2011-2012 Yamaha Apex Series Snowmobile Repair Manual

APEX SE / XTX 2011-2012 LIT-12618-RX-03 Service Manual

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 under- standing 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 ap- plicable, appear in future editions of this manual. RX1 OH/RX1 OSH RX1 OMH/RX1 OMSH RX1 ORH/RX1 ORSH SERVICE MANUAL © 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 HOW TO USE THIS MANUAL Particularly important information is distin- guished in this manual by the following nota- tions: ~ 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 orga- nized 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 prob- lem will follow the symbol, e.g., • Bearings Pitting/damage -+ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams be- fore each disassembly section to facilitate correct disassembly and assembly procedures.

@ @ ICHASI ~ II,.....--p~:'C1D1 (l) @ ICARSI " II~~L-EC"'---Iu-: I ® @ @ @ 1 1 1 ~ ~ ~ @ @ @ ~ ~ ~ @ 1m! 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 (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 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 INSPECTIONS AND ADJUSTMENTS CHASSIS POWER TRAIN ENGINE COOLING SYSTEM CARBURETION ELECTRICAL SPECIFICATIONS ~ GEN INFO CHAS crD POWR ~ TR CARB ELEC g-- SPEC

CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION 1-1 FRAME SERIAL NUMBER 1-1 ENGINE SERIAL NUMBER 1-1 IMPORTANT INFORMATION 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2 ALL REPLACEMENT PARTS 1-2 GASKETS, OIL SEALS, AND O-RINGS 1-3 LOCK WASHERS/PLATES AND COTTER PINS 1-3 BEARINGS AND OIL SEALS 1-3 CIRCLIPS 1-3 LOCTITE® 1-3 SPECIAL TOOLS 1-4 FOR TUNE UP 1-4 FOR ENGINE SERVICE 1-5 FOR POWER TRAIN SERViCE 1-7 FOR CARBURETION SERVICE 1-8 FOR ELECTRICAL SERVICE 1-8 CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION 2-1 PERIODIC MAINTENANCE TABLE ..... 2-1 ENGINE 2-3 SPARK PLUGS 2-3 FUEL LINE INSPECTION 2-4 COOLING SYSTEM 2-4 VALVE CLEARANCE ADJUSTMENT 2-9 CARBURETOR SYNCHRONIZATION 2-14 ENGINE IDLE SPEED ADJUSTMENT 2-16 THROTTLE CABLE FREE PLAY ADJUSTMENT 2-17 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK 2-18 COMPRESSION PRESSURE MEASUREMENT 2-18 ENGINE OIL LEVEL INSPECTION.................. .. 2-20 ENGINE OIL REPLACEMENT ..... 2-22 CRANKCASE BREATHER HOSE INSPECTION.................. .. 2-24 CABURETOR JOINTS INSPECTION.................. .. 2-24 EXHAUST SYSTEM INSPECTION.................. .. 2-25 POWER TRAIN ................... .. 2-26 SHEAVE OFFSET ADJUSTMENT 2-26 DRIVE V-BELT 2-27 ENGAGEMENT SPEED CHECK. .. 2-29 PARKING BRAKE ADJUSTMENT.. 2-30 BRAKE LEVER ADJUSTMENT . . .. 2-30 BRAKE FLUID LEVEL INSPECTION 2-31 BRAKE PAD INSPECTION ...... .. 2-32 BRAKE HOSE INSPECTION 2-32 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) .............. .. 2-32 DRIVE CHAIN 2-34 TRACK TENSION ADJUSTMENT.. 2-36 SLIDE RUNNER INSPECTION .... 2-37 MAXIMIZING DRIVE TRACK LIFE . 2-38 CHASSIS 2-39 SKI/SKI RUNNER 2-39 STEERING SYSTEM ........... .. 2-40 LUBRICATION 2-41 ELECTRICAL 2-43 HEADLIGHT BEAM ADJUSTMENT 2-43 BATTERY INSPECTION 2-44 FUSE INSPECTION............ .. 2-50 SPEEDOMETER UNIT INSPECTION 2-51 TUNING 2-52 CARBURETOR TUNING 2-52 CLUTCH ...................... .. 2-59 GEAR SELECTION 2-61 HIGH ALTITUDE TUNING 2-67 FRONT SUSPENSION 2-68 REAR SUSPENSION........... .. 2-69

CHAPTER 3. CHASSIS STEERING 3-1 INSPECTION 3-7 INSTALLATION 3-8 SKI 3-11 INSPECTION 3-12 INSTALLATION 3-12 FRONT SUSPENSION 3-13 HANDLING NOTES 3-15 INSPECTION 3-15 INSTALLATION 3-16 CHAPTER 4. POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT 4-1 REMOVAL 4-3 DISASSEMBLY 4-3 INSPECTION 4-5 ASSEMBLY 4-7 INSTALLATION 4-9 SECONDARY SHEAVE 4-10 DISASSEMBLY 4-12 INSPECTION 4-12 ASSEMBLY 4-13 INSTALLATION 4-15 DRIVE CHAIN HOUSING 4-16 WITHOUT REVERSE MODEL 4-16 INSPECTION 4-17 INSTALLATION 4-19 WITH REVERSE MODEL ....... .. 4-20 INSPECTION.................. .. 4-22 INSTALLATION ................ .. 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 BRAKE CALIPER INSPECTION AND REPAIR 4-32 BRAKE CALIPER ASSEMBLY. .. .. 4-33 BRAKE CALIPER INSTALLATION . 4-33 INSPECTION.................. .. 4-35 BRAKE MASTER CYLINDER ASSEMBLY 4-35 INSTALLATION ................ .. 4-35 SLIDE RAIL SUSPENSION 4-36 RX10, RX10S, RX10R, RX10RS 4-36 RX10M, RX10MS 4-41 INSPECTION.................. .. 4-46 ASSEMBLY 4-47 INSTALLATION ................ .. 4-47 FRONT AXLE AND TRACK ........ .. 4-49 INSPECTION.................. .. 4-50 INSTALLATION ................ .. 4-50 CHAPTER 5. ENGINE SEAT AND FUEL TANK 5-1 EXHAUST PIPE AND MUFFLER 5-2 INSTALLATION 5-3 ENGINE ASSEMBLy 5-4 INSPECTION 5-5 INSTALLATION 5-5 CAMSHAFTS 5-6 REMOVAL 5-9 INSPECTION 5-11 INSTALLATION 5-14 CYLINDER HEAD 5-17 REMOVAL 5-18 INSPECTION 5-19 INSTALLATION ................ .. 5-20 VALVES AND VALVE SPRINGS 5-21 REMOVAL 5-23 INSPECTION.................. .. 5-24 INSTALLATION ................ .. 5-29

A.C. MAGNETO AND STARTER CLUTCH 5-31 REMOVAL 5-33 INSTALLATION .. .............. .. 5-35 OIL PAN AND OIL PUMP 5-37 REMOVAL 5-39 INSPECTION.................. .. 5-40 INSTALLATION .. .............. .. 5-41 CRANKCASE 5-42 REMOVAL 5-45 INSPECTION 5-47 INSTALLATION .. .............. .. 5-58 CHAPTER 6. COOLING SYSTEM HEAT EXCHANGER 6-1 INSPECTION 6-3 INSTALLATION 6-4 THERMOSTAT 6-5 INSPECTOIN 6-6 INSTALLATION 6-7 WATER PUMP 6-8 DISASSEMBLY 6-9 INSPECTION 6-10 ASSEMBLY 6-10 CHAPTER 7. CARBURETION CARBURETORS 7-1 INSPECTION 7-5 ASSEMBLY 7-7 INSTALLATION 7-8 FUEL LEBEL ADJUSTMENT 7-9 THROTTLE POSITION SENSOR (T.P.S.) INSPECTION AND ADJUSTMENT 7-10 FUEL PUMP 7-12 INSPECTION 7-12 INSTALLATION 7-12 CHAPTER 8. ELECTRICAL SWITCH INSPECTION 8-1 SWITCH INSPECTION 8-1 INSPECTING A SWITCH SHOWN IN THE MANUAL 8-1 IGNITION SYSTEM 8-2 CIRCUIT DIAGRAM 8-2 TROUBLESHOOTING 8-4 A.C. MAGNETO 8-5 SPARK PLUG 8-5 IGNITION SPARK GAP 8-6 IGNITION COIL 8-6 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) 8-7 HANDLEBAR SWITCH (RIGHT) 8-8 CARBURETOR SWiTCH 8-8 MAIN SWiTCH 8-9 MAIN RELAy 8-9 ELECTRICAL STARTING SYSTEM 8-10 CIRCUIT DIAGRAM 8-10 TROUBLESHOOTING 8-11 MAIN SWITCH 8-12 STARTER MOTOR 8-13 CHARGING SySTEM 8-16 CIRCUIT DIAGRAM 8-16 TROUBLESHOOTING 8-17 BATTERy 8-18 STATOR COIL 8-18 LIGHTING SYSTEM ............... .. 8-19 CIRCUIT DIAGRAM 8-19 TROUBLESHOOTING 8-21 BULB(S) 8-23 HEADLIGHT BEAM SWITCH .... .. 8-23 HEADLIGHT RELAY 8-24

SIGNAL SYSTEM ................. .. 8-25 CIRCUIT DIAGRAM 8-25 TROUBLESHOOTING.......... .. 8-27 BRAKE LIGHT SWITCH 8-33 GEAR POSITION SWITCH (RX10R, RX10RS) 8-33 BACK BUZZER (RX10R, RX10RS) 8-33 WATER TEMPERATURE SENSOR 8-34 ENGINE OIL LEVEL SWITCH 8-35 FUEL SENDER. ............... .. 8-35 SPEED SENSOR 8-36 GRIP WARMER SYSTEM. ......... .. 8-37 CIRCUIT DIAGRAM 8-37 TROUBLESHOOTING.......... .. 8-39 GRIP AND THUMB WARMER COIL 8-40 THUMB WARMER SWITCH. .... .. 8-40 GRIP WARMER SWITCH 8-41 CHAPTER 9. SPECIFICATIONS GENERAL SPECiFiCATIONS 9-1 MAINTENANCE SPECIFICATIONS 9-4 ENGINE 9-4 POWER TRAIN 9-9 CHASSIS 9-13 ELECTRICAL 9-14 HIGH ALTITUDE SETTINGS 9-16 TIGHTENING TORQUE 9-17 ENGINE 9-17 POWER TRAIN 9-19 CHASSIS 9-21 GENERAL TORQUE SPECIFICATIONS 9-22 DEFINITION OF UNITS ............ .. 9-22 CARBURETOR HEATER SYSTEM 8-42 CIRCUIT DIAGRAM 8-42 TROUBLESHOOTING.......... .. 8-44 CARBURETOR HEATER RELAY .. 8-45 CARBURETOR HEATER 8-45 SELF-DIAGNOSIS 8-46 FUEL METER, FUEL LEVEL WARNING INDICATOR AND THE WARNING LIIGHT 8-46 COOLANT TEMPERATURE WARNING LIGHT AND THE WARNING LIGHT 8-47 SELF-DIAGNOSIS WARNING INDICATOR AND THE WARNING LIGHT 8-47 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

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2011-2012 Yamaha Apex Series Snowmobile Repair Manual

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