Yamaha Snoscoot SV80 SV 80 88 89 90 91 Snowmobile Service Repair Workshop Manual

CD ® IM'f=~l- ll~fl§tl ® @ I ENGI'-1 lcocxi Kl @ ® ICARBifl ITI41 (f) ® ICHASI~ I IELECiiii I ® @ ~ IAPPxl.~a'l (jJ) ~ @ [f] @ ~ @ § @ [mJ @ • . @i @i @i - m - m e ® @ ® ~ ~~ ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content. (!)General information ®Periodic inspection and adjustment @Engine @Cooling system @Carburetion @Power train (l)Chassis @Electrical ®Appendices Illustrated symbols ® to @ are used to iden- tify the specifications appearing. @Filling fluid @Lubricant @Tightening @Wear limit, clearance @Engine speed @n.v.A Illustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point. @Apply locking agent (LOCTITE®) @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

INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL APPENDICES ~ ~-· CHAS Iii ELEC ., APPX

CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ..................................... 1·1 FRAME SERIAL NUMBER .................................... 1-1 ENGINE SERIAL NUMBER .................................... 1-1 n STORAGE .................................................... 1-2 PRE-SEASON PREPARATION .................................... 1·2 IMPORTANT INFORMATION ..................................... 1-3 PREPARATION FOR REMOVAL AND DISASSEMBLY ............. 1-3 ALL REPLACEMENT PARTS .................................. 1-4 GASKETS, OIL SEALS, AND 0-RINGS .......................... 1-4 LOCK WASHERS/PLATES AND COTTER PINS .................... 1-4 BEARINGS AND OIL SEALS .................................. 1-4 CIRCLIPS .................................................. 1-5 SPECIAL TOOLS ............................................... 1-5 FOR ENGINE SERVICE ...................................... 1-5 FOR ELECTRICAL SERVICE .................................. 1-7

MACHINE IDENTIFICATION I Ml-~1- 1-1 GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number CD is located on the right-hand side of the frame. ENGINE SERIAL NUMBER The engine serial number CD is located on the left-hand side of the crankcase. NOTE=------------------------- The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. Starting Serial Number: SVSOM .......... 85G-0001 01 SVSOEM ..•..•... 85H-0001 01 NOTE:-------------------------- Designs and specifications are subject to change without notice.

STORAGE/PRE-SEASON PREPARATION I 1·2 STORAGE If a snowmobile will not be used for several months, it should be stored in a proper place so that both the engine and the track are not damaged. •Completely drain the fuel tank, and disconnect the fuel line from the carburetor. •With the engine running at idle, squirt oil into the carburetor until the engine dies. This will distribute oil evenly throughout the engine, and protect it against rust. • Disassemble the suspension, clean and grease all parts, and reassemble the suspension. • Lightly coat all shafts and axles with grease. • Oil all fittings and cable controls with a lightly oiled cloth. • Loosen the track. • Block the chassis so that the track is off the floor. • Protect the snowmobile with a covering. PRE-SEASON PREPARATION Perform the predelivery service as described in the predelivery check list before operating any snowmobile that has been stored for several months. (Refer to CHAPTER 2. "PERIODIC MAINTENANCE TABLE", page 2-1.)

IMPORTANT INFORMATION IM'f=~l- 1-3 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DIS- ASSEMBLY 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 mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced. 4. During the machines disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire. 6. Be sure to keep to tightening torque specifications. When tightening bolts, nuts, and screws, start with a larger-diameter one and from an inner-positioned one to an outer- positioned one in a criss-cross pattern.

IMPORTANT INFORMATION GEN INFO 300-000 300-002 300-003 1-4 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS, AND 0-RINGS 1. All gaskets, seals, and 0-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and 0-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 1. All lock washers/plates CD and cotter pins must be replaced when 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 01 L SEALS 1. Install the bearing(s) CD and oil seal(s) ® with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings libe- rally when installing. Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

300-001 1-5 SPECIAL TOOLS I ~'f='l>l- CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD , make sure that the sharp edged corner ® is positioned opposite to the thrust ® it receives. See the sectional view. @Shaft SPECIAL TOOLS The proper special tools are necessary. for com- plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or impro- vised techniques. FOR ENGINE SERVICE 1. Piston Pin Puller P/N. YU-01304 This tool is used to remove the piston pin. 2. Rotor Holder PIN. YU-01235 This tool is used to hold the rotor (CD I magneto). 3. Sheave Holder P/N. YS-01880 This tool is used to hold the clutch housing and clutch assembly.

1-6 SPECIAL TOOLS ~~lf:~l- 4. Clutch Spring Holder P /N. YS-28891 This tool is used to compress the clutch spring. 5. Rotor Puller P/N. YM-01189 This tool is used to remove the rotor (COl magneto). 6. Crankcase Separating Tool P/N. YU-01135 This tool is used to separate the crankcase. 7. Universal Puller P/N. YU-33270 This tool is used to remove the crankshaft from the crankcase (Left). 8. Crankshaft Installer P /N. Y U-90050 This tool is used to install the crankshaft.

1-7 SPECIAL TOOLS ~~'f=~l- 9. Adapter - CD P/N. YM-90062 Adapter-® P/N. YM-90063 These tools are used to install the crankshaft together with the crankshaft installer. 10. Yamabond #4® P/N. ACC-11 001-03-00 FOR ELECTRICAL SERVICE 1. Pocket Tester P/N YU-03112 This instrument is necessary for checking the electrical components. 2. Electro Tester P /N Y U-33260 This instrument is invaluable for checking the electrical system.

Yamaha Snoscoot SV80 SV 80 88 89 90 91 Snowmobile Service Repair Workshop Manual

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