2003-2007 Yamaha RX 1 Apex Series Snowmobile Repair

2003-2007 Yamaha Apex Series Service Manual RX-1, MOUNTAIN LE, ER RX WARRIOR, GT, RTX, ATTAK

Base Service Manual RX10H / RH10SH / RX10MH / RX10MSH / RX10RH / RX10RSH

10 SPEC ELEC CARB 8 1 2 3 4 5 6 7 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 GEN INFO INSP ADJ ENG CHAS POWR TR 9 COOL ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspections and adjustments 3 Chassis 4 Power train 5 Engine 6 Cooling system 7 Carburetion 8 Electrical 9 Specifications Illustrated symbols 10 to 16 are used to identify the specifications which appear. 10 Filling fluid 11 Lubricant 12 Tightening 13 Wear limit, clearance 14 Engine speed 15 Special tool 16 Ω, V, A Illustrated symbols 17 to 25 in the exploded diagram indicate grade of lubricant and location of lubrication point. 17 Apply locking agent (LOCTITE  ) 18 Apply Yamabond No.5  19 Apply engine oil 20 Apply gear oil 21 Apply molybdenum disulfide oil 22 Apply wheel bearing grease 23 Apply low-temperature lithium-soap base grease 24 Apply molybdenum disulfide grease 25 Use new one

1 9 8 6 5 4 INSP ADJ GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS POWER TRAIN ENGINE COOLING SYSTEM ELECTRICAL SPECIFICATIONS GEN INFO 2 3 POWR TR ENG COOL ELEC SPEC CHASSIS CHAS 7 CARBURETION CARB INDEX

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 . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . CABLE ROUTING 9-23 . . . . . . . . . . . . . . . . . .

1-1 MACHINE IDENTIFICATION GEN INFO NOTE: GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number 1 is located on the left-hand side of the crankcase. Designs and specifications are subject to change without notice.

1 1-2 IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. While cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc., from high pressure water splashes. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling the machine, keep mated parts together. This includes gears, cylinders, pistons, and other 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 criss- cross pattern. ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments.

2003-2007 Yamaha RX 1 Apex Series Snowmobile Repair

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