Manual Coverage
|
Systems Covered
|
Engine:
|
Engine assembly, camshafts, cylinder head, valves, valve springs, A.C. magneto, starter clutch, oil pan, oil pump, crankcase
|
Cooling System:
|
Heat exchanger, thermostat, water pump
|
Fuel System:
|
Carburetion (carburetors), EFI, fuel level adjustment, throttle position sensor, fuel pump
|
Electrical System:
|
Ignition system (A.C. magneto, spark plug, spark gap, ignition coil, T.O.R.S., handlebar switch, carburetor switch, main switch, main relay), Starting system (main switch, starter motor), Charging system (battery, stator coil), Lighting system (bulbs, headlight beam switch, headlight relay), Switch inspection
|
Chassis:
|
Steering, ski, front suspension, rear suspension, handling notes
|
Power Train:
|
Primary sheave, drive V-belt, secondary sheave, drive chain housing (with and without reverse), secondary shaft
|
Brakes:
|
Brake pad replacement, brake caliper disassembly, inspection and repair, assembly, installation, master cylinder assembly
|
Suspension:
|
Slide rail suspension, front axle, track
|
Procedures Included
|
Maintenance:
|
Periodic inspection and adjustment, periodic maintenance table, spark plug service, fuel line inspection, cooling system checks, valve clearance adjustment, carburetor synchronization, engine idle speed adjustment, throttle cable free play adjustment, T.O.R.S. check, compression pressure measurement, engine oil level inspection and replacement, crankcase breather hose inspection, carburetor joints inspection, exhaust system inspection
|
Troubleshooting:
|
Engine troubleshooting, power train troubleshooting, carburetion troubleshooting, electrical troubleshooting (ignition, starting, charging, lighting systems)
|
Repair Overhaul:
|
Engine repair, power train repair, carburetion repair, electrical repair, brake system overhaul, suspension component repair
|
Tuning:
|
Carburetor tuning, clutch tuning, gear selection, high altitude tuning
|
Assembly Disassembly:
|
Preparation for removal and disassembly, component replacement procedures (gaskets, oil seals, O-rings, lock washers, cotter pins, bearings, circlips)
|
Lubrication:
|
Steering system lubrication, slide rail lubrication, chassis lubrication points detailed.
|
Track Maintenance:
|
Drive chain track tension adjustment, maximizing drive track life.
|
Wheel Tire:
|
Ski/ski runner inspection and maintenance.
|
Lighting Adjustment:
|
Headlight beam adjustment procedure covered.
|
Technical Depth
|
Depth:
|
Comprehensive service and repair information, including detailed diagnostic procedures, specifications, and step-by-step instructions for maintenance, repair, and overhaul of all major vehicle systems.
|
Diagnostic Tools:
|
Includes information on special tools for tune-up, engine service, power train service, carburetion service, and electrical service.
|
Maintenance
|
Service Intervals
|
Engine Oil Change:
|
Typically every 2,000-3,000 miles or annually, refer to specific manual section for exact interval and capacity.
|
Spark Plug Replacement:
|
Recommended at specific mileage intervals or based on condition checks, detailed in manual.
|
V-Belt Inspection:
|
Regular inspection for wear and damage, replacement as needed based on mileage or condition.
|
Valve Adjustment Interval:
|
Intervals for valve clearance adjustment are specified, crucial for maintaining engine performance and longevity.
|
Clutch Inspection:
|
Clutch components, including sheave offset and drive belt engagement speed, are subject to periodic checks and adjustments.
|
Fluid Specifications
|
Engine Oil Type:
|
Yamalube 4-stroke oil (e.g., Yamalube 4W, 10W-40 or 20W-50 depending on temperature), refer to manual for precise specification.
|
Coolant Type:
|
Yamaha Supercoolant (50/50 mix of antifreeze and distilled water), or equivalent ethylene glycol-based coolant.
|
Brake Fluid Type:
|
DOT 4 hydraulic brake fluid.
|
Known Issues
|
Drive Belt Wear:
|
Drive belts can wear prematurely if subjected to excessive heat, improper alignment, or overloading. Regular inspection is crucial.
|
Suspension Bushings:
|
Bushings in suspension components can wear over time, leading to play and affecting handling. Manual covers inspection and replacement.
|
Carburetor Icing:
|
In very cold, humid conditions, carburetors can be susceptible to icing, impacting performance. Manual covers carburetor tuning and maintenance.
|