2021 Yamaha SIDEWINDER L-TX GT Service & Repair Manual

cm Repair&ServiceManual sewnaoSIDEWINDERB-TXLE153 SsvRMuALSIDEWINDERL-TXGT S;SIDEWINDERL-TXLE SIDEWINDERL-TXSE SIDEWINDERSRXLE SIDEWINDERS-TXGT SIDEWINDERX-TXLE SIDEWINDERX-TXSE ServiceManual

Foreword ThisYamahaServiceManualcontainsserviceandmaintenanceinformationfortheModelYear2021Yamaha SidewinderSnowmobile.Themanualisdesignedtoaidservicepersonnelinservice-orientedapplications. Thismanualisdividedintosections.Thesectionscoverspecificsnowmobilecomponentsorsystemsand,inaddi- tiontothestandardserviceprocedures,includesassembling,disassembling,andinspectinginstructions.When usingthismanualasaguide,thetechnicianshouldusediscretionastohowmuchdisassemblyisneededtocorrect anygivencondition. Theservicetechnicianshouldbecomefamiliarwiththeoperationandconstructionofthecomponentsorsystems bycarefullystudyingthecompletemanual.Thiswillassisttheservicetechnicianinbecomingmoreawareofand efficientwithservicingprocedures.Suchefficiencynotonlyhelpsbuildconsumerconfidencebutalsosavestime andlabor. AllYamahapublicationsandsnowmobiledecalsdisplaythewordsWarning,Caution,andNotetoemphasize importantinformation.Thesymbol4AWARNINGidentifiespersonalsafety-relatedinformation.Besureto followthedirectivebecauseitdealswiththepossibilityofseverepersonalinjuryorevendeath.ACAUTION identifiesunsafepracticeswhichmayresultinsnowmobile-relateddamage.Followthedirectivebecauseitdeals withthepossibilityofdamagingpartorpartsofthesnowmobile.ThesymboliNOTE:identifiessupplementary informationworthyofparticularattention. Atthetimeofpublication,allinformation,photographs,andillustrationsweretechnicallycorrect.Somephoto- graphsandillustrationsusedinthismanualareusedforclaritypurposesonlyandarenotdesignedtodepictactual conditions.BecauseYamahaconstantlyrefinesandimprovesitsproducts,noretroactiveobligationisincurred. Allmaterialsandspecificationsaresubjecttochangewithoutnotice. Keepthismanualaccessibleintheshopareaforreference. ©2020byYamahaMotorCorporation,U.S.A. November2020 AllRightsReserved. AnyreprintingorunauthorizedusewithoutthewrittenpermissionofYamahaMotorCorporation,U.S.A.is expresslyprohibited. International | Manufacearers

GeneralInformation. SpecialTools SnowmobileIdentification.. RecommendedGasolineandOil. EngineBreak-In. DriveBeltBreak-In GenuineParts... VaryingAltitudeOperation.. PreparationforStorage PreparationafterStorage AfterBreak-InCheckup/Checklist. EngineSpecifications... ElectricalSpecifications... DriveSystemSpecifications TrackSpecifications... TorqueConversions... TorqueSpecifications. SteeringandBody... SteeringPost. Ski(Trail Ski(Mountain)... WearBar(Mountain) WearBar(Trail)... Spindle(TouringStyle) Spindle(StandardStyle) Spindle(MountainStyle) SteeringTieRod. SkiAlignment. ‘A-Arms(TouringStyle) ‘A-Arms(StandardStyle) ‘A-Arms(MountainStyle). ‘SkiShockAbsorber.. ‘SwayBar FrontBumper. SeatAssembly...26 SeatAssembly(TouringStyle) .26 SeatCushion27 Taillight/BrakeLightAssembI Taillight/BrakeLightAssembly(TouringStyle).. RearBumper/Snowflap Windshield/Console/Headlight.28 AdjustingHeac Engine. Removing.. Install 9. TroubleshootingEngin Engine-RelatedItems WaterPump. PressureTestingEngine66 CheckingCompression.66 ChangingEngineOilFilter. EngineOilTank. LiquidCoolingSystem. CoolingSystemSchematic.70 HeatExchanger. AirSilencer Turbocharger/intercooler FuelSystems FuelSystem IndividualComponents. Self-DiagnosticSystem/Codes... ThrottleBodyAssembly.. TroubleshootingFuelSystem. ThrottleCable.. FuelPump GasTank. GasTank(TouringStyle) ElectricalSystem: IgnitionSystem.. ThrottlePositionSensor.. ElectricalResistanceTests VoltageRegulatorTests. TestingFuelGaugeSender. EmergencyStopSwitch .. StarterRelaySolen Fuse IgnitionSwitch StarterMoto’ TroubleshootingElectricStart. Magneto .. BrakeLightSwitch HeadlightDimmerSwitch TestingHandlebarWarmerElements..94 TestingPassengerHandwarmerElements..95 TestingThumbWarmerElement TestingHandlebarWarmer/ThumbWarmerSwitch....95 TestingSeatHeaterSwitches. TestingSpeedometerSensor TestingGearPositionSwitch .96 TestingShiftActuator..96 Drivetrain/Track/BrakeSystems DriveBelt. PrimaryClutch. SecondaryClute! PrimaryClutch/SecondaryClutch.. Drivetrain.. DriveSprockets. TrackTension/Alignment. BrakeSystem. BrakeLever/MasterCylinderAssembly . TroubleshootingTrack TroubleshootingHydraulicBrakeSystem TroubleshootingPrimarySheave/SecondarySheave119 Suspension ‘SuspensionSetupBasics ServicingSuspen125 WiringHarnesses140

GeneralInformation MNOTE:Wheneverapartiswornexcessively, cracked,ordamagedinanyway,replacementisnec- essary. NOTE:Someillustrationsandphotographsusedin thismanualareusedforclaritypurposesonlyandare notdesignedtodepictactualconditions. SpecialTools Anumberofspecialtoolsmustbeavailabletothetechni- cianwhenservicingsnowmobile. NOTE:SpecialtoolsareavailablefromtheYamaha ServicePartsDepartmentorK&LToolSupplyCom- pany. DescriptionYamahapin]K&Lpin lEngneTachometer0783-80009|Yu-08036-c FotorHolderfb0as0-0r205|Vu-o1e85 PistonPinPullerfb08s0-01504|Yu-01904 RadiatorPressureTestorjeoas0-01905|Yu-24460-01 FRadiaiorPressureTesterAdapterjaosso-01sse|YU-s396¢ HeavyDutyPulerjooss0-ora82|Yu.09070-8 (iFierWrenchleoss0-01465|YM-ot469 YRCluchBushingJigKtlsosso-o1625|VS-39762 ClutchBushingPresslooaso-o1629|VS-a2ao4 PrimarylatchHolderjeoaso-or701|¥S-01880-A (ClutchSpiderSeparatorjoosso-o1711|¥s-2aes0-c rackClipinstalationTooleosso-o172|ys-s1045-c ClutchSeparatorAdapierleosso-o1740|¥S-s4480 chPulerjooaso-o1698|¥s-o18s1-A Nesteiat EngineCompressionTestorjo0as0-03081|vu-ssess (CarbSynchronizerle0ss0-03004|YU-4a456 ialincicatorlo0880-03087|YU-Aedes IanalogPocketTesierleoaso-03112[Yu.osti2-< FuelPressureGaugeleosso-03155|Yu-0st53 90890-1111090890-11111 YS-11110YS-Aittt 90980-1114990890-11135 YS-1114935-1064 DescriptionYamahapin]K&Lpin FuelPressureTester'o0890-11143|YS-11143 (CarbAngleDriver2'90890-03173 ‘Model88Multimeter'90890-03174|YU-A1927 FuelPressureAdapter(90800-03176|YM-03176 agnosticsTool(YSOT)[90890-03233 \ValveSpringCompressor[90890-04019|YM-04019 BearingDriver40mm[90800-04058|YM-04058 (CrankshaftProtector[90800-04089|YM-33262 (ValveLappingTool[90890-04101|YM-AB9oa IVSCAdapter19.5mm[90800-04114|YM-04114 \ValveGuideRemover(4.5mm[90800-04116|YM-04116 \ValveGuideInstaller(4.5mm)[90800-04117|YM-04117 \ValveGuideReamer(4.5mm)[90800-04118|YM-04118 MechanicalSealInstaller[90800-01587|YM-01567 PistonRingCompressor[90800-05158|YM-08037 (OppamaPET-4000SparkChecker[90890-06754|YU-39951-B RearSpringInstallerlg0890-11110|YS-11110 HoseClampInstallationToollooseo-11111|YS-11111 Puller,IdlerWheelKit(Includes*below)[90890-11117|YS-11117 *AHandlelaose0-11118|YS-11118 *BInsertion Tool(1.0°)laose0-11119|YS-11119 *BInsertionTool(1.25")la0890-11120|YS-11120 *CPivotPlatelaose0-11121|YS-11121 *DAdapterPlate(1.0")la0ae0-11122|¥S-11122 *DAdapterPlate(1.25")lo0a90-11128|¥S-11123 *ECapSorewla0s90-11124|YS-11124 "FPullerBolt[90890-11125|YS-11125 ‘SnapRingPliers[90890-11126|YS-11126 ‘Socketlooae0-11128|YS-11128 'T50BallEndTorBitla0ae0-11148|YS-11148 BrakeCaliperBearingPuller[90890-11130|YS-11130 HoodHamassExtensionla0a90-11149|YS-11149 FuelHoseClampTool[90890-11135[85-1067 BatioryTesterlo0ae0-11138[a5-8517 ‘ShiftActuator TestHarnesslaoaeo-11141|YS-11141 FuelTankFilerNeckNutWrench[90890-11142|YS-11142 e \Yamalube®Yamabond4Locally F famalube®Yamabond68or[Locally (Loctite598Sourced [AngleGaugeLeealy 90890-1111790890-11126 YS-11117YS-11126 90890-11130 YS-11130 Snow_tool_2017A 3

SnowmobileIdentification TheYamahaSnowmobilehastwoimportantidentifica tionnumbers.TheVehicleIdentificationNumber(VIN) isstampedintothetunnelneartheright-sidefootrestand belowtheseat.Thereartunneldecalalsodisplaysperti- nentproductioninformation.TheEngineSerialNumber (ESN)isstampedintothecrankcaseoftheengine. Thesenumbersarerequiredtocompletewarrantyclaims properly.NowarrantywillbeallowedbyYamahaifthe engineserialnumberorVINisremovedormutilatedin anyway. RecommendedGasoline andOj iningmethanol | OnlyYamaha-approvedgasolineadditivesshould used. RECOMMENDEDGASOLINE Therecommendedgasolinetouseis91octanepremium unleaded(PONforNorthAmerica)or95octanepre- miumunleaded(RONforEurope,E5-E10),Inmany areas,oxygenatesareaddedtothegasoline,Oxygenated gasolinescontainingupto10%ethanolareacceptable gasolines. Whenusingethanol-blendedgasoline,itisnotnecessary toaddagasolineantifreezesinceethanolwillpreventthe accumulationofmoistureinthefuelsystem. RECOMMENDEDOIL ‘TherecommendedoiltouseisSemi-SyntheticYAMA- LUBE0W-30oil. Thereisneveramoreimportantperiodinthelifeofthe enginethanthefirst500km(300miles).Sincethe engineisbrandnew,donotputanexcessiveloadonit forthefirst500km(300miles).Thevariouspartsinthe enginewearandpolishthemselvestothecorrectoperat- ingclearances.Duringthisperiod,prolongedfullthrottle operationoranyconditionthatmightresultinengine overheatingmustbeavoided. Operatingyoursnowmobileforthefirsttime:Startthe engineandletitidlefor5minutes. 0-160km(0-100miles):Avoidprolongedoperation above6000RPM. 160-500km(100-300miles):Avoidprolongedoperation above8000RPM. 500km(300miles)andbeyond:Thesnowmobilecan nowbeoperatednormally. NOTE:After800km(500miles)ofoperation,the engineoilmustbechangedandtheoilfilterreplaced. Ifanyenginetroubleshouldoccurduringtheengine break-inperiod,immediatelyhaveaYamahadealer checkthesnowmobile. DriveBeltBreak-In Drivebeltsrequireabreak-inperiodof40km(25miles). Drivethesnowmobilefor40km(25miles)at3/4throttle orless,Byrevvingtheengineupanddown(butnot exceeding100km/h[60mph}),theexposedcordonthe sideof anewbeltwillbeworndown.Thiswillallowthe drivebelttogainitsoptimumflexibilityandwillextend drivebeltlife. NOTE:Beforestartingthesnowmobileinextremely coldtemperatures,thedrivebeltshouldberemoved andwarmeduptoroomtemperature.Oncethedrive beltisatroomtemperature,installthedrivebelt. ‘Theengineoilshouldbechangedevery4000km(2500 miles)beforeprolongedstorageandtheolfiltershould bechangedevery20,000km(12,500miles) EngineBreak-In Theengine(whenneworrebuilt)requiresashort break-inperiodbeforetheengineissubjectedtoheavy loadconditions. Thisenginedoesnotrequireanypre-mixedfuelduring thebreak-inperiod. GenuineParts ‘Whenreplacementofpartsisnecessary,useonlygenuine Yamahaparts.Theyareprecision-madetoensurehigh qualityandcorrectfit. VaryingAltitudeOperation Operatingasnowmobileatvaryingaltitudesrequires alibrationofdrivesystemcomponents. Followingarebasicaltitudetheoriesforclutching, engine,suspension,andtrack:

CLUTCHING 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traveled800m(2,500fi)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ha beenreached. "A.Enginespeed B.Good ‘condition .Shittingspeed D.Clute ‘engagement aon)800m=) t UTC 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 Tomaximizetheengineoutput,tuningfor ingclutchengagementspeedandshiftingspeedis wry.Thissettingiscalledhighaltitudetuning.The followingchangesareusuallyperformedinhighaltitude ‘tuning: +Toincreasetheclutchengagementandshiftingspeed, changingtoalargerspringconstantorusinglighter weightsandrivets.(decreasingprimarysheavethrust) +Increasingthereductionratioofthedrivengear/drive ‘gear.(increasingthedrivingperformance) AEngnespeed B.Speed att maximum ouput ©.Lowspeed D.Distance traveled ‘CLUTCH TURBOCHARGING Turbochargingisonemethodofcompensatingforlossof airdensitythatworksextremelywellwhenappliedto four-cycleinternalcombustionengines. Exhaustgasesaredirectedthroughtheturbochargertur- binewheelwhichisattachedtothecompressorthrougha commonshaft.Astheexhaustgasesspintheturbine,the compressorisspunatveryhighRPM.Inletairisdrawn intothecompressor,compressed,androutedtotheintake manifoldoftheengine.Intakepressure,therefore, maintainedattheoptimumlevelasaltitudeortempera- tureincreases. Theturbochargeroutputmustberegulatedtomaintain theoptimummanifoldpressurethroughoutthedesigned operatingrange.Thisisaccomplishedbyregulatingthe volumeofexhaustgasespassingthroughtheturbineby controllingadivertervalve(wastegate)attheturbo- chargerturbineinlet.Atloweraltitudes/temperatures, excessiveexhaustgasesaredivertedpasttheturbineand intotheexhaustdownstreamoftheturbochargerthus limitingthecompressoroutputtomaintaincorrectmani- foldpressure. Asaltitudeincreases,themanifoldpressureisheldcon- tantbydivertinglessexhaustpasttheturbine,thus increasingcompressorspeed.Thiswillcontinueuntilthe waste-gateiscompletelyclosedatwhichtimemanifold pressurewillstarttodecreasemuchthesameasanor- ‘allyaspiratedengine, Thewastegate iscontrolledbytheECUthatis totheintakemanifoldbyanairline.Amechani ageconnectsthediaphragmtothewastegatecontrol arm. Airisheatedbyfrictionandcompressionthroughthetu bochargerandairdensityislostbyheatingtheair;there- fore,anafter-coolerisinstalledbetweentheturbocharger compressorandtheintakemanifold.Thisisanair-t afier-coolerthatusesoutsideairdirectedthrougharadii tor-typecoolertocoolthecompressedairpriortoenter- ingtheintakemanifold. SUSPENSION Trailridingversuspowdersnowridingversuscombina- tionridingwillallrequiredifferentsuspensionsettings. Thedifferentridingstylesoftheindividualoperator,the varyingsnowconditions,andthetypeofterrainareall faciorsthataffectthesuspensionathighaltitude. Thenormalsettingforfrontskisuspensionisaslittle springpreloadtensionaspossibleforpowdersnowrid- ingallowingtheskistofloatacrossthesnowwiththe eastamountof resistance.Trailridingwillrequiremore springtensiontocarrythevaryingloadmoreeffectively. Manydifferentsettingsandspringtensionstoconsider existwhenadjustingforridingstyleandsnowcondi- tions. Therearsuspensionhasanumberofspringsettingsthat producedifferentridingcharacteristics. Thefrontarmspringandshockwillalsoaffecttheride andhandlingwheneitheronatrailorinpowdersnow.A strongspringsettingonthisshockwillcausethesnow- mobiletotendto“dig”morewhenridinginthepowder snowratherthanclimbingupontopofthesnow.But,it willworkmoreeffectivelywhenridingonatrail.A sofierspringsettingwillallowthefrontoftherearsus- pensiontocollapsemuchquickerandchangetheangleof thetracktothesnow.Amoregradualanglewilltendto raisethesnowmobileuponthesnowratherthandigging intoit.

Manypossiblevariablesand z pensionexistdependingonsnowconditions,ridingstyle, andtypeofterrain,Theseadjustmentscanbemadeto individualizethesnowmobiletotheridingstyleofthe operator. Assnowcoverandridingconditionschange,severaldif ferentadjustmentscanbemadetochangetherideand handlingcharacteristicsforoperatorpreference.Located onthefrontsuspensionarmarelimiterstraps.Theylimit theamountof“fallout”thefrontarmcanhave.These strapsmaybeadjusted inoroutduetoconditionsand ridingstyle.Themorethestrapsarebroughtup,themore steeringpowertheoperatorhasduetotheamountofski pressure Anotheradjustmentthatcanbemadeontherearsuspen- sionisthefrontarmshockspringtension.Astrailcondi- tionschange,thespringpreloadmaybeusedtodecrease thechanceofthefrontend“botiomingout”.Witha stifferspringpreload,therideofthesnowmobilewill improveonthetrailbutwillaffecttheperformanceinthe deeppowdersnow.Indeeppowdersnow,thestiffer springpreloadwillcausethefront-endto“dig”andpos- siblytakelongerforittoplaneoff.Severaldifferent-rate springsareavailablefordifferentridingstylesandterrain conditions. Onthestandardmodels,thefrontshockspringsarealso individuallyadjustablefortheterrainconditionsand drivingstyleof theoperator.Thespringadjusterhasbeen setatthefactorysothecorrectamountofthreadsare exposedbetweenthespringadjusterandtheshockhous- ingasaninitialsetting.Additionalskipressurecanbe obiainedbytighteningthespringtension;skipressure canbedecreasedbyrelaxingspringtension.Springswith differentspringratesareavailableforoperatorchoice andsnowconditions. Alimitexistsastohowfaryoucanpreloadthesprings before“coilbind”takeseffectwherethewireonthe springactuallyrunsintoitselfandcausesbinding.Equal adjustmentsshouldbemaintainedonbothsidesofthe snowmobile. Onmodelswithairshocks,theyareindividuallyadjust- ablefortheterrainconditionsanddrivingstyleofthe operator.Theshocksarepresetatthefactory(seechart) asaninitialsetting;however,itispossibleto“finetune” theshockstomatchtheoperator’sweight,ridingstyle, andterrainconditions. TRACK Carefullymatchingtheridingrequirementstothetypeof trackwillensurethemaximumuseofallavailableengine power.Lugheightandtrackdurometerarethetwomain concernswhenselectingatrackforvariousridingstyles. Tracksexistwithlugheightsfrom25-75mm(1.0-3.0in.) toaccommodatevarioussnowconditions.Generally,the deeperthesnow,thetallerthelug.Itmustbenotedthat theinstallationofanydeep-lugtrackmayreducetopend speedandpromoteprematurewearstripwearinmarginal snowconditions. Durometerisameasurementofhowhardarubberis.The lugsonmosttracksrangebetween60and80durometer. Onthedurometerscale,thehigherthenumber,theharder thelugs.Forridingindeeppowdersnow,asofterdurom- etertrackworksbest.Thesofterrubberallowsthetrack (0“give”alittleandpackthesnowcreatingliftrather thandiggingitswaystraightdown,Whenhill-climbing, theharderlugofan80durometertrackworksthebest duetopenetratingthehardsnowcreatingmorebite. Sometrackscomewithadualdurometerrating,such trackwitha80/60durometerrating.Thelugsonth trackare80%80durometerrubber,andthetop20% madeofthesofter60durometerrubber.Thistrackis designedtobeagoodall-aroundtrackforridingmostly indeeppowdersnowbutcanclimbtheoccasionalhard snowhill. PreparationforStorage Priortostoringthesnowmobile,itmustbeproperlyser- vicedtopreventcorrosionandcomponentdeterioration. 1.CleantheseatcushionwithadampclothandaVinyl Protectant. 2.Cleanthesnowmobilethoroughlybyhosingdirt,oil, grass,andotherforeignmatterfromtheskidframe, tunnel,hood,andbellypan.Allowthesnowmobile todrythoroughly.DONOTgetwaterintoanypart oftheengine, 3.Changetheengineoil. 4,Plugtheexhaustsystemoutletwithacleancloth. 5.Fillthegastanktoitsratedcapacity;thenadd ahaFuelStabilizertothe gastankfollowing directionsonthecontainerfortheetabilizer/easoline ratio.Tightenthegastankcapsecurely. 6.Withthesnowmobilelevel,checkthelubricantlevel inthechaincase.Iflow,addchainlubethroughthe fillplughole. 7.Removethedrivebeltfromtheprimarysheave/sec- ondarysheave.Laythebeltonaflatsurfaceorslide itintoacardboardsleevetopreventwarpingordis- tortionduringstorage. 8.Cleanandinspecttheprimarysheaveandsecondary sheave. 9.Applylightoiltotheuppersteeringpostbushingand shaftsoftheshockabsorbers. 10.LubricatetherearsuspensionwithYamahasnowmo- bilegrease. 11.Tightenallnuts,bolts,andcapscrewsmakingsure bolts,andcap’screwsaretightenedsecurely. Makesureallrivetsholdingthecomponentstogether aretight.Replacealllooserivets. 12.Cleanandpolishthehood,console,andchassis.DO NOTUSESOLVENTS.THEPROPELLANTWILL DAMAGETHEFINISH.

NOTE:Disconnectthebatterycablesmakingsure todisconnectthenegativecablefirst;thencleanthe batterypostsandcables.Chargethebattery. 13.Ifpossible,storethesnowmobileindoors.Raisethe trackoffthefloorbyblockingupthebackendmak- ingsurethesnowmobileissecure.Loosenthetrack adjustingboltstoreducetracktension.Coverthe snowmobilewithamachinecoveroraheavytarpau- lintoprotectitfromdirtanddust. 14,Ifthesnowmobilemustbestoredoutdoors,position thesnowmobileoutof directsunlight;thenblockthe entiresnowmobileoffthegroundmakingsurethe snowmobileissecure.Loosenthetrackadjusting boltstoreducetracktension.Coverwithamachine coveroraheavytarpaulintoprotectitfromdirt, dust,andrain, PreparationafterStorage Takingthesnowmobileoutofstorageandcorrectlypre- paringitforanotherseasonwillensuremanyhoursof trouble-freesnowmobiling.Yamaharecommendsthefol- lowingprocedure: 1,Cleanthesnowmobilethoroughly.Polishtheexterior ofthesnowmobile. 2.Cleantheengine.Removetheclothfromtheexhaust system,Checkexhaustsystemandair-intakesilencer forobstructions. 3.Inspectallcontrolwiresandcablesforsignsofwearor fraying.Replaceifnecessary,Usecabletiesortapeto routewiresandcablesawayfromhotorrotatingparts. 4,Inspectthedrivebeltforcracksandtears.Checkbelt specifications.Replaceifdamagedorworn.Install thedrivebelt. NOTE:Iftheoldbeltiswornbutinreasonablecon- dition,retainitwiththesnowmobileasaspareincase ofanemergency. 5.Tightenallnuts,bolts,andcapscrewsmakingsure allnuts,bolts,andcapscrewsaretightenedsecurely. 6.Ifnotdoneduringpreparationforstorage,lubricate therearsuspensionwithYamahasnowmobile grease. 7.Checkthecoolantlevelandallcoolanthosesand connectionsfordeteriorationorcracks.Addproperly mixedcoolantasnecessary. 8.Chargethebatteryuntilfullycharged;thenconnect thebatterycablesmakingsuretoconnecttheposi- tivecablefirst.Testtheelectricstartsystem. 9.Inspecttheentirebrakesystem,allcontrols,head- light,taillight,brakelight,skiwearbars,andhead- lightaim;adjustorreplaceasnecessary. 10.Adjustthetracktothepropertensionandalignment. AfterBreak-In Checkup/Checklist Certainareasrequireadjustmentafterthebreak-inperiodin ordertoobtainpeakperformanceandincludethefollowing: DRIVEBELTPOSITION—Drivebeltlength,condi- tion,andpositionareallimportantforpeakperformance. Afterthebreak-inperiod,drivebeltdeflectionshouldbe checkedaccordingtotheinstructionsgivenintheDrive- train/Track/BrakeSystemssectionofthismanual. PRIMARYSHEAVE/SECONDARYSHEAVEOFF- SET—Ifprematuredrivebeltwearisexperiencedorif thedrivebelttumsover,offsetmustbechecked.Also, offsetmustbecheckedwhenevereithertheprimary sheaveorsecondarysheaveisserviced, TRACKTENSIONANDALIGNMENT—Acertain amountofstretchoccursonalltracksduringthefirst800 km(500miles).Thetrackmustbeinspected/adjusted afierthefirst80to160km(50to100miles)tothespeci- ficationsgivenintheTrackSpecificationssub-sectionof thissectionandperiodicallythereafter,Iftheseadj mentsaren’tperformed,thetrackmay“derail”which leadstotrackandslideraildamage. Alongwiththesemajorareas,otherareasshouldbe checkedandadjusted,Belowisalist ofitemstocheckafter thebreak-inperiod.Therecommendedmileageforthis inspectionisbetween160and500km(100and300miles). 1Checkdrivebeltposition—primary sheave/secondarysheaveoffset (2Adjusttracktensionandalignment OCheckthrottlecabletension (Checkengineidle (Checkcoolantlevel OCheckchaincaselubricantlevel (Checkengineoillevel OChecklights(high/lowbeam,brakelight) OChecksafetyswitchoperation Checkenginecompartmentforanyrubbing components Checksteeringhardwarefortightness OCheckskidframeandA-armmountinghard- warefortightness OCheckbrakelevertravelandadjustment Greasealllubricationpoints

EngineSpecifications ElectricalSpecifications Component"TestValue[+TestConnections EngineModelNumbereK(NormallyClosedIgnition) jsplacementa8ooMagnetoCol(stesis)*—[o-160.25ohmsfhe [CompressionRatioaoarimaryIgnitionCol”[1-19-16ohms BorexStoke0.0x66armGISx2ET)[SecondaryIgnitionCal”—a.5k-1-5kohms (CoolingSystemIlquid[CrankshaftPostionSensarj46-545ohmslightgraydarkgray SparkPlug(NGK)icRaENotageHr2-1450CVolsferminal—ferminal [SparkPlugGap(0:71-0:79mm(0.028-0.087")[RegulatorRectiior*_ PistonSkit/GyinderClearance——|0.096-0.061mm(0.00%4-0.00287|[ManetoColl(noToad)56-44ACWatsjhifewhite Seenbos061man (0faritionSich28sthan1ohmferminal—erminal ascoasoa[keyinONpostion) istoPinBoreDiameter1.00821016mmSeepage89fortextprocedure. (o.azeo-0.8274")**Hamessplugged in stonPintoPistonPinBore(0.008-0.025mm(0.0008-0.00087)|Themainharnessconnectorsmustbeunplugged(except (Clearance (ConnectingRod:SmallEnd ameter (31.005-21.007mm (0.8269-0.8278") (CrankshaftPin/ConnectingRodBig [EndClearance (0.090-0.048mm(0.0012-0.0018°) (Connectingrod:BigEndDiameter 144.000-47.078mim (1.6142-1.6149") jatonRingEndGaprep)|0.35-0.45mm(0.074-0.071 (2nd)_|0.75-0.85mm(0.030-0. (©i)__[0:10-0.35 mm(0.004-0.014" PistonRing’(fat=Top)|0.030-0.065mm(0.0012-0.002% (GrooveClearance(2nd)—_|0.020-0.055mm(0:0008-0.002: (©i)__[0.040-0.140mm(0.0016-0.005: PistonDiameter179.95-79.96mm(8.1476-3.1480") (10mmfrombottomedge) (CamLobeHeight(Intake)(38.750-83850mm (1.8287-1.3327") (CamLobeHeight(Exhaust)[g8.750-83850mm (1.8287-1.3327") (CamLobeWidth(Intake)[24950-25050mim (0.9823-0.9862") (CamLobeWidth(Exhaust)[24950-25050mim (0.9823-0.9862") (CamshaftJoumalDiameter(2446-2447mm(0.9630-0.5635") (CamshaftJoumalClearance(0.028-0,062mm(0.0011-0.0024") (CrankPinDiameter (37.976-38000mm ((.4951-1.4961") (CrankshaftRunout(rax) [0.08mam(0.0072°) (CrankshaftMainBearingClearance (0.027-0.045mm(0,0011-0.0018") (Crankshafi/RodBearingClearance (0.080-0.048mm(0.0072-0.0019") \ValveClearane-Cold(Intake) (0.18-0.22mm(0,0058-0.0087") \ValveClearance-Cold(Exhaust) \ValveStemDiameter(Intake) (0.21-0.25mm(0.0083-0,0038") 14.476-4,490mm(0.1762-0.1677") \ValveStemDiameter(Exhaust) 14.460-4.475mm(0.1756-0.1762") ValveGuideInsideDiameter(Intake) 14.500-4.512mm(0.1772-0.1776") \ValveGuideInsideDiameter (Exhaust) 14.500-4.512mm(0.1772-0.1776") \ValveGuide/StemClearance(Intake) [0:070-0.087mm(0.0004-0.0018") \ValveGuide/StemClearance (Exhaust) (0.025-0,082mm(0.0010-0.0020") ValveFaceWidth(Intake) (0:90-1.10mm(0.085-0.043") ValveFaceWidth(Exhaust) (0.90-1.10mm(0.085-0.043") VALVETIMING(below) IntakeOpen(BTDC)[a5.0degrees IntakeClosed(ABDC)145.0degrees [ExhaustOpen(BBDC)145.0degrees ExhaustClosed(ATDC)[a5.0degrees \ValveOverlap(70.0degrees onprimarycoilandregulator/rectifiertests)andtestedby turningthekeytothestartposition, mNOTE: Mostvoltagesgeneratedbythjonsystemaresuf, ficienttointerruptpacemakers!Alltechnicians,espe+ iallythoseusingpacemakers,mustavoidcontactwith| allelectricalconnectionswhenpressingthestarterbut-| ttonoraftertheenginehasbeenstarted.