm1 ---------Do not attempt to straighten bent rods. This may dangerously weaken the rods.
4. Check: - Rod end movement Rod end free play exists -+ Replace the rod end. Rod end turns roughly -+ Replace the rod end.
5. Inspect: - Relay arm CD -Idler arm ® Cracks/damage
~---~ 3-7
-+
Replace.
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~
I
INSTALLATION 1. Install: - Relay arms CD - Bushings -Washers® ,
~~
Bolt (relay arm): 67 Nm (6.7 m-kg, 49 ft-Ib)
-Clips® 2. Install: -Idler arm @ - Bushings -Washers -Relay rod(§) Nut (idler arm): 35 Nm (3.5 m-kg, 25 ft-Ib) Nut (relay rod): 30 Nm (3.0 m-kg, 22 ft-Ib)
n
3. Install: -Tie rod CD - Locknuts ® -Joints®
®
II--@----
[A] Tie rod part number
~«
8FA-23831-00 (RX10, RX10S,
[BJ
Set length@
[Q] Tie rod length @
418.0 mm (16.4567 in)
355.0 mm (13.9764 in)
374.0 mm (14.7244 in)
311.0 mm (12.2441 in)
RX10R, RX10RS)
8EP-23831-00 (RX10M, RX10MS)
4. Install: -Tie rods CD NOTE: - - - - - - - - - - - - - Make sure that the indentation @ on the tie rod faces out. - The threads on both rod ends must be the same length.
3-8
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~
I
Always use new cotter pins. Locknut (rod end): 25 Nm (2.5 m-kg, 18 ft-Ib) LOCTITE® Nut (tie rod-idler arm): 30 Nm (3.0 m-kg, 22 ft-Ib) Nut (tie rod-steering arm): 35 Nm (3.5 m-kg, 25 ft-Ib)
5. Install: - Steering shaft CD -Locknuts® -Joints@
®
II--@-~ ~« I
[A] Steering Shaft part number
cb
8FA-23840-00
[BJ Set length
®
227.8 mm (8.9685 in)
[Q] Shaft length
@
170.0 mm (6.6929 in)
NOTE: - - - - - - - - - - - Make sure that the end of the steering shaft with the indentation ® is connected to the steering clumn.
Always use new cotter pins. Nut (steering shaft): 35 Nm (3.5 m-kg, 25 ft-Ib)
3-9
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~
I
6. Adjust: -Skis
Adjustment steps: - Temporarily install the handlebar. - Hold the handlebar straight and check that the skis and relay arms are at right angles to the handlebar. - Loosen the locknuts (steering shaft) CD. - Hold the handlebar straight. - Adjust the steering shaft® by turning so that the right and left relay arms point right under. - Adjust each angle of right and left skis by turning the tie rod respectively. Turning the steering shaft in direction @
Turning the handlebar in direction ©
Turning the steering shaft in direction ©
Turning the handlebar in direction @
- Tighten the locknuts (Steering shaft) CD.
'.t7
~~
Loknut (steering shaft): 25 Nm (2.5 m-kg, 18 ft-Ib) LOCTITE®
7. Install: - Handlebar SGH3150
a ~
- Be sure the projection on the handlebar is not installed into the area @ shown. - Be sure the side of the holder with the small gap © faces forward. - First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side. - Center the match mark © on the handlebar CD between the lower handlebar holders®.
b
(@t~]j f~l a < b
(FWDI SCH3160
Bolt (handlebar holder): 15 Nm (1.5 m-kg, 11 ft-Ib)
2 SCH3170
3-10
11 1 Nm (1 .1 m-kg ' 8 .0 tt-Ib) 17 Nm (1.7 m-kg, 12 tt-Ib) 9 Nm (19m 48 . -kg, 14 tt-Ib)
---t .
CD Nm (4.8 m-kg, 35 ft-Ib)
. 1 ESSO grease or Abeacon 325 grease #7Aeroshell
Sk"
Job name/P
Remarks
art name
I removal Cotter pin Ski stopper Collar Washer Ski column I Ski runner ower bracket
I Removethe parts in the order listed beow.
Collar Ski Washer Ski handle For installatio . n, reverse the rem oval procedure
3-11
________________S_KI_lcHASI~I INSPECTION 1. Inspect: ·Ski CD • Ski runner ® • Ski stopper @ • Ski column lower bracket @ • Ski handle @ Wear/cracks/damage -+ Replace. • Mounting bolt @ • Collar (f) .Bolts@ .Collars@ Wear/damage -+ Replace.
SCH3210
INSTALLATION 1. Install: • Ski column lower bracket CD NOTE: - - - - - - - - - - - - Be sure to install the ski column lower bracket with the arrow mark ® pointing forward the tip of the ski.
3-12
FRONT SUSPENSION
I J-I CHAS I
FRONT SUSPENSION
45 Nm (4.5 mekg, 33 ftelb) 37 Nm (3.7 mekg, 27 ftelb) 40 Nm (4.0 mekg, 29 ftelb) 35 Nm (3.5 mekg, 25 ftelb) 65 Nm (6.5 mekg, 47 ftelb) 34 Nm (3.4 mekg, 25 ftelb) 11 Nm (1.1 mekg, 8.0 ftelb)
~
: CD ESSO beacon 325 grease or Aeroshell grease #7A
Order
1 2 3
4 5 6 7 8 9 10 11 12
Job name/Part name
Q'ty
Front suspension removal Ski Front cover Shock absorber Cap Steering arm Ski column Bushing Upper arm Lower arm Collar Bushing Connecting rod Stabilizer arm
Remarks Remove the parts in the order listed below. Refer to "SKI".
1 1 1 1 1 1 1 1 2
4 1 1
3-13
FRONT SUSPENSION
~ : (
~-
~(.' ..., :::---;-
I
0
0
0
V~ -
\~,,--",,"""---<-r\~~ ~~ --
[Q] : 1==4=0=N=m=(4=.0=m=.=k=g,=2=9=tt=.lb=)=
~ ~
~-
I
Q_;
~: 1~_11_N_m_(1_.1_m_._kg__,_8_.0_tt_.lb_)_
<~~ :~rll
0
~10
7
d"1O~
~..
10 8
~
13 14 15
Y
·~13
qg:------14
...
~~~
;j; , ~
~~~~~ o1:LJ~~4 'C; r§f!j=
~
Order
<:)
\'
~
~
I=====::::::::==== 35 Nm (3.5 m-kg, 25 tt-Ib) [E: I 65 Nm (6.5 m-kg, 47 tt-Ib) 1========= [EJ : 34 Nm (3.4 m·kg, 25 ft·lb) [QJ :
2
~_-~:
~ =:\ 'f'--(J
Q
Q
~I
I
~J ~~~
• --1
I
[AJ : 45 Nm (4.5 m-kg, 33 tt-Ib) [B] : 1==3=7=N=m=(3=.7=m=.=k=g,=2=7=tt=.lb=)=
~
~
ICHAS
11
"'6
: CD
ESSO beacon 325 grease or Aeroshell grease #7A
Job name/Part name
Q'ty
Remarks
1 1
Stabilizer Steering knuckle Collar
2 For installation, reverse the removal procedure.
3-14
FRONT SUSPENSION
I J-I CHAS I
HANDLING NOTES
~
----------
This shock absorber contains highly compressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. - Do not tamper or attempt to open the gas chamber. - Do not subject the shock absorber to flames or any other source of high heat. This may cause the unit to explode due to excessive gas pressure. - Do not deform or damage the gas chamber in any way. Gas chamber damage will result in poor damping performance.
INSPECTION 1. Inspect: - Shock absorber CD Oil (gas) leaks/bends/damage
-+
Replace.
2. Inspect: - Ski column CD - Steering arm ÂŽ Cracks/bends/damage -+ Replace. -Sushing@ Wear/scratches/damage -+ Replace.
3. Inspect: - Upper arm CD -Lower arm ÂŽ Cracks/bends/damage -+ Replace. -Sushing@ -Collar@ Wear/scratches/damage -+ Replace.
3
3-15
FRONT SUSPENSION
ICHAS ~ I I
4. Inspect: - Connecting rod CD - Stabilizer ® - Stabilizer arm @ Cracks/bends/damage --+ Replace. -Sushing@ Wear/scratches/damage --+ Replace.
INSTALLATION 1. Install: - Steering arm CD NOTE: - - - - - - - - - - - - - Align the punch mark@ on the ski column with the punch mark @ on the steering arm. -Install sections © without any gaps. Nut (steering arm): 35 Nm (3.5 m-kg, 25 ft-Ib)
2. Install: - Stabilizer CD - Stabilizer arm ®
_~u
NOTE: - - - - - - - - - - - Install so that the angle shift between the right side stabilizer arm and the left stabilizer arm can be within 6°. Nut (stabilizer arm): 11 Nm (1.1m-kg, 8.0 ft-Ib)
3-16
FRONT SUSPENSION
I J-I CHAS I
Ski alignment NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Be sure to verify the spring preload setting and the ski spindle camber before adjusting the ski toe out since either of those adjustments may affect the ski toe out setting. Point the skis straight forward and measure the amount of ski toe out.
o~
[AJ Ski toe out: 15 mm (0 ~ 0.59 in)
® -@ = Toe out Refer to "STEERING SYSTEM" in CHAPTER 2. SCH3380
3-17
POTWRRI~I I ----------------------POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT
~
PRIMARY SHEAVE AND DRIVE V-BELT [AJ:
120 Nm (12 mekg, 85 ftelb)
......---+-----------1 60 Nm (6.0 mekg, 43 ftelb)
Order 1
2 3
Job name/Part name
Q'ty
Primary sheave removal Left side cover V-belt Primary sheave assembly
Remarks Remove the parts in the order listed below.
1 1 1
For installation, reverse the removal procedure.
4-1
POTWRRI~I I -------------------------~
PRIMARY SHEAVE AND DRIVE V-BELT
IAJ : I
6 Nm (0.6 m.kg, 4.3 tt.lb)
I 14 Nm (1 .4 m.kg, 10 tt.lb) [Q] : I 200 Nm (20.0 m.kg, 145 tt.lb) [BJ :
u
[Q] : Clean the threads. Apply LOCTITE648 as illustrated in [EJ . And then tighten the spider. (The spider must be turned counterclockwise to be tightened.)
Order
Job name/Part name
®
©
Q'ty
@ @ @
®
(f) @
®
@ @ @ @ @
Remarks Disassemble the parts in the order listed below.
Primary sheave disassembly
CD ®
16 mm (0.63 in) 30 mm (1.18 in)
Primary sheave cap Primary sheave spring Collar Roller Washer Collar Weight Washer Fixed sheave Stopper Sliding sheave Bushing Spider Slider
1 1
3 3 6 3 3 6 1 1 1 1 1
Left-handed thread.
6 For assembly, reverse the disassembly procedure.
4-2
POTWRRI~I I --------------------------PRIMARY SHEAVE AND DRIVE V-BELT
~
REMOVAL 1. Remove: - Primary sheave assembly CD
NOTE: - - - - - - - - - - - - - Use the primary sheave holder ® and primary sheave puller @.
Primary sheave holder: 90890-01701, YS-01880 Primary sheave puller: 90890-01898 YS-01881-1, YS-01882-1
DISASSEMBLY 1. Remove: - Fixed sheave CD -Stopper® - Sliding sheave @ -Sushing@ -Spider@
Removal steps: -Immerse the primary sheave assembly in 80 -- 100°C (176 -- 212°F) water for several minutes. - Attach the lower piece of the clutch spider separator@ onto a rigid table using suitable mounting bolts. Then, install the clutch separator adapter(J) onto the separator.
SCH4050
Clutch spider separator: 90890-01711, YS-28890-B Clutch separator adapter: 90890-01740, YS-34480
SCH4060
4-3
POTWRRI~I I ---------------------------PRIMARY SHEAVE AND DRIVE V-BELT
~
• Fit the primary sheave assembly onto the adapter and secure the supporting plates@.
NOTE: - - - - - - - - - - - - - Securely fit the projections on the adapter into the fixed sheave holes. • Set the bar wrench ® onto the spider and turn the special tool clockwise to loosen the spider.
SCH4070
Clutch spider separator (bar wrench): 90890-01711, YS-28890-B
• The spider has a left-handed thread. • Since a high torque is required to loosen the spider, make sure that the spider, fixed sheave and special tool are well secured. Loosen the spider carefully to prevent cracks and damage to the sheaves and spider. • Remove the fixed sheave, fixed sheave stopper, and sliding sheave from the spider.
4-4
POTWRRI~I I --------------------------PRIMARY SHEAVE AND DRIVE V-BELT
~
INSPECTION 1. Inspect: • Spider CD • Sliding sheave ® • Fixed sheave @ • Primary sheave cap @ Cracks/damage -+ Replace.
2. Inspect: • Primary sheave spring CD Cracks/damage -+ Replace. 3. Measure: • Primary sheave spring free length @ Out of specification -+ Replace the primary sheave spring.
®
Primary sheave spring free length:
RX10, RX10S, RX10R, RX10RS: 87.4 mm (3.44 in)
RX10M, RX10MS: 84.2 mm (3.32 in) NOTE: - - - - - - - - - - - - When changing the primary sheave springs, refer to "GEAR SELECTION" in CHAPTER 2.
4. Inspect: • Primary sheave cap bush CD • Sliding sheave bush ® Cracks/damage -+ Replace.
~l_C_I_Ut_C_h_b_U_s_h_in_g_p_re_s_s_: ~ YS-42424
4-5
.....
POTWRRI~I I --------------------------~
PRIMARY SHEAVE AND DRIVE V-BELT
5. Inspect: -WeightG) -RollerÂŽ -Bushing@ -Slider@ -Rivet@ -Collar Wear/scratches/damage
-+
Replace.
Slider inside clearance @ + @ Min. 0 mm (0 in) Max. 0.3 mm (0.0118 in)
SCH4110
:
Rivet replacement steps: - Remove old rivet with the appropriate drill. -Insert the rivet G) from the ID mark ÂŽ side. - Press or peen the rivet head so that the diameter @ of the rivet head measures 8.2 mm (0.32 in) or larger.
SCH4120
A
6. Measure: - Bushing inside diameter Out of specification -+ Replace as a set.
B
Bushing inside diameter: [A] Roller New: 9.077 mm (0.357 in) Wear limit: 9.3 mm (0.366 in) [BJ Weight New: 8.077 mm (0.318 in) Wear limit: 8.3 mm (0.327 in)
SCH4130
c
NOTE: - - - - - - - - - - - - - When replacing the weight and roller bushings, use the YXR clutch bushing jig kit.
D
. '.
YXR clutch bushing jig kit: YS-39752
[Q] Removing [Q] Installing
SCH4140
4-6
POTWRRI~I I --------------------------PRIMARY SHEAVE AND DRIVE V-BELT
~
ASSEMBLY 1. Install: • Sliding sheave (onto the spider)
NOTE: - - - - - - - - - - - - - Be sure the sliding sheave match mark (X) is aligned with the spider match mark (X). SCH4150
2. Install: • Fixed sheave (onto the spider)
NOTE: - - - - - - - - - - - - - • Clean the threads. • Apply LOCTITE648 to the fixed sheave as shown. SCH4160
LOCTITE® should be applied only to the specified area. Never apply it to the bushings and other areas.
@ @
16 mm (0.63 in) 30 mm (1.18 in)
3. Install: • Fixed sheave stoppers CD
NOTE: - - - - - - - - - - - - - Stopper tapered portion should face fixed sheave. 4. Tighten: • Spider
'--'--------/
Tightening steps: • Finger-tighten the spider until it is stopped by the fixed sheave stopper. • Hold the fixed sheave with the clutch spider separator CD.
.......
SCH4170
Clutch spider separator: 90890-01711, YS-28890-B NOTE: - - - - - - - - - - - - - Securely fit the projections on the clutch separator adapter ® into the fixed sheave holes.
SCH4180
4-7
POTWRRI~I I --------------------------PRIMARY SHEAVE AND DRIVE V-BELT
~
- Tighten the spider to specification using the bar wrench ®.
Spider: 200 Nm (20 m-kg, 145 ft-Ib)
The spider has a left-handed thread.
SCH4190
fimiIDIm]
----------
- Do not operate the primary sheave until the LOCTITE® has dried completely. Wait 24 hours before operating the primary sheave. - Since a high torque is required to tighten the spider, make sure the spider, fixed sheave, and special tool are well secured. Tighten the spider carefully to prevent cracks and damage to the sheaves and spider.
~ ,
~"
5. Install: -Weight - Bolts CD -Nuts®
\
j))l~
Nut: 6 Nm (0.6 m-kg, 4.3 ft-Ib) SCH4200
NOTE: - - - - - - - - - - - - - To maintain the primary sheave balance, the bolts ® must be installed with their threaded portions pointing in a counterclockwise direction, as illustrated.
6. Install: - Primary sheave spring CD - Primary sheave cap ®
NOTE: - - - - - - - - - - - - Be sure the sheave cap match mark (X) is aligned with the spider match mark (X). Primary sheave cap bolt: 14 Nm (1.4 m-kg, 10 ft-Ib)
SCH4210
4-8
POTWRRI~I I --------------------------PRIMARY SHEAVE AND DRIVE V-BELT
~
INSTALLATION 1. Install: - Primary sheave assembly
Be sure to remove any oil or grease from the tapered portion of the crankshaft and spider using a cloth dampened with thinner.
2. Apply: - Engine oil or an equivalent grease (to threads of primary sheave bolt)
oo---@ SCH4240
3. Tighten: - Bolt (primary sheave) CD Tightening steps: - Hold the primary sheave @ using the primary sheave holder ® and tighten the bolt (primary sheave) to specification. Primary sheave holder: 90890-01701, YS-01880
SCH4250
~
&'~
Bolt (primary sheave): (1st) 120 Nm (12 m-kg, 85 ft-Ib)
- Loosen the bolt (primary sheave) completely. - Retighten the bolt (primary sheave) to specification.
'ffJ
Bolt (primary sheave):
~~ (2nd)
60 Nm (6.0 m-kg, 43 ft-Ib)
4. Adjust: - V-belt position Refer to "DRIVE V-BELT" in CHAPTER 2. - Sheave offset - Secondary sheave free play (clearance) Refer to "SHEAVE OFFSET ADJUSTMENT" in CHAPTER 2. 4-9
POTWRRI~I I ------------------------SECONDARY SHEAVE
~
SECONDARY SHEAVE
IAJ : I
64 Nm (6.4 mekg, 46 ftelb)
A
Order
1 2 3
4 5
Job name/Part name
Q'ty
Secondary sheave removal Left side cover V-belt Washer and bolt Shim
-
Collar Secondary sheave assembly Shim
1 1 -
Remarks Remove the parts in the order listed below. Refer to "PRIMARY SHEAVE AND - V-BELT".
-~
1
Refer to "SHEAVE OFFSET ADJUSTMENT" in CHAPTER 2.
For installation, reverse the removal procedure.
4-10
POTWRRI~I I ------------------------SECONDARY SHEAVE
I [6] : I [Q] : I [AJ :
~
7 Nm (0.7 m-kg, 5.1 tt-Ib) 10 Nm (1.0 m-kg, 7.2 tt-Ib) 23 Nm (2.3 m-kg, 17 tt-Ib)
5
~:
Order
Job name/Part name
Q'ty
Secondary sheave disassembly
CD ®
@ @ @
CD
ESSO beacon 325 grease or Aeroshell grease #7A
Remarks Remove the parts in the order listed below.
1 1 1 1 1
Spring seat Secondary sheave spring Fixed sheave Stopper Sliding sheave
For assembly, reverse the disassembly procedure.
4-11
POTWRRI~I I ---------------------------SECONDARY SHEAVE
~
DISASSEMBLY
~ ---------• Use extreme CAUTION when disassembling the secondary sheave since serious injury can occur due to the sudden release of spring tension. Use the sheave compressor to contain the spring tension before removing the nuts (spring seat). • Do not attempt this procedure unless you have the proper tools and understand the instructions thoroughly. 1. Remove: • Nuts (spring seat)
INSPECTION 1. Inspect: • Sliding sheave CD • Fixed sheave ® • Spring seat ® Cracks/damage -+ Replace. • Stopper@ Wear/damage -+ Replace.
2
SCH4290
2. Inspect: • Bushing (spring seat) CD • Sliding sheave (V-belt contact surlace) ® Scratches/wear/damage -+ Replace. • Sliding bushing ® Unsymmetrical wear/damage -+ Replace.
2
SCH4300
3. Inspect: • Secondary sheave spring CD Cracks/damage -+ Replace. 4. Measure: • Secondary sheave spring free length ® Below specification -+ Replace the secondary sheave spring. @ SCH4310
4-12
I
~l
Free length:
:6]~_7_5_m_m_(2_.9_5_in_)
......
POTWRRI~I I --------------------------SECONDARY SHEAVE
~
5. Measure: - Ramp shoe thickness 速 Out of specification -+ Replace the ramp shoe.
I:6l ~
速
Wear limit: 1 _.0_m_ m _(0_._04_in_)- - - - - - -
SCH4320
ASSEMBLY 1. Install: -Stopper - Sliding sheave
Screw (stopper): 7 Nm (0.7 m-kg, 5.1 ft-Ib)
2. Install: - Fixed sheave CD -Bolts速 (along with the shims)
!
Bolt: 10 Nm (1.0 m-kg, 7.2 ft-Ib)
SCH4330
3. Install: - Secondary sheave spring CD - Spring seat 速 NOTE: - - - - - - - - - - - - Hook the end of the secondary sheave spring into the spring holes in the fixed sheave. Hook the other end of the spring into the holes in the spring seat. SCH4340
Standard spring position: 3-3 (RX10, RX10S, RX10R, RX10RS) 1-6 (RX10M, RX10MS)
4-13
POTWRRI~I I --------------------------SECONDARY SHEAVE
~
Installation steps: - Hold the spring seat CD and turn the fixed sheave ® counterclockwise to the specified angle®.
NOTE: - - - - - - - - - - - - - The holes in the spring seat should align with the bolts on the sliding sheave.
® =(sheave hole number + spring seat hole number) x 10 Twist angle: 60° (RX10, RX10S, RX10R, RX10RS) 70° (RX10M, RX10MS) - Push down on the spring seat until the bolts come through the holes. - While pushing down on the spring seat, install the nuts and tighten them to the specified torque.
Nut (spring seat): 23 Nm (2.3 m-kg, 17 ft-Ib)
4. Measure: - Secondary sheave clearance ® Out of specification -+ Adjust.
Secondary sheave clearance: 35.0 -- 35.8 mm (1.38 -- 1.41 in)
I.
®
5. Calculate: - Shim thickness
.1 SCH4370
NOTE: - - - - - - - - - - - - For example, if the clearance is 36 mm (1.42 in), install a 0.5 mm (0.02 in) shim on each bolt so the clearance is 35.5 mm (1.40 in). 6. Adjust: - Secondary sheave clearance
4-14
POTWRRI~I I --------------------------SECONDARY SHEAVE
~
Adjustment steps: • Disassemble the secondary sheave. • Remove the bolts and original shims CD. • Install new shims of the proper thickness and reassemble the secondary sheave. • Measure the secondary sheave clearance again. Repeat these steps until the clearance is within specification.
NOTE: - - - - - - - - - - - Yamaha recommends keeping the original shims. Shims: Part number
Thickness
90201-061 H1
0.5 mm (0.02 in)
90201-06037
1.0 mm (0.04 in)
INSTALLATION 1. Lubricate: • Splines (fixed sheave) Recommended grease: ESSO beacon 325 grease or Aeroshell grease #7A 2. Tighten:
'.#7
~~
Secondary sheave bolt: 64 Nm (6.4 mekg, 46 ftelb)
3. Adjust: • V-belt position Refer to "DRIVE V-BELT" in CHAPTER 2. • Sheave offset • Secondary sheave free play (clearance) Refer to "SHEAVE DISTANCE AND OFFSET ADJUSTMENT" in CHAPTER 2.
4-15
DRIVE CHAIN HOUSING
RE~~~ SE HOUSING MODEL
DRIVE CH
WITHOUT
I [B] : I [Q] : I [Q] : I [E: I [AJ :
Job name/P art name D . rive chain ho · Brak~ caliper usmg removal
Remarks Remove the a " Retfer to "BR~K~'In the order listed b I e er to "BRAKE": e ow. R
P?rklng brake Right side Brake d"ISC cover Chain ten" sion ad" Drain bolt Juster Drive chain ho " Chain tension uSing cover Roller er
g~~:rsprocket Dr~ve
chain g~~:~ sprocket Drive chain houslng " For installatio . n, reverse the rem oval procedure
4-16
POTWRRI~I I --------------------------~
DRIVE CHAIN HOUSING
INSPECTION 1. Inspect: • Drive chain housing CD • Drive chain housing cover ® Cracks/damage --+ Replace. ·Oil seals (drive chain housing) Wear/damage --+ Replace. • Bearings (drive chain housing and cover) ® Pitting/damage --+ Replace. • Bearing (chain tensioner) @ Pitting/damage --+ Replace the bearing and the inner race holder as a set.
5
Replacement steps: • Remove the circlip @ (drive chain housing). • Remove the bearing(s) ® using a general bearing puller. • Install the new bearing(s).
•
NOTE: - - - - - - - - - - - - - Use a socket@ that is the same size as the outside diameter of the bearing race.
Do not strike the inner race (f) or ball bearings@. Contact only the outer race @. • Install a new circlip (drive chain housing).
Always use new circlips.
2. Inspect: • Drive sprocket CD • Driven sprocket ® • Chain tensioner ® Pitting/wear/damage
4-17
--+
Replace.
POTWRRI~I I --------------------------DRIVE CHAIN HOUSING
3. Measure: • 14 link section ® of the drive chain Using a spring scale, pull on the drive chain with 36 kg (80 Ib) of force @. Out of specification --+ Replace the drive chain.
CD®@@@@(j)@@@)@@@C@@) 11
~
i:iii!i:i!iii:iii!i:i!iii!iii!
Maximum 14 link drive chain section length: 133.35 mm (5.25 in) Limit: 137.35 mm (5.41 in)
®
NOTE: - - - - - - - - - - - - • Measure the length between drive chain pin CD and ® as shown. • Perform this measurement at two or three different places.
---~
If replacement is necessary, always replace the chain and the sprockets as a set. 4. Inspect: • Drive chain CD Stiffness --+ Clean and lubricate or replace. • Drive chain plates ® Damage/wear --+ Replace the drive chain. Cracks --+ Replace the drive chain.
4-18
POTWRRI~I I ---------------------------DRIVE CHAIN HOUSING
~
INSTALLATION 1. During installation, pay attention to the following.
[A] Make sure that the bearing seals face towards the drive chain as shown. ~ Properly install the rubber seal onto the drive
chain housing, making sure that there are no gaps.
[QJ [QJ [gJ Be sure to install the spacers in their original positions, otherwise the brake disc and jackshaft will stick.
[Q] 0.2 -- 0.6 mm (0.008 -- 0.024 in) ---t : ESSO beacon 325 grease or Aeroshell grease #7A
For the jackshaft and drive chain housing installation, refer to "SECONDARYSHAFT". 2. Fill: • Drive chain housing oil Refer to "DRIVE CHAIN" in CHAPTER 2. 3. Adjust: • Drive chain slack Refer to "DRIVE CHAIN" in CHAPTER 2.
4-19
POTWRRI~I I ------------------------~
DRIVE CHAIN HOUSING
WITH REVERSE MODEL
I 16 Nm (1.6 m-kg, 12 tt-Ib) [BJ : I========== 24 Nm (2.4 m-kg, 17 tt-Ib) ========== [Q : I 48 Nm (4.8 m-kg, 35 tt-Ib) [Q] : I========== 90 Nm (9.0 m-kg, 65 tt-Ib) ========== [EJ : I 10 Nm (1 .0 m-kg, 7.2 tt-Ib) [AI :
==========
~~
[E] : lo....-_6_N_rn.......{0_.6_rn_._k....... 9,_4_.3_ft._lb....... }_
~-.....~~~,r::....:"""'--)
6
25
=-x
·
~~.~
r-~~~~23
~4 ~
..
4
e
~
~~
~~A
~
~ ~~~
~
~~_
/
['j
1
\"
9
2
;?(~\
B ~J[m
~
17
.,/ /
~
12
Order
1
2 3
4 5 6 7
8 9 10 11 12 13 14
M.
/'
On 0
--
0
o.
302~~~~ \:~!/
.~(Jd' ~I@
31
T
~
~~y//
~~ ,')~4 ~ 15 ~"' ~~~~ ~, !> ($
\:.
~~ ~ ~~ ~tJ /8 jA]
242~XJl16~Q 13
~
:
v
--
10<~~~~~~~
~ ,~ ~ ~Q}DJ \ ~~
~
~"
I
\
18
~~~ ~~\ ~\J~~'c ~/mD ~ 1 ~~r , \
/// /
,/
19 21
~
~~ ~ ~ ~ ~ ~~\
/5
~.' ~f~ '" , "---.
27!f2'-
~~;:'~ \()~~Ii ~ " . ,J< &\~~ 26
[Q]
/
>
3/
"
Job name/Part name
Q'ty
Drive chain housing removal Brake caliper Parking brake Right side cover Brake disc Chain tension adjuster Joint Shift rod Shift lever assembly Lever Drain bolt Collar Drive chain housing cover Lever rod Washer Counter gear Spring
Remarks Remove the parts in the order listed below. Refer to "BRAKE". Refer to "BRAKE".
1 1 1
Loosen.
4 1 1 1 1 1 1 1 1 1 1 4-20
Disconnect the gear position switch leads. Drain.
DRIVE CHAIN HOUSING
Job name/P Ch . art name aln tension Roller er Collar Spring Journal Reverse d nven . VVasher gear Forward d nven . Collar sprocket Reverse d rive . gear D . r~ve sprocket Dnve chain Collar Washer Plate Shaft Drive chain houslng . For installatio . n, reverse the rem oval procedure 4-21
POTWRRI~I I --------------------------DRIVE CHAIN HOUSING
~
INSPECTION 1. Inspect: • Drive chain housing CD • Drive chain housing cover ® Cracks/damage --+ Replace. • Shift fork ® Pitting/wear/damage --+ Replace. ·Oil seals (drive chain housing) Wear/damage --+ Replace. • Bearings (drive chain housing and cover) @ Pitting/damage --+ Replace. 2. Inspect: • Drive sprocket CD • Forward driven sprocket ® • Reverse driven gear ® • Reverse drive gear @ • Counter gear @ ·Journal ® • Chain tensioner (J) Pitting/wear/damage --+ Replace. • Drive chain ® Wear/damage --+ Replace. Shift --+ Clean or replace. • Shift lever assembly ® • Bearing (chain tensioner) @ Pitting/damage --+ Replace the bearing and the inner race holder as a set.
For the bearing replacement and drive chain inspection, refer to "WITHOUT REVERSE MODEL".
4-22
POTWRRI~I I ---------------------------DRIVE CHAIN HOUSING
~
INSTALLATION 1. During installation, pay attention to the following.
[A] Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. ~ Make sure that the bearing seals face towards
the drive chain as shown.
A
[QJ [QJ Be sure to install the spacers in their original positions, otherwise the brake disc and jackshaft will stick.
[Q] 0.2 -- 0.6 mm (0.008 -- 0.024 in) ---t : ESSO beacon 325 grease or Aeroshell [OJ
grease #7A
l
For the jackshaft and drive chain housing installation, refer to "SECONDARYSHAFT".
l
A
2. Install: • Lever rod CD 3. Adjust: • Lever rod length ® Adjustment steps: • Loosen the locknuts ®. • Turn the lever rod CD in or out until the specified length is obtained.
I~
Lever rod length: 27 mm (1.06 in)
• Tighten the locknuts.
4-23
POTWRRI~I I -------------------------DRIVE CHAIN HOUSING
~
4. Install: • Shift rod CD 5. Adjust: • Shift rod length @
Adjustment steps: • Move the shift lever to the "FWD." position. • Loosen the locknuts (ID. • Turn the shift rod CD so that shift rod free play is 0 mm (in direction where @ can be shortened appropriately) and then turn back the shift rod 1/4 turns. • Tighten the locknuts.
®
6. Fill: • Drive chain housing oil Refer to "DRIVE CHAIN" in CHAPTER 2. 7. Adjust: • Drive chain slack Refer to "DRIVE CHAIN" in CHAPTER 2.
4-24
POTWRRI~I I ------------------------SECONDARYSHAFT SECONDARVSHAFT
Order
1 2 3
Job name/Part name
Q'ty
~
Remarks Remove the parts in the order listed below. Refer to "SECONDARY SHEAVE". Refer to "DRIVE CHAIN HOUSING".
Secondaryshaft removal Secondary sheave Drive chain housing Circlip Secondaryshaft Bearing
1 1 1
For installation, reverse the removal procedure.
4-25
POTWRRI~I I --------------------------SECONDARVSHAFT
INSPECTION 1. Inspect: - Secondaryshaft CD Scratches (excessive)/damage -+ Replace. -Splines® Wear/ damage -+ Replace the secondaryshaft. - Bearing contact surface ® Scratches/wear/damage -+ Replace the secondaryshaft.
2
3
SCH4540
2. Inspect: -Bearing CD Pitting/damage
o
~
-+
Replace.
( 3. Measure: - Brake disc thickness ® Out of specification -+ Replace.
Minimum thickness: 4.5 mm (0.18 in) Measuring point: 1 ~ 3 mm (0.04 from the edge of the brake disc. SCH4560
4-26
~
0.12 in)
POTWRRI~I I --------------------------SECONDARVSHAFT
~
SECONDARYSHAFT AND DRIVE CHAIN HOUSING INSTALLATION 1. Install: - Secondaryshaft - Drive chain housing
Installation steps: -Install the secondaryshaft. -Install the drive chain housing CD. - Tighten the bolts.
'.#7
~~
Bolt (drive chain housing): 48 Nm (4.8 m-kg, 35 ft-Ib)
-Install the drive chain, drive sprocket and driven sprocket. - Tighten the nuts ®.
'.#7
~~
Nut (secondaryshaft): 90 Nm (9.0 m-kg, 65 ft-Ib)
-Install the drive chain housing cover@.
[A] Properly install the rubber seal onto the drive chain housing, making sure that these are no gaps.
- Tighten the bolts @.
l
~ ~~
Bolt (drive chain housing cover): 24 Nm (2.4 m-kg, 17 ft-Ib)
-Install the spacer. - Tighten the set screw ®.
,
~~
Set screw (spacer): 6 Nm (0.6 m-kg, 4.3 ft-Ib)
-Install the brake disc. - Adjust the brake disc clearance.
4-27
_______________BR_A_K_E_IP~:RICG)I BRAKE IAJ : I
6 Nm (0.6 m.kg, 4.3 tt.lb)
4
Order
1 2 3 4 5
Job name/Part name
Q'ty
Remarks Remove the parts in the order listed below.
Brake pad removal Cap bolt Retaining pin Pad spring Brake pad Brake caliper assembly
1 1 1 2 1 For installation, reverse the removal procedure.
4-28
_______________BR_A_K_E_IP~:RICG)I Disc brake components rarely require disassembly. DO NOT: • Do not disassemble components unless absolutely necessary. • Do not use solvents on internal brake components. • Do not use contaminated brake fluid for cleaning. Use only clean brake fluid. • Do not allow brake fluid to contact the eyes, otherwise eye injury may occur. • Do not allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur. • Do not disconnect any hydraulic connection, otherwise the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly. BRAKE PAD REPLACEMENT NOTE: - - - - - - - - - - - - - It is not necessary to disassemble the brake caliper and brake hose in order to replace the brake pads.
1. Remove: • Brake pads CD
NOTE: - - - - - - - - - - - - - • Do not depress the brake lever when the caliper or disc is off the machine otherwise the brake pads will be forced shut. • Install a new brake pad spring and shims when the brake pads are replaced. • Replace the pads as a set if either one is found to be worn to the wear limit@.
I
a
SCH4600
4-29
~
Wear limit:
:6l~_7_.5_m_m_(_O_.3_0_in_)
.....,j
_______________BR_A_K_E_IP~:RICG)I 2. Install: • Brake pads • Pad spring
Installation steps: • Connect a suitable hose CD tightly to the caliper bleed screw ®. Put the other end of this hose into an open container. • Loosen the caliper bleed screw and push the pistons into the caliper with your finger. • Tighten the caliper bleed screw ®. ,
~
Bleed screw: 6 Nm (0.6 m-kg, 4.3 ft-Ib)
• Install the brake pads and pad spring.
3. Inspect: • Brake fluid level Refer to "BRAKE FLUID LEVEL INSPECTION" in CHAPTER 2. 4. Check: • Brake lever operation A soft or spongy feeling -+ Bleed brake system. Refer to "AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)" in CHAPTER 2.
4-30
_______________BR_A_K_E_IP~:RICG)I I ============== 48 Nm (4.8 mekg, 35 ftelb) -- - - - - - -I 13 Nm (1.3 mekg, 9.4 ftelb) I ============ 16 Nm (1.6 mekg, 12 ftelb) -- - - - - - -I 30 Nm (3.0 mekg, 22 ftelb)
2
Order
1 2 3 4
5 6 7
Job name/Part name
Q'ty
Brake caliper and parking brake removal Brake fluid Brake hose Brake caliper assembly Parking brake cable Spring Lever Parking brake assembly Collar
Remarks Remove the parts in the order listed below. Drain.
1 1 1 1 1 1 1
For installation, reverse the removal procedure.
4-31
_______________BR_A_K_E_IP~:RICG)I BRAKE CALIPER DISASSEMBLY NOTE: - - - - - - - - - - - - - Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: • Pistons • Piston oil seals CD
Removal steps: • Using a wood of piece ®, lock the right piston. • Blow compressed air into the hose joint opening @ to force out the left piston from the caliper body. • Remove the piston seals and reinstall the piston. • Repeat the previous steps to force out the right piston from the caliper body.
ffmmIIm1 ---------• Never try to pry out the pistons. • Do not loosen the retaining pin @.
BRAKE CALIPER INSPECTION AND REPAIR Recommended brake component replacement schedule Brake pads
As required
Piston seals and dust seals
Every two years
Brake hose
Every two years
Brake fluid
Only when brakes are disassembled.
ffmmIIm1 ---------All internal brake components should be cleaned only with new brake fluid. Do not use solvents as they will cause seals to swell and distort.
4-32
_______________BR_A_K_E_IP~:RICG)I 1. Inspect: - Caliper piston CD Scratches/rust/wear -+ Replace the caliper assembly. - Caliper cylinder ® Wear/ scratches -+ Replace the caliper assembly. - Caliper body ® Cracks/damage -+ Replace. -Oil delivery passage (caliper body) Blowout with compressed air.
SCH4670
~ ---------Replace the piston seals and dust seals whenever a caliper is disassembled.
BRAKE CALIPER ASSEMBLY
~ ---------- All internal parts should be cleaned only with new brake fluid. -Internal parts should be lubricated with brake fluid when installed. ~
·u
Recommended brake fluid: DOT 4
- Replace the piston seals and dust seals whenever a caliper is disassembled.
BRAKE CALIPER INSTALLATION 1. Install: - Brake hose CD
When installing the brake hose CD onto the brake caliper ®, make sure that the brake pipe touches the projection ® on the brake caliper. 4-33
_______________BR_A_K_E_IP~:RICG)I I [6] : I [A] :
10 Nm (1.0 m-kg, 7.2 tt-Ib) 30 Nm (3.0 m-kg, 22 tt-Ib)
/
/
/
Order
Q'ty
Job name/Part name
Brake master cylinder removal 1 2 3
4 5 6 7
Remarks Remove the parts in the order listed below. Drain.
Brake fluid Parking brake cable Brake switch Brake lever Parking brake lever Union bolt Holder Master cylinder assembly
1 1 1 1 1 1 1 For installation, reverse the removal procedure.
Brake master cylinder disassembly
CD
ÂŽ ÂŽ
@
Disassemble the parts in the order listed below.
1 1 1 1
Reservoir cap set Diaphagm Master cylinder kit Master cylinder body
For assembly, reverse the disassembly procedure.
4-34
_______________BR_A_K_E_IP~:RICG)I INSPECTION 1. Inspect: - Master cylinder CD Wear/ scratches -+ Replace the master cylinder assembly. - Master cylinder body ® Cracks/damage -+ Replace. - Oil delivery passage (master cylinder body) Blowout with compressed air.
2
2. Inspect: - Master cylinder kit CD Scratches/wear/damage set.
-+
Replace as a
SCH4710
BRAKE MASTER CYLINDER ASSEMBLY
~ ---------- All internal parts should be cleaned only with new brake fluid. -Internal parts should be lubricated with brake fluid when installed. ~
·u
Recommended brake fluid: DOT 4
- Replace the piston seals and dust seals whenever a caliper is disassembled.
INSTALLATION 1. Connect: - Brake hose NOTE: - - - - - - - - - - - - - When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection @ as shown. Union bolt (brake hose): 30 Nm (3.0 m-kg, 22 ft-Ib) 4-35
POTWRRI~I I ------------------------SLIDE RAIL SUSPENSION
~
SLIDE RAIL SUSPENSION RX10, RX10S, RX10R, RX10RS
IAJ : I
Order
72 Nm (7.2 m-kg, 52 tt-Ib)
Job name/Part name
Q'ty
Slide rail suspension removal Rear axle nut Tension adjuster Left side cover 1 2
Remarks Remove the parts in the order listed below. Loosen. Loosen. Refer to "PRIMARY SHEAVE AND DRIVE VELT".
Slide rail suspension Collar
1 2
For installation, reverse the removal procedure.
4-36
__________ POTWRRI~I SLIDE RAIL SUSPENSION
~
4 Nm (0.4 mekg, 2.9 ftelb)
I
============= 16 Nm (1.6 mekg, 12 ftelb) I ============= 24 Nm (2.4 mekg, 17 ftelb) I ============= 30 Nm (3.0 mekg, 22 ftelb) I =============== 49 Nm (4.9 mekg, 35 ftelb) I
----------I 72 Nm (7.2 mekg, 52 ftelb)
============= 48 Nm (4.8 mekg, 35 ftelb) I
1000...--
_____
17
~
Order
CD ®
@ @ @
®
(J)
® ® ® ®
@ @
@ @
®
@
: CD
ESSO beacon 325 grease or Aeroshell grease #7A
Job name/Part name
Q'ty
Remarks Remove the parts in the order listed below.
Slide rail suspension disassembly Stopper band Hook Bushing Collar Front shock absorber Bracket Front suspension bracket Rubber damper Front pivot arm Bushing Shaft Bushing Collar Suspension wheel Collar Wheel bracket Front pivot arm bracket
2 2 4 2 1 2 1 2 1 2 1 4 2 2 2 2 2
4-37
POTWRRI~I I -----------------------SLIDE RAIL SUSPENSION
I [HJ : I [Q : I [AJ :
24 Nm (2.4 m-kg, 17 tt-Ib) 49 Nm (4.9 m-kg, 35 tt-Ib) 72 Nm (7.2 m-kg, 52 tt-Ib)
5
~~'r'
~'@m ~
, / '
~>~'~' a
---t :
Order
@ @ @ @ @ @ @ @ @ @ @ @
CD
ESSO beacon 325 grease or Aeroshell grease #7A
Job name/Part name
Q'ty
2 2 2 2 2 2 2 1 1 2 2 1
Suspension wheel Collar Wheel bracket Circlip Suspension wheel Collar Bushing Shaft Rear suspension bracket Spacer Bushing Collar
4-38
~
Remarks
I I I
POTWRRI~I I ------------------------SLIDE RAIL SUSPENSION
I [BJ : I [AJ :
---t :
Order
® ®
@ @ @
®
@
® ®
@
49 Nm (4.9 m.kg, 35 tt.lb) 72 Nm (7.2 m.kg, 52 tt.lb)
CD
ESSO beacon 325 grease or Aeroshell grease #7A
Job name/Part name
Q'ty
1 2 1 2 4 4 2 2 2 2
Rear shock absorber Bushing Collar Pull rod Collar Bushing Guide wheel Control rod assembly Bushing Bushing
4-39
Remarks
~
POTWRRI~I I ------------------------SLIDE RAIL SUSPENSION
l
~
24 Nm (2.4 mekg, 17 ftelb) 72 Nm (7.2 mekg, 52 ftelb)
48
75 Nm (7.5 mekg, 54 ftelb)
45
lTl
l
45
~
: CD ESSO beacon 325 grease or Aeroshell grease #7A
Order
@ @
® ®
@ @ @ @
® ® ®
@ @
®
@ @
Job name/Part name
Q'ty
Rear pivot arm Bushing Shaft Shaft Rear pivot arm bracket Shaft Circlip Suspension wheel Wheel bracket shaft Rear axle Guide wheel Collar Tension adjuster Collar Collar Sliding frame
Remarks
1 2 1 1 1 1 2 2 1 1 3 2 2 1 1 2 For assembly, reverse the disassembly procedure.
4-40
I I I
POTWRRI~I I -------------------------SLIDE RAIL SUSPENSION
~
RX10M, RX10MS
[AI :
I
Order
72 Nm (7.2 m.kg, 52 tt·lb)
Job name/Part name
Q'ty
Slide rail suspension removal Rear axle nut Tension adjuster Left side cover 1 2
Remarks Remove the parts in the order listed below. Loosen. Loosen. Refer to "PRIMARY SHEAVE AND DRIVE VELT".
Slide rail suspension Collar
1 2 For installation, reverse the removal procedure.
4-41
__________ POTWRRI~I SLIDE RAIL SUSPENSION
10
I~
e
P
Order
CD 速
@ @ @ @ (J)
@
速 速
CD) @ @ @ @
速
@
[A] : 1==4=N=m=(O="4=m=e=kg=,=2"=9=ft=lb=)=1 [.6J: 1 16 Nm (1.6 m-kg, 12 ft-Ib)
T~ [Q] :
1
24 Nm (2.4 m-kg, 17 ft-Ib)
~ [QJ:
1
30 Nm (3.0 m-kg, 22 ft-Ib)
I I I
[EJ : 1
49 Nm (4.9 m-kg, 35 ft-Ib)
1
[E] : 1
72 Nm (7.2 m-kg, 52 ft-Ib)
1
U
><@~,
---t :
~
CD ESSO beacon 325 grease or Aeroshell grease #7A Job name/Part name
Q'ty
Remarks Remove the parts in the order listed below.
Slide rail suspension disassembly Stopper band Hook Rubber collar Rubber collar Shaft Bushing Collar Front shock absorber Front pivot arm Bushing Collar Bushing Collar Front suspension bracket Suspension wheel Collar Wheel bracket
2 2 2 1 1
4 2 1 1
2 1
4 2 1
2 2 2
4-42
POTWRRI~I I -----------------------SLIDE RAIL SUSPENSION
24 Nm (2.4 mekg, 17 ftelb) 49 Nm (4.9 mekg, 35 ftelb) 72 Nm (7.2 mekg, 52 ftelb)
6
~
: CD ESSO beacon 325 grease or Aeroshell grease #7A
Order
@ @ @ @ @ @ @ @ @ @ @ @
®
Job name/Part name
Q'ty
Suspension wheel Collar Wheel bracket Front pivot arm bracket Circlip Suspension wheel Collar Bushing Collar Rear suspension bracket Spacer Bushing Collar
2 2 2 2 2 2 2 2 1 1
2 2 1
4-43
Remarks
~
POTWRRI~I I ------------------------SLIDE RAIL SUSPENSION
I [6] : I [A] :
49 Nm (4.9 mekg, 35 ftelb) 72 Nm (7.2 mekg, 52 ftelb)
3
~
: CD ESSO beacon 325 grease or Aeroshell grease #7A
Order
®
@ @ @
® ® ® ®
@ @
®
Job name/Part name
Q'ty
Rear shock absorber Bushing Collar Pull rod Collar Bushing Guide wheel Control rod assembly Bushing Bushing Shaft
1 2 1 2 4 4 2 2 2 2 1
4-44
Remarks
~
POTWRRI~I I ------------------------~
SLIDE RAIL SUSPENSION
I 24 Nm (2.4 mekg, 17 ftelb) I [6J : I 72 Nm (7.2 mekg, 52 ftelb) ========== [Q] : I 75 Nm (7.5 mekg, 54 ftelb) [A] :
5
~, ~, 4
56
l
B
~.
Il~ rs~~ I
~~
'R ~
50
49
~
Order
@ @ @ @
速 速
@ @ @
速
@ @
~
@ @
速
: CD
,///
~/
"
48
ESSO beacon 325 grease or Aeroshell grease #7A
Job name/Part name
~
5'
Q'ty
Rear pivot arm Bushing Collar Collar Rear pivot arm bracket Collar Circlip Suspension wheel Wheel bracket shaft Rear axle Guide wheel Collar Tension adjuster Collar Collar Sliding frame
I
0
/@~
~'~
49
5
~C ~
53
5 SCH4830
Remarks
1
2 1 1 1 1
2 2 1 1
4 2 2 2 1
2 For assembly, reverse the disassembly procedure. 4-45
POTWRRI~I I ---------------------------SLIDE RAIL SUSPENSION
~
INSPECTION 1. Inspect: • Suspension wheel • Guide wheel Cracks/damage --+ Replace. • Wheel bearing Wheel turns roughly --+ Replace.
SCH4840
2. Inspect: • Stopper band CD Frayed/damage --+ Replace. • Pull rod® Bends/damage --+ Replace. • Shock absorber @ Oil leaks/damage --+ Replace. • Bushings Wear/cracks/damage --+ Replace. • Front pivot arm @ • Rear pivot arm @ • Rear pivot arm bracket @ • Suspension wheel bracket ([) • Sliding frame ® Cracks/damage --+ Replace. • Slide runner ® Wear/damage --+ Replace.
A
[A] RX10, RX10S, RX10R, RX10RS [aJ RX10M, RX10MS SCH4850
B
SCH4860
4-46
POTWRRI~I I -------------------------SLIDE RAIL SUSPENSION
~
ASSEMBLY 1. Install: - Stopper band CD
NOTE: - - - - - - - - - - - - -For RX10, RX10S, RX10R, RX10RS: Install the stopper band with @ toward the hook and @ toward the front suspension bracket. - For RX10M, RX10MS: Install the stopper band with @ toward the hook and @ toward the shaft.
SCH4880
Nut (stopper band): 4 Nm (0.4 m-kg, 2.9 ft-Ib)
INSTALLATION 1. Adjust: - Slide rail suspension position Refer to "REAR SUSPENSION" in CHAPTER2.
4-47
POTWRRI~I I --------------------------~
SLIDE RAIL SUSPENSION
Control rod parts number
® ©
[A] Control rod 1
[aJ Length ® mm (in)
[Q] Length © mm (in)
[Q] Length © mm (in)
RX10, RX10S, RX10R, RX10RS
301.0 (11.85)
155.5 (6.12)
RX10M, RX10MS
257.5 (10.14)
165.0 (6.50)
2.5P x 3 = 7.5 (0.098P x 3 = 0.295)
[:EJ Control rod 1
[E] Control rod 2
parts number
parts number
8FA-4745A-00 (RX10, RX10S, RX10R, RX10RS)
~ Washer plate parts number
[8] Washer plate thickness mm (in) IT] Upper Q] Lower
8CR-4745B-00
8EP-4745A-00 (RX10M, RX10MS)
4-48
90202-16229 2.5 (0.098)
90202-16232 10.0 (0.394)
90202-16229 2.5 (0.098)
90202-16230 5.0 (0.197)
POTWRRI~I I -------------------------FRONT AXLE AND TRACK
~
FRONT AXLE AND TRACK
IAl : I
9 Nm (0.9 m.kg, 6.5 tt.lb)
[B] : ~========= 20 Nm (2.0 m.kg, 14 tt.lb) ~========= e
I
[Q : 1~_4_0_N_m_(_4._0_m_e...... kg_,_29_f_t_lb_}_
6
4
A
5
000
7
'---.. ---.0Order
Job name/Part name
Q'ty
Front axle and track removal
1 2 3
4 5 6 7
Remarks Remove the parts in the order listed below. Refer to "DRIVE CHAIN HOUSING". Refer to "SLIDE RAIL SUSPENSION". Refer to "SECONDARY SHEAVE".
Drive chain housing Slide rail suspension Secondary sheave Speed sensor Bearing holder Gear unit Set bolt Front axle assembly Bearing Track
1 1 1 2 1 1 1 For installation, reverse the removal procedure.
4-49
POTWRRI~I I -----------------------------FRONT AXLE AND TRACK
-----.JL----..:lL-
---L---
=
~
INSPECTION 1. Inspect: .TrackeD • Slide metal ® Wear/cracks/damage --+ Replace.
2. Inspect: • Sprocket wheel eD Wear/break/damage --+ Replace. • Front axle ® Bends/scratches (excessive)/damage --+ Replace.
SCH4920
INSTALLATION 1. Install: • Sprocket wheels • Guide wheels
A
132.6 mm (5.22 in)
NOTE: - - - - - - - - - - - - • When pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel. • Position each sprocket wheel on the axle as shown in the illustration.
182.8 mm (7.20 in)
164.1 mm (6.46 in)
B
[A] RX10, RX10S, RX10R, RX10RS [aJ RX10M, RX10MS
93.3 mm (3.67 in)
4-50
POTWRRI~I I --------------------------FRONT AXLE AND TRACK
~
2. Place the track in the chassis.
A
NOTE: - - - - - - - - - - - - For track with a direction of rotation mark @: Install the track with the mark pointing in the direction of track rotation.
[A] RX10, RX10S, RX10R, RX10RS [al RX10M, RX10MS
B
4-51
SEAT AND FUEL TANK
I ENG I @>
ENGINE SEAT AND FUEL TANK
6
Order 1
2 3 4 5 6 7
8
Job name/Part name
Q'ty
Seat and fuel tank removal Rear cover Muffler end pipe Muffler side cover Tail/brake light cover Seat Fuel tank cover Side cover Fuel tank
Remarks Remove the parts in the order listed below.
1
2 2 1 1 1
2 1
For installation, reverse the removal procedure.
5-1
EXHAUST PIPE AND MUFFLER
I ENG
I
@>
EXHAUST PIPE AND MUFFLER
I 20 Nm (2.0 m-kg, 14 tt-Ib) [BJ : I========== 25 Nm (2.5 m-kg, 18 tt-Ib) [Q] : I=====::::::::===~ 16 Nm (1.6 m-kg, 12 tt-Ib) [A] :
==========
e k_9_,8_f_t e _lb_}_ [Q] : 1__1_1_N_rn_{_1"_1_rn_
I
/
Order
Job name/Part name
Q'ty
Exhaust pipe and muffler removal Slide rail suspension
1 2 3 4 5
Remarks Remove the parts in the order listed below. Refer to "SLIDE RAIL SUSPENSION" in CHAPTER 4. Refer to "FRONT AXLE AND TRACK" in - CHAPTER 4. Refer to "SEAT AND FUEL TANK".
-0
Front axle assembly Track Seat and fuel tank Protector Muffler Exhaust pipe Gasket Band
1 1 2 2 2
For installation, reverse the removal procedure.
5-2
EXHAUST PIPE AND MUFFLER ==
I ENG I @>
INSTALLATION 1. Install: - Muffler CD
==
2. Install: - Exhaust pipe CD NOTE: - - - - - - - - - - - Hang the exhaust pipe to the frame ®.
3. Tighten: - Exhaust pipe bolts CD Bolt (band): 9 Nm (0.9 m-kg, 7 ft-Ib)
4. Tighten: - Exhaust pipe bolts CD - Muffler band bolts ® Bolt (exhaust pipe): 25 Nm (2.5 m-kg, 18 ft-Ib) Bolt (muffler band): 20 Nm (2.0 m-kg, 14 ft-Ib)
5. Tighten: - Muffler bolt CD Bolt (muffler): 16 Nm (1.6 m-kg, 12 ft-Ib)
5-3
ENGINE ASSEMBLY
I ENG II
ENGINE ASSEMBLY
I [al : I [Q] : I [Q] : I [A] :
Order
Job name/Part name
Q'ty
Engine assembly removal Intake silencer Fuel pump Carburetor assembly Primary sheave
85 Nm (8.5m·kg, 47 ft·lb) 30 Nm (3.0 m.kg, 22 ft·lb) 23 Nm (2.3 m.kg, 17 ft·lb)
Remarks Remove the parts in the order listed below.
-~ -
Refer to "CARBURETORS" in CHAPTER 7. Refer to"PRIMARY SHEAVE AND DRIVE V-BELT" in CHAPTER 4. Drain. Refer to"COOLING SYSTEM" in CHAPTER 2. Refer to "SEAT AND FUEL TANK". Refer to "STEERING" in CHAPTER 3. Refer to "A.C. MAGNETO AND STARTER CLUTCH".
Coolant
Fuel tank Relay rod Oil tank 1 2
7 Nm (0.7 m.kg, 5.1 ft·lb)
Frame cross member Engine assembly
1 1
For installation, reverse the removal procedure. 5-4
ENGINE ASSEMBLY
I ENG I @>
INSPECTION 1. Inspect: • Engine mounting adjust bolts Cracks/damage -+ Replace. INSTALLATION NOTE: - - - - - - - - - - - - After installing all parts, refer to "CABLE ROUT1NG" in CHAPTER 9, to check the cable, lead and hose routing.
1. Install: • Engine mounting adjust bolts • Engine • Engine mounting bolts and nuts NOTE: - - - - - - - - - - - - • Use the pivot shaft wrench to tighten the engine mounting adjust bolts.
Installation steps: • Tighten the rear engine mounting adjust bolt.
'J'J
~~
Bolt (engine mounting adjust): 7 Nm (0.7 mekg, 5.1 ftelb)
• Tighten the rear engine mounting nut.
'J'J
~~
Nut (engine mounting): 65 Nm (6.5 mekg, 47 ftelb)
• Tighten the front right and left engine mounting adjust bolts until they come to cantact with the engine damper. At this time, do not apply torque to the engine mounting adjust bolts. • Tighten the front right and left engine mounting nuts.
'J'J
~~
Nut (engine mounting): 65 Nm (6.5 mekg, 47 ftelb)
2. Fill: • Coolant Refer to "COOLING SYSTEM" in CHAPTER 2. 3. Fill: • Engine oil Refer to "ENGINE OIL REPLACEMENT" in CHAPTER 2.
5-5
CAMSHAFTS
I ENG II
CAMSHAFTS CYLINDER HEAD COVER
[AJ : 1 [H] : 1
========== _____
Order
Job name/Part name
Q'ty
Cylinder head cover removal Coolant Coolant hose and pipe 1 2 3 4
5
Remarks Remove the parts in the order listed below. Drain. Refer to "HEAT EXCHANGER" in CHAPTER 6.
Ignition coil Spark plug Cylinder head cover Cylinder head cover gasket Timing chain guide (top side)
4 4 1 1 1
For installation, reverse the removal procedure.
5-6
CAMSHAFTS
I ENG I @>
CAMSHAFTS
[AJ :
9
I
10 Nm (1.0 m.kg, 7.2 tt.lb) 24 Nm (2.4 m-kg, 17 ft-Ib) 6 Nm (0.6 m-kg, 4.3 ft-Ib) 10 Nm (1.0 m-kg, 7.2 ft-Ib)
Order
Job name/Part name
Q'ty
Remove the parts in the order listed below. Refer to "A.C. MAGNETO AND STARTER CLUTCH".
Camshaft removal Oil tank 1 2
3 4 5 6
7 8 9
Remarks
Timing chain tensioner cap bolt Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Intake camshaft sprocket Exhaust camshaft sprocket Intake camshaft cap Dowel pin Exhaust camshaft cap
1 1 1 1 1 1
NOTE:
3 - ~ During removal, the dowel pins may still 12
3 -
5-7
be connected to the camshaft caps.
CAMSHAFTS
!AI : I
9
I ENG II
10 Nm (1.0 m.kg, 7.2 tt.lb) 24 Nm (2.4 m-kg, 17 ft-Ib) 6 Nm (0.6 m-kg, 4.3 ft-Ib) 10 Nm (1.0 m-kg, 7.2 ft-Ib)
Order 10 11
Job name/Part name
Q'ty
Intake camshaft Exhaust camshaft
Remarks
1 1
For installation, reverse the removal procedure.
5-8
CAMSHAFTS
I ENG I @>
REMOVAL 1. Remove: • Timing plug 2. Align: • "I" mark @ on the A.C. magneto rotor (with the stationary pointer @ on the A.C. magneto cover) NOTE: - - - - - - - - - - - • Turn the crankshaft clockwise. • When piston #4 is at TDC on the compression stroke, align the "I" mark@ with the stationary pointer @ on the A.C. magneto rotor. • TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
3. Loosen: • Camshaft sprocket bolts CD
4. Loosen: • Timing chain tensioner cap bolt CD 5. Remove: • Timing chain tensioner ® • Gasket
/
~ \
6. Remove: • Camshaft sprockets CD NOTE: - - - - - - - - - - - - To prevent the timing chain from falling into the crankcase, fasten it with a wire ®.
5-9
CAMSHAFTS
I ENG II
7. Remove: -Timing chain guide (exhaust side) CD - Camshaft caps -Dowel pins
To prevent damage to the cylinder head, camshafts or camshafts caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the outside in. 8. Remove: -Intake camshaft CD - Exhaust camshaft ®
5-10
CAMSHAFTS
I ENG I @>
INSPECTION 1. Inspect: • Camshaft lobes Blue discoloration/pitting/scratches -+ Replace the camshaft.
2. Measure: • Camshaft lobe dimensions @ and @ Out of specification -+ Replace the camshaft. Camshaft dimensions: Intake: <Limit>:@ 32.40 mm @ 24.85 mm Exhaust: <Limit>: @ 32.85 mm @ 24.85 mm
11151001
(1.2756 in) (0.9783 in) (1.2933 in) (0.9783 in)
11151002
3. Measure: • Camshaft runout Out of specification -+ Replace. Camshaft runout: 0.03 mm (0.0012 in)
4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification -+ Measure the camshaft journal diameter. Camshaft-journal-to-camshaftcap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) 5-11
CAMSHAFTS
I ENG II
Measurement steps: -Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). - Position a strip of Plastigauge® CD onto the camshaft journal. -Install the dowel pins and camshaft caps. NOTE: - - - - - - - - - - - - - - Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. - Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®.
Bolt (camshaft cap): 10 Nm (1.0 m-kg, 7.2 ft-Ib) - Remove the camshaft caps and then measure the width of the Plastigauge® CD. 5. Measure: - Camshaft journal diameter ® Out of specification -+ Replace the camshaft. Within specification -+ Replace the cylinder head and the camshaft caps as a set.
Camshaft journal diameter: 24.459 --- 24.472 mm (0.9630 --- 0.9635 in)
11151003
6. Inspect: - Camshaft sprocket More than 1/4 tooth ® wear -+ Replace the camshaft sprockets and the timing chain as a set.
® 1/4 tooth @ Correct
CD Timing chain roller ® Camshaft sprocket 7. Inspect: - Timing chain guide (exhaust side CD and top side®) Damage/wear -+ Replace the timing drain guide.
5-12
CAMSHAFTS
I ENG I @>
8. Inspect: • Timing chain tensioner Cracks/damage -+ Replace.
Inspection steps: • While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver CD. • Remove the screwdriver and slowly release the timing chain tensioner rod. • Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough movement, replace the timing chain tensioner.
9. Inspect: • All parts Damage/wear -+ Replace the defective part (-s).
5-13
CAMSHAFTS
I ENG II
INSTALLATION 1. Install: - Exhaust camshaft CD -Intake camshaft ® NOTE: - - - - - - - - - - - - - Install the camshafts with the punch mark @ facing up.
2. Install: -Dowel pins -Intake camshaft caps - Exhaust camshaft caps
NOTE: - - - - - - - - - - - - - Make sure that the punch marks @ on the camshafts are aligned with the arrow marks @ on the camshaft caps. Out of alignment -+ Reinstall. 3. Install: - Camshaft cap bolts
Bolt (camshaft cap): 10 Nm (1.0 m-kg, 7.2 ft-Ib) NOTE: - - - - - - - - - - - - Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result.
4. Install: -Intake camshaft sprocket - Exhaust camshaft sprocket
Installation steps: - Turn the crankshaft clockwise - When piston #4 is at TDC on the compression stroke, align the "I" mark@ with the stationary pointer @ on the A.C. magneto rotor.
5-14
CAMSHAFTS
I ENG I @>
• Place the timing chain onto both camshaft sprockets and then install the camshaft sprockets onto the camshafts. NOTE: - - - - - - - - - - - - - When installing the camshaft sprockets, start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side.
Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. • Turn both camshafts opposite each other so that the punch marks © in the camshaft are aligned with the arrow marks @ in the camshaft caps as shown. • While holding the camshafts, temporarily tighten the camshaft sprocket bolts.
L
R
E
5. Install: • Timing chain tensioner
Installation steps: • While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver CD.
• With the timing chain tensioner rod turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed), install the gasket and the timing chain tensioner ® onto the cylinder block.
~ ---------Always use a new gasket.
5-15
CAMSHAFTS
I ENG II
• Tighten the timing chain tensioner bolts ® to the specified torque.
'ffJ
~~
Bolt (timing chain tensioner): 10 Nm (1.0 m-kg, 7.2 ft-Ib)
• Remove the screwdriver, make sure that the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque.
,
~~
Bolt (cap): 6 Nm (0.6 m-kg, 4.3 ft-Ib)
• Turn the crankshaft (several turns clockwise)
6. Inspect:
Inspection steps: ·"1" mark@ Make sure that the "I" mark on the A.C. magneto rotor is aligned with the stationery pointer@ on the A.C. magneto rotor cover.
• Camshaft punch marks © Make sure that the punch marks © on the camshaft are aligned with the arrow mark @ on the camshaft caps. Out of alignment -+ Adjust. Refer to the installation steps above.
7. Measure: • Valve clearance Out of specification -+ Adjust.
5-16
CYLINDER HEAD
I ENG
I
@>
CYLINDER HEAD
I [BJ : I [Q] : I [AJ :
[Q]:I [EJ :
Order
Job name/Part name
Q'ty
Cylinder head removal
1 2 3 4 5 6
7 8
I
20 Nm (2.0 m-kg, 14 tt-Ib) + 121 ° 20 Nm (2.0 m-kg, 14 tt-Ib) + 105° 20 Nm (2.0 m-kg, 14 tt-Ib) + 140° 12 Nm (1.2 m-kg, 8.7tt-lb) 25 Nm (2.5 m-kg, 18 tt-Ib)
I I
Remarks Remove the parts in the order listed below. Refer to "SEAT AND FUEL TANK". Refer to "CAMSHAFTS".
Seat and fuel tank Intake and exhaust camshafts Cover Exhaust joint pipe Exhaust joint pipe gasket Band Gasket Cylinder head Cylinder head gasket Dowel pin
1 4
1 4 4
1 1 2 For installation, reverse the removal procedure.
5-17
CYLINDER HEAD
I ENG II
REMOVAL 1. Remove: • Cylinder head nuts CD • Cylinder head cap nut ® • Cylinder head bolts @ NOTE: - - - - - - - - - - - - • Loosen the nuts in the proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
5-18
CYLINDER HEAD
I ENG I @>
INSPECTION 1. Eliminate: • Carbon deposits (from the combustion chambers) Use the rounded scraper. NOTE: - - - - - - - - - - - - Do not use a sharp instrument to avoid damaging or scratching: • Spark plug threads • Valve seats 2. Inspect: • Cylinder head Damage/scratches -+ Replace. • Cylinder head water jacket Mineral deposits/rust -+ Eliminate.
3. Measure: • Cylinder head warpage Out of specification -+ Resurface the cylinder head.
~~w_a_r_p_a_g_e_li_m_i_t: 1:6l
0.1 mm (0.004 in)
......1
Measurement steps: • Place a straightedge CD and a thickness gauge ® across the cylinder head. • Measure the warpage. ·If the limited is exceeded, resurface the cylinder head as follows. • Place a 400 -- 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: - - - - - - - - - - - - - To ensure an even surface, rotate the cylinder head several times.
5-19
CYLINDER HEAD INSTALLATION 1. Install: - Gasket (cylinder head) - Dowel pins ® - Cylinder head
I ENG II III CD
NOTE: - - - - - - - - - - - - Pass the timing chain through the timing chain cavity.
2. Tighten: - Cylinder head nuts CD -- @ - Cylinder head bolts @, @ NOTE: - - - - - - - - - - - - - First, tighten the nuts CD -- @ to approximately 20 Nm (2.0 m-kg, 15 ft-Ib) with a torque wrench. - Retighten the nuts to specification torque. Tightening steps: - Tighten the nuts CD, ® ,
~~
Nut (cylinder head): 1st 20 Nm (2.0 m-kg, 14 ft-Ib) 2nd 121 0
- Tighten the nuts @ -- @, @, ® ,
~~
Nut (cylinder head): 1st 20 Nm (2.0 m-kg, 14 ft-Ib) 2nd 105 0
- Tighten the nuts (f), @ ,
~~
Nut (cylinder head): 1st 20 Nm (2.0 m-kg, 14 ft-Ib) 2nd 140 0
- Cylinder head bolts @, @ Bolt (cylinder head): 12 Nm (1.2 m-kg, 8.7 ft-Ib) NOTE: - - - - - - - - - - - - - Apply engine oil onto the threads of the cylinder head nuts. - Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages.
5-20
VALVES AND VALVE SPRINGS
I ENG I @>
VALVES AND VALVE SPRINGS
Order
1 2 3 4 5
6 7 8
9
10 11 12 13
Job name/Part name
Q'ty
Valves and valve springs removal Cylinder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve retainer Intake valve spring Intake valve stem seal Intake valve spring seat Intake valve Intake valve guide Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve retainer
Remarks Remove the parts in the order listed below. Refer to "CYLINDER HEAD".
12 12 24 12 12 12 12 12 12 8 8
16 8
5-21
VALVES AND VALVE SPRINGS
Order
14 15 16 17 18
Job name/Part name Exhaust valve Exhaust valve Exhaust valve Exhaust valve Exhaust valve
Q'ty
spring stem seal spring seat
I ENG II
Remarks
8 8 8 8 8
guide
For installation, reverse the removal procedure.
5-22
VALVES AND VALVE SPRINGS
I ENG I @>
REMOVAL NOTE: - - - - - - - - - - - - - Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal.
1. Remove: • Valve lifter CD • Valve pad® NOTE: - - - - - - - - - - - - - Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 11172202
2. Inspect: • Valve sealing Leakage at the valve seat -+ Inspect the valve face, valve seat, and valve seat width.
Inspection steps: • Pour a clean solvent@ into the intake and exhaust ports. • Check that the valves properly seal. 11171401
NOTE: - - - - - - - - - - - There should be to leakage at the valve seatCD.
3. Remove: • Valve cotters CD NOTE: - - - - - - - - - - - - - Remove the valve cotters by compressing the valve spring with the valve spring compressor ® and attachment @.
5-23
VALVES AND VALVE SPRINGS
I ENG II
Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment Intake valve 90890-04114, YM-4114 Exhaust valve 90890-04108, YM-4108
4. Remove: • Valve retainer CD • Valve spring ® • Stem seal@ • Valve spring seat @ .Valve@ NOTE: - - - - - - - - - - - Identify the position of each part very carefully so that it can be reinstalled in its original place.
11171203
INSPECTION 1. Measure: • Valve-stem-to-valve-guide clearance
A
Valve-stem-to-valve-guide clearance Valve guide inside diameter [A] Valve stem diameter[a]
=
Out of specification -+ Replace the valve guide.
11170501
Valve-stem-to-valve-guide clearance: Intake 0.010 -- 0.037 mm (0.0004 -- 0.0015 in) Exhaust 0.025 -- 0.052 mm (0.0010 -- 0.0020 in)
B
11172102
2. Replace: • Valve guide NOTE: - - - - - - - - - - - To ease valve guide removal and installation, and to maintain the correct fit, hart the cylinder head to 100°C in an oven.
5-24
VALVES AND VALVE SPRINGS
I ENG I @>
Replacement steps: - Remove the valve guide with a valve guide remover CD. -Install the new valve guide with a valve guide installer ÂŽ and valve guide remover CD. - After installing the valve guide, bore the valve guide with a valve guide reamer @ to obtain the proper valve-stem-valve-guide clearance.
NOTE: - - - - - - - - - - - After replacing the valve guide, reface the valve seat. Valve guide remover: Intake (04) 90890-04111, YM-04111 Exhaust (04.5) 90890-04116, YM-04116 Valve guide installer: Intake (04) 90890-04112, YM-04112 Exhaust (04.5) 90890-04117, YM-04117 Valve guide reamer: Intake 90890-04113, YM-04113 Exhaust 90890-04118, YM-04118 11170601
3. Eliminate: - Carbon deposits (from the valve face and valve seat) 4. Inspect: -Valve face Pitting/wear -+ Grind the valve face. - Valve stem end Mushroom shape or diameter larger than the body of the valve stem -+ Replace the valve.
5. Measure: - Valve margin thickness ÂŽ Out of specification -+ Replace the valve. Valve margin thickness: 0.5 ~ 0.9 mm (0.020 ~ 0.035 in)
[][]--....
5-25
I ENG II
VALVES AND VALVE SPRINGS 6. Measure: - Valve stem runout Out of specification
-+
Replace the valve.
NOTE: - - - - - - - - - - - - - - When installing a new valve, always replace the valve guide. -If the valve is removed or replaced, always replace the oil seal. 11172103
Valve stem runout: 0.01 mm (0.0004 in)
7. Eliminate: - Carbon deposits (from the valve face and valve seat) 8. Inspect: -Valve seat Pitting/wear -+ Replace the cylinder head.
9. Measure: - Valve seat width ÂŽ Out of specification head.
-+
Replace the cylinder
Valve seat width: Intake: 0.9 --- 1.1 mm (0.035 --- 0.043 in) Exhaust: 0.9 --- 1.1 mm (0.035 --- 0.043 in)
ÂŽ
11171603
Measurement steps: - Apply Mechanic's blueing dye (Dykem) CD onto the valve face. -Install the valve into the cylinder head. - Press the valve through the valve guide and onto the valve seat to make a clear pattern. - Measure the valve seat width. NOTE: - - - - - - - - - - - Where the valve seat and valve face contacted one another, the blueing will have been removed.
11171601
10. Lap: -Valve face -Valve seat NOTE: - - - - - - - - - - - After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. 5-26
VALVES AND VALVE SPRINGS
I ENG I @>
Lapping steps: - Apply a coarse lapping compound valve face.
速
to the
Do not let the lapping compound enter the gap between the valve stem and the valve guide. 11171601
- Apply molybdenum disulfide oil onto the valve stem. -Install the valve into the cylinder head. - Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: - - - - - - - - - - - - - For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hand. - Apply a fine lapping compound to the valve face and repeat the above steps. - After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat.
11171504
- Apply Mechanic's blueing dye (Dykem) onto the valve face. -Install the valve into the cylinder head. - Press the valve through the valve guide and onto the valve seat to make a clear impression. - Measure the valve seat width 速 again. If the valve seat width is out of specification, reface and lap the valve seat.
速
11171603
11. Measure: - Valve spring free length 速 Out of specification -+ Replace the valve spring.
Free length (valve spring): Intake 38.90 mm (1.53 in) Exhaust 40.67 mm (1.60 in)
11171902
5-27
VALVE AND VALVE SPRINGS
I ENG II
12. Measure: • Compressed spring force ® Out of specification -+ Replace the valve spring.
@ Installed length Compressed spring force: Intake 82 -- 96 N at 34.5 mm (8.2 -- 9.6 kg at 34.5 mm, 18.1 -- 21.2 Ib at 1.36 in) Exhaust 110 -- 126 N at 35.0 mm (11.0 -- 12.6 kg at 35.0 mm, 24.3 -- 27.8 Ib at 1.38 in)
11171904
13. Measure: • Valve spring tilt ® Out of specification -+ Replace the valve spring. Spring tilt: Intake 2.5 0 /1.7 mm (0.067 in) Exhaust 2.5 0 /1.8 mm (0.071 in)
11171903
14. Inspect: • Valve lifter Damage/scratches -+ Replace the valve lifters and cylinder head.
11170701
5-28
VALVES AND VALVE SPRINGS
I ENG I @>
INSTALLATION 1. Deburr: • Valve stem end (with an oil stone)
2. Lubricate: • Valve stem CD • Valve stem seal ® (with the recommended lubricant)
Recommended lubricant Molybdenum disulfide oil
3. Install: • Valve CD • Lower spring seat ® ·Oil seal@ • Valve spring @ • Upper spring seat @ (into the cylinder head) NOTE: - - - - - - - - - - - Install the valve spring with the larger pitch @ facing up.
11172001
Smaller pitch @
NOTE: - - - - - - - - - - - - Make sure that each valve is installed in its original place. Refer to the following embossed marks. Right and left intake valve(-s): "4XV:" Middle intake valve(-s): "4XV." Exhaust valve(-s): "5LV"
5-29
VALVES AND VALVE SPRINGS
I ENG II
4. Install: • Valve cotters CD NOTE: - - - - - - - - - - - - - Install the valve cotters by compressing the valve spring with the valve spring compressor ® and attachment ®.
Valve spring compressor: 90890-04019, YM-04019 Attachment: Intake valve 90890-04114, YM-4114 Exhaust valve 90890-04108, YM-4108
5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
Hitting the valve tip with excessive force could damage the valve.
6. Install: • Valve pad CD • Valve lifter ® NOTE: - - - - - - - - - - - • Apply molybdenum disulfide oil onto the valve lifter and valve pad. • The valve lifter must move smoothly when rotated with a finger. • Each valve lifter and valve pad must be reinstalled in its original position.
11171102
5-30
A.C. MAGNETO AND STARTER CLUTCH
I ENG I @>
A.C. MAGNETO AND STARTER CLUTCH A.C. MAGNETO ROTOR COVER
[AJ : 1==12=N=rn={1="2=rn=e=k9=,=8="7=ft=e'b=}=1 [BJ : I 10 Nm (1.0 m-kg, 7.2 tt-Ib) I
[Q] : 10....-_1_9_N_rn_{1_"9_rn_e_k_9,_1_4_fte_lb_}_
) /
~
4
3
I
Order
Job name/Part name
Q'ty
A.C. magneto rotor cover removal Right side cover Engine oil
1 2 3 4 5
Oil level switch coupler Oil tank A.C. magneto rotor cover Gasket Dowel pin
1 1 1 1 2
Remarks Remove the parts in the order listed below. Refer to "DRIVE CHAIN HOUSING" in CHAPTER 4. Drain. Refer to "ENGINE OIL REPLACEMENT" in CHAPTER 2. Disconnect.
For installation, reverse the removal procedure.
5-31
A.C. MAGNETO AND STARTER CLUTCH
I ENG II
A.C. MAGNETO ROTOR AND STARTER CLUTCH
[A] :
I
130 Nm (13.0 m-kg, 94 tt-Ib)
[H] : 1__12_N_rn_{_1"_2_rn_.k......9_,8_"_7_ft._lb_}_
Order
1 2 3
4 5 6
5
Job name/Part name
Q'ty
A.C. magneto rotor and starter clutch removal A.C. magneto rotor Idle gear shaft Starter motor idle gear Starter clutch Woodruff key Starter clutch gear
Remarks Remove the parts in the order listed below.
1 1 1 1 1 1 For installation, reverse the removal procedure.
5-32
A.C. MAGNETO AND STARTER CLUTCH
I ENG I @>
REMOVAL 1. Remove: • A.C. magneto rotor bolt • Washer NOTE: - - - - - - - - - - - - - • While holding the A.C. magneto rotor CD with the sheave holder ®, loosen the magneto rotor bolt. • Do not allow the sheave holder to touch the projection on the A.C. magneto rotor.
Sheave holder: 90890-01701, YS-01880
2. Remove: • A.C. magneto rotor CD (with the rotor holding puller holding puller attachment) • Woodruff key
®
and rotor
To protect the end of the crankshaft, place an appropriate sized socket between the rotor holding puller set's center bolt and the crankshaft. NOTE: - - - - - - - - - - - - - Make sure the rotor holding puller is centered over the A.C. magneto rotor.
Rotor holding puller: 90890-01362, YU-33270 Flywheel puller attachment 90890-04089, YM-33282
5-33
A.C. MAGNETO AND STARTER CLUTCH
I ENG II
3. Remove: • Starter clutch NOTE: - - - - - - - - - - - - - • While holding the magneto rotor with the sheave holder, remove the starter clutch bolt
CD. • Do not allow the sheave holder to touch the projection on the magneto rotor.
Sheave holder 90890-01701, YS-01880 4. Inspect: • Starter clutch rollers CD Damage/wear --+ Replace.
5. Inspect: • Starter clutch idle gear CD • Starter clutch gear ® Burns/chips/roughness/wear --+ Replace the defective part(s). • Starter clutch gear's contacting surfaces @ Damage/pitting/wear --+ Replace the starter clutch gear.
2
6. Inspection: • Starter clutch operation
Installation steps: • Install the starter clutch gear CD onto the starter clutch ® and hold the starter clutch. • When turning the starter clutch gear clockwise [A] , the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. • When turning the starter clutch gear counterclockwise [al, it should turn freely, otherwise the starter clutch is faulty and must be replaced.
5-34
A.C. MAGNETO AND STARTER CLUTCH
I ENG I @>
INSTALLATION 1. Install: - Starter clutch NOTE: - - - - - - - - - - - - - - While holding the magneto rotor with the sheave holder, tighten the starter clutch bolt. - Do not allow the sheave holder to touch the projection on the magneto rotor. Sheave holder 90890-01701, YS-01880-A 2. Tighten: - Bolts CD
,
~
Bolt (starter clutch): 12 Nm (1.2 mekg, 8.7 ftelb) LOCTITEÂŽ
3. Install: - Woodruff key - Magneto rotor -Washer -Bolt NOTE: - - - - - - - - - - - - - - Clean the tapered portion of the crankshaft and the magneto rotor hub. - When installing the magneto rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft. 4. Tighten: - Bolt CD Bolt (A.C. magneto rotor): 130 Nm (13.0 m-kg, 94.0 ft-Ib) NOTE: - - - - - - - - - - - - - - While holding the A.C. magneto rotor ÂŽ with the sheave holder @, tighten the magneto rotor bolt. - Do not allow the sheave holder to touch the projection on the magneto rotor. Sheave holder 90890-01701, YS-01880
5-35
A.C. MAGNETO AND STARTER CLUTCH
I ENG II
5. Apply: -Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 Quick gasket® ACC-11 00-15-01
5-36
OIL PAN AND OIL PUMP
I ENG I @>
OIL PAN AND OIL PUMP
IAJ : I
10 Nm (1.0 m.kg, 7.2 tt.lb)
[BJ :
12 Nm (1.2 m.kg, 8.7 tt.lb)
I
Order
1 2 3
4 5 6
Job name/Part name
2
Q'ty
Oil pan and oil pump removal Engine Water pump Oil pipe Oil pan Gasket Dowel pin Oil pump assembly Oil pipe
Remarks Remove the parts in the order listed below. Refer to "ENGINE ASSEMBLY". Refer to "WATER PUMP" in CHAPTER 6.
1 1 1 4 1 1 For installation, reverse the removal procedure.
5-37
OIL PAN AND OIL PUMP
Order
Job name/Part name
Q'ty
Oil pump disassembly
CD
® ®
@
®
@ (!)
®
® ®
@ @
Oil pump Oil pump Pin Oil pump Oil pump Oil pump Oil pump Oil pump Valve Spring Pin Oil pump
I ENG II
Remarks Disassemble the parts in the order listed below.
cover 1 inner rotor 1
1 1 2 1 1 1 1 1 1 1 4 1
outer rotor 1 cover 2 inner rotor 2 outer rotor 2 shaft
housing
For assembly, reverse the disassembly procedure.
5-38
OIL PAN AND OIL PUMP r--~~------------
I ENG I @>
REMOVAL 1. Remove: • Pipe G) ·Oil pan ® ·Oil pump NOTE: - - - - - - - - - - - Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
5-39
OIL PAN AND OIL PUMP
r----------------
I ENG II
INSPECTION 1. Inspection: - Oil pump housing CD - Oil pump cover ® Cracks/damage/wear --+ Replace the defective part(-s).
2. Measure: -Inner-rotor-to-outer-rotor-tip clearance @ (between inner rotor CD and outer rotor ®) - Outer-rotor-to-oil-pump-housing clearance
@ (between outer rotor ® and pump housing
@) Out of specifications --+ Replace oil pump assembly. Inner-rotor-to-outer-rotor-tip clearance: 0.09 -- 0.15 mm (0.004 -- 0.006 in) Outer-rotor-to-oil-pump-housing clearance: 0.03 -- 0.08 mm (0.001 -- 0.003 in)
3. Inspect: - Check ball seat CD -Check ball ® -Spring@ -Valve@ Damage/wear --+ Replace the defective part (-s).
4. Inspect: -Pipe CD - Oil strainer ® Damage --+ Replace. Obstruction --+ Wash and blowout with compressed air. Contaminants --+ Clean with engine oil.
5-40
OIL PAN AND OIL PUMP
I ENG I @>
INSTALLATION 1. Lubricate: -Inner rotor - Outer rotor - Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil
2. Install: -Pin CD -Inner rotor ® - Outer rotor @ -Housing@ NOTE: - - - - - - - - - - - - When installing the inner rotor, align the pin CD in the oil pump shaft with the groove @ on the inner rotor ®. 3. Inspect: - Oil pump operation Unsmooth operation -+ Replace. 4. Install: - Oil pump assembly CD - Oil strainer ® -Pipe@
5. Install: -Dowel pin -Gasket -Oil pan 6. Tighten: - Oil pan bolts Bolt (oil pan): 10 Nm (1.0 m-kg, 7.2 ft-Ib) NOTE: - - - - - - - - - - - - Tighten the oil pan bolts in stages and in a crisscross pattern.
5-41
CRANKCASE
I ENG
I
@>
CRANKCASE CRANKCASE 12 Nm (1.2 m-kg, 8.7 ft-Ib)
B
7
15 Nm (1.5 m-kg, 11 ft-Ib) 12 Nm (1.2 m-kg, 8.7 ft-Ib)
10 Nm (1.0 m-kg, 7.2 ft-Ib)
[:EJ Tighten these bolts first. Order 1 2 3
4 5 6 7 8 9 10
[E] Tighten these bolts second.
Job name/Part name
Q'ty
Crankcase removal Countershaft cover Dowel pin Gasket Oil pump drive chain guide Timing chain Timing chain guide (intake side) Lower crankcase Dowel pin Counter shaft oil seal Cover
Remarks Remove the parts in the order listed below.
1 2 1 1 1 1 1 2 1 1
For installation, reverse the removal procedure.
5-42
CRANKCASE
I ENG I @>
CONNECTING RODS AND PISTONS
IAJ : I
20 Nm (2.0 m-kg, 14 tt-Ib) + 120
0
9
Order
1 2 3 4 5 6 7 8 9
Job name/Part name
Q'ty
Connecting rods and pistons removal Connecting rod cap Big end bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring
Remarks Remove the parts in the order listed below.
4 8 8 4 4 4 4 4 4 For installation, reverse the removal procedure.
5-43
CRANKCASE
I ENG
I
@>
CRANKSHAFT AND COUNTER SHAFT
!AI : I
75 Nm (7.5 m.kg, 54 tt.lb)
5
!AI
This bolt has a left-hand thread.
Order
1 2 3 4 5 6 7
Job name/Part name
Q'ty
Crankshaft and counter shaft removal Crankshaft Crankshaft journal bearing Drive gear Lock plate Counter shaft assembly Oil pump drive chain Oil pump driven gear
Remarks Remove the parts in the order listed below.
1 10 1 1 1 1 1
For installation, reverse the removal procedure.
5-44
CRANKCASE
I ENG I @>
REMOVAL 1. Remove: • Crankcase bolts NOTE: - - - - - - - - - - - - - • Place the engine upside down. • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). • The numbers embossed on the crankcase indicate the crankcase tightening sequence. 2. Remove: • Lower crankcase
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure that the crankcase halves separate evenly. 3. Remove: • Dowel pins • Crankshaft journal bearing NOTE: - - - - - - - - - - - Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place.
4. Remove: • Connecting rod cap CD • Big end bearing NOTE: - - - - - - - - - - - - Identify the position of each big end bearing so that it can be reinstalled in its original place.
5-45
CRANKCASE
I ENG
I
@>
5. Remove: - Piston pin clips CD - Piston pin ÂŽ -Piston@ - Connecting rod @
Do not use a hammer to drive the piston pin out.
3
NOTE: - - - - - - - - - - - - - - For reference during installation, put identification marks on the piston crown. - Before removing the piston pin, deburr the piston pin clip's groove and the piston's pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller CD.
Piston pin puller: 90890-01304, YU-01304
6. Remove: -Top ring -2nd ring -Oil ring
I
NOTE: - - - - - - - - - - - - - When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. 11221502
7. Remove: - Crankshaft - Crankshaft journal bearing NOTE: - - - - - - - - - - - - - Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place.
5-46
I ENG I @>
CRANKCASE
INSPECTION 1. Inspect: - Piston wall and cylinder wall Vertical scratches -+ Rebore or replace the cylinder, and replace the piston and piston rings as a set.
2. Measure: - Piston-to-cylinder clearance Measurement steps: 1st step: - Measure cylinder bore "C" with the cylinder bore gauge CD. NOTE: - - - - - - - - - - - - - Measure cylinder bore "C" by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements.
"~""'----D3---- " 04
" ......
-------------""
Cylinder bore "C"
74.000 -- 74.010 mm (2.9134 -- 2.9138 in)
Wear limit
74.06 mm (2.9157 in)
Taper limit "T"
0.05 mm (0.0020 in)
Out of round "R"
0.05 mm (0.0020 in)
,,"
"e" = maximum of 0 1 "T"
---
06
= maximum of 01 or 02 -
maximum of
Os or 0 6 "R"
= maximum of 01 03 or Os -
maximum of
O2 0 4 or 0 6
-If out of specification, replace the cylinder, and the piston and piston rings as a set.
5-47
CRANKCASE
I ENG
I
@>
2nd step: • Measure piston skirt diameter "P" with the micrometer.
®
® 5 mm (0.20 in) from the bottom edge of the piston. Piston size (standard) (P): 73.955 --- 73.970 mm (2.9116 --- 2.9122 in) • If out of specification, replace the piston and piston rings as a set. 3rd step: • Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance Cylinder bore "C" Piston skirt diameter "P"
=
Piston-to-cylinder clearance: 0.030 --- 0.055 mm (0.0012 --- 0.0022 in) <Limit>: 0.12 mm (0.0047 in) ·If out of specification, replace the cylinder, and the piston and piston rings as a set.
3. Measure: • Side clearance (piston rings) Use the thickness gauge CD Out of specification -+ Replace the piston and piston rings as a set. NOTE: - - - - - - - - - - - - - Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance.
......
11221402
Piton rings side clearance: Top ring 0.030 --- 0.065 mm (0.0012 --- 0.0026 in) 2nd ring 0.020 --- 0.055 mm (0.0008 --- 0.0022 in)
5-48
CRANKCASE
I ENG I @>
4. Install: • Piston ring (into the cylinder)
®
NOTE: - - - - - - - - - - - - - Level the piston ring in the cylinder with the piston crown.
® 5 mm (0.20 in) 11221401
5. Measure: • End gap (piston rings) Out of specification -+ Replace the piston rings as a set. NOTE: - - - - - - - - - - - - - The oil ring expander spacer's end gap cannot be measured. If the oil ring rail's gap is excessive, replace all three piston rings. Piston ring end gap: Top ring 0.32 -- 0.44 mm (0.010 -- 0.020 in) 2nd ring 0.43 -- 0.58 mm (0.017 -- 0.023 in) Oil ring 0.10 -- 0.35 mm (0.004 -- 0.014 in)
6. Inspect: • Piston pin Blue discoloration/grooves -+ Replace the piston pin and then check the lubrication system.
7. Measure: • Outside diameter (piston pin) Out of specification -+ Replace the piston pin. /
Piston pin outside diameter: 16.991 -- 17.000 mm (0.6689 -- 0.6693 in)
5-49
CRANKCASE
I ENG
I
@>
8. Measure: • Piston pin bore inside diameter Out of specification -+ Replace the piston.
Piston pin bore inside diameter: 17.002 -- 17.013 mm (0.6694 -- 0.6698 in)
9. Calculate: • Piston pin to piston pin bore clearance Out of specification -+ Replace the piston pin and piston as a set.
Piston pin to piston pin bore clearance Piston pin bore size Piston pin outside diameter Piston pin to piston pin bore clearance 0.002 -- 0.022 mm (0.00008 -- 0.0009 in) <Limit>: 0.072 mm (0.0028 in)
=
10. Measure: • Runout Use the V-blocks and a dial gauge. Out of specification -+ Replace the crankshaft.
Dial gauge: 90890-03097, YU-03097 11631006
Crankshaft runout: 0.03 mm (0.0012 in)
5-50
CRANKCASE
I ENG I @>
11. Inspect: • Crankshaft journal surfaces • Crankshaft pin surfaces • Bearing surfaces Scratches/wear --+ Replace the crankshaft. 12. Measure: • Crankshaft-journal-to-crankshaft-journalbearing clearance Out of specification --+ Replace the crankshaft journal bearings.
Crankshaft-journal-to-crankshaftjournal-bearing clearance: 0.004 ~ 0.028 mm (0.0002 ~ 0.0011 in) Measurement steps:
Do not interchange the crankshaft journal bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. • Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. • Place the upper crankcase upside down on a bench. • Install the crankshaft journal upper bearings CD and the crankshaft into the upper crankcase. NOTE: - - - - - - - - - - - Align the projections ® of the crankshaft journal upper bearings with the notches @ in the crankcase.
• Put a piece of Plastigauge® ® on each crankshaft journal. 2
NOTE: - - - - - - - - - - - - - Do not put the Plastigauge® over the oil hole in the crankshaft journal.
5-51
CRANKCASE
I ENG
I
@>
-Install the crankshaft journal lower bearingseD into the lower crankcase and assemble the crankcase halves. NOTE: - - - - - - - - - - - - - - Align the projections ® of the crankshaft journal lower bearings with the notches @ in the crankcase. - Do not move the crankshaft until the clearance measurement has been completed. - Tighten the bolts to specification in the tightening sequence cast on the crankcase. Crankcase bolt: BolteD ~ @ 1st: 15 Nm (1.5 m-kg, 11 ft-Ib) 2nd: 15 Nm (1.5 m-kg, 11 ft-Ib) + 45 ~ 50° Bolt@ ~ @ 12Nm (1.2 m-kg, 8.7 ft-Ib)
M9 M8 M5 M5 M5 M5 M5
x x x x x x x
105 mm bolts: eD ~ @ 65 mm bolts: @, @ 90 mm bolts: @ 80 mm bolts: @ 55 mm bolts:@ ~ ® 45mmbolts:@,@,@ ~@ 25 mm bolts: ®
NOTE: - - - - - - - - - - - - - Lubricate the crankcase bolt threads with engine oil.
- Remove the lower crankcase and the crankshaft journal lower bearings. - Measure the compressed Plastigauge@ width © on each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings.
5-52
CRANKCASE
I ENG I @>
13. Select: • Crankshaft journal bearings (J1 -- J5) NOTE: - - - - - - - - - - - - - • The numbers [A] stamped into the crankshaft web and the numbers[B] stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • "J1 -- J5" refer to the bearings shown in the crankshaft illustration. ·If "J1 -- J5" are the same, use the same size for all of the bearings. Selection of bearings: For example, if the crankcase "J 1" and crankshaft web "J 1" numbers are "6" and "2" respectively, then the bearing size for "J 1" is: Bearing size for J 1: J1 (crankcase) - J1 (crankshaft web) - 2 6 - 2 - 2 2 (black)
=
=
CRANKSHAFT JOURNAL BEARING COLOR CODE -1
Violet
0
White
1
Blue
2
Black
3
Brown
14. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification -+ Replace the big end bearings. Crankshaft-pin-to-big-endbearing clearance: 0.016 -- 0.040 mm (0.0006 -- 0.0016 in)
5-53
CRANKCASE
I ENG
I
@>
Measurement steps:
Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions. - Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods. -Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap.
NOTE: - - - - - - - - - - - - - Align the projections ÂŽ on the big end bearings with the notches @ in the connecting rod and connecting rod cap.
11630301
- Put a piece of PlastigaugeÂŽ CD on the crankshaft pin. - Assemble the connecting rod halves.
NOTE: - - - - - - - - - - - - - - Do not move the connecting rod or crankshaft until the clearance measurement has been completed. - Apply molybdenum disulfide grease onto the bolts, threads, and nut seats. - Make sure that the "Y" mark@ on the connecting rod faces towards the left side of the crankshaft. - Make sure that the characters @ on both the connecting rod and connecting rod cap are aligned. - Tighten the connecting rod nuts.
Nut (connecting rod): 20 Nm (2.0 m-kg, 14 ft-lb)+120°
11630601
5-54
CRANKCASE
I ENG I @>
• Replace the connecting rod bolts and nuts with new ones.
Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. • Clean the connecting rod bolts and nuts. • Tighten the connecting rod nuts. • Put a mark CD on the corner of the connecting rod nut ® and the connecting rod @. • Tighten the nut further to reach the specified angle (120°).
fimimIm]
----------
When the nut is tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the bolt with a new one and perform the procedure again.
• Do not use a torque wrench to tighten the nut to the specified angle. • Tighten the nut until it is at the specified angles. NOTE: - - - - - - - - - - - - - When using a hexagonal nut, note that the angle from one corner to another is 60° • Remove the connecting rod and big end bearings. • Measure the compressed Plastigauge® width on the crankshaft pin. If the clearance is out of specification, select replacement big end bearings.
5-55
CRANKCASE
I ENG
I
@>
15. Select: • Big end bearings (P 1 -- P4) NOTE: - - - - - - - - - - - - - • The numbers [A] stamped into the crankshaft web and the numbers CD on the connecting rods are used to determine the replacement big end bearing sizes. • "P1" -- "P4" refer to the bearings shown in the crankshaft illustration. Selection of bearings: For example, if the connecting rod "P 1" and the crankshaft web "P 1" numbers are "5" and "1" respectively, then the bearing size for "P1" is: Bearing size for "P1": "P 1 " (connecting rod) - "P 1 " (crankshaft) - 2 = 5 -1 - 2 2 (Black)
=
BIG END BEARING COLOR CODE
----~
-1
Violet
0
White
1
Blue
2
Black
3
Brown
16. Inspect: • Crankcase: Cracks/damage
--+
Replace.
NOTE: - - - - - - - - - - - - Thoroughly wash the crankcase halves in a mild solvent. Thoroughly clean all the gasket surfaces and crankcase mating surfaces.
• Oil delivery passages Obstruction --+ Blowout with compressed air.
5-56
CRANKCASE
I ENG I @>
17. Inspect: - Bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement --+ Replace. 18. Inspect: -Oil seals Damage/wear --+ Replace.
19. Inspect: - Primary drive gear CD - Oil pump driven gear ÂŽ Cracks/damage/wear --+ Replace the defective part(-s).
20. Inspect: - Timing chain CD - Oil pump drive chain ÂŽ Damage/stiffness --+ Replace the chain and sprocket as a set.
21. Inspect: -Timing chain guide (intake side) Damage/wear --+ Replace the timing chain guide.
22. Inspect: - Counter shaft assembly Damage --+ Replace.
5-57
CRANKCASE
I ENG
I
@>
INSTALLATION 1. Install: • Crankshaft journal bearing CD (into the upper crankcase) NOTE: - - - - - - - - - - - - - • Align the projections@ on the crankshaft journal upper bearings with the notches @ in the crankcase. • Be sure to install each crankshaft journal upper bearing in its original place. 2. Install: • Crankshaft
3. Install: • Top ring CD ·2nd ring ® • Upper oil ring rail ® • Oil ring expander @ • Lower oil ring rail @ NOTE: - - - - - - - - - - - - - Be sure to install the piston rings so that the manufacturer's marks or numbers @ face up. 4. Install: • Piston CD (onto the respective connecting rod ®) • Piston pin ® • Piston pin clip @
l1li
NOTE: - - - - - - - - - - - - - • Apply engine oil onto the piston pin. • Make sure that the "Y" mark@ on the connecting rod faces left when the arrow mark @ on the piston is pointing up. Refer to the illustration. • Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4).
b
5-58
CRANKCASE
I ENG I @>
5. Lubricate: • Piston • Piston rings • Cylinder • Crankshaft pins • Big end bearings (with the recommended lubricant) Recommended lubricant Engine oil
6. Offset: • Piston ring end gaps @Top ring
@ Lower oil ring rail
© Upper oil ring rail @ 2nd ring
® Oil ring expander 11221202
7. Install: • Big end bearings • Connecting rod assembly (into the cylinder and onto the crankshaft pin). • Connecting rod cap (onto the connecting rod) NOTE: - - - - - - - - - - - • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. • Be sure to reinstall each big end bearing in its original place. • While compressing the piston rings with one hand, install the connecting rod assembly into the cylinder with the other hand. • Make sure that the "Y" marks @ on the connecting rods face towards the right side of the crankshaft. • Make sure that the characters @ on both the connecting rod and connecting rod cap are aligned.
5-59
CRANKCASE
I ENG
I
@>
8. Align: - Bolt heads (with the connecting rod caps) 9. Tighten: - Connecting rod nuts
Nut (connecting rod): 20 Nm (2.0 m-kg, 14 ft-lb)+120°
- Replace the connecting rod bolts and nuts with new ones.
Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. - Clean the connecting rod bolts and nuts. - Tighten the connecting rod nuts. - Put a markeD on the corner of the connecting rod nut ® and the connecting rod @. - Tighten the nut further to reach the specified angle (120°).
~ ---------When the nut is tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the bolt with a new one and perform the procedure again.
- Do not use a torque wrench to tighten the nut to the specified angle. - Tighten the nut until it is at the specified angles. NOTE: - - - - - - - - - - - - When using a hexagonal nut, note that the angle from one corner to another is 60° .
5-60
CRANKCASE
I ENG I @>
10. Lubricate: - Crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil
11. Apply: -Sealant (onto the crankcase mating surfaces) ......
Yamaha bond No. 1215 90890-85505, ACC-11 00-15-01
NOTE: - - - - - - - - - - - Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 ~ 3 mm of the crankshaft journal bearings.
12. Install: - Crankcase journal bearings CD (into the lower crankcase) NOTE: - - - - - - - - - - - - - - Align the projections@ on the crankshaft journal lower bearings with the notches @ in the crankcase. -Install each crankshaft journal lower bearing in its original place. 13. Install: - Lower crankcase CD (onto the upper crankcase ÂŽ)
5-61
CRANKCASE
I ENG
I
@>
14. Install: - Crankcase bolts NOTE: - - - - - - - - - - - - - Lubricate the bolt threads with engine oil. - Tighten the bolts in increasing numerical order. -Install washers on bolts G) --- @.
Crankcase bolt BoltG) --- @ 1st: 15 Nm (1.5 m-kg, 11 ft-Ib) 2nd: 15 Nm (1.5 m-kg, 11 ft-Ib) + 45 --- 50° BOlt@ --- @ 12 Nm (1.2 m-kg, 8.7 ft-Ib) M9 x 105 mm bolts: G) --- @ M8 x 65 mm bolts: @, @ M5 x 90 mm bolts: @ M5 x 80 mm bolts: @ M5 x 55 mm bolts: @ --- Ž M5 x 45 mm bolts: @, @, @ --- @ M5 x 25 mm bolts: @ 15. Install: - Counter shaft assembly - Timing chain - Oil pump drive chain 16. Install: -Gasket - Counter shaft cover - Bolts Bolts (countershaft cover): 12 Nm (1.2 m-kg, 8.7 ft-Ib)
5-62
HEAT EXCHANGER
ICOOL I :,c I
COOLING SYSTEM
I
35 Nm (3.5 m.kg, 25 tt.lb)
18
'9
~1
1b(\bb(\b~ (\b~1C::::O 16 mil ~ 27 ral ~
r
~)
20
16
19
29
~
6 ~ W
3
~c!q;
..'
~
mil /' ~\J 22 ~ 10'
fI(~
mil
13 27
{/
~ 11 tl2~~,~~
~~28~' t:::o~ .
21
5
~ ~
9 8
I
(J~~ ~~ 23
~
1
~
~~
24~
.O~V ~25
'~
15
~~
~
l
\\~, ~~14 ~J "N~ /<~/ 12 ~ [R' 11
Order
Q'ty
Job name/Part name
Heat exchanger removal Coolant
Remove the parts in the order listed below. Drain. Refer to "COOLING SYSTEM" in CHAPTER 2. Refer to "PRIMARY SHEAVE AND DRIVE V-VELT" in CHAPTER 4.
Primary sheave assembly 1 2 3 4 5 6 7 8 9 10 11 12 13
Remarks
Coolant reservoir tank Coolant hose 1 Heat exchanger (right) Coolant hose 2 Heat exchanger (rear) Coolant hose 3 Heat exchanger (left) Coolant hose 4 Heat exchanger (front) Coolant hose 5 Water pump assembly Coolant hose 6 Coolant pipe 1
1 1 1 1 1 1 1 1 1 1 1 1 1 6-1
ICOOL
HEAT EXCHANGER
I
:,c I
[A] : 10....-_3_5 _N_rn_{_3o_5_rn_e _k9_,_25_f_te_lb_}_ 18
6
1 5
1b~b~~
~~Ic:::o~ 16 mil ~ 27
~
r
~)
20
16
19
mil
13 27
~c:!q;
..' ~
mil /' ~\J 22 ~ 10'
~~
~
f
(/
29 rl2~~,4~
\~ ~~ 28 ~:. T t::o~.
21
6 ~ W
3
I
~~~ ~~23
~ ~
~
7
.O~V ~25 ¡
1
~
~~
24~
'~
\\~,
15
~~
~
l
~ clJ-14 ~J ~~ ~ttIf;/ 12 ~ 'QR' 11
Order 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Job name/Part name
Q'ty
Coolant pipe 2 Coolant hose 7 Coolant hose 8 Thermostat assembly Coolant hose 9 Coolant hose 10 Oil cooler outlet hose Oil cooler Oil cooler inlet hose Pipe 3 Water pump hose Carburetor heater hose Heat exchanger hose a-ring Coolant hose 11 Coolant hose 12
Remarks
1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure. 6-2
HEAT EXCHANGER
ICOOL I :,c I
INSPECTION 1. Inspect: • Coolant hoses • Heat exchangers ·Oil cooler • Coolant pipes Cracks/damage -+ Replace.
2. Measure: • Filler cap opening pressure Cap opens with a pressure below the specified pressure -+ Replace. Filler cap opening pressure: 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm 2 , 14 ~ 18 psi) Measurement steps: • Attach the cooling system testerCD to the coolant filler cap ®. Cooling system tester: 90890-01325, YU-24460-01 Adapter: 90890-01352, YU-33984
• Apply the specified pressure for 10 seconds and make sure there is no pressure drop.
SCH6050
6-3
HEAT EXCHANGER
ICOOL
I
:,c I
INSTALLATION 1. Install: - Heat exchangers Use the rivet gun. 2. Install: -a-ring -Oil cooler - Lock washer - Bolt (oil cooler bolt)
Bolt (oil cooler): 35 Nm (3.5 m-kg, 25 ft-Ib)
NOTE: - - - - - - - - - - - - - Before installing the oil cooler, lubricate the oil cooler bolt and a-ring with a thin coat of engine oil. - Make sure the a-ring is positioned properly. - Align the projection @ on the oil cooler with the slot @ in the crankcase. - Bend the lock washer tab along a flat side of the bolt.
6-4
_____________ T_HE_R_M_O_S_TA_T_I COOL I
:,c
THERMOSTAT
)=1
[AJ : 1==1O=N=m=(=1"=O=m=ek=9=,7="2=ft=el=b [BJ : 1 23 Nm (2.3 mekg, 17 ftelb)
o
I~~ I
Order
~
1
Job name/Part name
~
Q'ty
Thermostat disassembly
CD ÂŽ ÂŽ
@
1
Remarks Disassemble the parts in the order listed below.
Thermostat housing cover Thermostat Thermostat housing Water temperature sensor
1 1 1 1 For assembly, reverse the disassembly procedure.
6-5
I
_____________ T_HE_R_M_O_S_TA_T_I COOL I INSPECTION 1. Inspect: • Thermostat Doesnotopenat71 --+ Replace.
~
85°C(160
:,c
~
I
185°F)
Inspection steps: • Suspend the thermostat in a container filled with water. • Slowly heat the water. Place a thermometer in the water. • While stirring the water, observe the thermostat and thermometer's indicated temperature.
14250202
CD Thermometer ®Water
® Thermostat @
[A] Fully closed [B] Fully open [Q] More than 7 mm (0.276 in)
14250201
[ID
NOTE: - - - - - - - - - - - - If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.
[g
[8J
71°C (160°F)
Container
2. Inspect: • Thermostat housing cover • Thermostat housing Cracks/damage --+ Replace.
85°C (185°F) 14250101
6-6
_____________ T_HE_R_M_O_S_TA_T_I COOL I
:,c
I
INSTALLATION 1. Install: - Thermostat (into the thermostat housing) NOTE: - - - - - - - - - - - - - Install the thermostat with its breather hole @ aligned with the this place @ on the thermostat housing. 2. Install: - Thermostat cover - Bolts (thermostat housing)
Bolt (thermostat housing): 10 Nm (1.0 m-kg, 7.2 ft-Ib)
3. Install: - Water temperature sensor CD (to the thermostat housing)
Water temperature sensor 23 Nm (2.3 m-kg, 17 ft-Ib)
Use extreme care when handling the water temperature sensor. Replace any part that was dropped or subjected to a strong impact.
6-7
W;ATTiEEFR~puUiMMipP----
~W~AT~E~R~P~U~M~P I
COOL I
Job name/Part name
~I
Remarks
Water pu mp disassembly ¡
Disassembly the parts .In the order listed below.
Oil pan Water pump cover Plate Circlip Impeller shaft W.ater pump seal 011 seal Bearing O-ring Water pum pausing h . . PIpe
Refer to "OIL PAN AND OIL PUMP".
For assembly, revers . procedure. e the disassembly
6-8
_ _ _ _ _ _ _ _ _ _ _ _ _W_A_TE_R_P_U_M_P_I COOL I
:,c
I
DISASSEMBLY 1. Remove: -Impeller - Water pump seal CD
I
NOTE: - - - - - - - - - - - - - Remove the water pump seal CD from the inside of the water pump housing 速.
2. Remove: -Bearing CD -Oil seal速 NOTE: - - - - - - - - - - - Remove the bearing CD and oil seal 速 from the inside of the water pump housing @.
\
3. Remove: - Rubber damper holder CD - Rubber damper 速 (from the impeller, with a thin, flat-head screwdriver) NOTE: - - - - - - - - - - - - Do not scratch the impeller shaft.
6-9
_ _ _ _ _ _ _ _ _ _ _ _ _W_A_TE_R_P_U_M_P_I COOL I
:,c
I
INSPECTION 1. Inspect: - Water pump housing cover CD - Water pump housing ÂŽ -Impeller@ - Rubber damper @ - Rubber damper holder @ - Water pump seal -Oil seal Cracks/damage/wear -+ Replace. 2. Inspect: - Bearing Rough movement -+ Replace.
ASSEMBLY 1. Install: -Oil seal CD (to the water pump housing)
011
NOTE: - - - - - - - - - - - - - - Before installing the oil seal, apply tap water or coolant onto its outer surface. -Install the oil seal with a socket that matches its outside diameter. 2. Install: - Bearing NOTE: - - - - - - - - - - - - - Install the bearing with a socket that matches its outside diameter. 3. Install: - Water pump seal
011
Never apply oil or grease onto the water pump seal surface.
6-10
_ _ _ _ _ _ _ _ _ _ _ _ _W_A_TE_R_P_U_M_P_I COOL I
:,c
I
NOTE: - - - - - - - - - - - - - -Install the water pump seal CD with the water pump seal installers @ @. - Before installing the water pump seal, apply Yamaha bond No.1215 ® to the water pump housing@.
Water pump seal installer: 90890-04078, YM-33221 40 and 50 mm Bearing driver: 90890-04058, YM-4058 Yamaha bond No.1215 90890-85505, ACC-11 001-05-01
14150501
[A] Push down
4. Install: - Rubber damper holder CD - Rubber damper ® NOTE: - - - - - - - - - - - - Before installing the rubber damper, apply tap water or coolant onto its outer surface.
......
.........IIIIIIIiiiioo..
5. Measure: - impeller shaft tilt Out of specification --+ Repeat steps (4) and (5).
----.I 141.')0204
Make sure the rubber damper and rubber damper holder are flush with the impeller.
Max. impeller shaft tilt: 0.15 mm (0.0059 in) <Limit>: 0.072 mm (0.0028 in)
14150203
CD Straightedge ® Impeller
6-11
CARBURETORS
ICARB ~ I I
CARBURETION CARBURETORS [AJ :
I
Order 1 2
3 4 5 6 7
8 9 10 11 12
10 Nm (1.0 m.kg, 7.2 tt.lb)
Job name/Part name
Q'ty
Carburetors removal Intake silencer Fuel pump Carburetor switch (T.O.R.S.) lead Starter cable Throttle position sensor coupler Carburetor heater lead Carburetor heating hose Fuel hose Throttle cable Carburetor assembly Caburetor joint Collar
Remarks Remove the parts in the order listed below.
1 1 2 1 1 1 2 2 1 1 4 4
Disconnect. Disconnect. Disconnect.
For installation, reverse the removal procedure.
7-1
CARBURETORS
ICARS I ~ I
4
Order
CD ® ®
@
® ®
(J)
® ® ®
@
Job name/Part name
Q'ty
Carburetor separation Carburetor heater harness Carburetor heating hose Starter plunger link Connecting bolt Spacer Fuel inlet pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Carburetor
Remarks Remove the parts in the order listed below.
1 3 1 2 3 2 1 2 2 1 4 For installation, reverse the removal procedure.
7-2
CARBURETORS
ICARS ~ I I
3
Order
Job name/Part name
Q'ty
Carburetor disassembly
CD ® ®
@
® ®
(j)
® ® ®
Remarks Disassemble the parts in the order listed below. NOTE: The following procedure applies to all of the carburetors.
Starter plunger Pilot air jet Vacuum chamber cover Piston valve spring Piston valve Jet needle holder Jet needle kit Pilot screw Fuel drain bolt Float pin
1 1 1 1 1 1 1 1 1 1
7-3
CARBURETORS
ICARS I ~ I
3
Order
@ @ @ ~
@
Ž Š
@ @ @
Job name/Part name
Q'ty
Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet Carburetor switch (T.O.R.S.) Carburetor heater Starter jet
Remarks
1 1 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
7-4
CARBURETORS
ICARS ~ I I
INSPECTION 1.lnspect: • Carburetor body • Float chamber • Jet housing Cracks/damage --+ Replace.
2. Inspect: • Fuel passages Obstruction --+ Clean. NOTE: - - - - - - - - - - - • Use a petroleum based solvent for cleaning. • Blowout all passage and jets with compressed air. 14510105
3. Inspect: • Float chamber body CD 4. Inspect: • Float chamber rubber gasket ® Cracks/damage/wear --+ Replace.
5. Inspect: • Float CD Damage --+ Replace.
6. Inspect: • Needle valve CD • Needle valve seat ® Damage/obstruction/wear --+ Replace the needle valve, needle valve seat and O-ring as a set. 7. Inspect: .O-ring@ Damage/wear --+ Replace the needle valve, needle valve seat and O-ring as a set.
2
3
14510702
7-5
CARBURETORS
ICARS I ~ I
8. Inspect: • Piston valve CD Damage/ scratches / wear -+ Replace. • Rubber diaphragm ® Cracks/tears -+ Replace.
14511403
9. Inspect: • Vacuum chamber cover CD • Piston valve spring ® • Jet needle holder @ Cracks/damage -+ Replace.
10. Inspect: • Jet needle kit CD • Starter jet ® ·Main jet@ • Main jet holder @ • Pilot jet@ • Pilot screw @ • Needle jet (f) • Pilot air jet @ Bends/damage/wear -+ Replace. Obstruction -+ Clean. Blowout the jets with compressed air. 11. Inspect: • Piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness -+ Replace the piston valve. 12. Inspect: • Fuel feed pipes • Hose joint Cracks/damage -+ Replace. Obstruction -+ Clean. Blowout the pipes with compressed air. 13. Inspect: • Fuel feed hoses • Fuel hoses Cracks/damage/wear -+ Replace. Obstruction -+ Clean. Blowout the hoses with compressed air.
5
14511501
7-6
CARBURETORS
ICARS ~ I I
ASSEMBLY NOTE: - - - - - - - - - - - - - • Before assembling the carburetors, wash all of the parts in a petroleum based solvent. • Always use a new gasket and a-rings. 1. Install: • Jet needle kit • Needle jet • Pilot jet • Main jet
2. Inspect: • Piston valve • Piston valve spring • Vacuum chamber cover .O-ring@
a
3. Measure: • Float hight @ Out of specification -+ Adjust.
Float height: 11 -- 15 mm (0.43 -- 0.59 in) Measurement and adjustment steps: • Hold the carburetor upside down. • Measure the distance between the carburetor body and top of the floats. NOTE: - - - - - - - - - - - - - The float arm should resting on the needle valve without exerting pressure on it. ·If the float height is not within specification, inspect the valve seat and needle valve. ·If either is worn, replace them both. ·If both are fine, adjust the float height by bending the float arm tang CD on the float. • Recheck the float height.
1
7-7
CARBURETORS
ICARS I ~ I
INSTALLATION NOTE: - - - - - - - - - - - - After installing all parts, refer to "CABLE ROUT1NG" in CHAPTER 9, to check the cable, lead and hose routing.
1. Adjust: • Carburetor synchronization Refer to "SYNCHRONIZING THE CARBURETORS" in CHAPTER 2. 2. Adjust: • Engine idling speed ~.
vt
Engine idle speed: 1,350 ± 100 r/min (1,250 -- 1,450 r/min)
Refer to "ENGINE IDLE SPEED ADJUSTMENT" in CHAPTER 2. 3. Adjust: • Throttle cable free play Refer to "THROTTLE CABLE FREE PLAY" in CHAPTER 2.
7-8
CARBURETORS
ICARS ~ I I
FUEL LEVEL ADJUSTMENT 1. Measure: - Fuel level ® Out of specification -+ Adjust. Fuel level (below the line on the float chamber): 3.0 ~ 4.0 mm (0.118 ~ 0.157 in)
2
14510804
Measurement steps: -Install the fuel level gauge CD to the fuel drain pipe®. . ..
Fuel level gauge 90890-01312, YU-01312-A
- Loosen the fuel drain screw. - Hold the fuel level gauge vertically next to the line on the float chamber. - Measure the fuel level ® on both sides of the carburetor assembly.
NOTE: - - - - - - - - - - - - The fuel level readings should be equal on both sides.
" h "
" "
,,t :' _ ,--------------------------"
~
2. Adjust: -Fuel level Adjustment steps: - Remove the carburetor assembly. -Inspect the needle valve seat and needle valve. -If either is worn, replace them as a set. -If both are fine, adjust the float height by bending the float tang CD or the float. - Recheck the fuel level.
1
7-9
CARBURETORS
ICARS I ~ I
THROTTLE POSITION SENSOR (T.P.S.) INSPECTION AND ADJUSTMENT NOTE: - - - - - - - - - - - - - Before adjusting the throttle position sensor, properly adjust the idle speed.
1. Inspect: • Throttle position sensor. Inspection steps: • Disconnect throttle position sensor coupler. • Connect the pocket tester (Q x 1k) to the throttle position sensor coupler. Tester (-) lead -+ Blue terminal CD Tester (+) lead -+ Black terminal ® • Check the throttle position sensor resistance. Throttle position sensor resistance "R 1 ": 4 ~ 6 kQ at 20°C (68°F) (Blue - Black) Out of specification -+ Replace the throttle position sensor. • Connect the pocket tester (Q x 1k) to the throttle position sensor coupler. Tester (-) lead -+ Yellow @ Tester (+) lead -+ Black ® • While slowly pushing the throttle check the throttle position sensor resistance. Throttle position sensor resistance "R 2 ": o ~ 4 kQ at 20°C (68°F) (Yellow - Black) Out of specification -+ Replace the throttle position sensor.
7-10
ICARS ~ I
CARBURETORS
I
2. Adjust: • Throttle position sensor position
Adjustment steps: • Disconnect the throttle position sensor coupler. • Connect the test coupler to the throttle position sensor. • Connect three dry cells (1.5 V x 3 pes.) in series to the test coupler. Dry cells (-) --+ CD Dry cells (+) --+ ®
2
• Connect the digital multimeter to the test coupler.
Digital multimeter (-) lead Digital multimeter (+) lead
--+ --+
CD ®
• Measure the voltage ®. NOTE: - - - - - - - - - - - - - When measuring the voltage ® be sure that the test coupler is connected to the throttle position sensor.
• Calculate the specified voltage @.
=
Specified voltage @ Voltage ® x (0.136) • Loosen the throttle position sensor bolts @. • Connect the digital multimeter to the test coupler Digital multimeter (-) lead Digital multimeter (+) lead
--+ --+
CD
®
• Adjust the throttle position sensor position to obtain the specified voltage @. • Tighten the throttle position sensor bolts @. • Disconnect the test coupler and connect the throttle position sensor coupler.
7-11
_ _ _ _ _ _ _ _ _ _ _ _ _F_U_EL_P_U_M_P_lcARB
I"
I
INSPECTION 1. Inspect: • Fuel hose CD • Vacuum hose ® Clogs/damage --+ Replace.
2. Inspect: • Fuel pump operation.
Inspection steps: • Connect the Mity vac CD to the vacuum hose
®.
~I
Mityvac: 90890-06756, YB-35956
• Place a container ® under the end of the fuel hoses@. • Operate the Mity vac CD while checking that fuel flows from the fuel hoses @. ·If fuel does not flow out, replace the fuel pump.
INSTALLATION NOTE: - - - - - - - - - - - - After installing all parts, refer to "CABLE ROUT1NG" in CHAPTER 9, to check the cable, lead and hose routings.
7-12
SWITCH INSPECTION
IELEC u I I
ELECTRICAL JI
00 "
JlO"
SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch.
JlOX1"
Pocket tester: 90890-03112, YU-03112 NOTE: - - - - - - - - - - - - - • Set the pocket tester to "0" before starting a test. • When testing the switch for continuity the pocket tester should be set to the" x 1" Q range. • When checking the switch turn it on and off a few times.
R
INSPECTING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches (main switch, handlebar switch, engine stop switch, light switch, etc.) are shown in a chart similar to the one on the left. This chart shows the switch positions in the column and the switch lead colors in the top row. For each switch position, "0---0" indicates the terminals with continuity.
Br R/WBr/W
OFF ON START
The example chart shows that:
CD There is continuity between the "Red and Brown" leads when the switch is set to "ON".
® There is continuity between the "Red/White and Brown/White" leads when the switch is set to "START".
8-1
IGNITION SYSTEM
8-2
IGNITION SYSTEM
IGNITION SYSTEM CIRCUIT DIAGRAM
CD A.C. magneto
~ Re~tifier/regulator ~ Main switch @ Main relay ® Fuse (MAIN) ® Battery ~ Engine stop switch ® Throttle switch ® Carburetor switch @CDI unit © ignition coil @ Spark plug @ Fuse (IGNITION)
8-3
IELEC u I I
IGNITION SYSTEM
u
I ELEC I
TROUBLESHOOTING NO SPARK OR WEAK SPARK.
Check the main fuse and ignition fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
~OK
---------.oIl>
FAULTY ... '
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
~OK
OUT OF SPECIFICATION
OUT OF SPECIFICATION
Check the spark plug gap.
~ OK
OUT OF SPECIFICATION
Check the ignition coil resistance.
~ OK
c:::::> Replace and/or charge the battery. Refer to "BATTERY CHARGING" in CHAPTER 2.
Check the stator coil and pickup coil.
~ OK
Replace the main fuse and/or ignition fuse.
OUT OF SPECIFICATION
c:::::> Replace the stator coil assembly. c:::::> Repair or replace the spark plug. c:::::> Replace the ignition coil.
Check the engine stop switch, throttle switch, carburetor switch and main switCh.
~OK
---------.oIl>
FAULTY ... '
Check the main relay.
~ OK
---------.oIl>
FAULTY ... '
Replace the handlebar switch (right), carburetor switch, and/or main switch.
Replace the main relay.
Correct the connection and/or replace the rectifier/regulator and/or the CDI unit.
8-4
I
IGNITION SYSTEM
IELEC u I I
A.C. MAGNETO 1. Disconnect: • A.C. magneto coupler CD 2. Connect: • Pocket tester (to the A.C. magneto coupler) 3. Measure: • Stator coil resistance @ / pickup coil resistance® Out of specification -+ Replace. Pickup coil resistance: (Gray - Black) 189 ~ 231 Q at 20°C (68°F) Stator coil resistance: (White - White) 0.19 ~ 0.24 Q at 20°C (68°F)
@
I
I
~---------------
I
SPARK PLUG 1. Remove: • Spark plugs 2. Measure: • Spark plug gap ®
® --.------..--'
Standard spark plug: CR9E (NGK) Spark plug gap: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
SCH8220
8-5
IGNITION SYSTEM
IELEC Iu I
IGNITION SPARK GAP 1. Remove: -Ignition coil 2. Measure: -Ignition spark gap Out of specification --+ Replace the ignition coil Measurement steps: - Disconnect the ignition coil ® from the spark plug. - Connect the dinamic spark tester CD. - Set the main switch to "ON". - Measure the ignition spark gap @.
18110202
I
~l
Spark gap:
:6]~_6_m_m_(0_.2_4_i_n_)
IGNITION COIL 1. Disconnect: -Ignition coil lead 2. Connect: - Pocket tester 3. Measure: - Primary coil resistance @ - Secondary coil resistance @ Out of specification --+ Replace.
@
Primary coil resistance: 0.16 ~ 0.22 Q at 20°C (68°F) Secondary coil resistance: 5.0 ~ 6.8 kQ at 20°C (68°F)
8-6
.......
IGNITION SYSTEM
IELEC u I I
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should malfunction during operation, T.O.R.S. will operate when the throttle lever is released. T.O. R.S. is designed to interrupt the ignition and keep the engine revolutions between 2,800 and 3,000 r/min if the carburetor fails to return to idle when the lever is released.
A
m!mmmmI ----------If T.O.R.S. operates, make sure that the cause of the malfunction is corrected and that the engine can be operated without a problem before restarting the engine. - Be sure to use the standard resistancetype spark plug and spark plug cap. Otherwise, T.O.R.S. will not work properly.
B
~
c
lAJ Idling l6J Running
Trouble
Switch
Throttle switch
OFF
ON
OFF
Carburetor switch
ON
OFF
OFF
Engine
Running Running
CD Carburetor switch
ÂŽ Throttle switch ÂŽ Throttle cable @ Throttle stop screw @ON @OFF
8-7
lQJ
or starting
T.O.R.S. operating
IGNITION SYSTEM
IELEC Iu I
HANDLEBAR SWITCH (RIGHT) Engine stop switch and throttle switch 1. Disconnect: • Handlebar switch (right) coupler CD 2. Connect: • Pocket tester
3. Inspect: • Engine stop switch continuity Faulty --+ Replace the handlebar switch (right).
Br B/Y - - - - - - - - - -......Br.
B
Switch position
Continuity
RUN (pulled out)
Yes
OFF (pushed in)
No
4. Inspect: • Throttle switch continuity Faulty --+ Replace the handlebar switch (right).
Throttle switch position
Continuity
Throttle lever is operated.
Yes
Throttle lever is not operated.
No
CARBURETOR SWITCH 1. Disconnect: • Carburetor switch lead CD 2. Connect: • Pocket tester 3. Inspect: • Carburetor switch continuity Faulty --+ Replace. Carburetor switch position
B
B/Y
I
I
SCH8330
8-8
Continuity
Throttle lever is operated.
No
Throttle lever is not operated.
Yes
IELEC u I
IGNITION SYSTEM
I
MAIN SWITCH 1. Disconnect: • Main switch coupler CD 2. Connect: • Pocket tester 3. Inspect: • Main switch continuity Faulty -+ Replace. Switch position
Continuity
OFF
Yes
ON
No
Switch position
Color code
Br
R/Y
Br/W
R/W
OFF ON
START
0---0
Continuity
MAIN RELAY 1. Inspect: • Main relay CD Inspection steps: • Disconnect the main relay from the coupler. • Connect the pocket tester (0 x 1) and battery (12 V) to the main relay terminals as shown. Positive battery terminal -+ Brown CD Negative battery terminal -+ Brownl White® Positive tester probe -+ Red ® Negative tester probe -+ Blue @ ·If main relay does not have continuity between the red and blue terminals, replace it.
R
SCH8350
8-9
ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM
m rm
o
-I ::IJ
o
ex> I .....L
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:::!
z
C)
en -< en -I
m
s::
ELECTRICAL STARTING SYSTEM
IELEC u I I
TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE.
~ ---------------------------Before starter motor operation, push the engine stop switch to "OFF". NO
1. Connect: • Starter relay terminals (battery side and starter motor side)
Check the battery and connectors. Refer to "BATTERY INSPECTION" in CHAPTER2.
ED
OK
e
Charge and/or replace the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
SCH8040
CD Jumper lead 2. Check: • Starter motor operation
I
Repair or replace the starter motor.
~OK
~ ----------
3. Disconnect: • Starter relay coupler 4. Connect: • Starter relay coupler terminals
,... -
-
-
-
-
-
-
-
-
-
-
A wire for the jumper lead CDmust have the equivalent capacity as that of the battery lead or more, otherwise it may cause the jumper lead to be burned. This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity.
-I 1 1
NO SCH8050
I
CD Jumper lead 5. Inspect: • Starter motor operation
Replace the starter relay.
~OK
* 8-11
IELEC Iu I
ELECTRICAL STARTING SYSTEM
* FAULTY
Check the main fuse and ignition fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
~OK
Replace the main fuse and/or ignition fuse.
I
FAULTY
Check the main switch.
~OK
I
Replace the main switch.
I
Correct the connection.
MAIN SWITCH 1. Disconnect: • Main switch coupler CD 2. Connect: • Pocket tester 3. Inspect: • Main switch continuity Faulty -+ Replace. Switch position
Continuity
OFF
Yes
ON
No
Switch position
Color code Br
OFF ON START
0--0
8-12
Continuity
R/Y
Br/W
R/W
ELECTRICAL STARTING SYSTEM
IELEC u I I
STARTER MOTOR
[AJ :
Order
27 Nm (2.7 mekg, 20 ftelb)
Job name/Part name
Q'ty
Starter motor disassembly
Disassemble the parts in the order listed below. Refer to "ENGINE REMOVAL" in CHAPTER 5.
Starter motor removal
eD ®
@ @ @ @ (J)
@
®
Remarks
Rear bracket Bearing Starter motor yoke O-ring Armature assembly Brush Brush holder Starter motor front cover Bearing
1 1 1
3 1
3 1 1 1
For assembly, reverse the disassembly procedure.
8-13
ELECTRICAL STARTING SYSTEM 3
IELEC Iu I
Inspection 1. Inspect: • Commutator (outer surlace) Dirty -+ Clean with #600 grit sandpaper G). Hold the armature in a vise ® and copper or aluminium plate @.
2
Lightly grip the armature with a vise.
SCH8080
2. Measure: • Commutator (diameter) Measure the diameter @ of the commutator at points where the brush comes in contact. Out of specification -+ Replace the starter motor.
Commutator wear limit: 27.5 mm (1.08 in) SCH8090
3. Measure: • Mica (insulation depth) G) (between commutator segments) Out of specification -+ Scrape mica to proper limits@. Use a hacksaw blade ® that is ground to fit.
.-----::-----@
I~
Mica undercut: 1.5 mm (0.059 In)
SCH8100
4. Measure: • Armature coil resistance (insulation/continuity) Defect(s) -+ Replace the starter motor.
I I
r~ ~~
.. II
nx
1
0
@
Inspection steps: • Connect the pocket tester for the continuity check G) and the insulation check ®. • Measure the armature coil resistances.
~--..;..------SCH8110
Armature coil resistance: Continuity check: 0.008 -- 0.010 Q at 20°C (68°F) Insulation check: More than 100 kQ at 20°C (68°F) • If the resistance is incorrect, replace the starter motor.
8-14
ELECTRICAL STARTING SYSTEM
IELEC u I I
5. Measure: • Brush length ® Out of specification -+ Replace the starter motor.
~",,""-B_r_us_h_w_e_a_r_li_m_it_: 1:6L
5 mm (0.20 in)
......1
6. Measure: • Brush spring pressure Fatigue/out of specification -+ Replace as a set.
Brush spring pressure: 7.36 ~ 11.04 N (736 ~ 1,104 g, 26.0
~
38.9 oz)
Assembly Reverse the "Disassembly"procedure. Note the following points. 1. Before installing the front bracket and rear bracket, apply bearing grease to the bearings of the front bracket and rear bracket. 2. Make sure the front bracket and rear bracket cover are fitted with a-rings.
3. When installing the rear bracket assembly, take care not to scratch the brushes. 4. Install: • Securing bolts (starter motor)
8-15
CHARGING SYSTEM CIRCUIT DIAGRAM
ex> I .....L
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C)
-z
C)
en -< en -I
m
s::
CHARGING SYSTEM
IELEC u I I
TROUBLESHOOTING BATTERY IS NOT CHARGED. 1. Connect: • Pocket tester (to the battery terminals) 2. Measure: • Battery voltage
OUT OF SPECIFICATIONS
•
Battery voltage: more than 12 V at 20°C (68°F)
• Check the battery. • Replace and/or charge the battery. Refer to "BATTERY INSPECTION" CHAPTER 2.
~OK
in
3. Start the engine and accelerate to 5,000 r/min. OUT OF SPECIFICATION 4. Measure: • Charging voltage
•
Charging voltage: 14 V/5,000 r/min
• Check the main fuse. Refer to "FUSE INSPECTION" in CHAPTER2. • Check the startor coil. OK
lFAULTY Replace the main fuse, rectifier/regulator and/or the startor coil assembly.
SCH8160
~ ----------
I
Replace the rectifier/regulator.
Be sure the V-belt is removed.
Never disconnect battery cables while generator is operating, otherwise, the rectifier/regulator will be damaged.
~OK Correct connecter.
8-17
CHARGING SYSTEM BATTERY Inspection 1. Inspect: • Battery condition Refer to "BATTERY CHAPTER 2.
IELEC Iu I INSPECTION"
in
Battery Storage The battery should be stored if the vehicle is not going to be used for a long period. 1. Remove: • Battery
~ ---------When removing the battery, disconnect the negative lead first. Battery storage and maintenance tips: • Recharge the battery periodically. • Store the battery in a cool, dry place. • Recharge the battery before reinstalling. Refer to "BATTERY INSPECTION" in CHAPTER2.
STATOR COIL 1. Measure: • Stator coil resistance Out of specification -+ Replace startor coil assembly.
11
Stator coil resistance: (White - White) 0.19 --- 0.24 at 20°C (68°F)
1I
8-18
LIGHTING SYSTEM
8-19
LIGHTING SYSTEM
LIGHTING SYSTEM CIRCUIT DIAGRAM
CD A.C. magneto
~ Re~tifier/regulator ~ Main switch @ Main relay ® Fuse (MAIN) ® Battery @CDI unit @ Tail/brake light @ Fuse (HEADLIGHT) @ Fuse (SIGNAL) @ Fuse (IGNITION) ~ Headlight beam switch ® Headlight relay @ Headlight @ Meter light @H·b . I earn Indicator light
8-20
IELEC Iu I
LIGHTING SYSTEM
IELEC u I I
TROUBLESHOOTING HEADLIGHT AND/OR METER LIGHT DO NOT COME ON.
Check the bulb(s).
~ OK
NO CONTINUITY .... '
:>
Replace the bulb(s).
Check the main fuse, ignition fuse and headlight fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
~OK
FAULTY!
:>
Replace the main fuse, ignition fuse and/or headlight fuse.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2. OUT OF SPECIFICATION
c:::::> Replace and/or charge the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the stator coil and pickup coil.
~ OK
OUT OF SPECIFICATION
Check the main switch. Refer to "IGNITION SYSTEM".
~OK
FAULTy .... '
Check the headlight beam switch.
~ OK
FAULTy .... '
Check the headlight relay.
~ OK
FAULTY .... '
Check the main relay. Refer to "IGNITION SYSTEM".
~OK
FAULTy .... '
c:::::> Replace the stator coil and pickup coil assembly.
:>
Replace the main switCh.
:>
Replace the headlight beam switCh.
:>
Replace the headlight relay.
:>
Replace the main relay.
Correct the connection and/or replace the rectifier/regulator and/or the CDI unit.
8-21
LIGHTING SYSTEM
IELEC Iu I
TAIL LIGHT DOES NOT COME ON.
Check the tail/brake light bulb(s).
~ OK
NO CONTINUITY ... '
~>
Replace the tail/brake light bulb(s).
Check the main fuse, ignition fuse and signal fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
~OK
>
FAULTY I
Replace the main fuse, ignition fuse and/or signal fuse.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2. OUT OF SPECIFICATION
¢
Replace and/or charge the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the stator coil and pickup coil.
~ OK
OUT OF SPECIFICATION
¢
Replace the stator coil and pickup coil assembly.
Check the main switch. Refer to "IGNITION SYSTEM".
~OK
' FAULTY ...
~> Replace the main switch.
Check the main ralay. Refer to "IGNITION SYSTEM"
~OK
FAULTY ... '
~> Replace the main relay.
Correct the connection and/or replace the rectifier/regulator and/or the CDI unit.
8-22
I
LIGHTING SYSTEM
IELEC u I I
BULB(S) 1. Remove: • Headlight bulb ® • Tail/brake light bulb @ • Meter light bulb © 2. Connect: • Pocket tester (to the bulb terminals)
®
m!mmmmI --------Keep flammable products and your hands away from the bulb while it is on; it will be hot. Do not touch the bulb until it cools down.
©
3. Inspect: • Bulb(s)
Terminal
Continuity
CD-® CD-@
Yes Yes
HEADLIGHT BEAM SWITCH 1. Disconnect: • Headlight beam switch coupler 2. Connect: • Pocket tester (to the headlight beam switch coupler)
CD
3. Inspect: • Headlight beam switch continuity Faulty --+ Replace.
8-23
Switch position
Continuity
HI
Yes
LO
No
LIGHTING SYSTEM
IELEC Iu I
HEADLIGHT RELAY 1. Inspect: - Headlight relay (black coupler)
CD
Inspection steps: - Disconnect the headlight relay from the coupler. - Connect the pocket tester (Q x 1) and battery (12 V) to the headlight relay terminals as shown. Low beam Positive tester probe --+ Blue/White CD Negative tester probe --+ Green ÂŽ High beam Positive battery terminal--+ Light green @ Negative battery terminal--+ Blue/green @ Positive tester probe --+ Blue/White CD Negative tester probe --+ Yellow @
4
3
-If headlight relay does not have continuity between the blue/white and yellow terminals, replace it.
8-24
SIGNAL SYSTEM CIRCUIT DIAGRAM
ex> I I\)
01
SIGNAL SYSTEM
SIGNAL SYSTEM CIRCUIT DIAGRAM
CD A.C. magneto ® Rectifier/regulator ® Main switch
@ Main relay
® Fuse (MAIN) ® Battery
@CDI unit
@ Water temperature sensor @ Back buzzer @ Gear position switch @ Brake light switch @ Tail/brake light @ Fuse (SIGNAL) @ Fuse (IGNITION) @ Water temperature indicator light @ Multi-function meter
® Warning light
@ Oil level switch @ Fuel sender @ Speedosensor
8-26
IELEC Iu I
SIGNAL SYSTEM
IELEC u I I
TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON.
Check the tail/brake light bulb(s). Refer to "LIGHTING SYSTEM".
~OK
NO CONTINUITY .... '
>
Replace the tail/brake light bulbs.
Check the main fuse, ignition fuse and signal fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
~OK
FAULTY I
Check the stator coil and pickup coil.
~ OK
OUT OF SPECIFICATION
>
Replace the main fuse, ignition fuse and/or signal fuse.
c:::::> Replace the stator coil and pickup coil assembly.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2. OUT OF SPECIFICATION
c:::::> Replace and/or charge the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the main switch. Refer to "IGNITION SYSTEM".
~OK
' FAULTY ....
Check the brake light switch.
~ OK
FAULTY .... '
Check the main relay. Refer to "IGNITION SYSTEM".
~OK
' FAULTy ....
> >
Replace the main switch.
Replace the brake light switch.
>
Replace the main relay.
Correct the connection and/or replace the rectifier/regulator and/or the CDI unit.
8-27
SIGNAL SYSTEM
IELEC Iu I
WATER TEMPERATURE INDICATOR LIGHT DOES NOT COME ON.
Check the water temperature indicator light bulb(s). Refer to "LIGHTING SYSTEM".
~OK
' NO CONTINUITY ...
~>
Replace the bulb(s).
Check the main fuse, ignition fuse and signal fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
~OK
>
Replace the main fuse, ignition fuse and/or signal fuse.
FAULTY I
Check the stator coil and pickup coil.
n
OK
OUT OF SPECIFICATION
~
¢
Replace the stator coil and pickup coil assembly.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2. OUT OF SPECIFICATION
Check the main switch. Refer to "IGNITION SYSTEM".
~OK
FAULTY ... '
Check the water temperature sensor.
~ OK
FAULTY ... '
Check the main relay. Refer to "IGNITION SYSTEM".
~OK
FAULTY ... '
¢
Replace and/or charge the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
----.> Replace the main switCh. ----.> Replace the water temperature sensor. ----.> Replace the main relay.
Correct the connection and/or replace the meter assembly and/or the rectifier/regulator and/or the CDI unit.
8-28
I
SIGNAL SYSTEM
IELEC u I I
FUEL METER AND/OR WARNING LIGHT DO NOT OPERATE.
Check the warning light bulb. Refer to "LIGHTING SYSTEM".
~OK
' NO CONTINUITY ...
>
......
Replace the bulb.
Check the main fuse, ignition fuse and signal fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
n
~
OK
FAULTY I
>
Replace the main fuse, ignition fuse and/or signal fuse.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
n
OK
OUT OF SPECIFICATION
Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the stator coil and pickup coil.
~ OK
OUT OF SPECIFICATION
Check the main switCh. Refer to "IGNITION SYSTEM".
~OK
' FAULTY ...
Checkthefuelsende~
~OK
' FAULTY ...
Check the main relay. Refer to "IGNITION SYSTEM".
~ OK
c:::::> Replace and/or charge the battery.
FAULTY ... '
c:::::> Replace the stator coil and pickup coil assembly
> >
Replace the main switCh.
Replace the fuel sender.
>
Replace the main relay.
Correct the connection and/or replace the meter assembly and/or the rectifier/regulator and/or the CDI unit.
8-29
I
SIGNAL SYSTEM
IELEC Iu I
ENGINE OIL INDICATOR LIGHT AND/OR WARNING LIGHT DO NOT COME ON.
Check the warning light bulb. Refer to "LIGHTING SYSTEM".
~OK
' NO CONTINUITY ...
~>
Replace the bulb.
Check the main fuse, ignition fuse and signal fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
n
~
OK
>
FAULTY I
Replace the main fuse, ignition fuse and/or signal fuse.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
n
OK
OUT OF SPECIFICATION
Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the stator coil and pickup coil.
~ OK
c:::::> Replace and/or charge the battery.
OUT OF SPECIFICATION
c:::::> Replace the stator coil and pickup coil assembly
Check the main switCh. Refer to "IGNITION SYSTEM".
~OK
---------.oIl>
' FAULTY ...
Check the oil level switch.
~OK
FAULTY ... '
Check the main relay. Refer to "IGNITION SYSTEM".
~ OK
FAULTY ... '
Replace the main switCh.
----.> Replace the oil level switCh. ----.> Replace the main relay.
Correct the connection and/or replace the meter assembly and/or the rectifier/regulator and/or the CDI unit.
8-30
I
SIGNAL SYSTEM
IELEC u I I
SPEEDOMETER DO NOT OPERATE.
Check the speedometer unit. Refer to "SPEEDOMETER UNIT INSPECTION" in CHAPTER 2.
~ OK
FAULTY
>
Replace the speedometer unit.
Check the main fuse, ignition fuse and signal fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
n
~
OK
FAULTY I
>
Replace the main fuse, ignition fuse and/or signal fuse.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
n
OK
OUT OF SPECIFICATION
Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the stator coil and pickup coil.
~ OK
OUT OF SPECIFICATION
Check the main switCh. Refer to "IGNITION SYSTEM".
~OK
' FAULTY ...
Check the speedosensor.
~ OK
FAULTY ... '
Check the main relay. Refer to "IGNITION SYSTEM".
~ OK
c:::::> Replace and/or charge the battery.
FAULTY ... '
c:::::> Replace the stator coil and pickup coil assembly
> >
Replace the main switCh.
Replace the speedosensor.
>
Replace the main relay.
Correct the connection and/or replace the meter assembly and/or the rectifier/regulator and/or the CDI unit.
8-31
I
SIGNAL SYSTEM
IELEC Iu I
BACK BUZZER DOES NOT SOUND. (RX10R, RX10RS)
Check the main fuse, ignition fuse and signal fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
n
~
OK
>
FAULTY I
Replace the main fuse, ignition fuse and/or signal fuse.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
n
OK
OUT OF SPECIFICATION
¢
Replace and/or charge the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the stator coil and pickup coil
~OK
OUT OF SPECIFICATION
Check the main switch. Refer to "IGNITION SYSTEM".
~OK
FAULTY ... '
Check the gear position switch.
~ OK
FAULTY ... '
Check the back buzzer.
~OK
Replace the stator coil and pickup coil assembly.
----.> Replace the main switch. ----.> Replace the gear position switch.
>
DOES NOT SOUND .... ' _ _......
Check the main relay. Refer to "IGNITION SYSTEM".
~ OK
¢
FAULTY ... '
Replace the back buzzer.
----.> Replace the main relay.
Correct the connection and/or replace the rectifier/regulator and/or the CDI unit.
8-32
I
IELEC u I
SIGNAL SYSTEM
I
BRAKE LIGHT SWITCH 1. Disconnect: • Brake light switch coupler CD 2. Inspect: • Brake light switch continuity Faulty --+ Replace. Switch position
Continuity
Brake lever operates
Yes
Brake lever does not operate
No
GEAR POSITION SWITCH (RX1 OR, RX10RS) 1. Inspect: • Gear position switch CD continuity Faulty --+ Replace. Shift lever position
Continuity
FORWARD
No
REVERSE
Yes
BACK BUZZER (RX10R, RX10RS) 1. Disconnect: • Back buzzer coupler CD
2. Connect: • Battery 3. Inspect: • Back buzzer Does not sound 12V SCH8530
8-33
--+
Replace.
SIGNAL SYSTEM
IELEC Iu I
WATER TEMPERATURE SENSOR 1. Disconnect the water temperature sensor coupler CD and remove the water temperature sensor.
Handle the water temperature sensor with special care. Never subject it to shock or allow it to be dropped. If it is dropped, it must be replaced. 2. Connect: - Pocket tester CD (to the water temperature sensor) NOTE: - - - - - - - - - - - - Set the tester selector to the "Q x 1" position. 3. Immerse the water temperature sensor® in coolant ® and check the water temperature sensor operation.
Water temperature sensor resistance: 5.2 --- 6.4 kQ at O°C (34°F) 0.300 --- 0.364 kQ at 80°C (176°F) 0.170 --- 0.208 kQ at 100°C (212°F)
@ Temperature gauge
SCH8460
Never heat the coolant to a temperature of 120°C (248.5 °F) or more. 4. If the water temperature sensor operation is defective, replace it. 5. Install the water temperature sensor and connect the water temperature sensor lead.
Water temperature sensor: 23 Nm (2.3 m-kg, 17 ft-Ib)
Do not overtighten the water temperature sensor.
8-34
SIGNAL SYSTEM
IELEC u I I
ENGINE OIL LEVEL SWITCH 1. Remove: - Oil level gauge CD
2. Connect: - Pocket tester (to the oil level switch coupler) 3. Inspect: - Oil level switch continuity Faulty --+ Replace. Switch position
Good condition
[AJ Down position
0
x
x
[6J Up position
x
0
x
o : Continuity
Bad condition
x : No continuity
FUEL SENDER 1. Remove: -Intake silencer Refer to "FUEL PUMP" in CHAPTER 7. - Fuel sender CD (from the fuel tank) 2. Connect: - Pocket tester (to the fuel sender coupler)
3. Measure: -FulI@ -Empty@ - Fuel sender resistance Out of specification --+ Replace. Fuel sender resistance (full): 4 -- 10 at 20째C (68째F) Fuel sender resistance (empty): 90 -- 100 at 20째C (68째F) 8-35
0 0
SIGNAL SYSTEM
IELEC Iu I
SPEED SENSOR 1. Inspect: • Speed sensor
Inspection steps: • Connect the pocket tester (DC 20 V) to the speed sensor coupler CD (wire harness side) as shown. Positive tester probe -+ White Negative tester probe -+ Black/Green Positive battery terminal -+ Blue/Yellow Negative battery terminal-+ Black/Green • Elevate the track and slowly rotate it. • Measure the voltage (DC 5 V) of white and black/green. With each fu II rotation of the track the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
~
u
Out of specification -+ Replace.
8-36
GRIP WARMER SYSTEM CIRCUIT DIAGRAM
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."
~
JJ
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m JJ
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GRIP WARMER SYSTEM
GRIP WARMER SYSTEM CIRCUIT DIAGRAM
CD A.C. magneto 速 Rectifier/regulator 速 Main switch @ Main relay 速 Fuse (MAIN) 速 Battery
@ Grip warmer @ Thumb warmer @CDI unit
@ Grip warmer switch @ Thumb warmer switch @ Fuse (SIGNAL) @ Fuse (IGNITION) @ Multi-function meter
8-38
IELEC Iu I
GRIP WARMER SYSTEM
IELEC u I I
TROUBLESHOOTING GRIP WARMER AND THUMB WARMER DO NOT OPERATE.
Check the main fuse and signal fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
~OK
FAULTY 1...
>
Replace the main fuse and/or ignition fuse.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
nn
OK
OUT OF SPECIFICATION
¢
Replace and/or charge the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the stator coil and pickup coil.
~
OK
OUT OF SPECIFICATION
Check the main switch. Refer to "IGNITION SYSTEM".
~ OK
NO CONTINUITY '"'"""-
Check the grip and thumb warmer.
~OK
NO CONTINUITY '"'"""-
Check the grip warmer switch and thumb warmer switch
n ~
CORRECT INCORRECT 1...
Check the main relay. Refer to "IGNITION SYSTEM".
~OK
FAULTY 1...
¢
Replace the stator coil and pickup coil assembly.
> >
Replace the main switch.
Replace the grip and/or thumb warmer.
>
Replace the left handlebar switch and/or right handlebar switch.
>
Replace the main switch.
Correct the connection and/or replace the rectifier/regulator and/or the CDI unit.
8-39
GRIP WARMER SYSTEM
IELEC Iu I
GRIP AND THUMB WARMER COIL 1. Disconnect: • Grip warmer leads CD • Thumb warmer coupler ® 2. Connect: • Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads)
3. Inspect: • Grip warmer CD continuity • Thumb warmer ® continuity No continuity -+ Replace both grips together or separately and/or the handlebar switch.
CD
®
(R)
(L)
I I
I I
I I
I I
I I
I I
I :
J
SCH8560
THUMB WARMER SWITCH 1. Disconnect: • Thumb warmer switch coupler CD 2. Connect: • Pocket tester (to the switch coupler)
3. Inspect: • Thumb warmer switch continuity Switch is operated. Faulty -+ Replace the handlebar switch (right).
Thumb warmer switch position
8-40
Continuity
Switch is operated.
Yes
Switch is not operated.
No
~~~~~~~~~~G=R~~RM~~~~ IELECI~1 GRIP WARMER SWITCH 1. Disconnect: • Grip warmer switch coupler CD 2. Connect: • Pocket tester (to the switch coupler)
3. Inspect: • Grip warmer switch continuity Switch is operated. Faulty -+ Replace the handlebar switch (left). Grip warmer switch position
8-41
Continuity
Switch is operated.
Yes
Switch is not operated.
No
CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM
0
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0
Ct
CARBURETOR HEATER SYSTEM
CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM
CD A.C. magneto 速 Rectifier/regulator 速 Main switch @ Main relay 速 Fuse (MAIN) 速 Battery
@ Carburetor heater relay @ Carburetor heater @CDI unit
@ Water temperature sensor @ Fuse (SIGNAL) @ Fuse (CARBURETOR HEATER) @ Fuse (IGNITION)
8-43
IELEC u I I
CARBURETOR HEATER SYSTEM
u
I ELEC I
TROUBLESHOOTING CARBURETOR HEATER DO NOT OPERATE.
Check the main fuse, signal fuse, carburetor heater fuse and ignition fuse. Refer to "FUSE INSPECTION" in CHAPTER 2.
~OK
-------...ot>
1 FAULTY ...
Replace the main fuse and/or signal fuse, and/or carburetor heater fuse and/or ignition fuse.
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
nn
OK
OUT OF SPECIFICATION
Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the stator coil and pickup coil.
~
OK
OUT OF SPECIFICATION
c:::::> Replace the stator coil and pickup coil assembly.
Check the main switch. Refer to "IGNITION SYSTEM".
~ OK
c:::::> Replace and/or charge the battery.
NO CONTINUITY
""------.. ot>
Replace the main switch.
""------.. ot>
Replace the carburetor heater relay.
Check the carburetor heater relay.
~OK
NO CONTINUITY
Check the carburetor heater.
~ CORRECT
-------.oIl>
INCORRECT 1...
Replace the carburetor heater.
Check the water temperature sensor. Refer to "SIGNAL SYSTEM".
~OK
-------...ot>
FAULTY ... 1
Replace the water temperature sensor.
Check the main relay. Refer to "IGNITION SYSTEM".
~OK
-------...ot>
1 FAULTY ...
Correct the connection and/or replace the rectifier/regulator and/or the CDI unit.
8-44
Replace the main relay.
I
CARBRETER HEATER SYSTEM
IELEC u I I
CARBURETOR HEATER RELAY 1. Inspect: • Carburetor heater relay CD Inspection steps: • Disconnect the carburetor heater relay from the coupler. • Connect the pocket tester (Q x 1) and battery (12 V) to the carburetor heater relay terminals as shown. Positive battery terminal --+ Blue/Red CD Negative battery terminal --+ BrownNeliow ® Positive tester probe --+ Black/Yellow @ Negative tester probe --+ Red/White @ ·If carburetor heater relay does not have continuity between the black/yellow and red/white terminals, replace it.
CARBURETOR HEATER 1. Remove: • Carburetor heater CD
2. Connect: • Pocket tester Positive tester probe --+ Heater terminal CD Negative tester probe --+ Heater body ® 3. Inspect: • Carburetor heater resistance Out off specification --+ Replace the carburetor heater
D
Carburetor heater resistance: 6 ~ 10 Q at 20°C (68°F)
188501
8-45
SELF-DIAGNOSIS
IELEC Iu I
SELF-DIAGNOSIS This model features a self-diagnosing system for following displays. 1. Fuel meter, fuel level warning indicator CD and the warning light @ 2. Coolant temperature warning light ® and the warning light @ 3. Self-diagnosis warning indicator @ and the warning light @
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - The oil level warning indicator and the warning light come on when the engine oil level is low. If the oil level warning indicator and the warning light come on, place the snowmobile on a level surface and allow it to idle for one minute. If the oil level warning indicator and the warning light go off, the engine oil level is sufficient, however it is getting low. Add engine oil as soon as possible. If the oil level warning indicator and the warning light do not go off, check the engine oil level in the oil tank, and add engine oil if necessary. 1. FUEL METER, FUEL LEVEL WARNING INDICATOR AND THE WARNING LIGHT The fuel meter, fuel level warning indicator and the warning light faults are displayed as follows • Fuel sender Item
-'£i-
1
2
r----
r----
. 8
3·
---1
~ -I- -1:--:1- -I- -- -I0.5s 0.5s 0.5s 0.5s 0.5s · -----J
r----
-'j;j-
ON
Warning light ON
~
OFF
Warning light OFF
Fuel sender
1---
1 1 1 1 1 1 1 1 1 1 1 1______ - -
1 1 1 1 1 1 1 1 1 1 1
-I- -I-
3s
0.5s
s Time (second)
8-46
-I
Condition ----
Disconnected Short-circuit
SELF-DIAGNOSIS
IELEC u I I
2. COOLANT TEMPERATURE WARNING LIGHT AND THE WARNING LIGHT The coolant temperature warning light and the warning light faults are displayed as follows - Thermo sensor Item
-'Q:-
1
2
......--
......--
. 8
3·
---1
-
~ -I- "1:--:-1- "I- . - "I-----J
Condition ----
..
"I- "I-
3s
0.5s
0.5s 0.5s 0.5s 0.5s 0.5s •
Thermo sensor
--
1 1 1 1 1 1 1 1 1 1 1 1______ - -
Disconnected Short-circuit
3. SELF-DIAGNOSIS WARNING INDICATOR AND THE WARNING LIGHT The self-diagnosis warning indicator and the warning light faults are displayed as follows -Throttle position sensor (T.P.S.) - Variable resistor (grip and thumb warmer) - Grip and thumb warmer -Voltage
-'Q:-
Item ......-----
~ -I-
......-----
·1::-10.75s
0.75s 0.25s
-----,
----
.....-
.
·1::-1" I-
0.25s 0.25s
1 1 1 1 1 1 1 1 1 1 1 1
.. _.
--
2s
T.P.S.
Condition Disconnected Short-circuit Locked Item
-'Q:-
-----1
......-----
~ -I-
·10.75s
1.75s
.
-----
1 1 1 1 1 1 1 1 1 1 1 1______ - - - - - - -
-'Q:-
ON
Warning light ON
~
OFF
Warning light OFF
s Time (second)
8-47
r----1 1 1 1 1 1 1 1 1 1 1 1
-----------_ ..
Grip warmer switch Condition Disconnected
IELEC Iu I
SELF-DIAGNOSIS
-'Q:-
Item ....----
~ -I-
0.758
-1::-1-
0.758
-----,
----
....----
-I-
1.758
I I I I I I I I I I I I
Grip warmer
i I I I I I I I I I I I
Condition
_..
. _------------
--
-
-----
Short-circuit
0.258
-'Q:-
Item ....----
~ -I-
0.758
-1::-1-
0.758
0.258
-----,
----
....----
-1::-1-
0.758
-I-
1.758
--
-
Condition
.. -
--------
Disconnected
Item
-----,
----
-1::-1-
0.758
0.758
0.258
-1::-1-
0.758
0.258
-1::-1-
0.758
-I-
1.758
-
-----
I I I I I I I I I I I I
Thumb warmer
Condition
.. -
--
--
Short-circuit
0.258
Item
-t;;~ -I-
Thumb warmer switch
0.258
-ti~ -I-
I I I I I I I I I I I I
-----
-
-1"'1- 0.758-1::-1- 0.758 _1 1_ 0.758-1::-1- 0.758 -I0
0.758
0.258
0.258
0.258
-t;;-
ON
Warning light ON
~
OFF
Warning light OFF
-----,
----
0.258
s Time (second)
8-48
1.758
-
--
I I I I I I I I I I I I
.. _.
Voltage
Condition Wrong
GENERAL SPECIFICATIONS
I
SPEC I
g--I
SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number:
Dimensions: Overall length Overall width Overall height Weight: Dry weight
Minimum turning radius: Clockwise Counterclockwise Engine: Engine type Cylinder type Displacement Bore x stroke Compression ratio Maximum hose power r/min Maximum torque r/min Standard compression pressure (at sea level) Starting system Lubrication system: Engine oil: Type Oil capacity Periodic oil change With oil filter replacement Total amount
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS 8FA1 (RX10 for U.S.A/Canada) 8EU1 (RX10S for U.S.A/Canada) 8ER1 (RX10R for U.S.A/Canada) 8EW1 (RX1 ORS for U.S.A/Canada) 8EP1 (RX10M for U.S.A/Canada) 8EV1 (RX10MS for U.S.A/Canada) 8FA2 (RX10 for Europe) 8ER2 (RX10R for Europe) 8EW2 (RX10RS for Europe) 8EP2 (RX10M for Europe) 2,755 mm 3,185 mm 1,210 mm 1,115 mm 1,190 mm
(108.5 in) (RX10, RX10S, RX10R, RX10RS) (125.4 in) (RX10M, RX10MS) (47.6 in) (RX10, RX10S, RX10R, RX10RS) (43.9 in) (RX10M, RX10MS) (46.9 in)
253 kg (557.9 Ib) (RX10, RX10S) 256 kg (564.5 Ib) (RX10R, RX10RS) 267 kg (588.7 Ib) (RX10M, RX10MS) 3.9 4.3 3.9 4.3
m m m m
(12.8 ft) (14.1 ft) (12.8 ft) (14.1 ft)
(RX10, RX10S, RX10R, RX10RS) (RX10M, RX10MS) (RX10, RX10S, RX10R, RX10RS) (RX10M, RX10MS)
Liquid-cooled, 4-stroke, DOHC Backward-inclined parallel 4-cylinder 998 cm 3 (60.9 cu.in) 74 X 58 mm (2.91 X 2.28 in) 11.8 10,250 r/min 7,500 r/min 1,450 kPa (14.5 kg/cm 2 , 206 psi) at 400 r/min Electric starter Dry sump API SE, SF, SG or highter SAE5W-30 2.8 L (2.5 Imp qt, 3.0 US qt) 3.0 L (2.6 Imp qt, 3.2 US qt) 3.8 L (3.3 Imp qt, 4.0 US qt)
9-1
GENERAL SPECIFICATIONS Model
Cartridge (paper)
Drive chain housing oil: Type Capacity
Gear oil API "GL-3" SAE#75 or #80 0.25 L (8.8 Imp OZ, 8.5 US oz)
Coolant: Capacity
4.7 L (4.1 Imp qt, 5.0 US qt)
Tank capacity
BSR37 x 4 MIKUNI
Spark plug: Type Manufacture Gap
CR9E NGK 0.7 --- 0.8 mm (0.028 --- 0.031 in)
Primary reduction: Primary reduction system Primary reduction ratio
Spur gear 1.19 (37/31)
Reverse system Chassis: Frame type Caster Ski stance (center to center) Suspension: Front suspension type Rear suspension type
g--I
Regular unleaded gasoline (Pump Octane R+M; 88 or higher) 2 Research Octane; 93 or higher (for Europe) 38 L (8.4 Imp gal, 10.0 US gal)
Carburetors: Type/Quantity Manufacture
Transm ission: Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio
SPEC I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
Oil filter: Oil filter type
Fuel: Type
I
V-Belt 3.8 : 1 --- 1 : 1 Automatic centrifugal engagement Chain 1.58 (38/24) (RX10, RX10S, RX10R, RX10RS) 1.90 (40/21) (RX10M, RX10MS) No (RX10, RX10S, RX10M, RX10MS) Yes (RX10R, RX10RS) Monocoque 23° 1,068 mm (42.0 in) (RX10, RX10S, RX10R, RX10RS) 980 mm (38.6 in) (RX10M, RX10MS) Independent double wishbone suspension Slide rail suspension
9-2
GENERAL SPECIFICATIONS Model Track: Track type Track width Length on ground Track deflection mm/ 100 N (10 kg, 22 Ib)
I
SPEC I
g--I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS Internal drive type 381 mm (15.0 in) 752 mm (29.6 in) (RX10, RX10S, RX10R, RX10RS) 1,071 mm (42.2 in) (RX10M, RX10MS) 25 ~ 30 mm (0.98 ~ 1.18 in)
Brake: Brake type Operation method
Caliper type disc brake handlebar, left hand operated
Electrical: Ignition system Generator system
DC-CDI/MITSUBISHI A.C. magneto
Bulb wattage X Quantity: Headlight Tail/Brake light Meter light High beam indicator light Information indicator light
12 V, 12 V, 14 V, 14 V, 14 V,
60 W / 55 W x 2 5 W /21 W x 2 50 mA x 6 80 mA 80 mA
9-3
MAINTENANCE SPECIFICATIONS
I
SPEC I
g--I
MAINTENANCE SPECIFICATIONS ENGINE Model Cylinder head: Volume (with spark plug) <Warpage limit>
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS 13.45 ~ 14.00 cm 3 (0.82 ~ 0.85 cu. in) 0.1 mm (0.004 in)
* Lines indicate straight edge measurement.
Cylinder: Material Bore size <Taper limit> <Out of round> <Wear limit> Camshaft: Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-jou rnal-to-camshaft-cap clearance
Aluminum alloy with dispersion coating 74.000 ~ 74.010 mm (2.9134 ~ 2.9138 in) 0.05 mm (0.002 in) 0.05 mm (0.002 in) 74.06 mm (2.9157 in) Chain drive (left) 24.500 ~ 24.521 mm (0.9646 24.459 ~ 24.472 mm (0.9630 0.028
~
Camshaft dimensions Intake "A" <Limit> "B" <Limit> Exhaust "A" <Limit> "B" f----B<Limit>
32.50 32.40 24.95 24.85 32.95 32.85 24.95 24.85
~ 32.60 mm (1.2795 mm (1.2756 in) ~ 25.05 mm (0.9823 mm (0.9783 in) ~ 33.05 mm (1.2972 mm (1.2933 in) ~ 25.05 mm (0.9823 mm (0.9783 in)
Camshaft runout
0.03 mm (0.0012 in)
0.062 mm (0.0011
Timing chain: Model/number of links Tensioning system
RH2015/130 Automatic
Valves, valve seats, valve guides: Valve clearance (cold) Intake Exhaust
0.11 0.21
~
~
0.20 mm (0.0043 0.25 mm (0.0083
9-4
~
~
~ ~
0.9654 in) 0.9635 in)
~
0.0024 in)
~
1.2835 in)
~
0.9862 in)
~
1.3012 in)
~
0.9862 in)
0.0079 in) 0.0098 in)
MAINTENANCE SPECIFICATIONS Model
I
SPEC I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
Valve dimensions: Valve head diameter A Intake Exhaust
6
~ A ==:j
22.9 ,-., 23.1 mm (0.9016 ,-., 0.9094 in) 24.4 ,-., 24.6 mm (0.9606 ,-., 0.9685 in)
Head Diameter
Valve face width B Intake Exhaust
1.76 ,-., 2.90 mm (0.0693 ,-., 0.1142 in) 1.76 ,-., 2.90 mm (0.0693 ,-., 0.1142 in) Face Width
Valve seat width C Intake Exhaust
b~
0.9 ,-., 1.1 mm (0.035 ,-., 0.043 in) 0.9 ,-., 1.1 mm (0.035 ,-., 0.043 in)
~l 1°
0.5 ,-., 0.9 mm (0.020 ,-., 0.035 in) 0.5 ,-., 0.9 mm (0.020 ,-., 0.035 in)
Seat Width
Valve margin thickness D Intake Exhaust
I
Margin Thickness
Valve stem diameter Intake <Limit> Exhaust <Limit> Valve guide inside diameter Intake <Limit> Exhaust <Limit> Valve-stem -to-valve-g uide clearance Intake <Limit> Exhaust <Limit> Valve stem runout limit
3.975 ,-., 3.900 mm (0.1565 ,-., 0.1535 in) 3.945 mm (0.1553 in) 4.460 ,-., 4.475 mm (0.1756 ,-., 0.1762 in) 4.43 mm (0.1744 in) 4.000 ,-., 4.012 mm (0.1575 ,-., 0.1580 in) 4.05 mm (0.1594 in) 4.500 ,-., 4.512 mm (0.1772 ,-., 0.1776 in) 4.55 mm (0.1791 in)
0.010 ,-., 0.037 mm(0.0004 ,-., 0.0015 in) 0.08 mm (0.0031 in) 0.025 ,-., 0.052 mm (0.0010 ,-., 0.0020 in) 0.10 mm (0.0039 in) 0.01 mm (0.0004 in)
911
~- Jlrr~
/////////////////////
Valve seal width Intake Exhaust
g--I
0.9 ,-., 1.1 mm (0.035 ,-., 0.043 in) 0.9 ,-., 1.1 mm (0.035 ,-., 0.043 in)
9-5
MAINTENANCE SPECIFICATIONS Model
I
SPEC I
g--I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
Valve spring: Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust
38.90 mm (1.53 in) 40.67 mm (1.60 in) 34.50 mm (1.36 in) 35.00 mm (1.38 in)
JlII*
Spring tilt Intake Exhaust Winding direction (top view) Intake Exhaust
%:
Valve lifter: Valve lifter outside diameter Intake <Limit> Exhaust <Limit> Valve lifter hole inside diameter Intake <Limit> Exhaust <Limit>
m
Piston: Piston size (D) - - - D - -------tMeasuring point (H) I H Piston to-cylinder clearance <Limit> Piston pin bore off set Off-set direction Piston pin bore inside diameter
82 ~ 96 N (8.2 ~ 9.6 kg, 18.1 ~ 21.2Ib) 110 ~ 126 N (11.0 ~ 12.6 kg, 24.3 ~ 27.8Ib) 2.5 0 /1.7 mm (0.067 in) 2.5 0 /1.8 mm (0.071 in) Clockwise Clockwise
27.978 ~ 28.002 mm (1.1015 27.958 mm (1.1007 in) 27.978 ~ 28.002 mm (1.1015 27.958 mm (1.1007 in)
~
1.1024 in)
~
1.1024 in)
27.996 ~ 28.020 mm (1.1022 28.05 mm (1.1043 in) 27.996 ~ 28.020 mm (1.1022 28.05 mm (1.1043 in)
~
1.1031 in)
~
1.1031 in)
73.955 ~ 73.970 mm (2.9116 ~ 2.9122 in) 5 mm (0.20 in) 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.12 mm (0.0047 in) 0.5 mm (0.0197 in) Intake side 17.002 ~ 17.013 mm (0.6694 ~ 0.6698 in)
9-6
I
SPEC I
MAINTENANCE SPECIFICATIONS Model Piston pin: Piston pin outside diameter Piston pin length Piston pin to piston pin bore clearance <Limit> Piston ring: Sectional sketch Top ring Ring type ~~B IT Dimensions (B x T) 2nd ring B Ring type I T I Dimensions (B x T) Oil ring
r
c==s=r
~=rB
~I Dimensions (B x T) End gap (installed) Top ring 2nd ring Oil ring Side clearance (installed) Top ring 2nd ring
Connecting rod: Crankshaft-pin-to-big-end-bearing clearance Bearing color code
g--I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS 16.991 -- 17.000 mm (0.6689 -- 0.6693 in) 51.4 -- 51.5 mm (2.0236 -- 2.0276 in) 0.002 -- 0.022 mm (0.00008 -- 0.0009 in) 0.072 mm (0.0028 in)
Barrel 0.90 x 2.75 mm (0.035 x 0.108 in) Taper 0.8 x 2.8 mm (0.031 x 0.110 in)
1.5 x 2.6 mm (0.059 x 0.101 in) 0.32 -- 0.44 mm (0.010 -- 0.020 in) 0.43 -- 0.58 mm (0.017 -- 0.023 in) 0.10 -- 0.35 mm (0.004 -- 0.0014 in) 0.030 -- 0.065 mm (0.0012 -- 0.0026 in) 0.020 -- 0.055 mm (0.0008 -- 0.0022 in) 0.016 -- 0.040 mm (0.0006 -- 0.0016 in) -1
= Violet
0
= White
1 = Blue 2
= Black
3
= Brown
Crankshaft:
Width A Width B Crankshaft runout C Big end side clearance D Crankshaft-journal-to-crankshaftjournal-bearing clearance Bearing color code
52.40 -- 57.25 mm (2.063 -- 2.254 in) 300.75 -- 302.65 mm (11.84 -- 11.92 in) 0.03 mm (0.0012 in) 0.160 -- 0.262 mm (0.006 -- 0.010 in) 0.004 -- 0.028 mm (0.0002 -- 0.0011 in) -1
= Violet
9-7
0
= White 1 = Blue
2
= Black 3 = Brown
MAINTENANCE SPECIFICATIONS Model Carburetor: Type/Quantity Manufacturer I.D. mark Main jet Main air jet Jet needle Needle jet Pilot jet Pilot air jet
(M.J) (M.A.J) (J.N) (N.J) (P.J) (P.A.J.1 ) (P.A.J.2) (P.O) Pilot outlet (B.P.1 ) Bypass 1 (B.P.2) (B.P.3) (P.S) Pilot screw (Th.V) Th rottle valve Valve seat size (V.S) Starter jet (G.S) (F.H) Float height Fuel level (below the line on the float chamber) Engine idle speed
Fuel pump: Type Manufacturer Oil filter: Oil filter type Bypass valve opening pressure Oil pump: Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Max. impeller shaft tilt <Limit> Relief valve operating pressure Oil pressure (hot) Cooling system: Filler cap opening pressure Water pump type Reduction ratio Coolant type Coolant mixing ratio (coolant: water) Capacity
I
SPEC I
g--I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS BSR37/4 MIKUNI 8FA100 #135 #120 Ab-3 P4M #17.5 #85 #125 1.0 0.8 0.8 0.8 Approx 2 #115 1.5 #95 11 ~ 15 mm (0.43 ~ 0.59 in) 3.0 ~ 4.0 mm (1.118 ~ 0.157 in) 1,350 Âą 100 r/min (1 ,250
~
1,450 r/min)
Diaphragm 8FA (MIKUNI) Cartridge (paper) 78 ~ 118 kPa (0.78 ~ 1.18 kg/cm 2 , 11.1 ~ 16.8 psi) Trochoidal 0.09 ~ 0.15 mm (0.004 0.03
~
0.08 mm (0.001
~
0.006 in)
~
0.003 in)
0.15 mm (0.0059 in) 0.072 mm (0.0028 in) 430 ~ 550 kPa (4.3 ~ 5.5 kg/cm 2 , 61.2 ~ 78.2 psi) 50 kPa (0.5 kg/cm 2 , 7.1 psi) at 1,450 r/min 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm 2 , 14 ~ 18 psi) Single-suction centrifugal pump (Impeller type) 37/31 x 23/18(1.525) High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors 3 : 2 (60% : 40%) 4.7 L (4.14 Imp qt, 4.97 US qt)
9-8
MAINTENANCE SPECIFICATIONS
I
SPEC I
g--I
POWER TRAIN
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
Model Transmission: Type Range of ratio Engagement speed Shift Sheave distance Sheave offset
V-belt automatic 3.8 --- 1.0 : 1 3,600 ± 200 r/min (3,400 --- 3,800 r/min) (RX10, RX10S, RX10R, RX10RS) 4,200 ± 200 r/min (4,000 --- 4,400 r/min) (RX10M, RX10MS) 10,250 ± 250 r/min (10,000 --- 10,500 r/min) 268.5 mm (10.57 in) (267 --- 270 mm (10.51 --- 10.63 in)) 15 mm (0.59 in) (13.5 --- 16.5 mm (0.53 --- 0.65 in))
r/min r/min
V-belt: Part number/Manufacturer A Circumference I~i Width "A" Wear limit "B"
0 .
8DN-17641-00/MITSUBOSHI 1,129 --- 1,137 mm (44.4 --- 44.8 in) 34.5 mm (1.36 in) 32.5 mm (1.28 in)
.
Primary sheave spring: Part number Color code Diameter Wire diameter Preload Spring rate Number of coils Free length Set length
90501-582L1 (RX10, RX10S, RX10R, RX10RS) 90501-624L8 (RX10M, RX10MS) Yellow - Silver - Yellow (RX1 0, RX10S, RX10R, RX10RS) Orange - Silver - Orange (RX10M, RX10MS) 60 mm (2.36 in) 5.8 mm (0.228 in) (RX10, RX10S, RX10R, RX10RS) 6.2 mm (0.244 in) (RX10M, RX10MS) 343 N (35 kg, 77 Ib) 24.5 N/mm (2.50 kg/mm, 140 Ib/in) (RX10, RX10S, RX10R, RX10RS) 31.9 N/mm (3.25 kg/mm, 182 Ib/in) (RX10M, RX10MS) 4.92 (RX10, RX10S, RX10R, RX10RS) 5.00 (RX10M, RX10MS) 87.4 mm (3.44 in) (RX10, RX10S, RX10R, RX10RS) 84.2 mm (3.32 in) (RX10M, RX10MS) 73.4 mm (2.89 in)
Primary sheave weight arm: Part number (with bush) Weight (without bush and rivets)
8FA-17605-00 69.43 g (2.449 oz)
Rivet: Outer Part number Material Size Quantity Hole quantity Inner Part number Material Size Quantity Hole quantity None (outer and inner)
None (RX10M, RX10MS) 90269-06006 (RX10, RX10S, RX10R, RX10RS) Steel (RX10, RX10S, RX10R, RX10RS) 17.2 mm (0.677 in) (RX10, RX10S, RX10R, RX10RS) 3 (RX10, RX10S, RX10R, RX10RS) 3 None (RX10M, RX10MS) 90261-06033 (RX10, RX10S, RX10R, RX10RS) Steel (RX10, RX10S, RX10R, RX10RS) 17.2 mm (0.677 in) (RX10, RX10S, RX10R, RX10RS) 3 (RX10, RX10S, RX10R, RX10RS) 3 RX10M, RX10MS
9-9
MAINTENANCE SPECIFICATIONS Model
I
SPEC I
g--I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
Secondary sheave spring: Part number Color code Outside diameter Wire diameter Hole position Sheave side-spring side (twist angle)
90508-60012 (RX10, RX10S, RX10R, RX10RS) 90508-60007 (RX10M, RX10MS) PINK (RX10, RX10S, RX10R, RX10RS) White (RX10M, RX10MS) 69.5 mm (2.736 in) 6 mm (0.236 in) 3-3 (60째) (RX10, RX10S, RX10R, RX10RS) 1-6 (70째) (RX10M, RX10MS)
,0
12.32 N/mm (1.256 kg/mm, 70.34 Ib/in) (RX10, RX10S, RX10R, RX10RS) 13.45 N/mmm (1.372 kg/mm, 76.84 Ib/in) (RX10M, RX10MS) 5.53 (RX10, RX10S, RX10R, RX10RS) 5.19 (RX10M, RX10MS) 75 mm (2.95 in) 51-43째 (RX10, RX10S, RX10R, RX10RS) 45째 (RX10M, RX10MS)
Spring rate
Number of coils Free length Torque cam angle Drive chain: Type Number of links Secondary reduction ratio Track: Part number
Width Length Pitch Number of links Thickness "A" Height "B"
~JB
Track deflection at 100 N (10 kg, 221b)
Borg Warner Automotive 23RH303-70ASM 70L 38/24 (1.58) (RX10, RX10S, RX10R, RX10RS) 40/21 (1.90) (RX10M, RX10MS) 8DY-4711 0-00 (RX10, RX10S, RX10R, RX10RS for U.S.A./Canada) 8ER-4711 0-00 (RX10, RX10R, RX10RS for EUR) 8EP-4711 0-00 (RX10M, RX10MS) 381 mm (15.0 in) 3,072 mm (120.9 in) (RX10, RX10S, RX10R, RX10RS) 3,840 mm (151.2 in) (RX10M, RX10MS) 64 mm (2.52 in) 48 (RX10, RX10S, RX10R, RX10RS) 60 (RX10M, RX10MS) 5.1 mm (0.20 in) (RX10, RX10S, RX10R, RX10RS) 5.8 mm (0.23 in) (RX10M, RX10MS) 25.4 mm (1.00 in) (RX10, RX10S, RX10R, RX10RS for U.S.A./Canada) 31.8 mm (1.25 in) (RX10, RX10R, RX1 ORS for EUR) 50.8 mm (2.00 in) (RX10M, RX10MS) 25 -... 30 mm (0.98 -... 1.18 in)
9-10
MAINTENANCE SPECIFICATIONS Model Slide rail suspension (Rear suspension): Center travel Rear travel Suspension spring rate Front
Rear
Suspension wire diameter Front Rear Suspension setting position: Hook setting length *(Standard)
(Maximum) (Minimum) Full rate adjusting position **
I
SPEC I
g--I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
221 188 298 237
mm mm mm mm
(8.70 in) (RX10, RX10S, RX10R, RX10RS) (7.40 in) (RX10M, RX10MS) (11.73 in) (RX10, RX10S, RX10R, RX10RS) (9.33 in) (RX10M, RX10MS)
28 - 50 N/mm (2.8 - 5.0 kg/mm, 157 - 280 Ib/in) (RX10, RX10S, RX10R, RX10RS) 44.1 N/mm (4.4 kg/mm, 247 Ib/in) (RX10M, RX10MS) 34.3 - 52 N/mm (3.4 - 5.2 kg/mm, 192 - 291 Ib/in) (RX10, RX10S, RX10R, RX10RS) 17.7 - 39.2 N/mm (1.8 - 3.9 kg/mm, 99 - 220 Ib/in) (RX10M, RX10MS) 8.8 mm (0.347 in) (RX10, RX10S, RX10R, RX10RS) 9.5 mm (0.374 in) (RX10M, RX10MS) 11.8 mm (0.465 in) (RX10, RX10S, RX10R, RX10RS) 10.5 mm (0.413 in) (RX10M, RX10MS) 25 ± 0.5 mm (0.98 ± 0.02 in) (RX10, RX10S, RX10R, RX10RS) 10 ± 0.5 mm (0.39 ± 0.02 in) (RX10M, RX10MS) 35 mm (1.37 in) 10 mm (0.40 in)
B
AB~** C
Shock absorber: Damping force Front Extension
Compression
Rear Extension
Compression
910 N/O.3 m/s (91 kg/0.3 mIs, 201 Ib/0.3 m/s) (RX10, RX10S, RX10R, RX10RS) 540 N/O.3 m/s (54 kg/0.3 mIs, 1191b/0.3 m/s) (RX10M, RX10MS) 2,280 N/O.3 m/s (228 kg/0.3 mIs, 503 Ib/0.3 m/s) (RX10, RX10S, RX10R, RX10RS) 1,820 N/O.3 m/s (182 kg/0.3 mIs, 401 Ib/0.3 m/s) (RX10M, RX10MS) 2,090 N/O.3 m/s (209 kg/0.3 mIs, 461 Ib/0.3 m/s) (RX10, RX10S, RX10R, RX10RS) 1,340 N/O.3 m/s (134 kg/0.3 mIs, 295 Ib/0.3 m/s) (RX10M, RX10MS) 470 N/O.3 m/s (47 kg/0.3 mIs, 1041b/0.3 m/s) (RX10, RX10S, RX10R, RX10RS) 970 N/O.3 m/s (97 kg/0.3 mIs, 2141b/0.3 m/s) (RX10M, RX10MS)
9-11
MAINTENANCE SPECIFICATIONS Model Slide runner: Thickness Wear limit Track sprocket wheel: Material Number of teeth
I
SPEC I
g--I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS 17.8 mm (0.70 in) 10 mm (0.39 in) High molecular weight polyethylene 9 T (RX10, RX10S, RX10R, RX10RS) 8 T (RX10M, RX10MS)
Rear guide wheel: Material Outside diameter
High molecular weight polyethylene with rubber 178 mm (7.01 in)
Brake: Pad thickness Pad wear limit Pad to disk clearance Disc outside diameter Disc minimum thickness
13 mm (0.51 in) 7.5 mm (0.30 in) 0.025 --- 0.115 mm (0.001 --- 0.005 in) 220 mm (8.66 in) 4.5 mm (0.18 in)
9-12
MAINTENANCE SPECIFICATIONS
I
SPEC I
g--I
CHASSIS Model
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
Frame: Frame material Seat height Luggage box location
Aluminum 738 mm (29.1 in) Front
Steering: Lock-to-Iock angle (left) (right) Ski alignment Toe-out size Caster angle
30.0° (R ski) 34.7° (L ski) 34.7° (R ski) 30.0° (L ski) Toe-out o -... 15 mm (0 -... 0.59 in) 23°
Ski: Ski material Length Width
Plastic 1,020 mm (40.2 in) 132.0 mm (5.20 in)
Ski suspension (Front suspension): Type Travel Spring type Spring rate
Wire diameter Shock absorber: damping force Extension
Compression
Double wishbone system 221 mm (8.70 in) (RN10, RX10S, RX10R, RX10RS) 175 mm (6.89 in) (RX10M, RX10MS) Coil spring 19 - 30 N/mm (1.9 - 3.0 kg/mm, 106 - 168 Ib/in) (RX10, RX10S, RX10R, RX10RS) 25 N/mm (2.5 kg/mm, 140 Ib/in) (RX10M, RX10MS) 8.5 mm (0.335 in) (RX10, RX10S, RX10R, RX10RS) 8.0 mm (0.315 in) (RX10M, RX10MS) 2,090 N/O.3 m/s (209 kg/0.3 mIs, 461 Ib/0.3 m/s) (RX10, RX10S, RX10R, RX10RS) 1,950 N/O.3 mIs, (195 kg/0.3 mIs, 430 Ib/0.3 m/s) (RX10M, RX10MS) 610 N/O.3 m/s (61 kg 10.3 mIs, 1351b/0.3 m/s) (RX10, RX10S, RX10R, RX10RS) 600 N/O.3 m/s (60 kg/0.3 mIs, 132 Ib/0.3 m/s) (RX10M, RX10MS)
9-13
MAINTENANCE SPECIFICATIONS
I
SPEC I
g--I
ELECTRICAL Model
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
Voltage
12 V
Ignition system: Ignition timing (B.T.D.C.) Advanced type
5° at 1,450 r/min Digital type
Ignition coil: Model/Manufacturer Primary coil resistance Secondary coil resistance
F6T54973/MITSUBISHI 0.16 -.; 0.22 Q at 20°C (68°F) 5.0 -.; 6.8 kQ at 20°C (68°F)
Charging system: Type Nominal output
AC magneto 14 V/21 A at 5,000 r/min
DC-CDI: Magneto model/Manufacturer Standard Pickup coil resistance (color code) Stator coil resistance (color code) CDI unit model/Manufacturer
F4T47371/MITSUBISHI 14 V 30 A, 420 W at 5,000 r/min 189 -.; 231 Q at 20°C (68°F) (G ray - Black) 0.19 -.; 0.24 Q at 20°C (68°F) (White - White) F8T39371/MITSUBISHI
Rectifier/ regulator: Type Model/Manufacturer No load regulated voltage (DC) Capacity (DC) Withstand voltage
Short circuit type FH001/SHINDENGEN 14.1 -.; 14.9 V 35A 40V
Battery: Specific gravity Manufacture Type Ten hour rate amperage
1.32 GS YTX20L-BS 12V-18Ah 18 A
Electric starter system: Type
Constant mesh type
Starter motor: Model/Manufacturer Output Armature coil resistance Continuity check Insulation check Brush Overall length Wear limit Spring pressure Commutator diameter Wear limit Mica undercut
8FA1/MORIC 12 V - 0.95 kW 0.008 -.; 0.010 Q at 20°C (68°F) More than 100 kQ at 20°C (68°F) 9.8 mm (0.39 in) 5 mm (0.20 in) 7.36 -.; 11.04 N (736 -.; 1,104 g, 26.0 -.; 38.9 oz) 28.5 mm (1.12 in) 27.5 mm (1.08 in) 1.5 mm (0.059 in)
9-14
MAINTENANCE SPECIFICATIONS Model
MS5F-441/JIDECO 180 A 4.2 ~ 4.6 Q at 20°C (68°F)
T.P.S. (throttle position sensor): Model/Manufacturer Resistance
Oil level switch: Model/Manufacturer
Full Empty
8FA/NIPPON SEIKI 4 ~ 10Qat20°C(68°F) 90 ~ 100 Q at 20°C (68°F) 5DM/OMRON 95 ~ 116 Q at 20°C (68°F)
(left) (right)
Thumb warmer: Heater resistance Circuit breaker: Type Amperage for individual circuit Main fuse Headlight fuse Signal fuse Ignition fuse Carburetor heater fuse Reserve fuse Reserve fuse Reserve fuse Water temperature sensor: Model/Manufacturer Resistance Indicator light
TS67/02-1 C/MIKUNI 4 ~ 6 KQ at 20°C (68°F) (Blue - Black) o ~ 4 KQ at 20°C (68°F) (Yellow - Black) 8FA/ASTI
Headlight relay: Model/Manufacturer Coil resistance Grip warmer: Heater resistance
SPEC I
g--I
RX10, RX10S, RX10R, RX10RS, RX10M, RX10MS
Starter relay: Model/Manufacturer Amperage rating Coil resistance
Fuel sender: Model/Manufacturer Sender resistance
I
(ON) (OFF)
1.53 1.53
~ ~
1.87 Q at 20°C (68°F) 1.87 Q at 20°C (68°F)
37.0
~
45.2 Q at 20°C (68°F)
x x x x x x x x
1 1 1 1 1 1 1 1
Fuse 30A 20 A 10 A 10 A 20A 30A 20A 10 A
8CC/MITSUBISHI 5.2 ~ 6.4 kQ at O°C (34°F) 0.300 ~ 0.364 kQ at 80°C (176°F) 0.170 ~ 0.208 kQ at 100°C (212°F) 90 ~ 110°C (194 ~ 230°F) 85 ~ 105 °C (185 ~ 221 °F)
Speed sensor: Model/Manufacture
8EK/NIPPON SEIKI
Carburetor heater: Model/Manufacture Wattage Resistance
5FU/NIPPON THERMOSTAT 30W 6 ~ 10Qat20°C(68°F)
9-15
I
SPEC I
HIGH ALTITUDE SETTINGS
g--I
HIGH ALTITUDE SETTINGS RX10, RX10S, RX10R, RX10RS
~ o ---Altitude
ture
-40°C
-20°C
O°C
(-40°F)
(-4° F)
(32° F)
16°C (60°F)
Idling speed (r/min)
200 m (0 ---- 670 ft)
MJ
#140
MJ
#137.5
MJ
#135
PS
STD
PS
STD
PS
STD
200 ---- 1000 m (---- 1700 ft)
MJ
#137.5
MJ
#135
MJ
#132.5
PS
STD
PS
STD
PS
STD
1350
MJ
MJ
#132.5 3/4
MJ
PS
#135 3/4
PS
#130 3/4
1350
MJ
#132.5
MJ
#130
MJ
#127.5
PS
1+1/4
PS
1+1/4
PS
1+1/4
1000 ---- 2000 (---- 6700 ft)
m
2000 ---- 3000 m (---- 10000 ft)
[Production spec]
MJ#1, 2, 3, 4:#135
PS
PS:Approx 2
#:Main jet number
1350
1400
PS:Pilot screw turns in
HIGH ALTITUDE SETTINGS RX10M, RX10MS
~ o ---Altitude
tu re
-40°C
-20°C
O°C
(-40°F)
(_4° F)
(32° F)
16°C (60°F)
Idling speed (r/min)
200 m (0 ---- 670 ft)
MJ
#140
MJ
#137.5
MJ
#135
PS
STD
PS
STD
PS
STD
200 ---- 1000 m (---- 1700 ft)
MJ
#137.5
MJ
#135
MJ
#132.5
PS
STD
PS
STD
PS
STD
1350
MJ
#135 3/4
MJ PS
#132.5 3/4
MJ
PS
PS
#130 3/4
1350
MJ
#132.5
MJ
#130
MJ
#127.5
PS
1+1/4
PS
1+1/4
PS
1+1/4
1000 ---- 2000 (---- 6700 ft)
m
2000 ---- 3000 m (---- 10000 ft)
[Production spec]
MJ#1, 2, 3, 4:#135
PS:Approx 2
9-16
#:Main jet number
1350
1400
PS:Pilot screw turns in
TIGHTENING TORQUE
I
SPEC I
g--I
TIGHTENING TORQUE ENGINE Parts to be tightened Spark plug Cylinder head nut (M1 0 x 1.25) x 2 Cylinder head nut (M1 0 x 1.25) x 6 Cylinder head nut x 2 Cylinder head bolt Camshaft cap and cylinder head Cylinder head cover Connecting rod and cap A.C. magneto rotor Crankshaft and drive gear Primary reduction gear bearing housing Timing chain tensioner Thermostat housing Water temperature sensor Timing chain tensioner cap Camshaft and camshaft sproket Hose band Water pump Coolant reservoir tank Pipe Oil cooler Oil pan Engine mounting adjust bolt Engine mounting nut Countershaft cover Oil pan drain bolt Oil filter union bolt Oil filter Oil pump Oil pump drive chain guide Oil tank drain bolt Oil tank and frame (bolt) Oil tank and frame (nut) Oil gallery bolt Exhaust joint Muffler band Exhaust pipe Exhaust sampling bolt Muffler Exhaust cover Muffler band Muffler protector Cylinder head stud bolt Crankcase (M9 x 1.5) (1 st) (2nd) Crankcase (M6 x 1.0) Countershaft cover A.C. magneto rotor cover Starter clutch Stator coil Starter motor Pickup coil
Tightening torque Nm
m-kg
ft-Ib
13
1.3
9.4
20 + 121 ° 20 + 105° 20 + 140°
2.0 + 121 ° 2.0 + 105° 2.0 + 140°
14+121° 14 + 105° 14 + 140°
12 10 12
1.2 1.0 1.2
8.7 7.2 8.7
20 + 120°
2.0 + 120°
14 + 120°
130 75 12 10 10 23 6 24 2 12 7 10 35 10 7 65 12 30 70 17 12 10 16 10 19 10 25 9 25 10 16 6 20 11 10 15
13.0 7.5 1.2 1.0 1.0 2.3 0.6 2.4 0.2 1.2 0.7 1.0 3.5 1.0 0.7 6.5 1.2 3.0 7.0 1.7 1.2 1.0 1.6 1.0 1.9 1.0 2.5 0.9 2.5 1.0 1.6 0.6 2.0 1.1 1.0 1.5
94 54 8.7 7.2 7.2 17 4.3 17 1.4 8.7 5.0 7.2 25 7.2 5.1 47 8.7 22 51 12 8.7 7.2 11 7.2 14 7.2 18 6.5 18 7.2 11 4.3 14 8.0 7.2 11
15+ 45--50°
1.5+ 45--50°
11+ 45--50°
12 12 12 12 10 27 6
1.2 1.2 1.2 1.2 1.0 2.7 0.6
8.7 8.7 8.7 8.7 7.2 20 4.3
9-17
Remarks
Left-hand thread.
See NOTE.
Apply LOCTITE® Apply LOCTITE®
TIGHTENING TORQUE Parts to be tightened Fuel pump Fuel pump stay
Tightening torque Nm
m-kg
ft-Ib
10 10
1.0 1.0
7.2 7.2
I
SPEC I
g--I
Remarks
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. First, tighten the bolt to approximately 15 Nm (1.5 m-kg, 11 ft-Ib) with a torque wrench, then loosen the bolt completely. 2. Retighten the bolt to 15 Nm (1.5 m-kg, 11 ft-Ib), and tighten another 45 ~ 50° with a angle gauge.
9-18
TIGHTENING TORQUE
I
SPEC I
g--I
POWER TRAIN Parts to be tightened
Tightening torque Nm
m-kg
ft-Ib
Primary sheave (1 st) (2nd) Spider and sliding sheave
120 60 200
12 6.0 20.0
85 43 145
Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave Stopper (secondary sheave) Spring seat (secondary sheave) Bolt (secondary sheave clearance) Drive sprocket Locknut chain tensioner Chain housing and frame Driven sprocket Drain bolt (drive chain housing) Chain housing cover Shift lever assembly Lever and drive chain housing cover
14 6 64 7 23 10 90 24 48 48 16 24 10 10
1.4 0.6 6.4 0.7 2.3 1.0 9.0 2.4 4.8 4.8 1.6 2.4 1.0 1.0
10 4.3 46 5.1 17 7.2 65 17 35 35 12 17 7.2 7.2
Shaft (reverse drive gear)
10
1.0
7.2
Reverse driven gear Counter gear Spacer set screw
48 10 6 48 6 30 30 8 13 4 16 24 72 30 72 72 72 75 72 24 49 49 49 49 72 49 49 72 72
4.8 1.0 0.6 4.8 0.6 3.0 3.0 0.8 1.3 0.4 1.6 2.4 7.2 3.0 7.2 7.2 7.2 7.5 7.2 2.4 4.9 4.9 4.9 4.9 7.2 4.9 4.9 7.2 7.2
35 7.2 4.3 35 4.3 22 22 5.8 9.4 2.9 12 17 52 22 52 52 52 54 52 17 35 35 35 35 52 35 35 52 52
Chain housing and brake caliper Bleed screw (brake caliper) Brake hose union bolt (caliper side) Brake hose union bolt (brake master cylinder side) Bearing set screw (Secondary shaft)
Parking brake Stopper band Hook and front pivot arm Wheel bracket and sliding frame Bracket bolt (front) Bracket bolt (rear) Front pivot arm and front pivot arm bracket Front pivot arm bracket and sliding frame Suspension wheel Rear axle Slide rail suspension mounting bolt (M1 0) Rear pivot arm and bracket Shock absorber and rear pivot arm Rear pivot arm and rod Rear suspension bracket and rod Shock absorber and rear suspension bracket Control rod and sliding frame Shock absorber and front pivot arm Shock absorber and front suspension bracket Rear pivot arm bracket Rear bracket and suspension wheel
9-19
Remarks Tighten the bolt in two stages. See NOTE. Left-hand thread. Apply LOCTITE®
Apply LOCTITE®
(RX10R, RX10RS) (RX10R, RX10RS) Apply LOCTITE® (RX10R, RX10RS) Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE®
TIGHTENING TORQUE Parts be tightened
Tightening torque Nm
mekg
ftelb
72 9 20 40
7.2 0.9 2.0 4.0
52 6.5 14 29
Wheel bracket shaft and sliding frame Set bolt (front axle) Speed sensor Gear unit (speed sensor)
I
SPEC I
g--I
Remarks Apply LOCTITE®
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tightening steps: 1. Tighten the bolt to a torque at 155 Nm (15.5 m-kg, 112 ft-Ib). 2. Loosen the bolt completely. 3. Retighten the bolt to a torque of 60 Nm (6.0 m-kg, 43 ft-Ib).
9-20
TIGHTENING TORQUE
I
SPEC I
CHASSIS Tightening torque
Parts to be tightened Handlebar holder Steering column Upper Lower Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod Tie rod and steering arm Idler arm Locknut (relay rod/tie rod) Ski Ski runner Ski column lower bracket Ski and ski handle Shock absorber (upper) Shock absorber (lower) Steering arm locknut Upper arm and frame Upper arm and knuckle Lower arm and frame Lower arm and knuckle Stabilizer bar and stabilizer arm Stabilizer arm and connecting rod Connecting rod and lower arm Frame cross member (front side) (rear side) Master cylinder assembly Brake lever adjuster locknut Rear cover Seat and frame Shroud
9-21
Nm
m-kg
ft-Ib
15
1.5
11
23 23 35 35 30 30 35 30 35 67 25 48 19 11 11 45 45 35 37 40 37 65 11 34 34 30 23 10 6 3 5 3
2.3 2.3 3.5 3.5 3.0 3.0 3.5 3.0 3.5 6.7 2.5 4.8 1.9 1.1 1.1 4.5 4.5 3.5 3.7 4.0 3.7 6.5 1.1 3.4 3.4 3.0 2.3 1.0 0.6 0.3 0.5 0.3
17 17 25 25 22 22 25 22 25 49 18 35 14 8.0 8.0 33 33 25 27 29 27 47 8.0 25 25 22 17 7.2 4.3 2.2 3.6 2.2
Remarks
g--I
GENERAL TORQUE SPECIFICATIONSI DEFINITION OF UNITS
GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.0. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
r
L
(nut)
B (bolt)
10mm
A
1SPEC 1.--.1 .., -
General torque specifications Nm
m-kg
ft-Ib
6mm
6
0.6
4.3
12 mm
8mm
15
1.5
11
14mm
10mm
30
3.0
22
17mm
12 mm
55
5.5
40
19 mm
14mm
85
8.5
61
22mm
16mm
130
13.0
94
-
A: Distance across flats B: Outside thread diameter
DEFINITION OF UNITS Unit
Read
Definition 10-3
Measurement
mm cm
Millimeter Centimeter
meter 10-2 meter
Length Length
kg
Kilogram
103 gram
Weight
m/sec2
N
Newton
1 kg x
Nm m-kg
Newton meter Meter kilogram
Nxm m x kg
Torque Torque
Pa N/mm
Pascal Newtons per millimeter
N/m 2 N/mm
Pressure Spring rate
L cm 3
Liter Cubic centimeter
-
Volume or capacity
r/min
Rotations per minute
-
Engine speed
9-22
Force
CABLE ROUTING
2 3
31 2
30 5
B-B
19
A 9-23
CABLE ROUTING
CD
To the headlight and meter assembly Battery negative lead @ Battery positive lead @ Oil level switch lead coupler @ Oil level switch 速 Carburetor switch lead connector (J) Coolant temperature sensor lead coupler To the brake caliper 速 To the heat exchanger @ Main switch @ Joint connector @ Tail/brake light lead coupler @ Throttle cable @ Right handlebar switch lead coupler @ Thumb warmer switch lead coupler @ Grip warmer switch lead connector @ To the tail/brake light @ Hi/Lo switch lead coupler @ Left handlebar switch lead coupler @ Starter cable @ Brake light switch lead coupler @ Brake hose @ Fuel sender lead coupler @ Clamp it with the lower fuel hose @ Clamp the throttle position sensor @ Route the coolant hose between the upper fuel hose and the lower fuel hose @ Route it under the coolant hose @ Route it with the coolant hose @ Throttle position sensor lead coupler @ Drive guard bracket
速
速
9-24
I
SPEC I
g--I
CABLE ROUTING
2 3
31 2
30 5
B-B
19
A 9-25
CABLE ROUTING
® Connect @ @ @
® ® ® @ @ @
® @ @ @
® ® ®
the battery negative lead to the starter motor mounting bolt Voltage regulator Relay Back buzzer (RX10R, RX10RS) Nut Bolt Battery negative lead Clamp the vacuum hose to the coolant hose Clamp the ignition coil lead to the frame Route the fuel hose under the clamp Clamp the fuel hose Clamp the coolant hose and vacuum hose 2 Clamp the coolant hose and vacuum hose Clamp the throttle position sensor Clamp the headlight sub-harness Carburetor heater lead coupler To the tail/brake light
9-26
I
SPEC I
g--I
CABLE ROUTING
3
9-27
ISPEC
I
g--I
CABLE ROUTING
CD ®
Headlight wire harness Align it with the positioning tape of the headlight wire harness @ Meter coupler (Securety fit in the rubber cover)
9-28
I
SPEC I
g--I
CABLE ROUTING
3
9-29
CABLE ROUTING
CD ®
Do not clamp the throttle cable Throttle cable @ Handlebar holder @ All leads and cables except brake hose and parking brake cable @ Clamp the tail/brake light lead, headlight beam switch lead and grip warmer lead ® Parking brake cable (J) Left handlebar switch @ Brake hose and parking brake cable through lower loop ® Clamp the speed sensor lead only @ Speed sensor coupler @ Clamp the fuel tank breather hose @ Fuel sender lead cover @ Route the fuel breather hose along the steering gate ~ Clamp the compression spring section of the fuel breather hose @ Compression spring @ Point the clip position to the upward © Insert the fuel breather hose until it contacts the pipe @ To the speed sensor @ Carburetor air vent hoses @ To the parking brake @ To the brake caliper @) Carburetor air vent hose @ Brake hose @ Fuel hose @ Clamp the wire harness and fuel breather hose from the lower side
9-30
I
SPEC I
g--I
CABLE ROUTING
3
9-31
CABLE ROUTING @ Right handlebar switch @ Clamp the wire harness only @ Clamp the fuel sender head and speed sensor lead
@ Less than 50 mm (2.0 in) @ Clamp the wire harness
ÂŽ Route
@ @
the carburetor air vent hose under the fuel hose Push into the end of clamp between frame and fuel tank Breather tank
9-32
I
SPEC I
g--I
CABLE ROUTING
I
SPEC I
g--I
8
21
9-33
CABLE ROUTING
CD ®
Coolant reservoir tank Reservoir tank hose @ Parking brake cable @ Brake hose @ Clamp the hose at the white paint position. Point the clamp position to the front outside @ Clamp the battery positive lead (J) Headlight lead @ Tighten the frame ground and voltage regulator upper bolt together ® Engine oil tank hose ® Point the clamp tightening direction to the downward @ to the tail/brake light @ Tighten the frame cross member and frame together @ Fuse box ~ Route the gear position switch lead to the reverse gear if the reverse function is equipped, or fold it back and secure it if the reverse function is not provided @ Wire harness ® Point the clamp position to the front outside © Drain hose @ Less than 30 mm (1.2 in) @ Clamp the coolant hose @ Clamp it at the white paint position @ Point the clamp position to the downward @ Point the clamp position to the inside
9-34
I
SPEC I
g--I
CABLE ROUTING
8
9-35
CABLE ROUTING
CD ® @ @
@
®
(j)
®
Fuel pump Coolant reservoir tank Point the pawl of clip to the upward Clamp the fuel tank breather and speed sensor lead. Thighten the frame cross member and frame together Wire harness clamp Rivets Speed sensor Point the pawl of clip to the downward
9-36
I
SPEC I
g--I
CABLE ROUTING
~-
I
5
t ·
I
A
!~----9
7
_.@ \
1
-,
------f} -Of
--\~\_-_\.\ -----~.. \
15
6
11
12
13
15
18
A-A B-B 9-37
CABLE ROUTING
CD ®
CDI unit Battery negative lead @ Starter motor @ Position the negative lead on the engine at 45° @ Battery positive lead ® CDI unit bracket (f) Battery band ® Battery cover ® To the carburetor @ Equip it with the frame cross member @ Wire harness holder @ Battery bracket @ Battery seat GJ Air box drain hose ® Plate cover @ 0 -- 5 mm (0.20 in) © Wire harness @ Frame cross member
9-38
I
SPEC I
g--I
CD A.C. magneto ® Rectifier/regulator ® Main switch @
Main relay
® Fuse (MAIN) ® Starter relay
(j) Starter motor
® Battery ® Engine stop switch ® Throttle switch ® Carburetor switch
@ Carburetor heater relay @ Carburetor heater @ Grip warmer @ Thumb warmer
® COl unit
@
Ignition coil
® Spark plug
@ Water temperature sensor @ Throttle position sensor @ Grip warmer switch @ Thumb warmer switch @ Body ground @ Back buzzer (RX10R, RX10RS) @ Gear position switch (RX10R, RX10RS) @ Brake light switch @ Tail/brake light @ Fuse (HEADLIGHT) @ Fuse (SIGNAL)
® Fuse (CARBURETOR HEATER)
@ @
®
@ @ @
® ®
@
®
@
® ®
@
Fuse (IGNITION) Headlight beam switch Headlight relay Headlight Meter assembly Tachometer Meter light Water temperature indicator light Multi-function meter Warning light Hi beam indicator light Oil level switch Fuel sender Speed sensor
COLOR CODE B Br G Gy L Lg . . . ..
Black Brown Green Gray Blue Light green o Orange P Pink Red R Sb Sky blue W White Y Yellow B/G Black/Green B/L Black/Blue B/R Black/Red B/W Black/White B/Y Black/Yellow Br/W .. Brown/White Br/Y Brown/Yellow G/B Green/Black G/R Green/Red
G/Y L/G L/R L/W L/Y Lg/G ..
Green/Yellow Blue/Green Blue/Red Blue/White Blue/Yellow Light green/ Green Lg/L ... Light green/Blue Lg/W .. Light green/White O/R Orange/Red R/B Red/Black R/W Red/White R/Y Red/Yellow white/Green W /G W/R White/Red W/Y White/Yellow Y/ B Yellow / Black Yellow/Green Y /G Yellow/Blue Y /L Yellow/Red Y /R Yellow/White Y /W
INSTALLATION
CHAPTER 1. GENERAL INFORMATION SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . .. FOR TUNE UP FOR ENGINE SERVICE FOR POWER TRAIN SERVICE
1 1 1 1
CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT
34
CHAPTER 5. ENGINE ENGINE ASSEMBLy INSTALLATION
35 35
CHAPTER 7. CARBURETION CARBURETORS. . . . . . . . . . . . . . . . . . . . .. 37
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . .. 2 PERIODIC MAINTENANCE TABLE
2
POWER TRAIN PARKING BRAKE ADJUSTMENT
4 4
CHASSiS LUBRICATION
5 5
TUNING CLUTCH GEAR SELECTION FRONT SUSPENSION REAR SUSPENSION
6 6 7 14 14
CHAPTER 3. CHASSIS STEERING . . . . . . . . . . . . . . . . . . . . . . . . . .. 17 INSTALLATION 17
CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS
40
MAINTENANCE SPECIFICATIONS ENGINE POWER TRAIN CHASSiS ELECTRICAL HIGH ALTITUDE SETTINGS
42 42 47 50 51 53
TIGHTENING TORQUE . . . . . . . . . . . . . . .. ENGINE POWER TRAIN CHASSiS
54 54 56 58
GENERAL TORQUE SPECIFICATIONS
59
DEFINITION OF UNITS . . . . . . . . . . . . . . .. 59 FRONT SUSPENSION
21 CABLE ROUTING
CHAPTER 4. POWER TRAIN SECONDARYSHAFT REMOVAL INSPECTION INSTALLATION
23 24 25 26
BRAKE
28
SLIDE RAIL SUSPENSION
29
60
SPECIAL TOOLS
II~~~ I~I
SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. NOTE: - - - - - - - - - - - - - - - - - - - - • Be sure to use the correct part number when ordering the tool, since the part number may differ according to country. • For USA and Canada, use part number starting with "YB-", "YM-", "YU-" or "YS-", "ACC-". • For others, use part number starting with "90890-". FOR TUNE UP • Steering linkage alignment plate PIN: YS-01487 (for U.S.A./Canada) 90890-01487 (for Europe) Locks steering relay arms in place while adjusting the steering linkage for front-end alignment. FOR ENGINE SERVICE • Engine mount spacer wrench PIN: YS-01489 (for U.S.A./Canada) 90890-01489 (for Europe) Used to turn the engine mounting bolts when removing/installing engine. FOR POWER TRAIN SERVICE • Secondaryshaft Slide & Holder PIN: YS-01492 (for U.S.A./Canada) 90890-01492 (for Europe) Remove and install secondaryshaft bearing tapered collar. Also used to hold the secondaryshaft when used with the drive gear socket (YS-01490/90890-01490). • Drive gear socket PIN: YS-01490 (for U.S.A./Canada) 90890-01490 (for Europe) Remove and install chaincase drive sprocket nut (36 mm (1.4 in) x 100 mm (4 in) deep well socket). • Ring nut wrench PIN: YU-01268 (for U.S.A./Canada) 90890-01268 (for Europe) Remove and install secondaryshaft bearing nut
D
IANDSJP I
INTRODUCTION/PERIODIC MAINTENANCE TABLE
------------------------------PERIODIC INSPECTION AND ADJUSTMENT I
to~
~
INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE
Item
Preoperation check (Daily)
Remarks
Spark plugs
Check condition. Adjust gap and clean. Replace if necessary.
*Valve clearance
Check clearance. Adjust clearance when engine is cold.
Engine oil
Check oil level. *Replace. Replace.
Fuel
Check fuel level.
*Fuel filter
Check condition. Replace if necessary.
*Fuelline
Check fuel hose for cracks or damage. Replace if necessary. Check coolant level. *Air bleed the cooling system if necessary.
•
• •
• •
•
Every 20,000 km (12,000 mi)
• • •
Whenever operating condition (elevation/temperature) is changed.
*Adjust the jets.
• • •
Engine stop switch
Check operation. *Repair if necessary.
Throttle override system (T.O.R.S.)
Check operation. *Repair if necessary.
Th rottle lever
Check operation. *Repair if necessary.
*Exhaust system
Check for leakage. Tighten or replace gasket if necessary.
Drive guard
Check for cracks, bends or damage. *Replace if necessary.
V-belt
Check for wear and damage. Replace if necessary.
Drive track and idler wheels
Check deflection, and for wear and damage. *Adjust/ replace if necessary.
Slide runners
Every 40,000 km (25,000 mi)
•
Check the throttle lever operation. Carburetor
Every Seasonally or 3,200 km (2,000 mi) (160 hr)
•
*Engine oil filter cartridge
Engine coolant
Initial 1 month or 800 km (500 mi) (40 hr)
Check for wear and damage. *Replace if necessary.
• • • •
* It is recommended that these items be serviced by a Yamaha dealer. 2
•
•
I
PERIODIC MAINTENANCE TABLE
Item
Preoperation check (Daily)
Remarks
Check operation and fluid leakage. Brake and parking brake
*Adjust free play and/or replace pads if necessary. *Repair brake fluid.
*Disc brake installation
Drive chain oil Drive chain Skis and ski runners Steering system Lights
ADJ Initial 1 month or 800 km (500 mi) (40 hr)
•
Check for slight free play. Lubricate shaft with specified grease as required.
•
Check oil level. *Replace.
Every Seasonally or 3,200 km (2,000 mi) (160 hr)
•
See NOTE.
Every 1,600 km (1,000 mi)
•
Initial at 500 km (300 mi) and every 800 km (500 mi) thereafter.
Check deflection. *Adjust if necessary. Check for wear and damage. *Repair if necessary. Check operation. *Adjust toe-out if necessary. Check operation. Replace bulbs if necessary. Check engagement and shift speed. Adjust if necessary.
*Primary and secondary clutches
INSP
• • •
Whenever operating elevation is changed.
Inspect sheaves for wear/damage. Inspect weights/ rollers and bushings for wear-for primary. Inspect ramp shoes/bushings for wear-for secondary. Replace if necessary. Lubricate with specified grease.
*Steering column bearing
Lubricate with specified grease.
*Ski and front suspension
Lubricate with specified grease.
*Suspension component
Lubricate with specified grease.
*Parking brake cable end and lever end / th rottle cable end
Check cable damage. Replace if necessary.
Shroud latches
Make sure that the shroud latches are hooked.
Fittings and fasteners
Check tightness. *Replace if necessary.
Tool kit and recommended equipment
Check for proper placement.
• • •
Lubricate with specified grease.
• • •
• ••• •• •
* It is recommended that these items be servised by a Yamaha dealer.
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required. 2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3. Replace the brake hoses every four years, or if cracked or damaged.
3
PARKING BRAKE ADJUSTMENT
--------------------------POWER TRAIN
I
IANOSJP I to~ ~
PARKING BRAKE ADJUSTMENT 1. Measure: • Parking brake cable distance @ Out of specification --+ Adjust. Parking brake cable distance: 43.5 -- 46.5 mm (1.713 -- 1.831 in)
2. Adjust: • Parking brake cable
Adjustment steps: .LoosenthelocknutGD • Turn the adjuster® in or out until the specified distance @ is obtained. Turning in --+ Distance @ is increased. Turning out --+ Distance @ is decreased. • Tighten the locknut. 3. Measure: • Brake pad clearance @ Out of specification --+ Adjust.
Brake pad clearance: 1.5 -- 2.0 mm (0.059 -- 0.079 in)
4. Adjust: • Brake pad clearance
Adjustment steps: .LoosenthelocknutGD • Turn the adjuster® in or out to until the specified clearance between the brake pad @ and brake disc @ is obtained. • Tighten the locknut.
4
I
LUBRICATION
INSP ADJ
CHASSIS LUBRICATION Brake lever, throttle lever and throttle cable end 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables. ...-..
l
Recommended lubricant: ESSO Beacon 325 Grease
~ ---------Apply a dab of grease onto only the end of the cables. Do not grease the throttle cables. They could freeze and cause a loss of control.
Front and rear suspension 1. Use a grease gun to inject grease into the nipples CD. 2. Apply grease ÂŽ.
A
Recommended lubricant: Esso Beacon 325 Grease or Aeroshell Grease #7A
[A] Front [BJ Rear A
B
5
INSP
CLUTCH
TUNING
G Green
CLUTCH High altitude
S ~
800 m 2,500 ft)
600 ~ 1,400 m (2,000 ~ 4,500 ft)
[A]
Elevation
[6] [Q] [Q] [:EJ
Engine idle speed
1,350 ± 100 r/min
+-
Engagement r 1min
3,600 ± 200 r 1min
+-
Shift r/min
10,250±250 r/min
+-
(~
1,200 (4,000
~
~
2,000 m 6,500 ft)
P Pink Y
±
Yellow
1,800 (6,000
+-
3,700
Wi White
~
~
2,600 m 8,500 ft)
2,400 (8,000
~
3,800
±
~
+-
200 r/min
+-
+-
I
3,000 m 10,000 ft)
+-
+-
200 r/min +-
Main jet
IrFl
Pilot jet*1
[G]
Pilot screw
[8]
Secondary reduction ratio (number of links)
rn
Silver
ADJ
[ill
Refer to "HIGH ALTITUDE SETTINGS" in "MAINTENANCE SPECIFICATIONS".
38/23 (70 L)
+-
38/22 (68 L)
38/21 (68 L)
+-
Primary sheave spring
90501-582L1
+-
90501-582L2
90501-602L3
+-
+-
G-S-G
P-S-P
+-
[JJ
Color
y-S-y
[K]
Free length
87.4 mm (3.44 in)
+-
+-
CD
Preload
343 N (35 kg, 77 Ib)
+-
+-
[M]
Spring rate
(2.50 kg/mm, 140lb/in)
+-
[N]
Wire diameter
5.8 mm (0.228 in)
+-
+-
I[Q] Outside diameter
60 mm (2.36 in)
+-
+-
+-
+-
[:EJ
Weight (10)
8FA-17605-10 (8FAOO)
+-
+-
+-
+-
[Q]
~eight
24.5 N/mm
27 N/mm
(2.75 kg 1mm, 154lb/in)
85.1 m (3.35 in)
+-
+-
+-
29.4 Nm (3.00 kg/mm, 168lb/in)
+-
6.0 mm (0.236 in)
+-
OUT
Steel 17.2 with-hole
Steel 13.3
Steel 13.3 with-hole
Aluminum 13.3 with-hole
None
IN
Steel 17.2 with-hole
Steel 13.3
Steel 13.3 with-hole
Steel 13.3 with-hole
None
rivet
IrRl Weight bushing
VESPEL TP-8549
+-
+-
+-
+-
Roller outer dia.
15.6 mm (0.61 in)
+-
+-
+-
+-
Roller bushing
VESPEL TP-8549
+-
+-
+-
+-
Pri. clutch shim
None
+-
+-
+-
+-
M Secondary sheave spring
90508-60007
+-
+-
+-
+-
Iw Color
W
+-
+-
+-
+-
[Xl
Free length
75 mm (2.95 in)
+-
+-
+-
+-
[y]
Preload rate
60° (3-3) 1290 kgemm/rad
+-
+-
+-
+-
[ZJ
Wire diameter
[S] [I] [Q]
6.0 mm (0.236 in)
+-
+-
+-
+-
~ Outside diameter
69.5 mm (2.736 in)
+-
+-
+-
+-
[li]
51 - 43°
+-
+-
+-
+-
1.0 mm (0.04 in)
+-
+-
+-
+-
Sec. torque cam angle
I[Q] Sec. clutch shim
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - *1: Number of return rotation of pilot screw may vary depending on each cylinder. Make sure to rotate the screw backward after listing its present number of return rotation on each cylinder.
6
CLUTCH/GEAR SELECTION
IANOSJP I to~ ~
----------------------------The clutch may require tuning depending upon I
where the machine will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the machine first begins to move from a complete stop. Clutch shifting speed is defined as the engine speed reached when the machine has travelled 800 m (2,500 ft) after being started at fullthrottle from a dead stop. Normally, when a machine reaches shifting speed, the vehicle speed increases but the engine speed remains nearly constant. Under unfavorable conditions (wet snow, icy snow, hills, or rough terrain), however, engine speed may decrease after the shifting speed has been reached.
o
t
[9---. -----
t
I
(400m)
~ SCH2845
[A] Engine speed [BJ Good condition [Q Clutch shifting speed [al Clutch engagement speed [EJ Starting position
[E] Distance travelled 800 m (2,500 ft)
GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions. If there are many rough surfaces or unfavorable snow conditions, the driveldriven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions exist, decrease the ratio.
Gear ratio chart The drive and driven gears and the chains shown in the gear ratio chart are available as options. The figures containing a decimal point represent the driveldriven gear ratios, while the bottom numbers designate the number of links in the chain.
7
I
INSP
GEAR SELECTION
ADJ
CD Chain and sprocket part number [AJ Parts name
~
[BJ Teeth & links
[:EJ Drive sprocket
[E] Driven sprocket
[G] Chain
[Q] Standard
Parts no.
20 teeth
8FA-17682-00
21 teeth
8FA-17682-10
22 teeth
8FA-17682-20
23 teeth
8FA-17682-30
24 teeth
8FA-17682-40
38 teeth
8FB-47587-80
39 teeth
8FB-47587-90
40 teeth
8FB-47587-00
68 links
94890-09068
70 links
94890-09070
RXW10J, RXW10SJ RXW10J, RXW10SJ
RXW10J, RXW10SJ
® Gear ratio [AJ Drive gear 20 teeth
21 teeth
22 teeth
23 teeth
24 teeth
38 teeth
1.90 68 links
1.81 68 links
1.73 68 links
1.65 70 links
1.58 70 links
39 teeth
1.95 68 links
1.86 68 links
1.77 70 links
1.70 70 links
1.63 70 links
1.91 70 links
1.82 70 links
1.74 70 links
1.67 70 links
[BJ Driven gear
/
40 teeth
@ Secondary sheave spring [6] Spring rate [A]
Part no.
(Torsion) Nemm/rad (kgemm/rad)
~ Spring rate ompression) N/mm (kg/mm) (Ib/in)
[Q]
Color
[EJWire gauge mm(in)
[E]
No. of coils
~Free ength mm(in)
[8]
Outside diameter mm(in)
90508-500B 1
6003 (613)
6.2 (0.63), 35.28
Brown
5.0 (0.196)
5.19
75 (2.95)
69.5 (2.736)
90508-536A9
7147 (729)
7.3 (0.74), 41.44
Red
5.3 (0.209)
5.53
75 (2.95)
69.5 (2.736)
90508-556A2
8314 (848)
8.5 (0.87), 48.72
Green
5.5 (0.217)
5.53
75 (2.95)
69.5 (2.736)
90508-556A7
9460 (965)
10.21 (1.04),58.24
Silver
5.5 (0.217)
4.86
75 (2.95)
69.5 (2.736)
90508-60012
11876 (1211)
12.32 (1.256), 70.34
Pink
6.0 (0.236)
5.53
75 (2.95)
69.5 (2.736)
90508-60007
12654 (1290)
13.45 (1.372) 76.84
White
6.0 (0.236)
5.19
75 (2.95)
69.5 (2.736)
IT] Standard
RXW10J, RXW10SJ
@ Secondary spring twist angle
ij Sheave
0
3
6
9
1
10°
40°
70°
100°
2
20°
50°
80°
110°
3
30°
60°
90°
120°
[A] Seat
8
GEAR SELECTION
-------------------------@ Torque cam
I
IANOSJP I to~ ~
(secondary spring seat)
[A] Identification mark
[BJ Effects
[G] Quicker upshifting during acceleration ..4~
~,
[8] Quicker backshifting under load
[Q] Part no.
[Q] Cam angle [E] Identification mark
8FA-17604-00
51-43°
8BVFA
8BV-17604-71
47°
8BV71
8BV-17604-51
45°
8BV51
8BV-17604-31
43°
8BV31
8BV-17604-11
41°
8BV11
8BV-17604-91
39°
8BV91
9
[E] Standard RXW10J, RXW10SJ
I
INSP
GEAR SELECTION
ADJ
® Primary spring [A] Spring identification color code
[BJ Spring rate color [Q] Preload color'
[Q]
Parts No.
90501 -551 L3
[EJ
[E]
Spring rate N/mm (kg/mm)
Preload N (kg)
19.6 (2.00)
294 (30)
[8]
IT]
Q]
[R]
Wire gauge mm(in)
Outside diameter mm(in)
No. of coils
Free length mm(in)
5.5 (0.216)
60 (2.36)
4.91
88.4 (3.48) 90.9 (3.58)
~ Color
Blue-Pink-Blue
90501 -551 L9
19.6 (2.00)
343 (35)
Blue-Silver-Blue
5.5 (0.216)
60 (2.36)
4.91
90501-552L5
19.6 (2.00)
392 (40)
Blue-Green-Blue
5.5 (0.216)
60 (2.36)
4.91
93.4 (3.68)
90501-581 L5
24.5 (2.50)
294 (30)
Yellow-Pink-Yellow
5.8 (0.228)
60 (2.36)
4.92
85.4 (3.36) 84.3 (3.32)
90501 -581 L6
27 (2.75)
294 (30)
Green-Pink-Green
5.8 (0.228)
60 (2.36)
4.66
90501-582L1
24.5 (2.50)
343 (35)
Yellow-Silver-Yellow
5.8 (0.228)
60 (2.36)
4.92
87.4 (3.44)
90501-582L2
27 (2.75)
343 (35)
Green-Silver-Green
5.8 (0.228)
60 (2.36)
4.66
86.1 (3.39)
90501 -582 L6
22.1 (2.25)
392 (40)
White-Green-White
5.8 (0.228)
60 (2.36)
5.25
91.2 (3.59)
90501 -582 L7
24.5 (2.50)
392 (40)
Yellow-Green-Yellow
5.8 (0.228)
60 (2.36)
4.92
89.4 (3.52)
90501-583LO
19.6 (2.00)
441 (45)
Blue-White-Blue
5.8 (0.228)
60 (2.36)
5.65
95.9 (3.78)
90501-583L1
22.1 (2.25)
441 (45)
White-White-White
5.8 (0.228)
60 (2.36)
5.25
93.4 (3.68)
90501-583L4
22.1 (2.25)
343 (35)
White-Silver-White
5.8 (0.228)
60 (2.36)
5.25
89.0 (3.50)
90501 -583 L5
22.1 (2.25)
294 (30)
White-Pink-White
5.8 (0.228)
60 (2.36)
5.25
86.7 (3.41)
90501-601 L7
29.4 (3.00)
294 (30)
Pink-Pink-Pink
6.0 (0.236)
60 (2.36)
4.82
83.4 (3.28)
90501-601 L8
31.9 (3.25)
294 (30)
Orange-Pink-Orange
6.0 (0.236)
60 (2.36)
4.60
82.6 (3.25)
90501 -602 L3
29.4 (3.00)
343 (35)
Pink-Silver-Pink
6.0 (0.236)
60 (2.36)
4.82
85.1 (3.35)
90501 -602 L8
27.0 (2.75)
392 (40)
Green-G reen-G reen
6.0 (0.236)
60 (2.36)
5.08
87.9 (3.46)
90501-602L9
29.4 (3.00)
392 (40)
Pink-Green-Pink
6.0 (0.236)
60 (2.36)
4.82
86.7 (3.41)
90501-603L2
24.5 (2.50)
441 (45)
Yellow-White-Yellow
6.0 (0.236)
60 (2.36)
5.39
91.4 (3.60)
90501 -603 L3
27.0 (2.75)
441 (45)
Green-White-Green
6.0 (0.236)
60 (2.36)
5.08
89.8 (3.54)
90501-624L8
31.9 (3.25)
343 (35)
Orange-Silver-Orange
6.2 (0.244)
60 (2.36)
5.00
84.2 (3.32)
10
[]Standard
RXW10J, RXW10SJ
GEAR SELECTION
----------------------(f)
I
IANOSJP I to~ ~
Clutch weight
[AJ Parts no.
[BJ Weight g (oz) without bush and rivets
8CH-17605-10
35.32 (1.247)
8CR-17605-10
38.09 (1.345)
8DG-17605-00
34.26 (1.209)
8DJ-17605-00
37.77 (1.333)
8DN-17605-20
42.09 (1.486)
8EK-17605-00
39.00 (1.376)
8FA-17605-00
63.8 (2.25)
~
Shape & ID mark
00808
11
[Q] Standard
I
GEAR SELECTION
INSP
ADJ
(J) Clutch weight [BJ Weight g (oz) [AJ Parts no.
without bush and rivets
8DN-17605-10
39.76 (1.40)
8FA-17605-10
63.8 (2.25)
~
Shape & ID mark
[Q] Standard
RXW10J, RXW10SJ
12
GEAR SELECTION
INSP
ADJ
® Weight rivets [A]
Parts No.
[6]
[Q]
Length mm(in)
Material
[Q]
Weight g (oz)
[EJ
Standard
90261-06033
Steel
17.2 (0.677)
4.5 (0.159)
IN: RXW10J, RXW10SJ
90269-06006
Steel
17.2 (0.677)
3.6 (0.127) with hole
OUT: RXW10J, RXW10SJ
90261-06019
Steel
13.3 (0.524)
3.1 (0.109)
90266-06002
Steel
13.3 (0.524)
2.4 (0.085) with hole
90266-06001
Aluminum
13.3 (0.524)
0.8 (0.028) with hole
[E]
Effects
[G]
Increased Force ~ ~
~,
[8]
None
Decreased Force
® Rollers 1.0. 9 mm (0.354 in)
[A]
Roller with bushing part number
8FG-17624-00
[6]
Outside diameter mm(in) 14.5 (0.57)
[Q]
[Q]
Bushing type (PIN) VESPEL TP-8549
[G]
Identification mark (Width)
[EJ
Standard
[E]
Grooved & Machined
[D
15.0 (0.59)
8FG-17624-20
15.6 (0.61)
Increased force
j~
II
90386-09001 8FG-17624-10
Effects
(14.6 mm)
[8]
VESPEL TP-8549
90386-09001
Grooved
(14.6 mm)
VESPEL TP-8549
[ ] No Mark
RXW10J, RXW10SJ
90386-09001 8FG-17624-30
16.0 (0.63)
VESPEL TP-8549
(14.6 mm)
Q]
Grooved & Grooved
90386-09001 8FG-17624-40
16.5 (0.65)
VESPEL TP-8549
(14.6 mm)
[KJ
Machined
~r
[M] 90386-09001
(14.6 mm)
13
Decreased force
INSP ADJ
FRONT SUSPENSION/REAR SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: • Spring preload
®
Adjustment steps: • Turn the spring seat CD in or out. Spring seat distance
Standard Shorter
Preload
Harder +--
+--
--+
--+
Min. Length@
248mm
(9.76 in)
Longer Softer Max.
258mm
258mm
(10.16 in) (10.16 in)
Be sure that the left and right spring preloads are the same.
~ ---------This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could cause it to explode.
REAR SUSPENSION Stopper band 1. Adjust: • Stopper band tension
Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. NOTE: - - - - - - - - - - - - - This adjustment affects the handling characteristics of the machine.
14
INSP ADJ
REAR SUSPENSION
Adjustment steps: -Loosen the locknut CD. - Turn the adjusting nut ® in or out to adjust the stopper band tension. Adjuster thread length ®
15 ± 0.5 mm (0.59 ± 0.02 in) Maximum: 35 mm (1.37 in) Minimum: 10 mm (0.40 in)
Effects
Longer More weight on skis; Less weight transfer Shorter Less weight on skis; More weight transfer
- Tighten the locknut.
Locknut: 16 Nm (1.6 m-kg, 12 ft-Ib)
Rear suspension damping force adjustment The damping force can be adjusted by turning the adjuster CD. 16 clicks out
,--1
Adjuster position
7 clicks out
I
1 click out
I
Minimum
I
Standard
Turns out
+--
-+
Maximum
Turns in
@* Damping force
Soft
+--
® -+
Hard
* With the adjuster fully turned lightly in direction
® - Do not continue to turn the adjuster in direction ® after it stops. The shock absorber can be damaged and damping force adjustments cannot be made. - Do not turn the adjuster in direction @ more than 16 clicks. Even if the adjuster is continually turned after 16 clicks, there will be no change in the damping force. - Be sure to stop the adjuster at a position where there is a click.
15
INSP ADJ
REAR SUSPENSION Control rod 1. Check e Control rod bolt ®
~-~-=:=:~-~ --- ----------:::----~--
-~,
'\,
Bolt (control rod bolt): 32 Nm (3.2 mekg, 23 ftelb)
\ \ ,/
/
,/' --------",.//
2. Adjust: e Control rod stroke ®
Make sure the adjusting bolt ends are set at the same position on each side.
Adjustment steps: e Loosen the lock nut CD. e Turn the adjusting nut ® in or out to adjust the control rod stroke. Adjusting position
1
3
2
Increase +weight transfer
Effect Standard
4
-.+Decrease pitching
3
~ ---------Never adjust the control rods beyond the maximum range indicated on the rods with red paint@. e
While holding the adjusting bolt securely, tighten the locknut CD.
Locknut: 25 Nm (2.5 mekg, 18 ftelb)
16
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~
CHASSIS STEERING INSTALLATION 1. Install: - Relay arms CD - Bushings -Washers® ,
~~
Bolt (relay arm): 67 Nm (6.7 mekg, 49 ftelb)
-Clips@ 2. Install: -Idler arm @ - Bushings -Washers -Relay rod@ Nut (idler arm): 35 Nm (3.5 m-kg, 25 ft-Ib) Nut (relay rod): 30 Nm (3.0 m-kg, 22 ft-Ib) 3. Install: -Tie rod CD - Locknuts ® -Joints @
®
II--@--" @
~a
~
[A] Tie rod part number 8FA-23830-00
Set length@
[Q] Tie rod length @
418.0 mm (16.4567 in)
355.0 mm (13.9764 in)
[6]
4. Check: - Tie rod angle @
1~~T_ie_:_~_~_a_n_g_le_:
A
®
~
'
~"
_
-----~--
After tightening the inside and outside ball joint locknut®, make sure the tie rod CD can be rotated freely through the ball joint travel. If not, loosen the locknut ® and re-position the ball joint so that the tie rod CD can br rotated freely. Tighten the locknut to specification.
17
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~
I
5. Install: -Tie rods CD
NOTE: - - - - - - - - - - - - - Make sure that the indentation @ on the tie rod faces out. - The threads on both rod ends must be the same length.
Always use new cotter pins. Locknut (rod end): 25 Nm (2.5 m-kg, 18 ft-Ib) LOCTITEÂŽ Nut (tie rod-idler arm): 30 Nm (3.0 m-kg, 22 ft-Ib) Nut (tie rod-steering arm): 35 Nm (3.5 m-kg, 25 ft-Ib) 6. Install: - Steering shaft CD - Locknuts ÂŽ -Joints @
[A] Steering shaft part number 8FA-23840-00
[aJ Set length @ 227.8 mm (8.9685 in)
[Q] Shaft length @ 170.0 mm (6.6929 in)
NOTE: - - - - - - - - - - - - Make sure that the end of the steering shaft (white plating side CD) is connected to the steering column.
~
Always use new cotter pins.
o
Nut (steering shaft): 35 Nm (3.5 m-kg, 25 ft-Ib)
18
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~
7. Adjust: - Handlebar
Adjustment steps: - Temporarily install the handlebar. -Install the steering linkage alignment plate
@. . ..
Steering linkage alignment plate 90890-01487, YS-01487
- Loosen the locknuts (steering shaft) CD. - Turn the steering shaft ® clockwise or counterclockwise and then secure the handle bar in the straight position.
Turning the steering shaft in direction @
Turning the handlebar in direction ©
Turning the steering shaft in direction @
Turning the handlebar in direction @
- Tighten the locknuts (steering shaft) CD.
'fi'J
~~
Locknut (steering shaft): 25 Nm (2.5 mekg, 18 ftelb) LOCTITE®
- Remove the steering linkage alignment plate
@. 8. Install: -Toe-out - Refer to "STEERING SYSTEM" in CHAPTER2.
19
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~
I
9. Install: - Handlebar
- Be sure the projection on the handlebar is not installed into the area ® shown. - Be sure the side of the holder with the small gap @ faces forward. @ 0 mm (0 in) - First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side. - Center the match mark © on the handlebar CD between the lower handlebar holders®.
=
SGH3150
a ~
b
(@t~j f~t
Bolt (handlebar holder): 15 Nm (1.5 m-kg, 11 ft-Ib)
a < b
(FWDI SCH3160
2 SCH3170
20
FRONT SUSPENSION
ICHAS
I.J-.I
FRONT SUSPENSION
IAl : I
45 Nm (4.5 m-kg, 33 tt-Ib)
========== [BJ : I 37 Nm (3.7 m-kg, 27 tt-Ib) ========== [Q] : I 40 Nm (4.0 m-kg, 29 tt-Ib) ========== [Q] : I 35 Nm (3.5 m-kg, 25 tt-Ib) ========== [EJ : I 65 Nm (6.5 m-kg, 47 tt-Ib) ========== [E] : I 34 Nm (3.4 m-kg, 25 tt-Ib) ========== [GJ : 1_ _11_Nrn_{1_._1_rn_.k......g_,8_.0_ft._lb_}_
10
~
: CD ESSO beacon 325 grease or Aeroshell grease #7A
Order
1 2
3 4 5
6 7 8 9 10 11
Q'ty
Job name/Part name
Remarks Remove the parts in the order listed below. Refer to "SKI".
Front suspension removal Ski Front cover Shock absorber Cap Steering arm Ski column Bushing Upper arm Lower arm Bushing Connecting rod Stabilizer arm
1 1 1 1 1 1 1 1
4 1 1
21
FRONT SUSPENSION
ESSO beacon 325 grease ~ : orCDAeros hell grease #7 A
. n , reverse the removal For installatlo procedure.
22
pOTWRRI~1 I ------------------------POWER TRAIN ~
SECONDARVSHAFT
SECONDARYSHAFT
mil 3 5 2
4
Order
1
2 3 4 5
Q'ty
Job name/Part name
Secondary shaft removal Secondary sheave Drive chain housing Collar nut Collar Circlip Secondary shaft Bearing
Remarks Remove the parts in the order listed below. Refer to "SECONDARY SHEAVE". Refer to "DRIVE CHAIN HOUSING".
1 1 1 1 1
For installation, reverse the removal procedure.
23
pOTWRRI~1 I --------------------------SECONDARVSHAFT
~
REMOVAL 1. Remove: • Drive chain housing parts Refer to "DRIVE CHAIN HOUSING WITH REVERSE MODEL" in CHAPTER 4 • Secondary sheave assembly Refer to "SECONDARY SHEAVE" in CHAPTER4
2. Install: • Secondary shaft slide & holder ®
[A] Outside [B] Inside
A
NOTE: - - - - - - - - - - - - • Do not use the collar @.
Contact the secondary shaft slide & holder only with the inner race of the bearing. . '.
Secondar yshaft Slide & Holder
90890-01492, YU-01492 3. Remove: • Bearing collar nut CD NOTE: - - - - - - - - - - - - Remove the bearing collar nut by ring nut wrench@.
Ring nut wrench
90890-01268,YU-01268
4. Install: • Secondary sheave mounting bolt washer.
CD
and
NOTE: - - - - - - - - - - - - Use the secondary sheave mounting bolt CD and washer. 5. Tighten: • Secondary sheave bolt CD 6. Remove • Secondary shaft 24
pOTWRRI~1 I --------------------------SECONDARVSHAFT
~
INSPECTION 1. Inspect: • Secondary shaft CD Scratches (excessive)/damage -+ Replace. ·Splines® Wear/damage -+ Replace the secondary shaft. • Bearing contact surface @ Scratches/wear/damage -+ Replace the secondary shaft.
2 3
SCH4540
2. Inspect: • Bearing CD Pitting/damage -+ Replace. NOTE: - - - - - - - - - - - - - When install the bearing CD, larger side of the inner race ® is outside of the frame.
3. Inspect: • Bearing collar nut CD Cracks/damage -+ Replace. ·Collar® Cracks/damage -+ Replace.
4. Measure: • Brake disc thickness ® Out of specification -+ Replace.
Minimum thickness: 5.0 mm (0.20 in) Measuring point: 1 --- 3 mm (0.04 --- 0.12 in) from the edge of the brake disc.
25
pOTWRRI~1 I -------------------------SECONDARVSHAFT
~
INSTALLATION 1. Install - Drive chain housing parts Refer to "DRIVE CHAIN HOUSING WITH REVERSE MODEL" in CHAPTER 4. 2. Install: - Bearing collar nut CD - Secondary shaft ®
[A] Engine side [B] Secondary clutch side 3. Install: - Drive gear socket ® Drive gear socket 90890-01490, YU-01490
4. Tighten: - Drive gear nut ® Drive gear nut 90 N-m (9.0 m-kg, 65 ft-Ib)
5. Install: -Collar@ 6. Install: - Secondary shaft slide & holder @
[A] Outside [B] Inside NOTE: - - - - - - - - - - - - - Use the collar @.
- Contact the secondary shaft slide & holder only with the inner race of the bearing. A
Secondary shaft Slide & Holder 90890-01492, YS-01492
26
pOTWRRI~1 I --------------------------SECONDARVSHAFT
~
7. Install: - Secondary sheave mounting bolt (l)
NOTE: - - - - - - - - - - - - - Use the secondary sheave mounting bolt (l) and washer which tighten the secondary clutch. 8. Tighten: - Secondary sheave mounting bolt (l)
'.#7
~~
Secondary sheave mounting bolt 30 N-m (3.0 m-kg, 22 ft-Ib)
9. Remove: - Secondary shaft & slide & holder CD - Secondary sheave mounting bolt ÂŽ
10. Install: - Secondary sheave mounting bolt CD 11. Tighten: - Bearing collar nut
Ring nut wrench 90890-01268, YU-01268 Bearing collar nut 55Nm (5.5m-kg, 40ft-lb) LOCTITEÂŽ NOTE: - - - - - - - - - - - - Install the ring nut wrench and then tighten the secondary sheave mounting bolt CD. 12. Check: - Secondary shaft stiffness
When the secondary shaft is operated in periodic motion, and if its movement is heavy, install it again correctly.
27
_______________BR_A_K_E_lp~:Rlo=Dl BRAKE
I [BJ : I ~ :I [Q] : I [AJ :
Order
1
2 3 4 5
6 7
Q'ty
Job name/Part name
30 Nm (3.0 m-kg, 22 ft-Ib) 48 Nm (4.8 m-kg, 35 ft-Ib) 13 Nm (1.3 m-kg, 9.4ft-lb) 16 Nm (1.6 m-kg, 12 ft-Ib)
Remarks Remove the parts in the order listed below.
Brake caliper and parking brake removal Brake fluid Brake hose Brake caliper assembly Parking brake cable Spring Lever Parking brake assembly Collar
Drain. 1 1 1 1 1 1 1
For installation, reverse the removal procedure.
28
pOTWRRI~1 I ------------------------SLIDE RAIL SUSPENSION
~
SLIDE RAIL SUSPENSION
I.8J : I
Order
72 Nm (7.2 m-kg, 52 tt-Ib)
Q'ty
Job name/Part name
Slide rail suspension removal Rear axle nut Tension adjuster Left side cover 1
Remarks Remove the parts in the order listed below. Loosen. Loosen. Refer to "PRIMARY SHEAVE AND DRIVE VELT".
Slide rail suspension
1
For installation, reverse the removal procedure.
29
pOTWRRI~1 I ------------------------SLIDE RAIL SUSPENSION
I ~ :I
[AJ :
4 Nm (0.4 mekg, 2.9 ftelb) 16 Nm (1.6 mekg, 12 ftelb)
I [Q] : I [EJ : I [E] : I ~ :I [Q] :
~
24 Nm (2.4 mekg, 17 ftelb) 30 Nm (3.0 mekg, 22 ftelb)
49 Nm (4.9 m.kg, 35 tt.lb) 72 Nm (7.2 mekg, 52 ftelb) 48 Nm (4.8 mekg, 35 ftelb)
I I I I I
'----l : CD
ESSO beacon 325 grease or Aeroshell grease #7A
Order
CD
速
@ @ @ @ (j) @
速 速
@ @ @ @ @
速
@ @
Job name/Part name
Q'ty
Remarks Remove the parts in the order listed below.
Slide rail suspension disassembly Stopper band Hook Bushing Bushing Front shock absorber Bracket Front suspension bracket Shaft Rubber damper Front pivot arm Bushing Shaft Bushing Collar Suspension wheel Collar Wheel bracket Front pivot arm bracket
2 2
4 2 1 2 1 1 2 1 2 1
4 2 2 2 2 2
30
pOTWRRI~1 I --------------------------SLIDE RAIL SUSPENSION
I [BJ : I [Q] : I [AJ :
~
24 Nm (2.4 m.kg, 17 tt.lb)
49 Nm (4.9 m.kg, 35 tt.lb) 72 Nm (7.2 m.kg, 52 tt.lb)
I I I
6
'----l : CD
ESSO beacon 325 grease or Aeroshell grease #7A
Order
@ @ @ @ @ @ @ @ @ @ @
ÂŽ
Job name/Part name
Q'ty
Suspension wheel Collar Wheel bracket Circlip Suspension wheel Collar Bushing Shaft Rear suspension bracket Spacer Collar Bushing
Remarks
2 2 2 2 2 2 2 1 1 2 1 2
[ill This model has a "Easy adjust" system for the full rate adjuster. The bolt has teeth on it. So when the bolt is turned, it rides up and down the bracket. NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - The nut has to be loosened first, while the bolt is held in place with a wrench. - Then the bolt can be turned to adjust the shock position up or down. -If the bolt is turned with the nut tight, it is possible to strip the teeth off the bolt.
31
pOTWRRI~1 I ------------------------SLIDE RAIL SUSPENSION
I [BJ : I [AJ :
---t :
Order
®
@ @ @
® ® ®
@) @
® ®
49 Nm (4.9 m-kg, 35 ft-Ib) 72 Nm (7.2 m-kg, 52 ft-Ib)
CD
ESSO beacon 325 grease or Aeroshell grease #7A
Job name/Part name
Q'ty
Rear shock absorber Collar Bushing Pull rod Collar Bushing Collar Suspension wheel Control rod Bushing Bushing
1 1 2 2
4 4 2 2 2 2 2
32
Remarks
~
pOTWRRI~1 I ------------------------~
SLIDE RAIL SUSPENSION
""-"l
24 Nm (2.4 m-kg, 17 tt-Ib) 72 Nm (7.2 m-kg, 52 tt-Ib) 75 Nm (7.5 m-kg, 54 tt-Ib)
5
49
....... : CD ESSO beacon 325 grease or Aeroshell grease #7A
Order
@ @ @
® ® ® ®
@ @
®
@) @ @
®
@
®
@
Job name/Part name
Q'ty
Rear pivot arm Bushing Shaft Shaft Rear pivot arm bracket Shaft Circlip Suspension wheel Wheel bracket shaft Rear axle Guide wheel Collar Tension adjuster Collar Collar Guide wheel Sliding frame
Remarks
1 2 1 1 1 1 2 2 1 1 2 2 2 1 1 1 2
For assembly, reverse the disassembly procedure.
33
I I I
SLIDE RAIL SUSPENSION
---------------------------
Ip~:Rlo=Dl
INSTALLATION Control rod parts number
® ©
[AJ Control rod 1
~ Length
® mm (in)
RXW10J, RXW10SJ
303.5(11 .95)
[:EJ Control rod 1
[E] Control rod 2
parts number
parts number
8FG-4745A-00
8CR-4745B-00
[Q Length @ mm (in) 160.0(6.30)
[Q] Length © mm (in) 2.5P x 3 (0.098P x 3
= 7.5 = 0.295)
[G] Washer plate parts number [8] Washer plate thickness mm (in) [] Upper [JJ Lower 90202-16229 2.5 (0.098)
34
90202-16232 10.0 (0.394)
ENGINE ASSEMBLY
I ENG II
ENGINE ENGINE ASSEMBLY INSTALLATION NOTE: - - - - - - - - - - - - After installing all parts, refer to "CABLE ROUT1NG" in CHAPTER 9, to check the cable, lead and hose routing.
1. Install: - Engine mounting adjust bolts - Engine - Engine mounting bolts and nuts NOTE: - - - - - - - - - - - - - Use the pivot shaft wrench to tighten the engine mounting adjust bolts.
Installation steps: -Install the special tool CD . ..
Engine mount spacer wrench
90890-01489,YS-01489 - Tighten the rear engine mounting adjust bolt.
'.#7
~~
Bolt (engine mounting adjust): 7 Nm (0.7 mekg, 5.1 ftelb)
- Tighten the rear engine mounting nut.
'.#7
~
Nut (engine mounting): 65 Nm (6.5 mekg, 47 ftelb)
- Tighten the front right and left engine mounting adjust bolts until they come to cantact with the engine damper. At this time, do not apply torque to the engine mounting adjust bolts. - Tighten the front right and left engine mounting nuts.
Nut (engine mounting): 65 Nm (6.5 m-kg, 47 ft-Ib)
35
ENGINE ASSEMBLY
I ENG II
2. Fill: • Coolant Refer to "COOLING SYSTEM" in CHAPTER 2. 3. Fill: • Engine oil Refer to "ENGINE OIL REPLACEMENT" in CHAPTER 2.
36
CARBURETORS
ICARS II:j1 I
CARBURETORS
4
Order
CD ® ®
@
® ®
(j)
® ® 19 @ @
Q'ty
Job name/Part name
Carburetor separation Carburetor heater harness Carburetor heating hose Starter plunger link Connecting bolt Spacer Fuel inlet pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Carburetor Band
Remarks Remove the parts in the order listed below.
1
3 1 2
3 2 1 2 2 1
4 2
For installation, reverse the removal procedure.
37
CARBURETORS
ICARS ~ I I
3
Order
Q'ty
Job name/Part name
Carburetor disassembly
CD ® ®
@ @
®
(J)
® ® ®
Starter plunger Pilot air jet Vacuum chamber cover Piston valve spring Piston valve Jet needle holder Jet needle kit Pilot screw Fuel drain bolt Float pin
1 1 1 1 1 1 1 1 1 1
38
Remarks Disassemble the parts in the order listed below. NOTE: The following procedure applies to all of the carburetors.
CARBURETORS
ICARS II:j1 I
3
Order
@ @ @ ~
® ®
@ @ @
®
Q'ty
Job name/Part name Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet Carburetor switch (T.O.R.S.) Carburetor heater Starter jet
Remarks
1 1 1 1 1 1 1 1 1 1
For assembly, reverse the disassembly procedure.
39
GENERAL SPECIFICATIONS
I
SPEC
I
g--I
SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number:
RXW10J, RXW10SJ 8FG1 8FH1 8FG2 8FH2
(for U.S.A./Canada) (for U.S.A./Canada) (for Europe) (for Europe)
Dimensions: Overall length Overall width Overall height
3,000 mm (118.1 in) 1,210 mm (47.6 in) 1,190 mm (46.9 in)
Weight: Dry weight
264 kg (581 Ib)
Minimum turning radius: Clockwise Counterclockwise
4.1 m (13.5 ft) 4.1 m (13.5 ft)
Engine: Engine type Cylinder type Displacement Bore x stroke Compression ratio Maximum hose power r/min Maximum torque r/min Standard compression pressure (at sea level) Starting system Lubrication system: Engine oil: Type Oil capacity Periodic oil change With oil filter replacement Total amount
Liquid-cooled, 4-stroke, DOHC Backward-inclined parallel 4-cylinder 998 cm 3 (60.9 cu.in) 74 X 58 mm (2.91 X 2.28 in) 11.8 10,250 r/min 7,500 r/min 1,450 kPa (14.5 kg/cm 2 , 206 psi) at 400 r/min Electric starter Dry sump API SE, SF, SG or highter SAE5W-30 2.8 L (2.5 Imp qt, 3.0 US qt) 3.0 L (2.6 Imp qt, 3.2 US qt) 3.8 L (3.3 Imp qt, 4.0 US qt)
Oil filter: Oil filter type
Cartridge (paper)
Drive chain housing oil: Type Capacity
Gear oil API "GL-3" SAE#75 or #80 0.25 L (8.8 Imp OZ, 8.5 US oz)
Coolant: Capacity
4.7 L (4.14 Imp qt, 4.97 US qt)
Fuel: Type
Tank capacity
Regular unleaded gasoline (Pump Octane R+M ; 88 or higher) 2 Research Octane; 93 or higher (for Europe) 38 L (8.4 Imp gal, 10.0 US gal)
40
GENERAL SPECIFICATIONS Model
I
SPEC I
RXW10J, RXW10SJ
Carburetors: Type/ Quantity Manufacture
BSR37 x 4 MIKUNI
Spark plug: Type Manufacture Gap
CR9E NGK 0.7 -... 0.8 mm (0.028 -... 0.031 in)
Primary reduction: Primary reduction system Primary reduction ratio
Spur gear 1.19 (37/31)
Transm ission : Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio Reverse system
V-Belt 3.8 : 1 -... 1 : 1 Automatic centrifugal engagement Chain 1.65 (38/23) Yes
Chassis: Frame type Caster Ski stance (center to center)
Monocoque 23° 1,068 mm (42.0 in)
Suspension: Front suspension type Rear suspension type
Independent double wishbone suspension Slide rail suspension
Track: Track type Track width Length on ground Track deflection mm/ 100 N (10 kg, 221b)
Internal drive type 381 mm (15.0 in) 944 mm (37.2 in) 25 -... 30 mm (0.98 -... 1.18 in)
Brake: Brake type Operation method
Caliper type disc brake handlebar, left hand operated
Electrical: Ignition system Generator system
DC-CDI/MITSUBISHI A.C. magneto
Bulb wattage x Quantity: Headlight Tail/Brake light Meter light High beam indicator light Information indicator light Low coolant temperature indicator light
12 V, 12 V, 14 V, 14 V, 14 V, 14 V,
60 W /55 W x 2 5 W /21 W x 2 50 rnA x 6 80 rnA 80 rnA 80 rnA
41
g--I
MAINTENANCE SPECIFICATIONS
I
SPEC
MAINTENANCE SPECIFICATIONS ENGINE Model Cylinder head: Volume (with spark plug) <Warpage limit>
RXW10J, RXW10SJ 13.45 --- 14.00 cm 3 (0.82 --- 0.85 cu. in) 0.1 mm (0.004 in)
* Lines indicate straight edge measurement.
Cylinder: Material Bore size <Taper limit> <Out of round> <Wear limit> Camshaft: Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance
Aluminum alloy with dispersion coating 74.000 --- 74.010 mm (2.9134 --- 2.9138 in) 0.05 mm (0.002 in) 0.05 mm (0.002 in) 74.06 mm (2.9157 in) Chain drive (left) 24.500 --- 24.521 mm (0.9646 --- 0.9654 in) 24.459 --- 24.472 mm (0.9630 --- 0.9635 in) 0.028 --- 0.062 mm (0.0011 --- 0.0024 in)
Camshaft dimensions Intake "A" <Limit> "B" <Limit> Exhaust "A" <Limit> "B" f----B<Limit>
32.50 32.40 24.95 24.85 32.95 32.85 24.95 24.85
Camshaft runout
0.03 mm (0.0012 in)
--- 32.60 mm (1.2795 mm (1.2756 in) --- 25.05 mm (0.9823 mm (0.9783 in) --- 33.05 mm (1.2972 mm (1.2933 in) --- 25.05 mm (0.9823 mm (0.9783 in)
--- 1.2835 in) --- 0.9862 in) --- 1.3012 in) --- 0.9862 in)
Timing chain: Model/number of links Tensioning system
RH2015/130 Automatic
Valves, valve seats, valve guides: Valve clearance (cold) Intake Exhaust
0.11 --- 0.20 mm (0.0043 --- 0.0079 in) 0.21 --- 0.30 mm (0.0083 --- 0.0118 in)
42
I
g--I
MAINTENANCE SPECIFICATIONS Model
I
SPEC I
RXW10J, RXW10SJ
Valve dimensions: Valve head diameter A Intake Exhaust
6 f=== A ==:j
22.9 --- 23.1 mm (0.9016 --- 0.9094 in) 24.4 --- 24.6 mm (0.9606 --- 0.9685 in)
Head Diameter
Valve face width B Intake Exhaust
1.76 --- 2.90 mm (0.0693 --- 0.1142 in) 1.76 --- 2.90 mm (0.0693 --- 0.1142 in) Face Width
Valve seat width C Intake Exhaust Seat Width
Valve margin thickness D Intake Exhaust
0.9 --- 1.1 mm (0.035 --- 0.043 in) 0.9 --- 1.1 mm (0.035 --- 0.043 in)
I
I ~=rD
! \
0.5 --- 0.9 mm (0.020 --- 0.035 in) 0.5 --- 0.9 mm (0.020 --- 0.035 in)
Margin Thickness
Valve stem diameter Intake <Limit> Exhaust <Limit> Valve guide inside diameter Intake <Limit> Exhaust <Limit> Valve-stem-to-valve-guide clearance Intake <Limit> Exhaust <Limit> Valve stem runout limit
3.975 --- 3.900 mm (0.1565 --- 0.1535 in) 3.945 mm (0.1553 in) 4.460 --- 4.475 mm (0.1756 --- 0.1762 in) 4.43 mm (0.1744 in) 4.000 --- 4.012 mm (0.1575 --- 0.1580 in) 4.05 mm (0.1594 in) 4.500 --- 4.512 mm (0.1772 --- 0.1776 in) 4.55 mm (0.1791 in)
0.010 --- 0.037 mm(0.0004 --- 0.0015 in) 0.08 mm (0.0031 in) 0.025 --- 0.052 mm (0.0010 --- 0.0020 in) 0.10 mm (0.0039 in) 0.01 mm (0.0004 in)
~
~- Jlrr~
/////////////////////
Valve seal width Intake Exhaust
0.9 --- 1.1 mm (0.035 --- 0.043 in) 0.9 --- 1.1 mm (0.035 --- 0.043 in)
43
g--I
MAINTENANCE SPECIFICATIONS Model
I
SPEC
RXW10J, RXW10SJ
Valve spring: Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust
d"
Spring tilt Intake Exhaust Winding direction (top view) Intake Exhaust
38.90 mm (1.53 in) 40.67 mm (1.60 in) 34.50 mm (1.36 in) 35.00 mm (1.38 in)
82 ~ 96 N (8.2 ~ 9.6 kg, 18.1 ~ 21.2 Ib) 11 0 ~ 126 N (11.0 ~ 12.6 kg, 24.3 ~ 27.8 Ib) * /j
2.5 0 /1.7 mm (0.067 in) 2.5 0 /1.8 mm (0.071 in) Clockwise Clockwise
Valve lifter: Valve lifter outside diameter Intake <Limit> Exhaust <Limit> Valve lifter hole inside diameter Intake <Limit> Exhaust <Limit>
19.982 ~ 19.988 mm (0.7867 19.957 mm (0.7857 in) 19.488 ~ 22.482 mm (0.7672 19.463 mm (0.7663 in)
~
0.7869 in)
~
0.8851 in)
20.000 ~ 20.018 mm (0.7874 20.048 mm (0.7893 in) 22.500 ~ 22.518 mm (0.8853 22.548 mm (0.8877 in)
~
0.7881 in)
~
0.8865 in)
Piston: Piston size (0) ---D-- --------L Measuring point (H) I H Piston to-cylinder clearance <Limit> Piston pin bore off set Off-set direction Piston pin bore inside diameter
73.955 ~ 73.970 mm (2.9116 ~ 2.9122 in) 5 mm (0.20 in) 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.12 mm (0.0047 in) 0.5 mm (0.0197 in) Intake side 17.002 ~ 17.013 mm (0.6694 ~ 0.6698 in)
m
44
I
g--I
I
SPEC I
MAINTENANCE SPECIFICATIONS Model Piston pin: Piston pin outside diameter Piston pin length Piston pin to piston pin bore clearance <Limit> Piston ring: Sectional sketch Top ring Ring type ~~B IT Dimensions (B x T) 2nd ring Ring type I T I Dimensions (B x T) Oil ring
r
c==s=rB
~=rB ~I
Dimensions (B x T) End gap (installed) Top ring 2nd ring Oil ring Side clearance (installed) Top ring 2nd ring Connecting rod: Crankshaft-pin-to-big-end-bearing clearance Bearing color code
g--I
RXW10J, RXW10SJ 16.991 --- 17.000 mm (0.6689 --- 0.6693 in) 51.4 --- 51.5 mm (2.0236 --- 2.0276 in) 0.002 --- 0.022 mm (0.00008 --- 0.0009 in) 0.072 mm (0.0028 in)
Barrel 0.90 x 2.75 mm (0.035 x 0.108 in) Taper 0.8 x 2.8 mm (0.031 x 0.110 in)
1.5 x 2.6 mm (0.059 x 0.101 in) 0.32 --- 0.44 mm (0.010 --- 0.020 in) 0.43 --- 0.58 mm (0.017 --- 0.023 in) 0.10 --- 0.35 mm (0.004 --- 0.0014 in) 0.030 --- 0.065 mm (0.0012 --- 0.0026 in) 0.020 --- 0.055 mm (0.0008 --- 0.0022 in) 0.016 --- 0.040 mm (0.0006 --- 0.0016 in) -1
= Violet
0
= White
1 = Blue 2
= Black
3
= Brown
Crankshaft:
Width A Width B Crankshaft runout C Big end side clearance D Crankshaft-journal-to-crankshaftjournal-bearing clearance Bearing color code
52.40 --- 57.25 mm (2.063 --- 2.254 in) 300.75 --- 302.65 mm (11.84 --- 11.92 in) 0.03 mm (0.0012 in) 0.160 --- 0.262 mm (0.006 --- 0.010 in) 0.004 --- 0.028 mm (0.0002 --- 0.0011 in) -1
= Violet
45
0
= White 1 = Blue
2
= Black 3 = Brown
MAINTENANCE SPECIFICATIONS Model Carburetor: Typel Quantity Manufacturer 1.0. mark (M.J) Main jet Main air jet (M.A.J) Jet needle (J.N) Needle jet (N.J) (P.J) Pilot jet Pilot air jet (P.A.J.1 ) Pilot outlet (P.O) (B.P.1 ) Bypass 1 (B.P.2) Bypass 2 Bypass 3 (B.P.3) (P.S) Pilot screw Throttle valve (Th.V) (V.S) Valve seat size Starter jet (G.S) Float height (F.H) Fuel level (below the line on the float chamber) Engine idle speed Fuel pump: Type Manufacturer Oil filter: Oil filter type Bypass valve opening pressure Oil pump: Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Max. impeller shaft tilt <Limit> Relief valve operating pressure Oil pressure (hot) Cooling system: Filler cap opening pressure Water pump type Reduction ratio Coolant type Coolant mixing ratio (coolant: water) Capacity
I
SPEC
I
g--I
RXW10J, RXW10SJ BSR37/4 MIKUNI 8FA101 #135 #120 5DHP50-53-3 P4M #17.5 #140 1.0 0.8 0.8 0.8 Approx 2 #115 1.5 #75 11 --- 15 mm (0.43 --- 0.59 in) 3.0 --- 4.0 mm (1.118 --- 0.157 in) 1,350
Âą 100 r/min (1,250 --- 1,450 r/min)
Diaphragm 8FA (MIKUNI) Cartridge (paper) 78 --- 118 kPa (0.78 --- 1.18 kg/cm 2 , 11.1 --- 16.8 psi) Trochoidal 0.09 --- 0.15 mm (0.004 --- 0.006 in) 0.03 --- 0.08 mm (0.001 --- 0.003 in) 0.15 mm (0.0059 in) 0.072 mm (0.0028 in) 430 --- 550 kPa (4.3 --- 5.5 kg/cm 2 , 61.2 --- 78.2 psi) 50 kPa (0.5 kg/cm 2 , 7.1 psi) at 1,450 r/min 95 --- 125kPa(O.95 --- 1.25kg/cm2 , 14 --- 18 psi) Single-suction centrifugal pump (Impeller type) 37/31 x 23/18(1.525) High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors 3 : 2 (60% : 40%) 4.7 L (4.14 Imp qt, 4.97 US qt)
46
MAINTENANCE SPECIFICATIONS
I
SPEC I
POWER TRAIN RXW10J, RXW10SJ
Model Transmission: Type Range of ratio Engagement speed Shift Sheave distance
V-belt automatic 3.8 --- 1.0 : 1 3,600 ± 200 r/min (3,400 --- 3,800 r/min) 10,250 ± 250 r/min (10,000 --- 10,500 r/min) 268.5 ± 1.5 mm (10.57 ± 5.91 in) (267 --- 270 mm (10.51 --- 10.63 in)) 15 ± 1.5 mm (0.59 ± 5.91 in) (13.5 --- 16.5 mm (0.53 --- 0.65 in))
r/min r/min
Sheave offset V-belt: Part number/Manufacturer Circumference A Width "A" I~I Wear limit "B"
0 .
8DN-17641-00/MITSUBOSHI 1,129 --- 1,137 mm (44.4 --- 44.8 in) 34.5 mm (1.36 in) 32.5 mm (1.28 in)
.
Primary sheave spring: Part number Color code Diameter Wire diameter Preload Spring rate Number of coils Free length Set length
90501-582L1 Yellow - Silver - Yellow 60 mm (2.36 in) 5.8 mm (0.228 in) 343 N (35 kg, 77 Ib) 24.5 N/mm (2.50 kg/mm, 140 Ib/in) 4.92 87.4 mm (3.44 in) 73.4 mm (2.89 in)
Primary sheave weight arm: Part number (with bush) Weight (without bush and rivets)
8FA-17605-10 63.8 g (2.25 oz)
Rivet: Outer Part number Material Size Quantity Hole quantity Inner Part number Material Size Quantity Hole quantity
90269-06006 Steel 17.2 mm (0.677 in) with-hole 3 3 90261 -06033 Steel 17.2 mm (0.677 in) with-hole 3 3
47
g--I
MAINTENANCE SPECIFICATIONS Model
I
SPEC
I
RXW10J, RXW10SJ
Secondary sheave spring: Part number Color code Outside diameter Wire diameter Hole position Sheave side-spring side (twist angle)
90508-60007 White 69.5 mm (2.736 in) 6 mm (0.236 in) 3-3 (60°)
\0
Spring rate Number of coils Free length Torque cam angle
13.45 N/mm (1.372 kg/mm, 76.84 Ib/in) 5.19 75 mm (2.95 in) 51-43°
Drive chain: Type Number of links Secondary reduction ratio
Borg Warner Automotive 23RH303-70ASM 70L 38/23 (1.65)
Track: Part number Width Length Pitch Number of links Thickness "A" Height "B"
8FG-47110-00 381 mm (15.0 in) 3,456 mm (136.1 in) 64 mm (2.52 in) 54 5.1 mm (0.20 in) 36.9 mm (1.45 in)
Track deflection at 100 N (10 kg, 221b) Slide rail suspension (Rear suspension): Center travel Rear travel Suspension spring rate Center Rear Suspension wire diameter Center Rear
25 --- 30 mm (0.98 --- 1.18 in)
221 mm (8.70 in) 298 mm (11.73 in) 28 - 50 N/mm (2.8 - 5.0 kg/mm, 157 - 280 Ib/in) 23 - 42 N/mm (2.3 - 4.3 kg/mm, 131 - 240 Ib/in) 8.8 mm (0.346 in) 10.6 mm (0.417 in)
48
g--I
MAINTENANCE SPECIFICATIONS Model Suspension setting position: Hook setting length * (Standard)
(Maximum) (Minimum) Full rate adjusting position **
I
SPEC I
g--I
RXW10J, RXW10SJ 15 Âą 0.5 mm (0.59
Âą 0.02 in)
35 mm (1.37 in) 10 mm (0.40 in) B
AB~** C
Shock absorber: Damping force Center Extension Compression Rear Extension Compression
2,050 N/O.3 m/s (209 kg/0.3 mis, 461 Ib/0.3 m/s) 1,350 N/O.3 m/s (138 kg/0.3 mis, 303 Ib/0.3 m/s)
Slide runner: Thickness Wear limit
17.8 mm (0.70 in) 10 mm (0.4 in)
Track sprocket wheel: Material Number of teeth
High molecular weight polyethylene 9T
Rear guide wheel: Material Outside diameter
High molecular weight polyethylene with rubber 178 mm (7.01 in)
Brake: Pad thickness Pad wear limit Pad to disk clearance Disc outside diameter Disc minimum thickness
13 mm (0.51 in) 7.5 mm (0.30 in) 0.025 --- 0.115 mm (0.001 --- 0.005 in) 220 mm (8.66 in) 5.0 mm (0.20 in)
910 N/O.3 m/s (93 kg/0.3 mis, 204 Ib/0.3 m/s) 1,800 N/O.3 m/s (183 kg/0.3 mis, 404 Ib/0.3 m/s)
49
MAINTENANCE SPECIFICATIONS
I
SPEC
I
g--I
CHASSIS Model
RXW10J, RXW10SJ
Frame: Frame material Seat height Luggage box location
Aluminum 680 mm (26.8 in) Front
Steering: Lock-to-Iock angle (left) (right) Ski alignment Toe-out size Caster angle
30.0° (R ski) 34.7° (L ski) 34.7° (R ski) 30.0° (L ski) Toe-out o '""-' 15 mm (0 '""-' 0.59 in) 23°
Ski: Ski material Length Width
Plastic 1,020 mm (40.2 in) 132.0 mm (5.20 in)
Ski suspension (Front suspension): Type Travel Spring type Spring rate Wire diameter
Double wishbone system 221 mm (8.70 in) Coil spring 21 N/mm (2.1 kg/mm, 118lb/in) 8.2 mm (0.323 in)
Shock absorber: damping force Extension Compression
1,300 N/O.3 m/s (133 kg/0.3 mis, 292 Ib/0.3 m/s) 610 N/O.3 m/s (62 kg 10.3 mis, 1371b/0.3 m/s)
50
MAINTENANCE SPECIFICATIONS
I
SPEC I
ELECTRICAL Model
RXW10J, RXW10SJ
Voltage
12 V
Ignition system: Ignition timing (B.T.D.C.) Advanced type
5° at 1,350 r/min Digital type
Ignition coil: Model/Manufacturer Primary coil resistance Secondary coil resistance
F6T54973/MITSUBISHI 0.16 ~ 0.22 Q at 20°C (68°F) 5.0 ~ 6.8 kQ at 20°C (68°F)
Charging system: Type Nominal output
AC magneto 14 V/30 A at 5,000 r/min
DC-CDI: Magneto model/Manufacturer Standard Pickup coil resistance (color code) Stator coil resistance (color code) CDI unit model/Manufacturer
F4T47371/MITSUBISHI 14 V 30 A, 420 W at 5,000 r/min 189 ~ 231 Q at 20°C (68°F) (Gray - Black) 0.19 ~ 0.24 Q at 20°C (68°F) (White - White) F8T39371/MITSUBISHI
Rectifier/ regulator: Type Model/Manufacturer No load regulated voltage (DC) Capacity (DC) Withstand voltage
Short circuit type FH001/SHINDENGEN 14.1 ~ 14.9 V 35A 40V
Battery: Specific gravity Manufacture Type Ten hour rate amperage
1.32 GS YTX20L-BS 12V-18Ah 18 A
Electric starter system: Type
Constant mesh type
Starter motor: Model/Manufacturer Output Armature coil resistance Continuity check Insulation check Brush Overall length Wear limit Spring pressure Commutator diameter Wear limit Mica undercut
8FA1/MORIC 12 V - 0.95 kW 0.008 ~ 0.010 Q at 20°C (68°F) More than 100 kQ at 20°C (68°F) 9.8 mm (0.39 in) 5 mm (0.20 in) 7.36 ~ 11.04 N (736 28.5 mm (1.12 in) 27.5 mm (1.08 in) 1.5 mm (0.059 in)
51
~
1,104 g, 26.0
~
38.90z)
g--I
MAINTENANCE SPECIFICATIONS Model
RXW10J, RXW10SJ
Starter relay: Model/Manufacturer Amperage rating Coil resistance
MS5F-441/JIDECO 180 A 4.2 ~ 4.6 Q at 20°C (68°F)
T.P.S. (throttle position sensor): Model/Manufacturer Resistance
Oil level switch: Model/Manufacturer Fuel sender: Model/Manufacturer Sender resistance
Full Empty
8FG/NIPPON SEIKI 10 ~ 12 Q at 20°C (68°F) 175 ~ 185 Q at 20°C (68°F) 5DM/OMRON 95 ~ 116 Q at 20°C (68°F)
(left) (right)
Thumb warmer: Heater resistance Circuit breaker: Type Amperage for individual circuit Main fuse Headlight fuse Signal fuse Ignition fuse Carburetor heater fuse Reserve fuse Reserve fuse Reserve fuse Coolant temperature sensor: Model/Manufacturer Resistance Indicator light
TS67 /02-1 C/MIKUNI 4 ~ 6 KQ at 20°C (68°F) (Blue - Black) o ~ 4 KQ at 20°C (68°F) (Yellow - Black) 8FA/ASTI
Headlight relay: Model/Manufacturer Coil resistance Grip warmer: Heater resistance
I
(ON) (OFF)
1.53 1.53
~ ~
1.87 Q at 20°C (68°F) 1.87 Q at 20°C (68°F)
37.0
~
45.2 Q at 20°C (68°F)
x x x x x x x x
1 1 1 1 1 1 1 1
Fuse 30 A 20 A 10 A 10 A 20 A 30 A 20 A 10 A
8CC/MITSUBISHI 5.2 ~ 6.4 kQ at O°C (34°F) 0.300 ~ 0.364 kQ at 80°C (176°F) 0.170 ~ 0.208 kQ at 100°C (212°F) 90 ~ 110°C (194 ~ 230°F) 85 ~ 105°C (185 ~ 221°F)
Speed sensor: Model/Manufacture
8EK/NIPPON SEIKI
Carburetor heater: Model/Manufacture Wattage Resistance
5FU/NIPPON THERMOSTAT 30W 6 ~ 10 Q at 20°C (68°F)
52
SPEC
I
g--I
I
SPEC I
MAINTENANCE SPECIFICATIONS
g--I
HIGH ALTITUDE SETTINGS
I~ o Altitude
tu re
~
(0
~
200
~
(~
1000 (~
2000 (~
200 m 670 ft)
1000 m 3300 ft) 2000 m 6700 ft)
~
3000 m 10000 ft) ~
[Production spec]
-40°C
-20°C
O°C
(-40° F)
(-4° F)
(32° F)
MJ PS MJ PS MJ PS MJ PS
#140
STD #137.5
STD #135 1+1/4 #132.5 3/4
MJ#1, 2, 3,4:#135
MJ PS MJ PS MJ PS MJ PS
#137.5
STD #135
STD #132.5 1+1/4 #130 3/4
PS:Approx 2
53
16°C
MJ PS MJ PS MJ PS MJ PS
(60° F)
Idling speed (r/min)
#135
STD
1350
#132.5
STD
1350
#130 1+1/4
1350
#127.5 3/4
1400
#:Main jet number
PS:Pilot screw turns out
TIGHTENING TORQUE
I
SPEC
I
g--I
TIGHTENING TORQUE ENGINE Tightening torque
Parts to be tightened Spark plug Cylinder head nut (M1 0 x 1.25) x 2 Cylinder head nut (M1 0 x 1.25) x 6 Cylinder head nut x 2 Cylinder head bolt Camshaft cap and cylinder head Cylinder head cover Connecting rod and cap A.C. magneto rotor Crankshaft and drive gear Primary reduction gear bearing housing Timing chain tensioner Thermostat housing Water temperature sensor Timing chain tensioner cap Camshaft and camshaft sproket Hose band Water pump Coolant reservoir tank Pipe Oil cooler Oil pan Engine mounting adjust bolt Engine mounting nut Countershaft cover Oil pan drain bolt Oil filter union bolt Oil filter Oil pump Oil pump drive chain guide Oil tank drain bolt Oil tank and frame (bolt) Oil tank and frame (nut) Oil gallery bolt Exhaust joint Muffler band Exhaust pipe Exhaust sampling bolt Muffler Exhaust cover Muffler band Muffler protector Cylinder head stud bolt Crankcase (M9 x 1.5) (1 st) (2nd) Crankcase (M6 x 1.0) Countershaft cover A.C. magneto rotor cover Starter clutch Stator coil Starter motor Pickup coil
Nm
m-kg
ft-Ib
13
1.3
9.4
20 + 121 0 20 + 105 0 20 + 140 0
2.0 + 121 0 2.0 + 105 0 2.0 + 140 0
14+121 0 14 + 105 0 14 + 140 0
12 10 12
1.2 1.0 1.2
8.7 7.2 8.7
20 + 120 0
2.0 + 120 0
14 + 120 0
130 75 12 10 10 23 6 24 2 12 7 10 35 10 7 65 12 30 30 17 12 10 16 10 19 10 25 9 25 10 16 6 20 11 10 15
13.0 7.5 1.2 1.0 1.0 2.3 0.6 2.4 0.2 1.2 0.7 1.0 3.5 1.0 0.7 6.5 1.2 3.0 3.0 1.7 1.2 1.0 1.6 1.0 1.9 1.0 2.5 0.9 2.5 1.0 1.6 0.6 2.0 1.1 1.0 1.5
94 54 8.7 7.2 7.2 17 4.3 17 1.4 8.7 5.0 7.2 25 7.2 5.1 47 8.7 22 22 12 8.7 7.2 11 7.2 14 7.2 18 6.5 18 7.2 11 4.3 14 8.0 7.2 11
15+
45~50°
12 12 12 12 10 27 6 54
1.5+
45~50°
1.2 1.2 1.2 1.2 1.0 2.7 0.6
11+
Remarks
Left-hand thread.
Apply LOCTITE®
See NOTE.
45~50°
8.7 8.7 8.7 8.7 7.2 20 4.3
Apply LOCTITE® Apply LOCTITE®
TIGHTENING TORQUE Parts to be tightened Fuel pump Fuel pump stay
Tightening torque Nm
m-kg
ft-Ib
10 10
1.0 1.0
7.2 7.2
I
SPEC I
g--I
Remarks
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. First, tighten the bolt to approximately 15 Nm (1.5 m-kg, 11 ft-Ib) with a torque wrench, then loosen the bolt completely. 2. Retighten the bolt to 15 Nm (1.5 m-kg, 11 ft-Ib), and tighten another 45 ~ 50° with a angle gauge.
55
TIGHTENING TORQUE
I
SPEC
I
g--I
POWER TRAIN Tightening torque
Parts to be tightened
Nm
mekg
ftelb
Primary sheave (1 st) (2nd) Spider and sliding sheave
120 60 200
12 6.0 20.0
85 43 145
Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave Stopper (secondary sheave) Spring seat (secondary sheave) Bolt (secondary sheave clearance) Drive sprocket Locknut chain tensioner Chain housing and frame Driven sprocket Drain bolt (drive chain housing) Chain housing cover Shift lever assembly Lever and drive chain housing cover Shaft (reverse drive gear) Reverse driven gear Counter gear Spacer set screw Chain housing and brake caliper Bleed screw (brake caliper) Brake hose union bolt (caliper side) Brake hose union bolt (brake master cylinder side) Bearing set screw (Secondary shaft) Parking brake Stopper band Hook and front pivot arm Wheel bracket and sliding frame Bracket bolt (front) Bracket bolt (rear) Front pivot arm and front pivot arm bracket Front pivot arm bracket and sliding frame Suspension wheel Rear axle Slide rail suspension mounting bolt (M1 0) Rear pivot arm and bracket Shock absorber and rear pivot arm Rear pivot arm and rod Rear suspension bracket and rod Shock absorber and rear suspension bracket Control rod and sliding frame Control rod bolt Shock absorber and front pivot arm Shock absorber and front suspension bracket Rear pivot arm bracket Rear bracket and suspension wheel
14 6 64 7 23 10 90 24 48 48 16 24 10 10 10 48 10 6 48 6 30 30 8 13 4 16 24 48 30 72 72 72 75 72 24 49 49 49 49 72 32 49 49 72 72
1.4 0.6 6.4 0.7 2.3 1.0 9.0 2.4 4.8 4.8 1.6 2.4 1.0 1.0 1.0 4.8 1.0 0.6 4.8 0.6 3.0 3.0 0.8 1.3 0.4 1.6 2.4 4.8 3.0 7.2 7.2 7.2 7.5 7.2 2.4 4.9 4.9 4.9 4.9 7.2 3.2 4.9 4.9 7.2 7.2
10 4.3 46 5.1 17 7.2 65 17 35 35 12 17 7.2 7.2 7.2 35 7.2 4.3 35 4.3 22 22 5.8 9.4 2.9 12 17 35 22 52 52 52 54 52 17 35 35 35 35 52 23 35 35 52 52
56
Remarks Tighten the bolt in two stages. See NOTE. Left-hand thread. Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE®
TIGHTENING TORQUE Tightening torque
Parts to be tightened Wheel bracket shaft and sliding frame Set bolt (front axle) Speed sensor Gear unit (speed sensor)
Bearing nut
Nm
mekg
ftelb
72 9 20 40 55
7.2 0.9 2.0 4.0 5.5
52 6.5 14 29 40
I
SPEC I
g--I
Remarks Apply LOCTITE®
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tightening steps: 1. Tighten the bolt to a torque at 120 Nm (12.0 m-kg, 85 ft-Ib). 2. Loosen the bolt completely. 3. Retighten the bolt to a torque of 60 Nm (6.0 m-kg, 43 ft-Ib).
57
TIGHTENING TORQUE
I
SPEC
CHASSIS Tightening torque
Parts to be tightened Handlebar holder Steering column (Upper) Steering column (Lower) Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod Tie rod and steering arm Relay arm Locknut (relay rod/tie rod) Ski Ski runner Ski column lower bracket Ski and ski handle Shock absorber (upper) Shock absorber (lower) Steering arm locknut Upper arm and frame Upper arm and knuckle Lower arm and frame Lower arm and knuckle Stabilizer bar and stabilizer arm Stabilizer arm and connecting rod Connecting rod and lower arm Frame cross member (front side) Frame cross member (rear side) Master cylinder assembly Brake lever adjuster locknut Rear cover Seat and frame Shroud
58
Nm
m-kg
ft-Ib
15 23 23 35 35 30 30 35 30 35 67 25 48 19 11 11 45 45 35 37 40 37 65 11 34 34 30 23 10 6 3 5 3
1.5 2.3 2.3 3.5 3.5 3.0 3.0 3.5 3.0 3.5 6.7 2.5 4.8 1.9 1.1 1.1 4.5 4.5 3.5 3.7 4.0 3.7 6.5 1.1 3.4 3.4 3.0 2.3 1.0 0.6 0.3 0.5 0.3
11 17 17 25 25 22 22 25 22 25 49 18 35 14 8.0 8.0 33 33 25 27 29 27 47 8.0 25 25 22 17 7.2 4.3 2.2 3.6 2.2
Remarks
I
g--I
GENERAL TORQUE SPECIFICATIONSI DEFINITION OF UNITS
GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.0. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
r
L
A
B
(nut)
(bolt)
10 mm
1SPEC 1.--.1 .., -
General torque specifications Nm
m-kg
ft-Ib
6mm
6
0.6
4.3
12 mm
8mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22mm
16 mm
130
13.0
94
-
A: Distance across flats B: Outside thread diameter
DEFINITION OF UNITS Unit
Read
Definition
Measurement
mm cm
Millimeter Centimeter
10-3 meter 10-2 meter
Length Length
kg
Kilogram
103 gram
Weight
N
Newton
1 kg x m/sec2
Force
Nm m-kg
Newton meter Meter kilogram
Nxm m x kg
Torque Torque
Pa N/mm
Pascal Newtons per millimeter
N/m 2 N/mm
Pressure Spring rate
L cm 3
Liter Cubic centimeter
-
Volume or capacity
r/min
Rotations per minute
-
Engine speed
59
_____________ C_A_B_LE_RO_U_T_I_NG_I
SPEC
B-B
A
60
I
g--I
CABLE ROUTING
CABLE ROUTING
CD
® @ @
@ @ (J)
@
® ®
@
@ @ @ @
® @ @ @
® @
@ @ @ @
@ @
@ @
®
To the headlight and meter assembly Clamp the lead at the position of white tape. Battery positive lead Battery negative lead Main harness Negative lead connector Carburetor heater lead coupler Oil level switch lead coupler Oil level switch Starter motor positive lead (under the battery bracket) Carburetor switch lead connector Clamp the throttle position switch lead and carburetor switch lead. Clamp the coated section of the lead. Clamp the vacuum hose 2. Coolant temperature sensor lead coupler To the brake caliper Clamp the ignition coil lead. Connectors To the heat exchanger Main switch Tail/brake light lead coupler Throttle cable Right handlebar switch lead coupler Thumb warmer switch lead coupler Grip warmer switch lead connector To the tail/brake light Headlight beam switch lead coupler Left handlebar switch lead coupler Brake light switch lead coupler Starter cable
61
I
SPEC I
g--I
_____________ C_A_B_LE_RO_U_T_I_NG_I
SPEC
B-B
A
62
I
g--I
CABLE ROUTING
®
Brake hose
@ Fuel sender lead coupler @ Set the coupler in the rear space of the instrument panel
@ Clamp the ignition coil lead under the fuel hose.
@ Clamp the fuel hose.
® There ®
@ @
® ® @ @ @
® ® ® ®
@ @
® @
should be no slack of leads. Clamp the throttle position switch lead. Route the coolant hose between the upper vacuum hose and lower vacuum hose. Route the vacuum hose under the coolant hose. Route the vacuum hose over the coolant hose. Clamp the coolant hose and vacuum hose. Clamp the coolant hose and vacuum hose 2. Throttle position sensor lead coupler. (under the vacuum hose) Drive guard bracket Connect the battery negative lead to the starter motor mounting bolt. Voltage regulator Carburetor heater relay Headlight relay Main relay Back buzzer (RXW10J, RXW 10SJ) Flange nut Hexagon bolt
63
I
SPEC I
g--I
CABLE ROUTING
64
ISPEC
I
g--I
CABLE ROUTING
CD ÂŽ @ @ @
Headlight wire harness Align it with the positioning tape of the headlight wire harness Clamp 1 Clamp Meter coupler (Securely fit in the rubber cover)
65
I
SPEC I
g--I
CABLE ROUTING
2
3
9
10
11
34 32
30 31 17
29
18
5
35
A-A 66
CABLE ROUTING
CD 速 @
@ @ @
(f) @
速 速
@ @ @
@ @
速 @ @ @ @ @ @ @
@ @
Right handlebar switch Clamp the main harness, main switch and harness. Clamp the grip warmer lead and the right handlebar switch lead. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Except for brake hose and parking brake cable.) Clamp the tail/brake light lead, headlight beam switch lead and grip warmer lead. Parking brake cable Left handlebar switch Pass the brake hose and the parking brake cable through the cable holder. Clamp the fuel sender lead and speed sensor lead. Speed sensor lead coupler Clamp the fuel tank breather hose. Fuel sender lead cover Route the fuel tank breather hose along the frame cross member. Clamp the speed sensor lead only. Clamp the compression spring section of the fuel tank breather hose. Compression spring Carburetor air vent hose Breather tank Pass the fuel hose over the engine oil breather hose. Point the clip position to the upward. Insert the fuel tank breather hose until it contacts the projection. Pass the carburetor air vent hose outside of the engine oil breather hose. To the speed sensor.
67
I
SPEC I
g--I
CABLE ROUTING
2
3
9
10
11
34 32
30 31 17
29
18
5
35
A-A 68
CABLE ROUTING @ @ @ @
® ®
@ @ @
®
Carburetor air vent hose To the parking brake. To the brake caliper Brake hose Clamp the wire harness and fuel tank breather hose from the top. Less than 50 mm (2.0 in). Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side. Push into the end of clamp between frame cross member and fuel tank.
69
I
SPEC I
g--I
CABLE ROUTING
2
70
ISPEC
I
g--I
CABLE ROUTING
CD 速
Headlight wire harness Tighten the frame ground and voltage regulator upper bolt together. @ Engine oil tank hose @ Point the clamp tightening direction to the downward. @ Drain hose @ Less than 30 mm (1.2 in). (f) Pass the coolant reservoir tank breather hose through between engine and heat exchanger. 速 Clamp the hose at the white paint position. Point the clamp position to the front outside. 速 To the tail/brake light. @ Clamp the coolant hose. Point the locked section of the clamp to the outside. @ Clamp the wire harness. Tighten the frame cross member and frame together. @ Fuse box @ Bracket Connect the gear position switch lead. (For model with the reverse) Fold back the gear position switch lead, and clamp it. (For model without reverse) @ Wire harness 速 Coolant reservoir tank @ Coolant reservoir tank breather hose @ Brake hose @ Parking brake cable @ Point the clamp position to the front outside. @ Clamp the battery positive lead and negative lead. @ Point the clamp position to the downward. @ Point the clamp position to the inside. @ Clamp the leads before the fixture.
CB
71
I
SPEC I
g--I
CABLE ROUTING
72
CABLE ROUTING
CD 速 @ @
@)
@ (J)
速 速 速
Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the upward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross member and frame. Wire harness clamp Rivets Speed sensor Nylon nuts Point the pawl of clip to the downward.
73
I
SPEC I
g--I
I
SPEC
CABLE ROUTING
I
g--I
2
~A
3 7
6
®
----!)
\;\_---------11:.-'---
9 10
17
16
9
10
18
B-B
A-A 74
CABLE ROUTING
CD ®
Starter motor Battery positive lead @ COl unit @ Battery negative lead @ Air box drain hose Battery band (f) Battery cover @ 0 -- 5 mm (0 -- 0.20 in) Wire harness @ Plate cover @ Clip it to the frame cross member @ To the carburetor. @ Wire harness holder @ Battery bracket @ Battery @ Battery seat @ COl unit bracket @ Frame cross member
® ®
75
I
SPEC I
g--I
CD A.C. magneto ® Rectifier/regulator @
Main switch
@ Main relay
® Fuse (MAIN) ® Starter relay
(J)
Starter motor
® Battery ® Engine stop switch
@ Throttle switch
® Carburetor switch
@ Carburetor heater relay @ Carburetor heater @ Grip warmer
® Thumb warmer
@ COl unit @ Ignition coil
@ Spark plug @ Coolant temperature sensor @ Throttle position sensor @ Grip warmer switch @ Thumb warmer switch @ Body ground @ Back buzzer @ Gear position switch @ Brake light switch @ Tail/brake light @ Fuse (HEADLIGHT) @ Fuse (SIGNAL)
® Fuse (CARBURETOR HEATER) ® Fuse (IGNITION)
@ Headlight beam switch
® Headlight relay
@ Headlight
® Meter assembly ® Tachometer ® Meter light ® Coolant temperature indicator light
@ Multi-function meter
® Warning light
@J) Hi beam indicator light
® Oil level switch ® Fuel sender @ Speed sensor
COLOR CODE B Br G Gy L Lg . . . ..
Black Brown Green Gray Blue Light green o Orange P Pink R Red Sb Sky blue W White Y Yellow B/G Black/Green B/L Black/Blue B/R Black/Red B/W Black/White B/Y Black/Yellow Br/W .. Brown/White Br / Y . .. Brown/Yellow G/B Green/Black G/R Green/Red
G/Y L/G L/ R L/W L/Y Lg/ B ..
Green/Yellow Blue/Green Blue/ Red Blue/White Blue/Yellow Light green/ Black Lg/L ... Light green/Blue Lg/W .. Light green/White 0/ R Orange/ Red R/B Red/Black R/W Red/White R/Y Red/Yellow white/Green W /G W/R White/Red W/Y White/Yellow Y/ B Yellow / Black Y/ G Yellow / Green Y/L Yellow/Blue Y/ R Yellow / Red Y/W Yellow/White
SUPPPPMPUUMUU SPUUICP MMUUML
Li t126180239
FOREWORD
HOW TO USE THIS MANUAL
This Supplementary Service Manual has been prepared to introduce new service and new data for the RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK. For complete information, on service procedures, it is necessary to use this Supplementary Service Manual together with following manual:
Particularly important information is distinguished in this manual by the following notations:
RX1 OH/RX1 OSH RX1 OMH/RX1 OMSH RX1 ORH/RX1 ORSH SERVICE MANUAL: 8FA-28197-10 (981073) (LIT-12618-02-28) RXW1 OJ/RXW1 OSJ SUPPLEMENTARY SERVICE MANUAL: 8FG-28197-10 (981089) (LIT-12618-02-33)
NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understanding of the mechanical concepts and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to this model may render it unfit and/or unsafe to use. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. RX10K RX1 ORKlRX1 ORSK RXW1 OKlRXW1 OSK RX1 OMKlRX1 OMSK SUPPLEMENTARY SERVICE MANUAL Š 2004 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N.LIT-12618-02-39
~ The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!
~ Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snowmobile.
A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile. NOTE: A NOTE provides key information that can make procedures easier or clearer. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g., â&#x20AC;˘ Bearings Pitting/damage --+ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.
CD
®
II~~~ I~II-I~-~~""""'I-,-0-1
@
@
ICHASI~II-p~:'ClDI (J)
@
ICARsl ~ II~EL-EC"'---II~-~ I
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content.
CD General information ® Periodic inspections and adjustments @ Chassis @ Power train @ Engine @ Cooling system (J) Carburetion @ Electrical
® Specifications
®
Illustrated symbols ® to @ are used to identify the specifications which appear.
® Filling fluid ® Lubricant @ Tightening @ Wear limit, clearance @ Engine speed
® Special tool @Q,V,A
Illustrated symbols@ to@ in the exploded diagram indicate grade of lubricant and location of lubrication point.
@
@
1
@
ImI
~
~ @
~
1
1
~ @
@
~
@
~
@ Apply locking agent (LOCTITE®)
® Apply Yamabond No.S® @ 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 @ Use new one
INDEX GENERAL INFORMATION
~
GEN INFO
PERIODIC INSPECTIONS AND ADJUSTMENTS CHASSIS POWER TRAIN ENGINE COOLING SYSTEM CARBURETION ELECTRICAL
INSP ADJ
.JCHAS
crD POWR TR
ENG
COOL
CARS
ELEC g--
SPECIFICATIONS
SPEC
~
INSPECTION
CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS
FRONT AXLE AND TRACK INSTALLATION
POWER TRAIN . BRAKE PAD INSPECTION . BRAKE HOSE INSPECTION . AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) . . . . .. 1 TRACK TENSION ADJUSTMENT 3 SLIDE RUNNER INSPECTION 3 LUBRICATION 4 CLUTCH 5 GEAR SELECTION 7 FRONT SUSPENSION 12 REAR SUSPENSION 13
CHAPTER 3. CHASSIS STEERING . . . . . . . . . . . . . . . . . . . . . . . . . .. 17 RX10MK, RX10MSK 17 SKI RX10K, RX10RK, RX10RSK RX10MK, RX10MSK
19 19 20
CHAPTER 4. POWER TRAIN DRIVE CHAIN HOUSING RX10K, RX10MK, RX10MSK INSTALLATION WITH REVERSE MODEL RX10RK, RX10RSK INSTALLATION
21 21 22 23 25
BRAKE BRAKE PAD REPLACEMENT BRAKE CALIPER DISASSEMBLY BRAKE CALIPER INSPECTION AND REPAIR BRAKE CALIPER ASSEMBLY BRAKE CALIPER INSTALLATION
27 28 31
SLIDE RAIL SUSPENSION RX10K, RX10RK, RX10RSK RX10MK, RX10MSK
33 33 37
43 43
CHAPTER 5. ENGINE SEAT AND FUEL TANK
44
EXHAUST PIPE AND MUFFLER
45
CHAPTER 6. COOLING SYSTEM HEAT EXCHANGER RX10MK, RX10MSK
46 46
CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS
49
MAINTENANCE SPECIFICATIONS ENGINE POWER TRAIN CHASSiS ELECTRICAL HIGH ALTITUDE SETTINGS
52 52 57 61 62 64
TIGHTENING TORQUE ENGINE POWER TRAIN CHASSiS
66 66 68 70
GENERAL TORQUE SPECIFICATIONS
71
DEFINITION OF UNITS . . . . . . . . . . . . . . .. 71 CABLE ROUTING
31 32 32
41
72
BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
~~----~-I--\ --®m ~[Ji~'-CD a I
-.=P-
'
\-' (
II~~~ ~O~ I
~
I
PERIODIC INSPECTIONS AND ADJUSTMENTS POWER TRAIN BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Inspect: • Brake pad wear @ Wear indicator CD nearly contacts the brake disc --+ Replace as a set.
~
I:6]
Wear limit: 7.5 mm (0.30 In)
Ig
BRAKE HOSE INSPECTION 1. Inspect: • Brake hose Cracks/ damage/wear --+ Replace. 2. Check: • Fluid leakage Apply the brake lever several times. Fluid leakage --+ Replace the defective parts.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
~ --------Bleed the brake system in the following cases: • The system has been disassembled. • A brake hose is loosened or removed. • The brake fluid has been very low. • Brake operation is faulty. If the brake system is not properly bled a loss of braking performance may occur. 1. Bleed: • Brake system
Air bleeding steps: • Fill the brake master cylinder reservoirwith the proper brake fluid. • Install the diaphragm. Be careful not to spill any fluid or allow the brake master cylinder reservoir to overflow. • Connect clear plastic hoses CD tightly to the brake caliper bleed screws ®. • Place the other ends of the hoses in a container.
IANOSJP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
I
~O~
~
I
--------------------------a. Slowly apply the brake lever several times. I
b. Pull the lever in, then hold the lever in position. c. Loosen the bleed screws and allow the brake lever to travel towards its limit. d. Tighten the bleed screws when the brake lever limit has been reached, then release the lever. - Repeat steps (a) to (d) until all of the air bubbles have disappeared from the fluid. - Tighten the bleed screws.
Bleed screw: 6 Nm (0.6 m-kg, 4.3 ft-Ib) NOTE: - - - - - - - - - - - - If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. - Add brake fluid to the proper level. Refer to "BRAKE FLUID LEVEL INSPECTION".
rfmmIImI --------After bleeding the brake system, check the brake operation.
2
II~~~ ~O~
TRACK TENSION ADJUSTMENTI SLIDE RUNNER INSPECTION
I
~
I
TRACK TENSION ADJUSTMENT
A
Track alignment
[IDShifted to right
[l]Shifted to left
@ Left adjuster
Turn out
Turn in
Turn in
Turn out
@ Right adjuster @ Slide runner
® Track
® Track metal
@ Gap
@ Forward
[AJ RX10K, RX10RK, RX10RSK [BJ RX10MK, RX10MSK c. Adjust the track deflection until the specified amount is obtained. More than specified
Less than specified
@ Left adjuster
Turn in
Turn out
@ Right adjuster
Turn in
Turn out
Track deflection
6
7
The adjusters should be turned an equal amount.
• Recheck the alignment and deflection. If necessary, repeat steps (a) to (c) until the specified amount is obtained. • Tighten the rear axle nut. ,
'I -
~~
Nut (rear aXle): 75 Nm (7.5 m-kg, 54 ft-Ib)
SLIDE RUNNER INSPECTION 1. Inspect: • Slide runner CD Cracks/ damage/wear --+ Replace. 2. Measure: • Slide runner thickness @ Out of specification --+ Replace.
JI
SCH2680
Slide runner wear limit: 10 mm (0.39 in)
3
IANOSJP
LUBRICATION
--------------------------LUBRICATION
I
I
~O~ ~
I
Brake lever, throttle lever and throttle cable end 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables.
---t
l
Recommended lubricant: ESSO Beacon 325 Grease
~ --------Apply a dab of grease onto only the end of the cables. Do not grease the throttle cables. They could freeze and cause a loss of control.
Front and rear suspension 1. Use a grease gun to inject grease into the nipples G). 2. Apply grease ÂŽ.
A
Recommended lubricant: Esso Beacon 325 Grease or Aeroshell Grease #7A
[AJ Front [BJ Rear (RX1 OMK, RX10MSK) A
B
4
INSP
CLUTCH CLUTCH High altitude
ADJ
G Green
P Pink
S Silver
Y Yellow
Specifications Model: RX10K, RX10RK, RX10RSK ~
800 m 2,500 ft)
600 ~ 1,400 m (2,000 ~ 4,500 ft)
1,200 (4,000
~
2,000 m 6,500 ft)
1,800 (6,000
~
2,600 m 8,500 ft)
2,400 (8,000
~
3,000 m 10,000 ft)
[A]
Elevation
[BJ
Engine idle speed
1,350 ± 100 r/min
+-
+-
+-
+-
[Q] [Q] [EJ
Engagement r 1min
3,600 ± 200 r/min
+-
+-
+-
+-
Shift r 1min
10,250 ± 250 r 1min
+-
+-
+-
+-
[E] [G]
(~
~
~
~
Main jet
[ill
Pilot jet*1
Refer to "HIGH ALTITUDE SETTINGS" in "MAINTENANCE SPECIFICATIONS".
Pilot screw Secondary reduction ratio (number of links)
38/24 (70 L)
+-
38/23 (70 L)
38/22 (68 L)
+-
Primary sheave spring
90501-582L1
+-
90501-582L2
90501-602L3
+-
Color
Y-S-Y
+-
G-S-G
P-S-P
+-
Free length
87.4 mm (3.44 in)
+-
+-
CD
Preload
343 N (35 kg, 77 Ib)
+-
+-
[M]
Spring rate
[N] [Q]
[8]
rn
[JJ [K]
24.5 N/mm
27 N/mm
85.1 m (3.35 in)
+-
+-
+-
29.4 Nm (3.00 kg/mm, 168lb/in)
(2.50 kg/mm, 140lb/in)
+-
Wire diameter
5.8 mm (0.228 in)
+-
+-
Outside diameter
59.5 mm (2.34 in)
+-
+-
+-
+-
[:eJ
Weight (10)
8FA-17605-10 (8FAOO)
+-
+-
+-
+-
[Q]
~eight rivet
[8]
Weight bushing
VESPEL TP-8549
+-
+-
+-
+-
[S] [I] [Q]
Roller outer dia.
15.6 mm (0.61 in)
+-
+-
+-
+-
Roller bushing
VESPEL TP-8549
+-
+-
+-
+-
Pri. clutch shim
None
+-
+-
+-
+-
90508-60012
+-
+-
+-
+-
~ Color
P
+-
+-
+-
+-
[Xl
Free length
75 mm (2.95 in)
+-
+-
+-
+-
[y]
Preload rate
60° (3-3) 1211 kgemm/rad
+-
+-
+-
+-
[lJ
Wire diameter
6.0 mm (0.236 in)
+-
+-
+-
+-
~ Outside diameter
69.5 mm (2.736 in)
+-
+-
+-
+-
[liJ @]
Sec. torque cam angle
51 -43°
+-
+-
+-
+-
Sec. clutch shim
1.0 mm (0.04 in)
+-
+-
+-
+-
OUT IN
M Secondary sheave spring
(2.75 kg/mm, 154lb/in)
+-
6.0 mm (0.236 in)
+-
Steel 17.2 with-hole
Steel 13.3
Steel 13.3 with-hole
Aluminum 13.3 with-hole
None
Steel 17.2
Steel 13.3
Steel 13.3 with-hole
Steel 13.3 with-hole
None
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Number of return rotation of pilot screw may vary depending on each cylinder. Make sure to rotate the screw backward after listing its present number of return rotation on each cylinder.
*1:
5
INSP ADJ
CLUTCH S Silver
0
W White
P Pink
Orange
Specifications Model: RX10MK, RX10MSK ~
800m
600
2,500 ft)
(2,000
~
1,400 m
1,200
~
2,000 m
1,800
~
2,600 m
2,400
~
3,000 m
(4,000
~
6,500 ft)
(6,000
~
8,500 ft)
(8,000
~
10,000 ft)
[AJ
Elevation
[6]
Engine idle speed
1,350 ± 100 r/min
+--
+--
+--
+--
[Q] [Q]
Engagement r1min
4,100 ± 200 r/min
+--
+--
4,200 ± 200 r1min
+--
Shift r/min
10,250±250 r/min
+--
+--
+--
+--
[E [E]
(~
~
4,500 ft)
Main jet
[ill Refer to "HIGH ALTITUDE SETTINGS" in "MAINTENANCE SPECIFICATIONS".
Pilot jet*1
~ Pilot screw
[8]
Secondary reduction ratio (number of links)
40/23 (70 L)
+--
40/22 (70 L)
40/21 (70 L)
+--
IT]
Primary sheave spring
90501-624L8
+--
90501 -601 L8
+--
+--
[JJ
Color
O-S-O
+--
O-P-O
+--
+--
[K]
Free length
84.2 mm(3.32 in)
+--
82.6
+--
+--
343 N (35 kg, 771b)
+--
294 N (30 kg, 66 Ib)
+--
+--
+--
+--
+--
+--
[ ] Preload
31.9 N/mm
M Spring rate
(3.25 kg/mm, 182lb/in)
[NJ [Q]
Wire diameter
6.2 mm (0.244 in)
+--
+--
+--
+--
Outside diameter
59.5 mm (2.34 in)
+--
+--
+--
+--
[E]
Weight (10)
+--
+--
8FA-17605-10 (8FAOO) OUT
[Q]
Steel 17.2 with-hole
Weight rivet IN
[8]
Weight bushing
[S]
IT] [0]
Steel 17.2
8BU-17605-20 +--
(8BU10)
Steel 13.3
Steel 13.3
Steel 13.3
Steel 13.3
with-hole
Steel 13.3
Aluminum 10.3
Aluminum
Aluminum
10.3
10.3
VESPEL TP-8549
+--
+--
+--
+--
Roller outer dia.
16.5 mm (0.65 in)
+--
14.5 mm (0.57 in)
+--
+--
Roller bushing
VESPEL TP-8549
+--
+--
+--
+--
Pri. clutch shim
None
+--
+--
+--
+--
M Secondary sheave spring
90508-60007
+--
+--
+--
+--
~ Color
W
+--
+--
+--
+--
[X]
Free length
75 mm (2.95 in)
+--
+--
+--
+--
[y]
Preload rate
+--
+--
+--
+--
[ZJ @] [li] [ill
Wire diameter
6 mm (0.236 in)
+--
+--
+--
+--
Outside diameter
69.5 mm (2.736 in)
+--
+--
+--
+--
Sec. torque cam angle
45°
+--
+--
+--
+--
Sec. clutch shim
1.0 mm (0.04 in)
+--
+--
+--
+--
70° (1-6) 1290 kgemm/rad
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - *1: Number of return rotation of pilot screw may vary depending on each cylinder.
Make sure to rotate the screw backward after listing its present number of return rotation on each cylinder.
6
GEAR SELECTION
INSP
ADJ
GEAR SELECTION
CD Chain and sprocket part number [AJ Parts name
[:EJ Drive sprocket
[E] Driven sprocket
~ Chain
[BJ Teeth & links
[Q] Parts no.
19 teeth
8FA-17682-90
20 teeth
8FA-17682-00
21 teeth
8FA-17682-10
22 teeth
8FA-17682-20
23 teeth
8FA-17682-30
RXW10K, RXW10SK
24 teeth
8FA-17682-40
RX10K, RX10RK, RX10RSK
37 teeth
8DW-47587-71
38 teeth
8DW-47587-81
RX10K
38 teeth
8FB-47587-80
RX10RK, RX10RSK, RXW10K, RXW10SK
39 teeth
8DW-47587-91
39 teeth
8FB-47587-90
40 teeth
8DW-47587-01
68 links
94890-09068
70 links
94890-09070
[Q] Standard
RX10MK, RX10MSK
RX10MK, RX10MSK RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
® Gear ratio [AJ Drive gear 19 teeth
20 teeth
21 teeth
22 teeth
23 teeth
24 teeth
1.76 68 links
1.68 68 links
1.61 68 links
1.54 70 links
1.90 68 links
1.81 68 links
1.73 68 links
1.65 70 links
1.58 70 links
[BJ Driven gear
V Iv V
37 teeth 38 teeth 39 teeth
2.05 68 links
1.95 68 links
1.86 68 links
1.77 70 links
1.70 70 links
1.63 70 links
40 teeth
2.11 68 links
2.00 68 links
1.91 70 links
1.82 70 links
1.74 70 links
1.67 70 links
@ Secondary sheave spring [A] Part no.
[6] Spring rate Nemm/rad (kgemm/rad)
[Q Preload N/mm (kg/mm) (Ib/in)
[Q] Color
[E]Wire gauge mm(in)
[E] No. of coils
~Free length mm(in)
[8] Outside diameter mm(in)
IT] Standard
90508-500B1
6003 (613)
6.2 (0.63), 35.28
Brown
5.0 (0.196)
5.19
75 (2.95)
69.5 (2.736)
90508-536A9
7147 (729)
7.3 (0.74), 41.44
Red
5.3 (0.209)
5.53
75 (2.95)
69.5 (2.736)
90508-556A2
8314 (848)
8.5 (0.87), 48.72
Green
5.5 (0.217)
5.53
75 (2.95)
69.5 (2.736)
90508-556A7
9460 (965)
10.21 (1.04), 58.24
Silver
5.5 (0.217)
4.86
75 (2.95)
69.5 (2.736)
90508-60012
11876 (1211)
12.32 (1.256), 70.34
Pink
6.0 (0.236)
5.53
75 (2.95)
69.5 (2.736)
RX10K, RX10RK, RX10RSK
90508-60007
12654 (1290)
13.45 (1.372) 76.84
White
6.0 (0.236)
5.19
75 (2.95)
69.5 (2.736)
RXW10K, RXW10SK, RX10MK, RX10MSK
@ Secondary spring twist angle at
[6]
1 2 3
0 10° 20° 30°
3 40° 50° 60° 7
6 70° 80° 90°
9 100° 110°
120°
IANOSJP
GEAR SELECTION
-------------------------@ Torque cam (secondary spring seat)
I
I
~O~ ~
[AJ Identification mark
[BJ Effects
[Q] Part no.
[Q] Cam angle [EJ Identification mark
~ Quicker upshifting
during acceleration
8FA-17604-00
51-43°
8BVFA
8BV-17604-71
47°
8BV71
8BV-17604-51
45°
8BV51
8BV-17604-31
43°
8BV31
8BV-17604-11
41°
8BV11
8BV-17604-91
39°
8BV91
J~
~,
[8] Quicker backshifting under load
8
[E] Standard RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK RX10MK, RX10MSK
I
INSP
GEAR SELECTION
ADJ
@ Primary spring [A] Spring identification color code [6] Spring
rate color
[Q Preload color'
[EJ Spring rate
[Q]
Parts No.
90501-551 L3
N/mm (kg/mm) 19.6 (2.00)
[8]
IT]
Wire
Outside
gauge mm(in)
diameter mm(in)
coils
length mm(in)
5.5 (0.216)
59.5 (2.34)
4.91
88.4 (3.48)
[E] Preload
~ Color
N (kg) 294 (30)
Blue-Pink-Blue
Q] No. of
[RJ Free
90501-551 L9
19.6 (2.00)
343 (35)
Blue-Silver-Blue
5.5 (0.216)
59.5 (2.34)
4.91
90.9 (3.58)
90501-552L5
19.6 (2.00)
392 (40)
Blue-Green-Blue
5.5 (0.216)
59.5 (2.34)
4.91
93.4 (3.68)
90501-581 L5
24.5 (2.50)
294 (30)
Yellow-Pi nk-YeIIow
5.8 (0.228)
59.5 (2.34)
4.92
85.4 (3.36)
90501-581 L6
27 (2.75)
294 (30)
Green-Pink-Green
5.8 (0.228)
59.5 (2.34)
4.66
84.3 (3.32)
90501-582 L1
24.5 (2.50)
343 (35)
Yellow-Silver-Yellow
5.8 (0.228)
59.5 (2.34)
4.92
87.4 (3.44)
90501-582 L2
27 (2.75)
343 (35)
Green-Silver-Green
5.8 (0.228)
59.5 (2.34)
4.66
86.1 (3.39)
[]Standard
RX10K, RX10RK,
90501-582 L6
22.1 (2.25)
392 (40)
White-Green-White
5.8 (0.228)
59.5 (2.34)
5.25
91.2 (3.59)
90501-582 L7
24.5 (2.50)
392 (40)
Yellow-Green-Yellow
5.8 (0.228)
59.5 (2.34)
4.92
89.4 (3.52)
90501-583LO
19.6 (2.00)
441 (45)
Blue-White-Blue
5.8 (0.228)
59.5 (2.34)
5.65
95.9 (3.78)
90501-583L1
22.1 (2.25)
441 (45)
White-White-White
5.8 (0.228)
59.5 (2.34)
5.25
93.4 (3.68)
90501-583L4
22.1 (2.25)
343 (35)
White-Silver-White
5.8 (0.228)
59.5 (2.34)
5.25
89.0 (3.50)
90501-583L5
22.1 (2.25)
294 (30)
White-Pink-White
5.8 (0.228)
59.5 (2.34)
5.25
86.7 (3.41)
90501-601 L7
29.4 (3.00)
294 (30)
Pink-Pink-Pink
6.0 (0.236)
59.5 (2.34)
4.82
83.4 (3.28)
90501-601 L8
31.9 (3.25)
294 (30)
Orange-Pink-Orange
6.0 (0.236)
59.5 (2.34)
4.60
82.6 (3.25)
90501-602L3
29.4 (3.00)
343 (35)
Pink-Silver-Pink
6.0 (0.236)
59.5 (2.34)
4.82
85.1 (3.35)
90501-602L8
27.0 (2.75)
392 (40)
Green-Green-Green
6.0 (0.236)
59.5 (2.34)
5.08
87.9 (3.46)
90501-602L9
29.4 (3.00)
392 (40)
Pink-Green-Pink
6.0 (0.236)
59.5 (2.34)
4.82
86.7 (3.41)
90501-603L2
24.5 (2.50)
441 (45)
Yellow-White-Yellow
6.0 (0.236)
59.5 (2.34)
5.39
91.4 (3.60)
90501-603L3
27.0 (2.75)
441 (45)
Green-White-Green
6.0 (0.236)
59.5 (2.34)
5.08
89.8 (3.54)
90501-624L8
31.9 (3.25)
343 (35)
Orange-Silver-Orange
6.2 (0.244)
59.5 (2.34)
5.00
84.2 (3.32)
9
RX10RSK, RXW10K, RXW10SK
RX10MK, RX10MSK
IANOSJP
GEAR SELECTION
----------------------(f) Clutch weight
I
I
~O~ ~
[BJ Weight g (oz) [AJ Parts no.
without bush and rivets
8BU-17605-20
45.41 (1.60)
80G-17605-00
34.26 (1.209)
80J-17605-00
37.77 (1.333)
80N-17605-10
39.76 (1.40)
[g Shape & 10 mark
[Q] Standard
RX10MK, RX10MSK
00808
000
om
8EK-17605-00
39.00 (1.376)
8ES-17605-00
54.6 (1.93)
8FA-17605-10
63.8 (2.25)
A
o
00 RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK
10
I
GEAR SELECTION
INSP
ADJ
® Weight rivets [A]
Parts No.
[BJ
[Q]
Length mm (in)
Material
[Q]
Weight g (oz)
[:EJ
[E]
Standard
Effects
~ Increased Force
90261-06033
Steel
17.2 (0.677)
4.5 (0.159)
IN: RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK
90269-06006
Steel
17.2 (0.677)
3.6 (0.127) with hole
OUT: RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK
.4~
90261 -0601 9
Steel
13.3 (0.524)
3.1 (0.109)
90266-06002
Steel
13.3 (0.524)
2.4 (0.085) with hole
90266-06001
Aluminum
13.3 (0.524)
0.8 (0.028) with hole
IN: RX10MK, RX10MSK OUT: RX10MK, RX10MSK
~,
[8] Decreased Force
None
® Rollers 1.0.9 mm (0.354 in)
[A]
Roller with bushing part number
8FG-17624-00
[BJ
Outside diameter mm(in) 14.5 (0.57)
[Q]
Bushing type (PIN) VESPEL TP-8549
[Q]
Identification mark (Width)
~ Grooved
[:EJ
Standard
[D
.. 8FG-17624-10
15.0 (0.59)
8FG-17624-20
15.6 (0.61)
[8]
90386-09001
8FG-17624-30
8FG-17624-40
16.0 (0.63)
16.5 (0.65)
Grooved
(14.6 mm)
IT]
VESPEL TP-8549
No Mark RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
90386-09001
(14.6 mm)
VESPEL TP-8549
[JJ Grooved & Grooved
90386-09001
(14.6 mm)
VESPEL TP-8549
Increased force
~~
(14.6 mm)
VESPEL TP-8549
Effects
& Machined
""
90386-09001
[E]
[K]
Machined
" M Decreased force
90386-09001
(14.6 mm)
11
INSP ADJ
FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: • Spring preload
2
Adjustment steps: • Loosen the lock nut CD • Turn the spring seat ® in or out. RX10K, RX10RK, RX10RSK, RXW10SK Spring seat distance
Shorter
Preload
Harder +--
RXW10K,
Standard +--
--+
Longer
--+
Min. Length@
Softer Max.
250mm (9.84 in)
258mm 260mm (10.16 in) (10.24 in)
RX10MK, RX10MSK
Spring seat distance
Shorter
Standard
Preload
Harder +--
+--
--+
--+
Min. Length@
213 mm (8.39 in)
Longer Softer Max.
223mm (8.78 in)
223mm (8.78 in)
Be sure that the left and right spring preloads are the same.
~ ---------This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could cause it to explode.
12
REAR SUSPENSION
INSP ADJ
REAR SUSPENSION Stopper band 1. Adjust: • Stopper band tension
A
Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. (RX10MK, RX10MSK) NOTE: - - - - - - - - - - - - This adjustment affects the handling characteristics of the machine.
A
o
o
o
o
Adjustment steps: • Loosen the stopper band nut CD. • The position of the hole of @ ~ ® or CD is changed and the tension of a stopper band is adjusted. Rength
RX10K, RX10RK, RX10RSK:
@
B
+--
--+
®
--+
CD
RX10MK, RX10MSK:
@
+--
Longer (Maximum) Effects
Less weight on skis; More weight transfer
Shorter (Minimum) More weight on skis; Less weight transfer
• Tighten the stopper band nut.
,
~~
Stopper band nut: 4 Nm (0.4 mekg, 2.9 ftelb)
[AJ RX10K, RX10RK, RX10RSK [BJ RX10MK, RX10MSK o
0
13
IANOSJP
REAR SUSPENSION
I
~O~ ~
I
--------------------------Spring preload (RX1 OK, RX1 ORK, RX10RSK) I
1. Adjust: - Spring preload
Adjustment step:
~ ---------This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could cause it to explode. - Turn the adjusting ring tion.
CD
to the proper posi-
Spring adjuster position
1
Preload
Softer
2
3 +--
Standard
5 --+
7
6
Harder
4
- Changing the stopper ring position.
Spring adjuster position Preload
4
ÂŽ
1
Softer
to the proper
3
2 +--
Standard
--+
Harder
1
Damping (RX10K, RX10RK, RX10RSK)
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: -Damping
Adjustment step: - Turn the adjusting handle CD in direction @ or@. (Maximum: 11 clicks) Adjustment dial S turning direction Damping force
14
Softer
H +--
--+
Harder
IANOSJP
REAR SUSPENSION
I
~O~ ~
-------------------------Spring preload (RX10MK, RX10MSK) I
1. Adjust: - Spring preload Adjustment steps: - Turn the adjusting ring tion.
CD to the proper posi-
Spring adjuster position
1
Preload
Softer
2
3
--+ Harder
+--
[AJ Front Standard
5
4
3
- Turn the adjusting hook ® to the proper position.
Spring adjuster position Preload
5
M
H
Soft
Medium
Hard
[BJ Rear Standard
M
Control rod (RX10K, RX10RK, RX10RSK) 1. Adjust: - Control rod stroke @ Adjustment steps: -Loosen the locknut CD. - Check the adjusting rod length using the scale on the special wrench ® included in the owner's tool kit.
®
- Turn the adjusting rod @ in direction @ or @ to adjust the control rod stroke.
Adjusting position
MIN Decrease @pitching
Effect Standard
STD
MAX Increase --+@weight transfer
+--
STD
- While holding the adjusting rod @ securely, tighten the locknut CD.
Locknut: 35 Nm (3.5 m-kg, 25 ft-Ib)
15
I
IANOSJP
REAR SUSPENSION
-------------------------Control rod (RX10MK, RX10MSK) I
I
~O~ ~
I
1. Adjust: - Control rod stroke ÂŽ
Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: - Loosen the lock nut CD. - Turn the adjusting nut ÂŽ in or out to adjust the control rod stroke.
321
Adjusting position
1 Increase weight transfer
Effect Standard
2
+--
3
--+
Decrease pitching
2
~ --------Never adjust the control rods beyond the maximum range indicated on the rods with red paint@.
- While holding the adjusting bolt securely, tighten the locknut CD.
Locknut: 25 Nm (2.5 m-kg, 18 ft-Ib)
16
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~ I
CHASSIS STEERING RX10MK, RX10MSK
2
I [BJ : I [AJ :
Order 1 2
3 4 S 6 7 8
9 10 11 12
Job name/Part name
Q'ty
Handlebar removal Handlebar cover Plastic band Thumb warmer lead coupler Thumb warmer switch lead coupler Engine stop switch coupler Brake switch coupler Headlight beam switch coupler Grip warmer lead coupler Grip warmer switch lead coupler Throttle cable holder Throttle cable Brake lever holder
10 Nm (1.0 mekg, 7.2 ftelb) 15 Nm (1.5 m-kg, 11 tt-Ib)
Remarks Remove the parts in the order listed below.
1
3 1 1 1 1 1 4 1 1 1 1
17
Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_N_G_I CHAS
I~ I
2
I [BJ : I
[A] :
Order
13 14 15 16 17 18
Job name/Part name Master cylinder assembly Handlebar holder (upper) Cable holder Handlebar Handlebar holder (lower) Handlebar joint
10 Nm (1.0 m-kg, 7.2 tt-Ib) 15 Nm (1.5 m-kg, 11 tt-Ib)
Q'ty
Remarks
1 2 1 1 1 1
NOTE: After installing all parts, refer to "CABLE ROUTING" in CHAPTER 9, to check the cable, lead and hose routings.
For installation, reverse the removal procedure.
18
________________S_KI_lcHASI~I SKI RX10K, RX10RK, RX10RSK
IAJ : I
19 Nm (1.9 mekg, 14 ftelb)
[BJ :
17 Nm (1.7 mekg, 12 ftelb)
I [Q] : I [Q] : I ~
11 Nm (1.1 mekg, 8.0 ftelb) 48 Nm (4.8 mekg, 35 ftelb)
: CD ESSO beacon 325
~
grease or Aeroshell grease #7A
~ ~
I
3
'6~~
~'
mlJ1
~'11
®
~5A
~
~® ~
B
3 4 5 6 7
~
C:~l ~I~!~ "P11 l'~_ @~
I
I
.
"x,
""?lJ
1 2
,_7
~~I~~' -~ ~~~I ',,~
c
Order
~
""@
Q'ty
Job name/Part name
~
5
/
~
2
Remarks Remove the parts in the order listed below.
Ski removal Cotter pin Bolt Collar Nut Collar Ski stopper Ski
1 1 1 1 2 1 1
For installation, reverse the removal procedure.
19
________________S_KI_lcHASI~I RX10MK, RX10MSK
IAJ : I
19 Nm (1.9 mekg, 14 ftelb)
[BJ :
17 Nm (1.7 mekg, 12 ftelb)
I [Q] : I [Q] : I ~
11 Nm (1.1 mekg, 8.0 ftelb) 48 Nm (4.8 mekg, 35 ftelb)
: CD ESSO beacon 325 grease or Aeroshell grease #7A
7
Order
Q'ty
Job name/Part name
Remove the parts in the order listed below.
Ski removal 1 2
3 4 5 6 7
Remarks
Cotter pin Bolt Collar Nut Collar Ski stopper Ski
1 1 1 1 2 1 1
For installation, reverse the removal procedure.
20
pOTWRRI~1 I -----------------------POWER TRAIN DRIVE CHAIN HOUSING
~
DRIVE CHAIN HOUSING RX10K, RX10MK, RX10MSK
[A] : 1 [BJ :
16 Nm (1.6 m-kg, 12 tt-Ib)
I
[Q] : 1=========~
I==========
[Q] : [E] : 1=====::::::::===~ _
Order
Job name/Part name
Q'ty
Drive chain housing removal 1 2 3 4 S 6 7 8
9 10 11 12 13 14
Remarks Remove the parts in the order listed below. Refer to "BRAKE". Refer to "BRAKE".
Brake caliper Parking brake Right side cover Collar Brake disc Chain tension adjuster Drain bolt Drive chain housing cover Chain tensioner Roller Drive sprocket Collar Drive chain Driven sprocket Collar Drive chain housing
1 1 1 1 1 1 1 1 1 1 1 1 1 1
Loosen. Drain.
For installation, reverse the removal procedure. 21
pOTWRRI~1 I ---------------------------DRIVE CHAIN HOUSING
~
INSTALLATION 1. During installation, pay attention to the following.
[AJ Make sure that the bearing seals face towards the drive chain as shown.
[BJ Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps.
[QJ [QJ [QJ Be sure to install the spacers in their original positions, otherwise the brake disc and jackshaft will stick.
[Q] 0.2
~ 0.7 mm (0.008 ~ 0.028 in)
...... : ESSO beacon 325 grease or Aeroshell grease #7A
For the jackshaft and drive chain housing installation, refer to "SECONDARYSHAFT". 2. Fill: • Drive chain housing oil Refer to "DRIVE CHAIN" in CHAPTER 2. 3. Adjust: • Drive chain slack Refer to "DRIVE CHAIN" in CHAPTER 2.
22
pOTWRRI~1 I -----------------------DRIVE CHAIN HOUSING
~
WITH REVERSE MODEL RX1 ORK, RX10RSK
e
e
[AJ : 1==1=6=N=m=(1=.6=m=e=k=9,=1=2=ft=lb=)=1 [Q] : 1==9=0=N=m=(9=.0=m=e=k=9,=6=5=ft=lb=)= [6J : 24 Nm (2.4 mekg, 17 ftelb) [8 : 10 Nm (1.0 mekg, 7.2 ftelb) =====::::::::===~ [Q] : 48 Nm (4.8 mekg, 35 ftelb) [E] : 1 6_N_m_(_0_.6_m_ek_9_,4_._3_fte_lb_)_
I I
Order
I I
I
Job name/Part name
Q'ty
Drive chain housing removal
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
Remarks Remove the parts in the order listed below. Refer to "BRAKE". Refer to "BRAKE".
Brake caliper Parking brake Right side cover Collar Brake disc Chain tension adjuster Joint Shift rod Shift lever assembly Lever Drain bolt Collar Drive chain housing cover Lever rod Washer Counter gear Spring
1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 23
Loosen.
Disconnect the gear position switch leads. Drain.
pOTWRRI~1 I -----------------------DRIVE CHAIN HOUSING
Order
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Job name/Part name
Q'ty
~
Remarks
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Chain tensioner Roller Collar Spring Journal Reverse driven gear Washer Forward driven sprocket Collar Reverse drive gear Drive sprocket Drive chain Collar Washer Plate Shaft Drive chain housing
For installation, reverse the removal procedure.
24
pOTWRRI~1 I ---------------------------DRIVE CHAIN HOUSING
~
INSTALLATION 1. During installation, pay attention to the following.
[AJ Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps.
[BJ Make sure that the bearing seals face towards the drive chain as shown.
[QJ [QJ Be sure to install the spacers in their original positions, otherwise the brake disc and jackshaft will stick.
[Q] 0.2
~ 0.7 mm (0.008 ~ 0.028 in)
...... : ESSO beacon 325 grease or Aeroshell grease #7A
For the jackshaft and drive chain housing installation, refer to "SECONDARYSHAFT".
2. Install: • Lever rod CD 3. Adjust: • Lever rod length @
Adjustment steps: • Loosen the locknuts ®. • Turn the lever rod CD in or out until the specified length is obtained.
I~
Lever rod length: 27 mm (1.06 in)
• Tighten the locknuts.
25
pOTWRRI~1 I -------------------------DRIVE CHAIN HOUSING
~
4. Install: • Shift rod CD 5. Adjust: • Shift rod length @
Adjustment steps: • Move the shift lever to the "FWD." position. • Loosen the locknuts ®. • Turn the shift rod CD so that shift rod free play is 0 mm (in direction where @ can be shortened appropriately) and then turn back the shift rod 1/4 turns. • Tighten the locknuts. 6. Fill: • Drive chain housing oil Refer to "DRIVE CHAIN" in CHAPTER 2. 7. Adjust: • Drive chain slack Refer to "DRIVE CHAIN" in CHAPTER 2.
26
_______________BR_A_K_E_lp~:RICU9)1 BRAKE
I [BJ : I
[AJ :
Order 1 2
3 4 5
6 Nm (0.6 mekg, 4.3 ftelb) 48 Nm (4.8 m-kg, 35 tt-Ib)
Job name/Part name
Q'ty
Brake pad removal Cap bolt Retaining pin Pad spring Brake pad Brake caliper assembly
Remarks Remove the parts in the order listed below.
1 1 1 2 1 For installation, reverse the removal procedure.
27
_______________BR_A_K_E_lp~:RICU9)1 Disc brake components rarely require disassembly. DO NOT: • Do not disassemble components unless absolutely necessary. • Do not use solvents on internal brake components. • Do not use contaminated brake fluid for cleaning. Use only clean brake fluid. • Do not allow brake fluid to contact the eyes, otherwise eye injury may occur. • Do not allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur. • Do not disconnect any hydraulic connection, otherwise the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly. BRAKE PAD REPLACEMENT NOTE: - - - - - - - - - - - - It is not necessary to disassemble the brake caliper and brake hose in order to replace the brake pads.
1. Remove: • Brake pads CD
NOTE: - - - - - - - - - - - - • Do not depress the brake lever when the caliper or disc is off the machine otherwise the brake pads will be forced shut. • Install a new brake pad spring and shims when the brake pads are replaced. • Replace the pads as a set if either one is found to be worn to the wear limit @.
~l
I:6l__ SCH4600
28
Wear limit: 7 ._ 5_m _m _{O_._30_in_>- - - - -
_______________BR_A_K_E_lp~:RICU9)1 2. Install: • Brake pads • Pad spring
Installation steps: • Connect a suitable hose CD tightly to the caliper bleed screw ®. Put the other end of this hose into an open container. • Loosen the caliper bleed screw and push the pistons into the caliper with your finger. • Tighten the caliper bleed screw ®. ,
~
Bleed screw: 6 Nm (0.6 mekg, 4.3 ftelb)
• Install the brake pads and pad spring. 3. Inspect: • Brake fluid level Refer to "BRAKE FLUID LEVEL INSPECTION" in CHAPTER 2. 4. Check: • Brake lever operation A soft or spongy feeling --+ Bleed brake system. Refer to "AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)" in CHAPTER 2.
29
_______________BR_A_K_E_lp~:RICU9)1
I [BJ : I [Q] : I [Q] : I [AJ :
Order
1 2
3 4 5 6 7
30 Nm (3.0 mekg, 22 ftelb) 48 Nm (4.8 mekg, 35 ftelb) 13 Nm (1.3 mekg, 9.4 ftelb) 16 Nm (1.6 mekg, 12 ftelb)
Job name/Part name
Q'ty
Brake caliper and parking brake removal Brake fluid Brake hose Brake caliper assembly Parking brake cable Spring Lever Parking brake assembly Collar
Remarks Remove the parts in the order listed below. Drain.
1 1 1 1 1 1 1 For installation, reverse the removal procedure.
30
_______________BR_A_K_E_lp~:RICU9)1 BRAKE CALIPER DISASSEMBLY NOTE: - - - - - - - - - - - - Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: • Pistons • Piston oil seals CD
Removal steps: • Using a piece of wood ®, lock the right piston. • Blow compressed air into the hose joint opening @ to force out the left piston from the caliper body. • Remove the piston seals and reinstall the piston. • Repeat the previous steps to force out the right piston from the caliper body.
~ ---------• Never try to pry out the pistons. • Do not loosen the retaining pin @.
BRAKE CALIPER INSPECTION AND REPAIR Recommended brake component replacement schedule Brake pads
As required
Piston seals and dust seals
Every two years
Brake hose
Every two years
Brake fluid
Only when brakes are disassembled.
~ ---------All internal brake components should be cleaned only with new brake fluid. Do not use solvents as they will cause seals to swell and distort.
31
_______________BR_A_K_E_lp~:RICU9)1 1. Inspect: • Caliper piston CD Scratches/rust/wear --+ Replace the caliper assembly. • Caliper cylinder ® Wear/scratches --+ Replace the caliper assembly. • Caliper body @ Cracks/ damage --+ Replace. • Oil delivery passage (caliper body) Blowout with compressed air.
~ ---------Replace the piston seals and dust seals whenever a caliper is disassembled.
BRAKE CALIPER ASSEMBLY
~ ---------• All internal parts should be cleaned only with new brake fluid. • Internal parts should be lubricated with brake fluid when installed. ~
·u
Recommended brake fluid: DOT 4
• Replace the piston seals and dust seals whenever a caliper is disassembled.
BRAKE CALIPER INSTALLATION 1. Install: • Brake hose CD
When installing the brake hose CD onto the brake caliper ®, make sure that the brake pipe touches the projection @ on the brake caliper. 32
pOTWRRI~1 I -----------------------SLIDE RAIL SUSPENSION
~
SLIDE RAIL SUSPENSION RX10K, RX10RK, RX10RSK
[A] :
I
Order
72 Nm (7.2 m-kg, 52 tt-Ib)
Job name/Part name
Q'ty
Slide rail suspension removal
1 2
Remarks Remove the parts in the order listed below. Loosen. Loosen.
Rear axle nut Tension adjuster Slide rail suspension Collar
1 2 For installation, reverse the removal procedure.
33
pOTWRRI~1 I ------------------------SLIDE RAIL SUSPENSION
Order
Job name/Part name
Q'ty
Slide rail suspension disassembly
CD 速
@ @ @ @
(J)
速 速 速
@ @ @ @
~
Remarks Remove the parts in the order listed below.
Shock absorber adjuster assembly Stopper band Shaft Rubber collar Shock absorber Spacer Collar Oil seal Bearing Control rod assembly Spacer Collar Oil seal Bearing
1 1 1 2 1 2 2 4 2 1 2 2 4 2
34
pOTWRRI~1 I --------------------SLIDE RAIL SUSPENSION
Order
® ®
@
@ @
@ @
@ @ @ @ @ @ @ @ @
®
@
Job name/Part name
Q'ty
Front pivot arm Bushing Collar Sliding runner Suspension wheel Suspension wheel bracket Shaft Collar Front pivot arm bracket Bushing Collar Shaft Rear pivot arm Circlip Guide wheel Bushing Shaft Rear pivot arm bracket
1 4 2 2 6 6 1 1 2 4 2 1 1 2 2 2 1 1 35
Remarks
~
pOTWRRI~1 I -----------------------SLIDE RAIL SUSPENSION
Order
@ @
®
@
Job name/Part name
Q'ty
~
Remarks
3
Guide wheel Collar Tension adjuster Rear axle shaft
4 2 1
For assembly, reverse the disassembly procedure.
36
pOTWRRI~1 I -------------------------SLIDE RAIL SUSPENSION
~
RX10MK, RX10MSK
[A] :
I
Order
72 Nm (7.2 m-kg, 52 tt-Ib)
Job name/Part name
Q'ty
Slide rail suspension removal
1 2
Remarks Remove the parts in the order listed below. Loosen. Loosen.
Rear axle nut Tension adjuster Slide rail suspension Collar
1 2 For installation, reverse the removal procedure.
37
pOTWRRI~1 I -----------------------SLIDE RAIL SUSPENSION
Order
Job name/Part name
Q'ty
Slide rail suspension disassembly
CD ®
@ @ @ @
(J)
® ® ®
@ @ @ @ @
®
~
Remarks Remove the parts in the order listed below.
2 1
Stopper band Shaft Rubber collar Front shock absorber Collar Bushing Front pivot arm Shaft Bushing Collar Suspension wheel assembly Shaft Suspension bracket Bushing Bracket Collar
3 1 2 4 1 1 2 2 2 1 1 2 1 2 38
_ _ _ _ _ _ _ _ _ _ pOTWRRI~1 SLIDE RAIL SUSPENSION
Order
@ @ @ @ @ @ @ @ @
®
@ @ @ @
®
@ @ @
®
Job name/Part name
Q'ty
2 2 1 2 2 4 4 1 2 2 1 2 2 2 2 1 2 2 1
Suspension wheel Hook assembly Rear shock absorber Collar Reay rod Collar Bushing Shaft Collar Bushing Braket Collar Guide wheel Spacer Rear spring Shaft Bushing Rear pivot arm protector Rear pivot arm
39
Remarks
~
SLIDE RAIL SUSPENSION
~
4
,~~oo /~~ ~,/ '-
C<-/
43
For assem bly, reverse the disassenbly procedure.
40
pOTWRRI~1 I --------------------------SLIDE RAIL SUSPENSION
~
INSPECTION 1. Inspect: • Suspension wheel • Guide wheel Cracks/ damage --+ Replace. • Wheel bearing Wheel turns roughly --+ Replace.
SCH4840
2. Inspect: • Stopper band CD Frayed/damage --+ Replace. • Relay rod ® (RX10MK, RX10MSK) Bends/damage --+ Replace. • Shock absorber @ Oil leaks/damage --+ Replace. • Bushings Wear/cracks/damage --+ Replace. • Front pivot arm @ • Rear pivot arm @ • Suspension wheel bracket @ • Sliding frame (J) Cracks/ damage --+ Replace. • Slide runner @ Wear/damage --+ Replace.
A
[AJ RX10K, RX10RK, RX10RSK [aJ RX10MK, RX10MSK
8
B
3
7
41
SLIDE RAIL SUSPENSION
---------------------------
Ip~:RICU9)1
Control rod parts number
B
A
®
®
00 I
~ -----------~- 0 @
[BJ RX10MK, RX10MSK
[AJ RX10K, RX10RK, RX10RSK [AJ Control rod 1
[BJ Length ® mm (in)
[Q] Length @ mm (in)
[Q] Length © mm (in)
RX10K, RX10RK, RX10RSK
292.3 (11.51)
150.5 (5.93)
-
RX10MK, RX10MSK
228.8 (9.01)
198.7 (7.82)
2.5P x 2 = 5 (0.098P x 2 = 0.196)
[:EJ Control rod 1
[E] Control rod 2
parts number
parts number
8FU-4745A-00 (RX10K, RX10RK, RX10RSK)
8FU-47458-00
[:EJ Control rod 1
~ Stopper control 1
parts number
parts number
8FK-4745A-00 (RX10MK, RX10MSK)
8ES-4745D-00
[8] Washer plate parts number IT] Washer plate thickness mm (in) [JJ Upper [K] Lower 90202-16229 2.5 (0.098)
8FU-47384-00 7.5 (0.300)
[8] Washer plate parts number IT] Washer plate thickness mm (in) [JJ Upper [K] Lower 90202-16229 2.5 (0.098)
42
90202-16230 5.0 (0.197)
pOTWRRI~1 I -----------------------------FRONT AXLE AND TRACK
A
102 mm (4.02 in)
123mm (4.84 in)
FRONT AXLE AND TRACK
102mm (4.02 in)
INSTALLATION 1. Install: • Sprocket wheels • Guide wheels NOTE: - - - - - - - - - - - - • When pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel. • Position each sprocket wheel on the axle as shown in the illustration.
93.3 mm (3.67 in) 182.8 mm (7.20 in)
132.6 mm (5.22 in)
~
164.1 mm (6.46 in)
B
[AJ RX10K, RX10RK, RX10RSK [BJ RX10MK, RX10MSK
93.3 mm (3.67 in)
2. Place the track in the chassis.
A
NOTE: - - - - - - - - - - - For track with a direction of rotation mark @: Install the track with the mark pointing in the direction of track rotation.
®
[AJ RX10K, RX10RK, RX10RSK [BJ RX10MK, RX10MSK
43
SEAT AND FUEL TANK
I ENG I @>
ENGINE SEAT AND FUEL TANK
4
Order
Job name/Part name
Q'ty
Seat and fuel tank removal 1 2
3 4 5 6 7 8
Remarks Remove the parts in the order listed below.
2 1 2 1 1 1 2 1
Muffler end pipe Rear cover Muffler side cover Tail/brake light cover Seat Fuel tank cover Side cover Fuel tank
For installation, reverse the removal procedure.
44
EXHAUST PIPE AND MUFFLER
I ENG I @>
EXHAUST PIPE AND MUFFLER
I [BJ : I [g : I [Q] : I [AJ :
20 Nm (2.0 mekg, 14 ftelb) 25 Nm (2.5 m-kg, 18 tt-Ib) 16 Nm (1.6 mekg, 12 ftelb) 11 Nm (1.1 m-kg, 8 tt-Ib)
I
/
Order
Job name/Part name
Q'ty
Exhaust pipe and muffler removal
Remove the parts in the order listed below. Refer to "SLIDE RAIL SUSPENSION" in CHAPTER 4. Refer to "FRONT AXLE AND TRACK" in - CHAPTER 4. Refer to "SEAT AND FUEL TANK".
Slide rail suspension
1 2
3 4 5
Remarks
-0
Front axle assembly Track Seat and fuel tank Protector Muffler Exhaust pipe Gasket Band
1 1 2 2 2 For installation, reverse the removal procedure.
45
HEAT EXCHANGER
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COOLING SYSTEM HEAT EXCHANGER RX10MK, RX10MSK
[AJ : 1~_3_5_N_m......(_3._5_m_ek.....g__,_25_f_te_lb...... } ___ 5
20
25
Order
Job name/Part name
Q'ty
Heat exchanger removal Coolant
Remove the parts in the order listed below. Drain. Refer to "COOLING SYSTEM" in CHAPTER 2. Refer to "PRIMARY SHEAVE AND DRIVE V-VELT" in CHAPTER 4.
Primary sheave assembly 1 2 3 4 5 6 7 8
9 10 11 12
Remarks
1 1 1 1 1 1 1 1 1 1 1 1
Coolant reservoir tank Coolant hose 1 Heat exchanger (right) Coolant hose 2 Heat exchanger (rear) Coolant hose 3 Heat exchanger (left) Coolant hose 4 Heat exchanger (front) Coolant hose 5 Water pump assembly Coolant hose 6 46
HEAT EXCHANGER
[AJ : 1
ICOOL I ~ I
3_5 _N_m_(_3,_5_m_e k_9_,_25_f_te_1b_)____ 5
20
25
Order 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Job name/Part name
Q'ty
Coolant pipe 1 Coolant pipe 2 Coolant hose 7 Coolant hose 8 Thermostat assembly Coolant hose 9 Coolant hose 10 Oil cooler outlet hose Oil cooler Oil cooler inlet hose Pipe 3 Water pump hose Carburetor heater hose Coolant cock 1 Carburetor heater hose 1 Heat exchanger hose a-ring
1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 47
Remarks
ICOOL I ~ I
HEAT EXCHANGER
[AJ : 1
35_N_m_(_3._5_me_ k9_,_25_f_te l_b)__
5
20
Order 30 31
Job name/Part name
Q'ty
Coolant hose 11 Coolant hose 12
Remarks
1 1 For installation, reverse the removal procedure.
48
GENERAL SPECIFICATIONS
I
SPEC I
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SPECIFICATIONS GENERAL SPECIFICATIONS RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Model code number:
Dimensions: Overall length
Overall width
Overall height Weight: Dry weight
Minimum turning radius: Clockwise
Counterclockwise
Engine: Engine type Cylinder type Displacement Bore x stroke Compression ratio Maximum hose power r/min Maximum torque r/min Standard compression pressure (at sea level) Starting system Lubrication system:
8FU1 (RX1 OK for U.S.A/Canada) 8FV1 (RX1 ORK for U.S.A/Canada) 8FY1 (RX1 ORSK for U.S.A/Canada) 8FX1 (RXW1 OK for U.S.A/Canada) 8GB1 (RXW1 OSK for U.S.A/Canada) 8FW1 (RX1 OMK for U.S.A/Canada) 8GA1 (RX10MSK, for U.S.A/Canada) 2,755 mm (108.5 in) (RX10K, RX10RK, RX10RSK) 3,000 mm (118.1 in) (RXW10K, RXW10SK) 3,185 mm (125.4 in) (RX10MK, RX10MSK) 1,210 mm (47.6 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 1,165 mm (45.8 in) (RX10MK, RX10MSK) 1,215 mm (47.8 in) (RX1 OK, RX10RK, RXW10K, RX10MK) 1,150 mm (45.3 in) (RX10RSK, RXW10SK, RX10MSK) 247 254 264 263
kg kg kg kg
3.9 4.2 4.3 3.9 4.2 4.3
m m m m m m
(545.0 (560.1 (582.1 (579.9
(12.8 (13.8 (14.1 (12.8 (13.8 (14.1
ft) ft) ft) ft) ft) ft)
Ib) Ib) Ib) Ib)
(RX10K) (RX10RK, RX10RSK) (RXW10K, RXW10SK) (RX10MK, RX10MSK)
(RX10K, RX10RK, RX10RSK) (RXW10K, RXW10SK) (RX10MK, RX10RSK) (RX10K, RX10RK, RX10RSK) (RXW10K, RXW10SK) (RX10MK, RX10MSK)
Liquid-cooled, 4-stroke, DOHC Backward-inclined parallel 4-cylinder 998 cm 3 (60.9 cu.in) 74 X 58 mm (2.91 x 2.28 in) 11.8 10,250 r/min 7,500 r/min 1,450 kPa (14.5 kg/cm 2 , 206 psi) at 400 r/min Electric starter Dry sump
49
GENERAL SPECIFICATIONS Model
2.8 L (2.5 Imp qt, 3.0 US qt) 3.0 L (2.6 Imp qt, 3.2 US qt) 3.8 L (3.3 Imp qt, 4.0 US qt)
Oil filter: Oil filter type
Cartridge (paper)
Drive chain housing oil: Type Capacity
Gear oil API "GL-3" SAE#75 or #80 0.25 L (8.8 Imp OZ, 8.5 US oz)
Fuel: Type
Tank capacity
4.9 L (4.32 Imp qt, 5.18 US qt) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 6.4 L (5.64 Imp qt, 6.76 US qt) (RX10MK, RX10MSK) Regular unleaded gasoline (Pump Octane R+M; 88 or higher) 2 Research Octane; 93 or higher (for Europe) 39.4 L (8.62 Imp gal, 10.4 US gal) BSR37 x 4 MIKUNI
Spark plug: Type Manufacture Gap
NGK R CR9E NGK 0.7 ~ 0.8 mm (0.028
Primary reduction: Primary reduction system Primary reduction ratio
Spur gear 1.19 (37/31)
Reverse system Chassis: Frame type Caster Ski stance (center to center)
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API SE, SF, SG or highter SAEOW-30
Carburetors: Type/Quantity Manufacture
Transmission: Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio
SPEC I
RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Engine oil: Type Oil capacity Periodic oil change With oil filter replacement Total amount
Coolant: Capacity
I
~
0.031 in)
V-Belt 3.8 : 1 ~ 1 : 1 Automatic centrifugal engagement Chain 1.58 (38/24) (RX10K, RX10RK, RX10RSK) 1.65 (38/23) (RXW10K, RXW10RK) 1.90 (40/21) (RX10MK, RX10MSK) No (RX1 OK, RX10MK, RX10MSK) Yes (RX1 ORK, RX10RSK, RXW10K, RXW10SK) Monocoque 23° 1,068 mm (42.0 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10RSK) 980 mm (38.6 in) (RX10MK, RX10MSK) 50
GENERAL SPECIFICATIONS
Track: Track type Track width Length on ground
Track deflection at 100 N (10 kg, 221b)
SPEC I
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RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Suspension: Front suspension type Rear suspension type
I
Independent double wishbone suspension Slide rail suspension Internal drive type 381 mm (15.0 in) 768 mm (30.2 in) (RX10K, RX10RK, RX10RSK) 944 mm (37.2 in) (RXW10K, RXW10SK) 1,068 mm (42.0 in) (RX10MK, RX10MSK) 25 ---- 30 mm (0.98 ---- 1.18 in) (RXW10K, RXW10SK) 30 ---- 35 mm (1.18 ---- 1.38 in) (RX10K, RX10RK, RX10RSK, RX10MK, RX10MSK)
Brake: Brake type Operation method
Caliper type disc brake handlebar, left hand operated
Electrical: Ignition system Generator system
DC-CDI/MITSUBISHI A.C. magneto
Bulb wattage x Quantity: Headlight Tail/Brake light Meter light High beam indicator light Information indicator light Low coolant temperature light
12 V, 12 V, 14 V, 14 V, 14 V, 14 V,
60 W/55 W x 2 5 W/ 21 W x 2 50 mA x 6 80 mA 80 mA 80 mA
51
MAINTENANCE SPECIFICATIONS
I
SPEC I
MAINTENANCE SPECIFICATIONS ENGINE RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Cylinder head: Volume (with spark plug) <Warpage limit>
13.45 ~ 14.05 cm 3 (0.82 ~ 0.86 cu. in) 0.1 mm (0.004 in)
* Lines indicate straight edge measurement.
Cylinder: Material Bore size <Taper limit> <Out of round> <Wear limit>
Aluminum alloy with dispersion coating 74.000 ~ 74.010 mm (2.9134 ~ 2.9138 in) 0.05 mm (0.002 in) 0.05 mm (0.002 in) 74.06 mm (2.9157 in)
Camshaft: Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance Camshaft dimensions Intake "A" <Limit> "B"
<Limit> Exhaust "A" <Limit> "B"
~B-
<Limit> Camshaft runout
Chain drive (left) 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in)
32.50 32.40 24.95 24.85 32.95 32.85 24.95 24.85
~ 32.60 mm (1.2795 mm (1.2756 in) ~ 25.05 mm (0.9823 mm (0.9783 in) ~ 33.05 mm (1.2972 mm (1.2933 in) ~ 25.05 mm (0.9823 mm (0.9783 in)
~
1.2835 in)
~
0.9862 in)
~
1.3012 in)
~
0.9862 in)
0.03 mm (0.0012 in)
Timing chain: Model/number of links Tensioning system
RH2015/130 Automatic
Valves, valve seats, valve guides: Valve clearance (cold) Intake Exhaust
0.11 0.21
~ ~
0.20 mm (0.0043 0.25 mm (0.0083
52
~ ~
0.0079 in) 0.0098 in)
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MAINTENANCE SPECIFICATIONS
I
SPEC I
RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Valve dimensions: Valve head diameter A Intake Exhaust
) \
~
22.9 24.4
~
1.76 1.76
~
~
23.1 mm (0.9016 24.6 mm (0.9606
~
2.90 mm (0.0693 2.90 mm (0.0693
~
~
0.9094 in) 0.9685 in)
Head Diameter
Valve face width B Intake Exhaust
~
~
0.1142 in) 0.1142 in)
Face Width
Valve seat width C Intake Exhaust
0.9 0.9
~
0.5 0.5
~
Seat Width
Valve margin thickness D Intake Exhaust
I ~~D
! \
~
~
1.1 mm (0.035 1.1 mm (0.035
~
0.9 mm (0.020 0.9 mm (0.020
~
~
~
0.043 in) 0.043 in)
0.035 in) 0.035 in)
Margin Thickness
Valve stem diameter Intake <Limit> Exhaust <Limit> Valve guide inside diameter Intake <Limit> Exhaust <Limit> Valve-stem-to-valve-guide clearance Intake <Limit> Exhaust <Limit> Valve stem runout limit
Valve seat width Intake Exhaust
3.975 ~ 3.990 mm (0.1565 3.945 mm (0.1553 in) 4.465 ~ 4.480 mm (0.1758 4.43 mm (0.1744 in)
~
0.1571 in)
~
0.1764 in)
4.000 ~ 4.012 mm (0.1575 4.05 mm (0.1594 in) 4.500 ~ 4.512 mm (0.1772 4.55 mm (0.1791 in)
~
0.1580 in)
~
0.1776 in)
0.01 0 ~ 0.037 mm (0.0004 0.08 mm (0.0031 in) 0.020 ~ 0.047 mm (0.0008 0.10 mm (0.0039 in) 0.01 mm (0.0004 in)
~
0.0015 in)
~
0.0019 in)
0.9 0.9
~ ~
1.1 mm (0.035 1.1 mm (0.035
53
~ ~
0.043 in) 0.043 in)
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MAINTENANCE SPECIFICATIONS
I
SPEC I
RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Valve spring: Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust W JI-----
- * Spring tilt Intake Exhaust /j Winding direction (top view) Intake Exhaust
Valve lifter: Valve lifter outside diameter Intake <Limit> Exhaust <Limit> Valve lifter hole inside diameter Intake <Limit> Exhaust <Limit>
m
Piston: Piston size (0) - - - D - ---------L Measuring point (H) I H Piston to-cylinder clearance <Limit> Piston pin bore off set Off-set direction Piston pin bore inside diameter
38.90 mm (1.53 in) 40.67 mm (1.60 in) 34.50 mm (1.36 in) 35.00 mm (1.38 in)
82 ---- 96 N (8.2 ---- 9.6 kg, 18.1 ---- 21.2 Ib) 110 ---- 126 N (11.0 ---- 12.6 kg, 24.3 ---- 27.8 Ib) 2.5 0 /1.7 mm (0.067 in) 2.5 0 /1.8 mm (0.071 in) Clockwise Clockwise
19.982 19.957 22.482 22.457
---- 19.988 mm (0.7867 ---- 0.7869 in) mm (0.7857 in) ---- 22.488 mm (0.8851 ---- 0.8854 in) mm (0.8841 in)
20.000 20.048 22.500 22.548
---- 20.018 mm (0.7874 ---- 0.7881 in) mm (0.7893 in) ---- 22.518 mm (0.8858 ---- 0.8865 in) mm (0.8877 in)
73.955 ---- 73.970 mm (2.9116 ---- 2.9122 in) 5 mm (0.20 in) 0.030 ---- 0.055 mm (0.0012 ---- 0.0022 in) 0.12 mm (0.0047 in) 0.5 mm (0.0197 in) Intake side 17.002 ---- 17.013 mm (0.6694 ---- 0.6698 in)
54
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I
SPEC I
MAINTENANCE SPECIFICATIONS
RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Piston pin: Piston pin outside diameter Piston pin length Piston pin to piston pin bore clearance <Limit> Piston ring: Sectional sketch Top ring Ring type ~~B IT Dimensions (B x T) 2nd ring B Ring type Dimensions (B x T) I T I Oil ring
r
c==s=r
~=rB
~I Dimensions (B x T) End gap (installed) Top ring 2nd ring Oil ring Side clearance (installed) Top ring 2nd ring
Connecting rod: Crankshaft-pin-to-big-end-bearing clearance Bearing color code
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16.991 ~ 17.000 mm (0.6689 ~ 0.6693 in) 51.4 ~ 51.5 mm (2.0236 ~ 2.0276 in) 0.002 ~ 0.022 mm (0.00008 ~ 0.0009 in) 0.072 mm (0.0028 in)
Barrel 0.90 x 2.75 mm (0.035 x 0.108 in) Taper 0.8 x 2.8 mm (0.031 x 0.110 in)
1.5 x 2.6 mm (0.059 x 0.101 in) 0.32 0.43 0.1 0
~ ~ ~
0.44 mm (0.01 0 0.58 mm (0.017 0.35 mm (0.004
0.030 0.020
~
0.016 -1
~ ~ ~
0.020 in) 0.023 in) 0.0014 in) ~
~
0.065 mm (0.0012 0.055 mm (0.0008
~
0.0026 in) 0.0022 in)
~
0.040 mm (0.0006
~
0.0016 in)
= Violet
0
= White
1 = Blue 2
= Black
3
= Brown
Crankshaft:
Width A Width B Crankshaft runout C Big end side clearance D Crankshaft-journal-to-crankshaftjournal-bearing clearance Bearing color code
52.40 ~ 57.25 mm (2.063 ~ 2.254 in) 300.75 ~ 302.65 mm (11.84 ~ 11.92 in) 0.03 mm (0.0012 in) 0.160 ~ 0.262 mm (0.006 ~ 0.010 in) 0.004 ~ 0.028 mm (0.0002 ~ 0.0011 in) -1
= Violet
55
0
= White 1 = Blue
2
= Black 3 = Brown
MAINTENANCE SPECIFICATIONS
(M.J) (M.A.J) (J.N) (N.J) (P.J) (P.A.J.) (P.O) (B.P.1 ) (B.P.2) (B.P.3) Pilot screw (P.S) Throttle valve (Th.V) Valve seat size (V.S) Starter jet (G.S) Float height (F.H) Fuel level (below the line on the float chamber) Engine idle speed
Fuel pump: Type Manufacturer Oil filter: Oil filter type Bypass valve opening pressure Oil pump: Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Max. impeller shaft tilt <Limit> Relief valve operating pressure Oil pressure (hot) Cooling system: Filler cap opening pressure Water pump type Reduction ratio Coolant type Coolant mixing ratio (coolant: water) Capacity
SPEC I
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RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Carburetor: Type/Quantity Manufacturer 1.0. mark Main jet Main air jet Jet needle Needle jet Pilot jet Pilot air jet Pilot outlet Bypass 1
I
BSR37/4 MIKUNI 8FA102 #135 #120 5DHP50-53-3 P4M #17.5 #140 1.0 0.8 0.8 0.8 Approx 2 #115 1.5 #75 11 ~ 15 mm (0.43 ~ 0.59 in) 3.0 ~ 4.0 mm (1.118 ~ 0.157 in) 1,350
Âą 100 r/min (1 ,250
~
1,450 r/min)
Diaphragm 8FA (MIKUNI) Cartridge (paper) 78 ~ 118 kPa (0.78 ~ 1.18 kg/cm 2 , 11.1 ~ 16.8 psi) Trochoidal 0.00 ~ 0.12 mm (0.000 0.09
~
0.15 mm (0.004
~
0.005 in)
~
0.006 in)
0.15 mm (0.0059 in) 0.072 mm (0.0028 in) 430 ~ 550 kPa (4.3 ~ 5.5 kg/cm 2 , 61.2 ~ 78.2 psi) 50 kPa (0.5 kg/cm 2 , 7.1 psi) at 1,450 r/min 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm 2 , 14 ~ 18 psi) Single-suction centrifugal pump (Impeller type) 37/31 x 23/18 (1.525) High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors 3 : 2 (60% : 40%) 4.9 L (4.32 Imp qt, 5.18 US qt) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 6.4 L (5.64 Imp qt, 6.76 US qt) (RX10MK, RX10MSK) 56
MAINTENANCE SPECIFICATIONS
I
SPEC I
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POWER TRAIN RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Transmission: Type Range of ratio Engagement speed r/min
Shift Sheave distance Sheave offset
r/min
V-belt: Part number/Manufacturer Circumference A Width "A" Wear limit "B"
0
Primary sheave spring: Part number Color code
Diameter Wire diameter
Preload Spring rate
Number of coils Free length
Set length Primary sheave weight arm: Part number (with bush)
Weight (without bush and rivets)
V-belt automatic 3.8 ~ 1.0 : 1 3,600 ± 200 r/min (3,400 ~ 3,800 r/min) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 4,200 ± 200 r/min (4,000 ~ 4,400 r/min) (RX10MK, RX10MSK) 10,250 ± 250 r/min (1 0,000 ~ 10,500 r/min) 268.5 mm (10.57 in) (267 ~ 270 mm (1 0.51 ~ 10.63 in)) 15 mm (0.59 in) (13.5 ~ 16.5 mm (0.53 ~ 0.65 in)) 8DN-17641-00/MITSUBOSHI 1,129 ~ 1,137 mm (44.4 ~ 44.8 in) 34.5 mm (1.36 in) 32.5 mm (1.28 in)
90501-582L1 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10RK) 90501-624L8 (RX10MK, RX10MSK) Yellow - Silver - Yellow (RX1 OK, RX1 ORK, RX1 ORSK, RXW1 OK, RXW10RK) Orange - Silver - Orange (RX10MK, RX10MSK) 59.5 mm (2.34 in) 5.8 mm (0.228 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10RK) 6.2 mm (0.244 in) (RX10MK, RX10MSK) 343 N (35 kg, 77 Ib) 24.5 N/mm (2.50 kg/mm, 140 Ib/in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10RK) 31.9 N/mm (3.25 kg/mm, 182 Ib/in) (RX10MK, RX10MSK) 4.92 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10RK) 5.00 (RX10MK, RX10MSK) 87.4 mm (3.44 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 84.2 mm (3.32 in) (RX10MK, RX10MSK) 73.4 mm (2.89 in) 8FA-17605-10 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 8BU-17605-20 63.8 g (2.25 oz) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 45.41 g (1.60 oz) (RX10MK, RX10MSK)
57
MAINTENANCE SPECIFICATIONS
Material Size Quantity Hole quantity Inner Part number Material Size Quantity Hole quantity Secondary sheave spring: Part number
Color code Outside diameter Wire diameter Hole position Sheave side-spring side (twist angle)
Spring rate
Number of coils Free length Torque cam angle
SPEC I
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RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Rivet: Outer Part number
I
90269-06006 (RX1 OK, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) Steel (RX1 OK, RX1 ORK, RX1 ORSK, RXW1 OK, RXW1 OSK, RX10MK, RX10MSK) 17.2 mm (0.677 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) 3 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK)
3 90261-06033 (RX1 OK, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) Steel (RX1 OK, RX1 ORK, RX1 ORSK, RXW1 OK, RXW1 OSK, RX10MK, RX10MSK) 17.2 mm (0.677 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK) 3 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK)
3 90508-60012 (RX10K, RX10RK, RX10RSK) 90508-60007 (RXW10K, RXW10SK, RX10MK, RX10MSK) PINK (RX10K, RX10RK, RX10RSK) White (RX10MK, RX10MSK, RXW10K, RXW10SK) 69.5 mm (2.736 in) 6 mm (0.236 in) 3-3 (60째) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 1-6 (70째) (RX10MK, RX10MSK)
11.88 N/mm (1.211 kg/mm, 67.80 Ib/in) (RX10K, RX10RK, RX10RSK) 12.66 N/mm (1.290 kg/mm, 72.25 Ib/in) (RXW10K, RXW10SK, RX10MK, RX10MSK) 5.53 (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 5.19 (RX10MK, RX10MSK) 75 mm (2.95 in) 51 째 - 43 (RX1 OK, RX10RK, RX10RSK, RXW10K, RXW10SK) 45째 (RX10MK, RX10MSK)
58
MAINTENANCE SPECIFICATIONS
Track: Part number
Width Length Pitch Number of links
Thickness "A"
Height "B"
~B
Track deflection at 100 N (10 kg, 221b) Slide rail suspension (Rear suspension): Front travel
Rear travel
Suspension spring rate Front
Rear
Spring wire diameter Front
Rear
SPEC I
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RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Drive chain: Type Number of links Secondary reduction ratio
I
Borg Warner Automotive 23RH303-70ASM 70L 38/23 (1.65) (RXW10K, RXW10SK) 38/24 (1.58) (RX10K, RX10RK, RX10RSK) 40/21 (1.90) (RX10MK, RX10MSK) 8FA-4711 0-00 (RX10K, RX10RK, RX10RSK) 8FG-4711 0-00 (RXW10K, RXW10SK) 8EP-47110-00 (RX10MK, RX10MSK) 381 mm (15.0 in) 3,072 mm (120.9 in) (RX10K, RX10RK, RX10RSK) 3,456 mm (136.1 in) (RXW10K, RXW10SK) 3,840 mm (151.2 in) (RX10MK, RX10MSK) 64 mm (2.52 in) 48 (RX10K, RX10RK, RX10RSK) 54 (RXW1 OK, RXW10SK) 60 (RX10MK, RX10MSK) 5.1 mm (0.20 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 5.8 mm (0.23 in) (RX10MK, RX10MSK) 31.8 mm (1.25 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 50.8 mm (2.00 in) (RX10MK, RX10MSK) 30 ---- 35 mm (1.18 ---- 1.38 in) (RX10K, RX10RK, RX10RSK, RX10MK, RX10MSK) 25 ---- 30 mm (0.98 ---- 1.18 in) (RXW10K, RXW10SK)
256 221 183 295 298 315
mm mm mm mm mm mm
(10.08 in) (RX10K, RX10RK, RX10RSK) (8.70 in) (RXW10K, RXW10SK) (7.20 in) (RX10MK, RX10MSK) (11.61 in) (RX10K, RX10RK, RX10RSK) (11.73 in) (RXW10K, RXW10SK) (12.40 in) (RX10MK, RX10MSK)
39.20 N/mm (4.0 kg/mm, 224 Ib/in) (RXW10K, RXW10SK) 20 N/mm (2.0 kg/mm, 114 Ib/in) (RX10MK, RX10MSK) 44.1 N/mm (4.5 kg/mm, 252 Ib/in) (RX10K, RX10RK, RX10RSK) 23 - 42 N/mm (2.4 - 4.3 kg/mm, 131 - 240 Ib/in) (RXW10K, RXW10SK) 1,900 Nmm/deg (193.74 kg/mm, 10,849 Ib/in) (RX10MK, RX10MSK) 8.8 mm (0.347 in) (RXW10K, RXW10SK) 7.5 mm (0.295 in) (RX10MK, RX10MSK) 11.5 mm (0.452 in) (RX10K, RX10RK, RX10RSK) 11.8 mm (0.465 in) (RXW10K, RXW10SK) 10.3 mm (0.406 in) (RX10MK, RX10MSK)
59
MAINTENANCE SPECIFICATIONS Model Suspension setting position: Hook setting length (Standard)
(Maximum) (Minimum) Full rate adjusting position **
I
SPEC I
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RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK 25 ± 0.5 mm RX10RSK) 15 ± 0.5 mm 10 ± 0.5 mm 35 mm (1.37 10 mm (0.40 B (RXW10K,
(0.98
± 0.02
in) (RX10K, RX10RK,
(0.59 ± 0.02 in) (RXW10K, RXW10SK) (0.39 ± 0.02 in) (RX10MK, RX10MSK) in) (RXW10K, RXW10SK) in) (RXW10K, RXW10SK) RXW10SK)
AB~** C
Shock absorber: Damping force Extension Compression Front Extension
Compression
Rear Extension
Compression
Slide runner: Thickness Wear limit Track sprocket wheel: Material Number of teeth
2,430 N/O.3 mls (247.61 kg/0.3 mIs, 546 Ib/0.3 m/s) (RX10K, RX10RX, RX10RSK) 1,490 N/O.3 mls (151.83 kg/0.3 mIs, 335 Ib/0.3 m/s) (RX10K, RX10RX, RX10RSK) 420 N/O.3 mls (42.83 kg/0.3 mIs, 94 Ib/0.3 m/s) (RXW10K, RXW10SK) 610 N/O.3 mls (62.15 kg/0.3 mIs, 137 Ib/0.3 m/s) (RX10MK, RX10MSK) 1,470 N/O.3 mls (149.90 kg/0.3 mIs, 330 Ib/0.3 m/s) (RXW10K, RXW10SK) 910 N/O.3 mls (92.73 kg/0.3 mIs, 204 Ib/0.3 m/s) (RX10MK, RX10MSK) 1,280 N/O.3 mls (130 kg/0.3 mIs, 288 Ib/0.3 m/s) (RXW10K, RXW10SK) 880 N/O.3 mls (89.67 kg/0.3 mIs, 198 Ib/0.3 m/s) (RX10MK, RX10MSK) 980 N/O.3 mls (100 kg/0.3 mIs, 220 Ib/0.3 m/s) (RXW10K, RXW10SK) 460 N/O.3 mls (46.87 kg/0.3 mIs, 103 Ib/0.3 m/s) (RX10MK, RX10MSK) 17.8 mm (0.70 in) 10 mm (0.39 in) High molecular weight polyethylene 9 T (RX1 OK, RX10RK, RX10RSK, RXW10K, RXW10SK) 8 T (RX1 OMK, RX10MSK)
Rear guide wheel: Material Outside diameter
High molecular weight polyethylene with rubber 178 mm (7.01 in)
Brake: Pad thickness Pad wear limit Pad to disk clearance Disc outside diameter Disc minimum thickness
10.2 mm (0.40 in) 7.5 mm (0.30 in) 0.025 ~ 0.115 mm (0.001 200 mm (7.87 in) 4 mm (0.16 in) 60
~
0.005 in)
MAINTENANCE SPECIFICATIONS
I
SPEC I
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CHASSIS Model
RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Frame: Frame material Seat height Luggage box location
Aluminum 720 mm (28.3 in) Front
Steering: Lock-to-Iock angle (left) (right) Ski alignment Toe-out size Caster angle
30.0° (R ski) 34.7° (L ski) 34.7° (R ski) 30.0° (L ski) Toe-out o ~ 15 mm (0 ~ 0.59 in) 23°
Ski: Ski material Length
Width
Ski suspension (Front suspension): Type Travel
Spring type Spring rate
Wire diameter
Shock absorber: damping force Extension
Compression
Plastic 1,020 mm (40.2 in) (RXW10K, RXW10SK) 1,021 mm (40.2 in) (RX10K, RX10RK, RX10RSK, RX10MK, RX10MSK) 132.0 mm (5.20 in) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK) 182.0 mm (7.17 in) (RX10MK, RX10MSK) Double wishbone system 221 mm (8.70 in) (RX1 OK, RX10RK, RX1 ORSK, RXW10K, RXW10SK) 175 mm (6.89 in) (RX10MK, RX10MSK) Coil spring 19 N/mm (1.9 kg/mm, 108 Ib/in) (RX10K, RX10RK, RX10RSK) 21 N/mm (2.1 kg/mm, 120 Ib/in) (RXW10K, RXW10SK, RX10MK, RX10MSK) 8.0 mm (0.315 in) (RX10K, RX10RK, RX10RSK) 8.2 mm (0.323 in) (RXW10K, RXW10SK) 7.8 mm (0.307 in) (RX10MK, RX10MSK) 2,090 N/O.3 m/s (209 kg/0.3 mIs, 461 Ib/0.3 m/s) (RX10K, RX10RK, RX10RSK) 1,300 N/O.3 m/s (132 kg/0.3 mIs, 292 Ib/0.3 m/s) (RXW10K, RXW10SX, RX10MK, RX10MSK) 610 N/O.3 m/s (61 kg 10.3 mIs, 135 Ib/0.3 m/s) (RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK)
61
MAINTENANCE SPECIFICATIONS
I
SPEC I
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ELECTRICAL RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model Voltage
12 V
Ignition system: Ignition timing (B.T.D.C.) Advanced type
5° at 1,450 r/min Digital type
Ignition coil: Model/Manufacturer Primary coil resistance Secondary coil resistance
F6T54975/MITSUBISHI 0.16 ---- 0.22 Q at 20°C (68°F) 5.0 ---- 6.8 kQ at 20°C (68°F)
Charging system: Type Nominal output
AC magneto 14 V/21 A at 5,000 r/min
DC-CDI: Magneto model/Manufacturer Standard Pickup coil resistance (color code) Stator coil resistance (color code) CDI unit model/Manufacturer
F4T47371/MITSUBISHI 14 V 30 A, 420 W at 5,000 r/min 189 ---- 231 Q at 20°C (68° F) (White/Red - White/Green) 0.19 ---- 0.24 Q at 20°C (68°F) (White - White) F8T40471/MITSUBISHI
Rectifier/ regulator: Type Model/Manufacturer No load regulated voltage (DC) Capacity (DC) Withstand voltage
Short circuit type FH001/SHINDENGEN 14.1 ---- 14.9 V 35A 40V
Battery: Specific gravity Manufacture Type
Ten hour rate amperage Electric starter system: Type Starter motor: Model/Manufacturer Output Armature coil resistance Continuity check Insulation check Brush Overall length Wear limit Spring pressure Commutator diameter Wear limit Mica undercut
1.32 YUASA YTX14L-BS 12V-12Ah (RX10K, RX10MK, RX10MSK) YTX20L-BS 12V-18Ah (RX10RK, RX10RSK, RXW10K, RXW10SK) 12 A (RX1 OK, RX10MK, RX10MSK) 18 A (RX1 ORK, RX10RSK, RXW10K, RXW10SK) Constant mesh type 8FA1/MORIC 12 V - 0.95 kW 0.008 ---- 0.010 Q at 20°C (68° F) More than 100 kQ at 20°C (68° F) 9.8 mm (0.39 in) 5 mm (0.20 in) 7.36 ---- 11.04 N (736 ---- 1,104 g, 26.0 ---- 38.9 oz) 28.5 mm (1.12 in) 27.5 mm (1.08 in) 1.5 mm (0.059 in) 62
MAINTENANCE SPECIFICATIONS
Starter relay: Model/Manufacturer Amperage rating Coil resistance
MS5F-421/JIDECO 180 A 4.2 ---- 4.6 Q at 20°C (68°F)
T.P.S. (throttle position sensor): Model/Manufacturer Resistance
Oil level switch: Model/Manufacturer
Full Empty
8FG/NIPPON SEIKI 10 ---- 12 Q at 20°C (68°F) 179 ---- 185 Q at 20°C (68°F) 5DM/OMRON 95 ---- 116 Q at 20°C (68°F)
(left) (right)
Thumb warmer: Heater resistance
1.53 ---- 1.87Qat20°C(68°F) 1.53 ---- 1.87Qat20°C(68°F) 37.0 ---- 45.2 Q at 20°C (68°F)
Circuit breaker: Type Amperage for individual circuit Main fuse Headlight fuse Signal fuse Ignition fuse Carburetor heater fuse Reserve fuse Reserve fuse Reserve fuse Water temperature sensor: Model/Manufacturer Resistance
Indicator light
TS67/02-1 C/MIKUNI 4 ---- 6 kQ at 20°C (68°F) (Blue - Black) o ---- 4 kQ at 20°C (68°F) (Yellow - Black) 8FA/ASTI
Headlight relay: Model/Manufacturer Coil resistance Grip warmer: Heater resistance
SPEC I
RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK
Model
Fuel sender: Model/Manufacturer Sender resistance
I
(ON) (OFF)
Fuse 30 A 20 A 10 A 10 A 20 A 30 A 20 A 10 A
x x x x x x x x
1 1 1 1 1 1 1 1
8CC/MITSUBISHI 5.2 ---- 6.4 kQ at O°C (34°F) 0.300 ---- 0.364 kQ at 80°C (176°F) 0.170 ---- 0.208 kQ at 100°C (212°F) 90 ---- 110°C (194 ---- 230°F) 85 ---- 105 °C (1 85 ---- 221 ° F)
Speed sensor: Model/ Manufacture
8EK/NIPPON SEIKI
Carburetor heater: Model/ Manufacture Wattage Resistance
5FU/NIPPON THERMOSTAT 30W 6 ---- 10 Q at 20°C (68°F) 63
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I
SPEC I
MAINTENANCE SPECIFICATIONS
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HIGH ALTITUDE SETTINGS RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK
~ o Altitude
tu re
~
(0
~
200
~
2000 m 6700 ft)
1000
~
(~
3000 m 10000 ft)
2000
~
(~
[Production spec]
-20°C
O°C
16°C
(-40°F)
(-4°F)
(32°F)
(60°F)
MJ PS MJ PS MJ PS MJ PS
200 m 670 ft)
1000 m 1700 ft)
(~
-40°C
#140
STD #137.5
STD #135 3/4 #132.5 1+1/4
MJ#1, 2, 3, 4:#135
MJ PS MJ PS MJ PS MJ PS
#137.5
STD #135
STD #132.5 3/4 #130 1+1/4
PS:Approx 2
MJ PS MJ PS MJ PS MJ PS
Idling speed (r/min)
#135
STD
1350
#132.5
STD
1350
#130 3/4
1350
#127.5 1400
1+1/4
#:Main jet number
PS:Pilot screw turns in
RX10MK, RX10MSK
~ o Altitude
tu re
~
(0
~
200
~
(~
1000 (~
2000 (~
200 m 670 ft)
1000 m 1700 ft)
2000 m 6700 ft)
~
~ 3000 m 10000 ft)
[Production spec]
-40°C
-20°C
O°C
16°C
(-40°F)
(-4°F)
(32°F)
(60°F)
MJ PS MJ PS MJ PS MJ PS
#140
STD #137.5
STD #135 3/4 #132.5 1+1/4
MJ#1, 2, 3, 4:#135
MJ PS MJ PS MJ PS MJ PS
#137.5
STD #135
STD #132.5 3/4 #130 1+1/4
PS:Approx 2
64
MJ PS MJ PS MJ PS MJ PS
Idling speed (r/min)
#135
STD
1350
#132.5
STD
1350
#130 3/4
1350
#127.5 1+1/4
#:Main jet number
1400
PS:Pilot screw turns in
MAINTENANCE SPECIFICATIONS
65
ISPEC
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TIGHTENING TORQUE
I
SPEC I
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TIGHTENING TORQUE ENGINE Parts to be tightened Spark plug Cylinder head nut (M1 0 x 1.25) x 2 Cylinder head nut (M1 0 x 1.25) x 6 Cylinder head nut x 2 Cylinder head bolt Camshaft cap and cylinder head Cylinder head cover Connecting rod and cap A.C. magneto rotor Crankshaft and drive gear Primary reduction gear bearing housing Timing chain tensioner Thermostat housing Water temperature sensor Timing chain tensioner cap Camshaft and camshaft sproket Hose band Water pump Coolant reservoir tank Pipe Oil cooler Oil pan Engine mounting adjust bolt Engine mounting nut Countershaft cover Oil pan drain bolt Oil filter union bolt Oil filter Oil pump Oil pump drive chain guide Oil tank drain bolt Oil tank and frame (bolt) Oil tank and frame (nut) Oil gallery bolt Exhaust joint Muffler band Exhaust pipe Exhaust sampling bolt Muffler Exhaust cover Muffler band Muffler protector Cylinder head stud bolt Crankcase (M9 x 1.5) (1 st) (2nd) Crankcase (M6 x 1.0) Countershaft cover A.C. magneto rotor cover Starter clutch Stator coil Starter motor Pickup coil
Tightening torque Nm
m-kg
ft-Ib
13
1.3
9.4
20 + 121 ° 20 + 105° 20 + 140°
2.0 + 121 ° 2.0 + 105° 2.0 + 140°
14+121° 14 + 105° 14 + 140°
12 10 12
1.2 1.0 1.2
8.7 7.2 8.7
20 + 120°
2.0 + 120°
14 + 120°
130 75 12 10 10 23 6 24 2 12 7 10 35 10 7 65 12 30 70 17 12 10 16 10 19 10 25 9 25 10 16 6 20 11 10 15
13.0 7.5 1.2 1.0 1.0 2.3 0.6 2.4 0.2 1.2 0.7 1.0 3.5 1.0 0.7 6.5 1.2 3.0 7.0 1.7 1.2 1.0 1.6 1.0 1.9 1.0 2.5 0.9 2.5 1.0 1.6 0.6 2.0 1.1 1.0 1.5
94 54 8.7 7.2 7.2 17 4.3 17 1.4 8.7 5.0 7.2 25 7.2 5.1 47 8.7 22 51 12 8.7 7.2 11 7.2 14 7.2 18 6.5 18 7.2 11 4.3 14 8.0 7.2 11
15+ 45--50°
1.5+ 45--50°
11 + 45--50°
12 12 12 12 10 27 6
1.2 1.2 1.2 1.2 1.0 2.7 0.6
8.7 8.7 8.7 8.7 7.2 20 4.3
66
Remarks
Left-hand thread.
See NOTE.
Apply LOCTITE®
TIGHTENING TORQUE Parts to be tightened Fuel pump Fuel pump stay
Tightening torque Nm
m-kg
ft-Ib
10 10
1.0 1.0
7.2 7.2
I
SPEC I
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Remarks
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. First, tighten the bolt to approximately 15 Nm (1.5 m-kg, 11 ft-Ib) with a torque wrench, then loosen the bolt completely. 2. Retighten the bolt to 15 Nm (1.5 m-kg, 11 ft-Ib), and tighten another 45 ~ 50° with a angle gauge.
67
TIGHTENING TORQUE
I
SPEC I
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POWER TRAIN Tightening torque
Parts to be tightened
Nm
mekg
ftelb
Primary sheave (1 st) (2nd) Spider and sliding sheave
120 60 200
12.0 6.0 20.0
85 43 145
Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave Stopper (secondary sheave) Spring seat (secondary sheave) Bolt (secondary sheave clearance) Drive sprocket Locknut chain tensioner Chain housing and frame Driven sprocket Drain bolt (drive chain housing) Chain housing cover Shift lever assembly
14 6 64 7 23 10 90 24 48 48 16 24 10
1.4 0.6 6.4 0.7 2.3 1.0 9.0 2.4 4.8 4.8 1.6 2.4 1.0
10 4.3 46 5.1 17 7.2 65 17 35 35 12 17 7.2
Lever and drive chain housing cover
10
1.0
7.2
Shaft (reverse drive gear)
10
1.0
7.2
Reverse driven gear Counter gear Spacer set screw Chain housing and brake caliper Bleed screw (brake caliper) Brake hose union bolt (caliper side) Brake hose union bolt (brake master cylinder side) Bearing set screw (Secondary shaft) Parking brake Parking brake assembly and lever (RX10K, RX10RK, RX10RSK) Shock absorber adjuster assembly and frame Front pivot arm and frame Front pivot arm and shockabsorber Front pivot arm and stopper band Shaft and stopper band Sliding runner and sliding frame Suspension wheel and sliding frame Front pivot arm and control rod Front pivot arm bracket and sliding frame Front pivot arm and bracket Rear pivot arm and shockabsorber Rear pivot arm bracket and control rod Rear pivot arm and frame Rear pivot arm and rear pivot arm bracket Rear pivot arm bracket and sliding frame Rear axle
48 10 6 48 6 30 30 8 13 16
4.8 1.0 0.6 4.8 0.6 3.0 3.0 0.8 1.3 1.6
35 7.2 4.3 35 4.3 22 22 5.8 9.4 12
10 72 49 4 4 10 60 74 30 72 49 72 74 72 72 75
1.0 7.2 4.9 0.4 0.4 1.0 6.0 7.4 3.0 7.2 4.9 7.2 7.4 7.2 7.2 7.5
7.2 52 35 2.9 2.9 7.2 43 53 22 52 35 52 53 52 52 54
68
Remarks Tighten the bolts in two stages. See NOTE. Left-hand thread. Apply LOCTITE®
Apply LOCTITE®
(RX10RK, RX10RSK, RXW10K, RXW10SK) (RX10RK, RX10RSK, RXW10K, RXW10SK) Apply LOCTITE® (RX10RK, RX10RSK, RXW10K, RXW10SK) Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE® Apply LOCTITE®
TIGHTENING TORQUE Tightening torque
Parts be tightened (RXW10K, RXW10SK) Stopper band Hook and front pivot arm Wheel bracket and sliding frame Bracket bolt (front) Bracket bolt (rear) Front pivot arm and front pivot arm bracket Front pivot arm bracket and sliding frame Suspension wheel Rear axle Slide rail suspension mounting bolt (M 10) Rear pivot arm and bracket Shock absorber and rear pivot arm Rear pivot arm and rod Rear suspension bracket and rod Shock absorber and rear suspension bracket Control rod and sliding frame Shock absorber and front pivot arm Shock absorber and front suspension bracket Rear pivot arm bracket Rear bracket and suspension wheel Wheel bracket shaft and sliding frame Set bolt (front axle) (RX10MK, RX10MSK) Front pivot arm and frame Front pivot arm and front shockabsorber Front pivot arm and stopper band Shaft and stopper band Shaft and sliding frame Suspension wheel assembly and sliding frame Front pivot arm and sliding frame Suspension wheel and sliding frame Rear pivot arm and sliding frame Bracket and front shockabsorber Front pivot arm bracket and bracket Front pivot arm and bracket Bracket and rear shockabsorber Relay rod and rear pivot arm Rear pivot arm and rear shockabsorber Rear pivot arm and frame Suspension wheel and sliding frame Pivot shaft and sliding frame Rear axle Speed sensor Gear unit (speed sensor)
Nm
mekg
ftelb
4 16 24 48 30 72 72 72 75 72 24 49 49 49 49 72 49 49 72 72 72 9
0.4 1.6 2.4 4.8 3.0 7.2 7.2 7.2 7.5 7.2 2.4 4.9 4.9 4.9 4.9 7.2 4.9 4.9 7.2 7.2 7.2 0.9
2.9 12 17 35 22 52 52 52 54 52 17 35 35 35 35 52 35 35 52 52 52 6.5
72 49 4 4 60 60 60 60 72 49 72 72 49 49 49 72 60 72 75 20 40
7.2 4.9 0.4 0.4 6.0 6.0 6.0 6.0 7.2 4.9 7.2 7.2 4.9 4.9 4.9 7.2 6.0 7.2 7.5 2.0 4.0
52 35 2.9 2.9 43 43 43 43 52 35 52 52 35 35 35 52 43 52 54 14 29
I
SPEC I
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Remarks
(RXW10K, RXW10SK) Apply LOCTITE® Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE® Apply LOCTITE®
NOTE: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tightening steps: 1. Tighten the bolt to a torque at 120 Nm (12.0 m-kg, 85 ft-Ib). 2. Loosen the bolt completely. 3. Retighten the bolt to a torque of 60 Nm (6.0 m-kg, 43 ft-Ib).
69
TIGHTENING TORQUE
I
SPEC I
CHASSIS Tightening torque
Parts to be tightened Handlebar holder Steering column Upper Lower Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod Tie rod and steering arm Idler arm Locknut (relay rod/tie rod) Ski Ski runner Ski column lower bracket Ski and ski handle (front) Ski and ski handle (rear) Shock absorber (upper) Shock absorber (lower) Steering arm locknut Upper arm and frame Upper arm and knuckle Lower arm and frame Lower arm and knuckle Stabilizer bar and stabilizer arm Stabilizer arm and connecting rod Connecting rod and lower arm Frame cross member (front side) (rear side) Master cylinder assembly Brake lever adjuster locknut Rear cover Seat and frame Shroud
70
Nm
m-kg
ft-Ib
15
1.5
11
23 23 35 35 30 30 35 30 35 67 25 48 19 11 11 17 45 45 35 37 40 37 65 11 34 34 30 23 10 6 3 5 3
2.3 2.3 3.5 3.5 3.0 3.0 3.5 3.0 3.5 6.7 2.5 4.8 1.9 1.1 1.1 1.7 4.5 4.5 3.5 3.7 4.0 3.7 6.5 1.1 3.4 3.4 3.0 2.3 1.0 0.6 0.3 0.5 0.3
17 17 25 25 22 22 25 22 25 49 18 35 14 8.0 8.0 12 33 33 25 27 29 27 47 8.0 25 25 22 17 7.2 4.3 2.2 3.6 2.2
Remarks
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GENERAL TORQUE SPECIFICATIONSI DEFINITION OF UNITS
GENERAL TORQUE SPECIFICATIONS
A
This chart specifies torque for standard fasteners with standard I.S.0. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
(nut)
B (bolt)
10 mm
1SPEC 1.--.1 .., -
General torque specifications Nm
m-kg
ft-Ib
6mm
6
0.6
4.3
12 mm
8mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
r
A
L..--. A: Distance across flats B: Outside thread diameter
DEFINITION OF UNITS Unit
Read
Definition
Measurement
mm cm
Millimeter Centimeter
10-3 meter 10-2 meter
Length Length
kg
Kilogram
103 gram
Weight
N
Newton
1 kg x m/sec2
Force
Nm m-kg
Newton meter Meter kilogram
Nxm m x kg
Torque Torque
Pa N/mm
Pascal Newtons per millimeter
N/m 2 N/mm
Pressure Spring rate
L cm 3
Liter Cubic centimeter
-
Volume or capacity
r/min
Rotations per minute
-
Engine speed
71
C_A_B_LE_R_O_UT_I~N_=G_ISPEC
_____________
I
g--I
3
4
5
6 7
56
45
c
53
54
B-B
31 30
o
9
! /:
~
jJ
II
1\
\\
II
[(II
~
@ 72
6
A
CABLE ROUTING
CABLE ROUTING FOR RX1 OK, RX10MK, RX10MSK To the headlight and meter assembly ® Clamp the lead at the position of white tape. @ Clamp the wire harness and A.C.magneto lead. @ Battery negative lead ® Battery positive lead @ Main harness (J) Negative lead connector @ Carburetor heater lead coupler ® Oil level switch lead coupler Oil level switch ® Starter motor positive lead (under the battery bracket) @ Carburetor switch lead connector @ Clamp the coated section of the lead. @ Coolant temperature sensor lead coupler @ To the brake caliper ® There should be no slack of leads. @ Clamp the vacuum hose 2. @ Clamp the ignition coil lead. @ Connectors @ To the heat exchanger @ Main switch @ Set the coupler in the rear space of the instrument panel @ Tail/brake light lead coupler @ Throttle cable @ Right handlebar switch lead coupler @ Thumb warmer switch lead coupler @ Grip warmer switch lead connector @ To the tail/brake light @ Headlight beam switch lead coupler @ Left handlebar switch lead coupler ® Brake light switch lead coupler
CD
®
73
I
SPEC I
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C_A_B_LE_R_O_UT_I~N_=G_ISPEC
_____________
I
g--I
3
4
5
6 7
56
45
c
53
54
B-B
31 30
o
9
! /:
~
jJ
II
1\
\\
II
[(II
~
@ 74
6
A
CABLE ROUTING @ Route the starter cable above the left handlebar switch lead.
@ Brake hose @ Fuel sender lead coupler @ Clamp the ignition coil lead under the fuel hose.
@ Clamp the fuel hose.
ÂŽ @ @ @
@) @ @ @ @ @
ÂŽ @ @ @ @ @ @ @ @ @
Route the coolant hose between the upper vacuum hose and lower vacuum hose. Route the vacuum hose under the coolant hose. Route the vacuum hose over the coolant hose. Clamp the coolant hose and vacuum hose. Clamp the coolant hose and vacuum hose 2. Point the pawl of clip to the upward. Clamp the throttle position switch lead. Throttle position sensor lead coupler. (under the vacuum hose) Drive guard bracket Connect the battery negative lead to the starter motor mounting bolt. Clamp the throttle position switch lead and carburetor switch lead. Voltage regulator Carburetor heater relay Headlight relay Main relay Back buzzer (RX10RK, RX10 RSK, RXW10K, RXW10SK) Flange nut Hexagon bolt Two pole coupler for A.C.magneto. Between two pole coupler for A.C.magneto leaf and the clamp is set to 20 mm (0.79 in) or less.
75
I
SPEC I
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CABLE ROUTING
A-A 76
ISPEC
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CABLE ROUTING
CD ÂŽ
@ @
Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securely fit in the rubber cover) Put the boots of the meter coupler in the boss root on the side of the meter.
77
I
SPEC I
g-ol
CABLE ROUTING
33
A-A 78
CABLE ROUTING
CD ® @ @ @
@
(/)
@
® ® @ @ @ @
® ® @ @ @ @ @ @ @
Clamp the grip warmer lead and the right handlebar switch lead. Clamp the main harness, main switch and harness. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Except for brake hose and parking brake cable.) Pass the brake hose and the parking brake cable through the cable holder. Clamp the fuel sender lead and speed sensor lead. Clamp the tail/brake light lead, headlight beam switch lead and grip warmer lead. Parking brake cable Left handlebar switch Speed sensor lead coupler Fuel sender lead cover Route the fuel tank breather hose along the frame cross member. Clamp the speed sensor lead only. Clamp the fuel tank breather hose. Clamp the compression spring section of the fuel tank breather hose. Compression spring Breather tank Point the clip position to the upward. Insert the fuel tank breather hose until it contacts the projection. Pass the fuel hose over the engine oil breather hose. Pass the carburetor air vent hose outside of the engine oil breather hose. To the speed sensor.
79
I
SPEC I
g-ol
CABLE ROUTING
33
A-A 80
CABLE ROUTING @ Carburetor air vent hose @ To the parking brake.
ÂŽ To the brake caliper @ Brake hose @ Clamp the wire harness and @ @
ÂŽ @ @ @ @
fuel tank breather hose from the top. Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side. Right handlebar switch Push into the end of clamp between frame cross member and fuel tank. Less than 50 mm (2.0 in). Route the starter cable above the left handlebar switch lead.
81
I
SPEC I
g-ol
CABLE ROUTING
2
82
ISPEC
Ig-ol
CABLE ROUTING
CD 速
@ @ @ @ ([)
@
速
速 @ @
@ @ @
速 @ @ @ @ @ @ @ @
Headlight wire harness Tighten the frame ground and voltage regulator upper bolt together. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through between engine and heat exchanger. To the tail/brake light. Clamp the coolant hose. Point the locked section of the clamp to the outside. Clamp the wire harness. Tighten the frame cross member and frame together. Bracket Connect the gear position switch lead. (For model with the reverse) Fold back the gear position switch lead, and clamp it. (For model without reverse) Wire harness Fuse box Coolant reservoir tank Coolant reservoir tank breather hose Parking brake cable Brake hose Point the clamp position to the front outside. Clamp the hose at the white paint position. Point the clamp position to the front outside. Clamp the battery positive lead and negative lead. Point the clamp position to the downward. Point the clamp position to the inside. Clamp the leads before the fixture.
83
I
SPEC I
g-ol
CABLE ROUTING
84
CABLE ROUTING
CD ®
@ @
(§)
@
(f) @
®
®
Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the upward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross member and frame. Wire harness clamp Rivets Speed sensor Nylon nuts Point the pawl of clip to the downward.
85
I
SPEC I
g-ol
I
SPEC I
CABLE ROUTING
~A
2
16
18
B-B
A-A 86
g-ol
CABLE ROUTING
CD ®
@ @
® @
(f) @
® ® @ @ @ @ @
® @ @ @
Battery positive lead COl unit Battery negative lead Air box drain hose Starter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat COl unit bracket Latch Battery band Battery cover To the carburetor. 0 ~ 5 mm (0 ~ 0.20 in) Frame cross member
87
I
SPEC I
g-ol
CABLE ROUTING
57 58
D
c
53
55
56
B-B
A 88
CABLE ROUTING FOR RX10RK, RX10RSK, RXW10K, RXW10SK CD To the headlight and meter assembly Clamp the lead at the position of white tape. @ Clamp the wire harness and A.C.magneto lead. @ Battery positivee lead Battery negative lead @ Main harness ([) Negative lead connector @ Carburetor heater lead coupler ® Oil level switch lead coupler ® Oil level switch @ Starter motor positive lead (under the battery bracket) @ Carburetor switch lead connector @ Clamp the coated section of the lead. @ Coolant temperature sensor lead coupler @ To the brake caliper ® There should be no slack of leads. @ Clamp the vacuum hose 2. @ Clamp the ignition coil lead. @ Connectors @ To the heat exchanger @ Main switch @ Set the coupler in the rear space of the instrument panel @ Tail/brake light lead coupler @ Throttle cable @ Right handlebar switch lead coupler @ Thumb warmer switch lead coupler @ Grip warmer switch lead connector @ To the tail/brake light @ Headlight beam switch lead coupler @ Left handlebar switch lead coupler Brake light switch lead coupler
®
®
®
89
I
SPEC I
g-ol
CABLE ROUTING
57 58
D
c
53
55
56
B-B
A 90
CABLE ROUTING @ Route the starter cable above the left handlebar switch lead.
@ Brake hose @ Fuel sender lead coupler @ Clamp the ignition coil lead under the fuel hose.
@ Clamp the fuel hose.
® @ @ @
@) @ @ @ @ @
® @ @ @ @ @ @ ~
@ @
®
@
Route the coolant hose between the upper vacuum hose and lower vacuum hose. Route the vacuum hose under the coolant hose. Route the vacuum hose over the coolant hose. Clamp the coolant hose and vacuum hose. Clamp the coolant hose and vacuum hose 2. Point the pawl of clip to the upward. Clamp the throttle position switch lead. Throttle position sensor lead coupler. (under the vacuum hose) Drive guard bracket Connect the battery negative lead to the starter motor mounting bolt. Clamp the throttle position switch lead and carburetor switch lead. Voltage regulator Carburetor heater relay Headlight relay Main relay Back buzzer (RX10RK, RX10 RSK, RXW10K, RXW10SK) Fuel pump (RX10MK, RX10 MSK) To the carburetor (RX10MK, RX10MSK) Flange nut Hexagon bolt Two pole coupler for A.C.magneto. Between two pole coupler for A.C.magneto lead and the clamp is set to 20 mm (0.79 in) or less.
91
I
SPEC I
g-ol
CABLE ROUTING
A-A 92
ISPEC
Ig-ol
CABLE ROUTING
CD ÂŽ
@ @
Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securely fit in the rubber cover) Put the boots of the meter coupler in the boss root on the side of the meter.
93
I
SPEC I
g-ol
CABLE ROUTING
33
A-A 94
CABLE ROUTING
CD ® @ @ @
@
(/)
@
® ® @ @ @ @
® ® @ @ @ @ @ @ @
Clamp the grip warmer lead and the right handlebar switch lead. Clamp the main harness, main switch and harness. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Except for brake hose and parking brake cable.) Pass the brake hose and the parking brake cable through the cable holder. Clamp the fuel sender lead and speed sensor lead. Clamp the tail/brake light lead, headlight beam switch lead and grip warmer lead. Parking brake cable Left handlebar switch Speed sensor lead coupler Fuel sender lead cover Route the fuel tank breather hose along the frame cross member. Clamp the speed sensor lead only. Clamp the fuel tank breather hose. Clamp the compression spring section of the fuel tank breather hose. Compression spring Breather tank Point the clip position to the upward. Insert the fuel tank breather hose until it contacts the projection. Pass the fuel hose over the engine oil breather hose. Pass the carburetor air vent hose outside of the engine oil breather hose. To the speed sensor.
95
I
SPEC I
g-ol
CABLE ROUTING
33
A-A 96
CABLE ROUTING @ Carburetor air vent hose @ To the parking brake.
ÂŽ To the brake caliper @ Brake hose @ Clamp the wire harness and @ @
ÂŽ @ @ @ @
fuel tank breather hose from the top. Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side. Right handlebar switch Push into the end of clamp between frame cross member and fuel tank. Less than 50 mm (2.0 in). Route the starter cable above the left handlebar switch lead.
97
I
SPEC I
g-ol
CABLE ROUTING
2
98
ISPEC
Ig-ol
CABLE ROUTING
CD 速
@ @ @ @ ([)
@
速
速 @ @
@ @ @
速 @ @ @ @ @ @ @ @
Headlight wire harness Tighten the frame ground and voltage regulator upper bolt together. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through between engine and heat exchanger. To the tail/brake light. Clamp the coolant hose. Point the locked section of the clamp to the outside. Clamp the wire harness. Tighten the frame cross member and frame together. Bracket Connect the gear position switch lead. (For model with the reverse) Fold back the gear position switch lead, and clamp it. (For model without reverse) Wire harness Fuse box Coolant reservoir tank Coolant reservoir tank breather hose Parking brake cable Brake hose Point the clamp position to the front outside. Clamp the hose at the white paint position. Point the clamp position to the front outside. Clamp the battery positive lead and negative lead. Point the clamp position to the downward. Point the clamp position to the inside. Clamp the leads before the fixture.
99
I
SPEC I
g-ol
CABLE ROUTING
100
CABLE ROUTING
CD ®
@ @
(§)
@
(f) @
®
®
Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the upward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross member and frame. Wire harness clamp Rivets Speed sensor Nylon nuts Point the pawl of clip to the downward.
101
I
SPEC I
g-ol
CABLE ROUTING
I
SPEC I
3
~A
2
B-B
A-A 102
g-ol
CABLE ROUTING
CD ®
@ @
® @
(f) @
® ® @ @ @ @ @
® @ @ @
Battery negative lead COl unit Battery positive lead Air box drain hose Starter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat COl unit bracket Latch Battery band Battery cover To the carburetor. 0 ~ 5 mm (0 ~ 0.20 in) Frame cross member
103
I
SPEC I
g-ol
CD A.C. magneto ® Rectifier/regulator @ Main switch @ Main relay
® Fuse (MAIN) ® Starter relay
o Starter motor
® Battery ® Engine stop switch
@ Throttle switch @ Carburetor switch @ Carburetor heater relay @ Carburetor heater @ Grip warmer @ Thumb warmer @ COl unit @ Ignition coil @ Spark plug @ Water temperature sensor @ Throttle position sensor @ Grip warmer switch @ Thumb warmer switch @ Body ground @ Back buzzer (RX1 ORK, RX10RSK, RXW10K, RXW10SK)
@ Gear position switch (RX10RK, RX10RSK, RXW10K, RXW10SK)
@ Brake light switch @ Tail/brake light @ Fuse (HEADLIGHT) @ Fuse (SIGNAL) @ Fuse (CARBURETOR HEATER) @ Fuse (IGNITION) @ Headlight beam switch @ Headlight relay @ Headlight @ Meter assembly @ Tachometer
® Meter light
@ Water temperature indicator light @ Multi-function meter @ Warning light @ Hi beam indicator light @ Oil level switch @ Fuel sender @ Speed sensor COLOR CODE B Br G Gy L Lg . . . ..
Black Brown Green Gray Blue Light green o Orange P Pink R Red Sb Sky blue W White Y Yellow B/G Black/Green B/L Black/Blue B/R Black/Red B/W Black/White B/Y Black/Yellow Br/W .. Brown/White Br /Y . .. Brown/Yellow G/B Green/Black G/R Green/Red
G/Y L/G L/R L/W L/Y Lg/B .. Lg / L . .. Lg / W .. O/R R/B R/W R/Y W /G W /R W/Y Y/ B Y/ G Y /L Y /R Y /W
Green/Yellow Blue/Green Blue/Red Blue/White Blue/Yellow Light green/Black Light green / Blue Light green /White Orange/Red Red/Black Red/White Red/Yellow white/Green White/Red White/Yellow Yellow / Black Yellow / Green Yellow/Blue Yellow/Red Yellow/White
I
FOREWORD
HOW TO USE THIS MANUAL
This Supplementary Service Manual has been prepared to introduce new service and new data for the RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML. For complete information, on service procedures, it is necessary to use this Supplementary Service Manual together with following manual:
Particularly important information is distinguished in this manual by the following notations:
RX1 OH/RX1 OSH/RX1 OMH/RX1 OMSHI RX1 ORH/RX1 ORSH SERVICE MANUAL: 8FA-28197-10 (981073) (LIT-12618-02-28) RXW10J/RXW10SJ SUPPLEMENTARY SERVICE MANUAL: 8FG-28197-10 (981089) (LIT-12618-02-33) RX1 OK/RX1 ORK/RX1 ORSK RXW1 OK/RXW1 OSK/RX1 OMK/RX1 OMSK SUPPLEMENTARY SERVICE MANUAL: 8FV-28197-10 (981098) (L1T-12618-02-39)
NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understanding of the mechanical concepts and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to this model may render it unfit and/or unsafe to use. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
RX1 ORTL/RX1 ORL RX10RTRL/RX10GTL RXW10L/RX10ML SUPPLEMENTARY SERVICE MANUAL Š 2005 by Yamaha Motor Corporation, U.S.A. 1st Edition, July 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N.LIT-12618-02-44
~ The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!
~
Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snowmobile.
A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile.
NOTE: A NOTE provides key information that can make procedures easier or clearer. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g., â&#x20AC;˘ Bearings Pitting/damage ~ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.
CD
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ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Periodic inspections and adjustments @Chassis ® Power train @Engine ® Cooling system (J) Fuel injection system ® Electrical ® Specifications
®
ISPEcl g--I
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@
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Illustrated symbols @ to @ are used to identify the specifications which appear. @ Filling fluid @Lubricant @ Tightening @ Wear limit, clearance @ Engine speed @ Special tool
1
B @
~
~
Illustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point.
@ Apply locking agent (LOCTITE®) @) Apply Yamabond No.S® @ 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 @Use new one
INDEX GENERAL INFORMATION
~
GEN INFO
PERIODIC INSPECTION AND ADJUSTMENT CHASSIS
~ CHAS
CU?) POWER TRAIN ENGINE
POWR TR
@ ENG
COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SPECIFICATIONS
FI
ELEC
~
CHAPTER 1. GENERAL INFORMATION SPECIAL TOOLS FOR FUEL INJECTION SERVICE
CHAPTER 4. POWER TRAIN 1 1
SLIDE RAIL SUSPENSiON RX10GTL RXW10L RX10ML
CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION
2
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
2
GENERAL MAINTENANCE AND LUBRICATION CHART FUEL LINE INSPECTION COOLING SYSTEM SYNCHRONIZING THE THROTTLE BODIES ENGINE IDLE SPEED ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT
PRIMARY SHEAVE AND DRIVE V-BELT .. 37
3 5 5 10 12 13
POWER TRAIN SHEAVE OFFSET ADJUSTMENT
14 14
CHASSIS LUBRICATION CLUTCH GEAR SELECTION FRONT SUSPENSiON REAR SUSPENSiON
15 15 17 20 27 28
CHAPTER 3. CHASSIS COWLINGS
30
STEERING RX10RTL, RX10RL, RX10RTRL, RXW10L RX10GTL RX10ML
31 31 33 35
39 39 43 47
CHAPTER 5. ENGINE SEAT AND FUEL TANK
52
EXHAUST PIPE AND MUFFLER
53
CHAPTER 6. COOLING SYSTEM HEAT EXCHANGER
54
CHAPTER 7. FUEL INJECTION SYSTEM FUEL INJECTION SySTEM WIRING DIAGRAM ECU'S SELF-DIAGNOSTIC FUNCTION SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) FAIL-SAFE ACTIONS TABLE TROUBLESHOOTING CHART DIAGNOSTIC MODE TROUBLESHOOTING DETAILS OIL PRESSURE SWITCH
58 59 61
62 62 64 65 72 86
THROTTLE BODIES 87 INJECTORS 88 CHECKING THE INJECTORS 89 CHECKING THE THROTTLE BODIES .. 89 CHECKING THE THROTTLE BODY JOINTS 89 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 90 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 91
CHAPTER 8. ELECTRICAL
ENGINE POWER TRAIN CHASSiS
IGNITION SySTEM CIRCUIT DIAGRAM THROTTLE OVERRIDE SYSTEM (T.O.R.S.) HANDLEBAR SWITCH (RIGHT) MAIN SWiTCH LOAD RELAy
93 93 95 96 97 97
ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM MAIN SWiTCH
98 98 99
CHARGING SySTEM CIRCUIT DIAGRAM
100 100
LIGHTING SYSTEM CIRCUIT DIAGRAM HEADLIGHT BEAM SWITCH HEADLIGHT RELAy
101 101 102 102
SIGNAL SySTEM CIRCUIT DIAGRAM ENGINE OIL LEVEL SWiTCH SPEED SENSOR
103 103 105 105
GRIP WARMER SYSTEM CIRCUIT DIAGRAM GRIP AND THUMB WARMER COIL
106 106 107
COOLING SySTEM CIRCUIT DIAGRAM TROUBLESHOOTING RADIATOR FAN MOTOR RADIATOR FAN MOTOR RELAy
108 108 109 110 11 0
CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS
111
MAINTENANCE SPECIFICATIONS ENGINE POWER TRAIN CHASSIS ELECTRiCAL
115 115 120 125 126
TIGHTENING TORQUE
129
129 131 133
GENERAL TORQUE SPECIFICATIONS .. 134 DEFINITION OF UNITS
134
CABLE ROUTING
135
SP_E_C_IA_L_T_O_O_L_S_II~~~I~I
_____________
GENERAL INFORMATION SPECIAL TOOLS Some special tools are necessary for a completely accurate tuneup and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. NOTE: _ Be sure to use the correct part number when ordering the tool, since the part number may differ according to country.
FOR FUEL INJECTION SERVICE • Vacuum/pressure pump gauge set PIN: YB-35956 (for U.S.A./Canada) 90890-06756 (for Europe) This tool is used to measure the vacuum pressure. • Fuel pressure adapter PIN: YM-03176 (for U.S.A./Canada) 90890-03176 (for Europe) This tool is needed to measure fuel pressure.
• Pressure gauge PIN: YU-03153 (for U.S.A./Canada) 90890-03153 (for Europe) This tool is used to measure fuel pressure.
• Vacuum gauge PIN: YU-08030 (for U.S.A./Canada) 90890-03094 (for Europe) This guide is used to synchronize the throttle bodies.
1
_
_____ IN_T_R_O_D_U_C_T_IO_N_' _P_E_R_IO_D_IC_M_A_IN_T_E_N_A_NC_E_IIANDSJP CHART FOR THE EMISSION CONTROL SYSTEM
~O~ ~
I
I
PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
Item
Remarks
Spark plugs
Check condition. Adjust gap and clean. Replace if necessary.
Valves clearance
Check clearance. Adjust clearance when engine is cold.
Crankcase breather system
Check breather hose for cracks or damage. Replace if necessary.
Fuel filter
Check condition. Replace if necessary.
Fuel line
Check fuel hose for cracks or damage. Replace if necessary.
Idle speed
Check and adjust engine idle speed.
Fuel injection
Adjust synchronization.
Exhaust system
Check for leakage. Tighten or replace gasket if necessary.
Pre-operation check (Daily)
Initial 1 month or 800 km (500 mi) (40 hr)
Every Seasonally or 4,000 km (2,500 mi) (200 hr)
e Every 40,000 km (25,000 mi)
-- -- -e
2
INSP ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
GENERAL MAINTENANCE AND LUBRICATION CHART Item
Pre-operation check (Daily)
Remarks
Check oil level. Engine oil Replace. Engine oil filter cartridge
Replace.
Fuel
Check fuel level. Check coolant level. Air bleed the cooling system if necessary.
Throttle lever (handlebar side)
Check operation. Repair if necessary.
Throttle override system (T.O.R.S.)
Check operation. Repair if necessary.
Engine stop switch
Check operation. Repair if necessary.
Drive guard
Check for cracks, bends or damage. Replace if necessary.
V-belt
Check for wear and damage. Replace if necessary.
Drive track and idler wheels.
Check deflection, and for wear and damage. Adjust/ replace if necessary. Check for wear and damage.
Slide runners Replace if necessary. Check operation and fluid leakage. Adjust free play and/or replace pads if necessary. Replace brake fluid. Disc brake installation
Check for slight free play. Lubricate shaft with specified grease as required. Check oil level. Replace. Check deflection. Adjust if necessary. Check for wear and damage. Replace if necessary. Check operation.
Steering system Adjust toe-out if necessary. Check operation. Replace bulbs if necessary.
Battery
Check condition. Charge if necessary.
- - -- ----- - -- - -
Every 1,600 km (1,000 mi)
Initial at 500 km (300 mi) and every 800 km (500 mi) thereafter.
Skis and ski runners
Lights
Seasonally or 4,000 km (2,500 mi) (200 hr)
See NOTE on page 4.
Drive chain oil
Drive chain
Every
Every 20,000 km (12,000 mi)
Engine coolant
Brake and parking brake
Initial 1 month or 800 km (500 mi) (40 hr)
3
GENERAL MAINTENANCE AND LUBRICATION CHART
Item
Remarks
Check engagement and shift speed. Adjust if necessary. Primary and secondary clutches
Pre-operation check (Daily)
Inspect sheaves for wear/damage. Inspect weights/rollers and bushings for wear-for primary. Inspect ramp shoes/bushings for wear-for secondary. Replace if necessary.
Lubricate with specified grease.
Ski and front suspension
Lubricate with specified grease.
Suspension component
Lubricate with specified grease. Lubricate with specified grease.
Parking brake cable end and lever end/throttle cable end
Check cable damage. Replace if necessary.
Shroud latches
Make sure that the shroud latches are hooked.
Fitting and fasteners
Check tightness. Repair if necessary.
Tool kit and recommended equipment
Check for proper placement.
NOTE:
Initial 1 month or 800 km (500 mi) (40 hr)
Every Seasonally or 4,000 km (2,500 mi) (200 hr)
----
Whenever operating elevation is changed.
Lubricate with specified grease. Steering column bearing
INSP ADJ
--
_
Brake system: 1. After disassembling the master cylinder or caliper cylinder, always change the brake fluid. Regularly check the brake fluid level and add fluid if necessary. 2. Replace the oil seals of the master cylinder and caliper cylinder every two years. 3. Replace the brake hose every four years, or if cracked or damaged.
4
FUEL LINE INSPECTION/COOLING SYSTEM
INSP ADJ
FUEL LINE INSPECTION 1. Remove: • Top cover Refer to "COWLINGS" in CHAPTER 3. 2. Remove: • Intake silencer Refer to "FUEL INJECTION" in CHAPTER 7. 3. Inspect: • Fuel hoses CD • Fuel delivery hoses ® Cracks/damage ~ Replace. 4. Install: • Intake silencer Refer to "FUEL INJECTION" in CHAPTER 7. 5. Install: • Top cover • Refer to "COWLINGS" in CHAPTER 3.
COOLING SYSTEM Coolant replacement NOTE:
_
The coolant should be changed at least every season. 1. Place the machine on a level surface. 2. Remove: • Top cover Refer to "COWLINGS" in CHAPTER 3. 3. Remove: • Intake silencer Refer to "FUEL INJECTION" in CHAPTER 7. 4. Remove: • Coolant filler cap CD
~ ----------
Do not remove the coolant filler cap CD when the engine is hot. Pressurized scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, place a thick rag or a towel over the coolant filler cap. Slowly turn the cap counterclockwise until it stop. This allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise to remove it.
5
COOLING SYSTEM
INSP ADJ
5. Remove: - Side cover (right) - Side under cover ÂŽ (right) Refer to "COWLINGS" in CHAPTER 3.
6. Place an open container under the coolant hose. 7. Disconnect: - Coolant hose CD 8. Drain the coolant. NOTE: _ Lift up the tail of the machine to drain the coolant.
9. Remove: - Rear cover
CD
1O. Disconnect: - Coolant hoses CD 11 .Drain the coolant. NOTE:
_
Lift up the front of the machine to drain the coolant completely.
~ ----------
Coolant is poisonous. It is harmful or fatal if swallowed. -If coolant is swallowed, induce vomiting immediately and get immediate medical attention. -If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. -If coolant splashes on your skin or clothes, quickly wash it away with soap and water. 6
__ _ IIANOSJP I COOLING SYSTEM _ ______
~O~
~
I
12.Connect: - Coolant hoses 13.lnstall: - Rear cover CD
Bolt (rear cover): 3 Nm (0.3 m-kg, 2.2 ft-Ib)
14.lnstall: - Coolant hose CD 15.lnstall: - Side under cover (right) Refer to "COWLINGS" in CHAPTER 3.
16.lnstall: - Intake silencer Refer to "FUEL INJECTION" in CHAPTER 7. 17.Fill: - Cooling system
Recommended coolant: High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors Coolant mixing ratio (coolant:water) 3:2 (600/0:400/0) Total amount: For RX1 ORTL I RX1 ORL I RX1 ORTRL I RXW10L 6.0 L (5.28 Imp qt, 6.34 US qt) For RX10ML 6.4 L (5.63 Imp qt, 6.76 US qt)
- Hard water or salt water is harmful to engine parts. If soft water is not available, use boiled or distilled water. - Do not use water containing impurities or oil.
7
COOLING SYSTEM
--------------------------
II~~~ I Q
I
18. Bleed the air from the cooling system. 19.1nspect: • Cooling system Decrease of pressure (leaks) ~ Repair as required.
Inspection steps: • Attach the cooling system tester adapter ® to the coolant filler @.
~
~-
CD
Cooling system tester: 90890-01325, YU-24460-01 Adapter: 90890-01352, YU-24460-01
• Apply 100 kPa (1.0 kg/cm 2 , 14 psi). • Measure the pressure with the gauge. Air bleeding 1. Remove: • Rear cover 2. Bleed air from the cooling system.
CD
8
and
__ _ IIANOSJP I COOLING SYSTEM _ ______
~O~
~
I
Air bleeding steps: • Lift up the tail of the machine. • Remove the bleed bolt CD on the heat exchanger. • While slowly adding coolant to the coolant filler, drain the coolant until no more air bubbles appear. • Tighten the bleed bolt CD. ,
~~
Bleed bolt: 13 Nm (1.3 m-kg, 9.4 ft-Ib)
• Remove the coolant reservoir tank cap and add coolant to the full level @. • Install the coolant reservoir tank cap. • Remove the coolant recovery tank cap and add coolant until it reaches the "COLD LEVEL.:' mark @. • Install the coolant recovery tank cap. • Apply and lock the parking brake. Start the engine and run it at approximately 2,500 . . . 3,000 r/min until the coolant circulates (approximately 3 . . . 5 minutes). The rear heat exchanger will be warm to the touch.
a
~ ----------
To avoid severe injury or death: • Make sure the machine is securely supported with a suitable stand. • Do not exceed 3,000 r/min. Drive line damage and excessive V-belt wear could occur, or the machine could unexpectedly move forward if the clutch engages. • Operate the engine only in a well-ventilated area. • Remove the coolant recovery tank cap and bleed the cooling system again, as described above. No air bubbles ~ OK. • Remove the coolant recovery tank cap add coolant until it reaches the "COLD LEVEL.:' mark@. • Check for any coolant leakage. 3. Install: • Rear cover
9
_ _ _THE _ __ _ IIANOSJP THROTTLE BODIES _ _ _SYNCHRONIZING
I
~O~
~ .I
SYNCHRONIZING THE THROTTLE BODIES NOTE: _ Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. 2. • • • •
Place the machine on a level surface. Remove: shroud hood (left and right) headlight assembly headlight stay Refer to "COWLINGS" in CHAPTER 3.
3. Install: • vacuum gauge CD (onto the synchronizing hose (2))
~ ,-
Vacuum gauge 90890-03094, YU-08030
4. Install: • headlight stay • headlight assembly • hood (left and right) Refer to "COWLINGS" in CHAPTER 3. 5. Start the engine and let it warm up for several minutes. 6. Measure: • engine idling speed Out of specification ~ Adjust. Refer to "ENGINE IDLE SPEED ADJUSTMENT". Engine idling speed 1,500 ± 100 r/min (1,400 - 1,600 r/min)
10
_ _ _THE _ __ _ IIANOSJP I THROTTLE BODIES _ _ _ SYNCHRONIZING
~O~
~
I
7. Adjust: - throttle body synchronization ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
I
a. With throttle body #1 as standard, adjust throttle bodies #2, #3, and #4 using the air screws CD. #1 (g), #2 @, #3 @, #4 @ NOTE: _
~
- After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. -If the air screw is removed, turn the screw 3/4 turn in and be sure to synchronize the throttle body.
Do not use the throttle valve adjusting screws to adjust the throttle body synchronization. Vacuum pressure at engine idling speed 27.3 kPa (205 mmHg, 8.0709 inHg) NOTE:
_
The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg, 0.39 inHg).
11
__ _ _ _ IIANOSJP IDLE_ SPEED ADJUSTMENT _ _ _ _ ENGINE
I
ENGINE IDLE SPEED ADJUSTMENT NOTE:
~O~
~ .I
_
Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Install: • Engine tachometer (near the spark plug)
~ ,-
Engine tachometer 90793-80009, YU-8036-B
3. Measure: • Engine idle speed Out of specification
~
Adjust.
Engine idle speed: 1,500 ± 100 r/min (1,400 - 1,600 r/min)
4. Adjust: • Engine idle speed
• Turn the throttle stop screw CD in or out until the specified engine idle speed is obtained. Turning in ~ Idle speed is increased. Turning out ~ Idle speed is decreased. NOTE: _ After adjusting the engine idle speed, the throttle cable free play should be adjusted.
12
__ _ _ _ _ _ IIANOSJP I THROTTLE CABLE FREE PLAY ADJUSTMENT _ __
~O~
~
THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE:
I
_
• Before adjusting the throttle cable free play, the engine idle speed should be adjusted. • Adjust the throttle cable free play while the cable is in the cable guide.
1. Measure: • Throttle cable free play @ Out of specification ~ Adjust.
~ Throttle cable free play:
v A~
2.0 - 3.0 mm (0.08 - 0.12 in)
2. Adjust: • Throttle cable free play
Adjustment steps: • Loosen the locknut CD. • Turn the adjusting nut ® in or out until the specified free play is obtained. Turning in ~ Free play is increased. Turning out ~ Free play is decreased. • Tighten the locknut. NOTE: _ After adjusting the free play, turn the handlebar to right and left, and make sure that the engine idling does not run faster.
13
_ OFFSET __ _ _ IIANOSJP SHEAVE ADJUSTMENT _ ____
I
~O~
~ I
POWER TRAIN SHEAVE OFFSET ADJUSTMENT 1. Measure: - Sheave offset ® Use the sheave gauge. Out of specification ~ Adjust. Sheave offset: 13.5 - 16.5 mm (0.53 - 0.65 in)
I~I
Sheave gauge: YS-42421-1
NOTE:
_
Push the secondary sheave toward the inside of vehicle frame first and measure the sheave offset.
2. Adjust: - Sheave offset Adjustment steps: - Apply the brake to lock the secondary sheave. - Remove the bolt (Secondary sheave) CD, washer ® and secondary sheave @. - Adjust the sheave offset by adding or removing shim(s) @. Adding shim ~ Offset is increased. Removing shim ~ Offset is decreased.
Shim size Part Number Thickness 90201-252F1 0.5 mm (0.02 in) 90201-25527 1.0 mm (0.04 in) 90201-25289 1.6 mm (0.06 in) 90201-25526 2.0 mm (0.08 in) - Install the secondary sheave, bolt (secondary sheave) and washer.
~ ~
Bolt (secondary sheave): 64 Nm (6.4 m-kg, 46 ft-Ib)
- Recheck the sheave offset. If out of specification, repeat the above steps. NOTE: _ When adjusting the sheave offset, the secondary sheave free play (clearance) should be adjusted.
14
_ _ ADJUSTMENT/LUBRICATION _ _ _ _ _ IIANOSJP I SHEAVE OFFSET _ __
~O~
~
3. Measure: • Secondary sheave freeplay (clearance) Use a feeler gauge. Out of specification ~ Adjust.
I
®
Secondary sheave free play (clearance): 1.0 - 2.0 mm (0.04 - 0.08 in) SCH2400
4. Adjust: • Secondary sheave freeplay (clearance)
Adjustment steps: • Apply the brake to lock the secondary sheave. • Remove the bolt CD and washer ®. • Adjust the secondary sheave freeplay (clearance) by adding or removing a shim(s) @. SCH2410
Shim size Part number Thickness 90201-222FO 0.5 mm (0.02 in) 90201-225A4 1.0 mm (0.04 in)
CHASSIS
A
LUBRICATION Front and rear suspension 1. Use a grease gun to inject grease into the nipples CD and ® (Both sides). 2. Apply grease @. Recommended lubricant: Esso Beacon 325 Grease or Aeroshell Grease #7A
15
_ _ IIANOSJP I LUBRICATION _ _______
~O~
I
~ .
CD Applay grease ® Applay grease (Both sides) ® Applay grease (Bpth sides) [8] Front ~ Rear (RX10RTL, RX10RL, RX10RTRL, RX10GTL)
[Q Rear (RXW1 OL) [Q] Rear (RX1 OML) A
@ (Both sides)
B
c
D
16
INSP ADJ
CLUTCH CLUTCH High altitude
L
Blue
W White
P
Pink
Y
Yellow
S
I
Silver
Specifications Model: RX10RTL, RX10RL, RX10RTRL, RX10GTL
[8J
-800 m (- 2,500 ft)
600 --- 1,400 m (2,000 --- 4,500 ft)
1,200 --- 2,000 m (4,000 --- 6,500 ft)
1,800 --- 2,600 m (6,000 --- 8,500 ft)
2,400 --- 3,000 m (8,000 --- 10,000 ft)
1,500 ± 100 r/min
~
~
~
~
3,500 ± 200 r/min
~
3,600 ± 200 r/min
~
3,700 ± 200 r/min
10,500 ± 250 r/min
~
~
~
~
Elevation
rnJ Engine idle speed [Q] Engagement r/min [Q] Shift r/min ~
E
Secondary reduction ratio (number of links)
38/24 (70 L)
~
[E]
Primary sheave spring
90501-582L1
~
[§] [8]
Color
y-S-y
~
~
Free length
87.4 mm (3.44 in)
~
86.1 mm (3.39 in)
343 N (35 kg, 77 Ib)
~
~
~
~
[]] Preload
38/23 (70 L) ~
38/22 (68 L)
~
~
~
~
~
85.1 m (3.35 in)
~
24.5 N/mm
Q] Spring rate
(2.50 kg/mm, 140lb/in)
~
~
~
~
[Kl Wire diameter
5.8 mm (0.228 in)
~
~
~
~
CD Outside diameter
59.5 mm (2.34 in)
~
~
~
~
[MJ Weight (10)
8FP-17605-00 (8FPOO)
~
~
~
~
IN] ~eight rivet
OUT
Steel 17.2
Steel 17.2 with-hole
Steel 13.3 with-hole
Aluminum 13.3 with-hole
None
CENTER
Steel 17.2
Steel 17.2 with-hole
Steel 13.3 with-hole
Aluminum 13.3 with-hole
None
IN
Steel 17.2
Steel 17.2 with-hole
Steel 13.3
Steel 13.3 with-hole
None
[Q] Weight bushing [EJ Roller outer dia.
VESPEL TP-8549
~
~
~
~
14.5 mm (0.57 in)
~
~
~
~
[Q] Roller bushing
VESPEL TP-8549
~
~
~
~
[8]
None
~
~
~
~
[§] Secondary sheave spring
90508-60012
~
~
~
~
IT] Color
P
~
~
~
~
[Q]
Free length
75 mm (2.95 in)
~
~
~
~
[YJ
Preload rate
80° (2-6) 1211 kgemm/rad
~
~
~
~
Pri. clutch shim
~ Wire diameter
6.0 mm (0.236 in)
~
~
~
~
[Xl Outside diameter [Yl Sec. torque cam angle
69.5 mm (2.736 in)
~
~
~
~
51 - 43°
~
~
~
~
~ Sec. clutch shim
1.0 mm (0.04 in)
~
~
~
~
17
I
INSP ADJ
CLUTCH L Blue W White
P Y
Pink Yellow
S
I
Silver
Specifications Model: RXW10L -800 m (- 2,500 ft)
600 --- 1,400 m (2,000 --- 4,500 ft)
~ Engine idle speed
1,500 ± 100 r/min
~
~
~
~
[Q] Engagement r/min [Q] Shift r/min
3,500 ± 200 r/min
~
3,600 ± 200 r/min
~
3,700 ± 200 r/min
10,500 ± 250 r/min
~
~
~
~
38/23 (70 L)
~
[8] Elevation
~
E
Secondary reduction ratio (number of links)
1,200 --- 2,000 m (4,000 --- 6,500 ft)
38/22 (68 L)
1,800 --- 2,600 m (6,000 --- 8,500 ft)
2,400 --- 3,000 m (8,000 --- 10,000 ft)
38/21 (68 L)
~
[E] Primary sheave spring [Q] Color [8] Free length
90501 -582 L1
~
~
~
~
y-S-y
~
~
~
~
87.4 mm (3.44 in)
~
~
~
~
[]] Preload
343 N (35 kg, 771b)
~
~
~
~
Q] Spring rate
24.5 N/mm (2.50 kg/mm, 140Ib/in)
~
~
~
~
[Kl Wire diameter
5.8 mm (0.228 in)
~
~
~
~
OJ Outside diameter
59.5 mm (2.34 in)
~
~
~
~
[MJ Weight (10)
8FP-17605-00 (8FPOO)
~
~
~
~
[N] ~eight rivet
OUT
Steel 17.2
Steel 17.2 with-hole
Steel 13.3 with-hole
Aluminum 13.3 with-hole
None
CENTER
Steel 17.2
Steel 17.2 with-hole
Steel 13.3 with-hole
Aluminum 13.3 with-hole
None
IN
Steel 17.2
Steel 17.2 with-hole
Steel 13.3
Steel 13.3 with-hole
None
[Q] Weight bushing [EJ Roller outer dia. [Q] Roller bushing [8] Pri. clutch shim [§] Secondary sheave spring IT] Color [Q] Free length
VESPEL TP-8549
~
~
~
~
14.5 mm (0.57 in)
~
~
~
~
VESPEL TP-8549
~
~
~
~
[YJ
None
~
~
~
~
90508-60007
~
~
~
~
W
~
~
~
~
75 mm (2.95 in)
~
~
~
~
60° (3-3) 1290 kgemm/rad
~
~
~
~
~ Wire diameter
6.0 mm (0.236 in)
~
~
~
~
[Xl Outside diameter [Yl Sec. torque cam angle
69.5 mm (2.736 in)
~
~
~
~
51 - 43°
~
~
~
~
~ Sec. clutch shim
1.0 mm (0.04 in)
~
~
~
~
Preload rate
18
I
INSP ADJ
CLUTCH L Blue W White
P Y
Pink Yellow
S
I
Silver
Specifications Model: RX10ML -800 m (- 2,500 ft)
[8J Elevation
600 --- 1,400 m (2,000 --- 4,500 ft)
1,200 --- 2,000 m (4,000 --- 6,500 ft)
1,800 --- 2,600 m (6,000 --- 8,500 ft)
2,400 --- 3,000 m (8,000 --- 10,000 ft)
lliJ Engine idle speed
1,500 ± 100 r/min
~
~
~
~
[Q]
3,600 ± 200 r/min
3,400 ± 200 r/min
~
3,500 ± 200 r/min
~
10,500 ± 250 r/min
~
~
~
~
40/22 (70 L)
~
Engagement r/min
[Q] Shift r/min ~
E
Secondary reduction ratio (number of links)
[E]
Primary sheave spring
40/21 (70 L)
40/20 (68 L)
~
90501-583L4
90501 -551 L3
~
90501 -581 L5
~
[Q] Color [8] Free length
W-S-W
L-P-L
~
y-p-y
~
89 mm (3.50 in)
88.4 mm (3.48 in)
~
85.4 mm (3.36 in)
~
[]] Preload
343 N (35 kg, 771b)
294 N (30 kg, 661b)
~
~
~
Q] Spring rate
22.1 N/mm (2.25 kg/mm, 126 Ib/in)
19.6 N/mm (2.00 kg/mm, 112 Ib/in)
~
24.5 N/mm (2.50 kg/mm, 140 Ib/in)
~
[Kl Wire diameter
5.8 mm (0.228 in)
5.5 mm (0.217 in)
~
5.8 mm (0.228 in)
~
CD Outside diameter
59.5 mm (2.34 in)
~
~
~
~
[MJ Weight (10)
8FP-17605-00 (8FPOO)
8FS-17605-00 (8FSOO)
~
~
~
OUT
Steel 17.2
Steel 17.2 with-hole
Steel 13.3
Steel 13.3
Steel 13.3 with-hole
CENTER
Steel 17.2
Steel 17.2 with-hole
Steel 13.3
Steel 13.3 with-hole
Steel 13.3 with-hole
IN
Steel 17.2
Steel 17.2
Steel 13.3
Steel 13.3 with-hole
None
IEJ ~eight rivet
[Q] Weight bushing [EJ Roller outer dia.
VESPEL TP-8549
~
~
~
~
14.5 mm (0.57 in)
15.6 mm (0.61 in)
~
~
~
[Q] Roller bushing [8] Pri. clutch shim [§] Secondary sheave spring
VESPEL TP-8549
~
~
~
~
None
~
~
~
~
90508-60007
~
~
~
~
IT] Color
W
~
~
~
~
[Q] Free length
75 mm (2.95 in)
[YJ
60° (3-3) 1,290 kgemm/rad
Preload rate
~
~
~
~
70° (1-6) 1,290 kgemm/rad
~
~
~
~ Wire diameter
6 mm (0.236 in)
~
~
~
~
[Xl Outside diameter [Yl Sec. torque cam angle
69.5 mm (2.736 in)
~
~
~
~
51 - 43°
~
~
~
~ Sec. clutch shim
1.0 mm (0.04 in)
~
~
~
45° ~
19
I
_ _ _ IIANOSJP GEAR SELECTION _ ______
I
~O~
~ I
GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions. If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions exist, decrease the ratio.
Gear ratio chart The drive and driven gears and the chains shown in the gear ratio chart are available as options. The figures containing a decimal point represent the drive/driven gear ratios, while the bottom numbers designate the number of links in the chain.
20
_ _ _ IIANOSJP I GEAR SELECTION _ ______ CD Chain and sprocket part number [8] Parts name
~ Drive sprocket
[E] Driven sprocket
[§] Chain
~O~
~
[Q] Standard
ffi] Teeth & links
[Q Parts no.
18 teeth
8FA-17682-80
19 teeth
8FA-17682-90
20 teeth
8FA-17682-00
21 teeth
8FA-17682-10
22 teeth
8FA-17682-20
23 teeth
8FA-17682-30
RXW10L
24 teeth
8FA-17682-40
RX10RTL, RX10RL, RX10RTRL, RX10GTL
37 teeth
8DW-47587-71
38 teeth
8DW-47587-81
RX10RTL
38 teeth
8FB-47580-80
RX10RL, RX10RTRL, RX10GTL, RXW10L
39 teeth
8DW-47587-91
39 teeth
8FB-47580-90
40 teeth
8DW-47587-01
40 teeth
8FB-47580-00
68 links
94890-09068
RX10ML
70 links
94890-09070
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L
RX10ML
RX10ML
® Gear ratio [8] Drive gear 18 teeth
19 teeth
21 teeth
22 teeth 23 teeth
24 teeth
1.76 68 links
1.68 68 links
1.61 68 links
1.54 70 links
1.90 68 links
1.81 68 links
1.73 68 links
1.65 70 links
1.58 70 links
20 teeth
ffi] Driven gear 37 teeth 38 teeth
/ / / /
/
39 teeth
2.17 68 links
2.05 68 links
1.95 68 links
1.86 68 links
1.77 70 links
1.70 70 links
1.63 70 links
40 teeth
2.22 68 links
2.11 68 links
2.00 68 links
1.91 70 links
1.82 70 links
1.74 70 links
1.67 70 links
21
I
INSP ADJ
GEAR SELECTION
® Secondary sheave spring [ill Spring rate
[E]
Nemm/rad (kgemm/rad)
[Q] Preload N/mm (kg / mm) (Ib/in)
90508-500B 1
6003 (613)
6.2 (0.63), 35.28
Brown
5.0 (0.196)
[A]
Part no.
[Q]
Color
Wire gauge mm(in)
[E]
No. of coils
~ Free
[8]
Outside diameter mm(in)
length mm(in)
5.19
75 (2.95)
69.5 (2.736)
IT]
Standard
90508-50746
7071 (721)
8.7 (0.89), 49.65
White
5.0 (0.196)
4.74
93.5 (3.68)
65.0 (2.559)
90508-536A9
7147 (729)
7.3 (0.74), 41.44
Red
5.3 (0.209)
5.53
75 (2.95)
69.5 (2.736)
90508-556A2
8314 (848)
8.5 (0.87), 48.72
Green
5.5 (0.217)
5.53
75 (2.95)
69.5 (2.736)
90508-556A7
9460 (965)
10.21 (1.04), 58.24
Silver
5.5 (0.217)
4.86
75 (2.95)
69.5 (2.736)
90508-60012
11876 (1211)
12.32 (1.256), 70.34
Pink
6.0 (0.236)
5.53
75 (2.95)
69.5 (2.736)
RX10RTL, RX10RL, RX10RTRL, RX10GTL
90508-60007
12654 (1290)
13.45 (1.372) 76.84
White
6.0 (0.236)
5.19
75 (2.95)
69.5 (2.736)
RXW10L, RX10ML
® Secondary spring twist angle Sheave ~ 1
0
3
6
9
10°
40°
70°
100°
2
20°
50°
80°
110°
3
30°
60°
90°
120°
~
@ Torque cam (secondary spring seat)
~ Effects
[Q Part no.
[A] Identification mark
[Q] Cam angle
~
Identification mark
~
Quicker upshifting during acceleration ~ ~
~
,
[8] Quicker backshifting under load
8FA-17604-00
51-43°
8BVFA
8BV-17604-71
47°
8BV71
8BV-17604-51
45°
8BV51
8BV-17604-31
43°
8BV31
8BV-17604-11
41 °
8BV11
8BV-17604-91
39°
8BV91
22
[E] Standard RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L RX10ML
GEAR SELECTION
INSP ADJ
@ Primary spring [AJ Spring identification color code [6] Spring rate color
[Q] Preload color
I
I
~
~.~ I
[Q]
[E] Parts No.
Spring rate N/mm (kg/mm)
[E]
Preload N (kg)
[8] Wire
[G]
Color
gauge mm(in)
[ ] Outside diameter mm(in)
W No. of coils
[R]
Free length mm(in)
90501-551 L3
19.6 (2.00)
294 (30)
Blue-Pink-Blue
5.5 (0.216)
59.5 (2.34)
4.91
88.4 (3.48)
90501-551 L9
19.6 (2.00)
343 (35)
Blue-Silver-Blue
5.5 (0.216)
59.5 (2.34)
4.91
90.9 (3.58)
90501-552L5
19.6 (2.00)
392 (40)
Blue-Green-Blue
5.5 (0.216)
59.5 (2.34)
4.91
93.4 (3.68)
90501-581 L5
24.5 (2.50)
294 (30)
Yellow-Pink-Yellow
5.8 (0.228)
59.5 (2.34)
4.92
85.4 (3.36)
90501-581 L6
27 (2.75)
294 (30)
Green-Pink-Green
5.8 (0.228)
59.5 (2.34)
4.66
84.3 (3.32)
90501-582L1
24.5 (2.50)
343 (35)
Yellow-Silver-Yellow
5.8 (0.228)
59.5 (2.34)
4.92
87.4 (3.44)
90501-582L2
27 (2.75)
343 (35)
Green-Silver-Green
5.8 (0.228)
59.5 (2.34)
4.66
86.1 (3.39)
90501-582L6
22.1 (2.25)
392 (40)
White-Green-White
5.8 (0.228)
59.5 (2.34)
5.25
91.2 (3.59)
90501-582L7
24.5 (2.50)
392 (40)
Yellow-G reen-Yellow
5.8 (0.228)
59.5 (2.34)
4.92
89.4 (3.52)
90501-583 LO
19.6 (2.00)
441 (45)
Blue-White-Blue
5.8 (0.228)
59.5 (2.34)
5.65
95.9 (3.78)
90501-583 L1
22.1 (2.25)
441 (45)
White-White-White
5.8 (0.228)
59.5 (2.34)
5.25
93.4 (3.68)
90501-583L4
22.1 (2.25)
343 (35)
White-Silver-White
5.8 (0.228)
59.5 (2.34)
5.25
89.0 (3.50)
90501-583 L5
22.1 (2.25)
294 (30)
White-Pink-White
5.8 (0.228)
59.5 (2.34)
5.25
86.7 (3.41)
90501-601 L7
29.4 (3.00)
294 (30)
Pink-Pink-Pink
6.0 (0.236)
59.5 (2.34)
4.82
83.4 (3.28)
90501-601 L8
31.9 (3.25)
294 (30)
Orange-Pink-Orange
6.0 (0.236)
59.5 (2.34)
4.60
82.6 (3.25) 85.1 (3.35)
90501-602L3
29.4 (3.00)
343 (35)
Pink-Silver-Pink
6.0 (0.236)
59.5 (2.34)
4.82
90501-602L8
27.0 (2.75)
392 (40)
Green-Green-Green
6.0 (0.236)
59.5 (2.34)
5.08
87.9 (3.46)
90501-602L9
29.4 (3.00)
392 (40)
Pink-Green-Pink
6.0 (0.236)
59.5 (2.34)
4.82
86.7 (3.41)
90501-603 L2
24.5 (2.50)
441 (45)
Yellow-White-Yellow
6.0 (0.236)
59.5 (2.34)
5.39
91.4 (3.60)
90501-603 L3
27.0 (2.75)
441 (45)
Green-White-Green
6.0 (0.236)
59.5 (2.34)
5.08
89.8 (3.54)
90501-624L8
31.9 (3.25)
343 (35)
Orange-Silver-Orange
6.2 (0.244)
59.5 (2.34)
5.00
84.2 (3.32)
23
[[] Standard
RX10ML
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L
_ _ _ IIANOSJP GEAR SELECTION _ ______
I
~O~
~ I
(J) Clutch weight
llil Weight g (oz) [8] Parts no.
without bush and rivets
8BU-17605-20
45.41 (1.60)
8CH-17605-10
35.32 (1.247)
[Q] Shape & 10 mark
00808
80G-17605-00
34.26 (1.209)
80J-17605-00
37.77 (1.333)
80N-17605-10
39.76 (1.40)
8ES-17605-00
54.6 (1.93)
8FA-17605-10
63.8 (2.25)
00
24
[Q] Standard
_ _ _ IIANOSJP I GEAR SELECTION _ ______
~O~
~
llil Weight g (oz) [Q] Shape & ID mark
[Q] Standard
[8] Parts no.
without bush and rivets
8FP-17605-00
67.81 (2.392)
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L
8FS-17605-00
65.52 (2.311)
RX10ML
® Weight rivets [A] Parts No.
[ill Material
[Q Length
[Q] Weight
mm(in)
g (oz)
90261-06033
Steel
17.2 (0.677)
4.5 (0.159)
90269-06006
Steel
17.2 (0.677)
3.6 (0.127) with hole
90261-06019
Steel
13.3 (0.524)
3.1 (0.109)
90266-06002
Steel
13.3 (0.524)
2.4 (0.085) with hole
90266-06001
Aluminum
13.3 (0.524)
0.8 (0.028) with hole
None
[E] Standard IN: RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L CENTER: RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L OUT: RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L
[E] Effects [Q] Increased Force
J~
CENTER: RX10ML OUT: RX10ML
~
,
[8] Decreased IN: RX10ML
25
Force
I
GEAR SELECTION
INSP ADJ
® Rollers 1.0. 9 mm (0.354 in)
[8] Roller with
[6J Outside
bushing part number
diameter mm (in)
8FG-17624-00
[Q Bushing
[Q] Identification
type (PIN)
mark (Width)
VESPEL TP-8549
[G] Grooved & Machined
[E] Standard
[] Increased force
1I
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L
14.5 (0.57)
[E] Effects
~~
II
(1.46 mm)
90386-09001
[8] Grooved
VESPEL TP-8549 8FG-17624-10
15.0 (0.59)
(1.46 mm)
90386-09001
IT] No Mark
VESPEL TP-8549 8FG-17624-20
15.6 (0.61)
RX10ML
(1.46 mm)
90386-09001 VESPEL TP-8549 8FG-17624-30
CD Grooved & Grooved
16.0 (0.63)
(1.46 mm) 90386-09001
[R] Machined
VESPEL TP-8549 8FG-17624-40
16.5 (0.65)
~ (1.46 mm)
90386-09001
26
,
M Decreased force
INSP ADJ
FRONT SUSPENSION FRONT SUSPENSION Spring preload 2
1. Adjust: • Spring preload
Adjustment steps:
• Loosen the locknut CD. • Adjust the spring preload by turning the spring seat ®.
RX10RTL, RX10RL, RX10RTRL, RXVV10L Spring seat distance Preload Length @
Standard Shorter ~ ~ Longer Harder ~ ~ Softer Min. Max. 243mm (9.57 in)
253mm (9.96 in)
257mm (10.12 in)
RX10GTL Spring seat distance Preload Length @
Standard Shorter ~ ~ Longer Harder ~ ~ Softer Min. Max. 243mm (9.57 in)
257mm (10.12 in)
257mm (10.12 in)
RX10ML Spring seat distance Preload Length @
Standard Shorter ~ ~ Longer Harder ~ ~ Softer Min. Max. 213 mm (8.39 in)
• Tighten the locknut
223mm (8.78 in)
223mm (8.78 in)
CD.
Be sure that the left and right spring preloads are the same.
~ ----------
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could cause it to explode.
27
_ _ _ IIANOSJP REAR SUSPENSION _ ______
I
~O~
~ I
REAR SUSPENSION Spring preload (RX10GTL) 1. Adjust: • Spring preload Adjustment step: • Loosen the locknut CD. • Adjust the spring preload by turning the spring seat ®. Front [8]
2
Spring seat distance Preload Length
®
Standard Shorter ~ ~ Longer Harder ~ ~ Softer Min. Max. 265mm (10.43 in)
• Tighten the locknut
285mm (11.22 in)
287mm (11.30 in)
CD.
~ ----------
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could cause it to explode.
Damping (RX10GTL) 1. Adjust • Damping Adjustment step: • Press the mode switch CD • Make sure to switch the multi-function meter to the electric suspension adjustment indicator ®. • To harden the suspension, push the electric suspension/ grip warmer adjustment switch located at the left handlebar switch @ to the "H I" side, or push it to the "LO" side to soften and adjust.
28
_ _ _ IIANOSJP I REAR SUSPENSION _ ______
~O~
~
I
• Press the electric suspension/grip warmer adjustment switch @ in direction ® or @. (Maximum: 16 push) Adjustment switch pushed direction Display Adjustment switch Damping force
o
@
®
S
H
1
2
3
4
5
6
7
8
112 31 4 51 6 71 e 91 10 111 12 13 114 15 116 Softer
~
~
Harder
• This display scale is set in 2-level for one graduation. NOTE: _
(
• The electric suspension indicator ® comes on and the display switch to the electric suspension level when the electric suspension/ grip warmer adjustment switch is pushed. • The electric suspension level is displayed for 5 seconds after releasing the electric suspension/grip warmer adjustment switch, then switch to the fuel meter. • The top segment of the electric suspension level indicator flashes once if the electric suspension/grip warmer adjustment switch is continually pushed at the maximum level. The bottom segment of the electric suspension level indicator flashes once if the electric suspension/grip warmer adjustment switch is continually pushed at the minimum level. • When the engine is started, the electric suspension level are set to the level saved when the engine was stopped.
29
______________ C_OW_LI_N_G_s_lcHAS I
J..I
CHASSIS COWLINGS
Order
Job/Part
Q'ty
Removing the cowlings 1 2
3 4 5
6 7
Shroud Side cover (left and right) Side under cover (left and right) Top cover Headlight assembly Headlight stay Intake silencer
Remarks Remove the parts in the order listed.
1 2 2 1 1 1 1 For installation, reverse the removal procedure.
30
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS I
~
STEERING RX10RTL, RX10RL, RX10RTRL, RXVV10L
2
10 Nm (1.0 m-kg, 7.2 ft-Ib) 15 Nm (1.5 m-kg, 11 ft-Ib)
Order
Job/Part
Q'ty
Handlebar removal 1 2
3 4 S
6 7 8
9 10 11 12
Top cover Handlebar cover Cable guide (front) Grip warmer lead coupler Throttle switch lead coupler Engine stop switch lead coupler Thumb warmer switch lead coupler Thumb warmer lead coupler Brake switch lead coupler Headlight beam switch lead coupler Grip warmer switch lead coupler Throttle cable Brake lever holder
1 1 2 2 1 1 1 1 1 1 1 1
31
Remarks Remove the parts in the order listed below. Refer to "COWLINGS".
Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.
I
STEERING
--------------------------
ICHASIJ..I
15
14
~
/
;'
2
10 Nm (1.0 m-kg, 7.2 ft-Ib) 15 Nm (1.5 m-kg, 11 ft-Ib)
Order
13 14 15 16 17 18
Job/Part Master cylinder assembly Handlebar holder (upper) Cable holder Handlebar Handlebar joint Cable guide (rear)
Q'ty
Remarks
1
NOTE: After installing all parts, refer to "CABLE ROUTING" to check the cable, lead and hose routings.
2
1 1 1 1
For installation, reverse the removal procedure.
32
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS I
~
RX10GTL
16
10 Nm (1.0 m-kg, 7.2 ft-Ib) 15 Nm (1.5 m-kg, 11 ft-Ib)
Order
1 2
3 4 S
6 7 8
9 10 11
Job/Part Handlebar removal Top cover Cable guide (front) Grip warmer lead coupler Throttle switvh lead coupler Engine stop switch lead coupler Thumb warmer switch lead coupler Thumb warmer lead coupler Brake switch lead coupler Headlight beam switch lead coupler Electric suspension/ grip warmer switch lead coupler Throttle cable Brake lever holder
Q'ty
2 2 1 1 1 1 1 1 1 1
33
Remarks Remove the parts in the order listed below. Refer to "COWLINGS". Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.
I
STEERING
--------------------------
ICHASIJ..I
16
10 Nm (1.0 m-kg, 7.2 ft-Ib) 15 Nm (1.5 m-kg, 11 ft-Ib)
Order
12 13 14 15 16 17
Job/Part Master cylinder assembly Handlebar holder (upper) Cable holder Handlebar Handlebar joint Cable guide (rear)
Q'ty
Remarks
1 2 1 1 1 1
NOTE: After installing all parts, refer to "CABLE ROUTING" to check the cable, lead and hose routings.
For installation, reverse the removal procedure.
34
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS I
~
RX10ML
16
10 Nm (1.0 m-kg, 7.2 ft-Ib) 15 Nm (1.5 m-kg, 11 ft-Ib)
Order
1 2
3 4 S
6 7 8
9 10 11
Job/Part Handlebar removal Top cover Cable guide (front) Grip warmer lead coupler Throttle switvh lead coupler Engine stop switch lead coupler Thumb warmer switch lead coupler Thumb warmer lead coupler Brake switch lead coupler Headlight beam switch lead coupler Grip warmer switch lead coupler Throttle cable Brake lever holder
Q'ty
1 2 2 1 1 1 1 1 1 1 1
35
Remarks Remove the parts in the order listed below. Remove to "COWLINGS". Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.
I
STEERING
--------------------------
ICHASIJ..I
14
13
ai
/
;'
16
10 Nm (1.0 m-kg, 7.2 ft-Ib) 15 Nm (1.5 m-kg, 11 ft-Ib)
Order
12 13 14 15 16 17
Job/Part Master cylinder assembly Handlebar holder (upper) Cable holder Handlebar Handlebar joint Cable guide (rear)
Q'ty
Remarks
1 2 1 1 1 1
NOTE: After installing all parts, refer to "CABLE ROUTING" to check the cable, lead and hose routings.
For installation, reverse the removal procedure.
36
__ _ _ _ _ PRIMARY SHEAVE AND DRIVE V-BELT _ ___
pOTWRRI~1 ~
POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT 120 Nm (12 m-kg, 85 ft-Ib) 60 Nm (6.0 m-kg, 43 ft-Ib)
2
Order
Job/Part
Q'ty
Primary sheave removal 1 2
Left side cover V-belt Primary sheave assembly
Remarks Remove the parts in the order listed below. Refer to "COWLINGS" in CHAPTER 3.
1 1 For installation, reverse the removal procedure.
37
_ _________ lpOTWRRI~1 PRIMARY SHEAVE AND DRIVE V-BELT
I :I :I
[AJ :
6 Nm (0.6 m-kg, 4.3 ft-Ib)
[aJ
14 Nm (1.4 m-kg, 10 ft-Ib)
~
~
200 Nm (20.0 m-kg, 145 ft-Ib)
[Q] : Clean the threads.
Apply LOCTITE648 AS illustrated in ~. And then tighten the spider. (The spider must be turned counterclockwise to be tightened.)
Order
Job/Part
@ 16 mm (0.63 in) ~ 30 mm (1.18 in)
Q'ty
Primary sheave disassembly
CD 速 速
@ @ @ (J)
速 速
@ @ @ @ @) @
Primary sheave cap Primary sheave spring Collar Roller Washer Collar Weight Washer Fixed sheave Stopper Sliding sheave Bushing Spider Slider Damper slider
Remarks Disassemble the parts in the order listed below.
1 1
3 3 6 3 3 6 1 1 1 1 1
Left-handed thread.
6 3 For assembly, reverse the disassembly procedure.
38
_ _ _ _ _ _ _ _ _ _ pOTWRRI~1 SLIDE RAIL SUSPENSION
~
SLIDE RAIL SUSPENSION RX10GTL
[AJ : I 60 Nm (6.0 m-kg, 43 ft-Ib)
I [ill : I 84 Nm (8.4 m-kg, 61 ft-Ib) I Order
Job/Part
Q'ty
Slide rail suspension removal
1 2
Rear axle nut Tension adjuster Slide rail suspension Collar
Remarks Remove the parts in the order listed below. Loosen. Loosen.
1 2 For installation, reverse the removal procedure.
39
_ _________ lpOTWRRI~1 SLIDE RAIL SUSPENSION
Order
CD ® ® ®
@ @ (J)
® ®
@ @
Job/Part Slide rail suspension disassembly Stopper band Shaft Rubber collar Electric suspension sub-wire lead Shock absorber Collar Control rod assembly Spacer Collar Oil seal Bearing
Q'ty 1 1 2 1 1 1 1 2 2
4 2
40
~.
Remarks Remove the parts in the order listed below.
SLIDE RAIL SUSPENSION
---------------------
Order
@ @ @ @ @ @ @ @) @ @ @ @ @ @ @
©
@
Job/Part
Q'ty 1
Front pivot arm Bushing Collar Sliding runner Suspension wheel Suspension wheel bracket Shaft Collar Front pivot arm bracket Bushing Collar Shaft Rear pivot arm Guide wheel Bushing Shaft Rear pivot arm bracket
4 2 2
6 6 1 1 2
4 2 1 1 2 2 1 1 41
Ip~:Rlo=Dl
Remarks
_ _________ lpOTWRRI~1 SLIDE RAIL SUSPENSION
Order
@ @ @ @
Job/Part
Q'ty
~.
Remarks
3 4
Guide wheel Collar Tension adjuster Rear axle shaft
2 1
For assembly, reverse the disassembly procedure.
42
_ _ _ _ _ _ _ _ _ _ pOTWRRI~1 SLIDE RAIL SUSPENSION
~
RXW10L
3
[A] : I 72 Nm (7.2 m-kg, 52 ft-Ib)
[ill : I 84 Nm (8.4 m-kg, 61 ft-Ib)
Order
1 2
3 4
I I
Job/Part Slide rail suspension removal Rear axle nut Tension adjuster Collar Shaft Guide wheel Slide rail suspension
Q'ty
Remarks Remove the parts in the order listed below. Loosen. Loosen.
2 1 2 1 For installation, reverse the removal procedure.
43
_ _________ lpOTWRRI~1 SLIDE RAIL SUSPENSION
Order
CD ® ® ®
@ @ (J)
® ®
@ @ @ @ @)
Job/Part Slide rail suspension disassembly Shock absorber adjuster assembly Stopper band Shaft Rubber collar Shock absorber Spacer Collar Oil seal Bearing Control rod assembly Spacer Collar Oil seal Bearing
Q'ty 1 1 1 2 1 2 2
4 2 1 2 2
4 2
44
~.
Remarks Remove the parts in the order listed below.
SLIDE RAIL SUSPENSION
_ _________ lpOTWRRI~1 ~.
SLIDE RAIL SUSPENSION
33
Order
@ @
® ®
Job/Part
Q'ty
Remarks
3 4
Guide wheel Collar Tension adjuster Rear axle shaft
2 1
For assembly, reverse the disassembly procedure.
46
_ _ _ _ _ _ _ _ _ _ pOTWRRI~1 SLIDE RAIL SUSPENSION
~
RX10ML
[A] : I
Order
1 2
72 Nm (7.2 m-kg, 52 ft-Ib)
I
Job/Part Slide rail suspension removal Rear axle nut Tension adjuster Slide rail suspension Collar
Q'ty
Remarks Remove the parts in the order listed below. Loosen. Loosen.
1 2
For installation, reverse the removal procedure.
47
_ _________ lpOTWRRI~1 SLIDE RAIL SUSPENSION
Order
CD ® ® ®
@ @ (J)
® ®
@ @ @ @ @) @ @ @
Job/Part Slide rail suspension disassembly Stopper band Shaft Rubber collar Front shock absorber Collar Bushing Front pivot arm Shaft Bushing Collar Suspension wheel assembly Shaft Shaft Suspension bracket Bushing Bracket Collar
Q'ty
2 1
3 1 2
4 1 1 2 2 2 1 1 1 2 1 2 48
~.
Remarks Remove the parts in the order listed below.
_ _ _ _ _ _ _ _ _ _ pOTWRRI~1 SLIDE RAIL SUSPENSION
Order
@ @) @ @ @ @ @ @ @ @ @ @
® C@ @ @ @
® ®
Job/Part Suspension wheel Hook assembly Rear shock absorber Collar Relay rod Collar Bushing Shaft Collar Bushing Bracket Collar Guide wheel Spacer Rear spring Shaft Bushing Rear pivot arm protector Rear pivot arm
Q'ty 2 2 1 2 2
4 4 1 2 2 1 2 2 2 2 1 2 2 1
49
Remarks
~
SLIDE RAIL SUSPENSION
For assem bly, reverse the disassenbly procedure.
50
_ _ _ _ _ _ _ _ _ _ pOTWRRI~1 ~
SLIDE RAIL SUSPENSION
Control rod parts number B
A
®
-++-+--++---------
[8] RX1 ORTL,
-----------
llil RX1 OML
RX10RL, RX10RTRL, RX10GTL,
RXW10L
[8] Control rod 1
llil
Length
® mm (in)
[Q Length @ mm (in)
© mm (in)
[Q] Length
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L
277.3 (10.92)
150.5 (5.93)
-
RX10ML
236.3 (9.30)
200.7 (7.90)
2.5P x 2 = 5 (O.098P x 2 = 0.196)
~ Control rod 1
[E] Control rod 2
parts number
parts number
8FR-4745A-00 (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L)
8FU-4745B-00
~ Control rod 1
[Q] Stopper control 1
parts number
parts number
8FS-4745A-00 (RX10ML)
8ES-4745D-00
[8] Washer plate parts number [IJ Washer plate thickness mm (in) Q] Upper
[Kl Lower
90202-16229 2.5 (0.098)
8FU-47384-20 10.0 (0.394)
[8] Washer plate parts number [IJ Washer plate thickness mm (in)
51
Q] Upper
[Kl Lower
90201-24015 2.0 (0.079)
90202-25001 2.0 (0.079)
_ _ _ _ _ _ _ _ _ _ _ _S_E_AT_A_N_D_F_U_E_L_TA_N_K_I
ENG
I
ENGINE SEAT AND FUEL TANK
Order
Job/Part
Q'ty
Seat and fuel tank removal 1 2
3 4 5
6 7 8
Remarks Remove the parts in the order listed below.
2 1 2 1 1 1 2 1
Muffler end pipe Tail/brake light cover Muffler side cover Seat Fuel tank cap Fuel tank cover Side cover Fuel tank
For installation, reverse the removal procedure.
52
_ _ _ _ _ _ _ _ _E_X_H_A_U_S_T_P_IP_E_A_N_D_M_U_F_F_LE_R_I
ENG
I
EXHAUST PIPE AND MUFFLER
I rn:J : I [Q : I [AJ :
[Q]:
I
16 Nm (1.6 m-kg, 12 ft-Ib)
I I I
11 Nm(1.1 m-kg,8ft-lb)
I
20 Nm (2.0 m-kg, 14 ft-Ib) 25 Nm (2.5 m-kg, 18 ft-Ib)
D
A
__
~ -~
I
~~~~:~
i~i ~ ~~ -~~ 4
y
3
~~y~~ ~~~~Y~~A' ~~~
-~7
1~'
I~
~~~
Order
Job/Part
3
Q'ty
Exhaust pipe and muffler removal
1
2
3 4 5
Front axle assembly Track Seat and fuel tank Protector Muffler Exhaust pipe Gasket Band
Remarks Remove the parts in the order listed below. ] Refer to "FRONT AXLE AND TRACK" in CHAPTER 4 Refer to "SEAT AND FUEL TANK".
1 1
2 2 2 For installation, reverse the removal procedure.
53
_ _ _ _ _ _ _ _ _ _ _ _H_E_AT_EX_C_H_A_N_G_E_R_ICOOL I
~
COOLING SYSTEM HEAT EXCHANGER
Order
Job/Part Heat exchanger removal Coolant
Q'ty
Primary sheave assembly 1 2 3 4 5
6 7 8
9 10 11 12
Coolant reservoir tank Coolant recovery tank Coolant recovery tank drain hose Coolant hose 1 Radiator Coolant hose 2 Heat exchanger (right) Coolant hose 3 Heat exchanger (rear) Coolant hose 4 Heat exchanger (left) Coolant hose 5
1 1 1 1 1 1 1 1 1 1 1 1 54
Remarks Remove the parts in the order listed below. Drain. Refer to "COOLING SYSTEM" in CHAPTER 2. Refer to "PRIMARY SHEAVE AND DRIVE V-VELT" in CHAPTER 4.
I
_ _ _ _ _ _ _ _ _ _ _ _H_E_AT_EX_C_H_A_N_G_E_R_lcOOL I
Order 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Job/Part Heat exchanger (front) Coolant hose 6 Water pump assembly Throttle body heater hose Coolant hose 7 Coolant pipe 1 Coolant hose 8 Coolant pipe 2 Coolant hose 9 Water jacket joint Coolant hose 10 Thermostat assembly Coolant hose 11 Coolant hose 12 Oil cooler outlet hose Oil cooler Oil cooler inlet hose
Q'ty 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 55
Remarks
~
I
_ _ _ _ _ _ _ _ _ _ _ _H_E_AT_EX_C_H_A_N_G_E_R_lcOOL I
Order 30 31 32 33 34
Job/Part Pipe 3 Water pump hose O-ring Coolant hose 13 Coolant hose 14
Q'ty 1 1 1 1 1
Remarks
For installation, reverse the removal procedure.
56
~
I
_ _ _ _ _ _ _ _ ICOOLI ~
57
I
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM
CD Ignition coil ® Spark plug ® Fuel tank ® Fuel pump ® Grip warmer
® Engine
temperature trouble warn- @Intake sensor ing light Cylinder identification @ Atmospheric pressure sensor sensor @ECU adjust- @ Fuel delivery hose Throttle position sen- @ Fuel injector ment down side switch @ Intake air pressure @ Fuel injection system sor @ Oil pressure switch relay sensor @ Battery (J) Speed sensor
®
®
58
@ Intake silencer @ Crankshaft position sensor
@ Oil level switch @ Pressure regulator @ Coolant temperature sensor
@ Fuel return hose
FUEL INJECTION SYSTEM WIRING DIAGRAM
59
FUEL INJECTION SYSTEM
CD Crankshaft position sensor
@ Main switch @ Fuse (MAl N)
® Fuse (FUEL INJECTION SYSTEM) ® Battery
@ Engine stop switch @ Oil pressure switvh @E.C.U. @ Ignition coil #1 @ Ignition coil #2 @ Ignition coil #3 @ Ignition coil #4 @Spark plug @ Fuel injection system relay @ Injector #1 @ Injector #2 Injector #3 @ Injector #4 @Fuel pump @ Throttle position sensor Speed sensor @ Cylinder identification sensor @ Intake air pressure sensor @ Atmospheric pressure sensor @ Water temperature sensor @ Intake air temperature sensor ® Grip warmer adjustment down side switch @ Fuse (BACKUP) @ Fuse (IGNITION) Multi function meter <@ Oil level switch
®
®
®
60
FI
FI
FUEL INJECTION SYSTEM EAS00899
ECU'S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU. • To inform the rider that the fuel injection system is not functioning, the engine trouble warning light flashes when the start switch is being pushed to start the engine. • If a malfunction is detected in the system by the self-diagnostic function, this mode provides an appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by flashing an engine trouble warning light. • The fault code number appears from the lowest value in order of precedence on the LCD meter. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted. EAS00900
Engine trouble warning light indication and FI system operating condition Warning light indication ECU's operation FI operation Flashing* Warning provided when Operation stopped unable to start engine Remains ON Malfunction detected Operated with substitute characteristics in accordance with the description of the malfunction
Vehicle operation Unable Able/Unable depending on the self-diagnostic fault code
* The warning light flashes when anyone of the conditions listed below is present and the start switch is pushed. The period for flashing is 160 ms. (Period during SELF-DIAGNOSTIC is 1000 ms.) 11: Cylinder identification sensor 12: Crankshaft position sensor
30: Oil pressure dropped. 50: ECU internal malfunction (memory check error)
EAS00901
Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned "ON" and when the main switch is being turned. If the warning light does not come on under these conditions, the warning LED may be defective.
Main switch Main switch ON OFF Engine trouble warning light
Light OFF
Light ON for 1.4 seconds
I
Light OFF
61
FUEL INJECTION SYSTEM
FI
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction. When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions. The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are given in the table below. FAIL-SAFE ACTIONS TABLE Fault Code No.
Item
Symptom
Fail-safe action
Able/unable to start
Able/unable to drive
Unable
Able
Unable
Unable
Able
Able
Able
Able
Cylinder identification sensor
No normal signals are received from the cylinder identification sensor.
Continues to operate the engine based on the results of the cylinder identification that existed up to that point.
12
Crankshaft position sensor
No normal signals are received from the crankshaft position sensor.
• Stops the engine (by stopping the injection and ignition).
13 14
Intake air pressure sensor (open or short circuit) (pipe system)
Intake air pressure sensor-open or short circuit detected. Faulty intake air pressure sensor system.
• Fixes the intake air pressure to 85.0 kpa.
Throttle position sensor (open or short circuit) (stuck)
Throttle position sensor-open or short circuit detected.
• Fixes the th rottle position sensor to fully open.
Intake air pressure Atmospheric pressure
Defective values are detected due to the internal malfunction.
• Fixes the intake air pressure and atmospheric pressure to 85.0 kpa.
Able
Able
Coolant temperature sensor
Coolant temperature sensoropen or short circuit detected.
• Fixes the coolant temperature to 60°C. After the engine starts, the radiator fan relay will be turned ON.
Able
Able
22
Intake temperature sensor
Intake temperature sensor-open or short circuit detected.
• Fixes the intake temperature to O°C.
Able
Able
23
Atmospheric pressure sensor (open or short circuit)
Atmospheric pressure sensoropen or short circuit detected.
• Fixes the atmospheric pressure to 85.0 kpa.
Able
Able
Oil pressure dropped
Engine stops when the oil pressure drop is detected.
• Fuel pump and fuel injection are stopped. (Main relay is off.)
Unable
Unable
Faulty ignition
Open circuit detected in the primary lead of the ignition coil.
• Cut the injection of other cylinder in the same group with the cylinder that the error is detected. (Example: when the #1 cylinder is detective, cut the injection of #1 and #4 cylinders, when the #2 cylinder is detective, cut the injection of #2 and #3 cylinders). Turn on the power to the air induction solenoid to always cut-off the air.
Able (depending on the number of faulty cylinders)
Able (depending on the number of faulty cylinders)
Able
Able
Able
Able
11
15 16
20
21
30
33 34 35 36
42
43
Speed sensor, neutral switch
No normal signals are received from the speed sensor; or, an open or short circuit is detected in the neutral switch.
• Fixes the gear to the top gear.
Fuel system voltage (monitor voltage)
The ECU is unable to monitor the battery voltage (an open circuit in the line to the ECU).
• Fixes the battery voltage to 12 V.
62
FUEL INJECTION SYSTEM Fault Code No.
Item Error in writing the amount of CO adjustment on EEPROM
An error is detected while reading or writing on EEPROM (CO adjustment value).
-
44
46
Vehicle system power supply (Monitor voltage)
Power supply to the FI system is not normal.
Grip warmer output is OFF.
ECU internal malfunction (memory check error)
Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter.
-
Grip warmer switch
Grip warmer switch-short circuit detected.
-
Grip warmer
Grip warmer-open or short circuit detected.
-
Thumb warmer switch
Thumb warmer switch-short circuit detected.
-
Thumb warmer
Thumb warmer-short circuit detected.
-
T.O.R.S.
Detecting conditions for T.O.R.S. are satisfied.
-
Oil pressure switch
Oil pressure switch-open circuit detected.
-
Start unable warning
Relay is not turned ON even if the crank signal is input while the start switch is turned ON. When the start switch is turned ON while an error is detected with the fault code of No.11 , 12, 30 or 50.
Engine trouble warning light flashes when the start switch is turned ON.
50
80 81 82 83 84 85
-
Symptom
Fail-safe action
FI Able/unable to start
Able/unable to drive
Able
Able
Able
Able
Unable
Unable
Able
Able
Able
Able
Able
Able
Able
Able
Able
Unable
Able
Able
Unable
Unable
Able/unable to start
Able/unable to drive
Unable
Unable
Unable
Unable
Unable
Unable
Unable
Unable
Communication error with the meter Fault Code No.
Item
Symptom
Er-1
ECU internal malfunction (output signal error)
No signals are received from the ECU.
-
ECU internal malfunction (output signal error)
No signals are received from the ECU within the specified duration.
-
Er-3
ECU internal malfunction (output signal error)
Data from the ECU cannot be received correctly.
-
Er-4
ECU internal malfunction (input signal error)
Non-registered data has been received from the meter.
-
Er-2
Fail-safe action
63
FI
FUEL INJECTION SYSTEM EAS00904
TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light flash. *Engine trouble warning light may not come on even if the engine operation is not normal.
â&#x20AC;˘
â&#x20AC;˘
The engine trouble warning light does not come on.
The engine trouble warning light flash. Check the fault code number displayed on the meter.
~
L . . . . . - - - - - - - - - - - - , _ - - - - - - - I
Identify the probable cause of malfunction. (Refer to the "Diagnostic fault code table".) Check and repair the probable case of malfunction. Fault code No. appear
Fault code No. disappear
!
Check and repair. Check and repair. (Refer to "TROU(Refer to "FAI L-SAFE ACTIONS TABLE".) BLESHOOTING DETAILS".) Monitor the operation of the sensors and actuators in the diagnostic mode. (Refer to "Diagnostic mode table" in chapter 7)
OK
Malfunction of engine
r-
!
!
Check and repair the inner parts of engine. (Refer to Chapter 5)
~
OK
! Check and repair the corresponding sensor or actuator. NG
Check the engine condition. Fault code number displayed
NG
Defective sensor or actuator
~-
Perform ECU reinstatement action. (Refer to "Reinstatement method" in "TROUBLESHOOTING DETAILS".) ... Turn the main switch to "OFF", turn the main switch back to "ON", and then check if the fault code number is still displayed.
Check the operation of following sensors and actuators in the diagnostic mode (Refer to "Diagnostic mode table" in chapter 7.) 01: Throttle position 30: Ignition coil #1 sensor (throttle 31: Ignition coil #2 angle) 32: Ignition coil #3 03: Intake air pressure 33: Ignition coil #4 07: Vehicle speed 36: Injector #1 pulse 37: Injector #2 09: Fuel system volt38: Injector #3 age (battery bolt) 39: Injector #4
~
OK
OK
~
Fault code number not displayed Repairs completed Erasing the malfunction history:* The malfunction history is stored even if the main switch is turned OFF. * Operated when the engine trouble warning light flash. The malfunction history must be erased in the diagnostic mode. (Refer to the "Diagnostic mode table (Diagnostic code No.62)")
64
FUEL INJECTION SYSTEM EAS00905
DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode.
Setting the diagnostic mode 1. Turn the main switch to "OFF" and set the engine stop switch to "ON". 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the "SELECT" and "RESET" buttons, turn the main switch to "ON", and continue to press the buttons for 8 seconds or more. 4. After selecting "dl", simultaneously press the "SELECT" and "RESET" buttons for 2 seconds or more to execute the selection. 5. SSelect the diagnostic code number that applies to the item that was verified with the fault code number by pressing the "SELECT" and "RESET" buttons. NOTE: _ • The diagnostic code number appears on the LCD meter (01-70). • To decrease the selected diagnostic code number, press the "RESET" button. Press the "RESET" button for 1 second or longer to automatically decrease the diagnostic code numbers. • To increase the selected diagnostic code number, press the "SELECT" button. Press the "SELECT" button for 1 second or longer to automatically increase the diagnostic code numbers.
65
FUEL INJECTION SYSTEM 6. Verify the operation of the sensor or actuator. â&#x20AC;˘ Sensor operation The data representing the operating conditions of the sensor appears on the trip LCD. â&#x20AC;˘ Actuator operation Set the grip warmer adjustment down side switch to "ON" to operate the actuator. * If the grip warmer adjustment down side switch is set to "ON", set it to "OFF", and then set it to "ON" again. 7. Turn the main switch to "OFF" to cancel the diagnostic mode. NOTE: _ To perform a reliable diagnosis, make sure to turn "OFF" the power supply before every check and then start right from the beginning.
66
FUEL INJECTION SYSTEM
FI
Diagnostic fault code table Fault Code No.
Symptom No normal signals are received from the cylinder identification sensor.
Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective cylinder identification sensor. Malfunction in ECU. Improperly installed sensor.
-
• • • • •
Open or short circuit in wiring harness. Defective crankshaft position sensor. Malfunction in pickup rotor. Malfunction in ECU. Improperly installed sensor.
-
Intake air pressure sensor-open or short circuit detected.
• • • •
Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective intake air pressure sensor. Malfunction in ECU.
03
Faulty intake air pressure sensor hose system; a hose is detached, causing constant application of the atmospheric pressure to the sensor; or, the hose is clogged.
• Intake air pressure sensor hose is detached, clogged, kinked, or pinched. • Malfunction in ECU.
Throttle position sensor-open or short circuit detected.
• • • • •
No normal signals are received from the crankshaft position sensor. 12
14
Diagnostic code
• • • • •
11
13
Probable cause of malfunction
15
Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective th rottle position sensor. Malfunction in ECU. Improperly installed throttle position sensor.
03
01
A stuck throttle position sensor is detected.
• Stuck th rottle position sensor. • Malfunction in ECU.
01
20
When the main switch is turned to ON, the atmospheric sensor voltage and intake air pressure sensor voltage differ greatly.
• Atmospheric pressure sensor hose is clogged. • Intake air pressure sensor hose is clogged, kinked, or pinched. • Malfunction of the atmospheric pressure sensor in the intermediate electrical potential. • Malfunction of the intake air pressure sensor in the intermediate electrical potential. • Malfunction in ECU.
03 02
21
Coolant temperature sensor-open or short circuit detected.
• Open or short circuit in wiring harness. • Defective coolant temperature sensor. • Malfunction in ECU.
06
22
Intake temperature sensor-open or short circuit detected.
• Open or short circuit in wiring harness. • Defective intake temperature sensor. • Malfunction in ECU.
05
23
Atmospheric pressure sensor-open or short circuit detected.
• Open or short circuit in wiring sub lead. • Defective atmospheric pressure sensor. • Malfunction in ECU.
02
30
Oil pressure dropped.
• Oil pressure dropped.
Open circuit is detected in the primary lead of the ignition coil (#1).
• • • •
Open or short Malfunction in Malfunction in Malfunction in
circuit in wiring harness. ignition coil. ECU. a component of ignition cut-off circuit system.
30
Open circuit is detected in the primary lead of the ignition coil (#2).
• • • •
Open or short Malfunction in Malfunction in Malfunction in
circuit in wiring harness. ignition coil. ECU. a component of ignition cut-off circuit system.
31
Open circuit is detected in the primary lead of the ignition coil (#3).
• • • •
Open or short Malfunction in Malfunction in Malfunction in
circuit in wiring harness. ignition coil. ECU. a component of ignition cut-off circuit system.
32
Open circuit is detected in the primary lead of the ignition coil (#4).
• • • •
Open or short Malfunction in Malfunction in Malfunction in
circuit in wiring harness. ignition coil. ECU. a component of ignition cut-off circuit system.
33
16
33
34
35
36
67
FUEL INJECTION SYSTEM Fault Code No.
Symptom
FI
Probable cause of malfunction
Diagnostic code
No normal signals are received from the speed sensor.
• • • •
43
The ECU is unable to monitor the battery voltage (an open circuit in the monitor line to the ECU).
• Open circuit in wiring harness. • Malfunction in ECU.
44
An error is detected while reading or writing on EEPROM.
• Malfunction in ECU. (The CO adjustment value is not properly written on or read from the internal memory).
46
Power supply to the FI system is not normal.
• Malfunction in "CHARGING SYSTEM".
50
Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter.
• Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.)
The grip warmer switch is not normal.
• Short circuit in wiring harness. • Defective grip warmer switch. • Malfunction in ECU.
-
• Open or short circuit in wiring harness. • Defective grip warmer. • Malfunction in ECU.
26
The thumb warmer switch is not normal.
• Short circuit in wiring harness. • Defective thumb warmer switch. • Malfunction in ECU.
-
The thumb warmer is not normal.
• Short circuit in wiring harness. • Defective thumb warmer. • Malfunction in ECU.
27
42
80 The grip warmer is not normal. 81
82
83
Open or short circuit in wiring harness. Defective speed sensor. Malfunction in vehicle speed sensor detected unit. Malfunction in ECU.
07
09
60
-
-
T.O.R.S.
• Detecting conditions for T.O.R.S. are satisfied.
The oil pressure switch is not normal.
• Open circuit in wiring harness. • Defective oil pressure switch. • Malfunction in ECU.
-
• • • •
-
84
85 No signal are received from the ECU. Er-1
Open or short circuit in wiring harness. Malfunction in meter. Malfunction in ECU. Defective wire connection of the ECU coupler.
1 24 42
Er-2
No signal are received from the ECU within the specified duration.
• Improper connection in wiring harness. • Malfunction in meter. • Malfunction in ECU.
-
Er-3
Data from the ECU can not be received correctly.
• Improper connection in wiring harness. • Malfunction in meter. • Malfunction in ECU.
-
Er-4
Non-registered data has been received from the meter.
• Improper connection in wiring harness. • Malfunction in meter. • Malfunction in ECU.
-
68
FI
FUEL INJECTION SYSTEM
Diagnostic mode table Switch the meter display from the regular mode to the diagnosis mode. To switch the display, refer to "DIAGNOSTIC MODE". NOTE: _ - Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively. -If it is not possible to check it with an atmospheric pressure gauge, judge it by using 101.3 kPa as the standard. -If it is not possible to check the intake air temperature, use the ambient temperature as reference. Diagnostic code
Item Throttle angle
01 Atmospheric pressure 02
Data displayed on meter (reference value)
Description of action Displays the throttle angle. • Check with throttle fully closed. • Check with throttle fully open.
o --- 125 degrees • Fully closed position (15 --- 18) • Fully open position (95 --- 100)
Displays the atmospheric pressure.
Compare it to the value displayed on the meter.
* Use an atmospheric pressure gauge to check the atmospheric
pressure. Intake air pressure 03
Intake temperature
Coolant temperature
Displays the intake air temperature.
Compare it to the value displayed on the meter. (min-30 [OCD
Displays the coolant temperature. * Check the temperature of the coolant.
06
Compare it to the value displayed on the meter. (min-30 [OCD
Vehicle speed pulse
Displays the accumulation of the vehicle pulses that are generated when the tire is spun.
(0 --- 999; resets to 0 after 999) OK if the numbers appear on the meter.
Fuel system voltage (battery voltage)
Displays the fuel system voltage (battery voltage). Engine stop switch is on.
0---18.7V Normally, approximately 12.0 V
Th rottle switch
The meter displays the following items: During the throttle switch ON (throttle open): ON During the throttle switch OFF (throttle close): OFF
-
Grip warmer drive
Drive the grip warmer when 1 second has passed after the grip warmer down side switch is changed from OFF to ON. However, if the input of grip warmer down side switch (Grip warmer down side switch: from OFF to ON) changed before the operation as mentioned above is finished, stop the driving operation and start the operation newly. Light the engine warning lamp while the grip warmer down side switch is turned ON. When it is moved to other code, the operation as mentioned above should be stopped immediately. The operation mentioned above is repeated every time the grip warmer down side switch is changed from OFF to ON.
-
Thumb warmer drive
Drive the grip warmer when 1 second has passed after the grip warmer down side switch is changed from OFF to ON. However, if the input of grip warmer down side switch (Grip warmer down side switch: from OFF to ON) changed before the operation as mentioned above is finished, stop the driving operation and start the operation newly. Light the engine warning lamp while the grip warmer down side switch is turned ON. When it is moved to other code, the operation as mentioned above should be stopped immediately. The operation mentioned above is repeated every time the grip warmer down side switch is changed from OFF to ON.
-
07
24
26
27
• Not cranking-atmospheric pressure • Cranking-intake air pressure It changes at the value whitch is smaller than in the atomospheric pressure.
* Check the temperature in the air cleaner case.
05
09
Displays the intake air pressure. Engine stop switch is on. * Generate the pressure difference by cranking the engine with the starter, without actually starting the engine.
69
FI
FUEL INJECTION SYSTEM Diagnostic code
Item Suspension for the adjustment of damping force
The following connection judgment result is transmitted to the meter. When the connection judgment is "Connected": H'OO When the connection judgment is "Not connected": H'FO The following item is performed only when the connection judgment is "Connected". Set ECS to Hard when 1 second has passed after the grip warmer down side switch is changed from OFF to ON. (Pattern 1): Set ECS to Soft when 5000 ms has passed after the power is supplied. (Pattern 2): Turn ECS OFF when 5000 ms has passed after the power is supplied. However, if the switch input (Grip warmer down side switch: from OFF to ON) changed before the operation as mentioned above is finished, stop the driving operation and start the operation newly. Light the engine warning lamp while the condition (Pattern 1) as mentioned above is turned ON. Blink the engine warning lamp while the condition (Pattern 2) as mentioned above is turned ON. (Period: 1 s, Duty: 50%) When it is moved to other code, the operation as mentioned above should be stopped immediately. The operation mentioned above is repeated every time the grip warmer down side switch is changed from OFF to ON.
-
Ignition coil #1
After the engine stop switch has been turned from OFF to ON, it actuates ignition coil #1 for five times every second and illuminates the engine trouble warning light. * Connect an ignition checker. * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Check that spark is generated, 5 times with the engine stop switch ON.
Ignition coils #2
After the engine stop switch has been turned from OFF to ON, it actuates ignition coil #2 for five times every second and illuminates the engine trouble warning light. * Connect an ignition checker. * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Check that spark is generated, 5 times with the engine stop switch ON.
Ignition coil #3
After the engine stop switch has been turned from OFF to ON, it actuates ignition coil #3 for five times every second and illuminates the engine trouble warning light. * Connect an ignition checker. * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Check that spark is generated, 5 times with the engine stop switch ON.
Ignition coil #4
After the engine stop switch has been turned from OFF to ON, it actuates ignition coil #4 for five times every second and illuminates the engine trouble warning light. * Connect an ignition checker. * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Check that spark is generated, 5 times with the engine stop switch ON.
Injector #1
After the engine stop switch has been turned from OFF to ON, it actuates the injector #1 five times every second and illuminates the engine trouble warning light. * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Check the operating sound of the injector five times with engine stop switch ON.
Injector #2
After the engine stop switch has been turned from OFF to ON, it actuates the injector #2 five times every second and illuminates the engine trouble warning light. * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Check the operating sound of the injector five times with engine stop switch ON.
Injector #3
After the engine stop switch has been turned from OFF to ON, it actuates the injector #3 five times every second and illuminates the engine trouble warning light. * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Check the operating sound of the injector five times with engine stop switch ON.
Injector #4
After the engine stop switch has been turned from OFF to ON, it actuates the injector #4 five times every second and illuminates the engine trouble warning light. * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Check the operating sound of the injector five times with engine stop switch ON.
29
30
31
32
33
36
37
38
39
Data displayed on meter (reference value)
Description of action
70
FI
FUEL INJECTION SYSTEM Diagnostic code
Item Fuel injection system relay
After the engine stop switch has been turned from OFF to ON, it Check the fuel injection system actuates the fuel injection system relay five times every second relay operating sound 5 times and illuminates the engine trouble warning light (the light is OFF with the engine stop switch ON. when the relay is ON, and the light is ON when the relay is OFF). * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Radiator fan motor relay
After the engine stop switch has been turned from OFF to ON, it actuates the radiator fan motor relay five times every 5 seconds and illuminates the engine trouble warning light. (ON 2 seconds, OFF 3 seconds) * If the grip warmer adjustment down side switch is ON, turn it OFF once, and then turn it back ON.
Check the radiator fan motor relay operating sound 5 times with the engine stop switch ON. (At that time, the fan motor rotates.)
Headlight relay 1
After the engine stop switch has been turned from OFF to ON, it actuates the headlight relay five times every 5 seconds and illuminates the engine trouble warning light. (ON 2 seconds, OFF 3 seconds) * If the engine stop switch is ON, turn it OFF once, and then turn it back ON.
Check the headlight relay operating sound 5 times with the engine stop switch ON. (At that time, the headlight turns ON.)
Odometer
Odometer is displayed on the meter.
-
EEPROM fault code display
• Transmits the abnormal portion of the data in the E2PROM that has been detected as a self-diagnostic fault code 44. • If multiple malfunctions have been detected, different codes are displayed at 2-second intervals, and this process is repeated.
(01 --- 04) Displays the cylinder number. (00) Displays when there is no malfunction.
Malfunction history code display
• Displays the codes of the history of the self-diagnosis malfunctions (i.e., a code of a malfunction that occurred once and which has been corrected). • If multiple malfunctions have been detected, different codes are displayed at 2-second intervals, and this process is repeated.
11 --- 85 (00) Displays when there is no malfunction.
Malfunction history code erasure
• Displays the total number of codes that are being detected through self diagnosis and the fault codes in the past history. • Erases only the history codes when the engine stop switch is turned from OFF to ON. If the engine stop switch is ON, turn it OFF once, and then turn it back ON.
00 --- 27 (00) Displays when there is no malfunction.
Control number
• Displays the program control number.
00 --- 255
50
51
52
58
60
61
62
70
Data displayed on meter (reference value)
Description of action
71
FI
FUEL INJECTION SYSTEM
TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the order. When the check and maintenance of malfunctioned part is completed, restore the meter display according to the "Restore method". Fault code No.: Fault code number displayed on the meter when the engine failed to work normally. (Refer to "Diagnostic fault code table".) Diagnostic code No.: Code number to be used when the diagnostic monitoring mode is operated. (Refer to "DIAGNOSTIC MODE".) Fault code No. I 11 I Symptom I No normal signals are received from the cylinder identification sensor. Used diagnostic code No. - Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method 1 Installed condition of sensor Check the installed area for looseness or pinching. Reinstated by 1---2--+--C-o-n-ne-c-te-d-co-n-d-it-io-n-o-f-c-on-n-e-c-to-r----+-I-ft-h-e-re-i-s-a-m-a-I-fu-n-ct-io-n-,-re-p-a-ir-it-a-n-d-c-o-n-n-e-ct-it----I starti ng the
3
4
Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in wiring harness and/or sub lead.
Defective cylinder identification sensor.
securely. engine and Cylinder identification sensor coupler operating it at idle. Main wiring harness ECU coupler Sub-wire harness coupler Repair or replace if there is an open or short circuit. Between sensor coupler and ECU coupler Blue - Blue White/Black - White/Black Black/Blue - Black/Blue Replace if defective. 1. Connect the pocket tester (DC 20 V) to the cylinder identification sensor coupler terminal as shown. Tester positive probe ~ white/black Tester negative probe ~ black/blue
CD ÂŽ
A)D ~~ W ~C ~ A
2. Set the main switch to "ON". 3. Measure the cylinder identification sensor output voltage. Cylinder identification sensor output voltage When sensor is on 4.8 V or more When sensor is off 0.8 V or less 4. Is the cylinder identification sensor OK?
72
FI
FUEL INJECTION SYSTEM
Fault code No. I 12 I Symptom I No normal signals are received from the crankshaft position sensor. Used diagnostic code No. - Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method 1 Installed condition of sensor Check the installed area for looseness or pinching. Reinstated by 1---2---+-C-o-n-n-e-c-te-d-co-n-d-it-io-n-of-c-o-n-n-e-c-to-r----+--If-th-e-r-e-is-a-m-a-I-fu-n-c-ti-o-n,-r-e-p-a-ir-it-a-n-d-c-o-n-n-e-c-t-it- - - - I cranki ng the Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler.
3
Open or short circuit in wiring harness.
4
Defective crankshaft position sensor.
securely. Crankshaft position sensor coupler Main wiring harness ECU coupler
engine.
Repair or replace if there is an open or short circuit between the main wiring harnesses. Between sensor coupler and ECU coupler Gray - Gray Black/Blue - Black/Blue Replace if defective. 1. Disconnect the crankshaft position sensor coupler from the wire harness. 2. Connect the pocket tester (0 x 100) to the crankshaft position sensor coupler as shown.
CD
Tester positive probe ~ gray Tester negative probe ~ black
®
)1---------11 Gy I B 2 3. Measure the crankshaft position sensor resistance. Crankshaft position sensor resistance 445 - 545 0 at 20°C (68°F) (between gray and black) 4. Is the crankshaft position sensor OK?
73
FI
FUEL INJECTION SYSTEM Fault code No.
I
13
I
Symptom
I Intake air pressure sensor -
open or short circuit detected.
Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable cause
Operation item and countermeasure
Reinstatement method
Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it securely. Intake air pressure sensor coupler Main wiring harness ECU coupler Sub-wire harness coupler
Reinstated by turning the main switch ON.
2
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit. Between sensor coupler and ECU coupler Black/Blue - Black/Blue Pink/White - Pink/White Blue - Blue
3
Defective intake air pressure sensor
Execute the diagnostic monitoring mode (Code No.03). Replace if defective. 1. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler terminal as shown.
Tester positive probe ~ pink/white Tester negative probe ~ black/blue
CD
ÂŽ
2. Set the main switch to "ON". 3. Measure the intake air pressure sensor output voltage.
Intake air pressure sensor output voltage 4.75 - 5.25 V 4. Is the intake air pressure sensor OK?
74
FUEL INJECTION SYSTEM Fault code No.
14
1
S ymptom
I
FI
Intake air pressure sensor - hose system malfunction (clogged or detached hose).
I
Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable cause
Operation item and countermeasure
Reinstatement method Reinstated by starting the engine and operating it at idle.
1
Intake air pressure sensor hose detached, clogged, kinked, or pinched. Intake air pressure sensor malfunction at intermediate electrical potential.
Repair or replace the sensor hose. Inspect and repair the connection.
2
Connected condition of connector Intake air pressure sensor coupler Main wiring harness ECU coupler
Check the coupler for any pins that may have pulled out. Check the looking condition of the coupler. If there is a malfunction, repair it and connect it securely.
3
Defective intake air pressure sensor.
Execute the diagnostic mode (Code No.03). Replace if defective. Refer to "Fault code No. 13".
Fault code No.
I
15
I
Symptom
I Throttle position sensor -
open or short circuit detected.
Used diagnostic code No. 01 (throttle position sensor) Order Inspection operation item and probable cause
Operation item and countermeasure
Reinstatement method
Installed condition of throttle position sensor.
Check the installed area for looseness or pinching. Check that it is installed in the specified position. Refer to "THROTTLE BODIES" section.
Reinstated by turning the main switch ON.
2
Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it securely. Throttle position sensor coupler Main wiring harness ECU coupler Sub-wire harness coupler
3
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit. Between sensor coupler and ECU coupler Black/Blue - Black/Blue Yellow - Yellow Blue - Blue
4
Throttle position sensor lead wire open ci rcu it output voltage check.
Check for open circuit and replace the throttle position sensor. Black/Blue - Yellow Open circuit item
Output voltage
Ground wire open circuit 5 V
5
Defective throttle position sensor.
Output wire open circuit
0V
Power supply wire open circuit
0V
Execute the diagnostic mode (Code No.01). Replace if defective. Refer to "THROTTLE BODIES" section.
75
FUEL INJECTION SYSTEM
FI
Fault code No. I 16 I Symptom I Stuck throttle position sensor detected. Used diagnostic code No. 01 (throttle position sensor) Order Inspection operation item and probable Operation item and countermeasure cause 1 When detecting fault code No.15. Refer to "Fault code No.15". 2 Installed condition of throttle position Check the installed area for looseness or pinching. sensor. Check that it is installed in the specified position. Refer to "THROTTLE BODIES" section. Defective throttle position sensor Execute the diagnostic mode (Code No.01). 3 Replace if defective. Refer to "THROTTLE BODIES" section.
Fault code No.
20 I
1
St ymp om
I
Defective values are detected due to the internal malfunction of the intake air pressure sensor or the atmospheric pressure sensor.
Used diagnostic code No. 02 (atmospheric pressure sensor) ~ 1 03 (intake air pressure sensor) ~ 2 Order Inspection operation item and probable Operation item and countermeasure cause 1 Defective atmospheric pressure sensor Execute the diagnostic mode (Code No.02). Replace if defective. Refer to "Fault code No.23". 2 Defective intake air pressure sensor Execute the diagnostic mode (Code No.03). Replace if defective. Refer to "Fault code No.13". Fault code No.
I
21
Reinstatement method Reinstated by turning the main switch ON.
I Symptom IOpen or short circuit is detected from the coolant temperature sensor.
Used diagnostic code No. 06 (coolant temperature sensor) Order Inspection operation item and probable Operation item and countermeasure cause 1 Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that securely. may have pulled out. Coolant temperature sensor coupler Check the locking condition of the Main wiring harness ECU coupler coupler. Sub-wire harness coupler Repair or replace if there is an open or short circuit. 2 Open or short circuit in wiring harness and/or sub lead. Between sensor coupler and ECU coupler Black/Blue - Black/Blue Green/White - Green/White 3
Reinstatement method Reinstated by starting the engine, operating it at idle, and then racing it.
Defective coolant temperature sensor.
Execute the diagnostic mode (Code No.06). Replace if defective. Refer to "COOLING SYSTEM" in CHAPTER 8.
76
Reinstatement method Reinstated by turning the main switch ON.
FI
FUEL INJECTION SYSTEM
Fault code No. I 22 I Symptom I Open or short circuit detected from the intake temperature sensor. Used diagnostic code No. 05 (intake temperature sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement method cause Connected condition of connector Reinstated by If there is a malfunction, repair it and connect it securely. Inspect the coupler for any pins that turning the main Intake temperature sensor coupler may have pulled out. switch ON. Main wiring harness ECU coupler Check the locking condition of the Sub-wire harness coupler coupler. 2 Repair or replace if there is an open or short circuit. Open or short circuit in wiring harness and/or sub lead. Between sensor coupler and ECU coupler Black/Blue - Black/Blue Green/White - Green/White Execute the diagnostic mode (Code No.05). Defective intake temperature sensor. 3 Replace if defective. 1. Remove the intake air temperature sensor from the air filter case. 2. Connect the pocket tester (0 x 100) to the intake air temperature sensor terminal as shown.
CD ®
Tester positive probe ~ green/white Tester negative probe ~ black/blue
2 3. Measure the intake air temperature sensor resistance.
Intake air temperature sensor resistance 2.21 - 2.69 kO at 20°C (68°F)
~----------
• Handle the intake air temperature sensor with special care. • Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it. 4. Is the intake air temperature sensor OK?
77
FI
FUEL INJECTION SYSTEM Fault code No.
I
23
I
Symptom
I Open or short circuit detected from the atmospheric pressure sensor.
Used diagnostic code No. 02 (atmospheric pressure sensor) Operation item and countermeasure
Reinstatement method
Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it securely. Atmospheric pressure sensor coupler Main wiring harness ECU coupler
Reinstated by turning the main switch ON.
2
Open or short circuit in wiring harness.
Repair or replace if there is an open or short circuit. Between sensor coupler and ECU coupler Blue - Blue Black/Blue - Black/Blue Pink - Pink
3
Defective atmospheric pressure sensor.
Execute the diagnostic mode (Code No.02). Replace if defective. 1. Connect the pocket tester (DC 20 V) to the atmospheric pressure sensor coupler terminal as shown.
Order Inspection operation item and probable cause
CD
Tester positive probe ~ pink Tester negative probe ~ black/blue
ÂŽ
2. Set the main switch to "ON". 3. Measure the atmospheric pressure sensor output voltage.
Atmospheric pressure sensor output voltage 4.75 - 5.25 V 4. Is the atmospheric pressure sensor OK?
78
FUEL INJECTION SYSTEM
FI
Fault code No. I 30 I Symptom I Oil pressure dropped. Used diagnostic code No. - Order Inspection operation item and probable Operation item and countermeasure cause 1 Oil pressure dropped Keep the snow mobi Ie horizontal and then measu re the oil pressure after the sufficient warm-up, and check that the value is 25 kpa or more. 2 Oil pressure switch lead-short circuit It measures between engine earths from the oil detected. pressure switch connector (Yellow/Green) with the circuit tester.
Reinstatement method
NOTE: Disconnect is ECU coupler. 3
Defective oil pressure switch
After 1 minute has passed since the engine start, measure the resistance between the oil pressure switch and switch body with a circuit tester, and it will be OK if the result showed 00.
Fault code No. I 33 I Symptom I Malfunction detected in the primary lead of the ignition coil (#1). Used diagnostic code No. 30 (ignition coil #1) Order Inspection operation item and probable cause 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. 2 Open or short circuit in lead.
3
Detective ignition coil (test the primary and secondary coils for continuity).
Operation item and countermeasure
Reinstatement method
If there is a malfunction, repair it and connect it securely. Ignition coil primary side coupler - Orange Main wiring harness ECU coupler
Reinstated by starting the engine and operating it at idle.
Repair or replace if there is an open or short circuit. Between ignition coil coupler (#1) and ECU coupler/main harness Orange - Orange RedlWhite - Red/White Execute the diagnostic mode (Code No.30). Replace if defective. Refer to "IGNITION SYSTEM" in CHAPTER 8.
Fault code No. I 34 I Symptom I Malfunction detected in the primary lead of the ignition coil (#2). Used diagnostic code No. 31 (ignition coil #2) Order Inspection operation item and probable Operation item and countermeasure Reinstatement method cause 1 Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that securely. starting the may have pulled out. Ignition coil primary side coupler - Gray/Red engine and Check the locking condition of the Main wiring harness ECU coupler operating it at coupler. idle. 2
Open or short circuit in lead wire.
3
Defective ignition coil (test the primary and secondary coils for continuity).
Repair or replace if there is an open or short circuit. Between ignition coil coupler (#2) and ECU coupler/main harness Gray/Red - Gray/Red Red/White - RedlWhite Execute the diagnostic mode (Code No.31). Replace if defective. Refer to "IGNITION SYSTEM" in CHAPTER 8.
79
FUEL INJECTION SYSTEM
FI
Fault code No. I 35 I Symptom I Malfunction detected in the primary lead of the ignition coil (#3). Used diagnostic code No. 32 (ignition coil #3) Order Inspection operation item and probable Operation item and countermeasure Reinstatement method cause 1 Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that securely. starting the may have pulled out. Ignition coil primary side coupler - Orange/ engine and Check the locking condition of the Green operating it at coupler. Main wiring harness ECU coupler idle. 2 Open or short circuit in lead wire. Repair or replace if there is an open or short circuit. Between ignition coil coupler (#3) and ECU coupler/main harness Orange/Green - Orange/Green Red/White - Red/White Defective ignition coil (test the primary Execute the diagnostic mode (Code No.32). 3 and secondary coils for continuity). Replace if defective. Refer to "IGNITION SYSTEM" in CHAPTER 8.
Fault code No. I 36 I Symptom I Malfunction detected in the primary lead of the ignition coil (#4). Used diagnostic code No. 33 (ignition coil #4) Order Inspection operation item and probable cause 1 Connected state of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. 2 Open or short circuit in lead wire.
3
Defective ignition coil (test the primary and secondary coils for continuity).
Operation item and countermeasure
Reinstatement method
If there is a malfunction, repair it and connect it securely. Ignition coil primary side coupler - Green Main wiring harness ECU coupler
Reinstated by starting the engine and operating it at idle.
Repair or replace if there is an open or short circuit. Between ignition coil coupler (#4) and ECU coupler/main harness Green - Green Red/White - Red/White Execute the diagnostic mode (Code No.33). Replace if defective. Refer to "IGNITION SYSTEM" in CHAPTER 8.
80
FI
FUEL INJECTION SYSTEM
Fault code No. 1 42 1 Symptom 1 1 No normal signals are received from the speed sensor. Used diagnostic code No. 07 (speed sensor) ~ A 1 -- A4 Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of speed sensor If there is a malfunction, repair it and connect it Reinstated by A1 connector securely. starting the Inspect the coupler for any pins that Speed sensor coupler engine, and inputting the may have pulled out. Main wiring harness ECU coupler Check the locking condition of the vehicle speed coupler. signals by t---A-2-t-O-p-e-n-o-r-s-h-o-rt-c-i-rc-u-it-in-sp-e-e-d-s-e-n-s-o-r--+--R-e-p-a-ir-o-r-re-p-Ia-c-e-i-f-th-e-re-is-a-n-o-p-e-n-o-r-s-h-o-rt-c-i-rc-u-it---l. operati ng the lead.
A3
Defective speed sensor
snowmobile at a Between sensor coupler and ECU coupler. Blue - Blue low speed of 20 White - White to 30 km/h. Black/Blue - Black/Blue Execute the diagnostic mode (Code No.07). Replace if defective. 1. Measure the speed sensor output voltage. 2. Connect the pocket tester (DC 20 V) to the speed sensor coupler terminal as shown.
CD
Tester positive probe ~ pink Tester negative probe ~ black/white
~A
ÂŽ
A
~~~ W
~
B/L
3. Measure the speed sensor output voltage. Speed sensor output voltage When sensor is on DC 4.8 V or more When sensor is off DC 0.6 V or less
A4
Gear for detecting vehicle speed has broken.
4. Is the speed sensor OK? Replace if defective. Refer to "FRONT AXLE AND TRACK" in CHAPTER 4.
81
FI
FUEL INJECTION SYSTEM Fault code No.
I
43
I
Symptom
I The ECU
is unable to monitor the battery voltage.
Used diagnostic code No. 09 (fuel system voltage) Order Inspection operation item and probable cause
Operation item and countermeasure
Reinstatement method
Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it securely. Starting circuit cut-off relay coupler (fuel injection system relay) ECU coupler
Reinstated by starting the engine and operating it at idle.
2
Malfunction in ECU
Fuel injection system relay is on.
3
Open or short circuit in the wiring harness.
Repair or replace if there is an open or short circuit. Between battery terminal and ECU coupler Red/white - Red/white Red - Blue/Red (Main switch and engine stop switch are on.) Red - Red/Blue (Fuel injection system relay is on.)
4
Malfunction or open circuit in fuel injection system relay
Execute the diagnostic mode (Code No.09). Replace if defective. NOTE: When the leads are disconnected, the voltage check by the code No.09 is impossible. 1. Disconnect the fuel injection system relay from the wi re harness. 2. Connect the pocket tester (0 x 1) and battery (12 V) to the fuel injection system relay terminals as shown. Battery positive terminal ~ red/white Battery positive terminal ~ blue/red
CD
®
Tester positive probe ~ red/green Tester negative probe ~ red/blue
®
®
A.
IIL/R==R~
l ~11
R/G~
3. Does the fuel injection system relay have continuity between blue/white and black?
82
FUEL INJECTION SYSTEM Fault code No.
I
44
I
Symptom
I Error is detected while reading or writing on
FI
EEP-ROM (CO adjustment value).
Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Order 1
Inspection operation item and probable cause
Operation item and countermeasure
Malfunction in ECU
Execute diagnostic code 60 Reinstated by 1. Check the faulty cylinder. (If there are multiple turning the main cylinders, the number of the faulty cylinders switch ON. appear alternately at 2-second intervals.) 2. Readjust the CO of the displayed cylinder. Replace ECU if defective.
Fault code No.
I
46
Reinstatement method
I Symptom I Power supply to the Fuel injection system relay is not normal.
Used diagnostic code No. - Inspection operation item and probable cause
Operation item and countermeasure
Reinstatement method
Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it securely. ECU coupler.
Reinstated by starting the engine and operating it at idle.
2
Faulty battery
Replace or change the battery Refer to "BATTERY INSPECTION" in chapter 2.
3
The malfunction of the rectifier/regulator. Replace if defective. Refer to "CHARGING SYSTEM" in chapter 8.
4
Open or short circuit in wiring harness.
Order
Fault code No.
50
1
I
St ymp om
I
Repair or replace if there is an open or short circuit. • Between battery and fuse (ignition) Red - Red • Between fuse (ignition) and main switch Red/Yellow - Red/Yellow • Between main switch and load relay Brown - Brown • Between load relay and ECU Brown/Blue - Brown/Blue
Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.)
Used diagnostic code No. - Order 1
Inspection operation item and probable cause
Operation item and countermeasure
Reinstatement method
Malfunction in ECU
Replace the ECU.
Reinstated by turning the main switch ON.
Fault code No.
I
80
I Symptom I Grip warmer switch-short circuit detected.
Used diagnostic code No. - Order 1
Inspection operation item and probable cause
Operation item and countermeasure
Reinstatement method
Short circuit in wiring harness.
Repair or replace if there is an short circuit. Between switch coupler and switch coupler Orange/White - Chocolate Orange/Blue - Chocolate
Reinstated by turning the main switch ON.
83
FI
FUEL INJECTION SYSTEM Fault code No. I 81 I Symptom Used diagnostic code No. 26
I Grip warmer-short circuit detected.
Order Inspection operation item and probable cause 1 Short circuit in wiring harness.
Fault code No. I 82 I Symptom Used diagnostic code No. - -
Operation item and countermeasure
Reinstatement method
Repair or replace if there is an short circuit. Between switch coupler and ECU coupler Orange/White - Orange/White Orange/Blue - Orange/Blue
Rei nstated by turning the main switch ON.
IThumb warmer switch-short
Order Inspection operation item and probable cause 1 Short circuit in wiring harness.
circuit detected.
Operation item and countermeasure
Reinstatement method
Repair or replace if there is an short circuit. Between switch coupler and switch coupler Light green/White - Chocolate Light green/Black - Chocolate
Rei nstated by turning the main switch ON.
Fault code No. I 83 I Symptom I Thumb warmer-short circuit detected. Used diagnostic code No. 27 Order Inspection operation item and probable Operation item and countermeasure cause 1 Short circuit in wiring harness. Repair or replace if there is an short circuit. Between switch coupler and ECU coupler Light green/White - Light green/White Light green/Black - Light green/Black Fault code No. I 85 I Symptom Used diagnostic code No. - -
I Oil pressure switch detected.
Order Inspection operation item and probable cause 1 Check the connector and coupler for the pin coming-off from the coupler and locking of the coupler. 2 Check the wire harness for its disconnection.
Operation item and countermeasure
Reinstatement method
If the malfunction is found, repair or connect it.
Rei nstated by starting the engine and operating it at idle.
Repair or replace if there is an open circuit. Between wire harness (Yellow/Green) and ECU coupler (No.8 pin) Yellow/Green - Yellow/Green
EHHHB mmf6mB 14
3
Defective oil pressure switch
Reinstatement method Rei nstated by turning the main switch ON.
26
Without loading the oil pressure, there should be continuity between the oil pressure switch terminals and oil pressure switch body metal components.
84
FUEL INJECTION SYSTEM
Fault code No.
Er-1 Er-2 Er-3 Er-4
Symptom Symptom Symptom Symptom
No signal are received from the ECU. No signal are received from the ECU within the specified duration. Data from the ECU cannot be received correctly. Non-registered data has been received from the meter.
Used diagnostic code No. - Order Inspection operation item and probable cause 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. 2 Open or short circuit in wiring harness and/or sub lead.
3 4
Malfunction in meter Malfunction in ECU
FI
Operation item and countermeasure If there is a malfunction, repair it and connect it securely. Cylinder identification sensor coupler Main wiring harness ECU coupler Sub-wire harness coupler Repair or replace if there is an open or short circuit. Between sensor coupler and ECU coupler Yellow/Blue - Yellow/Blue Black/White - Black/White Replace the meter. Replace the ECU.
85
Reinstatement method Reinstated by turning the main switch ON.
FUEL INJECTION SYSTEM OIL PRESSURE SWITCH 1. Disconnect: • Oil pressure switch coupler 2. Connect: • Pocket tester (to the switch coupler)
CD
3. Inspect: • Oil pressure switch continuity Switch is operated. Faulty ~ Replace the oil pressure switch.
Main switch position OFF
86
Continuity
Yes
THROTTLE BODIES
THROTTLE BODIES
2
Order
Job/Part
Q'ty
Removing the throttle bodies
1 2 3
4 5
6
Intake silencer Headlight stay Sub wire harness coupler Fuel hose Throttle cable Throttle bodies Throttle body heater hose Throttle body joint
1 2 1 1 1
Remarks Remove the parts in the order listed below. Refer to "COWLINGS" in CHAPTER 3. Refer to "COWLINGS" in CHAPTER 3. Disconnect.
4 For installation, reverse the removal procedure.
87
THROTTLE BODIES EAS00910
INJECTORS
Order
Job/Part
Q'ty
Removing the injectors 1 2 3 4 5
6 7 8
9 10 11 12 13 14
Throttle position sensor coupler Intake air pressure sensor coupler Cylinder #4-injector coupler Cylinder #3-injector coupler Cylinder #2-injector coupler Cylinder #1-injector coupler Sub wire harness Negative pressure hose Intake air pressure sensor Fuel distributor Injector Throttle position sensor Fuel pressure regulator Throttle body assembly
1 1 1 1 1 1 1 1 1 1 4 1 1 1
Remarks Remove the parts in the order listed. Disconnect. Disconnect.
For installation, reverse the removal procedure. 88
THROTTLE BODIES
FI
EAS00911
The throttle bodies should not be disassembled.
EAS00912
CHECKING THE INJECTORS 1. Check: • injectors Damage ~ Replace.
EAS00913
CHECKING THE THROTTLE BODIES 1. Check: • throttle bodies Cracks/damage ~ Replace the throttle bodies as a set. 2. Check: • fuel passages Obstructions ~ Clean. TTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Wash the throttle bodies in a petroleumbased solvent. Do not use any caustic carburetor cleaning solution. b. Blowout all of the passages with compressed air.
••••••••••••••••••••••••••••• EAS00095
CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: • throttle bodies Refer to "THROTTLE BODIES". 2. Check: • throttle body joints CD Cracks/damage ~ Replace. 3. Install: • throttle bodies
89
THROTTLE BODIES CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • fuel pump operation Refer to "SEAT AND FUEL TANK" in CHAPTER 5. TTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Remove the seat and fuel tank. Refer to "SEAT AND FUEL TANK" in CHAPTER 5. b. Connect the pressure gauge CD and adapter ® onto the fuel injection pipe.
Pressure gauge 90890-03153, YU-03153 Adapter 90890-03176, YM-03176 c. Install the fuel tank. Refer to "SEAT AND FUEL TANK" in CHAPTER 5. d. Start the engine. e. Measure the fuel pressure.
~ Fuelpressure v
A'
Faulty
~
250 kPa (2.5 kg/cm 2 , 36.3 psi)
Replace the fuel pump assembly.
•••••••••••••••••••••••••••••
90
THROTTLE BODIES EAS00916
CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE:
_
Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor ~~~~~.~
..
~.~~~~~~~~~.~~
...
~~~
a. Disconnect the throttle position sensor coupler. b. Remove the throttle position sensor from the throttle body. c. Connect the pocket tester (0 x 1k) to the throttle position sensor.
Positive tester probe ~ black/blue terminal Negative tester probe ~ blue terminal
CD ®
d. Measure the maximum throttle position sensor resistance. Out of specification ~ Replace the throttle position sensor.
Maximum throttle position sensor resistance 3.5 - 6.5 kO at 20°C (68°F) (blue - black/blue) e. Connect the pocket tester (0 x 1k) to the throttle position sensor.
Positive tester probe ~ yellow terminal ® Negative tester probe ~ blue terminal ®
91
THROTTLE BODIES
FI
f.
While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly ~ Replace the throttle position sensor. The slot is worn or broken ~ Replace the throttle position sensor. NOTE: _
Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified.
Throttle position sensor resistance o - 5 ± 1.5 kQ at 20°C (68°F) (yellow - black/blue)
2. Adjust: • throttle position sensor angle ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
a. Connect the throttle position sensor coupler to the wire harness. b. Connect the digital circuit tester to the throttle position sensor.
Tester positive probe ~ yellow terminal CD Tester negative probe ~ blue terminal ®
~
~-
Digital circuit tester 90890-03174
c. Measure the throttle position sensor voltage. d. Adjust the throttle position sensor angle so the measured voltage is within the specified range.
Throttle position sensor voltage 0.63 - 0.73 V (yellow - black/blue) e. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws.
•••••••••••••••••••••••••••••
92
IGNITION SYSTEM
ELECTRICAL IGNITION SV
EM
CIRCUIT DIAGR::
93
IGNITION SYSTEM
CD A.C. magneto ® @ Re~tifier/regulator
3 Main switch @Load relay @ Fuse (MAl N) Battery !f1\ . stop switch ~ Englne ® Throttle switch @ Ignition coil #1 @ Ignition coil #2 @ Ignition coil #3 @ Ignition coil #4 @Spark plug @ Fuse (IGNITION)
®
94
IELEClr:J1
____________ IG_N_IT_IO_N_S_y_S_T_EM_1
ELEC
10
I
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should malfunction during operation, T.O.R.S. will operate when the throttle lever is released. T.O.R.S. is designed to interrupt the fuel injection and keep the engine revolutions between 2,800 and 3,000 r/min if the throttle body fails to return to idle when the lever is released.
~ ----------
-If the T.O.R.S. is activated, make sure that the cause of the malfunction has been corrected and that the engine can be operated without a problem before restarting the engine. - Be sure to use the specified spark plug and spark plug cap. Other wise, the T.O.R.S. will not work properly.
::s:
~
l8J Idling lI2J
Switch Throttle switch Throttle position sensor Engine
or starting
Running
Trouble
OFF
ON
OFF
CLOSED
OPEN
OPEN
Running Running
T.O.R.S. will operate
CD Th rottle position sensor (th rottle valve position) ® Throttle switch ® Throttle cable @ON @OFF @Open @Closed
NOTE:
_
-When the T.O.R.S. is activated, the warning light ® and self-diagnosis warning indicator @ will flash and the two-digit code "84" @ will flash in the clock display. - The T.O. R.S. monitors the condition of the throttle position sensor, speedometer assembly, and speed sensor, and will operate if any on the monitored items is disconnected or malfunctioning.
95
____________ IG_N_IT_IO_N_S_y_S_T_EM_1 ELEC I
r:J
I
HANDLEBAR SWITCH (RIGHT) Engine stop switch and throttle switch 1. Disconnect: • Engine stop switch coupler CD • Throttle switch coupler ® 2. Connect: • Pocket tester
3. Inspect: • Engine stop switch continuity Faulty ~ Replace the handlebar switch (right).
Switch position RUN (pulled out) OFF (pushed in)
Continuity Yes No
4. Inspect: • Throttle switch continuity Faulty ~ Replace the handlebar switch (right). B/Y~----/
B/L
Throttle switch position Throttle lever is operated. Throttle lever is not operated.
~-------""
96
Continuity Yes No
____________ IG_N_IT_IO_N_S_y_S_T_EM_1
ELEC
10
I
MAIN SWITCH 1. Disconnect: • Main switch coupler CD 2. Connect: • Pocket tester 3. Inspect: • Main switch continuity Faulty ~ Replace.
o
Switch position OFF ON Switch position OFF ON START
0--0
R
Continuity Yes No Color code Br R/W
0- ~ 0- ~
Br/W
0- ~
Continuity
LOAD RELAY 1. Inspect: • Load relay CD Inspection steps: • Disconnect the load relay from the coupler. • Connect the pocket tester (0 x 1) and battery (12 V) to the load relay terminals as shown. Positive battery terminal ~ Brown CD Negative battery terminal ~ Brown/Blue ® Positive tester probe ~ Red ® Negative tester probe ~ White @ • If load relay does not have continuity between the red and blue terminals, replace it.
97
________ E_LE_C_T_R_IC_A_L_S_TA_R_T_IN_G_S_Y_S_T_EM_I ELEC I
r:J
ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM ..c
o ~o en_
~z
0..10-- 0
Oz
~«~E We!) ~~30....30....~Q)
en-Q)Q)30.... c c Q) ....... ....... Q) .- Q) ~ ~ ::::: 0> en ~::::J .............. ctSc::::J
.- en
..:::::::U-(J)(J)COWU-
@@(8@@©®
98
I
________ E_LE_C_T_R_IC_A_L_S_TA_R_T_IN_G_S_Y_S_T_EM_I
ELEC I
0
MAIN SWITCH 1. Disconnect: • Main switch coupler CD 2. Connect: • Pocket tester 3. Inspect: • Main switch continuity Faulty ~ Replace.
o
Switch position OFF ON Switch position OFF ON START
0--0
99
R
Continuity Yes No Color code Br R/W
0- ~ 0- ~ Continuity
Br/W
0- ~
I
CHARGING SYSTEM
I ELEC I
[=.:oJ
CHARGING SYSTEM CIRCUIT DIAGRAM
~
o 10
o"S
....... 0 > Q)Q)Z
c~-
0> ...........
<e
ctS~~
E·~ ~ ........
Q)
~
~
Q)
oocn::=: • Q) :::J ctS
<eo::u.co
8@)@@
100
I
QroG)
:IJ-
c:::I:
=i-l gz
~G)
:IJ en >-(
sen -I
m
s:
...... o ......
rG)
:::I:
:::!
z
G)
en -< en -I
m
s:
CD A.C. magneto 速 Rectifier/regulator 速 Main switch 速 Load relay @ Fuse (MAIN) 速 Battery @ E.C.U.
@ Tail/brake @ Fuse
light
(HEADLIGHT)
@ Fuse (SIGNAL) @ Fuse (IGNITION) @ Headlight beam switch
~ Headlight relay @Headlight @ Multi-function meter @ Hi beam indicator light @Meter light
m rm o
o
_ _ _ _ _ _ _ _ _ _ _L_IG_H_T_IN_G_S_Y_S_T_EM_I
ELEC I
r:J
I
HEADLIGHT BEAM SWITCH 1. Disconnect: • Headlight beam switch coupler CD 2. Connect: • Pocket tester (to the headlight beam switch coupler)
3. Inspect: • Headlight beam switch continuity Faulty ~ Replace.
Switch position HI LO
Continuity Yes No
HEADLIGHT RELAY 1. Inspect: • Headlight relay (black coupler)
CD
Inspection steps: • Disconnect the headlight relay from the coupler. • Connect the pocket tester (0 x 1) and battery (12 V) to the headlight relay terminals as shown. Low beam Positive tester probe ~ Blue/White Negative tester probe ~ Green ®
L/W
5
CD
High beam Positive battery terminal ~ Black @ Negative battery terminal ~ Blue/green ® Positive tester probe ~ Blue/White CD Negative tester probe ~ Yellow @
4
3
• If headlight relay does not have continuity between the blue/white and yellow terminals, replace it.
102
SIGNAL SYSTEM
SIGNAL SYSTEM CIRCUIT DIAGRAM
103
____________ S_IG_N_A_LS_Y_S_T_EM_I
CD A.C. magneto ® Rectifier/regulator
@ Main switch @Load relay @ Fuse (MAl N) Battery @E.C.U. Speed sensor @ Water temperature sensor @ Back buzzer @ Gear position switch @ Brake light switch @ Tail/brake light @ Fuse (SIGNAL) @ Fuse (IGNITION) Multi-function meter Warning light @ Water temperature indicator light <@ Oil level switch @ Fuel sender
® ®
® ®
104
ELEC I
r:J
I
____________ S_IG_N_A_LS_Y_S_T_EM_I
ELEC
10
I
ENGINE OIL LEVEL SWITCH 1. Remove: • Oil level gauge
CD
2. Connect: • Pocket tester (to the oil level switch coupler) 3. Inspect: • Oil level switch continuity Faulty ~ Replace.
Good Bad condition condition
Switch position [8] ffi]
Down position Up position
o : Continuity
0
x
x
x
0
x
0 0
x: No continuity
SPEED SENSOR 1. Inspect: • Speed sensor
Inspection steps: • Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown.
CD
Positive tester probe ~ White Negative tester probe ~ Black/Blue Positive battery terminal ~ Blue Negative battery terminal ~ Black/Blue • Elevate the track and slowly rotate it. • Measure the voltage (DC 5 V) of white and black/green. With each full rotation of the track the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V. Out of specification 105
~
Replace.
CD A.C. magneto
速 Rectifier/regulator 速 Main switch
@) Thumb warmer @E.C.U.
@ Grip warmer
@Load relay
switch
@ Fuse (MAl N)
@ Thumb warmer
@ Grip warmer
switch Tail/brake light
速 Battery
@
@ Fuse (SIGNAL) @ Fuse (BACK UP) @ Fuse (IGNITION)
速 Multi-function meter
OG)
ii:c
0-
c:-c
~~
~:c
:rJ$
>m
s:c
en -< en -I
m $
G)
::c
...... 0 m
1"'0
~
::c
s:
m
::c
en -< en -I
m
s:
m rm 0
0
__________ GR_I_P_W_A_RM_E_R_S_Y_S_T_EM_I
ELEC
10
I
GRIP AND THUMB WARMER COIL 1. Disconnect: • Grip warmer leads CD • Thumb warmer coupler ® 2. Connect: • Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads)
(L)
CD
3. Inspect: • Grip warmer CD continuity • Thumb warmer ® continuity No continuity ~ Replace both grips together or separately and/or the handlebar switch.
(R)
~ 1
1
:
:
~ 1
I I I I I I I I
-=:i===f--I
L . . . . - -_ _
:
1
I
____I
LsFrfr 1
1 1 1 1 1 1 1 1 :
i I
107
QO
:rJO
-.
go -1-
c Z
i>G)
Glen
~-< sen -I m
s:
...... o
o
CO
o orZ
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en -< en -I
m
s:
® Main switch
@ Fuse (MAl N)
®
Battery @E.C.U. @ Fuse (RADIATOR FAN MOTOR) @ Fuse (IGNITION) ® Radiator fan motor relay @ Radiator fan motor
m rm o
o
___________ C_O_OL_I_NG_S_y_S_T_EM_1
ELEC
10
TROUBLESHOOTING RADIATOR FAN MOTOR AND RADIATOR FAN MOTOR RELAY
Check the main fuse and radiator fan motor fuse. Refer to "FUSE INSPECTION" in CHAPTER 2. OK FAULTV ~ ~>RePlace the main fuse and/or radiator fan ~ motor fuse.
n
Check the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
n
OUT OF SPECIFICATION
OK
¢RePlace and/or charge the battery. Refer to "BATTERY INSPECTION" in CHAPTER 2.
Check the stator coil and pickup coil.
~OK
OUT OF SPECIFICATION
¢Replace the stator coil and pickup coil assembly.
Check the main switch. Refer to "IGNITION SYSTEM".
~OK
NO CONTINUITY
~_ _~>RePlace the main switch.
Check the radiator fan motor.
~OK
FAULTY
... 1
~>Replace the radiator fan motor.
Check the radiator fan motor relay.
~OK
FAULTY
~
~>Replace the radiator fan motor relay.
Check the load relay. Refer to "IGNITION SYSTEM".
~OK
FAULTY
... 1
>RePlace the main switch.
Correct the connection and/or replace the rectifier/regulator and/or the E.C.U. unit.
109
I
___________ C_O_OL_IN_G_S_y_S_T_EM_1 ELEC I RADIATOR FAN MOTOR 1. Disconnect: • Radiator fan motor coupler 2. Connect: • Battery
r:J
I
CD
3. Inspect: • Radiator fan motor
Positive battery terminal ~ Blue CD Negative battery terminal ~ Black ® Does not move motor.
~
Replace the radiator fan
12V
RADIATOR FAN MOTOR RELAY 1. Disconnect: • Radiator fan motor relay coupler
CD
Inspection steps: • Disconnect the headlight relay from the coupler. • Connect the pocket tester (0 x 1) and battery (12 V) to the headlight relay terminals as shown. Positive battery terminal ~ Red/White CD Negative battery terminal ~ Green/ Yellow® Positive tester probe ~ Brown/Green ® Negative tester probe ~Blue @ • If radiator fan motor relay does not have continuity between the brown/white and blue terminals, replace it.
110
__________ G_E_N_ER_A_L_S_P_E_C_IF_IC_A_T_IO_N_S_I SPEC
I
g--I
SPECIFICATIONS GENERAL SPECIFICATIONS RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Model Model code number:
Dimensions: Overall length
Overall width
Overall height
Weight: Dry weight
Minimum turning radius: Clockwise
Counterclockwise
8FP1 (RX1 ORTL for U.S.A/Canada) 8FR1 (RX1 ORL for U.S.A/Canada) 8FR3 (RX1 ORTRL for U.S.A/Canada) 8GD1 (RX1 OGTL for U.S.A/Canada) 8FT1 (RXW1 OL for U.S.A/Canada) 8FS1 (RX1 OML for U.S.A/Canada) 2,805 mm (110.4 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 3,000 mm (118.1 in) (RXW10L) 3,330 mm (131.1 in) (RX10ML) 1,225 mm (48.2 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 1,165 mm (45.9 in) (RX10ML) 1,070 mm (42.1 in) (RX10RTL, RX10RTRL, RX10GTL) 1,160 mm (45.7 in) (RX10RL, RXW10L) 1,240 mm (48.8 in) (RX10ML) 247 263 254 262 264 280
kg kg kg kg kg kg
(545 (580 (560 (578 (582 (617
Ib) Ib) Ib) Ib) Ib) Ib)
(RX10RTL) (RX10RL) (RX10RTRL) (RX10GTL) (RXW10L) (RX10ML)
4.1 m (13.1 ft) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 4.0 m (13.5 ft) (RX10ML) 4.1 m (13.1 ft) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 4.0 m (13.5 ft) (RX10ML)
Engine: Engine type Liquid-cooled, 4-stroke, DOHC Cylinder type Backward-inclined parallel 4-cylinder Displacement 998 cm 3 (60.9 cu.in) Bore x stroke 74 x 58 mm (2.91 x 2.28 in) Compression ratio 11.8 Maximum hose power r/min 10,500 r/min Maximum torque r/min 9,000 r/min Standard compression pressure 1,450 kPa (14.5 kg/cm 2 , 206 psi) at 400 r/min (at sea level) Starting system Electric starter Lubrication system:
Dry sump
111
__________ G_E_N_ER_A_L_S_P_E_C_IF_IC_A_T_IO_N_S_I SPEC I Model Engine oil: Type Oil capacity Periodic oil change With oil filter replacement Total amount
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML API SE, SF, SG or higher SAEOW-30 2.8 L (2.5 Imp qt, 3.0 US qt) 3.0 L (2.6 Imp qt, 3.2 US qt) 3.8 L (3.3 Imp qt, 4.0 US qt)
Oil filter: Oil filter type
Cartridge (paper)
Drive chain housing oil: Type Capacity
Gear oil API "GL-3" SAE#75 or #80 0.25 L (8.8 Imp OZ, 8.5 US oz)
Coolant: Capacity
Fuel: Type Tank capacity Carburetors: Type/Quantity Manufacture Spark plug: Type Manufacture Gap Primary reduction: Primary reduction system Primary reduction ratio (driven/drive gear) Transmission: Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio
Reverse system Chassis: Frame type Caster angle Ski stance (center to center)
g--I
6.0 L (5.29 Imp qt, 6.34 US qt) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 6.4 L (5.64 Imp qt, 6.76 US qt) (RX10ML) Regular unleaded gasoline (Pump Octane higher) 38.3 L (8.4 Imp gal, 10.1 US gal)
R~M; 88 or
39EIDW x 2 MIKUNI NGK R CR9EB NGK 0.7 . . . 0.8 mm (0.028 . . . 0.031 in) Spur gear 1.23 (37/30)
V-Belt 3.8 : 1 . . . 1 : 1 Automatic centrifugal engagement Chain 1.58 (38/24) (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 1.65 (38/23) (RXW10L) 2.00 (40/20) (RX10ML) No (RX10RTL, RX10ML) Yes (RX1 ORL, RX10RTRL, RX10GTL, RXW10L) Monocoque 23° 1,068 mm (42.0 in) (RX10RTL, RX10RL, RX10RTRL, RXW10L) 1,086 mm (42.7 in) (RX10GTL) 980 mm (38.6 in) (RX10ML) 112
__________ G_E_N_ER_A_L_S_P_E_C_IF_IC_A_T_IO_N_S_I SPEC I Model Suspension: Front suspension type Rear suspension type Track: Track type Track width Length on ground
Track deflection at 100 N (10 kg, 221b)
g--I
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML Independent double wishbone suspension Slide rail suspension Internal drive type 381 mm (15.0 in) 768 mm (30.2 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 959 mm (37.8 in) (RXW10L) 1,201 mm (47.3 in) (RX10ML) 30 ~ 35 mm (1.18 ~ 1.38 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RX10ML) 25 ~ 30 mm (0.98 ~ 1.18 in) (RXW10L)
Brake: Brake type Operation method
Caliper type disc brake Handlebar, left hand operated
Electrical: Ignition system Generator system
DC-T.C.I/MITSUBISHI A.C. magneto
Bulb wattage x Quantity: Headlight Tail/Brake light Meter light High beam indicator light Information indicator light Low coolant temperature light
12 V, 60 W/55 W x 2 LED LED LED LED LED
113
_ _ _ _ _ _ _ _ _ ISPECI g--I
114
_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_I_CA_T_IO_NS_I SPEC I
g--I
MAINTENANCE SPECIFICATIONS ENGINE RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Model Cylinder head: Volume (with spark plug) <Warpage limit>
13.45 ..... 14.05 cm 3 (0.82 ..... 0.86 cu. in) 0.1 mm (0.04 in) * Lines indicate straight edge measurement.
Cylinder: Material Bore size <Taper limit> <Out of round> <Wear limit> Camshaft: Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance
Aluminum alloy with dispersion coating 74.000 ..... 74.010 mm (2.9134 ..... 2.9138 in) 0.05 mm (0.002 in) 0.05 mm (0.002 in) 74.06 mm (2.9157 in) Chain drive (left) 24.500 24.521 mm (0.9646 0.9654 in) 24.459 24.472 mm (0.9630 0.9635 in) 0.028 ..... 0.062 mm (0.0011 ..... 0.0024 in)
Camshaft dimensions Intake "A" <Limit> "B" <Limit> Exhaust "A" <Limit> "B" ----8<Limit>
32.95 32.85 24.96 24.86 33.60 33.50 24.96 24.86
Camshaft runout
0.03 mm (0.0012 in)
Timing chain: Model/number of links Tensioning system
RH2015/130 Automatic
Valves, valve seats, valve guides: Valve clearance (cold) Intake Exhaust
0.11 0.21
..... 33.05 mm mm (1.2933 ..... 25.06 mm mm (0.9787 ..... 33.70 mm mm (1.3189 ..... 25.06 mm mm (0.9787
(1.2972 in) (0.9827 in) (1.3228 in) (0.9827 in)
0.20 mm (0.0043 0.25 mm (0.0083
115
..... 1.3012 in) ..... 0.9866 in) ..... 1.3268 in) ..... 0.9866 in)
0.0079 in) 0.0098 in)
M_A_ _N_TE_N_A_N_C_E_s_P_E_C_ F_ C_A_~_IO_NS_ISPEC I g--I
________
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Model Valve dimensions: Valve head diameter A
Intake Exhaust
)\
~
22.9 24.4
23.1 mm (0.9016 24.6 mm (0.9606
0.9094 in) 0.9685 in)
~z
1.76 1.76
2.90 mm (0.0693 2.90 mm (0.0693
0.1142 in) 0.1142 in)
Head Diameter
Valve face width B Intake Exhaust
Face Width
Valve seat width C Intake Exhaust
! \
",c
~"
0.9 0.9
1.1 mm (0.035 1.1 mm (0.035
0.043 in) 0.043 in)
0.5 0.5
0.9 mm (0.020 0.9 mm (0.020
0.035 in) 0.035 in)
Seat Width
Valve margin thickness D
I
I ~~D
Intake Exhaust
!\
Margine Thickness
Valve stem diameter Intake <Limit> Exhaust <Limit> Valve guide inside diameter Intake <Limit> Exhaust <Limit> Valve-stem-to-valve-guide clearance Intake <Limit> Exhaust <Limit> Valve stem runout limit
3.975 . . . 3.990 mm (0.1565 . . . 0.1571 in) 3.945 mm (0.1553 in) 4.465 . . . 4.480 mm (0.1758 . . . 0.1764 in) 4.43 mm (0.1744 in) 4.000 . . . 4.012 mm (0.1575 . . . 0.1580 in) 4.05 mm (0.1594 in) 4.500 . . . 4.512 mm (0.1772 . . . 0.1776 in) 4.55 mm (0.1791 in) 0.010 . . . 0.037 mm (0.0004 . . . 0.0015 in) 0.08 mm (0.0031 in) 0.020 . . . 0.047 mm (0.0008 . . . 0.0019 in) 0.10 mm (0.0039 in) 0.01 mm (0.0004 in)
o~
~ VJl. rr~
/////////////////////
Valve seat width Intake Exhaust
0.9 0.9
1.1 mm (0.035 1.1 mm (0.035
116
0.043 in) 0.043 in)
_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_I_CA_T_IO_NS_I SPEC I
g--I
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Model Valve spring: Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt * Intake ~ Exhaust Winding direction (top view) Intake Exhaust
d"
Valve lifter: Valve lifter outside diameter Intake <Limit> Exhaust <Limit> Valve lifter hole inside diameter Intake <Limit> Exhaust <Limit>
m
Piston: Piston size (0) ---D--Measuring point (H) Piston to-cylinder clearance <Limit> Piston pin bore off set Off-set direction Piston pin bore inside diameter
-----i
H
43.59 mm (1.72 in) 40.62 mm (1.60 in) 34.50 mm (1.36 in) 35.00 mm (1.38 in) 126 111
146 N (12.8 127 N (11.3
14.9 kg, 28.3 12.9 kg, 24.9
32.8 Ib) 28.5 Ib)
2.5°/1.9 mm (0.075 in) 2.5°/1.8 mm (0.071 in) Clockwise Clockwise
19.982 19.957 22.482 22.457
. . . 19.988 mm (0.7867 . . . 0.7869 in) mm (0.7857 in) . . . 22.488 mm (0.8851 . . . 0.8854 in) mm (0.8841 in)
20.000 20.048 22.500 22.548
. . . 20.018 mm (0.7874 . . . 0.7881 in) mm (0.7893 in) . . . 22.518 mm (0.8858 . . . 0.8865 in) mm (0.8877 in)
73.955 . . . 73.970 mm (2.9116 . . . 2.9122 in) 5 mm (0.20 in) 0.030 . . . 0.055 mm (0.0012 . . . 0.0022 in) 0.12 mm (0.0047 in) 0.5 mm (0.0197 in) Intake side 17.002 . . . 17.013 mm (0.6694 . . . 0.6698 in)
Piston pin: Piston pin outside diameter 16.991 . . . 17.000 mm (0.6689 . . . 0.6693 in) Piston pin length 51.4 . . . 51.5 mm (2.0236 . . . 2.0276 in) Piston pin to piston pin bore clearance 0.002 . . . 0.022 mm (0.00008 . . . 0.0009 in) <Limit> 0.072 mm (0.0028 in)
117
M_A_ _N_TE_N_A_N_C_E_s_P_E_C_ F_ C_A_~_IO_NS_ISPEC I g--I
________
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Model Piston ring: Sectional sketch Top ring Ring type ~~B IT Dimensions (B x T) 2nd ring Ring type B Dimensions (B x T) I T I Oil ring
r
c=\----=r C~JB
D ·· (B x T) Imenslons End gap (installed) Top ring 2nd ring Oil ring Side clearance (installed) Top ring 2nd ring Connecting rod: Crankshaft-pin-to-big-end-bearing clearance Bearing color code Crankshaft: ~I
Width A Width B Crankshaft runout C Big end side clearance D Crankshaft-journal-to-crankshaftjournal-bearing clearance Bearing color code Carburetor: Type/Quantity Manufacturer I.D. mark Throttle valve Engine idle speed
Barrel 0.90 x 2.75 mm (0.035 x 0.108 in) Taper 0.8 x 2.8 mm (0.031 x 0.110 in)
1.5 x 2.5 mm (0.059 x 0.098 in) 0.32 0.43 0.10 0.030 0.020
0.44 mm (0.010 0.58 mm (0.017 0.35 mm (0.004
0.020 in) 0.023 in) 0.0014 in)
0.065 mm (0.0012 0.055 mm (0.0008
0.0026 in) 0.0022 in)
0.031 . . . 0.055 mm (0.0012 . . . 0.0022 in) -1
= Violet
0
= White
1 = Blue 2
= Black
3
= Brown
3
= Brown
52.40 . . . 57.25 mm (2.063 . . . 2.254 in) 300.75 . . . 302.65 mm (11.84 . . . 11.92 in) 0.03 mm (0.0012 in) 0.160 0.262 mm (0.006 . . . 0.010 in) 0.031 0.055 mm (0.0012 . . . 0.0022 in) -1
= Violet
0
= White
1 = Blue 2
= Black
39EIDW X 2 MIKUNI 8FP1 00 #100 1,500 ± 100 r/min (1 ,400 . . . 1,600 r/min)
Fuel pump: Type Manufacturer
Electrical 8FP (DENSO)
Oil filter: Oil filter type Bypass valve opening pressure
Cartridge (paper) 78 . . . 118 kPa (0.78 . . . 1.18 kg/cm 2 , 11.1 . . . 16.8 psi)
118
_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_I_CA_T_IO_NS_
I
SPEC I
g--I
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Model Oil pump: Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Max. impeller shaft tilt <Limit> Relief valve operating pressure Oil pressure (hot) Cooling system: Radiator capacity Radiator core Width Height Depth Filler cap opening pressure Water pump type Reduction ratio Coolant type
Trochoidal 0.00 . . . 0.12 mm (0.000 . . . 0.005 in) 0.09 . . . 0.15 mm (0.004 . . . 0.006 in) 0.15 mm (0.0059 in) 0.072 mm (0.0028 in) 430 . . . 550 kPa (4.3 . . . 5.5 kg/cm 2 , 61.2 . . . 78.2 psi) 50 kPa (0.5 kg/cm 2 , 7.1 psi) at 1,450 r/min 0.3 L (0.26 Imp qt, 0.32 US qt)
Coolant mixing ratio (coolant: water) Capacity
Transmission: Type Range of ratio Engagement speed r/min Shift r/min Sheave distance Sheave offset V-belt: Part number/Manufacturer ~ A Circumference i B Width "A" Wear limit "B" I
130.2 mm (5.13 in) 140.0 mm (5.51 in) 28.0 mm (1.10 in) 95 . . . 125 kPa (0.95 . . . 1.25 kg/cm 2 , 14 . . . 18 psi) Single-suction centrifugal pump (Impeller type) 37/31 x 23/18 (1.525) High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors 3 : 2 (60% : 40%) 6.0 L (5.29 Imp qt, 6.34 US qt) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 6.4 L (5.64 Imp qt, 6.76 US qt) (RX10ML) V-belt automatic 3.8 . . . 1.0 : 1 3,500 Âą 200 r/min (3,300 . . . 3,700 r/min) 10,500 Âą 250 r/min (10,250 . . . 10,750 r/min) 268.5 mm (10.57 in) (267 . . . 270 mm (10.51 . . . 10.63 in)) 13.5 . . . 16.5 mm (0.53 . . . 0.65 in)
II
CJ
8DN-17641-00/MITSUBOSHI 1,129 . . . 1,137 mm (44.4 . . . 44.8 in) 34.5 mm (1.36 in) 32.5 mm (1.28 in)
119
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________ POWER TRAIN Model Primary sheave spring: Part number
Color code
Diameter Wire diameter Preload
Spring rate Number of coils Free length
Set length Primary sheave weight arm: Part number (with bush)
Weight (without bush and rivets)
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML 90501-582L1 (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 90501-581 L5 (RX10ML) Yellow - Silver - Yellow (RX1 ORTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) Yellow - Pink - Yellow (RX1 OML) 59.5 mm (2.34 in) 5.8 mm (0.228 in) 343 N (35 kg, 77 Ib) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 294 N (30 kg, 66 Ib) (RX10ML) 24.5 N/mm (2.50 kg/mm, 140 Ib/in) 4.92 87.4 mm (3.44 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 85.4 mm (3.36 in) (RX10ML) 73.4 mm (2.89 in) 8FP-17605-00 (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 8FS-17605-00 (RX10ML) 67.81 g (2.392 oz) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 65.52 g (2.311 oz) (RX10ML)
120
_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_I_CA_T_IO_NS_I SPEC I Model Rivet: Outer Part number
Material Size
Quantity Hole quantity Center Part number
Material Size
Quantity Hole quantity Inner Part number
Material Size Quantity Hole quantity
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RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
90261-06033 (RX1 ORTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 90266-06002 (RX10ML) Steel 17.2 mm (0.677 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 13.3 mm (0.524 in) with hole (RX1 OML) 3 3 90261-06033 (RX1 ORTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 90266-06002 (RX10ML) Steel 17.2 mm (0.677 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 13.3 mm (0.524 in) with hole (RX10ML) 3 3 90261-06033 (RX1 ORTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) None (RX10ML) Steel 17.2 mm (0.677 in) 3 3
121
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________ Model Secondary sheave spring: Part number
Color code
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML 90508-60012 (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 90508-60007 (RXW1 OL, RX10ML) PINK (RX1 ORTL, RX10RL, RX10RTRL, RX10GTL) White (RXW10L, RX10ML) 69.5 mm (2.736 in) 6 mm (0.236 in)
Outside diameter Wire diameter Hole position Sheave side-spring side (twist angle) 2-6 (80째) (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 3-3 (60째) (RXW10L, RX10ML)
Spring rate
Number of coils
Free length Torque cam angle
Drive chain: Type Number of links Secondary reduction ratio
11.88 N/mm (1.211 kg/mm, 67.80 Ib/in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 12.66 N/mm (1.290 kg/mm, 72.25 Ib/in) (RXW10L, RX10ML) 5.53 (RX1 ORTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 5.19 (RX10ML) 75 mm (2.95 in) 51 째 - 43 (RX1 ORTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 45째 (RX10ML) Borg Warner Automotive 23RH303-70ASM 70 L 38/24 (1.58) (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 38/23 (1.65) (RXW10L) 40/20 (2.00) (RX10ML)
122
_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_I_CA_T_IO_NS_I SPEC I Model
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RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Track: Part number
8FA-47110-00 (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 8FG-47110-00 (RXW10L) 8FS-47110-00 (RX10ML) Width 381 mm (15.0 in) Length 3,072 mm (120.9 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 3,456 mm (136.1 in) (RXW10L) 4,115 mm (162.0 in) (RX10ML) Pitch 64 mm (2.52 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 76.2 mm (3.00 in) (RX10ML) Number of links 48 (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 54 (RXW1 OL, RX10ML) Thickness "A" 5.1 mm (0.20 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 5.5 mm (0.23 in) (RX10ML) Height "8" 36.9 mm (1.45 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 57.2 mm (2.25 in) (RX10ML) Track deflection at 100 N (10 kg, 22 Ib) 30 ~ 35 mm (1.18 ~ 1.38 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RX10ML) 25 ~ 30 mm (0.98 ~ 1.18 in) (RXW10L)
~B
Slide rail suspension (Rear suspension): Front travel
Rear travel
Suspension spring rate Front Rear
Spring wire diameter Front
Rear Suspension setting position: Full rate adjusting position
256 mm (10.08 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 183 mm (7.20 in) (RX10ML) 295 mm (11.61 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL) 297 mm (11.69 in) (RXW10L) 356 mm (14.02 in) (RX10ML) 29.4 N/mm (3.0 kg/mm, 168 Ib/in) (RX10ML) 58.8 N/mm (6.0 kg/mm, 336 Ib/in) (RX10RTL, RX10RL, RX10RTRL) 58.0 N/mm (5.9 kg/mm, 331 Ib/in) (RX10GTL) 53.9 N/mm (5.5 kg/mm, 308 Ib/in) (RXW10L) 1,500 Nmm/deg (152.85 kg/mm, 8,561 Ib/in) (RX10ML) 12.2 mm (0.480 in) (RX10RTL, RX10RL, RX10RTRL) 11.8 mm (0.465 in) (RX10GTL) 12.0 mm (0.472 in) (RXW10L) 8.0 mm (0.315 in) (RX10ML) 10.0 mm (0.394 in) (RX10ML) M (RX10ML)
123
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________ Model
Shock absorber: Damping force Extension
Compression
Front Extension Compression Rear Extension Compression Slide runner: Thickness Wear limit Track sprocket wheel: Material Number of teeth
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
1,950 N/O.3 mls (198.71 kg/0.3 mIs, 438 Ib/0.3 m/s) (RX10RTL, RX10RL, RX10RTRL) 1,069 . . . 1,167 N/O.3 mls (108.93 . . . 118.92 kg/0.3 mIs, 240 . . . 262 Ib/0.3 m/s) (RX10GTL) 1,830 N/O.3 mls (186.48 kg/0.3 mIs, 411 Ib/0.3 m/s) (RXW10L) 1,130 N/O.3 mls (115.15 kg/0.3 mIs, 2541b/0.3 m/s) (RX10RTL, RX10RL, RX10RTRL) 857 . . . 1,185 N/O.3 mls (87.33 . . . 120.75 kg/0.3 mIs, 193 . . . 266 Ib/0.3 m/s) (RX10GTL) 1,270 N/O.3 mls (129.41 kg/0.3 mIs, 285 Ib/0.3 m/s) (RXW10L) 620 N/O.3 mls (63.18 kg/0.3 mIs, 139 Ib/0.3 m/s) (RX10ML) 990 N/O.3 mls (100.88 kg/0.3 mIs, 222 Ib/0.3 m/s) (RX10ML) 790 N/O.3 mls (80.50 kg/0.3 mIs, 178 Ib/0.3 m/s) (RX10ML) 460 N/O.3 mls (46.87 kg/0.3 mIs, 103 Ib/0.3 m/s) (RX10ML) 17.8 mm (0.70 in) 10 mm (0.39 in) High molecular weight polyethylene 9 T (RX1 ORTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 7 T (RX10ML)
Rear guide wheel: Material Outside diameter
High molecular weight polyethylene with rubber 178 mm (7.01 in)
Brake: Pad thickness Pad wear limit Pad to disk clearance Disc outside diameter Disc minimum thickness
10.2 mm (0.40 in) 7.5 mm (0.30 in) 0.025 . . . 0.115 mm (0.001 . . . 0.005 in) 200 mm (7.87 in) 3.5 mm (0.14 in)
124
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CHASSIS Model Frame: Frame material Seat height
Luggage box location Steering: Lock-to-Iock angle (left)
(right)
Ski alignment Toe-out size Caster angle Ski: Ski material Length Width
Ski suspension (Front suspension): Type Travel
Spring type Spring rate
Wire diameter
Shock absorber: damping force Extension
Compression
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML Aluminum 765 mm (30.1 in) (RX10RTL, RX10RL, RX10RTRL, RXW10L, RX10ML) 770 mm (30.3 in) (RX10GTL) Rear 29.0° (R ski) 34.5° (L ski) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 30.1 ° (R ski) 35.0° (L ski) (RX10ML) 34.5° (R ski) 29.0° (L ski) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 35.0° (R ski) 30.1 ° (L ski) (RX10ML) Toe-out o.. . 15 mm (0 . . . 0.59 in) 23° Plastic 1,021 mm (40.2 in) 132.0 mm (5.20 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 182.0 mm (7.17 in) (RX10ML) Double wishbone system 219 mm (8.62 in) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) 175 mm (6.89 in) (RX10ML) Coil spring 29.5 N/mm (3.0 kg/mm, 168lb/in) (RX10RTL, RX10RL, RX10RTRL, RXW10L) 26.5 N/mm (2.7 kg/mm, 151 Ib/in) (RX10GTL, RX10ML) 8.5 mm (0.335 in) (RX10ML) 8.8 mm (0.346 in) (RX10GTL) 9.0 mm (0.354 in) (RX10RTL, RX10RL, RX10RTRL, RXW10L) 870 N/O.3 m/s (89 kg/0.3 mIs, 195 Ib/0.3 m/s) (RX10RTL, RX10RL, RX10RTRL, RXW10L) 1,120 N/O.3 m/s (114 kg/0.3 mIs, 252 Ib/0.3 m/s) (RX10GTL) 1,420 N/O.3 m/s (145 kg/0.3 mIs, 319 Ib/0.3 m/s) (RX10ML) 520 N/O.3 m/s (53 kg/0.3 mIs, 117 Ib/0.3 m/s) (RX10RTL, RX10RL, RX10RTRL, RXW10L) 885 N/O.3 m/s (90 kg/0.3 mIs, 199 Ib/0.3 m/s) (RX10GTL) 500 N/O.3 m/s (51 kg/0.3 mIs, 112 Ib/0.3 m/s) (RX10ML) 125
M_A_ _N_TE_N_A_N_C_E_s_P_E_C_ F_ C_A_~_IO_NS_ISPEC I g--I
________ ELECTRICAL
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Model Voltage
12 V
Ignition system: Ignition timing (B.T.D.C.) Advanced type
5° at 1,500 r/min Digital type
Ignition coil: Model/Manufacturer Primary coil resistance Secondary coil resistance
F6T567/MITSUBISHI 1.19 ~ 1.61 n at 20°C (68°F) 8.5 ~ 11.5 kn at 20°C (68°F)
Charging system: Type Normal output
AC magneto 14 V/35 A at 5,000 r/min
DC-T.C.I: Magneto model/Manufacturer Standard Pickup coil resistance (color code) Stator coil resistance (color code) T.C.I unit model/Manufacturer
F4T47971/MITSUBISHI 14 V 35 A, 490 W at 5,000 r/min 446 ~ 545 n at 20°C (68°F) (White/Red - White/Green) 0.19 ~ 0.24 n at 20°C (68°F) (White - White) F8T83171/MITSUBISHI (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) F8T83172/MITSUBISHI (RX10ML)
Rectifier/ regulator: Type Model/Manufacturer No load regulated voltage (DC) Capacity (DC) Withstand voltage
Short circuit type FH001/SHINDENGEN 14.1 ~ 14.9 V 35A 40V
Battery: Specific gravity Manufacture Type Ten hour rate amperage
1.32 YUASA YTX14-BS 12V-12Ah 12 A
Electric starter system: Type Starter motor: Model/Manufacturer Output Armature coil resistance Continuity check Insulation check Brush Overall length Wear limit Spring pressure Commutator diameter Wear limit Mica undercut
Constant mesh type 8FP1/MORIC 12 V - 0.95 kW 0.008 ~ 0.010 n at 20°C (68°C) More than 100 kn at 20°C (68°F) 9.8 mm (0.39 in) 5 mm (0.20 in) 7.36 ~ 11.04 N (736 28.5 mm (1.12 in) 27.5 mm (1.08 in) 1.5 mm (0.059 in)
126
~
1,104 g, 26.0
~
38.9 oz)
_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_I_CA_T_IO_NS_I SPEC I
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Model Starter relay: Model/Manufacturer Amperage rating Coil resistance
2768081-A/JIDECO 180 A 4.2 ~ 4.6 n at 20°C (68°F)
T.PS. (throttle position sensor): Model/Manufacturer Resistance Oil level switch: Model/Manufacturer Fuel sender: Model/Manufacturer Sender resistance
TS62/146/MIKUNI 4 ~ 6 kn at 20°C (68°F) (Blue - Black/Blue) 8FAlASTI
Full Empty
Headlight relay: Model/Manufacturer Coil resistance Grip warmer: Heater resistance
g--I
8FP/NIPPON SEIKI 10 ~ 12 n at 20°C (68°F) 179 ~ 185 n at 20°C (68°F) 5DM/OMRON 95 ~ 116 n at 20°C (68°F) 1.83 1.83
~ ~
2.24 n at 20°C (68°F) 2.24 n at 20°C (68°F)
Thumb warmer: Heater resistance
37.0
~
45.2 n at 20°C (68°F)
Cylinder identification sensor: Model/Manufacture
5VY/NIPPON SEIKI
Crankshaft position sensor: Model/Manufacture Resistance
8FP/MITSUBISHI 445 ~ 545 n at 20°C (68°F) (between Gray and Black)
Intake air pressure sensor: Model/Manufacture
5PS/DENSO
Intake air temperature sensor: Model/Manufacture Resistance
8FP/MITSUBISHI 2.21 ~ 2.69 kn at 20°C (68°F)
(left) (right)
Atmospheric pressur sensor: Model/Manufacture Throttle position sensor: Model/Manufacture Resistance
5PS/DENSO TS62 146/MITSUBISHI o ~ 5 ± 1.5 kn at 20°C (68°F) (Yellow - Black/Blue)
Water temperature sensor: Model/Manufacturer Resistance
Indicator light Speed sensor: Mode/Manufacture
(ON) (OFF)
8CC/MITSUBISHI 5.2 ~ 6.4 kn at O°C (34°F) 0.300 ~ 0.364 kn at 80°C (176°F) 0.170 ~ 0.208 kn at 100°C (212°F) 90 ~ 110°C (194 ~ 230°F) 85 ~ 105°C (185 ~ 221°F) 8EK/NIPPON SEIKI
127
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________
RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML
Model Circuit breaker: Type Amperage for individual circuit Main fuse Fuel injection system fuse Headlight fuse Signal fuse Ignition fuse Electronic control suspension fuse Radiator fan motor fuse Backup fuse Auxiliary DC jack fuse Reserve fuse
Fuse 40 A x 1 10 A x 1 20 A x 1 10 A x 1 20 A x 1 10 A x 1 (RX10GTL) 4Ax 1 3Ax 1 3Ax 1 20 A, 10 A, 4 A, 3 A x 1
128
_ _ _ _ _ _ _ _ _ _ _T_I_G_HT_E_N_IN_G_TO_R_Q_U_E_I SPEC I
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TIGHTENING TORQUE ENGINE Parts to be tightened Spark plug Cylinder head nut (M1 0 x 1.25) x 2 Cylinder head nut (M1 0 x 1.25) x 6 Cylinder head nut x 2 Cylinder head bolt Camshaft cap and cylinder head Cylinder head cover Connecting rod and cap A.C. magneto rotor Crankshaft and drive gear Primary reduction gear bearing housing Timing chain tensioner Thermostat housing Water temperature sensor Timing chain tensioner cap Camshaft and camshaft sprocket Hose band Water pump Coolant reservoir tank Coolant recovery tank Radiator Pipe Oil cooler Oil pan Engine mounting adjust bolt Engine mounting nut Countershaft cover Oil pan drain bolt Oil hose and suction pipe Oil filter union bolt Oil filter Oil pump Oil pump drive chain guide Oil tank drain bolt Oil tank and frame (bolt) Oil tank and frame (nut) Oil gallery bolt Cylinder head and carburetor joint Carburetor joint and throttle bodies Throttle bodies and silencer Exhaust joint Muffler band Exhaust pipe Muffler Exhaust cover Muffler band Muffler protector Cylinder head stud bolt
Tightening torque Nm
m-kg
ft-Ib
13
1.3
9.4
20 + 121°
2.0 + 121°
14 + 121 °
20 + 105°
2.0+105°
14 + 105°
20 + 140°
2.0+140°
14 + 140°
12 10 12
1.2 1.0 1.2
8.7 7.2 8.7
20 + 120°
2.0+120°
14 + 120°
130 75 12 10 10 23 6 24 2 12 10 10 10 10 35 10 9 65 12 30 2 30 17 12 10 16 10 19 10 3 3 3 25 9 25 16 6 20 11 10
13.0 7.5 1.2 1.0 1.0 2.3 0.6 2.4 0.2 1.2 1.0 1.0 1.0 1.0 3.5 1.0 0.9 6.5 1.2 3.0 0.2 3.0 1.7 1.2 1.0 1.6 1.0 1.9 1.0 0.3 0.3 0.3 2.5 0.9 2.5 1.6 0.6 2.0 1.1 1.0
94 54 8.7 7.2 7.2 17 4.3 17 1.4 8.7 7.2 7.2 7.2 7.2 25 7.2 6.5 47 8.7 22 1.4 22 12 8.7 7.2 11 7.2 14 7.2 2.2 2.2 2.2 18 6.5 18 11 4.3 14 8.0 7.2
129
Remarks
Left-hand thread.
_ _ _ _ _ _ _ _ _ _ _T_I_G_HT_E_N_IN_G_TO_R_Q_U_E_I SPEC I Parts to be tightened Crankcase (M9 x 1.5) (1 st) (2nd) Crankcase (M6 x 1.0) Countershaft cover A.C. magneto rotor cover Starter clutch Stator coil Starter motor Pickup coil Pickup coil plate Fuel pump Oil pressure switch Cylinder identification sensor Ignition coil
Tightening torque Nm
m-kg
ft-Ib
15
1.5
11
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Remarks See NOTE.
15 + 65 --- 70 0 1.5 + 65 --- 70 0 11 + 65 --- 70 0
12 12 12 12 10 27 6 10 7 15 8 10
NOTE:
1.2 1.2 1.2 1.2 1.0 2.7 0.6 1.0 0.7 1.5 0.8 1.0
8.7 8.7 8.7 8.7 7.2 20 4.3 7.2 5.1 11 5.8 7.2
Apply LOCTITEÂŽ
_
1. First, tighten the bolt to approximately 15 Nm (1.5 m-kg, 11 ft-Ib) with a torque wrench, then loosen the bolt completely. 2. Retighten the bolt to 15 Nm (1.5 m-kg, 11 ft-Ib), and tighten another 65 . . . 70° with a angle gauge.
130
_ _ _ _ _ _ _ _ _ _ _T_I_G_HT_E_N_IN_G_TO_R_Q_U_E_I SPEC I
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POWER TRAIN Tightening torque
Parts to be tightened Primary sheave (1 st) (2nd) Spider and sliding sheave
Nm 120 60 200
m-kg 12.0 6.0 20.0
ft-Ib 85 43 145
Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave Stopper (secondary sheave) Spring seat (secondary sheave) Bolt (secondary sheave clearance) Drive sprocket Locknut chain tensioner Chain housing and frame Driven sprocket
14 6 64 8 23 10 90 25 48 48
1.4 0.6 6.4 0.7 2.3 1.0 9.0 2.5 4.8 4.8
10 4.3 46 5.1 17 7.2 65 18 35 35
Drain bolt (drive chain housing) Chain housing cover Shift lever assembly
16 24 23
1.6 2.4 2.3
12 17 17
Lever and drive chain housing cover
10
1.0
7.2
Shaft (reverse drive gear)
10
1.0
7.2
Reverse driven gear
55
5.5
40
Counter gear
10
1.0
7.2
Spacer set screw Chain housing and brake caliper Bleed screw (brake caliper) Brake hose union bolt (caliper side) Brake hose union bolt (brake master cylinder side) Bearing nut (secondary shaft) Parking brake Parking brake assembly and lever
6 48 6 30 30 55 10 23
0.6 4.8 0.6 3.0 3.0 5.5 1.0 2.3
4.3 35 4.3 22 22 40 7.2 17
131
Remarks Tighten the bolts in two stages. See NOTE. Left-hand thread. Apply LOCTITE®
(RX10RTL, RX10ML) Apply LOCTITE®
(RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) (RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) Apply LOCTITE® (RX10RL, RX10RTRL, RX10GTL, RXW10L) Apply LOCTITE® (RX10RL, RX10RTRL, RX10GTL, RXW10L) Apply LOCTITE® (RX10RL, RX10RTRL, RX10GTL, RXW10L) Apply LOCTITE® Apply LOCTITE®
_ _ _ _ _ _ _ _ _ _ _T_IG_HT_E_N_IN_G_TO_R_Q_U_E_I SPEC I Tightening torque
Parts to be tightened
Nm
m-kg
ft-Ib
9
0.9
6.5
Front pivot arm and frame Front pivot arm and shockabsorber Front pivot arm and stopper band Shaft and stopper band Sliding runner and sliding frame Suspension wheel and sliding frame Front pivot arm and control rod Front pivot arm bracket and sliding frame Front pivot arm and bracket Rear pivot arm and shockabsorber Rear pivot arm bracket and control rod Rear pivot arm and frame Shaft and frame
60 49 4 4 10 60 74 30 72 49 74 84 84
6.0 4.9 0.4 0.4 1.0 6.0 7.4 3.0 7.2 4.9 7.4 8.4 8.4
43 35 2.9 2.9 7.2 43 53 22 52 35 53 61 61
Rear pivot arm and rear pivot arm bracket Rear pivot arm bracket and sliding frame Rear axle (RX10ML) Front pivot arm and frame Front pivot arm and front shockabsorber Front pivot arm and stopper band Shaft and stopper band Shaft and sliding frame Suspension wheel assembly and sliding frame Front pivot arm and sliding frame Suspension wheel and sliding frame Rear pivot arm and sliding frame Bracketandfrontshockabsorber Front pivot arm bracket and bracket Front pivot arm and bracket Bracket and rear shockabsorber Relay rod and rear pivot arm Rear pivot arm and rear shockabsorber Rear pivot arm and frame Suspension wheel and sliding frame Pivot shaft and sliding frame Rear axle Speed sensor Gear unit (speed sensor)
72 72 75
7.2 7.2 7.5
52 52 54
72 49 4 4 60 60 60 60 72 49 72 72 49 49 49 72 60 72 75 20 40
7.2 4.9 0.4 0.4 6.0 6.0 6.0 6.0 7.2 4.9 7.2 7.2 4.9 4.9 4.9 7.2 6.0 7.2 7.5 2.0 4.0
52 35 2.9 2.9 43 43 43 43 52 35 52 52 35 35 35 52 43 52 54 14 29
(RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L) Shockabsorber adjuster assembly and frame
NOTE:
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Remarks
(RX10RTL, RX10RL, RX10RTRL, RXW10L)
Apply LOCTITE速 Apply LOCTITE速 (RXW10L) Apply LOCTITE速 Apply LOCTITE速
_
Tightening steps: 1. Tighten the bolt to a torque at 120 Nm (12.0 m-kg, 85 ft-Ib). 2. Loosen the bolt completely. 3. Retighten the bolt to a torque of 60 Nm (6.0 m-kg, 43 ft-Ib).
132
_ _ _ _ _ _ _ _ _ _ _T_I_G_HT_E_N_IN_G_TO_R_Q_U_E_I SPEC I CHASSIS Tightening torque
Parts to be tightened Handlebar holder Steering joint cover Steering column Upper Lower Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod Tie rod and steering arm Idler arm Locknut (relay rod/tie rod) Ski Ski runner Ski and ski handle (front) Ski and ski handle (rear) Shock absorber (upper) Shock absorber (lower) Steering arm locknut Upper arm and frame Upper arm and knuckle Lower arm and frame Lower arm and knuckle Stabilizer bar and stabilizer arm Stabilizer arm and connecting rod Connecting rod and lower arm Frame cross member Frame cross member and steering bracket Master cylinder assembly Brake lever adjuster locknut Rear cover Seat and frame Headlight stay
133
Nm
m-kg
15 3
1.5 0.3
ft-Ib 11 2.2
23 23 35 35 35 30 35 30 35 67 25 48 19 12 17 45 45 35 37 40 37 65 11 34 34 23 47 10 6 4 7 7
2.3 2.3 3.5 3.5 3.5 3.0 3.5 3.0 3.5 6.7 2.5 4.8 1.9 1.2 1.7 4.5 4.5 3.5 3.7 4.0 3.7 6.5 1.1 3.4 3.4 2.3 4.7 1.0 0.6 0.4 0.7 0.7
17 17 25 25 25 22 25 22 25 49 18 35 14 8.7 12 33 33 25 27 29 27 47 8.0 25 25 17 34 7.2 4.3 2.9 5.1 5.1
Remarks
g--I
_
_ _ _ _ _ _G_E_N_E_R_A_L_T_O_R_Q_U_E_S_P_E_CI_F_IC_A_T_IO_N_S_'_I SPEC DEFINITION OF UNITS
GENERAL TORQUE SPECIFICATIONS
A
B (bolt)
(nut)
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
10 12 14 17 19 22
mm mm mm mm mm mm
6mm 8mm 10 mm 12 mm 14 mm 16 mm
1.--.1 v -
General torque specifications Nm m-kg ft-Ib 6 0.6 4.3 15 1.5 11 30 3.0 22 55 5.5 40 85 8.5 61 130 13.0 94
r
A L _____
A: Distance across flats B: Outside thread diameter
DEFINITION OF UNITS Unit
Read
Definition
mm cm
Millimeter Centimeter
10-3 meter
kg
Kilogram
103 gram
Measurement Length Length
10-2 meter
Weight 2
N
Newton
1 kg x m/sec
Nm m-kg
Newton meter Meter kilogram
Nxm m x kg
Pa N/mm
Pascal N/m 2 Newtons per millimeter N/mm
Pressure Spring rate
L cm 3
Liter Cubic centimeter
-
Volume or capacity
r/min
Rotations per minute
-
Engine speed
134
Force Torque Torque
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
g--I
9
4
~ BB
~
A
c 135
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CABLE ROUTING
CD Clamp the A.C. magneto lead and wire harness ground lead. ® Clamp the wire harness and A.C. magnet lead to the raised portion of the battery bracket. ® Battery positive lead @Main fuse Main harness @ Battery negative lead (J) Flange bolt Clamp the wire harness to the steering gate clamp. Make sure to place the wire harness junction at the rear end behind the clamp. Fit it to the sub-lead wire 3. @Clamp Route the sub-lead wire 3 and cell motor positive lead over the battery bracket and clamp them to the battery bracket. @ Oil level switch lead coupler @ Oil level switch @ Point both clips at two points upward. @Clip @Pipe2 @ Coolant temperature sensor lead coupler @ To the brake caliper. @ Main switch lead coupler To the heat exchanger @Clip @ Route the tail/brake light leads over the raised portion. @ Fuel pipe Clamp
®
®
®
®
®
'9
136
g--I
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
g--I
9
4
17
-@) l{\~~~_+Pk_~---~14
~ BB
~
A
A
c 137
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I @ Place
the damper locating between the fuel tank and sheet. @ To the tail/brake light. Sub-wire harness @Brake hose @ Fuel sender lead cover @ Auxiliary DC jack coupler Headlight lead coupler @ To the meter assembly. @ Clamp the headlight lead. @ Rout the headlight stay. @ Align the hole of dia. 3 mm (0.12 in) of the steering gate with the white tape position of the harness and secure them. Install the 12 pin connector to the top surface. @ Fit it to the extension wire harness. 速 To the headlight. @ Drive guard bracket @ Attach the battery negative lead to the cell motor fixing bolt. @ Front cover @Screw @ Rectifier/regulator @ Flange bolt @ Put the boots of the meter coupler in the boss root on the side of the meter. @ Fuel injection system relay @ Headlight relay @Load relay @ Radiator fan motor relay @ Installation position of each relay can be selected freely. @ Clamp the wire harness and speed sensor lead. (Be sure to fold so that the harnesses cannot be disconnected.) 速 Sub-wire lead (ignition coil lead) @ Wire harness @ Clamp the ignition coil lead so that it can be set within this range. (It should not be caught between the wire harness and steering gate.) ~ Clamp the leads of the radiator fan motor and back buzzer and then fold the clamp by 90 degrees.
速
速
138
g--I
CABLE ROUTING
29
AA
139
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CD
Right handlebar switch (g)Tube lead @ Handlebar holder (Route the wire harness, parking brake cable, throttle cable.) Parking brake cable @ Left handlebar switch Pass all the wire harness, brake hose, brake cable and throttle cable through it. Arrange the line of cables and hoses as shown in the illustration and they should not lap over each other. (J) Pass all the wire harness, brake hose, brake cable and throttle cable through it. @ Clamp the cover and bearing holder. Auxiliary DC jack @ Clamp the steering gate and fuel tank breather hose. @ After fitting, bundle the couplers of the brake light switch, lever holder 1, lever holder 3, thumb warmer, head light beam switch, lever holder 2, grip warmer x 2, grip warmer switch handle and thumb warmer switch handle with the cover, and then close at two points of bosses. Fit the wire harness from the handle with the wire harness of the white tape.
® ®
®
140
g--I
CABLE ROUTING
29
AA
141
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I @ Route
the fuel tank breather hose along the steering gate. @ Clamp the compression spring section of the fuel tank breather hose. Compression spring @ Point the clip position to the upward. @ Insert the fuel tank breather hose until it contacts the projection. To insert the hose, it is allowed to apply oils. @ To the speed sensor. @ Clamp the back buzzer lead. @ Back buzzer (RX10RL, RX10RTRL, RX10GTL, RXW10L) @ Clamp the radiator fan motor lead and back buzzer lead. @ To the parking brake. @ To the brake caliper. @Brake hose @ Clamp the fuel tank breather hose. @ Bind the two tube leads on the steering column side at one point by wrapping the tape (black) 3 to 5 turns. The end section of tape should not be peeled. @ Main switch Flange nut @ Hexagon bolt @ Route the lead by the inside of the wire harness and sub-wire lead (ignition coil lead). @ Clamp the wire harness, cylinder identification sensor (together with the connector cover) and sub-lead wire (ignition coil lead). Cylinder identification sensor @ Clamp the wire harness and sub-wire lead (ignition coil lead).
®
®
®
142
g--I
CABLE ROUTING
28
6
A
143
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CD Route the fuel tank breather hose behind the steering gate. 速 Wire harness @ Bracket 速 When the gear position switch lead is equipped with reverse, route it to the reverse gear. If it is not equipped with reverse, insert it to the inner side. @Fuse box Coolant reservoir tank (j)Clamp @Brake hose Parking brake cable @ After clamping, bend it 90 0 downward. @Clamp @ Clamp the hose at the white paint position. Point the clamp position to the front outside. @ Clamp the battery positive lead and battery negative lead. @Latch @ Engine oil tank hose @ Point the clamp tightening direction to the downward. @ Drain hose @ Less than 30 mm (1.2 in). @ Pass the coolant reservoir tank breather hose through between engine and heat exchanger. @ Clamp the rear suspension sublead. (RX10GTL) @ To the tail/brake light. @ Pass the wire harness and unused lead for the electronic rear suspension between the ribs of side cover 2 and frame.
速 速
144
g--I
CABLE ROUTING
28
6
A
145
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I @ Fit
it to the rear suspension lead. (Other types are attached with plugs.) (RX10GTL) @ Clamp the wire harness and radiator fan motor lead. (RX10RTL, RX10RL, RX10RTRL, RXW10L, RX10ML) Clamp the wire harness, radiator fan motor lead and electronic rear suspension lead. (RX10GTL) Tighten the frame cross member and frame together. @ Pass the electronic rear suspension sub-lead between the guide plate for the reverase lever and the frame. @ Point the clamp position to the downward. Point the clamp position to the inside. @ Clamp the leads before the fixture.
ÂŽ
146
g--I
___________
---..:C~A~B~L~E~R~O~UT~I~N~G_ISPEC I g--I
2
147
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CD Coolant recovery tank ® Coolant reservoir tank
@ 10 ,..; 30 mm (0.4 ,..; 1.2 in) (1)20,..; 40 mm (0.8,..; 1.6 in) @ Clamp the fuel pipe and subwire lead. Pass the fuel tank breather hose between the relay harness and the speed sensor harness. CV Two harness untis should not contact the pipe end. @ Clamp the fuel tank breather hose and two wire harness. Tighten the frame cross member and frame. Clamp the fuel pipe, sub-wire lead, speed sensor lead and relay harness. @ Wire harness clamp @ Speed sensor @ Nylon nuts @ Point the pawl of clip to the downward.
®
®
148
g--I
CABLE ROUTING
I
SPEC I
4
149
g--I
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CD Tail/brake light lead coupler (Place the tail/brake light lead coupler leads so that they are not caught between the seat bottom and taillight bracket.) Tail/brake light lead coupler (RX10ML) @ Clamp (RX10ML) Tail/brake light lead (RX10ML) @ Tail/brake light lead cover (RX10ML) Cover plate (RX10ML) (J) Rear frame (RX10ML) @ Protector (RX1 OML)
® ® ®
150
g--I
cD A.C. magneto ®
Rectifier/regulator Main switch @ Load relay ® Fuse (MAIN) ® Fuse (FUEL INJECTION SYSTEM) (J) Starter relay ® Starter motor ® Battery @ Diode @ Engine stop switch @ Throttle switch @ Grip warmer @ Thumb warmer @ Oil presser switch @ Fuse (ELECTRONIC CONTROL SUSPENSION) (RX10GTL) @ Electronic control suspension solenoid (RX10GTL) @ E.C.U. @ Ignition coil #1 ® Ignition coil #2 @ Ignition coil #3 @ Ignition coil #4 @ Spark plug @ Fuel injection relay @ Injector #1 @ Injector #2 @ Injector #3 @ Injector #4 @ Fuel pump @ Throttle position sensor @ Speed sensor @ Cylinder identification sensor @ Intake air pressure sensor @) Atmospheric pressure sensor ® Water temperature sensor ® Intake air temperature sensor @ Grip warmer switch ® Thumb warmer switch @ Body ground @ Back buzzer (RX10RL, RX10RTRL, RX10GTL, RXW10L) @ Gear position switch (RX10RL, RX10RTRL, RX10GTL, RXW10L) @ Brake light switch ® Tail/brake light @ Fuse (AUXILIARY DC JACK) @ Fuse (HEADLIGHT) @ Fuse (SIGNAL) @ Fuse (RADIATOR FAN MOTOR) @ Fuse (BACK UP) @ Fuse (IGNITION) ® Auxiliary DC jack @ Radiator fan motor relay @ Radiator fan motor @ Headlight beam switch ~ Headlight relay ® Headlight ® Meter assembly @ Multi-function meter ® Warning light @ Water temperature indicator light (@ Hi beam indicator light ®) Meter light @ Oil level switch @ Fuel sender
®
COLOR CODE B. . . . .. Br . . . .. Ch . . . .. G. . . . .. Gy. . . .. L Lg . . . .. O. . . . .. P...... R W Y...... B/L . . .. B/R . . .. B/Y . . .. Br/G . .. Br/L. . .. Br/W. .. Br/Y . .. G/B. . .. G/R. . .. G/W . .. G/Y. . .. Gy/R. .. L/B . . .. L/R . . .. L/W. . .. L/Y . . .. Lg/B . .. Lg/W. .. O/B. . .. O/G. . .. OIL . . .. O/R. . .. O/W . .. P/W . .. R/B . . .. R/G. . .. R/L . . .. R/W . .. R/Y . . .. W/B . .. Y/G. . .. Y/L . . .. Y/R. . ..
Black Brown Chocolate Green Gray Blue Light green Orange Pink Red White Yellow Black/Blue Black/Red Black/Yellow Brown/Green Brown/Blue Brown/White Brown/Yellow Green/Black Green/Red Green/White Green/Yellow Gray/Red Blue/Black Blue/Red Blue/White Blue/Yellow Light green/Black Light green/White Orange/Black Orange/Green Orange/Blue Orange/Red Orange/White Pink/White Red/Black Red/Green Red/Blue Red/White Red/Yellow White/Black Yellow/Green Yellow/Blue Yellow/Red
I
FOREWORD
HOW TO USE THIS MANUAL
This Supplementary Service Manual has been prepared to introduce new service and new data for the RX10RTW, RX10RTRW, RXW10GTW, RX10MSW. For complete information, on service procedures, it is necessary to use this Supplementary Service Manual together with following manual:
Particularly important information is distinguished in this manual by the following notations:
RX1 OH/RX1 OSH/RX1 OMH/RX1 OMSHI RX1 ORH/RX1 ORSH SERVICE MANUAL: 8FA-28197-10 (981073) (LIT-12618-02-28) RXW10J/RXW10SJ SUPPLEMENTARY SERVICE MANUAL: 8FG-28197-10 (981089) (LIT-12618-02-33) RX1 OK/RX1 ORK/RX1 ORSK RXW1 OK/RXW1 OSK/RX1 OMK/RX1 OMSK SUPPLEMENTARY SERVICE MANUAL: 8FV-28197-10 (981098) (L1T-12618-02-39) SUPPLEMENTARY SERVICE MANUAL: 8FS-28197-10 (LIT-12618-02-44)
NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understanding of the mechanical concepts and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to this model may render it unfit and/or unsafe to use. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
RX1 ORTW IRX1 ORTRW RXW1 OGTW IRX1 OMSW SUPPLEMENTARY SERVICE MANUAL Š 2006 by Yamaha Motor Corporation, U.S.A. 1st Edition, May 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N.LIT-12618-02-53
~ The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!
~
Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snowmobile.
A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile.
NOTE: A NOTE provides key information that can make procedures easier or clearer. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g., â&#x20AC;˘ Bearings Pitting/damage ~ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.
CD
®
II~~~ I~II~I~-~~""""'I'l-o-I ®
@
ICHASI ~ II-P~:~o=Dl ®
@ 1
ENG II
II~COO--'-LI~~I ®
(J)
I FI___.._I\__ ELEC [I~ 11
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Periodic inspections and adjustments @Chassis ® Power train @Engine ® Cooling system (J) Fuel injection system ® Electrical ® Specifications
1
®
ISPECI g--I
@
@
@
@
@
~ 8 ~ §@~ ~ , ~ a @
@
1
@
1
@
m m @
@
~
@n,V,A
@)
c&JI
@
Illustrated symbols @ to @ are used to identify the specifications which appear. @ Filling fluid @Lubricant @ Tightening @ Wear limit, clearance @ Engine speed @ Special tool
1
B @
~
~
Illustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point.
@ Apply locking agent (LOCTITE®) @) Apply Yamabond No.S® @ 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 @Use new one
INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN
~ GEN INFO
Q INSP ADJ
~ CHAS
ere POWR TR
ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL
FI
ELEC
g--
SPECIFICATIONS
SPEC
~
CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT ENGINE
1
ENGINE OIL LEVEL INSPECTION................................................
CHASSiS............................................................................................. LUBRICATION CLUTCH......................................................................................... GEAR SELECTION FRONT SUSPENSION SPRING PRELOAD (For RXW1 OGTW) FRONT SHOCK ABSORBER AIR PRESSURE (Except for RXW1 OGTW) REAR SUSPENSION STOPPER BAND TENSiON....................... REAR SUSPENSION SPRING PRELOAD (For RXW10GTW) ..... REAR SUSPENSION SPRING PRELOAD (For RX10RTW, RX10RTRW)........................................................ CONTROL ROD ADJUSTMENT (For RXW1 OGTW) CONTROL ROD ADJUSTMENT (Except for RXW1 OGTW)
1
3 3 5 8 15 15 18 19 20 21 22
CHAPTER 4. POWER TRAIN SLIDE RAIL SUSPENSiON................................................................
RX10RTW, RX1 ORTRW................................................................. RXW10GTW...................................................................................
24 24 28
CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS
33
MAINTENANCE SPECIFICATIONS
36 36 41 45 46
ENGINE.......................................................................................... POWER TRAIN CHASSiS........................................................................................ ELECTRiCAL................................................................................. TIGHTENING TORQUE......................................................................
ENGINE.......................................................................................... POWER TRAIN CHASSiS........................................................................................
49 49 51 53
GENERAL TORQUE SPECIFICATIONS
54
DEFINITION OF UNITS.......................................................................
54
CABLE ROUTING...............................................................................
55
_OIL _ _ _ _ IIANDSJP I ENGINE LEVEL INSPECTION _ ____
~O~
~
I .
PERIODIC INSPECTION AND ADJUSTMENT ENGINE ENGINE OIL LEVEL INSPECTION 1. Inspect: • Engine oil level
Do not run the engine with too much or not enough oil in the oil tank. Oil could flow into the intake silencer and the engine could be damaged. Inspection steps: • Place the snowmobile on a level surface and apply the parking brake. • Start the engine, warm it up for 10 -- 15 minutes, and then turn off. • Disconnect the oil level gauge coupler.
Disconnect the oil level gauge coupler before removing the oil level gauge. Otherwise the lead can twist and become severed. • Remove the oil level gauge, wipe it clean, insert it back into the filler hole (without screwing it in), and then remove it again to check the oil level. • The engine oil level should be between the minimum level mark @ and maximum level mark@. Below the minimum level mark ~ Add the recommended engine oil to the proper level.
When adding the engine oil, be careful not to fill above the maximum level mark and minimum level mark on the oil level gauge.
1
_ _ _ _ _ IIANOSJP I ENGINE OIL LEVEL INSPECTION _ ____
~O~
~
I
Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard API SE, SF, SG or higher SAE OW-30
SAE -40°
-20°
0°
20°
I
I,
I,
I,
: I
..
I
SAE OW-3D
Do not allow foreign materials to enter the crankcase.
API 40° 60° F
I, I
I
.: I
I I
I I
I
I
I I
I I
I I
I I
I I
I I
I I
I I
_40°
_29°
_18°
_7°
4°
SE,SF,SG
NOTE:
or higher
_
Before checking the engine oil level, wait a few minutes until the oil has settled.
16°C
- Start the engine, warm it up for several minutes, and then turn it off. - Check the engine oil level again. NOTE: _ Before checking the engine oil level, wait a few minutes until the oil has settled.
- Use only 4-stroke engine oil. -In order to prevent starter clutch slippage, do not mix any chemical additives. Do not use oils with a diesel specification of "CD" or oils of a higher quality than specified. In addition, do not use oils labeled "ENERGY CONSERVING II" or higher.
2
LUBRICATION
----------------------A CHASSIS
II~~~ I Q
I
LUBRICATION Front and rear suspension 1. Use a grease gun to inject grease into the nipples CD and ® (Both sides). 2. Apply grease @. Recommended lubricant: Esso Beacon 325 Grease or Aeroshell Grease #7A
CD Applay grease
® Applay grease (Both sides) @ Applay grease (Both sides) [8] Front
ffi] Rear (RX1 ORTW, RX10RTRW) [Q Rear (RXW1 OGTW)
[Q] Rear (RX1 OMSW)
A
B
c
3
_ _ IIANOSJP I LUBRICATION _ _______ D
CD Applay grease ® Applay grease (Both sides) ® Applay grease (Both sides) [8] Front
llil Rear (RX1 ORTW, RX10RTRW)
[Q] Rear (RXW1 OGTW) [Q] Rear (RX1 OMSW)
4
~O~
~
I
INSP ADJ
CLUTCH L
CLUTCH High altitude
Blue
W White
P
Pink
Y
Yellow
S
I
Silver
Specifications Model: RX10RTW, RX10RTRW -800 m (- 2,500 ft)
600 --- 1,400 m (2,000 --- 4,500 ft)
1,200 --- 2,000 m (4,000 --- 6,500 ft)
1,800 --- 2,600 m (6,000 --- 8,500 ft)
2,400 --- 3,000 m (8,000 --- 10,000 ft)
~ Engine idle speed
1,500 ± 100 r/min
~
~
~
~
[Q] Engagement r/min [Q] 8hift r/min
3,500 ± 200 r/min
~
3,600 ± 200 r/min
~
3,700 ± 200 r/min
10,500 ± 250 r/min
~
~
~
~
[8]
Elevation
~
E
8econdary reduction ratio (number of links)
38/22 (68 L)
[E]
Primary sheave spring
90501 -582 L1
~
~
~
~
[§]
Color
Y-8-Y
~
~
~
~
[8]
Free length
87.4 mm (3.44 in)
~
~
~
~
343 N (35 kg, 771b)
~
~
~
~
[]] Preload
38/24 (70 L)
38/23 (70 L)
38/22 (68 L)
~
24.5 N/mm
Q] 8pring rate
(2.50 kg/mm, 140lb/in)
~
~
~
~
[Kl Wire diameter
5.8 mm (0.228 in)
~
~
~
~
OJ Outside diameter
59.5 mm (2.34 in)
~
~
~
~
[MJ Weight (10)
8FP-17605-00 (8FPOO)
~
~
~
~
[N] ~eight rivet
OUT
8tee117.2
8tee117.2 with-hole
8tee113.3 with-hole
Aluminum 13.3 with-hole
None
CENTER
8tee117.2
8tee117.2 with-hole
8tee113.3 with-hole
Aluminum 13.3 with-hole
None
IN
8tee117.2
8tee117.2 with-hole
8tee113.3
8tee113.3 with-hole
None
[Q] Weight bushing
VE8PEL TP-8549
~
~
~
~
[EJ
14.5 mm (0.57 in)
~
~
~
~
VE8PEL TP-8549
~
~
~
~
None
~
~
~
~
90508-60012
~
~
~
~
IT] Color
P
~
~
~
~
[Q] Free length
75 mm (2.95 in)
~
~
~
~
[YJ
70° (1-6) 1,211 kgemm/rad
~
~
~
~
~ Wire diameter
6.0 mm (0.236 in)
~
~
~
~
[Xl Outside diameter [Yl 8ec. torque cam angle [Z] 8ec. clutch shim
69.5 mm (2.736 in)
~
~
~
~
51 - 43°
~
~
~
~
1.0 mm (0.04 in)
~
~
~
~
Roller outer dia.
[Q] Roller bushing [8] Pri. clutch shim [§] 8econdary sheave spring
Preload rate
5
I
INSP ADJ
CLUTCH L
Blue
W White
P
Pink
Y
Yellow
S
I
Silver
Specifications Model: RXW10GTW -800 m (- 2,500 ft)
600 --- 1,400 m (2,000 --- 4,500 ft)
lliJ Engine idle speed
1,500 ± 100 r/min
~
~
~
~
[Q]
3,500 ± 200 r/min
~
3,600 ± 200 r/min
~
3,700 ± 200 r/min
10,500 ± 250 r/min
~
~
~
~
38/23 (70 L)
~
[8J Elevation Engagement r/min
[Q] 8hift r/min ~
E
8econdary reduction ratio (number of links)
1,200 --- 2,000 m (4,000 --- 6,500 ft)
38/22 (68 L)
1,800 --- 2,600 m (6,000 --- 8,500 ft)
2,400 --- 3,000 m (8,000 --- 10,000 ft)
38/21 (68 L)
~
[E] Primary sheave spring [Q] Color [8] Free length
90501-582L1
~
~
~
~
Y-8-Y
~
~
~
~
87.4 mm (3.44 in)
~
~
~
~
[]] Preload
343 N (35 kg, 77 Ib)
~
~
~
~
Q] 8pring rate
24.5 N/mm (2.50 kg/mm, 140Ib/in)
~
~
~
~
[Kl Wire diameter
5.8 mm (0.228 in)
~
~
~
~
OJ Outside diameter
59.5 mm (2.34 in)
~
~
~
~
[MJ Weight (10)
8FP-17605-00 (8FPOO)
~
~
~
~
IN] ~eight rivet
OUT
8tee117.2
8tee117.2 with-hole
8tee113.3 with-hole
Aluminum 13.3 with-hole
None
CENTER
8tee117.2
8tee117.2 with-hole
8tee113.3 with-hole
Aluminum 13.3 with-hole
None
IN
8tee117.2
8tee117.2 with-hole
8tee113.3
8tee113.3 with-hole
None
[Q] Weight bushing [EJ Roller outer dia.
VE8PEL TP-8549
~
~
~
~
14.5 mm (0.57 in)
~
~
~
~
[Q] Roller bushing [B] Pri. clutch shim [§] 8econdary sheave spring IT] Color [Q] Free length
VE8PEL TP-8549
~
~
~
~
None
~
~
~
~
90508-60007
~
~
~
~
W
~
~
~
~
75 mm (2.95 in)
~
~
~
~
[YJ Preload rate
60° (3-3) 1,290 kgemm/rad
~
~
~
~
~ Wire diameter
6.0 mm (0.236 in)
~
~
~
~
[K] Outside diameter
69.5 mm (2.736 in)
~
~
~
~
[YJ 8ec. torque cam angle
51 - 43°
~
~
~
~
~ 8ec. clutch shim
1.0 mm (0.04 in)
~
~
~
~
6
I
INSP ADJ
CLUTCH L
Blue
W White
P
Pink
Y
Yellow
S
I
Silver
Specifications Model: RX10MSW -800 m (- 2,500 ft)
[8] Elevation
600 --- 1,400 m (2,000 --- 4,500 ft)
1,200 --- 2,000 m (4,000 --- 6,500 ft)
1,800 --- 2,600 m (6,000 --- 8,500 ft)
2,400 --- 3,000 m (8,000 --- 10,000 ft)
~ Engine idle speed
1,500 ± 100 r/min
~
~
~
~
[Q] Engagement r/min [Q] 8hift r/min
3,600 ± 200 r/min
3,400 ± 200 r/min
~
3,500 ± 200 r/min
~
10,500 ± 250 r/min
~
~
~
~
40/22 (70 L)
~
~
E
8econdary reduction ratio (number of links)
40/21 (70 L)
40/20 (68 L)
~
[E] Primary sheave spring [Q] Color [8] Free length
90501-583L4
90501 -551 L3
~
90501-581 L5
~
W-8-W
L-P-L
~
y-p-y
~
89 mm (3.50 in)
88.4 mm (3.48 in)
~
85.4 mm (3.36 in)
~
[]] Preload
343 N (35 kg, 771b)
294 N (30 kg, 66 Ib)
~
~
~
Q] 8pring rate
22.1 N/mm (2.25 kg/mm, 126 Ib/in)
19.6 N/mm (2.00 kg/mm, 112 Ib/in)
~
24.5 N/mm (2.50 kg/mm, 140 Ib/in)
~
[Kl Wire diameter
5.8 mm (0.228 in)
5.5 mm (0.217 in)
~
5.8 mm (0.228 in)
~
OJ Outside diameter
59.5 mm (2.34 in)
~
~
~
~
[MJ Weight (10)
8FP-17605-00 (8FPOO)
8F8-17605-00 (8F800)
~
~
~
OUT
8tee117.2
8tee117.2 with-hole
8tee113.3
8tee113.3
8tee113.3 with-hole
CENTER
8tee117.2
8tee117.2 with-hole
8tee113.3
8tee113.3 with-hole
8tee113.3 with-hole
IN
8tee117.2
8tee117.2
8tee113.3
8tee113.3 with-hole
None
[N] ~eight rivet
[Q] Weight bushing [E] Roller outer dia. [Q] Roller bushing [8] Pri. clutch shim [§] 8econdary sheave spring
VE8PEL TP-8549
~
~
~
~
14.5 mm (0.57 in)
15.6 mm (0.61 in)
~
~
~
VE8PEL TP-8549
~
~
~
~
None
~
~
~
~
90508-60007
~
~
~
~
IT] Color
W
~
~
~
~
[Q] Free length
75 mm (2.95 in)
[YJ
60° (3-3) 1,290 kgemm/rad
Preload rate
~
~
~
~
70° (1-6) 1,290 kgemm/rad
~
~
~
~ Wire diameter
6 mm (0.236 in)
~
~
~
~
[Xl Outside diameter [Yl 8ec. torque cam angle
69.5 mm (2.736 in)
~
~
~
~
~
~
~
~ 8ec. clutch shim
1.0 mm (0.04 in)
~
~
~
51 - 43°
45° ~
7
I
_ _ _ IIANOSJP I GEAR SELECTION _ ______
~O~
~
I
GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions. If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions exist, decrease the ratio.
Gear ratio chart The drive and driven gears and the chains shown in the gear ratio chart are available as options. The figures containing a decimal point represent the drive/driven gear ratios, while the bottom numbers designate the number of links in the chain.
8
_ _ _ IIANOSJP GEAR SELECTION _ ______
~O~
~ I
I
CD Chain and sprocket part number [8] Parts name
~ Drive sprocket
[E] Driven sprocket
[§] Chain
~ Teeth & links
[Q Parts no.
18 teeth
8FA-17682-80
19 teeth
8FA-17682-90
20 teeth
8FA-17682-00
21 teeth
8FA-17682-10
22 teeth
8FA-17682-20
RX10RTW, RX10RTRW, RX10MSW
23 teeth
8FA-17682-30
RXW10GTW
24 teeth
8FA-17682-40
37 teeth
8DW-47587-71
38 teeth
8DW-47587-81
RX10RTW
38 teeth
8FB-47587-80
RX10RTRW, RXW10GTW
39 teeth
8DW-47587-91
39 teeth
8FB-47580-90
40 teeth
8DW-47587-01
40 teeth
8FB-47580-00
68 links
94890-09068
RX10RTW, RX10RTRW
70 links
94890-09070
RXW10GTW, RX10MSW
[Q] Standard
RX10MSW
® Gear ratio [8] Drive gear 18 teeth
20 teeth 21 teeth
19 teeth
22 teeth
23 teeth 24 teeth
1.76 68 links
1.68 68 links
1.61 68 links
1.54 70 links
1.90 68 links
1.81 68 links
1.73 68 links
1.65 70 links
1.58 70 links
~ Driven gear
37 teeth 38 teeth
/ / 1//
/
39 teeth
2.17 68 links
2.05 68 links
1.95 68 links
1.86 68 links
1.77 70 links
1.70 70 links
1.63 70 links
40 teeth
2.22 68 links
2.11 68 links
2.00 68 links
1.91 70 links
1.82 70 links
1.74 70 links
1.67 70 links
9
INSP ADJ
GEAR SELECTION
@ Secondary sheave spring [A]
[ill Spring rate Part no.
[:EJ
Nemm/rad (kgemm/ rad)
[Q Preload N/mm (kg / mm) (Ib/in)
6003 (613)
6.2 (0.63), 35.28
Brown
90508-500B 1
[Q]
Color
Wire gauge mm(in)
[E]
No. of coils
5.0 (0.196)
[gJ
[8]
Free length mm(in)
Outside diameter mm(in)
5.19
75 (2.95)
69.5 (2.736) 65.0 (2.559)
IT]
Standard
90508-50746
7071 (721)
8.7 (0.89), 49.65
White
5.0 (0.196)
4.74
93.5 (3.68)
90508-536A9
7147 (729)
7.3 (0.74), 41.44
Red
5.3 (0.209)
5.53
75 (2.95)
69.5 (2.736)
90508-556A2
8314 (848)
8.5 (0.87), 48.72
Green
5.5 (0.217)
5.53
75 (2.95)
69.5 (2.736)
90508-556A7
9460 (965)
10.21 (1.04),58.24
Silver
5.5 (0.217)
4.86
75 (2.95)
69.5 (2.736)
90508-60012
11876 (1211)
12.32 (1.256), 70.34
Pink
6.0 (0.236)
5.53
75 (2.95)
69.5 (2.736)
RX10RTW, RX10RTRW
90508-60007
12654 (1290)
13.45 (1.372) 76.84
White
6.0 (0.236)
5.19
75 (2.95)
69.5 (2.736)
RXW10GTW, RX10MSW
® Secondary spring twist angle lliJ ~
0
3
6
9
1
10°
40°
70°
100°
2
20°
50°
80°
110°
3
30°
60°
90°
120°
Sheave
@ Torque cam (secondary spring seat)
lliJ
Effects
[§] Quicker upshifting during acceleration
[Q Part no.
[A] Identification mark
[Q] Cam angle
~ Identification mark
[E] Standard RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
8FA-17604-00
51-43°
8BVFA
8BV-17604-71
47°
8BV71
8BV-17604-51
45°
8BV51
8BV-17604-31
43°
8BV31
8BV-17604-11
41 °
8BV11
8BV-17604-91
39°
8BV91
~ ~
~
,
[8] Quicker backshifting under load
10
GEAR SELECTION
INSP ADJ
@ Primary spring [AJ Spring identification color code
llil Spring rate color [Q] Preload color
I
I
~ ~.~ I
[Q]
[E] Parts No.
Spring rate N/mm (kg/mm)
[E]
Preload N (kg)
[8] Wire
[G]
Color
gauge mm(in)
IT]
Outside diameter mm(in)
Q] No. of coils
[R]
Free length mm(in)
90501-551 L3
19.6 (2.00)
294 (30)
Blue-Pink-Blue
5.5 (0.216)
59.5 (2.34)
4.91
88.4 (3.48)
90501-551 L9
19.6 (2.00)
343 (35)
Blue-Silver-Blue
5.5 (0.216)
59.5 (2.34)
4.91
90.9 (3.58)
90501-552 L5
19.6 (2.00)
392 (40)
Blue-Green-Blue
5.5 (0.216)
59.5 (2.34)
4.91
93.4 (3.68)
90501-581 L5
24.5 (2.50)
294 (30)
Yellow-Pink-Yellow
5.8 (0.228)
59.5 (2.34)
4.92
85.4 (3.36)
90501-581 L6
27 (2.75)
294 (30)
Green-Pink-Green
5.8 (0.228)
59.5 (2.34)
4.66
84.3 (3.32)
90501-582 L1
24.5 (2.50)
343 (35)
Yellow-Silver-Yellow
5.8 (0.228)
59.5 (2.34)
4.92
87.4 (3.44)
90501-582 L2
27 (2.75)
343 (35)
Green-Silver-Green
5.8 (0.228)
59.5 (2.34)
4.66
86.1 (3.39)
90501-582 L6
22.1 (2.25)
392 (40)
White-G reen-White
5.8 (0.228)
59.5 (2.34)
5.25
91.2 (3.59)
90501-582 L7
24.5 (2.50)
392 (40)
Yellow-Green-Yellow
5.8 (0.228)
59.5 (2.34)
4.92
89.4 (3.52)
90501-583 LO
19.6 (2.00)
441 (45)
Blue-White-Blue
5.8 (0.228)
59.5 (2.34)
5.65
95.9 (3.78) 93.4 (3.68)
90501-583 L1
22.1 (2.25)
441 (45)
White-White-White
5.8 (0.228)
59.5 (2.34)
5.25
90501-583L4
22.1 (2.25)
343 (35)
White-Silver-White
5.8 (0.228)
59.5 (2.34)
5.25
89.0 (3.50)
90501-583 L5
22.1 (2.25)
294 (30)
White-Pink-White
5.8 (0.228)
59.5 (2.34)
5.25
86.7 (3.41)
9050 1-600A1
29.4 (3.00)
294 (30)
Pink-Blue-Pink
6.0 (0.236)
59.5 (2.34)
4.82
80.1 (3.15)
90501-601 L7
29.4 (3.00)
294 (30)
Pink-Pink-Pink
6.0 (0.236)
59.5 (2.34)
4.82
83.4 (3.28) 82.6 (3.25)
90501-601 L8
31.9 (3.25)
294 (30)
Orange-Pink-Orange
6.0 (0.236)
59.5 (2.34)
4.60
90501-602 L3
29.4 (3.00)
343 (35)
Pink-Silver-Pink
6.0 (0.236)
59.5 (2.34)
4.82
85.1 (3.35)
90501-602 L8
27.0 (2.75)
392 (40)
Green-Green-Green
6.0 (0.236)
59.5 (2.34)
5.08
87.9 (3.46)
90501-602 L9
29.4 (3.00)
392 (40)
Pink-Green-Pink
6.0 (0.236)
59.5 (2.34)
4.82
86.7 (3.41)
90501-603 L2
24.5 (2.50)
441 (45)
Yellow-White-Yellow
6.0 (0.236)
59.5 (2.34)
5.39
91.4 (3.60)
90501-603 L3
27.0 (2.75)
441 (45)
Green-White-Green
6.0 (0.236)
59.5 (2.34)
5.08
89.8 (3.54)
90501-624L8
31.9 (3.25)
343 (35)
Orange-Silver-Orange
6.2 (0.244)
59.5 (2.34)
5.00
84.2 (3.32)
11
[[] Standard
RX10RTW, RX10RTRW, RXW10GTW
RX10MSW
_ _ _ IIANOSJP I GEAR SELECTION _ ______
~O~
~
(J) Clutch weight
llil Weight g (oz) [8] Parts no.
without bush and rivets
8BU-17605-20
45.41 (1.60)
8CH-17605-10
35.32 (1.247)
[Q] Shape & ID mark
00808
8DG-17605-00
34.26 (1.209)
8DJ-17605-00
37.77 (1.333)
8DN-17605-10
39.76 (1.40)
8ES-17605-00
54.6 (1.93)
8FA-17605-10
63.8 (2.25)
12
[Q] Standard
I
_ _ _ IIANOSJP GEAR SELECTION _ ______
I
~O~
~ I
llil Weight g (oz) [8] Parts no.
[Q Shape & 10 mark
without bush and rivets
8FP-17605-00
67.81 (2.392)
8FS-17605-00
65.52 (2.311)
8FN-17605-00
75.28 (2.655)
[Q] Standard
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
@ Weight rivets [A] Parts No.
[6] Material
[Q] Length
[Q] Weight
mm (in)
g (oz)
90261-06033
Steel
17.2 (0.677)
4.5 (0.159)
90269-06006
Steel
17.2 (0.677)
3.6 (0.127) with hole
90261-06019
Steel
13.3 (0.524)
3.1 (0.109)
90266-06002
Steel
13.3 (0.524)
2.4 (0.085) with hole
90266-06001
Aluminum
13.3 (0.524)
[E] Standard
[E] Effects
IN: RX10RTW, RX10RTRW, RXW10GTW, RX10MSW CENTER: RX10RTW, RX10RTRW, RXW10GTW, RX10MSW OUT: RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
~ Increased Force
J~
~
,
[8] Decreased
0.8 (0.028) with hole
Force
13
GEAR SELECTION
INSP ADJ
® Rollers 1.0.9 mm (0.354 in)
[A] Roller with
[ill Outside
bushing part number
diameter mm (in)
8FG-17624-00
[Q Bushing
[Q] Identification
type (PIN)
mark (Width)
VESPEL TP-8549
[BJ Grooved & Machined
•
[8] Grooved
15.0 (0.59)
(1.46 mm)
90386-09001
IT] No Mark
VESPEL TP-8549 15.6 (0.61)
(1.46 mm)
90386-09001 VESPEL TP-8549 8FG-17624-30
[] Increased force
(1.46 mm)
VESPEL TP-8549
8FG-17624-20
[E] Effects
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
14.5 (0.57)
90386-09001
8FG-17624-10
[E] Standard
GD Grooved &Grooved
16.0 (0.63)
(1.46 mm) 90386-09001
8FG-17624-40
VESPEL TP-8549
[R] Machined
90386-09001
(1.46 mm)
16.5 (0.65)
[M] Decreased
14
force
_ _ _F_R_O_N_T_S_U_S_P_EN_S_I_O_N_S_PR_I_N_G_P_R_E_LO_A_D_(_F_Or_R_X_W_1_0_G_TW_) FRONT SHOCK ABSORBER AIR PRESSURE (Except for RXW1 OGTW) _IIANOSJP _
~O~
~ .I
I
FRONT SUSPENSION SPRING PRELOAD (For RXW10GTW)
~ ----------
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to open flame or high heat, which could cause it to explode. 2
Be sure that the left and right spring preloads are the same. 1. LoosenthelocknutGD. 2. Adjust the spring preload by turning the spring seat (2). Spring seat distance Preload Length
ÂŽ
Standard Shorter ~ Harder ~ Min. 243mm (9.57 in)
~
Longer Softer Max.
~
253mm (9.96 in)
257mm (10.12 in)
3. Tighten the locknut GD.
FRONT SHOCK ABSORBER AIR PRESSURE (Except for RXW10GTW) This snowmobile is equipped with FOX shock absorbers as standard equipment. The air pressure of the shock absorbers can be adjusted using the special pump GD included with your snowmobile. NOTE: _ The following procedure applies to both shock absorbers. 1. Place the snowmobile on a level surface and apply the parking brake. 2. Lift the front of the snowmobile onto a suitable stand to raise the skis off the ground.
15
FRONT SHOCK ABSORBER AIR PRESSURE (Except for RXW10GTW)
INSP ADJ
~ ----------
Support the snowmobile securely on a suitable stand before adjusting the shock absorbers.
Make sure that there is no load on the shock absorbers and that they are fully extended before making any air pressure adjustments. 3. Remove the air valve cap ÂŽ from the shock absorber. 4. Install the hose connector ÂŽ of the special pump onto the air valve of the shock absorber and tighten it approximately six turns until the pressure registers on the pump gauge.
Do not overtighten the connector onto the air valve as this will damage the connector seal.
_--J----LJ--...-.....--.=O
NOTE:
_
If the shock absorber has no air pressure, the gauge reading will be zero. 5. To increase the air pressure, operate the pump a few times. The pressure should increase slowly. If the pressure increases rapidly, check to make sure that the pump is properly connected and tightened onto the air valve. To decrease the air pressure, push the black bleed valve button @. NOTE: _ To allow pressure to escape from the pump and the shock absorber, push the button halfway down and hold it. To allow only a small amount of pressure to escape, push the button all the way down and quickly release it.
16
(Except for RXW1 OGTW) _ _ _ _ _F_R_O_N_T_S_H_O_CK_A_B_SO_R_B_E_R_A_I_R_P_R_E_SS_U_R_E_IIANOSJP
I
~O~
~ I
6. Remove the hose connector from the air valve. NOTE: _ When removing the connector, the sound of air escaping may be heard, but this is from the pump hose, not the shock absorber.
Air pressure range: 345 kPa (3.4 kgf/cm 2 , 50 psi) to 1,034 kPa (10.3 kgf/cm 2 , 150 psi) Recommended air pressure: 483 kPa (4.8 kgf/cm 2 , 70 psi)
Do not exceed 1,034 kPa (10.3 kgf/cm 2 , 150 psi) 7. Install the air valve cap. NOTE:
_
If the front suspension bottoms too easily or rolls too much during cornering, increase the air pressure by 34 kPa (0.3 kgf/cm 2 , 5 psi). If the suspension is too firm and you want a more compliant ride, decrease the air pressure by 34 kPa (0.3 kgf/cm 2 , 5 psi)
The air pressure of the left and right shock absorbers must be set to the same setting. Uneven settings can cause poor handling and loss of stability.
~ ----------
This shock absorber contains highly pressurized nitrogen gas. It could explode by improper handling, causing injury or property damage. • Do not tamper with or attempt to open the shock absorber. • Do not subject the shock absorber to an open flame or other high heat source, which could cause it to explode. • Do not deform or damage the shock absorber in any way. • Do not dispose of a worn or damaged shock absorber by yourself. Take the unit to a Yamaha dealer.
17
__ __ _ IIANOSJP I REAR_ SUSPENSION STOPPER BAND _ TENSION _ __
~O~
I
~
REAR SUSPENSION STOPPER BAND TENSION 1. Loosen the stopper band nut CD 2. Adjust the stopper band tension by changing the position of the hole of ® . . . ® or CD.
A
Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. (Except for RXW10GTW) A
NOTE:
_
This adjustment affects the handling characteristics of the machine.
o
0
o
0
Adjuster Thread Length
For RXW10GTW:
® ®
B
Effects
~
~
~
Longer (Maximum) Less weight on skis. More weight transfer
~
~ Stopper band nut: B
A'l
4 Nm (0.4 m-kg, 2.9 ft-Ib)
[8] For RXW1 OGTW
llil Except for RXW1 OGTW
o
18
CD
Shorter (Minimum) More weight on skis. Less weight transfer
3. Tighten the stopper band nut.
v
®
Except for RXW10GTW:
_ _ _SPRING __ _(For _ _ _ IIANOSJP SUSPENSION PRELOAD RXW1 OGTW) _REAR
~O~
~ I
I
REAR SUSPENSION SPRING PRELOAD (For RXW10GTW) 1. LoosenthelocknutGD. 2. Adjust the spring preload by turning the spring seat (2). Spring seat distance Preload
2
Front: Length
®
Standard Shorter ~ Harder ~ Min. 269mm (10.59 in)
279mm (10.98 in)
~
Longer Softer Max.
~
287mm (11.29 in)
3. Tighten the locknut GD.
~---------
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to open flame or high heat, which could cause it to explode.
19
~O~
I ~ I (For RX10RTW, RX1 ORTRW) _ _ _ _ _ _ _R_E_A_R_S_U_SP_E_N_S_IO_N_SP_R_I_NG_P_R_EL_O_A_D_IIANOSJP REAR SUSPENSION SPRING PRELOAD (For RX10RTW, RX10RTRW) Front shock absorber 1. LoosenthelocknutQD. 2. Adjust the spring preload by turning the spring seat (2). Standard Increased ~ ~ Decreased Harder ~ ~ Softer Max. Min. [8] Length @ 127.5 mm 113.5 mm 112.5 mm
Spring seat length Preload
(4.47 in)
(5.02 in)
Rear shock absorber Turn the adjusting hook tion. Spring adjuster position Preload llil Rear Standard
(4.43 in)
ÂŽ to the proper posi-
S
M
H
Soft
Medium M
Hard
~---------
Always adjust both spring preloads (left and right) to the same setting. Uneven adjustment can cause poor handling and loss of stability.
20
_ _ _ _(For _ _ _ IIANOSJP CONTROL ROD ADJUSTMENT RXW10GTW) _ __
~O~
~ I
I
CONTROL ROD ADJUSTMENT (For RXW10GTW) Control rod stroke ® 1. LoosenthelocknutGD. 2. Check the adjusting rod length using the scale on the special wrench ® included in the owner's tool kit.
®
3. Turn the adjusting rod @ in direction @ to adjust the control rod stroke.
Adjusting position
MIN
I
Decrease ® pitching
Effect Standard
STD ~
~
I
® or
MAX Increase @weight transfer
STD
4. While holding the adjusting rod @ securely, tighten the locknut GD.
Locknut: 35 Nm (3.5 m-kg, 25 ft-Ib)
21
__ _ _ _(Except __ _ _ IIANOSJP I ROD ADJUSTMENT for RXW1 OGTW) _ CONTROL
~O~
~
I
CONTROL ROD ADJUSTMENT (Except for RXW10GTW) Control rod stroke ®
Make sure the adjusting bolt ends are set at the same position on each side.
1. Loosen the lock nut CD. 2. Turn the adjusting nut ® in or out to adjust the control rod stroke. 321
Adjusting position
1 Increase weight transfer
Effect Standard 3
~
2
I ~
3
I ~
Decrease pitching
2
----------
Never adjust the control rods beyond the maximum range indicated on the rods with red paint @.
3. While holding the adjusting bolt securely, tighten the locknut CD. ,
~~
Locknut: 25 Nm (2.5 m-kg, 18 ft-Ib)
Damping (For RXW10GTW) 1. Adjust • Damping Adjustment step: • Press the mode switch CD • Make sure to switch the multi-function meter to the electric suspension adjustment indicator ®. • To harden the suspension, push the electric suspension/ grip warmer adjustment switch located at the left handlebar switch @ to the "HI" side, or push it to the "LO" side to soften and adjust.
22
__ _ _ _(Except __ _ _ IIANOSJP ROD ADJUSTMENT for RXW1 OGTW) _ CONTROL
I
~O~
~ .I
• Press the electric suspension/grip warmer adjustment switch @ in direction ® or @. (Maximum: 16 push) Adjustment switch pushed direction Display
o
@
®
S
H
1
2
3
4
5
6
7
8
Adjustment switch
112 31 4 51 6 71 s 91 10 111 12 13 114 15 116
Damping force
Softer
~
~
Harder
• This display scale is set in 2-level for one graduation. NOTE: _
(
• The electric suspension indicator ® comes on and the display switch to the electric suspension level when the electric suspension/ grip warmer adjustment switch is pushed. • The electric suspension level is displayed for 5 seconds after releasing the electric suspension/grip warmer adjustment switch, then switch to the fuel meter. • The top segment of the electric suspension level indicator flashes once if the electric suspension/grip warmer adjustment switch is continually pushed at the maximum level. The bottom segment of the electric suspension level indicator flashes once if the electric suspension/grip warmer adjustment switch is continually pushed at the minimum level. • When the engine is started, the electric suspension level are set to the level saved when the engine was stopped.
23
_ _ __ SLIDE RAIL SUSPENSION _ _____ POWER TRAIN
pOTWRRI~1 ~
SLIDE RAIL SUSPENSION RX10RTW, RX10RTRW
[AJ : I 72 Nm (7.2 m-kg, 52 ft-Ib)
Order
I
Job/Part
Q'ty
Slide rail suspension removal
1 2
Rear axle nut Tension adjuster Slide rail suspension Collar
Remarks Remove the parts in the order listed below. Loosen. Loosen.
1 2 For installation, reverse the removal procedure.
24
__________ lpOTWRRI~1 SLIDE RAIL SUSPENSION
Order
CD
® ®
@ @ @ (J)
® ®
@ @ @ @ @)
®
@ @ @ @
Job/Part Slide rail suspension disassembly Stopper band Shaft Rubber collar Front shock absorber Collar Bushing Suspension wheel Hook assembly Suspension wheel assembly Shaft Front pivot arm Shaft Bushing Collar Shaft Suspension bracket 1 Bushing Suspension bracket 2 Collar
Q'ty 2 1 3 1 2 2 2 2 2 1 1 1 2 2 1 1 2 1 2 25
~.
Remarks Remove the parts in the order listed below.
_ _ _ _ _ _ _ _ _ _ pOTWRRI~1 SLIDE RAIL SUSPENSION
Order
@ @ @ @ @ @ @ @ @ @
Job/Part Rear shock absorber Collar Collar Guide wheel Spacer Rear spring Shaft Bushing Rear pivot arm protector Rear pivot arm
Q'ty 1 2 2 2 2 2 1 2 2 1
26
Remarks
~
Ip~:RICG)1 SLIDE RAIL SUSPENSION --_-----.:::=~--
Circlip Hook Control rod assembly Shaft Pivot shaft Collar Guide wheel Rear axle shaft Collar Tension adjuster For assem bly, reverse the disassenbly procedure.
27
_ _ _ _ _ _ _ _ _ _ pOTWRRI~1 SLIDE RAIL SUSPENSION
~
RXW10GTW
3
I 84 Nm (8.4 m-kg, 61 ft-Ib) I
[A] : ~ 72 Nm (7.2 m-kg, 52 ft-Ib)
[ID : ~
Order
Job/Part
Q'ty
Slide rail suspension removal
1 2
3 4
Rear axle nut Tension adjuster Collar Shaft Guide wheel Slide rail suspension
Remarks Remove the parts in the order listed below. Loosen. Loosen.
2 1 2 1 For installation, reverse the removal procedure.
28
v...v. _ _________ lpOTWRRI~1 SLIDE RAIL SUSPENSION
Order
CD ® ® ®
@ @ (J)
® ®
@ @ @ @
Job/Part Slide rail suspension disassembly Stopper band Shaft Rubber collar Shock absorber Spacer Collar Oil seal Bearing Control rod assembly Spacer Collar Oil seal Bearing
Q'ty 1 1 2 1 2 2
4 2 1 2 2
4 2
29
Remarks Remove the parts in the order listed below.
SLIDE RAIL SUSPENSION
__________ lpOTWRRI~1 SLIDE RAIL SUSPENSION
Order
@ @ @ @
Job/Part
Q'ty
~.
Remarks
3 4
Guide wheel Collar Tension adjuster Rear axle shaft
2 1
For assembly, reverse the disassembly procedure.
31
_ _ _ _ _ _ _ _ _ _ pOTWRRI~1 ~
SLIDE RAIL SUSPENSION
Control rod parts number B
A
®
-++-+--++---------
-----------
llil RX1 ORTW, RX10RTRW, RX10MSW
[8] RXW10GTW [8] Control rod 1
llil
Length
® mm (in)
[Q Length @ mm (in)
© mm (in)
[Q] Length
RXW10GTW
277.3 (10.92)
150.5 (5.93)
-
RX10RTW, RX10RTRW, RX10MSW,
228.8 (9.01)
198.7 (7.82)
2.5P x 2 = 5 (O.098P x 2 = 0.196)
~ Control rod 1
[E] Control rod 2
parts number
parts number
8FR-4745A-00 (RXW10GTW)
8FU-4745B-00
~ Control rod 1
parts number 8FS-4745A-00 (RX10RTW, RX10RTRW, RX10MSW)
[8] Washer plate parts number [IJ Washer plate thickness mm (in) Q] Upper
[Kl Lower
90202-16229 2.5 (0.098)
8FU-47384-20 10.0 (0.394)
[8] Washer plate parts number [IJ Washer plate thickness mm (in)
[§] Stopper control 1 parts number
8ES-4745D-00
32
Q] Upper
[Kl Lower
90201-24015 2.0 (0.079)
90202-25001 2.0 (0.079)
__________ G_E_N_ER_A_L_S_P_E_C_IF_IC_A_T_IO_N_S_I SPEC I
g--I
SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number:
Dimensions: Overall length
Overall width
Overall height
Weight: Dry weight
Minimum turning radius: Clockwise Counterclockwise
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW 8GT1 8GU1 8GV1 8GY1
(RX1 ORTW for U.S.A) (RX1 ORTRW for U.S.A) (RXW1 OGTW for U.S.A) (RX1 OMSW for U.S.A)
2,805 mm (110.4 in) (RX10RTW, RX10RTRW) 3,000 mm (118.1 in) (RXW10GTW) 3,330 mm (131.1 in) (RX10MSW) 1,225 mm (48.2 in) (RX10RTW, RX10RTRW, RXW10GTW) 1,165 mm (45.9 in) (RX10MSW) 1,075 mm (42.3 in) (RX10RTW, RX10RTRW) 1,160 mm (45.7 in) (RXW10GTW) 1,185 mm (46.7 in) (RX10MSW) 257 260 269 281
kg kg kg kg
4.1 4.0 4.1 4.0
m m m m
(567 (573 (593 (620
(13.1 (13.5 (13.1 (13.5
Ib) Ib) Ib) Ib) ft) ft) ft) ft)
(RX10RTW) (RX10RTRW) (RXW10GTW) (RX10MSW)
(RX10RTW, RX10RTRW, RXW10GTW) (RX10MSW) (RX10RTW, RX10RTRW, RXW10GTW) (RX10MSW)
Engine: Engine type Liquid-cooled, 4-stroke, DOHC Cylinder type Backward-inclined parallel 4-cylinder Displacement 998 cm 3 (60.9 cu.in) Bore x stroke 74 x 58 mm (2.91 x 2.28 in) Compression ratio 11.8 Maximum hose power r/min 10,500 r/min Maximum torque r/min 9,000 r/min Standard compression pressure 1,450 kPa (14.5 kg/cm 2 , 206 psi) at 400 r/min (at sea level) Starting system Electric starter Lubrication system: Engine oil: Type Oil capacity Periodic oil change With oil filter replacement Total amount Oil filter: Oil filter type
Dry sump API SE, SF, SG or higher SAEOW-30 2.8 L (2.5 Imp qt, 3.0 US qt) 3.0 L (2.6 Imp qt, 3.2 US qt) 3.8 L (3.3 Imp qt, 4.0 US qt) Cartridge (paper)
33
__________ G_E_N_ER_A_L_S_P_E_C_IF_IC_A_T_IO_N_S_I SPEC I Model Drive chain housing oil: Type Capacity Coolant: Capacity
Fuel: Type Tank capacity
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW Gear oil API "GL-3" SAE#75 or #80 0.25 L (8.8 Imp OZ, 8.5 US oz) 6.0 L (5.29 Imp qt, 6.34 US qt) (RX10RTW, RX10RTRW, RXW10GTW) 6.4 L (5.64 Imp qt, 6.76 US qt) (RX10MSW) Regular unleaded gasoline (Pump Octane R;M; 86 or higher) 38.3 L (8.4 Imp gal, 10.1 US gal)
Carburetors: Type/Quantity Manufacture
39EIDW x 2 MIKUNI
Spark plug: Type Manufacture Gap
NGK CR9EB NGK 0.7 . . . 0.8 mm (0.028 . . . 0.031 in)
Primary reduction: Primary reduction system Primary reduction ratio (driven/drive gear) Transmission: Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio
Reverse system Chassis: Frame type Caster angle Ski stance (center to center)
Suspension: Front suspension type Rear suspension type
g--I
Spur gear 1.23 (37/30)
V-Belt 3.8 : 1 . . . 1 : 1 Automatic centrifugal engagement Chain 1.58 (38/24) (RX10RTW, RX10RTRW) 1.65 (38/23) (RXW10GTW) 2.00 (40/20) (RX10MSW) No (RX1 ORTW, RX10MSW) Yes (RX10RTRW, RXW10GTW) Monocoque 23° 1,086 mm (42.7 in) (RX10RTW, RX10RTRW, RXW10GTW) 980 mm (38.6 in) (RX10MSW) Independent double wishbone suspension Slide rail suspension
34
__________ G_E_N_ER_A_L_S_P_E_C_IF_IC_A_T_IO_N_S_I SPEC I Model Track: Track type Track width Length on ground
Track deflection at 100 N (10 kg, 221b)
g--I
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW Internal drive type 381 mm (15.0 in) (RX1 ORTW, RX10RTRW, RXW10GTW) 406 mm (16.0 in) (RX10MSW) 723 mm (28.5 in) (RX10RTW, RX10RTRW) 960 mm (37.8 in) (RXW10GTW) 1,201 mm (47.3 in) (RX10MSW) 30 ~ 35 mm (1.18 ~ 1.38 in) (RX10RTW, RX10RTRW, RX10MSW) 25 ~ 30 mm (0.98 ~ 1.18 in) (RXW10GTW)
Brake: Brake type Operation method
Caliper type disc brake Handlebar, left hand operated
Electrical: Ignition system Generator system
DC-T.C.I/MITSUBISHI A.C. magneto
Bulb wattage x Quantity: Headlight Tail/Brake light Meter light High beam indicator light Information indicator light Low coolant temperature light
12 V, 60 W / 55 W x 2 LED LED LED LED LED
35
_ _ _ _ _ _ _ _M_A_I_NT_E_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_I SPEC I
g--I
MAINTENANCE SPECIFICATIONS ENGINE Model Cylinder head: Volume (with spark plug) <Warpage limit>
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW 13.45 ..... 14.05 cm 3 (0.82 ..... 0.86 cu. in) 0.1 mm (0.04 in) * Lines indicate straight edge measurement.
Cylinder: Material Bore size <Taper limit> <Out of round> <Wear limit> Camshaft: Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance
Aluminum alloy with dispersion coating 74.000 ..... 74.010 mm (2.9134 ..... 2.9138 in) 0.05 mm (0.002 in) 0.05 mm (0.002 in) 74.06 mm (2.9157 in) Chain drive (left) 24.500 24.521 mm (0.9646 0.9654 in) 24.459 24.472 mm (0.9630 0.9635 in) 0.028 ..... 0.062 mm (0.0011 ..... 0.0024 in)
Camshaft dimensions Intake "A" <Limit> "B" <Limit> Exhaust "A" <Limit> "B" f---B<Limit>
32.95 32.85 24.96 24.86 33.60 33.50 24.96 24.86
Camshaft runout
0.03 mm (0.0012 in)
Timing chain: Model/number of links Tensioning system
RH2015/130 Automatic
Valves, valve seats, valve guides: Valve clearance (cold) Intake Exhaust
0.11 0.21
..... 33.05 mm mm (1.2933 ..... 25.06 mm mm (0.9787 ..... 33.70 mm mm (1.3189 ..... 25.06 mm mm (0.9787
(1.2972 in) (0.9827 in) (1.3228 in) (0.9827 in)
0.20 mm (0.0043 0.25 mm (0.0083
36
..... 1.3012 in) ..... 0.9866 in) ..... 1.3268 in) ..... 0.9866 in)
0.0079 in) 0.0098 in)
M_A_ _NT_E_N_A_N_C_E_s_P_E_C_ F_ C_A_~_IO_N_S_ISPEC I g--I
________ Model
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
Valve dimensions: Valve head diameter A
Intake Exhaust
)\
~
22.9 24.4
23.1 mm (0.9016 24.6 mm (0.9606
0.9094 in) 0.9685 in)
~z
1.76 1.76
2.90 mm (0.0693 2.90 mm (0.0693
0.1142 in) 0.1142 in)
Head Diameter
Valve face width B Intake Exhaust
Face Width
Valve seat width C Intake Exhaust
! \
'yc
~,
0.9 0.9
1.1 mm (0.035 1.1 mm (0.035
0.043 in) 0.043 in)
0.5 0.5
0.9 mm (0.020 0.9 mm (0.020
0.035 in) 0.035 in)
Seat Width
Valve margin thickness D
I
I ~1D
Intake Exhaust
!\
Margine Thickness
Valve stem diameter Intake <Limit> Exhaust <Limit> Valve guide inside diameter Intake <Limit> Exhaust <Limit> Valve-stem-to-valve-guide clearance Intake <Limit> Exhaust <Limit> Valve stem runout limit
3.975 . . . 3.990 mm (0.1565 . . . 0.1571 in) 3.945 mm (0.1553 in) 4.465 . . . 4.480 mm (0.1758 . . . 0.1764 in) 4.43 mm (0.1744 in) 4.000 . . . 4.012 mm (0.1575 . . . 0.1580 in) 4.05 mm (0.1594 in) 4.500 . . . 4.512 mm (0.1772 . . . 0.1776 in) 4.55 mm (0.1791 in) 0.010 . . . 0.037 mm (0.0004 . . . 0.0015 in) 0.08 mm (0.0031 in) 0.020 . . . 0.047 mm (0.0008 . . . 0.0019 in) 0.10 mm (0.0039 in) 0.01 mm (0.0004 in)
~
~ VJl rr~
/////////////////////
Valve seat width Intake Exhaust
0.9 0.9
1.1 mm (0.035 1.1 mm (0.035
37
0.043 in) 0.043 in)
_ _ _ _ _ _ _ _M_A_I_NT_E_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_
I
SPEC I
g--I
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
Model Valve spring: Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust n Spring tilt -- * Intake Exhaust ~ Winding direction (top view) Intake Exhaust
Jl-----
Valve lifter: Valve lifter outside diameter Intake <Limit> Exhaust <Limit> Valve lifter hole inside diameter Intake <Limit> Exhaust <Limit>
m
Piston: Piston size (0) - - - D - --------JMeasuring point (H) I H Piston to-cylinder clearance <Limit> Piston pin bore off set Off-set direction Piston pin bore inside diameter
43.59 mm (1.72 in) 40.62 mm (1.60 in) 34.50 mm (1.36 in) 35.00 mm (1.38 in) 126 111
146 N (12.8 127 N (11.3
14.9 kg, 28.3 12.9 kg, 24.9
32.8 Ib) 28.5 Ib)
2.5°/1.9 mm (0.075 in) 2.5°/1.8 mm (0.071 in) Clockwise Clockwise
19.982 19.957 22.482 22.457
. . . 19.988 mm (0.7867 . . . 0.7869 in) mm (0.7857 in) . . . 22.488 mm (0.8851 . . . 0.8854 in) mm (0.8841 in)
20.000 20.048 22.500 22.548
. . . 20.018 mm (0.7874 . . . 0.7881 in) mm (0.7893 in) . . . 22.518 mm (0.8858 . . . 0.8865 in) mm (0.8877 in)
73.955 . . . 73.970 mm (2.9116 . . . 2.9122 in) 5 mm (0.20 in) 0.030 . . . 0.055 mm (0.0012 . . . 0.0022 in) 0.12 mm (0.0047 in) 0.5 mm (0.0197 in) Intake side 17.002 . . . 17.013 mm (0.6694 . . . 0.6698 in)
Piston pin: Piston pin outside diameter 16.991 . . . 17.000 mm (0.6689 . . . 0.6693 in) Piston pin length 51.4 . . . 51.5 mm (2.0236 . . . 2.0276 in) Piston pin to piston pin bore clearance 0.002 . . . 0.022 mm (0.00008 . . . 0.0009 in) <Limit> 0.072 mm (0.0028 in)
38
M_A_ _NT_E_N_A_N_C_E_s_P_E_C_ F_ C_A_~_IO_N_S_ISPEC I g--I
________ Model
Piston ring: Sectional sketch Top ring Ring type ~~B IT Dimensions (B x T) 2nd ring Ring type B Dimensions (B x T) I T I Oil ring
r
c=\--=r C~JB
D ·· (B x T) Imenslons End gap (installed) Top ring 2nd ring Oil ring Side clearance (installed) Top ring 2nd ring
~I
Connecting rod: Crankshaft-pin-to-big-end-bearing clearance Bearing color code Crankshaft:
Width A Width B Crankshaft runout C Big end side clearance D Crankshaft-journal-to-crankshaftjournal-bearing clearance Bearing color code Carburetor: Type/Quantity Manufacturer I.D. mark Throttle valve Engine idle speed
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
Barrel 0.90 x 2.75 mm (0.035 x 0.108 in) Taper 0.8 x 2.8 mm (0.031 x 0.110 in)
1.5 x 2.5 mm (0.059 x 0.098 in) 0.32 0.43 0.10 0.030 0.020
0.44 mm (0.010 0.58 mm (0.017 0.35 mm (0.004
0.020 in) 0.023 in) 0.0014 in)
0.065 mm (0.0012 0.055 mm (0.0008
0.0026 in) 0.0022 in)
0.031 . . . 0.055 mm (0.0012 . . . 0.0022 in) -1
= Violet
0
= White
1 = Blue 2
= Black
3
= Brown
3
= Brown
52.40 . . . 57.25 mm (2.063 . . . 2.254 in) 300.75 . . . 302.65 mm (11.84 . . . 11.92 in) 0.03 mm (0.0012 in) 0.160 0.262 mm (0.006 . . . 0.010 in) 0.031 0.055 mm (0.0012 . . . 0.0022 in) -1
= Violet
0
= White
1 = Blue 2
= Black
39EIDW X 2 MIKUNI 8FP1 02 #100 1,500 ± 100 r/min (1 ,400 . . . 1,600 r/min)
Fuel pump: Type Manufacturer
Electrical 8FP (DENSO)
Oil filter: Oil filter type Bypass valve opening pressure
Cartridge (paper) 78 . . . 118 kPa (0.78 . . . 1.18 kg/cm 2 , 11.1 . . . 16.8 psi)
39
_ _ _ _ _ _ _ _M_A_I_NT_E_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_I SPEC I Model
g--I
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
Oil pump: Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Max. impeller shaft tilt <Limit> Relief valve operating pressure Oil pressure (hot) Cooling system: Radiator capacity Radiator core Width Height Depth Filler cap opening pressure Water pump type Reduction ratio Coolant type
Trochoidal 0.00 . . . 0.12 mm (0.000 . . . 0.005 in) 0.09 . . . 0.15 mm (0.004 . . . 0.006 in) 0.15 mm (0.0059 in) 0.072 mm (0.0028 in) 430 . . . 550 kPa (4.3 . . . 5.5 kg/cm 2 , 61.2 . . . 78.2 psi) 50 kPa (0.5 kg/cm 2 , 7.1 psi) at 1,450 r/min 0.3 L (0.26 Imp qt, 0.32 US qt)
Coolant mixing ratio (coolant: water) Capacity
Transmission: Type Range of ratio Engagement speed r/min Shift r/min Sheave distance Sheave offset V-belt: Part number/Manufacturer ~ A Circumference i B Width "A" Wear limit "B" I
130.2 mm (5.13 in) 140.0 mm (5.51 in) 28.0 mm (1.10 in) 95 . . . 125 kPa (0.95 . . . 1.25 kg/cm 2 , 14 . . . 18 psi) Single-suction centrifugal pump (Impeller type) 37/31 x 23/18 (1.525) High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors 3 : 2 (60% : 40%) 6.0 L (5.29 Imp qt, 6.34 US qt) (RX10RTW, RX10RTRW, RXW10GTW) 6.4 L (5.64 Imp qt, 6.76 US qt) (RX10MSW) V-belt automatic 3.8 . . . 1.0 : 1 3,500 Âą 200 r/min (3,300 . . . 3,700 r/min) 10,500 Âą 250 r/min (10,250 . . . 10,750 r/min) 268.5 mm (10.57 in) (267 . . . 270 mm (10.51 . . . 10.63 in)) 13.5 . . . 16.5 mm (0.53 . . . 0.65 in)
II
CJ
8DN-17641-00/MITSUBOSHI 1,129 . . . 1,137 mm (44.4 . . . 44.8 in) 34.5 mm (1.36 in) 32.5 mm (1.28 in)
40
M_A_ _NT_E_N_A_N_C_E_s_P_E_C_ F_ C_A_~_IO_N_S_ISPEC I g--I
________ POWER TRAIN Model Primary sheave spring: Part number Color code
Diameter Wire diameter Preload Spring rate
Number of coils Free length
Set length Primary sheave weight arm: Part number (with bush) Weight (without bush and rivets) Rivet: Outer Part number Material Size Quantity Hole quantity Center Part number Material Size Quantity Hole quantity Inner Part number Material Size Quantity Hole quantity
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW 90501-582L1 (RX10RTW, RX10RTRW, RXW10GTW) 90501-583L4 (RX1 OMSW) Yellow - Silver - Yellow (RX1 ORTW, RX10RTRW, RXW10GTW) White - Silver - White (RX10MSW) 59.5 mm (2.34 in) 5.8 mm (0.228 in) 343 N (35 kg, 77 Ib) 24.5 N/mm (2.50 kg/mm, 140 Ib/in) (RX10RTW, RX10RTRW, RXW10GTW) 22.1 N/mm (2.25 kg/mm, 126Ib/in) (RX10MSW) 4.92 87.4 mm (3.44 in) (RX10RTW, RX10RTRW, RXW10GTW) 89.0 mm (3.50 in) (RX10MSW) 73.4 mm (2.89 in) 8FP-17605-00 67.81 g (2.392 oz)
90261 -06033 Steel 17.2 mm (0.677 in) 3 3 90261 -06033 Steel 17.2 mm (0.677 in) 3 3 90261 -06033 Steel 17.2 mm (0.677 in) 3 3
41
_ _ _ _ _ _ _ _M_A_I_NT_E_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_ Model
I
SPEC I
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
Secondary sheave spring: Part number
90508-60012 (RX10RTW, RX10RTRW) 90508-60007 (RXW1 OGTW, RX10MSW) PINK (RX10RTW, RX10RTRW) White (RXW10GTW, RX10MSW) 69.5 mm (2.736 in) 6 mm (0.236 in)
Color code
Outside diameter Wire diameter Hole position Sheave side-spring side (twist angle) 1-6 (70°) (RX10RTW, RX10RTRW) 3-3 (60°) (RXW10GTW, RX10MSW) \0
Spring rate
Number of coils Free length Torque cam angle Drive chain: Type Number of links Secondary reduction ratio
g--I
11.88 N/mm (1.211 kg/mm, 67.80 Ib/in) (RX10RTW, RX10RTRW) 12.66 N/mm (1.290 kg/mm, 72.25 Ib/in) (RXW10GTW, RX10MSW) 5.53 (RX1 ORTW, RX10RTRW, RXW10GTW) 5.19 (RX10MSW) 75 mm (2.95 in) 51 ° - 43 Borg Warner Automotive 23RH303-70ASM 70 L 38/24 (1.58) (RX10RTW, RX10RTRW) 38/23 (1.65) (RXW10GTW) 40/20 (2.00) (RX10MSW)
42
M_A_ _NT_E_N_A_N_C_E_s_P_E_C_ F_ C_A_~_IO_N_S_ISPEC I g--I
________ Model
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
Track: Part number
8FA-47110-00 (RX10RTW, RX10RTRW) 8FG-47110-00 (RXW10GTW) 8FS-47110-00 (RX10MSW) Width 381 mm (15.0 in) (RX1 ORTW, RX10RTRW, RXW10GTW) 406 mm (16.0 in) (RX10MSW) Length 3,072 mm (120.9 in) (RX10RTW, RX10RTRW) 3,456 mm (136.1 in) (RXW10GTW) 4,115 mm (162.0 in) (RX10MSW) Pitch 64 mm (2.52 in) (RX10RTW, RX10RTRW, RXW10GTW) 76.2 mm (3.00 in) (RX10MSW) Number of links 48 (RX10RTW, RX10RTRW) 54 (RXW1 OGTW, RX10MSW) Thickness "A" 5.1 mm (0.20 in) (RX10RTW, RX10RTRW, RXW10GTW) 5.5 mm (0.23 in) (RX10MSW) Height "8" 36.9 mm (1.45 in) (RX10RTW, RX10RTRW, RXW10GTW) 57.2 mm (2.25 in) (RX10MSW) Track deflection at 100 N (10 kg, 22 Ib) 30 ~ 35 mm (1.18 ~ 1.38 in) (RX10RTW, RX10RTRW, RX10MSW) 25 ~ 30 mm (0.98 ~ 1.18 in) (RXW10GTW)
~B
Slide rail suspension (Rear suspension): Front travel
Rear travel
Suspension spring rate Front Rear
Spring wire diameter Front
Rear Suspension setting position: Full rate adjusting position
256 mm (10.08 in) (RX10RTW, RX10RTRW, RXW10GTW) 183 mm (7.20 in) (RX10MSW) 295 mm (11.61 in) (RX10RTW, RX10RTRW) 297 mm (11.69 in) (RXW10GTW) 356 mm (14.02 in) (RX10MSW) 29.4 N/mm (3.0 kg/mm, 168 Ib/in) (RX10MSW) 58.0 N/mm (5.9 kg/mm, 331 Ib/in) (RXW10GTW) 1,900 Nmm/deg (193.61 kg/mm, 10,844 Ib/in) (RX10RTW, RX10RTRW) 1,500 Nmm/deg (152.85 kg/mm, 8,561 Ib/in) (RX10MSW) 7.8 mm (0.307 in) (RX10RTW, RX10RTRW) 12.0 mm (0.472 in) (RXW10GTW) 8.0 mm (0.315 in) (RX10MSW) 10.0 mm (0.394 in) (RX10MSW) 10.6 mm (0.417 in) (RX10RTW, RX10RTRW) M (RX10RTW, RX10RTRW, RX10MSW)
43
_ _ _ _ _ _ _ _M_A_I_NT_E_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_I SPEC I Model Shock absorber: Damping force Extension Compression Front Extension
Compression
Rear Extension
Compression
Slide runner: Thickness Wear limit Track sprocket wheel: Material Number of teeth
g--I
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW 1,069 240 . . . 949 . . . . . . 329
. . . 1,167 N/O.3 mls (108.93 . . . 118.92 kg/0.3 mIs, 262 Ib/0.3 m/s) (RXW10GTW) 1,466 N/O.3 mls (96.70 . . . 149.39 kg/0.3 mIs, 213 Ib/0.3 m/s) (RXW10GTW)
520 N/O.3 mls 620 N/O.3 mls (RX10MSW) 270 N/O.3 mls 990 N/O.3 mls (RX10MSW)
(53.00 kg/0.3 mIs, 117 Ib/0.3 m/s) (63.18 kg/0.3 mIs, 139 Ib/0.3 m/s) (27.51 kg/0.3 mIs, 61 Ib/0.3 m/s) (100.88 kg/0.3 mIs, 222 Ib/0.3 m/s)
930 N/O.3 mls (94.77 kg/0.3 mIs, 209 Ib/0.3 m/s) (RX10RTW, RX10RTRW) 790 N/O.3 mls (80.50 kg/0.3 mIs, 178 Ib/0.3 m/s) (RX10MSW) 580 . . . 970 N/O.3 mls (59.10 . . . 98.84 kg/0.3 mIs, 130 . . . 218 Ib/0.3 m/s) (RX10RTW, RX10RTRW) 460 N/O.3 mls (46.87 kg/0.3 mIs, 103 Ib/0.3 m/s) (RX10MSW) 17.8 mm (0.70 in) 10 mm (0.39 in) High molecular weight polyethylene 9 T (RX1 ORTW, RX10RTRW, RXW10GTW) 7 T (RX1 OMSW)
Rear guide wheel: Material Outside diameter
High molecular weight polyethylene with rubber 178 mm (7.01 in)
Brake: Pad thickness Pad wear limit Pad to disk clearance Disc outside diameter Disc minimum thickness
10.2 mm (0.40 in) 7.5 mm (0.30 in) 0.025 . . . 0.115 mm (0.001 . . . 0.005 in) 200 mm (7.87 in) 3.5 mm (0.14 in)
44
M_A_ _NT_E_N_A_N_C_E_s_P_E_C_ F_ C_A_~_IO_N_S_ISPEC I g--I
________ CHASSIS Model Frame: Frame material Seat height Luggage box location Steering: Lock-to-Iock angle (left)
(right)
Ski alignment Toe-out size Caster angle Ski: Ski material Length Width
Ski suspension (Front suspension): Type Travel Spring type Spring rate Wire diameter Shock absorber: damping force Extension Compression
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW Aluminum 765 mm (30.1 in) Rear 29.0° (R ski) 34.5° (L ski) RXW10GTW) 30.1 ° (R ski) 35.0° (L ski) 34.5° (R ski) 29.0° (L ski) RXW10GTW) 35.0° (R ski) 30.1 ° (L ski) Toe-out o.. . 15 mm (0 . . . 0.59 in) 23°
(RX10RTW, RX10RTRW, (RX10MSW) (RX10RTW, RX10RTRW, (RX10MSW)
Plastic 1,021 mm (40.2 in) 132.0 mm (5.20 in) (RX10RTW, RX10RTRW, RXW10GTW) 182.0 mm (7.17 in) (RX10MSW) Double wishbone system 219 mm (8.62 in) (RX10RTW, RX10RTRW, RXW10GTW) 175 mm (6.89 in) (RX10MSW) Coil spring 29.5 N/mm (3.0 kg/mm, 168lb/in) (RXW10GTW) 9.0 mm (0.354 in) (RXW10GTW)
870 N/O.3 m/s (89 kg/0.3 mIs, 195 Ib/0.3 m/s) (RXW10GTW) 520 N/O.3 m/s (53 kg/0.3 mIs, 117 Ib/0.3 m/s) (RXW10GTW)
45
_ _ _ _ _ _ _ _M_A_I_NT_E_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_I SPEC I
g--I
ELECTRICAL Model
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
Voltage
12 V
Ignition system: Ignition timing (B.T.D.C.) Advanced type
5° at 1,500 r/min Digital type
Ignition coil: Model/Manufacturer Primary coil resistance Secondary coil resistance
F6T567/MITSUBISHI 1.19 ~ 1.61 n at 20°C (68°F) 8.5 ~ 11.5 kn at 20°C (68°F)
Charging system: Type Normal output
AC magneto 14 V/35 A at 5,000 r/min
DC-T.C.I: Magneto model/Manufacturer Standard Pickup coil resistance (color code) Stator coil resistance (color code) T.C.I unit model/Manufacturer
F4T47971/MITSUBISHI 14 V 35 A, 490 W at 5,000 r/min 446 ~ 545 n at 20°C (68°F) (Gray - Black) 0.19 ~ 0.24 n at 20°C (68°F) (White - White) F8T83171/MITSUBISHI
Rectifier/ regulator: Type Model/Manufacturer No load regulated voltage (DC) Capacity (DC) Withstand voltage
Short circuit type FH001/SHINDENGEN 14.1 ~ 14.9 V 35A 40V
Battery: Specific gravity Manufacture Type Ten hour rate amperage Electric starter system: Type Starter motor: Model/Manufacturer Output Armature coil resistance Continuity check Insulation check Brush Overall length Wear limit Spring pressure Commutator diameter Wear limit Mica undercut
1.32 YUASA YTX14-BS 12V-12Ah 12 A Constant mesh type 8FP1/MORIC 12V-0.95kW 0.008 ~ 0.010 n at 20°C (68°C) More than 100 kn at 20°C (68°F) 9.8 mm (0.39 in) 5 mm (0.20 in) 7.36 ~ 11.04 N (736 28.5 mm (1.12 in) 27.5 mm (1.08 in) 1.5 mm (0.059 in)
46
~
1,104 g, 26.0
~
38.9 oz)
M_A_ _NT_E_N_A_N_C_E_s_P_E_C_ F_ C_A_~_IO_N_S_ISPEC I g--I
________ Model
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW
Starter relay: Model/Manufacturer Amperage rating Coil resistance
2768081-A/JIDECO 180 A 4.2 ~ 4.6 n at 20°C (68°F)
T.P.S. (throttle position sensor): Model/Manufacturer Resistance Oil level switch: Model/Manufacturer Fuel sender: Model/Manufacturer Sender resistance
8FAlASTI
Full Empty
Headlight relay: Model/Manufacturer Coil resistance Grip warmer: Heater resistance
TS62/146/MIKUNI 4 ~ 6 kn at 20°C (68°F) (Blue - Black/Blue)
8FP/NIPPON SEIKI 10 ~ 12 n at 20°C (68°F) 179 ~ 185 n at 20°C (68°F) 5DM/OMRON 95 ~ 116 n at 20°C (68°F) 1.83 1.83
~ ~
2.24 n at 20°C (68°F) 2.24 n at 20°C (68°F)
Thumb warmer: Heater resistance
37.0
~
45.2 n at 20°C (68°F)
Cylinder identification sensor: Model/Manufacture
5VY/NIPPON SEIKI
Crankshaft position sensor: Model/Manufacture Resistance
8FP/MITSUBISHI 445 ~ 545 n at 20°C (68°F) (between Gray and Black)
(left) (right)
Intake air pressure sensor: Model/Manufacture Intake air temperature sensor: Model/Manufacture Resistance Atmospheric pressur sensor: Model/Manufacture Throttle position sensor: Model/Manufacture Resistance Water temperature sensor: Model/Manufacturer Resistance
Indicator light Speed sensor: Mode/Manufacture
5PS/DENSO 8FP/MITSUBISHI 2.21 ~ 2.69 kn at 20°C (68°F) 5PS/DENSO TS62 146/MITSUBISHI o ~ 5 ± 1.5 kn at 20°C (68°F) (Yellow - Black/Blue)
(ON) (OFF)
8CC/MITSUBISHI 5.2 ~ 6.4 kn at O°C (34°F) 0.300 ~ 0.364 kn at 80°C (176°F) 0.170 ~ 0.208 kn at 100°C (212°F) 90 ~ 110°C (194 ~ 230°F) 85 ~ 105°C (185 ~ 221°F) 8EK/NIPPON SEIKI
47
_ _ _ _ _ _ _ _M_A_I_NT_E_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_I SPEC I Model Circuit breaker: Type Amperage for individual circuit Main fuse Fuel injection system fuse Headlight fuse Signal fuse Ignition fuse Electronic control suspension fuse Radiator fan motor fuse Backup fuse Auxiliary DC jack fuse Reserve fuse
g--I
RX10RTW, RX10RTRW, RXW10GTW, RX10MSW Fuse 40 A x 1 10 A x 1 20 A x 1 10 A x 1 20 A x 1 10 A x 1 (RXW10GTW) 4Ax1 3Ax1 3Ax1 20 A, 10 A, 4 A, 3 A x 1
48
_ _ _ _ _ _ _ _ _ _ _T_IG_H_T_E_N_IN_G_TO_R_Q_U_E_I SPEC I
g--I
TIGHTENING TORQUE ENGINE Parts to be tightened Spark plug Cylinder head nut (M1 0 x 1.25) x 2 Cylinder head nut (M1 0 x 1.25) x 6 Cylinder head nut x 2 Cylinder head bolt Camshaft cap and cylinder head Cylinder head cover Connecting rod and cap A.C. magneto rotor Crankshaft and drive gear Primary reduction gear bearing housing Timing chain tensioner Thermostat housing Water temperature sensor Timing chain tensioner cap Camshaft and camshaft sprocket Hose band Water pump Coolant reservoir tank Coolant recovery tank Radiator Pipe Oil cooler Oil pan Engine mounting adjust bolt Engine mounting nut Countershaft cover Oil pan drain bolt Oil hose and suction pipe Oil filter union bolt Oil filter Oil pump Oil pump drive chain guide Oil tank drain bolt Oil tank and frame (bolt) Oil tank and frame (nut) Oil gallery bolt Cylinder head and carburetor joint Carburetor joint and throttle bodies Throttle bodies and silencer Exhaust joint Muffler band Exhaust pipe Muffler Exhaust cover Muffler band Muffler protector Cylinder head stud bolt
Tightening torque Nm
m-kg
ft-Ib
13
1.3
9.4
20 + 121 0
2.0 + 121 0
14+ 121 0
20+105 0
2.0+105 0
14 + 105 0
0
0
14 + 140 0
20 + 140
2.0 + 140
12 10 12
1.2 1.0 1.2
8.7 7.2 8.7
20 + 120 0
2.0 + 120 0
14 + 120 0
130 75 12 10 10 23 6 24 2 12 10 10 10 10 35 10 9 65 12 30 2 30 17 12 10 16 10 19 10 3 3 3 25 9 25 16 6 20 11 10
13.0 7.5 1.2 1.0 1.0 2.3 0.6 2.4 0.2 1.2 1.0 1.0 1.0 1.0 3.5 1.0 0.9 6.5 1.2 3.0 0.2 3.0 1.7 1.2 1.0 1.6 1.0 1.9 1.0 0.3 0.3 0.3 2.5 0.9 2.5 1.6 0.6 2.0 1.1 1.0
94 54 8.7 7.2 7.2 17 4.3 17 1.4 8.7 7.2 7.2 7.2 7.2 25 7.2 6.5 47 8.7 22 1.4 22 12 8.7 7.2 11 7.2 14 7.2 2.2 2.2 2.2 18 6.5 18 11 4.3 14 8.0 7.2
49
Remarks
Left-hand thread.
_ _ _ _ _ _ _ _ _ _ _T_IG_HT_E_N_IN_G_TO_R_Q_U_E_I SPEC I Parts to be tightened Crankcase (M9 x 1.5) (1 st) (2nd) Crankcase (M6 x 1.0) Countershaft cover A.C. magneto rotor cover Starter clutch Stator coil Starter motor Pickup coil Pickup coil plate Fuel pump Oil pressure switch Cylinder identification sensor Ignition coil
Tightening torque Nm 15 15 + 65 --- 70 0
12 12 12 12 10 27 6 10 7 15 8 10
NOTE:
m-kg
ft-Ib
1.5
11
g--I
Remarks See NOTE.
1.5 + 65 --- 70 0 11 + 65 --- 70 0
1.2 1.2 1.2 1.2 1.0 2.7 0.6 1.0 0.7 1.5 0.8 1.0
8.7 8.7 8.7 8.7 7.2 20 4.3 7.2 5.1 11 5.8 7.2
Apply LOCTITE®
_
1. First, tighten the bolt to approximately 15 Nm (1.5 m-kg, 11 ft-Ib) with a torque wrench, then loosen the bolt completely. 2. Retighten the bolt to 15 Nm (1.5 m-kg, 11 ft-Ib), and tighten another 65 . . . 70° with a angle gauge.
50
_ _ _ _ _ _ _ _ _ _ _T_IG_H_T_E_N_IN_G_TO_R_Q_U_E_I SPEC I
g--I
POWER TRAIN Tightening torque
Parts to be tightened Primary sheave (1 st) (2nd) Spider and sliding sheave
Nm 120 60 200
m-kg 12.0 6.0 20.0
ft-Ib 85 43 145
Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave Stopper (secondary sheave) Spring seat (secondary sheave) Bolt (secondary sheave clearance) Drive sprocket Locknut chain tensioner Chain housing and frame Driven sprocket
14 6 64 8 23 10 90 25 48 48
1.4 0.6 6.4 0.7 2.3 1.0 9.0 2.5 4.8 4.8
10 4.3 46 5.1 17 7.2 65 18 35 35
Drain bolt (drive chain housing) Chain housing cover Shift lever assembly
16 24 23
1.6 2.4 2.3
12 17 17
Lever and drive chain housing cover
10
1.0
7.2
Shaft (reverse drive gear)
10
1.0
7.2
Reverse driven gear
55
5.5
40
Counter gear
10
1.0
7.2
Spacer set screw Chain housing and brake caliper Bleed screw (brake caliper) Brake hose union bolt (caliper side) Brake hose union bolt (brake master cylinder side) Bearing nut (secondary shaft) Parking brake Parking brake assembly and lever
6 48 6 30 30 55 10 23
0.6 4.8 0.6 3.0 3.0 5.5 1.0 2.3
4.3 35 4.3 22 22 40 7.2 17
51
Remarks Tighten the bolts in two stages. See NOTE. Left-hand thread. Apply LOCTITE®
(RX10RTW, RX10MSW) Apply LOCTITE®
(RX1 ORTW, RX10RTRW, RXW10GTW) (RX1 ORTW, RX10RTRW, RXW10GTW) Apply LOCTITE® (RX10RTRW, RXW10GTW) Apply LOCTITE® (RX10RTRW, RXW10GTW) Apply LOCTITE® (RX10RTRW, RXW10GTW) Apply LOCTITE® Apply LOCTITE®
_ _ _ _ _ _ _ _ _ _ _T_IG_HT_E_N_IN_G_TO_R_Q_U_E_I SPEC I Tightening torque
Parts to be tightened (RXW10GTW) Front pivot arm and frame Front pivot arm and shockabsorber Front pivot arm and stopper band Shaft and stopper band Sliding runner and sliding frame Suspension wheel and sliding frame Front pivot arm and control rod Front pivot arm bracket and sliding frame Front pivot arm and bracket Rear pivot arm and shockabsorber Rear pivot arm bracket and control rod Rear pivot arm and frame Shaft and frame Rear pivot arm and rear pivot arm bracket Rear pivot arm bracket and sliding frame Rear axle (RX10RTW, RX10RTRW, RX10MSW) Front pivot arm and frame Front pivot arm and front shockabsorber Front pivot arm and stopper band Shaft and stopper band Shaft and sliding frame Suspension wheel assembly and sliding frame Front pivot arm and sliding frame Suspension wheel and sliding frame Rear pivot arm and sliding frame Bracketandfrontshockabsorber Front pivot arm bracket and bracket Front pivot arm and bracket Bracket and rear shockabsorber Relay rod and rear pivot arm Rear pivot arm and rear shockabsorber Rear pivot arm and frame Suspension wheel and sliding frame Pivot shaft and sliding frame Rear axle Speed sensor Gear unit (speed sensor)
Nm
m-kg
ft-Ib
60 49 4 4 10 60 74 30 72 49 74 84 84 72 72 75
6.0 4.9 0.4 0.4 1.0 6.0 7.4 3.0 7.2 4.9 7.4 8.4 8.4 7.2 7.2 7.5
43 35 2.9 2.9 7.2 43 53 22 52 35 53 61 61 52 52 54
72 49 4 4 60 60 60 60 72 49 72 72 49 49 49 72 60 72 75 20 40
7.2 4.9 0.4 0.4 6.0 6.0 6.0 6.0 7.2 4.9 7.2 7.2 4.9 4.9 4.9 7.2 6.0 7.2 7.5 2.0 4.0
52 35 2.9 2.9 43 43 43 43 52 35 52 52 35 35 35 52 43 52 54 14 29
NOTE:
g--I
Remarks
Apply Apply Apply Apply
LOCTITE速 LOCTITE速 LOCTITE速 LOCTITE速
_
Tightening steps: 1. Tighten the bolt to a torque at 120 Nm (12.0 m-kg, 85 ft-Ib). 2. Loosen the bolt completely. 3. Retighten the bolt to a torque of 60 Nm (6.0 m-kg, 43 ft-Ib).
52
_ _ _ _ _ _ _ _ _ _ _T_IG_H_T_E_N_IN_G_TO_R_Q_U_E_I SPEC I CHASSIS Tightening torque
Parts to be tightened Handlebar holder Steering joint cover Steering column Upper Lower Steering column 2 and steering shaft Steering shaft and steering column 1 Steering column 1 and relay rod Relay rod and relay arm Relay arm and idler arm Idler arm and tie rod Tie rod and steering arm Idler arm Locknut (relay rod/tie rod) Ski Ski runner Ski and ski handle (front) Ski and ski handle (rear) Shock absorber (upper) Shock absorber (lower) Steering arm locknut Upper arm and frame Upper arm and knuckle Lower arm and frame Lower arm and knuckle Stabilizer bar and stabilizer arm Stabilizer arm and connecting rod Connecting rod and lower arm Frame cross member Frame cross member and steering bracket Master cylinder assembly Brake lever adjuster locknut Rear cover Seat and frame Headlight stay
53
Nm
m-kg
15 3
1.5 0.3
ft-Ib 11 2.2
23 23 35 35 35 30 35 30 35 67 25 48 19 12 17 45 45 35 37 40 37 65 11 34 34 23 47 10 6 4 7 7
2.3 2.3 3.5 3.5 3.5 3.0 3.5 3.0 3.5 6.7 2.5 4.8 1.9 1.2 1.7 4.5 4.5 3.5 3.7 4.0 3.7 6.5 1.1 3.4 3.4 2.3 4.7 1.0 0.6 0.4 0.7 0.7
17 17 25 25 25 22 25 22 25 49 18 35 14 8.7 12 33 33 25 27 29 27 47 8.0 25 25 17 34 7.2 4.3 2.9 5.1 5.1
Remarks
g--I
_
_ _ _ _ _ _G_E_N_E_R_A_L_T_O_R_Q_U_E_S_P_EC_I_F_IC_A_T_I0 _N_S_'_I SPEC DEFINITION OF UNITS
GENERAL TORQUE SPECIFICATIONS
A
B (bolt)
(nut)
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
10 12 14 17 19 22
mm mm mm mm mm mm
6mm 8mm 10 mm 12 mm 14 mm 16 mm
1.--.1 ~
General torque specifications Nm m-kg ft-Ib 6 0.6 4.3 15 1.5 11 30 3.0 22 55 5.5 40 85 8.5 61 130 13.0 94
r
A L ____
A: Distance across flats B: Outside thread diameter
DEFINITION OF UNITS Unit
Read
Definition
mm cm
Millimeter Centimeter
10-3 meter
kg
Kilogram
103 gram
Measurement Length Length
10-2 meter
Weight 2
N
Newton
1 kg x m/sec
Nm m-kg
Newton meter Meter kilogram
Nxm m x kg
Pa N/mm
Pascal N/m 2 Newtons per millimeter N/mm
Pressure Spring rate
L cm 3
Liter Cubic centimeter
-
Volume or capacity
r/min
Rotations per minute
-
Engine speed
54
-
Force Torque Torque
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
g--I
45
~
~
C
A
23 24 5
c 55
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CABLE ROUTING
CD Clamp the A.C. magneto lead and wire harness ground lead. ® Clamp the wire harness and A.C. magnet lead to the raised portion of the battery bracket. Battery positive lead @Main fuse ® Main harness @ Battery negative lead (J) Flange bolt Clamp the wire harness to the steering gate clamp. Make sure to place the wire harness junction at the rear end behind the clamp. Fit it to the sub-lead wire 3. @Clamp @ Route the sub-lead wire 3 and cell motor positive lead over the battery bracket and clamp them to the battery bracket. @ Oil level switch lead coupler @ Oil level switch @ Point both clips at two points upward. @Clip @Pipe2 @ Coolant temperature sensor lead coupler @ To the brake caliper. @ Main switch lead coupler @ To the heat exchanger @Clip @ Route the tail/brake light leads over the raised portion. @Fuel pipe @Clamp @ Place the damper locating between the fuel tank and sheet. @ To the tail/brake light. @ Sub-wire harness @Brake hose @ To the handlebar switch
®
®
®
56
g--I
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
g--I
45
~ 3h': ,
~'
\
BB
c 57
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I @ Auxiliary DC jack coupler The auxiliary DC jack coupler must be located on the wire harness. @ Fuel sender lead cover @ Headlight lead coupler @ To the meter assembly. @ Clamp the headlight lead. Rout the headlight stay. <® Align the hole of dia. 3 mm (0.12 in) of the steering gate with the white tape position of the harness and secure them. Install the 12 pin connector to the top surface. @ Fit it to the extension wire harness. @ To the headlight. @ Drive guard bracket Attach the battery negative lead to the cell motor fixing bolt. @) Front cover @Screw @ Rectifier/regulator @ Flange bolt @ Put the boots of the meter coupler in the boss root on the side of the meter. @ Fuel injection system relay @ Headlight relay @Load relay @ Radiator fan motor relay @ Installation position of each relay can be selected freely. @) Clamp the wire harness and speed sensor lead. (Be sure to fold so that the harnesses cannot be disconnected.) @ Sub-wire lead (ignition coil lead) @ Wire harness @ Clamp the ignition coil lead so that it can be set within this range. (It should not be caught between the wire harness and steering gate.) @ Clamp the leads of the radiator fan motor and back buzzer and then fold the clamp by 90 degrees.
®
®
58
g--I
CABLE ROUTING
29
AA
59
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CD
Right handlebar switch (g)Tube lead @ Handlebar holder (Route the wire harness, throttle cable.) Parking brake cable ® Left handlebar switch @ Pass all the wire harness, brake hose, brake cable and throttle cable through it. Arrange the line of cables and hoses as shown in the illustration and they should not lap over each other. (j) Pass all the wire harness, brake hose, brake cable and throttle cable through it. @ Clamp the cover and bearing holder. Auxiliary DC jack @ Clamp the steering gate and fuel tank breather hose. @ After fitting, bundle the couplers of the brake light switch, lever holder 1, lever holder 3, thumb warmer, head light beam switch, lever holder 2, grip warmer x 2, grip warmer switch handle and thumb warmer switch handle with the cover, and then close at two points of bosses. Fit the wire harness from the handle with the wire harness of the white tape.
®
®
60
g--I
CABLE ROUTING
29
AA
61
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I @ Route
the fuel tank breather hose along the steering gate. @ Clamp the compression spring section of the fuel tank breather hose. @) Compression spring @ Point the clip position to the upward. @ Insert the fuel tank breather hose until it contacts the projection. To insert the hose, it is allowed to apply oils. @ To the speed sensor. @) Clamp the back buzzer lead. @ Back buzzer (RX10RTRW, RXW10GTW) @ Clamp the radiator fan motor lead and back buzzer lead. @ To the parking brake. @ To the brake caliper. @Brake hose @ Clamp the fuel tank breather hose. @ Bind the two tube leads on the steering column side at one point by wrapping the tape (black) 3 to 5 turns. The end section of tape should not be peeled. @ Main switch @ Flange nut @ Hexagon bolt @ Route the lead by the inside of the wire harness and sub-wire lead (ignition coil lead). @ Clamp the wire harness, cylinder identification sensor (together with the connector cover) and sub-lead wire (ignition coil lead). @ Cylinder identification sensor @ Clamp the wire harness and sub-wire lead (ignition coil lead).
62
g--I
___________
26
---.:C=A=B::L:.E.:.:R~O~UT~I~NG~ SPEC I g--I I
A 63
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CD Route the fuel tank breather hose behind the steering gate. ® Wire harness @Bracket ® When the gear position switch lead is equipped with reverse, route it to the reverse gear. If it is not equipped with reverse, insert it to the inner side. @Fuse box @ Coolant reservoir tank (j)Clamp @Brake hose Parking brake cable @ After clamping, bend it 90 0 downward. @Clamp @ Clamp the hose at the white paint position. Point the clamp position to the front outside. @ Clamp the battery positive lead and battery negative lead. @) Latch @ Engine oil tank hose @ Point the clamp tightening direction to the downward. @Drain hose @) Less than 30 mm (1.2 in). @ Pass the coolant reservoir tank breather hose through between engine and heat exchanger. @ To the tail/brake light. @ Pass the wire harness and unused lead for the electronic rear suspension between the ribs of side cover 2 and frame. @ Clamp the wire harness and radiator fan motor lead. Tighten the frame cross member and frame together. @ Pass the electronic rear suspension sub-lead between the guide plate for the reverase lever and the frame. @ Point the clamp position to the downward. @ Point the clamp position to the inside. @ Clamp the leads before the fixture.
®
64
g--I
~CA~B~L=E~R~O~UT~I~NG~ SPEC I g--I
___________
2
65
I
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CD Coolant recovery tank ® Coolant reservoir tank
@ 10 ,..; 30 mm (0.4 ,..; 1.2 in) @20,..; 40 mm (0.8,..; 1.6 in) ® Clamp the fuel pipe and subwire lead. @ Pass the fuel tank breather hose between the relay harness and the speed sensor harness. (j) Two harness untis should not contact the pipe end. @ Clamp the fuel tank breather hose and two wire harness. Tighten the frame cross member and frame. Clamp the fuel pipe, sub-wire lead, speed sensor lead and relay harness. @ Wire harness clamp @ Speed sensor @ Nylon nuts @ Point the pawl of clip to the downward.
®
66
g--I
CABLE ROUTING
67
I SPEC I
g--I
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC I
CD Tail/brake light lead coupler (Place the tail/brake light lead coupler leads so that they are not caught between the seat bottom and taillight bracket.) Tail/brake light lead coupler (RX10MSW) @ Clamp (RX10MSW) Tail/brake light lead (RX10MSW) ® Tail/brake light lead cover (RX10MSW) @ Cover plate (RX10MSW) (j) Rear frame (RX10MSW) @ Protector (RX1 OMSW)
® ®
68
g--I
cD A.C. magneto ®
Rectifier/regulator Main switch @ Load relay ® Fuse (MAIN) ® Fuse (FUEL INJECTION SYSTEM) (J) Starter relay ® Starter motor ® Battery @ Diode @ Engine stop switch @ Throttle switch @ Grip warmer @ Thumb warmer @ Oil presser switch @ Fuse (ELECTRONIC CONTROL SUSPENSION) (RXW10GTW) @ Electronic control suspension solenoid (RXW10GTW) @ E.C.U. @ Ignition coil #1 ® Ignition coil #2 @ Ignition coil #3 @ Ignition coil #4 @ Spark plug @ Fuel injection relay @ Injector #1 @ Injector #2 @ Injector #3 @ Injector #4 @ Fuel pump @ Throttle position sensor @ Speed sensor @ Cylinder identification sensor @ Intake air pressure sensor @) Atmospheric pressure sensor ® Water temperature sensor ® Intake air temperature sensor @ Grip warmer switch ® Thumb warmer switch @ Body ground @ Back buzzer (RX10RTRW, RXW10GTW) @ Gear position switch (RX10RTRW, RXW10GTW) @ Brake light switch ® Tail/brake light @ Fuse (AUXILIARY DC JACK) @ Fuse (HEADLIGHT) @ Fuse (SIGNAL) @ Fuse (RADIATOR FAN MOTOR) @ Fuse (BACK UP) @ Fuse (IGNITION) ® Auxiliary DC jack @ Radiator fan motor relay © Radiator fan motor @ Headlight beam switch ~ Headlight relay ® Headlight ® Meter assembly @ Multi-function meter ® Warning light @ Water temperature indicator light (@ Hi beam indicator light @) Meter light @ Oil level switch @ Fuel sender
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COLOR CODE B. . . . .. Br . . . .. Ch . . . .. G. . . . .. Gy. . . .. L Lg . . . .. O. . . . .. P...... R W Y...... B/L . . .. B/R . . .. B/Y . . .. Br/G . .. Br/L. . .. Br/W. .. Br/Y . .. G/B. . .. G/R. . .. G/W . .. G/Y. . .. Gy/R. .. L/B . . .. L/R . . .. L/W. . .. L/Y . . .. Lg/B . .. Lg/W. .. O/B. . .. O/G. . .. OIL . . .. O/R. . .. O/W . .. P/W . .. R/B . . .. R/G. . .. R/L . . .. R/W . .. R/Y . . .. W/B . .. Y/G. . .. Y/L . . .. Y/R. . ..
Black Brown Chocolate Green Gray Blue Light green Orange Pink Red White Yellow Black/Blue Black/Red Black/Yellow Brown/Green Brown/Blue Brown/White Brown/Yellow Green/Black Green/Red Green/White Green/Yellow Gray/Red Blue/Black Blue/Red Blue/White Blue/Yellow Light green/Black Light green/White Orange/Black Orange/Green Orange/Blue Orange/Red Orange/White Pink/White Red/Black Red/Green Red/Blue Red/White Red/Yellow White/Black Yellow/Green Yellow/Blue Yellow/Red
I
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the RX10PA, RX10PSA, RX10PXTA. For complete information, on service procedures, it is necessary to use this Supplementary Service Manual together with following manual: RX10H, RX10SH, RX10MH, RX10MSH, RX10RH, RX10RSH SERVICE MANUAL: 8FA-28197-10 (LIT-12618-02-28) RXW10J, RXW10SJ SUPPLEMENTARY SERVICE MANUAL: 8FG-28197-10 (LIT-12618-02-33) RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK, RX10MK, RX10MSK SUPPLEMENTARY SERVICE MANUAL: 8FV-28197-10 (LIT-12618-02-39) RX10RTL, RX10RL, RX10RTRL, RX10GTL, RXW10L, RX10ML SUPPLEMENTARY SERVICE MANUAL: 8FS-28197-10 (LIT-12618-02-44) RX10RTW, RX10RTRW, RXW10GTW, RX10MSW SUPPLEMENTARY SERVICE MANUAL: 8GY-28197-10 (LIT-12618-02-53)
RX10PA,RX10PSA,RX10PXTA SUPPLEMENTARY SERVICE MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N.LIT-12618-02-97
MAJOR SPECIFICATIONS Model
RX10PA
RX10PSA
RX10PXTA
Model code
8HG1
8JC1
8HN1
Catalogue name
Apex
Apex SE
Apex XTX
Class
Trail
Cross Country
Seati ng capacity
One
Engine type
Liquid cooled 4-stroke, 20 valves
Cylinder arrangement/ Displacement
Backward-inclined parallel 4-cylinder/998 cm 3
Fuel system type
Electronic fuel injection
Track length
3,264.4 mm (128 in)
Front suspension
Independent, double wishbone
Front shock absorber
Fox速 FLOATTM 2 (air shock)
40 mm aluminum HPG
Mono Shock速 II RA 128
Rear suspension Front Rear shock absorber
3,648.5 mm (144 in)
Rear
Dual Shock速 CK 144 40 mm aluminum HPG
-
46 mm KYB@ aluminum HPG with remote damping force adjuster
40 mm aluminum HPG
Fox速 MEGA-FLOATTM (air shock)
40 mm aluminum HPG
Ski type
Lightweight plastic, saddleless design
Electric start
Standard
Reverse
Standard
IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha snowmobiles should have a basic understanding of mechanics and the techniques to repair these types of snowmobiles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the snowmobile unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the snowmobile will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his snowmobile and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. TIP _ â&#x20AC;˘ This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. â&#x20AC;˘ Designs and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the snowmobile or other property. TIP
A TIP provides key information to make procedures easier or clearer.
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ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Periodic inspection and adjustment @ Chassis @ Power train ® Engine @ Cooling system (J) Fuel injection system ® Electrical ® Specifications
®
Illustrated symbols @ to @ are used to identify the specifications which appear. @ Filling fluid @Lubricant @ Tightening torque @ Wear limit, clearance @ Engine speed @ Special tool @ Electrical data (0, V, A)
1
1
m m
1
B @
Illustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point. @ Apply locking agent (LOCTITE®)
@ Apply Yamabond No. 5® @ Apply engine oil @ Apply gear oil @ Apply molybdenum disulfide oil @ Apply brake fluid @ Apply wheel bearing grease @ Apply low-temperature lithium-soap-based grease
@ Apply molybdenum disulfide grease @ Apply silicone grease @ ESSO beacon 325 grease or Aeroshell grease #7A @Use new one
CONTENTS GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS
~ GEN INFO
Q INSP ADJ
J.. CHAS
([D POWER TRAIN
POWR TR
ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SPECIFICATIONS
FI
~
CHAPTER 1. GENERAL INFORMATION
CHAPTER 4. POWER TRAIN
FEATURES OIL PRESSURE SENSING SYSTEM
1 1
SPECIAL TOOLS FOR FUEL INJECTION SERVICE
2 2
CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT ENGINE THROTTLE BODY SYNCHRONIZATION ENGINE OIL REPLACEMENT EXHAUST SYSTEM INSPECTION EXUP CABLE ADJUSTMENT EXUP SERVO MOTOR INSPECTION TRACK TENSION ADJUSTMENT EXTROVERT SPROCKET WHEELS LUBRICATION TUNING CLUTCH GEAR SELECTION HIGH ALTITUDE TUNING FRONT SUSPENSiON REAR SUSPENSiON TROUBLESHOOTI NG (SKI, SUSPENSION)
3 3 5 10 12 15 16 18 19 20 20 31 32 34 38 49
CHAPTER 3. CHASSIS GENERAL CHASSiS WINDSHIELD AND HEADLIGHT AIR FILTER CASE SEAT AND TAIL/BRAKE LIGHT
52 52 53 54
STEERING STEERING REMOVAL INSPECTION INSTALLATION
55 55 57 57 58
SLIDE RAIL SUSPENSION INSPECTION INSTALLATION
66 68 68
CHAPTER 5. ENGINE EXHAUST PIPE AND MUFFLER INSTALLATION
70 73
CAMSHAFTS INSPECTION INSTALLATION
79 79 83
CRANKCASE
87
CHAPTER 7. FUEL INJECTION SYSTEM FUEL INJECTION SySTEM WIRING DIAGRAM ECU SELF-DIAGNOSTIC FUNCTION SELF-DIAGNOSTIC FUNCTION TABLE TROUBLESHOOTING CHART DIAGNOSTIC MODE TROUBLESHOOTING DETAILS OIL PRESSURE SENSING SYSTEM TROUBLESHOOTING ISC (IDLE SPEED CONTROL) UNIT
88 89
108 109
THROTTLE BODy THROTTLE BODy INJECTORS REMOVAL INSPECTION INSPECTION AND ADJUSTMENT
110 110 112 113 113 114
91 91 94 95 104
CHAPTER 8. ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION
116 116
KNOCK SENSOR
117
EPS (ELECTRIC POWER STEERING) SYSTEM CIRCUIT DIAGRAM EPS CONTROL UNIT'S SELF-DIAGNOSTIC FUNCTION EPS WARNING DISPLAY DURING NORMAL OPERATION DIAGNOSTIC MODE SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM) TROUBLESHOOTING DETAILS (EPS SySTEM) EPS MOTOR INSPECTION EPS TORQUE SENSOR INSPECTION
118 118 119 120 121 124 125 129 129
CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS
131
MAINTENANCE SPECIFICATIONS ENGINE POWER TRAIN CHASSIS ELECTRiCAL
132 132 132 135 136
GENERAL TORQUE SPECIFICATIONS
137
DEFINITION OF UNITS
137
TIGHTENING TORQUE ENGINE POWER TRAIN CHASSIS
138 138 139 140
CABLE ROUTING
141
FEATURES
GENERAL INFORMATION FEATURES OIL PRESSURE SENSING SYSTEM This model is equipped with an oil pressure sensing system. When the oil pressure drops, the rpm limiter is activated, and the engine rpm is reduced, or the engine is shut off, if necessary. If the oil pressure is incorrect upon starting the engine 1. "OP-LO" CD appears and the oil level/pressure warning indicator ÂŽ illuminates on the meter display.
2. When the two items, above, are displayed, they indicate the rpm limiter is in operation; the rpm is reduced to less than or equal to the clutch engagement rpm, even though the throttle is open. If the incorrect oil pressure persists, the engine stops automatically after approximately one minute. 3. When the oil pressure stabilizes to the correct level, the limiter is automatically canceled as long as the throttle is not operated and then "OP-LO" disappears and the oil level/pressure warning indicator goes off. 4. Note that it may take a few seconds for the oil pressure to rise to the optimum level after the engine is started, even in normal conditions. If the meter display described in (1.) is no longer displayed after a few seconds, this indicates that everything is normal. TIP _ When disassembling the engine, replacing the engine oil or oil filter, etc., if the oil is drained entirely from the piping, there may be delay before the oil pressure rises.
1
_____________S_P_E_C_IA_L_T_O_O_LS_II~~~I~I SPECIAL TOOLS Some special tools are necessary for a completely accurate tuneup and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. TIP _ • Be sure to use the correct part number when ordering the tool, since the part number may differ according to country. • For USA and Canada, use part number starting with "YB-", "YM-", "YU-" or "YS-". • For others, use part number starting with "90890-".
FOR ELECTRICAL SERVICE • Test harness-TPS (3P) PIN: YU-03204 PIN: 90890-03204 This tool is used to measure voltage of the throttle position sensor.
2
_
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___ __ _ _ _ _ 1 IANDSJP I ~ THROTTLE BODY SYNCHRONIZATION
I
PERIODIC INSPECTION AND ADJUSTMENT ENGINE THROTTLE BODY SYNCHRONIZATION TIP
_
Prior to synchronizing the throttle bodies, the valve clearance should be properly adjusted. 1. Remove: • Shroud Refer to "COWLINGS" in CHAPTER 3. • Top cover • Headlight assembly Refer to "GENERAL CHASSIS". • Headlight stay Refer to "THROTTLE BODY". 2. Remove: • Vacuum caps G) 3. Install: • Vacuummate (vacuum gauge) G) • Digital tachometer (Use goods on the market. Recommended goods: Kaise SK-8401)
Vacuummate: YU-44456 Vacuum gauge: 90890-03094 4. Start the engine and let it warm up for several minutes, and then let it run at specified engine idling speed. ~
V
t
Engine idle speed: 1,550 -1,650 r/min
5. Adjust: • Throttle body synchronization
3
__ _ _ _ _ IIANOSJP I THROTTLE BODY SYNCHRONIZATION _ ___
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~ I
Adjustment steps: • With throttle body #1 as standard, adjust throttle body #2, #3 and #4 using the synchronizing screws CD. TIP _ After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
Vacuum pressure at engine idling speed: 20.97 - 23.63 kPa (157 - 177 mmHg, 6.2 - 7.0 inHg) TIP
_
The difference in vacuum pressure between two throttle bodies should not exceed 1.3 kPa (10 mmHg, 0.4 inHg). 6. Check the engine idle speed. Engine idle speed: 1,550 - 1,650 r/min 7. Stop the engine and remove the measuring equipment. 8. Adjust: • Throttle cable free play Refer to "THROTTLE CABLE FREE PLAY ADJUSTMENT". 9. Install: • Headlight stay Refer to "THROTTLE BODY". • Headlight assembly • Top cover Refer to "GENERAL CHASSIS". • Shroud Refer to "COWLINGS" in CHAPTER 3.
4
_ _ _ IIANOSJP I ENGINE OIL _ REPLACEMENT _ _____
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ENGINE OIL REPLACEMENT This model is equipped with an oil pressure sensing system. When the oil pressure drops, the rev limiter is activated, and the engine is stopped, if necessary. If the oil pressure is incorrect when the engine is started, "OP-LO" appears and the oil level/pressure warning indicator illuminates. Note that it may take a few seconds for the oil pressure to rise to the optimum level after the engine is started, even in normal conditions. Refer to "OIL PRESSURE SENSING SySTEM". TIP _ If "OP-LO" remains on and the oil level/ pressure warning indicator remains illuminated for more than a few seconds after starting the engine, this indicates that oil pressure is incorrect. In this case, check the oil pressure sensing system. 1. Place the snowmobile on a level surface and apply the parking brake. 2. Start the engine, warm up for several minutes, and then turn it off. 3. Place a containers under the engine oil drain bolt and oil tank.
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4. Remove: â&#x20AC;˘ Bottom panel
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_ _ _ IIANOSJP I ENGINE OIL _ REPLACEMENT _ _____
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5. Remove: • Shroud • Side cover (left and right) • Side under cover (right) Refer to "COWLINGS" in CHAPTER 3. • Headlight assembly • Air filter case Refer to "GENERAL CHASSIS". • Battery • Battery bracket 6. Disconnect: • Oil level gauge coupler Refer to "ENGINE OIL LEVEL INSPECTION" in CHAPTER 2. 7. Remove: • Oil level gauge/dipstick Refer to "ENGINE OIL LEVEL INSPECTION" in CHAPTER 2.
8. Remove: • Cylinder head oil filler cap
CD
9. Remove: • Oil pan engine oil drain bolt
CD
10.Remove: • Oil tank engine oil drain bolt CD 11.Drain: • Engine oil (completely from the oil pan and oil tank) 12.lf the oil filter cartridge is also to be replaced, perform the following procedure.
6
_ _ _ IIANOSJP I ENGINE OIL _ REPLACEMENT _ _____ Replacement steps: - Remove the oil filter cartridge filter wrench ÂŽ. TIP
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CD with
an oil _
Make sure that the a-ring is removed together with the oil filter cartridge. If the a-ring remains attached to the crankcase, oil leakage may occur. /'
Oil filter wrench: YM-01469 90890-01469 - Apply a thin coat of engine oil onto the a-ring ÂŽ of the new oil filter cartridge.
Make sure that the a-ring is positioned correctly in the groove of the oil filter cartridge. - Tighten the new oil filter cartridge to specification with an oil filter wrench.
Oil filter cartridge: 17 Nm (1.7 m-kgf, 12 ft-Ibf)
13.lnstall: - Drain bolts (along with the new gaskets)
Oil tank engine oil drain bolt: 16 Nm (1.6 m-kgf, 12 ft-Ibf) Oil pan engine oil drain bolt: 30 Nm (3.0 m-kgf, 22 ft-Ibf)
7
ENGINE OIL REPLACEMENT
INSP ADJ
14.Fill: • Engine oil (with the specified amount of the recommended engine oil) Add 2.0 L (2.11 US qt, 1.76 Imp.qt) of the recommended engine oil to the oil tank, and then install and tighten the oil level gauge/ dipstick and the cylinder head oil filter cap. Quantity: Total amount: 3.8 L (4.02 US qt, 3.34 Imp.qt) Without oil filter cartridge replacement: 2.8 L (2.96 US qt, 2.46 Imp.qt) With oil filter cartridge replacement: 3.0 L (3.17 US qt, 2.64 Imp.qt) 15.lnspect: • Engine and oil tank (for engine oil leaks) 16.lnspect: • Engine oil level Refer to "ENGINE OIL LEVEL INSPECTION" in CHAPTER 2. TIP _ If "OP-LO" remains on and the oil level/ pressure warning indicator remains illuminated for more than a few seconds after starting the engine, this indicates that oil pressure is incorrect. In this case, check the oil pressure sensing system. Refer to "OIL PRESSURE SENSING SYSTEM TROUBLESHOOTI NG".
8
ENGINE OIL REPLACEMENT
INSP ADJ
17.1nspect: • Engine oil pressure
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Inspection steps: • Slightly loosen the oil check bolt CD. • Start the engine and keep it idling until engine oil starts to seep from the oil check bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. • Check the engine oil passages, the oil filter and the oil pump for damage or leakage. • Start the engine after solving the problem(-s) and check the engine oil pressure again. • Tighten the oil check bolt to specification.
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Oil check bolt: 10 Nm (1.0 m-kgf, 7.2 ft-Ibf)
18.lnstall: • Bottom panel
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Bottom panel bolt: 10 Nm (1.0 m-kgf, 7.2 ft-Ibf)
19.1nstall: • All removed parts TIP
_
For installation, reverse the removal procedure.
9
__ _ _ _ IIANOSJP I EXHAUST SYSTEM INSPECTION _ ____
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EXHAUST SYSTEM INSPECTION 1. Remove: • Left side cover Refer to "COWLINGS" in CHAPTER 3. • Seat • Rear cover Refer to "GENERAL CHASSIS". • Fuel tank Refer to "FUEL TANK" in CHAPTER 5. • Muffler cover plate • Muffler cover Refer to "EXHAUST PIPE AND MUFFLER".
2. Inspect: • Exhaust pipe joints CD • Muffler ® • Exhaust pipe ® • Muffler band ® • Exhaust pipe bands @ • EXUP cable holder @ • EXUP valve housing (J) • EXUP valve pulley ® • Collar ® • Plate @ • Spring @ • EXUP valve @ • Collar@ Cracks/damage ~ Replace.
10
__ _ _ _ IIANOSJP I EXHAUST SYSTEM INSPECTION _ ____
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3. Inspect: • Tightening torque Exhaust pipe joint bolt @: 25 Nm (2.5 m-kgf, 18 ft-Ibf) Muffler bolt @: 16 Nm (1.6 m-kgf, 12 ft-Ibf) Exhaust pipe bolt (front side) @: 25 Nm (2.5 m-kgf, 18 ft-Ibf) Exhaust pipe bolt (rear side) @: 16 Nm (1.6 m-kgf, 12 ft-Ibf) Muffler band bolt @: 20 Nm (2.0 m-kgf, 14 ft-Ibf) Exhaust pipe band bolt @: 18 Nm (1.8 m-kgf, 13 ft-Ibf) EXUP valve housing bolt @: 10 Nm (1.0 m-kgf, 7.2 ft-Ibf) EXUP valve bolt @: 7 Nm (0.7 m-kgf, 5.1 ft-Ibf)
4. Inspect: • EXUP cable (black metal) @ • EXUP cable (white metal) @ Damage ~ Replace. 5. Install: • All removed parts Refer to "EXHAUST PIPE AND MUFFLER".
11
_ _ _ IIANOSJP I EXUP _ CABLE ADJUSTMENT _ _____
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~ I
EXUP CABLE ADJUSTMENT 1. Remove: • Left side cover Refer to "COWLINGS" in CHAPTER 3. • Seat Refer to "GENERAL CHASSIS". • Fuel tank Refer to "FUEL TANK" in CHAPTER 5.
2. Remove: • EXUP valve pulley cover
CD
3. Inspect: • EXUP system operation
Inspection steps: • Activate the diagnostic mode and select the diagnostic code number d: 53.
Refer to "DIAGNOSTIC MODE". • Check that the EXUP valve operates properly. TIP _ Check that the 04 pin (93604-29184) can be inserted into the boss ® of the EXUP valve housing. If the rod cannot be inserted, adjust the EXUP cable.
12
_ _ _ IIANOSJP I EXUP_ CABLE ADJUSTMENT _ _____
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4. Adjust: • EXUP cable
Adjustment steps: a. Turn the main switch to "ON" b. Slide the rubber cover CD of the EXUP cable (white metal). c. Loosenthelocknut~. d. Turn the EXUP valve pulley to the left so that the notch ® of the EXUP valve pulley is positioned further to the left than the boss @ of the EXUP valve housing. e. Turn the adjusting nut ® of the EXUP cable (white metal) to direction ® or CD so that the end of the snowmobile front notch @ of the EXUP valve pulley is aligned with the alignment mark @ of the exhaust pipe. Direction ® EXUP cable (white metal) free play is increased Direction CD EXUP cable (white metal) free play is decreased
f.
Slide the rubber cover cable (black metal).
®
of the EXUP
g. Loosenthelocknut~. h. Turn the adjusting nut ® of the EXUP cable (black metal) in direction CD or CD so that the notch ® of the EXUP valve pulley is aligned with the boss @ of the EXUP valve housing.
Direction CD EXUP cable (black metal) free play is increased Direction CD EXUP cable (black metal) free play is decreased
13
_ _ _ IIANOSJP I EXUP _ CABLE ADJUSTMENT _ _____
~O~
~ I
Check that the 04 pin (93604-29184) can be inserted into the boss of the EXUP valve housing. If the rod cannot be inserted, repeat the procedure from step (a). j. Tighten the locknut, and then restore the rubber cover to its original position. k. Activate the diagnostic mode and select the diagnostic code number d: 53. Refer to "DIAGNOSTIC MODE". I. Again, check that the 04 pin (93604-29184) can be inserted into the boss of the EXUP valve housing. If the rod cannot be inserted, repeat the procedure from step (a). TIP _ i.
The center of the notch of the EXUP valve pulley and the center of the boss of the EXUP valve housing may be misaligned up to 2 mm (0.08 in).
® 2 mm (0.08 in)
5. Install: • EXUP valve pulley cover
CD
EXUP valve pulley cover bolt: 10 Nm (1.0 m-kgf, 7.2 ft-Ibf)
6. Install: • Fuel tank Refer to "FUEL TANK" in CHAPTER 5. • Seat • Left side cover Refer to "COWLINGS" in CHAPTER 3.
14
_ _ _ _ IIANOSJP I EXUP _ SERVO MOTOR INSPECTION _ ____
~O~
~ I
EXUP SERVO MOTOR INSPECTION
1. Inspect: • EXUP servo motor operation Rough movement ~ Replace. Inspection steps: a. Check that the EXUP valve is not firmly fixed. • Disconnect the EXUP cable and check that the EXUP valve is moved smoothly by hand. • When the valve is not moved smoothly, repair or replace it. Refer to "EXUP CABLE ADJUSTMENT". b. With the EXUP cable installed, check that the EXUP valve is neither smoothly nor manually moved. • When the EXUP valve is moved smoothly, replace the EXUP servo motor. c. Perform the self-diagnosis mode and check the operation of EXUP valve by visual inspection (code number d: 53). Refer to "DIAGNOSTIC MODE".
15
_TENSION __ _ _ IIANOSJP I TRACK ADJUSTMENT _ ____
~O~
~ I
TRACK TENSION ADJUSTMENT
~----------
A broken track or track fittings, and debris thrown by the track could be dangerous to an operator or bystanders. Observe the following precautions. - Do not allow anyone to stand behind the snowmobile when the engine is running. - When the rear of the snowmobile is raised to allow the track to spin, a suitable stand must be used to support the rear of the snowmobile. Never allow anyone to hold the rear of the snowmobile off the ground to allow the track to spin. Never allow anyone near a rotating track. -Inspect the condition of the track frequently. Replace the track if it is damaged to a level where the fabric reinforcement material is visible. 1. Lift the rear of the snowmobile onto a suitable stand to raise the track off the ground. 2. Measure: - Track deflection ÂŽ Using a spring scale CD, pull down on the center of the track with 100 N (10 kgf, 22 Ibf) of force. Out of specification ~ Adjust.
Track deflection: 30.0 - 35.0 mm (1.18 - 1.38 in)
3. Adjust: - Track deflection
Adjustment steps: a. Place the snowmobile onto a suitable stand to raise the track off of the ground. b. Loosen the rear axle nut CD. c. Start the engine and rotate the track once or twice. Stop the engine.
J--<D
16
_TENSION __ _ _ IIANOSJP I TRACK ADJUSTMENT _ ____
~O~
~ I
d. Check the track alignment with the slide runner ®. If the alignment is incorrect, turn the left and right adjusters to adjust.
Track alignment
@ Left adjuster
® Right adjuster
[Q Shifted to right Turn out Turn in
[Q] Shifted to left Turn in Turn out
@ Slide runner @Track
A
(J) Track clip @Gap [8J RX1 OPA, RX10PSA llil RX1 OPXTA ~ Forward
e. Adjust the track deflection until the specified amount is obtained.
Track deflection
@ Left adjuster
® Right adjuster
More than specified Turn in Turn in
Less than specified Turn out Turn out
The adjusters should be turned an equal amount. f.
c
Recheck the alignment and deflection. If necessary, repeat steps (c) to (e) until the specified amount is obtained. g. Apply ESSO beacon 325 grease or Aeroshell grease #7A to the rear axle nut. h. Tighten the rear axle nut.
D
Rear axle nut: 75 Nm (7.5 m-kgf, 54 ft-Ibf)
17
__ __ _ IIANOSJP I EXTROVERT SPROCKET WHEELS _ ____
~O~
~ I
EXTROVERT SPROCKET WHEELS 1. Inspect: • Extrovert sprocket wheels Cracks/damage ~ Replace. 2. Measure: • Teeth ® a. Measuring point @ 20 mm (0.79 in) b. Extrovert sprocket wheel wear limit Out of specification ~ Replace.
CD
Extrovert sprocket wheel wear limit @: 13 mm (0.51 in)
®
18
_ _ IIANOSJP I LUBRICATION _ _______
~O~
~ I
LUBRICATION Front and rear suspension 1. Remove: â&#x20AC;¢ Front cover Refer to "FRONT SUSPENSION" in CHAPTER3. 2. Use a grease gun to inject grease into the nipples (both sides) CD and nipples (2). 3. Apply grease to the pivoting parts.
A
Recommended lubricant: ESSO Beacon 325 grease or Aeroshell grease #7A [8] Front ffi] Rear (RX1 OPA, RX10PSA)
[Q] Rear (RX1 OPXTA)
CD Nipple (both sides)
(2) Nipple
A
l
8
c
19
CLUTCH
INSP ADJ
TUNING
(400m)
800m ~
CLUTCH The clutch may require tuning depending upon where the snowmobile will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the snowmobile first begins to move from a complete stop. Shifting speed is defined as the engine speed reached when the snowmobile has travelled 800 m (2,500 ft) after being started at full-throttle from a dead stop. Normally, when a snowmobile reaches shifting speed, the snowmobile speed increases but the engine speed remains nearly constant. Under unfavorable conditions (wet snow, icy snow, hills, or rough terrain), however, engine speed may decrease after the shifting speed has been reached.
[E]
[8] Engine speed
llil Good condition
[Q Shifting speed
[Q] Clutch engagement speed ~ Starting position
[E] Distance travelled
20
_II~~~ Q
_____________ C_LU_T_C_H
I
I
High altitude tuning Atmospheric pressure decreases and engine output becomes low at high altitude locations. Because of this, clutch engagement speed and shifting speed also decrease and unable to maximize the engine output power. To maximize the engine output, tuning for increasing clutch engagement speed and shifting speed is necessary. This setting is called high altitude tuning. The following changes are usually performed in high altitude tuning. â&#x20AC;˘ To increase the clutch engagement and shifting speed, changing to a larger spring constant or using lighter weights and rivets. (decreasing primary sheave thrust) â&#x20AC;˘ Increasing the reduction ratio of the driven gear/drive gear. (increasing the driving performance) Refer to "HIGH ALTITUDE TUNING".
[8] Engine speed
llil Speed at maximum output
[Q] Low speed [Q] Distance travelled
21
_II~~~ Q
_____________ C_LU_T_C_H
I
I
Parts that affect transmission characteristics Among the components of the V-belt transmission, those that have direct impact on the shifting function are described below.
Part [8] Primary sheave CD Spring
Element Preload
Spring rate
® Weight
Shape, weight
Impact on the shifting function • A larger preload increases the clutch engagement speed, and the shifting speed tends to rise accordingly. Shifting tends to become somewhat harder. (increasing the spring reaction force) • A smaller preload decreases the clutch engagement speed, and the shifting speed tends to drop accordingly. Shifting tends to become somewhat easier. (decreasing the spring reaction force) • A larger spring rate increases the shifting speed. It also slightly increases the clutch engagement speed. Shifting tends to become somewhat harder. (increasing the spring reaction force) • A smaller spring rate decreases the shifting speed. It also slightly decreases the clutch engagement speed. Shifting tends to become somewhat easier. (decreasing the spring reaction force) Shape and weight determine, the size of moment about the center of the weight rotation when the sheave is running. • Heavier weight decreases the clutch engagement and shifting speed. Shifting tends to become somewhat easier. (increasing the sheave thrust) • Lighter weight increases the clutch engagement and shifting speed. Shifting tends to become somewhat harder. (decreasing the sheave thrust)
22
CLUTCH
®
Part Weight rivet
Element Quantity Material (iron, aluminum)
®
Roller
Outside diameter
®
Shim
Quantity
INSP ADJ
Impact on the shifting function Rivets are fastened through the hole in the weight. • Using more rivets decreases the clutch engagement and shifting speed. Shifting tends to become somewhat easier. (increasing the sheave thrust) • Using less rivets increases the clutch engagement and shifting speed. Shifting tends to become somewhat harder. (decreasing the sheave thrust) The outside diameter affects the contact angle with the weight. • A smaller diameter decreases the clutch engagement speed. (increasing the sheave thrust) • A larger diameter increases the clutch engagement speed. (decreasing the sheave thrust) • Using more shims increases the preload and clutch engagement speed. (increasing the spring reaction force) • Using less shim decreases the preload and clutch engagement speed. (decreasing the spring reaction force)
ffi] Secondary sheave
@ Spring
Preload Spring rate (compression, torsion)
(J) Fixed sheave
Spring fitting hole
@ Spring seat
• A larger preload, spring rate or twist angle increases the shifting speed and makes shifting somewhat harder. (increasing the sheave thrust) • A smaller preload, spring rate or twist angle decreases the shifting speed and makes shifting somewhat easier. (decreasing the sheave thrust) One of the holes may be used selectively to change the spring twist angle (preload). Refer to "@ Spring".
23
CLUTCH
Part
® Torque cam
Element Cam angle
(spring seat)
®
Shim
Quantity
INSP ADJ
Impact on the shifting function The cam angle determines the degree of sensitivity of load torque detection. • A smaller cam angle increases sensitivity, which in turn increases the sheave thrust to make back shifting easier. The shifting speed tends to increase and shifting becomes somewhat harder. (increasing the sheave thrust) • A larger cam angle makes back shifting harder. The shifting speed tends to decrease and shifting becomes somewhat easier. (decreasing the sheave thrust) Size of the secondary sheave clearance (between fixed sheave and sliding sheave) can be adjusted by the number of shims used. Adjust the clearance when the V-belt wear deteriorates and belt width becomes smaller. • Using more shims makes secondary sheave clearance smaller. • Using less shim makes secondary sheave clearance larger. When the V-belt width is smaller, wrap-around diameter of the V-belt on the primary sheave is larger and clutch engagement speed is slightly increased.
24
CLUTCH
CD
INSP ADJ
Primary spring
[A] Spring identification color code Actual coloring
[ill
Part number
[Q]
Spring rate N/mm (kgf/mm)
[Q]
Preload N (kgf)
[EJ
Wire gauge mm(in)
[E]
Outside diameter mm(in)
[Q] Number of coils
[8] Free length mm(in)
Blue-Blue-Blue
90501-550A2
19.6 (2.00)
196 (20)
5.5 (0.217)
59.5 (2.34)
4.89
83.4 (3.28)
Blue-Pink-Blue
90501-551 L3
19.6 (2.00)
294 (30)
5.5 (0.217)
59.5 (2.34)
4.91
88.4 (3.48)
Blue-Silver-Blue
90501-551 L9
19.6 (2.00)
343 (35)
5.5 (0.217)
59.5 (2.34)
4.91
90.9 (3.58)
Blue-Green-Blue
90501-552L5
19.6 (2.00)
392 (40)
5.5 (0.217)
59.5 (2.34)
4.91
93.4 (3.68)
Yellow-Blue-Yellow
9050 1-580A1
24.5 (2.50)
196 (20)
5.8 (0.228)
59.5 (2.34)
4.91
81.4 (3.20)
Yellow-Pink-Yellow
90501-581 L5
24.5 (2.50)
294 (30)
5.8 (0.228)
59.5 (2.34)
4.92
85.4 (3.36)
Green-Pink-Green
90501-581 L6
27.0 (2.75)
294 (30)
5.8 (0.228)
59.5 (2.34)
4.66
84.3 (3.32)
Yellow-Silver-Yellow
90501-582 L1
24.5 (2.50)
343 (35)
5.8 (0.228)
59.5 (2.34)
4.92
87.4 (3.44)
Green-Silver-Green
90501-582L2
27.0 (2.75)
343 (35)
5.8 (0.228)
59.5 (2.34)
4.66
86.1 (3.39)
White-Green-White
90501-582L6
22.1 (2.25)
392 (40)
5.8 (0.228)
59.5 (2.34)
5.25
91.2 (3.59)
Yellow-Green-Yellow
90501-582 L7
24.5 (2.50)
392 (40)
5.8 (0.228)
59.5 (2.34)
4.92
89.4 (3.52) 95.9 (3.78)
Blue-White-Blue
90501-583LO
19.6 (2.00)
441 (45)
5.8 (0.228)
59.5 (2.34)
5.65
White-White-White
90501-583 L1
22.1 (2.25)
441 (45)
5.8 (0.228)
59.5 (2.34)
5.25
93.4 (3.68)
White-Silver-White
90501-583L4
22.1 (2.25)
343 (35)
5.8 (0.228)
59.5 (2.34)
5.25
89.0 (3.50)
White-Pink-White
90501-583L5
22.1 (2.25)
294 (30)
5.8 (0.228)
59.5 (2.34)
5.25
86.7 (3.41)
Pink-Blue-Pink
9050 1-600A1
29.4 (3.00)
196 (20)
6.0 (0.236)
59.5 (2.34)
4.81
80.1 (3.15)
Pink-Pink-Pink
90501-601 L7
29.4 (3.00)
294 (30)
6.0 (0.236)
59.5 (2.34)
4.82
83.4 (3.28)
Orange-Pink-Orange
90501-601 L8
31.9 (3.25)
294 (30)
6.0 (0.236)
59.5 (2.34)
4.60
82.6 (3.25)
Pink-Silver-Pink
90501-602L3
29.4 (3.00)
343 (35)
6.0 (0.236)
59.5 (2.34)
4.82
85.1 (3.35)
Green-Green-Green
90501-602 L8
27.0 (2.75)
392 (40)
6.0 (0.236)
59.5 (2.34)
5.08
87.9 (3.46)
Pink-Green-Pink
90501-602L9
29.4 (3.00)
392 (40)
6.0 (0.236)
59.5 (2.34)
4.82
86.7 (3.41)
Yellow-White-Yellow
90501-603 L2
24.5 (2.50)
441 (45)
6.0 (0.236)
59.5 (2.34)
5.39
91.4 (3.60)
Green-White-Green
90501-603 L3
27.0 (2.75)
441 (45)
6.0 (0.236)
59.5 (2.34)
5.08
89.8 (3.54)
Orange-Silver-Orange
90501-624L8
31.9 (3.25)
343 (35)
6.2 (0.244)
59.5 (2.34)
5.00
84.2 (3.31)
25
IT]
Standard
RX10PA, RX10PSA, RX10PXTA
_II~~~ Q
_____________ C_LU_T_C_H
I
(g)Weight
[8J Part number
ffi] Weight g (oz) without bush and rivets
80N-17605-30
39.76 (1.403)
8ES-17605-00
54.63 (1.927)
8FN-17605-00
75.28 (2.655)
8FP-17605-00
67.81 (2.392)
8FS-17605-00
65.52 (2.312)
8GC-17605-00
47.28 (1.668)
8GL-17605-00
49.43 (1.745)
[Q Shape & 10 mark
26
[Q] Standard
I
INSP ADJ
CLUTCH
llil Weight g (oz) [8J Part number
without bush and rivets
8H F-17605-00
81.51 (2.875)
8HG-17605-00
82.96 (2.926)
[Q] Standard
[Q] Shape & 10 mark
RX10PA, RX10PSA, RX10PXTA
® Weight rivet [8J
llil Material
[Q] Length
[Q] Weight
mm (in)
g (oz)
90261 -06033
Steel
17.2 (0.677)
4.5 (0.159)
CENTER: RX10PA, RX10PSA, RX10PXTA
90269-06006
Steel with hole
17.2 (0.677)
3.6 (0.127)
IN: RX10PA, RX10PSA, RX10PXTA
90261 -06034
Steel
13.9 (0.547)
3.6 (0.127)
90261 -0601 9
Steel
13.3 (0.524)
3.1 (0.109)
OUT: RX10PXTA
90266-06002
Steel with hole
13.3 (0.524)
2.44 (0.086)
OUT: RX10PA, RX10PSA
90261 -06015
Steel
10.3 (0.406)
2.44 (0.086)
90261 -06028
Aluminum
10.3 (0.406)
0.85 (0.030)
90266-06001
Aluminum with hole
13.3 (0.524)
0.85 (0.030)
Part number
~ Standard
[E] Effects [§] Increased force
~ ~
~,
[8] Decreased force
27
INSP ADJ
CLUTCH
® Roller 1.0. 9 mm (0.354 in)
[8] Roller with
~Outside
bushing part number
diameter mm(in)
[Q] Identification mark (Width)
[Q] Standard
[E] Grooved & Machined • 8FG-17624-00
~ Effects
[Kli ncreased force RX10PA, RX10PSA, RX10PXTA
14.5 (0.571)
J
~
~
,
. (14.6 mm [0.57 in])
~Grooved
8FG-17624-10
15.0 (0.591)
(14.6 mm [0.57 in])
[8] No Mark
8FG-17624-20
15.6 (0.614)
(14.6 mm [0.57 in])
[IJ Grooved & Grooved 8FG-17624-30
16.0 (0.630)
(14.6 mm [0.57 in])
Q] Machined
8FG-17624-40
16.5 (0.650)
CD Decreased (14.6 mm [0.57 in])
force
@ Shim (primary sheave) [8] Part number
~ Thickness mm (in)
90201-483P9
1.0 (0.039)
[Q] Standard RX10PA, RX10PSA, RX10PXTA
None
28
INSP ADJ
CLUTCH @ Secondary sheave spring
[8] Spring identification color code Actual coloring
[Q]
[6J
Part number
Brown
90508-500B 1
Spring rate
[E]
Wire gauge mm(in)
[Q]
[:EJ
6003 (613)
6.2 (0.63), 35.40
5.0 (0.197)
Torsion Nemm/rad (kgfemm/rad)
Compression N/mm (kgf/mm) (Ibf/in)
[8] Free
IT] Outside
length mm(in)
diameter mm(in)
5.19
75 (2.95)
69.5 (2.74)
[gJ
No. of coils
Red
90508-536A9
7147 (729)
7.3 (0.74), 41.68
5.3 (0.209)
5.53
75 (2.95)
69.5 (2.74)
Green
90508-556A2
8314 (848)
8.5 (0.87), 48.53
5.5 (0.217)
5.53
75 (2.95)
69.5 (2.74)
Silver
90508-556A7
9460 (965)
10.2 (1.04), 58.24
5.5 (0.217)
4.86
75 (2.95)
69.5 (2.74)
Pink
90508-60012
11876 (1211)
12.3 (1.26), 70.23
6.0 (0.236)
5.53
75 (2.95)
69.5 (2.74)
Pink-Pink
90508-60018
11876 (1211)
12.3 (1.26), 70.23
6.0 (0.236)
5.53
75 (2.95)
69.5 (2.74)
White
90508-60007
12654 (1290)
13.5 (1.38) 77.08
6.0 (0.236)
5.19
75 (2.95)
69.5 (2.74)
White-White
90508-60016
12654 (1290)
13.5 (1.38) 77.08
6.0 (0.236)
5.19
75 (2.95)
69.5 (2.74)
(j) Secondary spring twist angle
Q]
Standard
RX10PA, RX10PSA, RX10PXTA
2
o 6
Sheave ~
0
3
6
9
1
10°
40°
70° *
100°
2
20°
50°
80°
110°
3
30°
60°
90°
120°
~
[Q] Standard *:RX10PA,RX10PSA, RX10PXTA
29
_II~~~ Q
_____________ C_LU_T_C_H
I
® Torque cam (secondary spring seat)
[8] Identification mark
llil
Part number
[Q] Cam angle
[Q] Standard
~ Effects
RX10PA, RX10PSA, RX10PXTA
[E] Quicker
8BVFA
8FA-17604-00
51 °-43°
8BV71
8BV-17604-71
47°
8BV51
8BV-17604-51
45°
8BV31
8BV-17604-31
43°
8BV11
8BV-17604-11
41 °
8BV91
8BV-17604-91
39°
up shifting during acceleration
t
[Q] Quicker back shifting under load
® Shim (secondary sheave) [8] Part number
llil Thickness mm (in)
90201-061 H1
0.5 (0.020)
90201-06037
1.0 (0.039)
30
[Q] Standard RX10PA, RX10PSA, RX10PXTA
I
_ _ _ IIANOSJP I GEAR SELECTION _ ______
~O~
~ I
GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to where the snowmobile will be operated and driving conditions. If the load on the snowmobile is big such as driving at high altitude mountain or towing, the driven/drive gear ratio should be increased. If the load on the snowmobile is small such as driving on the fairly smooth surfaces or hard-compacted snow, decrease the ratio.
CD Chain and sprocket The drive and driven gears and the chains shown in the gear ratio chart are available as options. [8] Part name
~ Drive sprocket
[E] Driven sprocket
[§] Chain
~ Teeth & links
[Q Part number
18 teeth
8FA-17682-80
19 teeth
8FA-17682-90
20 teeth
8FA-17682-00
21 teeth
8FA-17682-10
22 teeth
8FA-17682-20
23 teeth
8FA-17682-30
RX10PXTA
24 teeth
8FA-17682-40
RX10PA, RX10PSA
37 teeth
8FB-47587-70
RX10PA, RX10PSA, RX10PXTA
38 teeth
8FB-47587-80
39 teeth
8FB-47587-90
40 teeth
8FB-47587-00
68 links
94890-09068
RX10PXTA
70 links
94890-09070
RX10PA, RX10PSA
[Q] Standard
ÂŽ Gear ratio The figures containing a decimal point represent the driven/drive gear ratios, while the bottom numbers designate the number of links in the chain. [8] Drive gear 18 teeth
19 teeth 20 teeth 21 teeth 22 teeth 23 teeth 24 teeth
~ Driven gear
37 teeth
-
-
38 teeth
-
-
1.76 68 links
1.68 68 links
1.61 68 links
1.54 70 links
1.90 68 links
1.81 68 links
1.73 68 links
1.65 70 links
1.58 70 links
-
39 teeth
2.17 68 links
2.05 68 links
1.95 68 links
1.86 68 links
1.77 70 links
1.70 70 links
1.63 70 links
40 teeth
2.22 68 links
2.11 68 links
2.00 68 links
1.90 70 links
1.82 70 links
1.74 70 links
1.67 70 links
31
INSP ADJ
HIGH ALTITUDE TUNING HIGH ALTITUDE TUNING Specifications Model: RX10PA, RX10PSA 600 ---1,400 m (2,000 --- 4,500 ft)
1,200 --- 2,000 m (4,000 --- 6,500 ft)
1,800 --- 2,600 m (6,000 --- 8,500 ft)
2,400 --- 3,000 m (8,000 --- 10,000 ft)
1,550 --- 1,650 r/min
~
~
~
~
[Q] Engagement speed
Approx.3,400 r/min
~
~ Shift speed
Approx. 10,500 r/min
~
[E] Secondary reduction
24/37 (70 L)
~
90501-551 L9
~
~
~
90501-624L8
[8] Color*
L-S-L
~
~
~
O-S-O
[]] Free length
90.9 mm (3.58 in)
~
~
~
84.2 mm (3.31 in)
Q]
Preload
343 N (35 kgf, 771bf)
~
~
~
[Kl Spring rate
19.6 N/mm (2.00 kgf/mm, 111.9 Ibf/in)
~
~
~
31.9 N/mm (3.25 kgf/mm, 182.2 Ibf/in)
OJ Wire diameter
5.5 mm (0.217 in)
~
~
~
6.2 mm (0.244 in)
[MJ Outside diameter
59.5 mm (2.34 in)
~
~
~
~
8HG-17605-00 (8HGOO)
~
~
~
~
Steel with hole 13.3 (OUT)
~
~
~
--- 800 m (--- 2,500 ft)
[8] Elevation
llil Production 8
[Q]
F
[§]
Standard
specification Engine idle speed
ratio (number of links) Prir:nary sheave spnng
IE] Weight (10)
[Q] Weight rivet
[EJ
Approx. 3,600 r/min ~
23/37 (68 L)
None (OUT)
Steel 17.2 (CENTER)
Steel with hole 13.3 (CENTER)
Steel with hole 17.2 (IN)
Steel 13.3 (IN)
~
Steel with hole 13.3 (IN)
~
Approx. 3,800 r/min
~
~
22/37 (68 L)
~
~
None (CENTER)
~
None (IN)
~
14.5 mm (0.571 in)
~
~
~
~
None
~
~
~
~
90508-60012
~
~
~
~
P
~
~
~
~
75 mm (2.95 in)
~
~
~
~
[Q] Preload rate
70° (1-6) 11,876 Nemm/rad (1,211 kgfemm/rad)
~
~
~
~
[YJ Wire diameter
6.0 mm (0.236 in)
~
~
~
~
~ Outside diameter
69.5 mm (2.74 in)
~
~
~
~
51 °-43°
~
~
~
~
1.0 mm (0.039 in)
~
~
~
~
Roller outer diameter
[Q] Primary sheave shim [B] Se~ondary sheave spnng
[§] Color* IT] Free length
[Xl Secondary torque cam angle
[Yl S~condary
sheave
shim
*. Color code
L
Blue
P
Pink
0 S
Orange Silver
32
INSP ADJ
HIGH ALTITUDE TUNING Specifications
Model: RX10PXTA --- 800 m (--- 2,500 ft)
[8]
Elevation
ffi]
Production specification
600 ---1,400 m (2,000 --- 4,500 ft)
1,200 --- 2,000 m (4,000 --- 6,500 ft)
1,800 --- 2,600 m (6,000 --- 8,500 ft)
2,400 --- 3,000 m (8,000 --- 10,000 ft)
~
~
~
Standard
[Q] Engine idle speed
1,550 --- 1,650 r/min
~
[Q] Engagement speed
Approx.3,400 r/min
~
~ Shift speed
Approx. 10,500 r/min
~
23/37 (68 L)
~
90501-551 L9
~
~
~
90501-624L8
[8] Color*
L-S-L
~
~
~
O-S-O
[]] Free length
90.9 mm (3.58 in)
~
~
~
84.2 mm (3.31 in)
Q] Preload
343 N (35 kgf, 771bf)
~
~
~
[Kl Spring rate
19.6 N/mm (2.00 kgf/mm, 111.9 Ibf/in)
~
~
~
31.9 N/mm (3.25 kgf/mm, 182.2 Ibf/in)
CD Wire diameter
5.5 mm (0.217 in)
~
~
~
6.2 mm (0.244 in)
[MJ Outside diameter
59.5 mm (2.34 in)
~
~
~
~
8HG-17605-00 (8HGOO)
~
~
~
~
~
~
[E] Secondary reduction F
[§]
ratio (number of links) Prir:nary sheave spnng
[N] Weight (10)
[Q] Weight rivet
[EJ
Approx. 3,600 r/min ~
22/37 (68 L)
Steel 13.3 (OUT)
Steel with hole 13.3 (OUT)
None (OUT)
Steel 17.2 (CENTER)
Steel 13.3 (CENTER)
Steel with hole 13.3 (CENTER)
Steel with hole 17.2 (IN)
Steel 13.3 (IN)
~
~
Approx. 3,800 r/min
~
~
21/37 (68 L)
~
~
None (CENTER)
~
None (IN)
~
14.5 mm (0.571 in)
~
~
~
~
None
~
~
~
~
90508-60012
~
~
~
~
llil Color*
P
~
~
~
~
IT]
75 mm (2.95 in)
~
~
~
~
[Q] Preload rate
70° (1-6) 11,876 Nemm/rad (1,211 kgfemm/rad)
~
~
~
~
[YJ Wire diameter
6.0 mm (0.236 in)
~
~
~
~
~ Outside diameter
69.5 mm (2.74 in)
~
~
~
~
51 °-43°
~
~
~
~
1.0 mm (0.039 in)
~
~
~
~
Roller outer diameter
[Q] Primary sheave shim [B] Se~ondary sheave spnng
Free length
[Xl Secondary torque cam angle
[Yl S~condary
sheave
shim
*. Color code
L
Blue
P
Pink
0 S
Orange Silver
33
INSP ADJ
FRONT SUSPENSION FRONT SUSPENSION Spring Preload RX10PA, RX10PXTA
~----------
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assemblies. Do not subject the shock absorber assemblies to open flame or high heat, which could cause it to explode. 1. Adjust: - Spring preload
Adjustment steps: - Loosen the locknut CD. - Turn the spring seat 速 in or out.
Be sure that the left and right spring preloads are the same.
I_
速
2
1
RX10PA
---------
Spring seat distance Preload Length
速
Standard Short
~
~
Long Hard~ ~ Soft Minimum Maximum 242.5 mm 252.5 mm 264.5 mm (9.55 in)
(9.94 in)
(10.41 in)
RX10PXTA Spring seat distance Preload Length
速
Standard Short
~
~
Long Hard~ ~ Soft Minimum Maximum 247.0 mm 257.0 mm 257.0 mm (9.72 in)
- Tighten the locknut
(10.12 in)
(10.12 in)
CD.
Shock absorber spring preload adjusting locknut: 42 Nm (4.2 m-kgf, 30 ft-Ibf)
34
FRONT SUSPENSION
INSP ADJ
Air Pressure RX10PSA
The left and right shock absorber air pressure must be set to the same setting. Uneven settings can cause poor handling and loss of stability. This snowmobile is equipped with FOX shock absorbers as standard equipment. The air pressure of the shock absorbers can be adjusted using the shock absorber pump CD included with your snowmobile. This shock absorber pump has low pressure gauge ® and high pressure gauge @.
Low pressure gauge measuring range: o kPa (0 kgf/cm 2 , 0 psi) to 620 kPa (6.2 kgf/cm 2 , 90 psi) High pressure gauge measuring range: o kPa (0 kgf/cm 2 , 0 psi) to 2,068 kPa (20.7 kgf/cm 2 , 300 psi)
Adjustment steps:
~----------
Support the snowmobile securely on a suitable stand before adjusting the shock absorbers.
Make sure that there is no load on the shock absorbers and that they are fully extended before making any air pressure adjustments. • Place the snowmobile on a level surface and apply the parking brake. • Lift the front of the snowmobile onto a suitable stand to raise the skis off the ground. • Remove the air valve cap CD from the shock absorber. 35
_ _ _ IIANOSJP I FRONT SUSPENSION _ ______
~O~
~ I
• Install the hose connector ® of the shock absorber pump to the shock absorber air valve. TIP _ When installing, make sure the shock absorber pump lever ® is down as shown in the illustration.
Do not overtighten the connector onto the air valve as this will damage the connector seal. • Lift up the shock absorber pump lever @. TIP _ • Use the low pressure gauge © of the shock absorber pump and measure. ·If the shock absorber has no air pressure, the gauge reading will be zero. • To increase the air pressure, operate the pump a few times. The pressure should increase slowly. If the pressure increases rapidly, check to make sure that the pump is properly connected and tightened onto the air valve. To decrease the air pressure, push the bleed valve button @. TIP _ To allow pressure to escape from the pump and the shock absorber, push the button halfway down and hold it. To allow only a small amount of pressure to escape, push the button all the way down and quickly release it. • Lay flat the shock absorber pump lever. • Remove the hose connector from the air valve. TIP _ When removing the connector, the sound of air escaping may be heard, but this is from the pump hose, not the shock absorber.
Air pressure range: 448 - 1,034 kPa (4.5 - 10.3 kgf/cm 2 , 65 - 150 psi) Standard air pressure: 586 kPa (5.9 kgf/cm 2 , 85 psi)
36
FRONT SUSPENSION
INSP ADJ
Do not exceed 1,034 kPa (10.3 kgf/cm 2 , 150 psi). â&#x20AC;¢ Install the air valve cap. TIP
_
If the front suspension bottoms too easily or rolls too much during cornering, increase the air pressure by 34 kPa (0.3 kgf/cm 2 , 5 psi). If the suspension is too firm and you want a more compliant ride, decrease the air pressure by 34 kPa (0.3 kgf/cm 2 , 5 psi).
37
_ _ _ IIANOSJP I REAR SUSPENSION _ ______
~O~
~ I
REAR SUSPENSION Limiter strap 1. Adjust: • Limiter strap length
Make sure the left and right rear suspension limiter straps are adjusted evenly. (RX10PXTA) TIP
_
This adjustment affects the handling characteristics of the snowmobile.
Adjustment steps: • Remove the limiter strap bolts CD, nuts and washers. • Adjust the length of the limiter strap ® by inserting the bolts in different holes.
\ No.1 ~ ] ~ NO.2~
No.3
-iLl\)
NO.4~
I
NO.5+~
Standard setting: No.1 hole
• Tighten the limiter strap nuts.
, NO.1~
~~
Limiter strap nut: 4.0 Nm (0.40 m-kgf, 2.9 tt-Ibfl
[8] RX1 OPA, RX10PSA
NO.2~ ] NO.3~
llil RX1 OPXTA
N0.41
38
_ _ _ IIANOSJP I REAR SUSPENSION _ ______
~O~
~ I
Choosing other settings:
The standard settings work well under most general riding conditions. The suspension can be adjusted to work better in one condition, but only at the expense of another. Keep this in mind when you adjust the suspension.
[8]: No.5 hole ~: No.4 hole
(shortest) More weight on skis: • Heavy steeringl oversteer • More maneuverability Favors: hardpack snow, ice, smooth trails, tight turns
No.1 hole (longest) Less weight on skis: • Light steeringl understeer • Better acceleration and speed Favors: deep snow, straight line acceleration, top speed
[8] RX1 OPA,
RX10PSA ~ RX10PXTA
Spring preload
~----------
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to open flame or high heat, which could cause it to explode.
39
_ _ _ IIANOSJP I REAR SUSPENSION _ ______
~O~
~ I
1. Adjust: - Spring preload Adjustment steps:
Front side RX10PXTA - Loosen the locknut CD. - Adjust the spring preload by turning the spring seat (2). Spring Standard seat ~ Long Short ~ distance ~ Soft Preload Hard~ Min. Max. Length 181.0 mm 191.0 mm 207.0 mm ÂŽ (8.15 in) (7.13 in) (7.52 in) - Tighten the locknut
CD.
Shock absorber spring preload adjusting locknut: 42 Nm (4.2 m-kgf, 30 ft-Ibf)
40
_ _ _ IIANOSJP I REAR SUSPENSION _ ______ Rear side RX10PA • Turn the adjusting ring tion.
~ I
CD to the proper posi-
Spring adjuster position
1
Preload
Soft~
2
Standard RX10PXTA • Turn the adjuster
~O~
3
4
5 ~
7
6
Hard
4
® to
proper position by the
tool@.
Spring preload adjuster position Spring preload Standard
S
M
H
Soft
Medium M
Hard
~---------
Always adjust both spring preload (left and right) to the same setting. Uneven adjustment can cause poor handling and loss of stability.
41
INSP ADJ
REAR SUSPENSION
o
o
o 0
(
Rebound damping force
a
o
RX10PA The rebound damping force can be adjusted by turning the rebound damping force remote adjustment dial CD in direction @ "HARD" or direction @ "SOFT".
2
.~. .---@
@
®~
® Standard position
~----------
(Q
Do not turn the remote adjustment dial while the snowmobile is moving as this could cause loss of control, an accident, and injury.
Dial position
22 clicks
o click
o click
I
I
I
"MAX SOFT"
Standard
Direction @*~ Damping force
Soft
~
"MAX HARD"
~ Direction @ ~Hard
* With the adjustment dial fully turned lightly in direction @.
Be sure to stop the remote adjustment dial at a marked position around the dial where there is a click.
~----------
This shock absorber contains highly pressurized nitrogen gas. It could explode by improper handling, causing injury, or property damage. • Do not tamper with or attempt to open the shock absorber. • Do not subject the shock absorber to an open flame or other high heat source, which could cause it to explode. • Do not deform or damage the shock absorber in any way.
42
_ _ _ IIANOSJP I REAR SUSPENSION _ ______
~O~
~ I
Compression damping force RX10PXTA Adjust the damping force by turning the adjusting knob CD. 12 clicks out 6 clicks out 2 clicks out Adjusting knob position
I
I
Minimum
Standard
Direction @*~
CompresSoft sion force
~
I
Maximum
~ Direction @ ~Hard
* With the adjusting knob fully turned lightly in direction @.
• Do not continue to turn the adjusting knob in direction @ after it stops. The shock absorber can be damaged and compression damping force adjustments cannot be made. • Do not turn the adjusting knob in direction @ more than 12 clicks. Even if the adjusting knob is continually turned after 12 clicks, there will be no change in the compression damping force. • Be sure to stop the adjusting knob at a position where there is a click.
~----------
This shock absorber contains highly pressurized nitrogen gas. It could explode by improper handling, causing injury, or property damage. • Do not tamper with or attempt to open the shock absorber. • Do not subject the shock absorber to an open flame or other high heat source, which could cause it to explode. • Do not deform or damage the shock absorber in any way.
43
REAR SUSPENSION
INSP ADJ
Air pressure RX10PSA This snowmobile is equipped with FOX shock absorbers as standard equipment. The air pressure of the shock absorbers can be adjusted using the shock absorber pump CD included with your snowmobile. This shock absorber pump has low pressure gauge @ and high pressure gauge @. Low pressure gauge measuring range: o kPa (0 kgf/cm 2 , 0 psi) to 620 kPa (6.2 kgf/cm 2 , 90 psi) High pressure gauge measuring range: o kPa (0 kgf/cm 2 , 0 psi) to 2,068 kPa (20.7 kgf/cm 2 , 300 psi) Adjustment steps:
~----------
Support the snowmobile securely on a suitable stand before adjusting the shock absorbers.
Make sure that there is no load on the shock absorbers and that they are fully extended before making any air pressure adjustments. • Place the snowmobile on a level surface and apply the parking brake. • Lift the rear of the snowmobile onto a suitable stand to raise the track off the ground. • Remove the air valve cap CD from the shock absorber. • Install the hose connector ® of the shock absorber pump to the shock absorber air valve. TIP _ When installing, make sure the shock absorber pump lever @ is down as shown in the illustration.
Do not overtighten the connector onto the air valve as this will damage the connector seal.
44
_ _ _ IIANOSJP I REAR SUSPENSION _ ______
~O~
~ I
• Lift up the shock absorber pump lever @. TIP _ • When measuring the front shock absorber, use the low pressure gauge @ of the shock absorber pump and measure. • When measuring the rear shock absorber, use the high pressure gauge © of the shock absorber pump and measure. ·If the shock absorber has no air pressure, the gauge reading will be zero. • To increase the air pressure, operate the pump a few times. The pressure should increase slowly. If the pressure increases rapidly, check to make sure that the pump is properly connected and tightened onto the air valve. To decrease the air pressure, push the bleed valve button @. TIP _ To allow pressure to escape from the pump and the shock absorber, push the button halfway down and hold it. To allow only a small amount of pressure to escape, push the button all the way down and quickly release it. • Lay flat the shock absorber pump lever. • Remove the hose connector from the air valve. TIP _ When removing the connector, the sound of air escaping may be heard, but this is from the pump hose, not the shock absorber.
Air pressure range: 965 - 1,551 kPa (9.7 - 15.5 kgf/cm 2 , 140 - 225 psi) Standard air pressure: 1,138 kPa (11.4 kgf/cm 2 , 165 psi)
45
INSP ADJ
REAR SUSPENSION
Do not exceed 1,551 kPa (15.5 kgf/cm 2 , 225 psi). • Install the air valve cap. TIP
_
If the slide rail suspension bottoms too easily, increase the air pressure by 34 kPa (0.3 kgf/ cm 2 , 5 psi). If the suspension is too firm and you want a more compliant ride, decrease the air pressure by 34 kPa (0.3 kgf/cm 2 , 5 psi).
Control rod RX10PA, RX10PSA The weight transfer can be adjusted by turning the control rod adjuster ®. 1. Adjust: • Control rod stroke Adjustment steps: • Loosen the locknut CD. • Turn the control rod adjuster ® in direction ® or @ to adjust the control rod stroke. Adjusting position
46
MIN
STD
I @
I
Effect
Decrease Pitching
Standard
Fourth mark to the left of MAX
~
~®
MAX Increase weight transfer
_ _ _ IIANOSJP I REAR SUSPENSION _ ______
~O~
~ I
- Check the adjuster length © using the scale on the special wrench ® included in the owner's tool kit as shown. Make sure that the rim @ of the control rod body is within the range ® of the scale. - While holding the adjuster securely, tighten the locknut. Control rod adjusting locknut: 35 Nm (3.5 m-kgf, 25 ft-Ibf)
When using the special wrench, make sure that it is situated at a right angle to the control rod, and that it is tightly fitted to the locknut or the control rod adjuster.
~----------
Never adjust the control rod beyond the range of the scale on the special wrench.
RX10PXTA The weight transfer can be adjusted by turning the control rod adjusting nut CD. 1. Adjust: - Control rod stroke Adjustment steps: - Loosen the locknut ® while holding the control rod adjusting nut CD. - To increase weight transfer, turn the adjusting nut in direction @. To decrease weight transfer, turn the adjusting nut in direction @. Adjusting nut position Effect Standard
47
1 Increase weight transfer
2
3 ~
~
1
Decrease weight transfer
_ _ _ IIANOSJP I REAR SUSPENSION _ ______
~O~
~ I
- Tighten the locknut.
Control rod adjusting locknut: 25 Nm (2.5 m-kgf, 18 ft-Ibf) 3
2
The left and right adjusting nut must be set to the same position. Uneven settings can cause poor handling and loss of stability.
~---------
Never adjust the control rods beyond the maximum range indicated on the rods with red paint @.
48
___ _ _ _ IIANOSJP I TROUBLESHOOTING (SKI, SUSPENSION) _ ___
~O~
~ I
TROUBLESHOOTING (SKI, SUSPENSION) This section will point you towards possible solutions for resolving handling or ride comfort complaints. When making adjustments, do it in a small increments. Also, in general, making just one adjustment may not correct the problem. You may need to make several small adjustments to get the best overall results. Keep in mind that how the snowmobile handles going down the trail is usually controlled by the front suspension, the center shock, and the limiter straps. How the snowmobile rides (ride comfort) is usually controlled by the rear shock. Also, remember that snowmobile suspension adjustments may involve compromises. Tuning a snowmobile to do one thing very well may come at the sacrifice of something else. For example, if the snowmobile is setup to provide optimum weight transfer for best acceleration, this same setting will not be ideal for trail riding, because excessive under steering may be experienced during cornering. You must have a good working knowledge of the suspension and tune the suspension to provide best overall balance for specific conditions and usages. SYMPTOM DESCRIPTION POSSIBLE CAUSE Front of the snowmobile darts • Too much weight on skis. from side to side on a straightaway.
Under steering - front end (skis) pushes when cornering.
• Skis out of alignment. • Loose steering ball joints. • Too much carbide on ski runners. • Worn or missing carbides on ski runners. • Not enough weight on skis.
Over steering. Front end (skis) • Too much weight on skis. bites too much during cornering - rear of the snowmobile starts to come around.
Heavy steering - excessive force is needed to turn the handlebars.
• Too much carbides on ski runners. • Too much weight on skis.
• Too much carbides on ski runners. • Steering linkage binding.
49
POSSIBLE REMEDY • Extend limiter straps and/or increase center shock spring preload or reduce rear shock spring preload or reduce front shock spring preload. • Adjust "ski-toe-out." • Replace worn ball joints. • Use ski runners with less earbide. • Replace carbide runners. • Reduce center shock spring preload and/or shorten limiter straps. Increase front shock spring preload. • Extend limiter straps and/or increase center shock spring preload or reduce rear shock spring preload or reduce front shock spring preload. • Use ski runners with less earbides. • Extend limiter straps and/or increase center shock spring preload or reduce rear shock spring preload or reduce front shock spring preload. • Use ski runners with less earbides. • Clean and lubricate steering ball joints and column.
TROUBLESHOOTING (SKI, SUSPENSION) SYMPTOM DESCRIPTION Front suspension bottoming out frequently.
Front suspension is too harsh over small bumps.
Front suspension bouncing over bumps.
Excessive inside ski lift during cornering. Front end is tippy.
Rear suspension bottoming out frequently.
Rear suspension bouncing over bumps (feels like spring only).
POSSIBLE CAUSE • Not enough front shock spring preload and/or spring used is too soft. • Blown shock absorbers (oil leaking out of shocks). • Loss of nitrogen gas pressure in the shocks. • Too much front shock spring preload and/or the spring used is too stiff. • The shock absorber oil is contaminated. • Blown shock absorbers (oil leaking out of shocks). • Loss of nitrogen gas pressure in the shocks. • Stabilizer bar binding or damaged joint linkage bushings.
INSP ADJ
POSSIBLE REMEDY • Increase spring preload and/or select stiffer springs. • Replace shocks. • Replace shocks. • Reduce spring preload and/or select softer spring. • Replace shocks. • Replace shocks. • Replace shocks.
• Check for free movement of stabilizer bar. Check the condition of the joint linkage bushing and replace as necessary. • Control rod adjusted to pro• Adjust control rod to allow less vide too much weight transfer. weight transfer. • Too much front shock spring • Reduce spring preload and/or preload and/or the spring used select a softer spring. is too stiff. • Center shock limiter straps are • Shorten limiter straps. too long. • Not enough rear shock spring • Increase rear spring preload preload and/or the spring used (set rear spring preload for caris too soft. rect ride height). If necessary, select stiffer springs. • Blown shock absorbers (oil • Replace shocks. leaking out of shocks). • Loss of nitrogen gas pressure • Replace shocks. in the shocks. • Blown shock absorbers (oil • Replace shocks. leaking out of shocks). • Loss of nitrogen gas pressure • Replace shocks. in the shocks.
50
TROUBLESHOOTING (SKI, SUSPENSION) SYMPTOM DESCRIPTION Rear suspension is too harsh over small bumps.
Not enough weight transfer. Track won't hook up.
POSSIBLE CAUSE -Too much rear/center shock spring preload and/or the spring used is too stiff.
INSP ADJ
POSSIBLE REMEDY - Reduce rear/center spring preload (set rear spring preload for correct ride height). If necessary, select softer spring. - Replace shocks.
- Shock absorber oil is contaminated. - Rear suspension linkages and/ -Inspect for free movement of or pivot arms binding. rear suspension linkages and arms. Replace damaged components and apply grease to all pivot areas. - Limiter straps length has been - Lengthen limiter straps length. shortened. - Control rod adjustment does - Adjust control rod to allow not provide enough weight more weight transfer. transfer. -Increase center shock spring - Not enough center shock spring preload and/or the limpreload and lengthen limiter iter straps are too short. straps. - Too much rear shock spring - Reduce rear shock spring prepreload. load.
51
____________ G_E_N_ER_A_L_C_H_A_S_S_IS_ICHAS
I
~I
CHASSIS GENERAL CHASSIS WINDSHIELD AND HEADLIGHT
I
[8]: 0.4 Nm (0.04 m-kgf, 0.29ft-lbf)
5
2
Order
Job name/Part name
Q'ty
Windshield and headlight removal 1 2 3
4 S
6 7 8
9 10 11 12 13
Windshield Fairing Top cover Main switch coupler Auxiliary DC jack coupler Main switch Auxiliary DC jack Headlight cover Headlight side cover Speedometer coupler Speedometer Headlight coupler Headlight
1 2 1 1 1 1 1 1 2 1 1 2 1
Remarks Remove the parts in the order listed below.
Disconnect. Disconnect.
Disconnect. Disconnect. For installation, reverse the removal procedure.
52
____________ G_E_N_ER_A_L_C_H_A_S_S_IS_lcHAS I
~I
AIR FILTER CASE
[A]:
I 3.0 Nm (0.30 m-kgf, 2.2 ft-Ibf) I
3
5
6
9
7
7 7
10
Order
Job name/Part name
Q'ty
Air filter case removal
1 2
3 4 5
6 7 8
9 10
Headlight Shroud Side cover (left and right) Intake air temperature sensor coupler Intake air temperature sensor Air filter case cover Crankcase breather hose 1 Air filter element frame Air filter element Air filter case joint clamp screw Crankcase breather hose 2 ISC (idle speed control) unit inlet hose Air filter case
Remarks Remove the parts in the order listed below. Refer to "GENERAL CHASSIS".
D- Refer to "COWLINGS" in CHAPTER 3. 1 1 1 1 1 1
Disconnect.
4
Loosen. Disconnect. Disconnect.
1 1 1
For installation, reverse the removal procedure.
53
____________ G_E_N_ER_A_L_C_H_A_S_S_IS_lcHAS I
~I
SEAT AND TAIL/BRAKE LIGHT
Order
1 2
3 4 5
6 7
Job name/Part name Seat and fuel tank removal Fuel tank side cover (right) Seat Tail/brake light coupler Rear cover Muffler end cap Muffler side cover Tail/brake light cover Tail/brake light
Q'ty
1 1 1 2 2 1 1
Remarks Remove the parts in the order listed below. Refer to "FUEL TANK" in CHAPTER 5. Disconnect.
For installation, reverse the removal procedure.
54
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS
I
~I
STEERING STEERING
Order
1 2
3 4 5
6 7 8
9 10
Job name/Part name Q'ty Remarks Steering column and tie rod removal Remove the parts in the order listed below. Fuel tank Refer to "FUEL TANK" in CHAPTER 5. Oil tank Refer to "OIL TANK" in CHAPTER 5. Shift lever assembly Refer to "DRIVE CHAIN HOUSING" in CHAPTER 4. Clip 3 Relay rod 1 Cotter pin 12 Steering shaft 1 Lock washer 2 Bearing 4 Bearing holder 4 Plate 2 Collar 4 Steering column 1 1
55
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS
I
~I
15 /
/
Order 11 12 13 14 15 16 17 18 19 20 21 22 23
Job name/Part name EPS motor cover Steering column 2 Pitman arm EPS motor Tie rod Idler arm Clip Washer Washer Collar Bushing Collar Relay arm
Q'ty 1 1 1 1 2 1 2 4 2 2 4 2 2
Remarks
For installation, reverse the removal procedure.
56
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS
I
~I
REMOVAL 1. Straighten the lock washer tabs.
INSPECTION 1. Inspect: • Handlebar • Steering column 1 ® • Steering column 2 ®
CD
• Pitman arm @ • EPS motor splines
@
Bends/cracks/damage
~
Replace.
~---------
Do not attempt to straighten a bent column. This may dangerously weaken the column.
2. Inspect: • Bearings (steering column) • Collars ® Wear/damage
~
CD
Replace.
• Steering column 1 ® (bearing contact surfaces) • Steering column 2 @ (bearing contact surfaces) Scratches/wear/damage ~ Replace.
@ \
57
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS 3. Inspect: • Relay rod CD • Tie rods ® • Steering shaft ® Bends/cracks/damage
~
I
~I
Replace.
~---------
Do not attempt to straighten bent rods. This may dangerously weaken the rods. 4. Check: • Rod end movement Rod end free play exists ~ Replace the rod end. Rod end turns roughly ~ Replace the rod end.
5. Inspect: • Right relay arm CD • Left relay arm ® • Idler arm ® Cracks/damage ~ Replace. • Bearings ® Wear/damage ~ Replace.
INSTALLATION 1. Install: • Relay arms CD • Bushings • Washers ® • Clips ® Relay arm bolt: 67 Nm (6.7 m·kgf, 48 ft·lbf)
58
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS
I
~I
2. Install: - Idler arm CD - Bushings - Washers - Relay rod ® - Locknuts @ - Joints ®
[8] Relay rod part number 8HG-23821-00
~ Set
length ® 183.3 mm (7.22 in)
[Q] Shaft length @ 125.3 mm (4.93 in)
® I
I'--®-b--
~
Always use new cotter pins.
~«
TIP
_
Install the idler arm with the "R" mark © on the right side facing towards the rear of the snowmobile.
Idler arm nut: 35 Nm (3.5 m-kgf, 25 ft-Ibf) Relay arm-relay rod nut: 30 Nm (3.0 m-kgf, 22 ft-Ibf)
n I
3. Install: - Tie rod CD - Locknuts ® - Joints @
®
I'--®-b--
[8] Tie rod part
~«
number 8ES-23831-00
59
~ Set length ® 424.0 mm (16.69 in)
[Q] Tie rod length @ 361.0 mm (14.21 in)
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS 4. Install: - Tie rods TIP
I
~I
CD
_
Make sure that the indentation @ on the tie rod faces out.
- After tightening the inside and outside ball joint locknut ®, make sure the tie rod CD can be rotated freely through the ball joint travel. If not, loosen the locknut ® and reposition the ball joint so that the tie rod CD can be rotated freely. Tighten the locknut to specification. - Always use new cotter pins. Tie rod end locknut: 25 Nm (2.5 m-kgf, 18 ft-Ibf) LOCTITE® Tie rod-idler arm nut: 30 Nm (3.0 m-kgf, 22 ft-Ibf) Tie rOd-steering arm nut: 35 Nm (3.5 m-kgf, 25 ft-Ibf)
60
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS 5. Install: - Pitman arm TIP
I
~I
CD _
Align the punch mark @ on the EPS unit with the groove @ in the pitman arm. - Nut速 Pitman arm nut 205 Nm (20.5 m-kgf, 148 ft-Ibf)
Always use new cotter pin. TIP
_
Restrict the rotation of the pitman arm and then tighten the nut. ~\
6. Install (temporary tighten): - EPS motor CD - Steering column 2 速 TIP
_
Align the punch mark @ on the EPS unit with the groove @ in the steering column 2. c
61
Bearing 速 Collar Plate Bearing holder 速 Lock washer @
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS
I
~I
7. Tighten: (Tighten in the order below.) 1.EPS motor nut
,
~~
EPS motor nut 30 Nm (3.0 m-kgf, 22 ft-Ibfl
2. Bearing holder nut
,
~~
Bearing holder nut 23 Nm (2.3 m-kgf, 17 ft-Ibfl
3. Steering column 2 bolt
Steering column 2 bolt 35 Nm (3.5 m-kgf, 25 ft-Ibf) LOCTITE®
Always use new cotter pins.
8. Bend: 1.Bending the lock washer tabs
62
11m
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS 9. Install: - Steering shaft - Locknuts ® - Joints ®
@ I
I--®-b--
~ I
(v
~«
I
~I
CD
[8] Steering Shaft part number 8FA-23828-00
llil Set length ® 227.8 mm (8.97 in)
[Q Shaft length @ 169.8 mm (6.69 in)
TIP
_
-Install the pink-colored end of the joint ® to the steering column 1. -Install the "C" measure side of the steering shaft to the steering column 1.
© 50 mm (1.97 in)
@ 65 mm
(2.56 in)
Always use new cotter pins. Steering shaft end locknut: 25 Nm (2.5 m-kgf, 18 ft-Ibf) LOCTITE® Steering shaft nut: 35 Nm (3.5 m-kgf, 25 ft-Ibf)
63
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS
I
~I
10.Adjust: - Skis
Adjustment steps: - Temporarily install the handlebar. - Hold the handlebar straight and check that the skis and relay arms are at right angles to the handlebar. - Install the steering linkage alignment plate CD to the relay arms ®. Steering linkage alignment plate: YS-01487 Steering link holder: 90890-01487 - Loosen the locknuts (steering shaft) @. - Turn the steering shaft ® left to right and adjust the handle so that it is set in a straight line.
Turning the steering shaft in direction ® Turning the steering shaft in direction @
Turning the handlebar in direction © Turning the handlebar in direction @
- Tighten the locknuts (steering shaft)
©
®.
~
Steering shaft locknut: 25 Nm (2.5 m-kgf, 18 ft-Ibf) ......--... LOCTITE®
~
~
- Adjust each angle of right and left skis by turning the tie rod respectively. - Measure the ski toe-out. Refer to "STEERING SYSTEM" in CHAPTER
2. - Remove the steering linkage alignment plate (steering link holder) CD.
64
_ _ _ _ _ _ _ _ _ _ _ _ _ _S_T_E_ER_I_NG_lcHAS
I
~I
11.lnstall:
CD
- Handlebar - Handlebar holders
ÂŽ
First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. TIP
_
- The handlebar holders should be installed with the punch marks ÂŽ facing forward. - Align the match mark @ on the handlebar with the upper surface of the steering joint. Handlebar holder bolt: 23 Nm (2.3 m-kgf, 17 ft-Ibf)
65
_ _________ lpOTWRRI~1 ~
SLIDE RAIL SUSPENSION
POWER TRAIN SLIDE RAIL SUSPENSION Control rod part numbers (RX10PA, RX10PSA) A
~ ~ ~----'
®
---------------
[8] Control rod 1 part number
~ Length
8JA-4745A-00
® mm (in)
277.3 (10.92)
[Q] Length @ mm (in) 359.5 . . . 360.5 (14.15 . . . 14.19)
[Q] Control rod 2
~ Washer plate part number
part number
[E] Washer plate thickness mm (in)
8JA-47458-00
8GM-47384-10 15.0 (0.59)
c
@
/
[8J [§] Standard position
66
~
SLIDE RAIL SUSPENSION
------------------------Control rod part numbers (RX10PXTA)
Ip~:RIC£B1
l8J
E-----==EEIffirnJ@
~@
t
~©
I
E-----~BErm[8] Control rod 1
~ Length
® mm (in)
[Q] Length @ mm (in)
RX10PXTA
238.3 (9.38)
~ Control rod 1
[E] Control rod stopper
part number
part number
[Q] Length
© mm (in)
2.5P x 2 = 5 (O.098P x 2 = 0.196)
199.7 (7.86)
[Q] Washer part numbers [8] Washer thickness mm (in) [Kl Q'ty
[]] Upper
Q] Lower
[Kl Q'ty
90202-25001 2.0 (0.079)
1
[N] 902028HL-4745A-00
25001 2.0 (0.079)
8ES-4745D-00
1
[MJ 9020124015 2.0 (0.079)
I
rf'11
....
... ~
1
o
( II
I
[] Standard position
I
E
F
[MJ Metal washer [N] Plastic washer
67
J
~
_ _________ lpOTWRRI~1 ~
SLIDE RAIL SUSPENSION INSPECTION
~~~~~~
,~~
1. Inspect: • Track CD • Track clips ® Wear/cracks/damage
~~
~
Replace.
\ 2. Inspect: • Sprocket wheels CD Wear/break/damage ~ Replace. • Front axle ® Bends/scratches (excessive)/damage Replace. 3. Inspect: • Bearing Pitting/damage ~ Replace.
~
INSTALLATION
1. Install: • Track clips
CD (to the track ®)
TIP
_
Install the track clip installer @ and track clip on the track as shown in the illustration.
~ ,-
Track clip installer: YS-91045-C 90890-01533
[8] outside
68
_ _________ lpOTWRRI~1 SLIDE RAIL SUSPENSION 2. Install: • Sprocket wheels TIP
9.3mm (0.37 in)
65.0 mm (2.56 in)
_
• When pressing the sprocket wheels onto the front axle, align the "R" mark @ and "I..:' mark @ on the sprocket wheels as shown in the illustration. • When pressing the sprocket wheels onto the front axle, align the arrow mark on each sprocket wheel. • Position each sprocket wheel on the axle as shown in the illustration.
9.3mm (0.37 in)
• -tHR---++--- t --+-------+-1 -t-\\-----+---+
~
---+---:Y- - -------EEJ]
189.4mm (7.46 in) 237.4 mm (9.35 in)
3. Place the track in the chassis. TIP
_
For track with a direction of rotation mark @: Install the track with the mark pointing in the direction of track rotation.
4. Install: • Bearing holder CD TIP
_
Align the punch mark @ on the bearing holder CD with the rivet (2).
69
_ _ _ _ _ _ _ _ _E_X_H_A_U_S_T_P_IP_E_A_N_D_M_U_F_F_LE_R_I
ENG I
ENGINE EXHAUST PIPE AND MUFFLER
Order
Job name/Part name
Q'ty
Exhaust pipe and muffler removal Slide rail suspension
1 2
3 4 5
6 7
Shroud Left side cover Seat Fuel tank EXUP servo motor coupler EXUP maintenance window cover EXUP valve pulley cover EXUP servo motor EXUP servo motor pulley cover EXU P cable (black metal) EXUP cable (white metal)
Remarks Remove the parts in the order listed below. Refer to "SLIDE RAIL SUSPENSION" in CHAPTER 4.
~ Refer to "COWLINGS" in CHAPTER 3.
1 1 1 1 1 1 1
70
Refer to "GENERAL CHASSIS". Refer to "FUEL TANK" in CHAPTER 5. Disconnect.
_ _ _ _ _ _ _ _ _E_X_H_A_U_S_T_P_IP_E_A_N_D_M_U_F_F_LE_R_I
Order
8 9 10 11 12 13 14 15 16 17 18 19 20
Job name/Part name Muffler cover plate Muffler cover Muffler band bolt Muffler Muffler band Muffler gasket Exhaust pipe joint cover Exhaust pipe band Exhaust pipe joint Exhaust pipe gasket Exhaust pipe joint gasket Frame protector Exhaust pipe
Q'ty
1 1 1 1 1 1 1 4 4 4 1 2 1
71
ENG I
Remarks
Loosen.
_ _ _ _ _ _ _ _ _E_X_H_A_U_S_T_P_IP_E_A_N_D_M_U_F_F_LE_R_I
Order
21 22 23 24 25 26 27
Job name/Part name EXUP cable holder EXUP valve housing EXUP valve pulley Plate Collar Spring EXUP valve
Q'ty
ENG I
Remarks
1 1 1 1 1 1 1 For installation, reverse the removal procedure.
72
_ _ _ _ _ _ _ _ _E_X_H_A_U_S_T_P_IP_E_A_N_D_M_U_F_F_LE_R_I
ENG I
INSTALLATION 1. Assemble: - Collar CD - EXUP valve ® - EXUP valve housing ® - Spring @ - Plate @ - Collar@ - EXUP valve pulley (J) - Washer ® - EXUP valve nut ® Assembly steps: - Install the collar to the EXUP valve and then, install the EXUP valve to the EXUP valve housing. - Install the spring, plate, collar, EXUP valve pulley, washer, and EXUP valve nut to the EXUP valve housing. TIP _
Before installation, set the plate and collar to the EXUP valve pulley. EXUP valve nut: 7 Nm (0.7 m-kgf, 5.1 ft-Ibf)
2. Install: - Gasketlm!l - EXUP valve assembly CD TIP
_
-Install the gasket with tabs ® down and install the EXUP valve housing with boss @ up. -Temporarily tighten the EXUP valve housing bolt ®, do not torque them at this point.
73
EXHAUST PIPE AND MUFFLER
------------------------3. Install:
I ENG I
- EXUP cable holder CD TIP
_
- Align the projection @ on the EXUP valve housing ÂŽ with the hole @ in the EXUP cable holder. -Temporarily tighten the EXUP valve housing bolts @, do not torque them at this point.
4. Tighten: - EXUP valve housing bolts
CD
EXUP valve housing bolt: 10 Nm (1.0 m-kgf, 7.2 ft-Ibf)
5. Install: - Exhaust pipe CD (temporarily) - Frame protectors ÂŽ TIP ~Install the exhaust pipe to the brackets @ on the frame, making sure to position it as far rearward as possible, and then temporarily tighten the exhaust pipe bolts.
Frame protector bolt: 16 Nm (1.6 m-kgf, 12 ft-Ibf)
74
_ _ _ _ _ _ _ _ _E_X_H_A_U_S_T_P_IP_E_A_N_D_M_U_F_F_LE_R_I
ENG I
6. Install: • Exhaust pipe joint gasket • Exhaust pipe joints
~ ~
ImII
Exhaust pipe joint bolt: 25 Nm (2.5 m·kgf, 18 ft·lbf)
• Exhaust pipe gaskets • Exhaust pipe bands TIP
ImII _
• After installing the exhaust pipe joints, fit the exhaust pipe into them. • Temporarily tighten the exhaust pipe band bolts, do not torque them at this point.
7. Install: • Muffler gasket (to muffler) TIP
CD ImII _
When installing the muffler gasket, insert it with the carbon side @ facing to the rear of the snowmobile.
8. Install: • Muffler band • Muffler ® TIP
CD _
• Align the projection @ on the muffler band with the slot @ on the muffler. • During installation, projection @ of the muffler band should not make contact with end © of the muffler gasket. • Temporarily tighten the muffler band bolt and muffler bolts; do not torque them at this point.
b
75
_ _ _ _ _ _ _ _ _E_X_H_A_U_S_T_P_IP_E_A_N_D_M_U_F_F_LE_R_I
ENG I
9. Tighten: - Exhaust pipe band bolts Exhaust pipe band bolt: 18 Nm (1.8 m-kgf, 13 ft-Ibf)
10.lnstall: - Exhaust pipe joint cover CD Exhaust pipe joint cover bolt: 6 Nm (0.6 m-kgf, 4.3 ft-Ibf)
11.Tighten: - Exhaust pipe bolts (front side) CD - Exhaust pipe bolts (rear side) ® Exhaust pipe bolt (front side): 25 Nm (2.5 m-kgf, 18 ft-Ibf) Exhaust pipe bolt (rear side): 16 Nm (1.6 m-kgf, 12 ft-Ibf)
12.Tighten: - Muffler bolts ,
~~
CD
Muffler bolt: 16 Nm (1.6 m-kgf, 12 ft-Ibfl
TIP _ Before tightening muffler bolts CD, align the center of the bolt with the marks ® on the muffler seating surface.
76
_ _ _ _ _ _ _ _ _E_X_H_A_U_S_T_P_IP_E_A_N_D_M_U_F_F_LE_R_I 13.Tighten: - Muffler band bolt
~~~ ®~ ~~~o
ENG I
CD
Muffler band bolt: 20 Nm (2.0 m-kgf, 14 ft-Ibf)
@oo~
-.J
LJ 0
"" n
n 14.lnstall: - Muffler cover CD - Muffler cover plate
®
Muffler cover nut: 16 Nm (1.6 m-kgf, 12 ft-Ibf) Muffler cover plate bolt: 7 Nm (0.7 m-kgf, 5.1 ft-Ibf)
15.lnstall: - EXUP cable (white metal) - EXUP cable (black metal) (to EXUP servo motor)
CD ®
Installation steps: - Install the EXUP cable (white metal) to the EXUP servo motor pulley @. (Install it on the side with embossed number "2" @.) - Install the EXUP cable (black metal) to the EXUP servo motor pulley. (Install it on the side with embossed number "1" @.) - Install the EXUP servo motor pulley cover @ and EXUP servo motor pulley cover bolt. EXUP servo motor pulley cover bolt: 2.0 Nm (0.20 m-kgf, 1.5 ft-Ibf)
16.lnstall - EXUP servo motor EXUP servo motor bolt: 10 Nm (1.0 m-kgf, 7.2 ft-Ibf)
77
_ _ _ _ _ _ _ _ _E_X_H_A_U_S_T_P_IP_E_A_N_D_M_U_F_F_LE_R_I
ENG I
17.lnstall: - EXUP cable (white metal) CD - EXUP cable (black metal) ® (to EXUP valve pulley @) TIP
_
- Cross the EXUP cable (black metal) and EXUP cable (white metal) between the EXUP servo motor and frame clamp once @. Route the cables to the EXUP cable holder with the EXUP cable (black metal) on the top in the frame clamp area @. - First install the EXUP cable (white metal) to the EXUP valve pulley @, and then install the EXU P cable (black metal) to the EXU P valve pulley.
@ EXUP servo motor
18.Tighten: - EXUP cable locknuts ,
~~
CD
EXUP cable locknut: 6 Nm (0.6 m-kgf, 4.3 ft-Ibf)
19.Adjust: - EXUP cable Refer to "EXUP CABLE ADJUSTEMENT".
20.lnstall: - EXUP valve pulley cover
CD
EXUP valve pulley cover bolt: 10 Nm (1.0 m-kgf, 7.2 ft-Ibf)
78
_ _ _ _ _ _ _ _ _ _ _ _ _ _C_A_M_S_H_A_FT_S_I
ENG I
CAMSHAFTS INSPECTION 1. Inspect: • Camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft.
~
2. Measure: • Camshaft lobe dimensions ® and @ • Out of specification ~ Replace the camshaft. Camshaft dimensions: Intake: <Limit>: ® 32.851 mm (1.2933 @ 24.862 mm (0.9788 Exhaust: <Limit>: ® 33.500 mm (1.3189 @ 24.856 mm (0.9786
3. Measure: • Camshaft runout Out of specification
~
Replace.
Camshaft runout: 0.03 mm (0.0012 in)
79
in) in)
in) in)
_ _ _ _ _ _ _ _ _ _ _ _ _ _C_A_M_S_H_A_FT_S_I
ENG I
4. Measure: - Camshaft-journal-to-camshaft-cap clearance Out of specification ~ Measure the camshaft journal diameter. Camshaft-journal-to-camshaftcap clearance: 0.028 - 0.062 mm (0.0011 - 0.0024 in)
Measurement steps: - Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). - Position a strip of Plastigauge® CD onto the camshaft journal. - Install the dowel pins and camshaft caps. TIP _ - Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. - Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®.
~ Camshaft cap bolt:
v A~
10 Nm (1.0 m-kgf, 7.2 ft-Ibf)
- Remove the camshaft caps and then measure the width of the Plastigauge® CD.
80
_ _ _ _ _ _ _ _ _ _ _ _ _ _C_A_M_S_H_A_FT_S_I
ENG I
5. Measure: • Camshaft journal diameter @ Out of specification ~ Replace the camshaft. Within specification ~ Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter: 24.459 - 24.472 mm (0.9630 - 0.9635 in)
6. Inspect: • Camshaft sprocket More than 1/4 tooth @ wear ~ Replace the camshaft sprockets and the timing chain as a set.
@ 1/4 tooth @Correct Timing chain (2) Camshaft sprocket
CD
7. Inspect: • Timing chain guide (exhaust side CD and top side (2)) Damage/wear ~ Replace the timing chain guide.
81
_ _ _ _ _ _ _ _ _ _ _ _ _ _C_A_M_S_H_A_FT_S_I
ENG I
8. Inspect: • Timing chain tensioner Cracks/damage ~ Replace.
Inspection steps: • Using a hand press, push and insert timing chain tensioner rod CD into the timing chain tensioner housing. TIP _ Push the timing chain tensioner rod in direction
@, and turn the timing chain tensioner body
® in direction @ until it stops. @Hand press
® Bearing
• Keep pressing the timing chain tensioner rod, mount clip @ into groove @, and lock the timing chain tensioner rod. • Push the timing chain tensioner rod in direction@. • Make sure that the timing chain tensioner rod can smoothly move out from the timing chain tensioner housing in direction @. If not smooth, replace the timing chain tensioner assembly.
9. Inspect: • All parts Damage/wear part (-s).
82
~
Replace the defective
_ _ _ _ _ _ _ _ _ _ _ _ _ _C_A_M_S_H_A_FT_S_I
ENG I
INSTALLATION 1. Install: - Exhaust camshaft CD - Intake camshaft ® TIP
_
Install the camshafts with the punch mark @ facing up.
2. Install: - Dowel pins - Intake camshaft caps - Exhaust camshaft caps TIP
_
Make sure that the punch marks @ on the camshafts are aligned with the arrow marks @ on the camshaft caps. Out of alignment ~ Reinstall. 3. Install: - Camshaft cap bolts Camshaft cap bolt: 10 Nm (1.0 m-kgf, 7.2 ft-Ibf) TIP
_
Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result.
83
_ _ _ _ _ _ _ _ _ _ _ _ _ _C_A_M_S_H_A_FT_S_I
ENG I
4. Install: - Intake camshaft sprocket - Exhaust camshaft sprocket
Installation steps: - Turn the crankshaft counterclockwise. - When piston #4 is at TOC on the compression stroke, align the "I" mark @ on the AC magneto rotor with the stationary pointer @ on the AC magneto rotor cover. - Place the timing chain onto both camshaft sprockets and then install the camshaft sprockets onto the camshafts. TIP _ When installing the camshaft sprockets, start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side.
Do not turn the crankshaft when installing the camshaft sprockets to avoid damage or improper valve timing. - Make sure that the punch marks Š on the camshafts are aligned with the arrow marks @ on the camshaft caps. - While holding the camshafts, tighten the camshaft sprocket bolts.
Camshaft sprocket bolt: 24 Nm (2.4 m-kgf, 17 ft-Ibf)
84
_ _ _ _ _ _ _ _ _ _ _ _ _ _C_A_M_S_H_A_FT_S_I
ENG I
5. Install: - Timing chain tensioner gasket - Timing chain tensioner
l1li
Installation steps: - Using a hand press, push and insert timing chain tensioner rod CD into the timing chain tensioner housing. TIP _ Push the timing chain tensioner rod in direction
@, and turn the timing chain tensioner body ÂŽ in direction @ until it stops. @Hand press
ÂŽ Bearing
- Pressing and holding the timing chain tensioner rod, set clip @ to groove @ and then lock the timing chain tensioner rod. - With the timing chain tensioner rod locked, install the timing chain tensioner to the cylinder block. TIP _ Always use a new gasket.
~
&'~
Timing chain tensioner bolt: 10 Nm (1.0 m-kgf, 7.2 ft-Ibf)
- Unlock the timing chain tensioner by turning the crankshaft clockwise, and tension the timing chain. 6. Turn: - Crankshaft (several turns counterclockwise)
85
_ _ _ _ _ _ _ _ _ _ _ _ _ _C_A_M_S_H_A_FT_S_I
ENG I
7. Inspect:
Inspection steps: • "I" mark ® Make sure that the "I" mark on the AC magneto rotor is aligned with the stationery pointer @ on the AC magneto rotor cover.
• Camshaft punch marks © Make sure that the punch marks © on the camshafts are aligned with the arrow marks @ on the camshaft caps. Out of alignment ~ Adjust. Refer to the installation steps above.
8. Measure: • Valve clearance Out of specification ~ Adjust. Refer to "VALVE CLEARANCE ADJUSTMENT" in CHAPTER 2.
86
______________ C_R_A_N_KC_A_S_E_I
ENG I
CRANKCASE [8]: 1 10 Nm (1.0 m-kgf, 7.2 ft-Ibf)
D
[ill: 1 12 Nm (1.2 m-kgf, 8.7 ft-Ibf) [9: 1 27 Nm (2.7 m-kgf, 20 ft-Ibf)
I~
[QJ:
1st 15 Nm (1.5 m-kgf, 11 ft-Ibf) 2nd 15 Nm (1.5 m-kgf, 11 ft-Ibf) Final Specified angle 65-70°
[EJ Tighten these bolts first.
[E] Tighten these bolts second.
Order
Q'ty
Job name/Part name Crankcase separate Engine Cylinder head AC magneto rotor/Starter clutch gear
1 2
3 4 5
6
Oil pump Water pump Starter motor Knock sensor Water pump outlet hose/Joint Countershaft cover Dowel pin Lower crankcase Dowel pin
Remarks Remove the parts in the order listed below. Refer to "ENGINE ASSEMBLY". Refer to "CYLINDER HEAD". Refer to "AC MAGNETO ROTOR AND STARTER CLUTCH". Refer to "OIL PAN AND OIL PUMP". Refer to "WATER PUMP". Refer to "STARTER MOTOR".
1 1/1 1 2 1 2 For installation, reverse the removal procedure.
* Yamaha bond NO.1215 (Three bond No.
1215®) 87
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM
CD Ignition coil ® Speed sensor ® Spark plug ® Engine trouble ® Thumb warmer adjust- ing light
warn-
@ Atmospheric pressure @ Intake silencer @ Crankshaft position sensor @ Fuel injector sensor @ Oil pressure switch @ Coolant temperature
@ Fuel hose @ Cylinder identification @ECU @ Knock sensor sensor @ Grip warmer adjust- @ Throttle position sen- @ Battery @ Intake air pressure ment switch sor ([) Fuel injection system @ Intake temperature sensor @ Oil level switch relay sensor ment switch
® Fuel pump ® Fuel tank
a
I I
I
I
I
/
@
14
\ \
I
4 88
sensor
\\
\
\
c@
FUEL INJECTION SYSTEM WIRING DIAGRAM
89
FI
FUEL INJECTION SYSTEM
CD Crankshaft position sensor ® Main switch @Main fuse
(J) Fuel injection system fuse
® Starter relay ® Battery
@ Engine stop switch @ Throttle switch @ Grip warmer @ Thumb warmer @ Grip warmer adjustment switch @ Thumb warmer adjustment switch
@ Oil pressure switch @ CO adjustment coupler @ ECU (engine control unit) @ Ignition coil sub-wire harness @ Cylinder-#1 ignition coil @Spark plug
@ Cylinder-#2 ignition coil @ Cylinder-#3 ignition coil @ Cylinder-#4 ignition coil @ Fuel injection system relay @Fuel pump
@ Injector #1 @ Injector #2 @ Injector #3 @ Injector #4 @ Throttle position sensor @ Speed sensor @ Cylinder identification sensor
® Atmospheric pressure sensor
@ Intake air pressure sensor
® Coolant temperature sensor
@ Intake air temperature sensor
® Knock sensor
@j) ISC (idle speed control) @ EXUP servo motor
unit
~ Speedometer unit
@ Multi-function meter @ Warning light @ Radiator fan motor <@ Radiator fan motor relay @ Ignition fuse ~ Radiator fan motor fuse
90
FI
FI
FUEL INJECTION SYSTEM
ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and the warning light and self-diagnostic warning indicator on the upper LCD flash to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU. â&#x20AC;˘ If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appropriate substitute characteristic operation, and the warning light and self-diagnostic warning indicator on the upper LCD flash to alert the rider of the detected malfunction. â&#x20AC;˘ The lowest fault code number appears on the lower LCD. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted. SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the snowmobile is being driven, the warning light and self-diagnostic warning indicator on the upper LCD flash to alert the rider that a malfunction has occurred and the ECU provides the engine with alternate operating instructions that are appropriate for the type of malfunction. When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions.
Self-Diagnostic-Function table Fault code No.
Item
Symptom
Cylinder identification sensor 11 12 13
14
15 16 17 18
20
Crankshaft position sensor
No normal signals are received from the cylinder identification sensor.
No the Intake air pressure sensor (cylin- No ders #1, #2, #3, and #4) (open or the short ci rcuit)
normal signals are received from crankshaft position sensor. normal signals are received from intake air pressure sensor.
Intake air pressure sensor (cylin- Intake air pressure sensor: hose sysders #1, #2, #3, and #4) (hose tem malfunction (clogged or detached line) hose). Intake air system failure (the pressure is not supplied to the intake air pressure sensor in a stable condition.) Throttle position sensor (open or No normal signals are received from short circuit) the throttle position sensor. Throttle position sensor (stuck) Signal from throttle position sensor will not change. EXUP servo motor circuit (open or No normal signals are received from short circuit) the EXUP servo motor circuit. EXUP servo motor (stuck) Signal from EXUP servo motor position will not change. Intake air pressure or atmospheric When turning the main switch to "ON", pressure the voltage value shows great difference between the intake air pressure sensor and atmospheric pressure sensor.
Able/unable to start Unable
Able/unable to drive Able (under certain conditions)
Unable
Unable
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
21
Coolant temperature (open or short circuit)
sensor No normal signals are received from the coolant temperature sensor.
Able
Able
22
Intake air temperature (open or short circuit)
sensor No normal signals are received from the intake air temperature sensor.
Able
Able
91
FI
FUEL INJECTION SYSTEM Fault code No. 23 30
Item Atmospheric pressure (open or short circuit) Oil pressure dropped Cylinder-#1 ignition)
ignition coil
33
Cylinder-#2 ignition coil ignition) 34
Symptom sensor No normal signals are received from the atmospheric pressure sensor. Detection of the low oil pressure signal
36
37 42 43
44 46
50
65 80 81 82 83 84 85
Able/unable to drive
Able
Able
Unable
Unable
(faulty No normal signals are received from Able Able the ignition circuit. (depending on (depending on the number of the number of faulty faulty cylinders) cylinders) (faulty No normal signals are received from Able Able the ignition circuit. (depending on (depending on the number of the number of faulty faulty cylinders) cylinders)
Cylinder-#3 ignition coil ignition)
35
Able/unable to start
(faulty No normal signals are received from Able Able the ignition circuit. (depending on (depending on the number of the number of faulty faulty cylinders) cylinders) Cylinder-#4 ignition coil (faulty No normal signals are received from Able Able ignition) the ignition circuit. (depending on (depending on the number of the number of faulty cylinfaulty cylinders) ders) ISC (idle speed control) valve Engine speed is high when the engine Able Able (stuck fully open) is idling. Speed sensor No normal signals are received from Able Unable the speed sensor. Fuel system voltage (monitor volt- ECU is unable to monitor the battery age) voltage (an open or short circuit in the Able Able line to the ECU). Error in writing the amount of CO Error is detected while reading or writUnder certain Under certain adjustment on EEPROM ing on EEPROM (CO adjustment conditions conditions value). Snowmobile system power supply The rectifier/regulator does not funcAble Able (monitor voltage) tion properly. ECU internal malfunction (mem- Faulty ECU memory. (When this malory check error) function is detected in the ECU, the Unable Unable fault code number might not appear on the meter.) Knock sensor (open or short cir- No normal signals are received from Able Able cuit) the knock sensor. Grip warmer switch (short circuit) No normal signals are received from Able Able the grip warmer switch. Grip warmer Grip warmer: open or short circuit Able Able detected. Thumb warmer switch (short cir- No normal signals are received from Able Able cuit) the thumb warmer switch. Thumb warmer (short circuit) Thumb warmer: short circuit detected. Able Able T.O.R.S. Conditions requiring T.O.R.S. operation Able Unable are detected. Oil pressure switch (open circuit) Oil pressure switch: open circuit Able Able detected.
92
FI
FUEL INJECTION SYSTEM Communication error with the meter Fault code No. Er-1 Er-2 Er-3 Er-4
Item
Symptom
ECU internal malfunction (output No signals are received from the ECU. signal error) ECU internal malfunction (output No signals are received from the ECU signal error) within the specified signal time. ECU internal malfunction (output Data from the ECU cannot be received signal error) correctly. ECU internal malfunction (input Non-registered data has been received signal error) from the meter.
93
Able/unable Able/unable to start to drive Able or unable Able or unable when ECU is when ECU is defective defective Able
Able
Able
Able
Able
Able
FI
FUEL INJECTION SYSTEM TROUBLESHOOTING CHART
Engine operation is not normal or the warning light and self-diagnostic warning indicator on the LCD flash. * The warning light and self-diagnostic warning indicator on the upper LCD may not flash even if the engine operation is not normal. The warning light and self-diagnostic warning indicator on the upper LCD does not flash.
The warning light and self-diagnostic warning indicator on the upper LCD flash. Check the fault code number displayed on the me-I __ ter.
Check the operation of the following sensors and actuators in the diagnostic mode. (Refer to "Diagnostic mode table".) d:01 :Throttle position sensor (throttle angle) d:02:Atmospheric pressure d:03:lntake air pressure d:05:lntake air temperature d:06:Coolant temperature d:07:Snowmobile speed pulse d:09:Fuel system voltage (battery voltage) d:30:Cylinder-#1 ignition coil d:31 :Cylinder-#2 ignition coil d:32:Cylinder-#3 ignition coil d:33:Cylinder-#4 ignition coil d:36:lnjector #1 d:37:lnjector #2 d:38:lnjector #3 d:39:lnjector #4
I
Identify the system with the malfunction. (Refer to "Self-Diagnostic-Function table".)
Identify the probable cause of the malfunction. (Refer to "Fault code table".)
Check and repair the probable cause of the malfunction. Fault code No.
No fault code No.
Check and repair. Check and repair. (Refer to "TROUBLESHOOTING DETAILS".) Monitor the operation of the sensors and actuators in the diagnostic mode. (Refer to "Diagnostic mode table".)
,
OK
Engine malfunction
NG
Defective sensor or actuator
~
Check and repair the inner parts of the engine. (Refer to CHAPTER 5.)
Perform the fuel injection system reinstatement action. (Refer to "Reinstatement method" in "TROUBLESHOOTING DETAILS".)
,
OK
Check and repair the corresponding sensor or actuator. NG
OK
Check the engine condition.
Turn the main switch off, turn the main switch back on, and then check if the fault code number is still displayed.
Fault code number displayed
OK
Fault code number not displayed Repairs completed
Erasing the malfunction history:* The malfunction history is stored even if the main switch is turned off. The malfunction history must be erased in the diagnostic mode. (Refer to the "Diagnostic mode table (Diagnostic code No. 62)".) * Operated when the warning light and self-diagnosis warning indicator flash.
94
FUEL INJECTION SYSTEM
FI
DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode.
Setting the diagnostic mode 1. Turn the main switch off and set the engine stop switch to "RUN". 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the "SELECT" and "RESET" buttons, turn the main switch on, and continue to press the buttons for 8 seconds or more. TIP _ • All displays on the LCDs disappear except the clock display. • "dl" appears on the clock display. 4. Check that "dl" appears, and then simultaneously press the "SELECT" and "RESET" buttons for 2 seconds or more to activate the diagnostic mode. The diagnostic code number "d:01" appears on the clock display. 5. Select the diagnostic code number corresponding to the fault code number by pressing the "SELECT" and "RESET" buttons. TIP _ • To decrease the selected diagnostic code number, press the "RESET" button. Press the "RESET" button for 1 second or longer to automatically decrease the diagnostic code numbers. • To increase the selected diagnostic code number, press the "SELECT" button. Press the "SELECT" button for 1 second or longer to automatically increase the diagnostic code numbers.
95
FUEL INJECTION SYSTEM
FI
6. Verify the operation of the sensor or actuator. â&#x20AC;˘ Sensor operation The data representing the operating conditions of the sensor appears on the odometer/tripmeter/fuel reserve tripmeter/ oil change tripmeter/display. â&#x20AC;˘ Actuator operation Push the grip warmer side of the grip/ thumb warmer adjustment switch to operate the actuator. If the grip warmer side of the switch is pushed again while the actuator is operating, the actuator operation will stop and restart from the beginning. 7. Turn the main switch off to cancel the diagnostic mode. TIP _ To perform a reliable diagnosis, make sure to turn off the power supply before every check and then start right from the beginning.
96
FUEL INJECTION SYSTEM
FI
Fault code table Fault code No.
11
Symptom No normal signals are received from the cylinder identification sensor.
• • • • • •
No normal signals are received from the crankshaft position sensor.
• • • •
12
13
14
15
16
17
18
20
Probable cause of malfunction
No normal signals are received from the intake air pressure sensor.
Coupler defective between sensor - ECU. Open or short circuit in wire harness. Defective cylinder identification sensor. Malfunction in pickup rotor. Malfunction in ECU. Improperly installed cylinder identification sensor.
Coupler defective between sensor - ECU. Open or short circuit in wire harness. Defective crankshaft position sensor. Malfunction in pickup rotor (primary sheave drive shaft assembly). • Malfunction in ECU. • Improperly installed crankshaft position sensor.
• • • •
Coupler defective between sensor - ECU. Open or short circuit in wire harness. Defective intake air pressure sensor. Malfunction in ECU.
Intake air pressure sensor: hose system malfunction (clogged or detached hose). • Intake air pressure sensor hoses are detached, clogged, Intake air system failure (the kinked, or pinched. pressure is not supplied to the • Defective intake air pressure sensor. intake air pressure sensor in a stable condition) No normal signals are • received from the throttle posi- • tion sensor. • • • Signal from throttle position • sensor will not change. • • • No normal signals are • received from the EXU P servo • motor circuit. • • Signal from EXUP servo motor • position will not change. • • • • • When turning the main switch • to "ON", the voltage value • shows great difference between the intake air pres• sure sensor and atmospheric pressure sensor.
Coupler defective between sensor - ECU. Open or short circuit in wire harness. Defective throttle position sensor. Malfunction in ECU. Improperly installed throttle position sensor. Defective throttle position sensor. Improperly installed throttle position sensor. Mechanical connection malfunction between sensor - throttie body. Malfunction in ECU. Coupler defective between motor - ECU. Open or short circuit in wire harness. Defective EXU P servo motor. Malfunction in ECU. Coupler defective between motor - ECU. Open or short circuit in wire harness. Improperly installed EXUP servo motor. Defective EXUP cable. Defective EXUP servo motor. (stuck) Malfunction in ECU. Malfunction in ECU. Intake air pressure sensor hose is detached, clogged, kinked, or pinched. Defective intake air pressure sensor or atmospheric pressure sensor.
97
Diagnostic code No.
-
-
d:03
d:03
d:01
d:01
d:53
d:53
d:02 d:03
FUEL INJECTION SYSTEM Fault code No.
21
22
23
30
33
34
35
36
37
Symptom
FI
Probable cause of malfunction
No normal signals are • received from the coolant tem- • perature sensor. • • • No normal signals are • received from the intake air • temperature sensor. • • • No normal signals are • received from the atmo• spheric pressure sensor. • • • Detection of the low oil pres• sure signal • No normal signals are • received from the ignition cir- • cuit. • • • • • No normal signals are • received from the ignition cir- • cuit. • • • • • No normal signals are • received from the ignition cir- • cuit. • • • • • No normal signals are • received from the ignition cir- • cuit. • • • • • Engine speed is high when the • engine is idling. • • • • • • •
Diagnostic code No.
Coupler defective between sensor - ECU. Open or short circuit in wire harness. Defective coolant temperature sensor. Malfunction in ECU. Improperly installed coolant temperatue sensor.
d:06
Coupler defective between sensor - ECU. Open or short circuit in wire harness. Defective intake air temperature sensor. Malfunction in ECU. Improperly installed intake air temperatue sensor.
d:05
Coupler defective between sensor - ECU. Open or short circuit in wire harness. Improperly installed atmospheric pressure sensor. Defective atmospheric pressure sensor. Malfunction in ECU. Oil pressure dropped. Defective oil pressure switch. Coupler defective between cylinder-#1 ignition coil - ECU. Open or short circuit in wire harness. Open or short circuit in ignition system sub-wire harness. Improperly installed cylinder-#1 ignition coil. Malfunction in cylinder-#1 ignition coil. Malfunction in ECU. Malfunction in a component of ignition system. Coupler defective between cylinder-#2 ignition coil - ECU. Open or short circuit in wire harness. Open or short circuit in ignition system sub-wire harness. Improperly installed cylinder-#2 ignition coil. Malfunction in cylinder-#2 ignition coil. Malfunction in ECU. Malfunction in a component of ignition system. Coupler defective between cylinder-#3 ignition coil - ECU. Open or short circuit in wire harness. Open or short circuit in ignition system sub-wire harness. Improperly installed cylinder-#3 ignition coil. Malfunction in cylinder-#3 ignition coil. Malfunction in ECU. Malfunction in a component of ignition system.
d:02
-
d:30
d:31
d:32
Coupler defective between cylinder-#4 ignition coil - ECU. Open or short circuit in wire harness. Open or short circuit in ignition system sub-wire harness. Improperly installed cylinder-#4 ignition coil. Malfunction in cylinder-#4 ignition coil. Malfunction in ECU. Malfunction in a component of ignition system.
d:33
Coupler defective between ISC - ECU. Open or short circuit in wire harness. Defective speed sensor. Malfunction in throttle valve. Malfunction in throttle cable. ISC hose is detached, clogged, kinked, or pinched. Improperly installed ISC unit. ISC valve is stuck fully open due to disconnected ISC unit hose or coupler. (High engine idle speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuously being transmitted by the ECU.) • Malfunction in ECU.
d:54
98
FUEL INJECTION SYSTEM Fault code No.
Symptom
FI
Probable cause of malfunction
Diagnostic code No.
42
No normal signals are received from the speed sensor.
43
ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU).
44
Error is detected while reading or writing on EEPROM (CO adjustment value).
• Malfunction in ECU. (The CO adjustment value is not properly written on or read from the internal memory.)
d:60
46
The rectifier/regulator does not function properly.
• Malfunction in the charging system. (Refer to "CHARGING SYSTEM" in CHAPTER 8.)
d:09
50
Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.)
• Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.)
65
No normal signals are received from the knock sensor.
80
81
82
83
84
85
Er-1
• • • • • • •
• • • No normal signals are • received from the grip warmer • switch. • Grip warmer: open or short • ci rcu it detected. • • • • No normal signals are • received from the thumb • warmer switch. • Thumb warmer: short circuit • detected. • • • • Conditions requiring T.O.R.S. • operation are detected. • • • • • Oil pressure switch: open • ci rcu it detected. • • • • • No signals are received from • the ECU. • • •
Open or short circuit in sensor - ECU. Defective speed sensor. Malfunction in ECU. Open or short circuit in main relay - ECU. Open circuit in ECU monitor voltage lead. Defective main relay. Malfunction in ECU.
Open or short circuit in sensor - ECU. Defective knock sensor. Malfunction in ECU. Short circuit in switch - ECU. Defective grip warmer switch. Malfunction in ECU. Coupler defective between grip warmer - ECU. Open or short circuit in wire harness. Improperly installed grip warmer. Malfunction in grip warmer. Malfunction in ECU. Short circuit in switch - ECU. Defective thumb warmer switch. Malfunction in ECU. Coupler defective between thumb warmer - ECU. Open or short circuit in wire harness. Improperly installed thumb warmer. Malfunction in thumb warmer. Malfunction in ECU. Open or short circuit in wire harness. Defective throttle position sensor. Defective throttle switch. Defective speed sensor. Malfunction in ECU. Improperly installed throttle position sensor. Coupler defective between switch - ECU. Open or short circuit in wire harness. Open or short circuit in oil pressure switch sub-lead. Defective oil pressure switch. Improperly installed oil pressure switch. Malfunction in ECU. Coupler defective between speedometer unit - ECU. Open or short circuit in wire harness. Malfunction in speedometer unit. Malfunction in ECU.
99
d:07
d:09
-
-
-
d:57
-
d:27
-
-
-
FUEL INJECTION SYSTEM Fault code No. Er-2
Er-3
Er-4
Symptom No signals are received from the ECU within the specified signal time. Data from the ECU cannot be received correctly.
Non-registered data has been received from the meter.
Probable cause of malfunction • • • • • • • • • • • •
Coupler defective between speedometer unit - ECU. Open or short circuit in wire harness. Malfunction in speedometer unit. Malfunction in ECU. Coupler defective between speedometer unit - ECU. Open or short circuit in wire harness. Malfunction in speedometer unit. Malfunction in ECU. Coupler defective between speedometer unit - ECU. Open or short circuit in wire harness. Malfunction in speedometer unit. Malfunction in ECU.
100
FI Diagnostic code No.
-
-
-
FUEL INJECTION SYSTEM
FI
Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to "DIAGNOSTIC MODE". TIP _
- Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively. -If it is not possible to check the intake air temperature, use the ambient temperature as reference. Diagnostic code No. d:01
Item
Description of action
Throttle position sensor Displays the throttle angle. (throttle angle) • Check with throttle fully closed. • Check with throttle fully open.
o- 125 degrees • Fully closed position (12 22)
Atmospheric pressure
Atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: Approx.1 01 kPa 3000 m above sea level: Approx. 70 kPa
Displays the atmospheric pressure. * Use an atmospheric pressure gauge to check
the atmospheric pressure.
d:02
Intake ai r pressu re sensor
Displays the intake air pressure for cylinders #1, #2, #3, and #4. • Check the intake manifold pressure. • Push the starter switch and check the change in the intake air pressure.
• Not cranking: atmospheric pressure • Cranking: intake air pressu re decreases to less than the atmospheric pressure.
Intake air temperature
Displays the intake air temperature. • Check the temperature in the intake manifold.
Compare it to the value displayed on the meter. (Minimum displayed value: -30 [OCl)
Coolant temperatu re
Displays the coolant temperature. • Check the temperatu re of the coolant.
Compare it to the value displayed on the meter. (Minimum displayed value: -30 [OCl)
Snowmobile speed pulse
Displays the cumulative number of snowmobile pulses that are generated when the track is spun.
(0 - 999; resets to 0 after 999) OK if the numbers appear on the meter.
Fuel system voltage (battery voltage)
Displays the fuel system voltage (battery voltage).
0-18.7V Normally, approximately 12.0 V
Th rottle switch
Displays that the switch is on or off. • Check the th rottle switch. If the grip warmer side of the grip/thumb warmer adjustment switch is pushed, actuates the thumb warmer and displays the self-diagnosis warning indicator for 120 seconds.
Throttle open: on Throttle closed: off
d:03
d:05
d:06
d:07
d:09 d:24
d:27
Checking method or meter display
Thumb warmer operation
After pushing the switch, check that the warmer becomes warm.
d:30
Cylinder-#1 ignition coil If the grip warmer side of the grip/thumb warmer After pushing the switch, adjustment switch is pushed, actuates the cylin- check that a spark is produced der-#1 ignition coil and displays the self-diagno- five times. sis warning indicator (five times at one-second intervals).
d:31
Cylinder-#2 ignition coil If the grip warmer side of the grip/thumb warmer After pushing the switch, adjustment switch is pushed, actuates the cylin- check that a spark is produced der-#2 ignition coil and displays the self-diagno- five times. sis warning indicator (five times at one-second intervals).
101
FUEL INJECTION SYSTEM Diagnostic code No.
d:32
d:33
d:36
d:37
d:38
d:39
d:50
d:51
d:52
d:53
d:54
FI
Checking method or meter display Cylinder-#3 ignition coil If the grip warmer side of the grip/thumb warmer After pushing the switch, adjustment switch is pushed, actuates the cylin- check that a spark is produced der-#3 ignition coil and displays the self-diagno- five times. sis warning indicator (five times at one-second intervals). Cylinder-#4 ignition coil If the grip warmer side of the grip/thumb warmer After pushing the switch, adjustment switch is pushed, actuates the cylin- check that a spark is produced der-#4 ignition coil and displays the self-diagno- five times. sis warning indicator (five times at one-second intervals). Injector #1 If the grip warmer side of the grip/thumb warmer After pushing the switch, check that the injector operadjustment switch is pushed, actuates injector #1 and displays the self-diagnosis warning indi- ates five times by listening to cator (five times at one-second intervals). its operating sound. Injector #2 If the grip warmer side of the grip/thumb warmer After pushing the switch, check that the injector operadjustment switch is pushed, actuates injector #2 and displays the self-diagnosis warning indi- ates five times by listening to cator (five times at one-second intervals). its operating sound. Injector #3 If the grip warmer side of the grip/thumb warmer After pushing the switch, check that the injector operadjustment switch is pushed, actuates injector #3 and displays the self-diagnosis warning indi- ates five times by listening to cator (five times at one-second intervals). its operating sound. Injector #4 If the grip warmer side of the grip/thumb warmer After pushing the switch, adjustment switch is pushed, actuates injector check that the injector oper#4 and displays the self-diagnosis warning indi- ates five times by listening to cator (five times at one-second intervals). its operating sound. Main relay If the grip warmer side of the grip/thumb warmer After pushing the switch, adjustment switch is pushed, actuates the fuel check that the fuel injection injection system relay and displays the self-diag- system relay operates five nosis warning indicator (five times at one-sectimes by listening to its operatond intervals). (The indicator is off when the ing sound. relay is on and it is on when the relay is off.) Radiator fan motor If the grip warmer side of the grip/thumb warmer After pushing the switch, relay adjustment switch is pushed, actuates the radia- check that the radiator fan tor fan motor relay and displays the self-diagno- motor relay operates five times sis warning indicator (for five cycles of five by listening to its operating sound. seconds each). (The relay and indicator are on for two seconds and off for three seconds.) Headlight relay If the grip warmer side of the grip/thumb warmer After pushing the switch, adjustment switch is pushed, actuates the head- check that the headlight relay light relay (on/off) and displays the self-diagno- operates five times by listening sis warning indicator (for five cycles of five to its operating sound. (At that time, the headlight and taillight seconds each). (The relay and indicator are on for two seconds and off for three seconds.) come on.) EXUP servo motor Actuate the servo motor turns to open side and Check the operating sound of to close side and then stop standard position for the EXU P servo motor. appoximately 3 seconds. Illuminates the engine trouble warning light only while the motor is running. ISC (idle speed control) Actuate the ISC (idle speed control) valve to After pushing the switch, unit close side and to open side and then stop stan- check that the ISC unit dard position for approximately 3 seconds. vibrates. The ISC vibrates when the ISC valve operates. Item
Description of action
102
FI
FUEL INJECTION SYSTEM Diagnostic code No.
Item
Checking method or meter display
Grip warmer operation
If the grip warmer side of the grip/thumb warmer After pushing the switch, adjustment switch is pushed, actuates the grip check that the warmer warmer and displays the self-diagnosis warning becomes warm. indicator for 120 seconds.
EEPROM fault code display
• Displays the cylinder number if an error is detected in the EEPROM CO adjustment value for the cylinder as fault code No. 44. • If multiple cylinders are defective, the display alternates every 2 seconds.
Malfunction history code display
• Displays the code numbers of past malfunc11 -- 85 tions (i.e., a code number of a malfunction that (00) Displays when there is no occurred once and which has been corrected). malfunction. • If more than one code number is detected, the display alternates every 2 seconds to show all the detected code numbers. When all code numbers are shown, the display repeats the same process.
Malfunction history code erasure
• Displays the total number of codes that are 00 -- 27 being detected through self diagnosis and the (00) Displays when there is no malfunction. fault codes in the past history. • Erases only the history codes when the grip warmer side of the grip/thumb warmer adjustment switch is pushed.
Control number
• Displays the program control number.
d:57
d:60
d:61
d:62
d:70
Description of action
103
(01 -- 04) Displays the cylinder number. (00) Displays when there is no malfunction.
00 -- 254
FUEL INJECTION SYSTEM
FI
TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the meter display according to the reinstatement method. Fault code No.: Code number displayed on the meter when the engine failed to work normally. (Refer to "Fault code table".) Diagnostic code No.: Code number to be used when the diagnostic mode is operated. (Refer to "Diagnostic mode table".) Fault code No.
I
17
I Symptom I EXUP servo motor circuit: open or short circuit detected.
Diagnostic code No. d:53 Item/components and probable cause
Check or maintenance job
Reinstatement method
Connections EXUP servo motor coupler Wire harness ECU coupler
Check the couplers for any pins that may be pulled out. Check the locking condition of the couplers. If there is a malfunction, repair it and connect the coupler securely.
Turning the main switch on.
Open or short circuit in wire harness.
Repair or replace if there is an open or short circuit. Between EXUP servo motor coupler and ECU coupler (Blue - Blue) (White/Red - White/Red) (Black/Blue - Black/Blue)
3
Defective EXU P servo motor (potention circuit).
Execute the diagnostic mode. (code No. d:53) Replace if defective. Refer to "EXUP SERVO MOTOR INSPECTION".
4
Malfunction in ECU.
Replace the ECU.
Order
1
2
TIP
_
If fault codes 17 and 18 are indicated simultaneously, take the actions specified for fault code 17 first.
104
FUEL INJECTION SYSTEM Fault code No.
I
18
FI
I Symptom I EXU P servo motor is stuck.
Diagnostic code No. d:53 Item/components and probable cause
Check or maintenance job
Reinstatement method
Connections EXUP servo motor coupler Wire harness ECU coupler
Check the couplers for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely.
Turning the main switch on.
Open or short circuit in wire harness.
Repair or replace if there is an open or short circuit. Between EXUP servo motor coupler and ECU coupler. (Red - Red) (Black/Red - Black/Red)
Defective EXUP servo motor
Execute the diagnostic mode. (Code No.53) Replace if defective. Refer to "EXUP SERVO MOTOR INSPECTION".
4
Defective EXUP valve, pulley, and cables
Replace if defective.
5
Malfunction in ECU.
Replace the ECU.
Order
1
2
3
TIP
_
If fault codes 17 and 18 are indicated simultaneously, take the actions specified for fault code 17 first.
105
FUEL INJECTION SYSTEM Fault code No.
I
37
FI
I Symptom I Engine speed is high when the engine is idling.
Diagnostic code No. d:54 (ISC (idle speed control) unit) Order
Item/components and probable cause
Check or maintenance job
Reinstatement method
Check the speed sensor signal.
Check the speed sensor. ISC valve returns to its Check in the diagnostic code (code No. d:07). With the rear wheel rotated, check the pulse input. original posiIndication incorrect ~ Refer to "TROUBLESHOOT- tion by setting the ING DETAI~' in fault code No. d:42. I-------t-C-o-n-ne-c-t-io-ns------------+-C-h-e-c-k-th-e-c-o-u-p-Ie-rs-f-o-r-an-y-p-i-ns-t-h-a-tm-ay-ha-v-e-----f eng ine stop 2
ISC coupler Wire harness ECU coupler
pulled out. Check the locking condition of the couplers. If there is a malfunction, repair it and connect the coupler securely.
switch to "RUN" and turning the main switch
Repair or replace if there is an open or short circuit. on and off. Between ISC coupler and ECU coupler. Reinstated if Red/Green - Red/Green the engine 3 Pink/Blue - Pink/Blue idle speed is White/Green - White/Green within specifiBrown/Blue - Brown/Blue cation after I - - - - - - - t - - - - - - - - - - - - - - - - + - - - - - - - - - - - - - - - - - - - - - f starting the Installed condition of ISC. Check the couplers for any pins that may have engine. pulled out. Check the locking condition of the couplers. 4 If there is a malfunction, repair it and connect the coupler securely. Check the ai r leak. Open or short circuit in wire harness.
Throttle valve does not fully close.
Check the th rottle body. Refer to "THROTTLE BODY". Check the th rottle cable. Refer to "THROTTLE CABLE FREE PLAY ADJUSTMENT" in CHAPTER 2.
ISC valve is not moving correctly.
Execute the diagnostic mode (code No. d:54). After fully closing the ISC valve, it returns to full open. This takes approximately 3 seconds. Check the operating noise at this time. If there is no operating noise, replace the throttle body assembly.
Malfunction in ECU.
Replace the ECU.
5
7
8
TIP -If fault first. -If fault first. -If fault first. -If fault first. -If fault first. -If fault first. -If fault first. -If fault first. -If fault first.
_ codes 13 and 37 are indicated simultaneously, take the actions specified for fault code 13 codes 14 and 37 are indicated simultaneously, take the actions specified for fault code 14 codes 15 and 37 are indicated simultaneously, take the actions specified for fault code 15 codes 16 and 37 are indicated simultaneously, take the actions specified for fault code 16 codes 21 and 37 are indicated simultaneously, take the actions specified for fault code 21 codes 22 and 37 are indicated simultaneously, take the actions specified for fault code 22 codes 25 and 37 are indicated simultaneously, take the actions specified for fault code 25 codes 26 and 37 are indicated simultaneously, take the actions specified for fault code 26 codes 37 and 46 are indicated simultaneously, take the actions specified for fault code 46 106
FUEL INJECTION SYSTEM
FI
-If fault codes 37 and 42 are indicated simultaneously, take the actions specified for fault code 42 first.
Fault code No.
I 65 I Symptom I Knock sensor:
open or short circuit detected.
Diagnostic code No. - Order
1
Item/components and probable cause
Check or maintenance job
Reinstatement method
Connections Knock sensor coupler Wire harness ECU coupler
Check the couplers for any pins that may have pulled out. Check the locking condition of the couplers. If there is a malfunction, repair it and connect the coupler securely.
Turning the main switch on.
Open or short circuit in wire harness.
Repair or replace if there is an open or short circuit. Between knock sensor coupler and ECU coupler. White - White
Installed condition of knock sensor
Check for looseness or pinching.
Defective knock sensor.
Replace if defective. Refer to "KNOCK SENSOR".
Malfunction in ECU.
Replace the ECU.
2
3 4 5
107
FUEL INJECTION SYSTEM OIL PRESSURE SENSING SYSTEM TROUBLESHOOTING If "OP - LO" display/limiter control is not canceled or the meter displays fault code No. 30.
1. Check the engine oil level in the oil tank. Ensure that the engine oil level is correct, Refer to "ENGINE OIL LEVEL INSPEC- .....--.....~.. start the engine, and then check the level TION" in CHAPTER2. NG again. OK 2. Air may have entered the oil hoses and/or oil pump. The step below may resolve the issue. a. With the engine shut off, tip the snowmobile 90° to the left with the oil tank facing upward and wait 2 to 3 minutes. b. Set the snowmobile back down on the skis on a level surface. Start the engine and rev several times without engaging the clutch, then return to idle RPM. Do this repeatedly.
NG
3. Check the engine oil pressure. Refer to "ENGINE OIL REPLACEMENT". NG 4. Check the engine internal components such as the oil pump, etc., and carry out repairs if necessary. Refer to CHAPTERS.
If abnormally low oil pressure is detected when the snowmobile is running (fault code No. 30), resulting in the engine stop. 1. Air may have entered the oil hoses due to the snowmobile falling over during running, etc. Carry out steps (1) to (3) above. 2. If fault code No. 30 continues in the meter display, carry out the check and repair work. Refer to "TROUBLESHOOTING DETAILS". 3. Carry out step (4) above.
If the oil pressure switch error (fault code No. 85) is detected. According to fault code No. 8S in the meter display, carry out the check and repair work. Refer to "TROUBLESHOOTING DETAILS" in CHAPTER 7.
108
FUEL INJECTION SYSTEM ISC (IDLE SPEED CONTROL) UNIT TIP
_
Do not remove the ISC (idle speed control) unit completely from the throttle body. 1. Inspect: • ISC (idle speed control) unit Inspection steps: • Disconnect the ISC (idle speed control) unit coupler from the ISC (idle speed control) unit. • Connect the analog pocket tester (pocket tester) (0 x 10) to the terminals of the ISC (idle speed control) unit. Positive tester probe ~ Red/Green CD Negative tester probe ~ White/Green ® Positive tester probe ~ Brown/Blue ® Negative tester probe ~ Pink/Blue ® Analog pocket tester: YU-03112-C Pocket tester: 90890-03112
• Measure the ISC (idle speed control) unit resistance. Out of specification ~ Replace the throttle body. ISC (idle speed control) unit resistance:
57 - 630
109
THROTTLE BODY
THROTTLE BODY THROTTLE BODY
I [ill: I 6 Nm (0.6 m-kgf, 4.3 ft-Ibf) [g: I 7 Nm (0.7 m-kgf, 5.1 ft-Ibf)
,
[8]: 3.0 Nm (0.30 m-kgf, 2.2 ft-Ibf)
,~ I
Order
Job name/Part name Throttle body removal
Q'ty
Coolant
1 2 3 4 S
6 7
Shroud Side cover (left and right) Top cover Headlight assembly Air filter case Headlight stay Fuel hose Throttle position sensor coupler Cylinder-#1 injector coupler Cylinder-#2 injector coupler Cylinder-#3 injector coupler Cylinder-#4 injector coupler
Remarks Remove the parts in the order listed below. Drain. Refer to "COOLING SYSTEM" in CHAPTER2.
~
Refer to "COWLINGS" in CHAPTER 3.
~
Refer to "GENERAL CHASSIS".
Refer to "AIR FILTER CASE". 1 1 1 1 1 1 1 110
Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.
THROTTLE BODY
,
,~ I 0
1
14
9 A
4
Order 8 9
10 11 12 13 14 15 16
Job name/Part name Intake air pressure sensor coupler ISC (idle speed control) unit coupler ISC (idle speed control) unit inlet hose Throttle cable Throttle body heater inlet hose Throttle body heater outlet hose Throttle body joint clamp screw Throttle body assembly Throttle body joint
Q'ty
1 1 1 1 1 1 8
Remarks Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Loosen.
1 4 For installation, reverse the removal procedure.
111
THROTTLE BODY
INJECTORS
I [ill: I 3.6 Nm (0.36 m-kgf, 2.6 ft-Ibf) [8]: 3.5 Nm (0.35 m-kgf, 2.5 ft-Ibf)
3
Order
Job name/Part name
Q'ty
Injectors removal 1 2
3 4 5
6 7 8
9 10
Throttle position sensor Negative pressure hose ISC (idle speed control) unit outlet hose Intake air pressure sensor Fuel rail Fuel rail joint Fuel joint Pulsation dumper plate Pulsation dumper Injector
Remarks Remove the parts in the order listed below.
1
6 2 1 2 1 1 1 1
4 For installation, reverse the removal procedure.
112
THROTTLE BODY REMOVAL 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose
t
~----------
Cover fuel hose connections with a cloth when disconnecting them. Residual pressure in the fuel lines could cause fuel to spurt out when removing the hoses.
Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. TIP
_
• To remove the fuel hose from the throttle body, slide the fuel hose connector cover CD on the end of the hose in direction of the arrow shown, press the two buttons ® on the sides of the connector, and then remove the hose. • Before removing the hose, place a few rags in the area under where it will be removed.
INSPECTION 1. Inspect: • Fuel rails Cracks/damage parts.
~
Replace the defective
~----------
• When disassembling the fuel joint CD and fuel rail ®, do not leave the O-ring ® in the fuel rail. Remove the O-ring. • When assembling the fuel joint and fuel rail, install the O-ring to the fuel joint as shown in the illustration and then install them to the fuel rail. Do not forget to install the O-ring. Do not pinch the O-ring.
2
113
THROTTLE BODY INSPECTION AND ADJUSTMENT 1. Inspect: • Throttle position sensor Inspect steps: • Disconnect the throttle position sensor coupler. • Remove the throttle position sensor from the throttle body. • Connect the analog pocket tester (pocket tester) (0 x 1k) to the throttle position sensor.
Positive tester probe ~ Terminal CD Negative tester probe ~ Terminal ® Analog pocket tester: YU-03112-C Pocket tester: 90890-03112 • Measure the maximum throttle position sensor resistance. Out of specification ~ Replace the throttle position sensor.
Throttle position sensor resistance: 2.6 - 6.2 kO
114
THROTTLE BODY 2. Adjust: • Throttle position sensor angle Adjustment steps:
• Connect the test harness-TPS (3P) CD to the throttle position sensor and wire harness as shown. • Connect the model 88 multimeter with tachometer (digital circuit tester) to the test harness-TPS (3P). Positive tester probe ~ Yellow (wire harness color) Negative tester probe ~ Black/blue (wire harness color) Model 88 Multimeter with tachometer YU-A1927 Digital circuit tester 90890-03174 Test harness-TPS (3P) YU-03204 90890-03204
• Measure the throttle position sensor voltage. • Adjust the throttle position sensor angle so that the voltage is within the specified range.
11J' 1
I Output voltage 0.63-0.73 V
• After adjusting the throttle position sensor angle, tighten the throttle position sensor screws ®. Throttle position sensor screw 3.5 Nm (0.35 m.kgf, 2.5 ft·lbf)
115
_ _ _ _ _ _ _ _ _ _ _S_W_IT_C_H_IN_S_P_E_CT_IO_N_I
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0
I
ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Analog pocket tester: YU-03112-C Pocket tester: 90890-03112 TIP
_
• Set the pocket tester to "0" before starting a test. • When testing the switch for continuity the pocket tester should be set to the "x 1 n" range. • When checking the switch turn it on and off a few times.
• For waterproof couplers, never insert the tester probes directly into the coupler. When performing any checks using a waterproof coupler, use the specified test harness or a suitable commercially available test harness. • Precautions when removing/installing the sensor coupler. When removing/installing the coupler, carefully wipe peripheral components with a soft cloth. Be careful to prevent liquid such as water or oil from dropping into the coupler. If water or oil comes into contact with the coupler, this may result in a sensor malfunction. The same also applies to other FI-related sensors.
116
____________ K_N_OC_K_S_E_N_SO_R_I
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0
I
KNOCK SENSOR 1. Remove: - Knock sensor
Handle the knock sensor with special care. Never subject it to shock or allow it to be dropped. If it is dropped, it must be replaced.
2. Connect: - Pocket tester (to the knock sensor coupler and sensor body) 3. Measure: - Knock sensor resistance Out of specification ~ Replace. Knock sensor resistance: 504 - 616 kQ 4. Install the knock sensor and connect the knock sensor coupler.
Knock sensor: 27 Nm (2.7 m-kgf, 20 ft-Ibf)
Do not overtighten the knock sensor.
117
...... ...... co
(engine control unit) ~ Speed sensor @ EPS (electric power steering) control unit @ EPS self-diagnosis signal connector @ EPS (electric power steering) motor @ EPS (electric power steering) fuse <§ Speedometer unit C® Multi-function meter <@ Ignition fuse
@ ECU
® Main switch @Main fuse ® Battery
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0
I
EPS CONTROL UNIT'S SELF-DIAGNOSTIC FUNCTION The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in the EPS system, it lights the EPS warning display to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, it becomes stored in the EPS control unit memory in the form of a fault code. - The EPS warning display comes on when the main switch is turned to "ON", and then goes off once the engine is started. If the warning light remains on or comes on after the engine is started, the EPS system may be defective. - The electrical circuit of the warning display can be checked by turning the main switch to "ON". If the warning display does not come on, the electrical circuit may be defective.
CD EPS warning display
TIP
_
-If the engine is stopped using the engine stop switch and the main switch is in the "ON" position, the EPS warning display comes on to indicate that the power assistance for the steering is not functioning. -If the steering usage is too heavy (i.e., excessive steering use when the snowmobile is traveling at a slow speed), the power assist is reduced to protect the EPS motor from overheating.
119
_ _ _ _E_P_S_(E_L_E_C_TR_I_C_P_O_W_E_R_S_T_EE_R_IN_G_>_S_Y_ST_E_M_I
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0
I
EPS WARNING DISPLAY DURING NORMAL OPERATION The EPS warning display comes on initially for 2 seconds after the main switch is turned to "ON". However, the warning display remains on until the engine is started. In addition, if a malfunction is detected while the warning light comes on initially, the warning light remains on. Furthermore, the warning display comes on whenever a malfunction has occurred. TIP _ The EPS system does not operate while the EPS warning display is on.
e
b __ f _......;
9 i
9
h a b. c. d. e.
Main switch EPS warning display (no malfunction detected) EPS warning display (malfunction detected) OFF ON
f. g. h. i.
120
Off Comes on. Initial lighting: 2 seconds Goes off.
_ _ _ _E_P_S_(E_L_E_C_TR_I_C_P_O_W_E_R_S_T_EE_R_IN_G_>_S_Y_ST_E_M_I
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I
DIAGNOSTIC MODE
Setting the diagnostic mode (present and past malfunctions) 1. Turn the main switch to "ON".
2. Disconnect the EPS self-diagnosis signal connector TIP
CD.
_
Do not disconnect the EPS self-diagnosis signal connector before turning the main switch to "ON". 3. Select the signaling mode by grounding the EPS self-diagnosis signal connector (male or disconside) to the EPS control unit necting it from the unit as follows. a) Present malfunction signaling mode Ground the EPS self-diagnosis signal connector within 5 seconds after turning the main switch to "ON", and leave it grounded. The signaling mode is activated after 5 seconds. b) Past malfunction signaling mode While the present malfunction mode is activated, briefly disconnect the EPS self-diagnosis signal connector, ground it again, and leave it grounded. The signaling mode is activated after 5 seconds. 4. Turn the main switch to "OFF" to cancel the diagnostic mode. TIP _
®
• The diagnostic mode can also be canceled by riding the snowmobile at speeds above 2 km/h. • When the diagnostic mode is selected and during the initial lighting of the EPS warning display, the EPS control unit does not receive input from the EPS self-diagnosis signal connector.
121
_ _ _ _E_P_S_(E_L_E_C_TR_I_C_P_O_W_E_R_S_T_EE_R_IN_G_>_S_Y_ST_E_M_I
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Identifying fault codes When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are signaled by the EPS warning display as follows. â&#x20AC;˘ Present malfunction signaling mode: Currently detected fault codes are signaled. â&#x20AC;˘ Past malfunction signaling mode: Both previously detected fault codes and currently detected fault codes are signaled. Signaling method Example 1: Fault code No. 23
a
b-J
L-J--L-------i
k
c
0.. 5
3
0.5x5
a EPS self-diagnosis signal connector g. Grounded b. Diagnostic mode h. Normal mode (diagnostic mode not activated) c. EPS warning display i. Mode selection judgment d. Disconnected j. Present malfunction signaling mode e. On k. Past malfunction signaling mode f. Off *1 The EPS warning display comes on for 5 seconds during the diagnostic mode selection judgment. *2 Display of the present malfunctions stops when the past malfunction display mode is selected. After the mode selection judgment is completed (present or past malfunction mode), the current fault code signaling stops immediately, and then the first code of the mode is signaled 2 seconds later.
When a fault code is signaled, the EPS warning display goes off for 1 second between the units of 10 and the units of 1 for the code. After a fault code is signaled, the warning light goes off for 3 seconds, and then the next code is signaled. Example 2: No malfunctions are detected
a G
--,---------------------d
b e
a EPS self-diagnosis signal connector e. Goes off. b. EPS warning display f. Grounded c. Disconnected g. Mode selection judgment d. Comes on. *1 The EPS warning display comes on for 5 seconds during the diagnostic mode selection judgment. After the mode selection judgment is completed (present display or past malfunction mode), the current fault code signaling stops immediately, and then the EPS warning display starts flashing at 1.5-second intervals.
122
_ _ _ _E_P_S_(E_L_E_C_TR_I_C_P_O_W_E_R_S_T_EE_R_IN_G_>_S_Y_ST_E_M_I
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0
I
Deleting fault codes To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 seconds while the present or past malfunction mode is activated. The currently selected mode remains active after the fault codes of that mode are deleted.
b
a
_c_. LJLJLJ
a EPS self-diagnosis signal connector c. Grounded b. Disconnected T1: Connector grounded - - - - 0.1 ~ T1 ~ 1.6 seconds T2: Fault codes deleted - - - - - Maximum 1.5 seconds required
123
EPS (ELECTRIC POWER STEERING) SYSTEM SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM) Fault code No.
Item
Probable cause of malfunction
Symptom
11 13 15 16
EPS torque sensor
No normal signals are received from the torque sensor.
• Open or short circuit in wire harness. • Malfunction in torque sensor. • Malfunction in EPS control unit.
21
Speed sensor
No normal signals are received from the speed sensor.
• Open or short circuit in wire harness. • Malfunction in speed sensor. • Malfunction in EPS control unit.
22
Engine speed signal
No normal signals are received from the ECU.
• Open or short circuit in wire harness. • Malfunction in ECU. • Malfunction in EPS control unit.
41 42 43 45
EPS motor
No normal signals are received from the EPS motor.
• Open or short circuit in wire harness. • Malfunction in EPS motor. • Malfunction in EPS control unit.
52
EPS control unit
Relay contacts in the EPS control unit are welded together.
• Malfunction in EPS control unit.
53
EPS control unit
Battery voltage has dropped.
• Faulty battery. • Malfunction in the charging system. Refer to "CHARGING SYSTEM". • Malfunction in EPS control unit.
54
EPS control unit
Relay contacts in the EPS control unit are shorted or open.
• Malfunction in EPS control unit.
55
EPS control unit
Battery voltage has increased. Abnormality exists between the EPS and the ECU.
• Malfunction in the charging system. Refer to "CHARGING SYSTEM". • Malfunction in EPS control unit.
124
_ _ _ _E_P_S_(E_L_E_C_TR_I_C_P_O_W_E_R_S_T_EE_R_IN_G_>_S_Y_ST_E_M_I
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0
TROUBLESHOOTING DETAILS (EPS SYSTEM) TIP
I _
The malfunction history is stored even if the main switch is turned to "OFF", therefore, be sure to erase the history (present and past malfunction signaling modes) after repairing the cause of the EPS system malfunction. The malfunction history must be erased in the diagnostic mode. Refer to "DIAGNOSTIC MODE" and "Deleting fault codes".
Fault code No. Order
I ~i, ~~ I Symptom IEPS torque sensor: open or short circuit detected.
Item/components and probable cause
Check or maintenance job
Reinstatement method
Connections EPS torque sensor coupler
Check the coupler for any pi ns that may have pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely.
Turning the main switch to "OFF".
Defective EPS torque sensor.
Replace if defective. Refer to "CHECKING THE EPS TORQUE SENSOR".
Open or short circuit in EPS torque sensor lead.
Repair or replace if there is an open or short circuit. Between EPS torque sensor coupler and EPS control unit coupler. (White - White) (Red - Red) (Green - Green) (Black - Black)
1
2
3
125
EPS (ELECTRIC POWER STEERING) SYSTEM Fault code No. Order
I
21
I Symptom I Speed sensor: open or short circuit detected.
Item/components and probable cause
Check or maintenance job
Connections Speed sensor coupler EPS control unit coupler at the wire harness
Check the coupler for any pins that may have pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. --------+--O-p-e-n-o-r-s-ho-r-t-c-ir-cu-i-t-in-w-i-re-ha-r-n-e-ss-.---------+-R-e-p-a-ir-o-r-re-p-I-ac-e-if-th-e-r---le is an open or short circuit. Between speed sensor coupler and EPS control unit coupler. (White - White)
2
Defective speed sensor.
Order
I
22
MODE" and "Deleting fault codes".
I Symptom I No normal signals are received from the ECU.
Item/components and probable cause
Check or maintenance job
Reinstatement method
Connections EPS control unit coupler at the wire harness ECU coupler at the wi re harness
Check the coupler for any pi ns that may have pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely.
Turning the main switch to "OFF".
Open or short circuit in wire harness.
Repair or replace if there is an open or short circuit. Between ECU coupler and EPS control unit coupler. (Sky blue - Sky blue)
Malfunction in ECU.
Replace the ECU.
2
3
Starting the engine and activating the snowmobile speed sensor by operating the snowmobile above 5 km/h, or turning the main switch to "OFF", then to "ON", and then deleting the fault codes. Refer to "D lAG NOSTI C
Execute the diagnostic mode. (Code No. 21) Replace if defective. Refer to "SIGNALING SYSTEM".
3
Fault code No.
Reinstatement method
126
EPS (ELECTRIC POWER STEERING) SYSTEM Fault code No. Order
I~,~ I Symptom IEPS motor: open or short circuit detected.
Item/components and probable cause
Check or maintenance job
Reinstatement method
Connections EPS motor coupler
Check the coupler for any pi ns that may have pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely.
Turning the main switch to "OFF".
Open or short circuit in EPS motor lead.
Repair or replace if there is an open or short circuit. Between EPS motor and EPS control unit coupler. (Red - Red) (Black - Black)
Defective EPS motor.
Replace if defective. Refer to "CHECKING THE EPS MOTOR".
1
2
3
Fault code No. Order 1
Reinstatement method
Malfunction in EPS control unit.
Replace the EPS control unit.
Turning the main switch to "OFF".
I
53
I Symptom I Power supply to the EPS control
Check or maintenance job
Reinstatement method
Faulty battery.
Replace or charge the battery. Refer to "CHECKING AND CHARGING THE BATTERY" in chapter 3.
Turning the main switch to "OFF".
Malfunction in rectifier/regulator or charging system.
Replace if defective. Refer to "CHARGING SYSTEM".
Malfunction in EPS control unit.
Replace the EPS control unit.
Fault code No. Order 1
unit is not normal (low battery voltage).
Item/components and probable cause
2
3
unit are welded together.
Check or maintenance job
Fault code No. Order
I 52 I Symptom I Relay contacts in the EPS control
Item/components and probable cause
I
54
I Symptom I Relay contacts in the EPS control
unit are shorted or open.
Item/components and probable cause
Check or maintenance job
Reinstatement method
Malfunction in EPS control unit.
Replace the EPS control unit.
Turning the main switch to "OFF".
127
_ _ _ _E_P_S_(E_L_E_C_TR_I_C_P_O_W_E_R_S_T_EE_R_IN_G_>_S_Y_ST_E_M_I F It d N au co e o. Order
I
55
1
S ymptom
I
I
0 I
Power supply to the EPS control unit is not normal (High battery voltage). Malfunction in control unit.
Item/components and probable cause
Check or maintenance job
Reinstatement method
Faulty battery.
Replace the battery. Refer to "CHECKING AND CHARGING THE BATTERY" in chapter 3.
Turning the main switch to "OFF".
Malfunction in rectifier/regulator.
Replace if defective. Refer to "CHARGING SYSTEM".
Malfunction in EPS control unit.
Replace the EPS control unit.
2
3
ELEC
128
_ _ _ _E_P_S_(E_L_E_C_TR_I_C_P_O_W_E_R_S_T_EE_R_IN_G_>_S_Y_ST_E_M_I
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EPS MOTOR INSPECTION 1. Remove: • EPS unit
2. Check: • EPS motor Out of specification TIP
~
Replace.
_
The pocket tester and the analog pocket tester readings are shown in the following table.
Continuity Positive tester probe ~ red CD Negative tester probe ~ black ® No continuity Positive tester probe ~ red CD Negative tester probe ~ EPS motor body ® No continuity Positive tester probe ~ black ® Negative tester probe ~ EPS motor body ®
2
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
a. Connect the pocket tester (0 x 1) to the EPS motor coupler terminal and EPS motor body.
Analog pocket tester: YU-03112-C Pocket tester: 90890-03112 b. Check the EPS motor for continuity. c. Check the EPS motor for no continuity.
•••••••••••••••••••••••••••••
EPS TORQUE SENSOR INSPECTION 1. Remove: • EPS unit 2. Check: • EPS torque sensor resistance Out of specification ~ Replace. EPS torque sensor resistance 1.00 -1.50 kO
129
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I
TTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Connect the pocket tester (0 x 1k) to the EPS torque sensor coupler terminal as shown. 2
Analog pocket tester: YU-03112-C Pocket tester: 90890-03112 Positive tester probe ~ red CD Negative tester probe ~ black ® b. Measure the EPS torque sensor resistance.
•••••••••••••••••••••••••••••
130
__________ G_E_N_ER_A_L_S_P_E_C_IF_IC_A_T_IO_N_S_I SPEC
SPECI FICATIONS GENERAL SPECIFICATIONS Item
Description
Model:
RX10PA, RX10PSA, RX10PXTA
Model code number:
8HG1 (RX10PA) 8JC1 (RX10PSA) 8HN1 (RX10PXTA)
Dimensions: Overall length Overall width Overall height Weight: With oil and fuel
Minimum turning radius: Clockwise Counterclockwise Fuel: Type Minimum pump octane (R+M)/2 Fuel tank capacity Transmission: Secondary reduction ratio Secondary reduction ratio [R] Overall reduction ratio Drive track: Length on ground
2,835 3,000 1,230 1,210
mm mm mm mm
(111.6 in) (RX10PA, RX10PSA) (118.1 in) (RX10PXTA) (48.4 in) (47.6 in)
313 kg (690 Ib) (RX10PA) 309 kg (681 Ib) (RX10PSA) 317 kg (699 Ib) (RX10PXTA) 3.7 3.9 3.7 3.9
m m m m
(12.14 (12.80 (12.14 (12.80
ft) ft) ft) ft)
(RX10PA, RX10PSA) (RX10PXTA) (RX10PA, RX10PSA) (RX10PXTA)
Premium unleaded gasoline only 91 34.6 L (9.14 US gal, 7.61 Imp.gal) 37/24 (1.54) (RX10PA, RX10PSA) 37/23 (1.61) (RX10PXTA) 2.08 (RX10PA, RX10PSA) 2.17 (RX10PXTA) 5.86 ~ 1.54 : 1 (RX10PA, RX10PSA) 6.11 ~ 1.61 : 1 (RX10PXTA) 864 mm (34.0 in) (RX10PA, RX10PSA) 1,051 mm (41.4 in) (RX10PXTA)
131
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_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_I SPEC
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MAINTENANCE SPECIFICATIONS ENGINE Item
Description
Piston ring: Oil ring Dimensions (B x T)
1.50 x 2.30 mm (0.06 x 0.09 in)
Connecting rod: Small end diameter
17.005 . . . 17.027 mm (0.6695 . . . 0.6704 in)
Throttle body: Idling speed
1,550 . . . 1,650 r/min
Coolant: Total amount
6.2 L (6.55 US qt, 5.46 Imp.qt) (RX10PA, RX10PSA) 6.3 L (6.66 US qt, 5.54 Imp.qt) (RX10PXTA)
Fuel pump Fuel pressure
324.0 kPa (3.24 kgf/cm 2 , 47.0 psi)
POWER TRAIN Item Transmission: Engagement speed (Subject to change according to elevation settings.) V-belt: Part number (-17641-)
Description 3,200 . . . 3,600 r/min
8DN-17641-01
Primary sheave spring: Part number (90501-) Color code Outside diameter Wire diameter Preload Spring rate Number of coils Free length
90501 -551 L9 Blue - Silver - Blue 59.5 mm (2.34 in) 5.5 mm (0.22 in) 343 N (35 kgf, 77 Ibf) 19.6 N/mm (2.00 kgf/mm, 111.92 Ibf/in) 4.91 90.9 mm (3.58 in)
Primary sheave weight arm: Part number Weight Rivet hole quantity
8HG-17605-00 82.96 g (2.926 oz) 3
132
_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_I SPEC Item Rivet: Inner Part number Size Outer Part number Size Part number Size Center Part number Size Material Quantity
I
Description
(90261-)
90269-06006 17.2 mm (0.68 in) with hole
(90261-)
90269-06002 13.3 mm (0.52 in) with hole (RX1 OPA, TX10PSA) 90261 -0601 9 13.3 mm (0.52 in) (RX10PXTA)
(90261-)
(90261-)
Secondary sheave spring: Part number Color code Outside diameter Wire diameter Hole position Sheave side-spring seat side (twist angle)
Spring rate Compression Torsion Number of coils Free length Drive chain: Number of links Secondary reduction ratio Maximum 14 link drive chain section length <Limit>
90261 -06033 17.2 mm (0.68 in) Steel 3 pcs 90508-60012 Pink 69.5 mm (2.74 in) 6.0 mm (0.236 in)
12.32 N/mm (1.26 kgf/mm, 70.35 Ibf/in) 11,876 Nemm/rad (1 ,211 kgfemm/rad, 67,825.6 Ibfein/rad) 5.53 75.0 mm (2.95 in) 70 (RX10PA, RX10PSA) 68 (RX10PXTA) 37/24 (1.54) (RX10PA, RX10PSA) 37/23 (1.61) (RX10PXTA) 133.35 mm (5.25 in) 137.35mm(5.41 in)
133
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_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_ Item
Width Length Pitch Number of links
~B
Height "8" Track deflection at 100 N (10 kgf, 22 Ibf) Slide rail suspension: Rear travel Suspension spring type Front Rear
Suspension spring rate Front Rear
Suspension spring range Rear Standard air pressure Spring wire diameter Front Rear Shock absorber damping force: Rebound damping force Front Rear
Compression damping force Front Rear
SPEC
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Description
Track: Part number
Thickness "A"
I
8HG-47110-00 (RX10PA, RX10PSA) 8ET-47110-30 (RX1 OPXTA) 381.0 mm (15.0 in) 3,264.4 mm (128.52 in) (RX10PA, RX10PSA) 3,648.5 mm (143.6 in) (RX10PXTA) 64.0 mm (2.520 in) 51 (RX10PA, RX10PSA) 57 (RX1 OPXTA) 5.1 mm (0.20 in)
31.80 mm (1.250 in) 30.0 . . . 35.0 mm (1.18 . . . 1.38 in)
295.0 mm (11.61 in) (RX10PA, RX10PSA) 297.0 mm (11.69 in) (RX10PXTA) Coil spring (RX10PXTA) Coil spring (RX10PA) Air spring (RX10PSA) Torsion spring (RX10PXTA)
15.0 N/mm (1.53 kgf/mm, 85.65 Ibf/in) (RX10PXTA) 53.9 N/mm (5.50 kgf/mm, 307.77 Ibf/in) (RX10PA) 1,500 Nemm/degree (152.96 kgfemm/degree, 8,565.00 Ibfein/degree) (RX10PXTA) 965 . . . 1,551 kPa (9.7 . . . 15.5 kgf/cm 2 , 140 . . . 225 psi) (RX10PSA) 1,138 kPa (11.4 kgf/cm 2 , 165 psi) (RX10PSA) 7.0 mm (0.28 in) (RX10PXTA) 12.2 mm (0.48 in) (RX10PA) 10 x 10 mm (0.39 x 0.39 in) (RX10PXTA)
995.0 N/O.3 m/s (101.46 kgf/0.3 mIs, 223.68Ibf/0.3 m/s) (RX10PXTA) 2,500 N/O.3 m/s (254.93 kgf/0.3 mIs, 562.00 Ibf/0.3 m/s) (RX10PA) 1,695 N/O.3 m/s (172.84 kgf/0.3 mIs, 381.04Ibf/0.3 m/s) (RX10PXTA) 565.0 N/O.3 m/s (57.61 kgf/0.3 mIs, 127.01 Ibf/0.3 m/s) (RX10PXTA) 1,570 N/O.3 m/s (160.09 kgf/0.3 mIs, 352.94Ibf/0.3 m/s) (RX10PA) 775 N/O.3 m/s (79.03 kgf/0.3 mIs, 174.22 Ibf/0.3 m/s) (RX10PXTA) 134
_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_I SPEC Item
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Description
Slide runner: Wear limit
10.5 mm (0.41 in)
Track sprocket wheel: Type
Extrovert drive and internal drive type
Brake: Brake pad wear limit Parking brake pad wear limit
4.7 mm (0.19 in) 1.2 mm (0.047 in)
CHASSIS Item
Description
Frame: Seat height
755.0 mm (29.72 in)
Ski: Length Width Ski runner wear limit Ski wear limit
1,050 mm (41.34 in) 136 mm (5.35 in) 8.0 mm (0.31 in) 12.0 mm (0.47 in)
Ski suspension: Travel Spring type Spring rate Spring range Standard air pressure Wire diameter Shock absorber damping force: Rebound damping force
Compression damping force
219.0 mm (8.62 in) Coil spring (RX10PA, RX10PXTA) Air spring (RX10PSA) 22.0 N/mm (2.24 kgf/mm, 125.62 Ibf/in) (RX10PA) 26.5 N/mm (2.70 kgf/mm, 151.32 Ibf/in) (RX10PXTA) 448 . . . 1,034 kPa (4.5 . . . 10.3 kgf/cm 2 , 65 . . . 150 psi) (RX10PSA) 586 kPa (5.9 kgf/cm 2 , 85 psi) (RX10PSA) 8.4 mm (0.33 in) (RX10PA) 8.8 mm (0.35 in) (RX10PXTA)
1,125 N/O.3 m/s (114.72 kgf/0.3 mIs, 252.90 Ibf/0.3 m/s) (RX10PA) 1,150 N/O.3 m/s (117.27 kgf/0.3 mIs, 258.52 Ibf/0.3 m/s) (RX10PXTA) 780 N/O.3 m/s (79.54 kgf/0.3 mIs, 175.34 Ibf/0.3 m/s) (RX10PA) 655 N/O.3 m/s (66.79 kgf/0.3 mIs, 147.24 Ibf/0.3 m/s) (RX10PXTA)
135
_ _ _ _ _ _ _ _M_A_I_N_TE_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_NS_I SPEC ELECTRICAL Item
Description
Ignition timing (B.T.D.C)
5° at 1,600 r/min
A.C. magneto: Standard output Stator coil resistance
14.0 V, less than 38.5 A at 5,000 r/min 0.15 ~ 0.23 Qat 20°C (68 OF)
Starter motor: Brush overall length wear limit Commutator diameter <Wear limit> Grip warmer: Resistance (left) (right) Crankshaft position sensor: Resistance
248
Throttle position sensor: Resistance
2.6
ISC (idle speed control) unit: Resistance
57
Knock sensor: Resistance EPS torque sensor: Resistance Fuses: Helmet shield heater jack fuse Radiator fan fuse EPS fuse Reserve fuse
4.4 mm (0.17 in) 28.0 mm (1.10 in) 27.0 mm (1.06 in) 6.75 6.75
372 Q at 20°C (68 OF)
~
6.2 kQ
~
~
504 1.00
8.25 Q 8.25 Q
~ ~
63 Q ~
616 kQ 1.50 kQ
~
3.0 A 5.0 A 40.0A 5.0 A
136
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_______ G_EN_E_R_A_L_T_O_R_Q_U_E_5_P_E_C_IF_IC_A_T_IO_N5_1 SPEC
GENERAL TORQUE SPECIFICATIONS
A
B (bolt)
(nut)
This chart specifies torque for standard fasteners with standard I.S.0. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
10 12 14 17 19 22
mm mm mm mm mm mm
6mm 8mm 10 mm 12 mm 14 mm 16 mm
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General torque specifications Nm m-kgf tt-Ibf 6 0.6 4.3 15 1.5 11 30 3.0 22 55 5.5 40 85 8.5 61 130 13 94
IA L..--. A: Distance across flats B: Outside thread diameter
DEFINITION OF UNITS Unit
Read
Definition
mm cm
Millimeter Centimeter
10-3 meter
kg
Kilogram
103 gram
Measurement Length Length
10-2 meter
Weight 2
N
Newton
1 kg x m/sec
Nm m-kgf
Newton meter Meter kilogram force
Nxm m x kgf
Pa N/mm
Pascal N/m 2 Newtons per millimeter N/mm
Pressure Spring rate
L cm 3
Liter Cubic centimeter
-
Volume or capacity
r/min
Rotations per minute
-
Engine speed
137
Force Torque Torque
_ _ _ _ _ _ _ _ _ _ _T_IG_HT_E_N_IN_G_TO_R_Q_U_E_I SPEC
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TIGHTENING TORQUE ENGINE Tightening torque
Parts to be tightened Oil filter union bolt Exhaust pipe bolt (rear side) Exhaust pipe band bolt EXUP maintenance window cover bolt Muffler cover plate bolt Muffler cover nut Exhaust pipe joint cover bolt EXUP valve pulley cover bolt EXUP cable locknut EXUP servo motor bolt EXUP servo motor pulley cover bolt EXUP valve housing bolt EXUP valve nut Starter clutch bolt Crankshaft position sensor bolt Cylinder identification sensor bolt Knock sensor
138
Nm
m-kgf ft-Ibf
80 16 18 7 7 16 6 10 6 10 2.0 10 7 16 10 8 27
8.0 1.6 1.8 0.7 0.7 1.6 0.6 1.0 0.6 1.0 0.20 1.0 0.7 1.6 1.0 0.8 2.7
58 12 13 5.1 5.1 12 4.3 7.2 4.3 7.2 1.5 7.2 5.1 12 7.2 5.8 20
Remarks
Apply LOCTITE® Apply LOCTITE® Apply LOCTITE®
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POWER TRAIN Tightening torque
Parts to be tightened
Nm
Drive chain housing cover bolt Drive chain housing and frame bolt Driven sprocket bolt Brake caliper bleed screw RX10PA, RX10PSA Limiter strap nut Sliding runner and sliding frame screw Front pivot arm and control rod nut Front pivot arm and front pivot arm bracket bolt Rear pivot arm bracket and sliding frame bolt Rear pivot arm and control rod nut RX10PXTA Slide rail suspension mounting bolt (M1 0) Limiter strap nut Sliding runner and sliding frame screw Set bolt (front suspension wheel collar) Shock absorber and front pivot arm nut Sliding frame and shaft bolt Front pivot arm and sliding frame bolt Shock absorber and front suspension bracket nut Suspension wheel nut Front suspension bracket and connecting arm nut Front pivot arm and connecting arm nut Set bolt (guide wheel collar) Control rod adjusting nut and locknut Control bracket, shaft and sliding frame bolt (front side) Control bracket, shaft and sliding frame bolt (rear side) Rear suspension bracket shaft and sliding frame Rear suspension bracket, rear shock absorber and pull rod nut Rear pivot arm and pull rod nut Rear pivot arm and rear shock absorber nut Rear pivot arm and control rod stopper nut Control bracket and control rod shaft bolt Rear axle nut
139
m-kgf ft-Ibf
24 43 55 5
2.4 4.3 5.5 0.5
17 31 40 3.6
3.8 2.5 105 72 72 105
0.38 0.25 10.5 7.2 7.2 10.5
2.8 1.8 76 52 52 76
72 3.8 2.5 6 49 60 60 49 60 72 72 9 25 42
7.2 0.38 0.25 0.6 4.9 6.0 6.0 4.9 6.0 7.2 7.2 0.9 2.5 4.2
52 2.8 1.8 4.3 35 43 43 35 43 52 52 6.5 18 30
42
4.2
30
60 49
6.0 4.9
43 35
49 49 60 72 75
4.9 4.9 6.0 7.2 7.5
35 35 43 52 54
Remarks Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE® Apply LOCTITE®
Apply LOCTITE®
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CHASSIS Tightening torque
Parts to be tightened Rear cover bolt Seat and muffler cover bolt Muffler side cover screw Muffler end cap bolt Tail/brake light screw Frame protector nut Handlebar holder and steering joint bolt Steering joint cover screw Steering column 2 and EPS motor bolt EPS motor and frame cross member nut EPS motor and pit man arm nut EPS motor cover bolt Pit man arm and steering shaft nut Shock absorber lower nut Upper arm and steering knucle nut Lower arm and steering knuckle nut Stabilizer arm and connecting rod nut Connecting rod and lower arm nut
140
Nm
m-kgf ft-Ibf
8 30 1.5 1.5 1.0 16 23 2.5 35 30 205 7 35 50 65 105 37 37
0.8 3.0 0.15 0.15 0.10 1.6 2.3 0.25 3.5 3.0 20.5 0.7 3.5 5.0 6.5 10.5 3.7 3.7
Remarks
5.8 22 1.1 1.1 0.72 12 17 1.8 25 Apply LOCTITEÂŽ 22 148 5.1 25 36 47 76 27 27
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ISPEC g--I --------------------CABLE ROUTING
4
46
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4
4 6
8
8 9
10
11
12 13
8 14
38
36 21
34
33
26
8
141
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC
CABLE ROUTING Frame (top view)
CD Face the rivet side of the ground
@ Fuel injector #3 coupler lead terminal down. @ Clamp the wire harness to the ® EPS (electric power steering) fuel delivery pipe with clamp. self-diagnosis signal connector Face the head of the clamp to @ Clamp the AC magneto lead to the front of the vehicle and the the wire harness connected the end of the clamp to the top. Cut EPS (electric power steering) off the end of the clamp so that control unit. the length of the end is 3 mm @ Rectifier/regulator (0.12 in.) or shorter. ® Rectifier/regulator and EPS @ To the meter (electric power steering) control ® Fuel injector #2 coupler unit bracket @) Clamp the headlight lead with @ Battery negative lead coupler clamp. (j) Fasten the AC magneto lead @ Idle speed control and wire harness with the @ Fuel injector #1 coupler @ Face the end of the clamp to the clamp. @ Insert the clamp into the frame bottom. cross member. ® Throttle position sensor @Main fuse @Clamp @O,..; 10 mm (0,..; 0.39 in) @ Wire harness AC magneto lead To the intake air temperature sensor @ EPS (electric power steering) @ Drive guard bracket fuse @ Connect the coupler of the wire ® Attach the battery negative lead to the starter motor fixing bolt. harness to the knock sensor @ Atmospheric pressure sensor lead coupler. @ Connect the coupler of the wire coupler harness to the oil pressure @ ECU (engine control unit) coupler 1 (Route the harness so switch lead coupler. @ Clamp the battery negative lead that the harness neither twisted and battery positive lead with nor run off the frame.) @ ECU (engine control unit) couthe clamp. @ Battery negative lead pler 2 (Route the harness so @ Battery positive lead that the harness neither twisted @ Oil level switch coupler nor run off the frame.) @ Oil level switch @ EPS (electric power steering) @ Pass the starter motor positive control unit lead under the oil cooler outlet @ EPS (electric power steering) control unit upper bracket hose. @ Pass the starter motor positive @ Soapy water may be applied lead above the battery bracket. during installation. @ Insert the clamp into the battery @ Store the couplers of the EPS bracket and then clamp the oil (electric power steering) control pressure switch lead and knock unit under the rubber cover prosensor lead (at the positioning vided with the wire harness. tape marks) with the clamp. Face the end of the clamp to right side of the vehicle. @ Press the clamp against the expanded section of the fuel rail. @ To the headlight @ Fuel injector #4 coupler @ Intake air pressure sensor coupler
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®
142
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CABLE ROUTING
18
3
143
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SPEC
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_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC Frame (top view)
CD Insert
the clamp from behind into the headlight stay to clamp the brake hose. Face the clamp opening up. Coolant temperature sensor coupler To the brake Gear position switch @ Main switch coupler @ Main switch (J) Insert the clamp into the frame cross member. @ To the heat exchanger Set the notch of the fuel tank breather hose joint pipe in the same direction as the fuel tank breather hose is inserted (on the fuel tank side). @ Set the knob of the clip in the same direction as the fuel tank breather hose is inserted (on the fuel tank side). @ Install the fuel tank breather hose so that the hose faces to the right of the vehicle. @ Pass the tail/brake light coupler above the frame projection. @Fuel hose @ Fuel hose connector holder @ Fuel pump coupler @ Clamp the fuel hose and fuel pump lead at the positioning tapes with the clamp. Face the head of the clamp to the tank. @ Face the clip knob to the front. @ Route in the order of parking brake cable, throttle cable, brake hose and corrugated tubes from the bottom within the two-dot-dashed line. @ Parking brake cable @ Helmet shield heater jack @Brake hose @ Auxiliary DC jack @ Fuel sender coupler @ To the handlebar switch @ Auxiliary DC jack coupler @ Headlight lead coupler @ To the EPS (electric power steering) actuator coupler (4P) @ Ignition sub-wire harness coupler @ Clamp the Back buzzer lead and bend the holder 90 0 •
®
® ®
®
@ Clamp the radiator fan motor lead and bend the holder 90 0 • @ Back buzzer @ Install the wire harness with color tape on the left of the vehicle. @ Headlight relay @ Load control relay Radiator fan motor relay ® Clamp the wire harness and speed sensor lead with the clamp. @ Clamp the wire harness and EXUP servo motor lead with the clamp. @ Clamp the wire harness then bend the holder to downward.
®
144
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CABLE ROUTING
15
16
145
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC Handlebar (front view)
CD Right handlebar switch ® Corrugated tube (engine
stop switch lead, throttle switch leads, right grip warmer lead, and thumb warmer lead) Upper guide (Pass the corrugated tubes and throttle cable.) Corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) ® Parking brake cable @ Pass the helmet shield heater jack in behind of the brake hose. (J) Helmet shield heater jack lead @ Route the brake light switch lead and left grip warmer lead under the helmet shield heater jack and then between the brake hose and parking brake cable. Left handlebar switch @ Auxiliary DC jack @ Clamp the rubber cover to the bearing holder with a clamp. @ After fitting, bundle the couplers of the brake light switch, lever holder 1, lever holder 3, thumb warmer, headlight beam switch, lever holder 2, grip warmer x 2, grip warmer switch handle, terminal complete and thumb warmer switch handle with the cover, and then close at two points of bosses. @ Point the knob of the clip position to the upward. @ Insert the fuel tank breather hose until it contacts the projection. To insert the hose, it is allowed to apply oils. @ Pass the throttle body outlet hose in behind of the battery bracket. @ Oil pressure switch lead @ Pass the oil cooler outlet hose above the oil tank inlet hose. @ To the parking brake @ To the brake @Srake hose @ Main switch @ Throttle cable
®
®
®
@ Clamp the frame cross member and fuel tank breather hose. Face the head of the clamp to the front of the vehicle and the end of the clamp to the bottom of the vehicle. @ The fuel tank breather hose should not have any slack between the exit of the fuel tank and the clamp. @ Clamp the wire harness, EPS (electric power steering) actuator lead, and ignition sub-wire harness with the clamp. Face the head of the clamp to the top of the vehicle and the end of the clamp to the rear of the vehicle. @ Auxiliary DC jack coupler @ Clamp the wire harness and cylinder identification sensor lead with the clamp. @ EPS (electric power steering) actuator coupler (4P) @ Pass the cylinder identification sensor lead under the EPS (electric power steering) actuator (4P) lead. ®> Cylinder identification sensor coupler @) Completely cover the ignition sub-wire harness coupler with the rubber cover. @ Clamp the wire harness, cylinder identification sensor lead, EPS (electric power steering) actuator lead, and Ignition coil lead (with rubber cover) with the clamp. Face the head of the clamp to the top of the vehicle and the end of the clamp to the rear of the vehicle. @ Clamp the wire harness and EPS (electric power steering) actuator lead with the clamp. @ Meter coupler installation area Put the boots of the meter coupler in the boss root on the side of the meter.
®
146
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CABLE ROUTING
147
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SPEC
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_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC Engine (right side view)
CD Clamp
the wire harness. Tighten the frame cross member and frame together. ® Clamp the fuel tank breather hose to the hose holder. @ The clamp position is above the hose protector. Clamp it from outside. @) Pass the fuel tank breather hose in behind of the frame cross member. @ Wire harness @ Fuse box bracket (J) Fuse box Coolant recovery Coolant reservoir @Srake hose @ Parking brake cable @Clamp @ Clamp the parking brake cable with the holder, and then bend the holder 90 0 downward. @ Air filter case latch @ Oil tank outlet hose @ Point the clamp tightening direction to the downward. @ Route the coolant reservoir breather hose behind the engine and front of the heat exchanger. @ Clamp the coolant reservoir breather hose at the white paint mark. Face the head of the clamp outside and the end of the clamp to the front. @ Tail/brake light coupler @ To the tail/brake light @ Gear position switch lead @ Clamp the gear position switch lead. Any slack is not allowed between the terminal and clamp. @ Route the wire harness outside of side cover 2.
® ®
148
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CABLE ROUTING
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SPEC
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13
149
_ _ _ _ _ _ _ _ _ _ _ _ _C_A_B_L_E_R_O_U_T_IN_G_I SPEC Engine (left side view)
CD Fasten the EPS (electric power steering) actuator coupler to the bracket of the frame cross member. Clamp the fuel pump lead and fuel hose with the clamp. Route the fuel tank breather hose along the frame cross member. @) Clamp the fuel tank breather hose to the hose holder. (§) Hose protector @ EXUP servo motor coupler (J) Route the wire harness inside of the EXUP cable. @ Speed sensor coupler Speed sensor lead holder @ Align the punch mark with the rivet. @ Front axle housing @ Nylon nuts @ Speed sensor @ Front axle assembly @ Bearing holder reinforcement @Gear unit
®
®
®
150
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WIRING DIAGRAM 2011 RX10PA, RX10PSA, RX10PXTA
CD ®
Crankshaft position sensor ®AC magneto Rectifier/regulator @ Main switch @Main fuse @ Load control relay (J) Fuel injection system fuse Starter relay Battery @ Starter motor @Diode @ Engine stop switch @ Throttle switch @ Grip warmer @ Thumb warmer @ Grip warmer adjustment switch @ Thumb warmer adjustment switch @ Oil pressure switch @ CO adjustment coupler @ ECU (engine control unit) @ Ignition coil sub-wire harness @ Cylinder-#1 ignition coil @Spark plug @ Cylinder-#2 ignition coil @ Cylinder-#3 ignition coil @ Cylinder-#4 ignition coil @ Fuel injection system relay @Fuel pump @ Injector #1 Injector #2 @ Injector #3 @ Injector #4 @ Throttle position sensor @ Speed sensor @ Cylinder identification sensor Atmospheric pressure sensor @ Intake air pressure sensor Coolant temperature sensor @ Intake air temperature sensor @ Knock sensor @ ISC (idle speed control) unit @ EXUP servo motor @ Frame ground @ EPS (electric power steering) control unit @ EPS self-diagnosis signal connector EPS (electric power steering) motor @ EPS (electric power steering) fuse @ Back buzzer @ Gear position switch @ Brake light switch ® Tail/brake light C@ Fuel sender @ Oil level switch (§ Speedometer unit @ Multi-function meter @ Warning light
® ®
®
® ®
®
® Low coolant temperature indicator light C@ High beam indicator light (@ Meter light <@ Headlight <@ Headlight relay <@ Headlight beam switch @ Radiator fan motor (@ Radiator fan motor relay <@ Auxiliary DC jack <@ Helmet shield heater jack <@ Ignition fuse @ Radiator fan motor fuse @ Signal fuse @ Headlight fuse
® Auxiliary DC jack fuse
@
Helmet shield heater jack fuse
COLOR CODE B Br Ch G Gy L Lg 0 P R Sb W Y B/L B/R B/W B/Y Br/G Br/L Br/W G/B G/R G/W G/Y Gy/R L/B L/R L/W L/Y Lg/B Lg/L Lg/W O/B O/G O/L O/R O/W P/L P/W R/B R/G R/L R/W R/Y W/B WIG W /R Y/G Y/R Y/W
Black Brown Chocolate Green Gray Blue Light green Orange Pink Red Sky blue White Yellow Black/Blue Black/Red Black/White Black/Yellow Brown/Green Brown/Blue Brown/White Green/Black Green/Red Green/White Green/Yellow Gray/Red Blue/Black Blue/Red Blue/White Blue/Yellow Light green/Black Light green/Blue Light green/White Orange/Black Orange/Green Orange/Blue Orange/Red Orange/White Pink/Blue Pink/White Red/Black Red/Green Red/Blue Red/White Red/Yellow White/Black White/Green White/Red Yellow/Green Yellow/Red Yellow/White
LIT12618RX03 1-1
WIRING DIAGRAM 2011 RX10PA, RX10PSA, RX10PXTA