1991-1997 Yamaha Venture XL GT & TF Snowmobile Service & Repair Manual

Q) ® I~EF~I~I Irgjl~1 ® @ ICHASI~ I ~141 ® ® IENGIJiI ICARSI'I (J) ® I ElEC I iii I IAPPXI~'1 ® ~ @ ~ (jJ) ~ @ ~ @ § ® [ml @ 1 @ 1 @ 1 m Gl Gl @ @) @ ~ ~ ~ ® A @a @a ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols Q) to ® are designed as thumb tabs to indicate the chapter's number and content. Q) General information ® Periodic inspection and adjustment ® Chassis @ Power train ® Engine ® Carburetion (J) Electrical ® Appendices Illustrated symbols ® to ® are used to identify the specifications which appear. ® Filling fluid @ Lubricant (jJ) Tightening @ Wear limit, clearance @ Engine speed ® Q,V,A Illustrated symbols @ to ® in the exploded diagrams indicate the grade of lubricant and the location of lubrication points. @ Apply engine oil @ Apply gear oil @ Apply molybdenum disulfide oil @ Apply low-temperature lithium-soap base grease (j]) Apply wheel bearing grease (Esso-Beacon 325 grease or Aero Shell grease #7) ® Apply molybdenum disulfide grease Illustrated symbols ® to @ in the exploded diagrams indicate the grade of sealing or locking agent and the location of application points. ® Apply locking agent (LOCTITE®) @ Apply Yamabond No. 4® @ Apply Yamabond No.5®

INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE OVERHAUL CARBURETION ELECTRICAL APPENDICES ~ ENG • CARB Iii ELEC ~, APPX

______________________________ ~~~I~I CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ............................. 1-1 FRAME SERIAL NUMBER ........................... 1-1 ENGINE SERIAL NUMBER ......................... 1-1 IMPORTANT INFORMATION ........................... 1-2 ALL REPLACEMENT PARTS ....................... 1-2 GASKETS, OIL SEALS, AND O-RINGS ...... 1-2 BEARINGS AND OIL SEALS ....................... 1-2 CIRCLIPS ...................................................... 1-2 SPECIAL TOOLS ............................................... 1-3 FOR TUNE UP .............................................. 1-3 FOR ENGINE SERVICE ................................ 1-4 FOR POWER TRAIN SERVICE .................... 1-4 FOR ELECTRICAL SERVICE ........................ 1-6

---- MACHINE IDENTIFICATION I ~~~lujzJl GENERAL 1-1 INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number CD is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER (Primary I.D.' The engine serial number CD is located on the right-hand side of the crankcase. NOTE: ______________________ _ The first three digits of these numbers are for model identification; the remaining digits are the unit production number. Starting Serial Number VT480R ........................ 88T-000101 NOTE: _____________________ __ Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION I g.EF~I*'1 IMPORTANT INFORMATION 300-002 300-003 300-001 1-2 ALL REPLACEMENT PARTS 1. We recommend the use of Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS, AND a-RINGS 1. All gaskets, seals, and O-rings should be re- placed when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. BEARINGS AND OIL SEALS 1.lnstall 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 liberally when installing. Do not use compressed air to spin the bearings dry. This causes damage to the surface of the bearings. CIRCUPS 1.AII circlips should be inspected carefully be- fore reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing a circlip CD , make sure that the sharp edged corner ® is positioned opposite the thrust ® it receives. See the sectional view. @ Shaft

1-3 SPECIAL TOOLS I~EF~IJtztI SPECIAL TOOLS Some special tools are necessary for complete accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be ca used by the use of improper tools or im provised techniques. NOTE: ______________________ __ Be sure to use the correct part number when ordering the tool, since the part number differs according to the destination as shown below. The first part number is for Europe and the other number is for the U.S.A. and Canada. e.g. 90890-****, YU-**** FORTUNE UP 1. Vacuum Gauge ®P/N YS-33275 ®Sealing Plug PIN YU-91035-3 (2 required) This tool is used for carburetor synchronization. 2. Sheave Gauge PIN 90890-01702, YS-91047 This gauge is used to measure sheave distance and for offset adjustment. 3. Dial Gauge P/N-90890-03097, YU-03097 This gauge is used for ignition timing adjustment.

I GINEFNOldwl SPECIAL TOOLS ~ ------------------------------------------------------- 1-4 FOR ENGINE SERVICE 1. Piston Pin Puller P/N-90890-01304, YU-01304 This tool is used to remove the piston pin. 2. Universal Rotor Holder P/N-90890-01235, YU-01235 This tool is used to hold the CDI magneto. 3. Rotor Puller P/N-90890-0 1362, YU-33270 This tool is used to remove the magneto rotor. FOR POWER TRAIN SERVICE 1. Primary Sheave Holder P/N-90890-01701, YU-01880 This tool is used to hold the primary sheave. 2. Primary Sheave Puller (18 mm) P/N-90890-01898, YS-01882-A This tool is used for removing the primary sheave.

1-5 SPECIAL TOOLS I ~ EF~ jJa I 3. Sheave Compressor P/N-90890-01712, YS-28891 This tool is used when disassembling and assembling the sheave. 4. Clutch Spider Separator P/N-90890-01711, YS-28890-B This tools are used when disassembling and assembling the primary sheave. 5. Clutch Separator Adapter P/N-90890-01740, YS-34480 This tool is used when disassembling and assembling the primary sheave. 6. Eccentric Bearing Installer P/N-90890-01721, YS-91045 This tool is used when removing and installing the front axle.

1-6 SPECIAL TOOLS I~EF~IJsI FOR ELECTRICAL SERVICE 1. Pocket Tester P/N-90890-03112, YU-03112 Th is instrument is necessa ry for checki ng the electrical components. 2. Electro Tester P/N-90890-03021, YU-33260 This instrument is used to check the electrical system.

_________ lrgr ~1 CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ................................................ 2-1 PERIODIC MAINTENANCE TABLE ................... 2-1 ENGINE .............................................................. 2-3 SPARK PLUG ............................................... 2-3 FUEL FILTER INSPECTION ......................... 2-3 FUEL LINE INSPECTION ............................. 2-4 ENGINE OIL LINE INSPECTION ................. 2-4 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK ........................................................ 2-5 THROTTLE CABLE FREE PLAY ADJUSTMENT ........................................... 2-5 CARBURETOR SYNCHRONIZATION ......... 2-6 ENGINE IDLE SPEED ADJUSTMENT ........ 2-8 EXHAUST SYSTEM .................................... 2-9 STARTER CABLE FREE PLAY ADJUSTMENT ........................................... 2-9 OIL PUMP .................................................. 2-10 COOLING FAN BELT ................................. 2-11 COOLING FAN BELT TENSION ADJUSTMENT ......................................... 2-12 SHEAVE DISTANCE AND OFFSET ADJUSTMENT ......................................... 2-13 POWER TRAIN ................................................. 2-16 DRIVE V-BELT ............................................ 2-16 ENGAGEMENT SPEED CHECK ................ 2-18 BRAKE PAD INSPECTION ........................ 2-18 BRAKE ADJUSTMENT .............................. 2-19 DRIVE CHAIN HOUSING OIL LEVEL INSPECTION ............................................ 2-19 DRIVE CHAIN TENSION ADJUSTMENT ......................................... 2-20 TRACK TENSION ADJUSTMENT ............ 2-21 SLIDE RUNNER INSPECTION .................. 2-23 CHASSIS .......................................................... 2-23 SKI/SKI RUNNER ....................................... 2-23 STEERING SYSTEM .................................. 2-23 SKI ADJUSTMENT .................................... 2-24 HANDLEBAR ADJUSTMENT ................... 2-25 LUBRICATION ........................................... 2-26 ELECTRICAL .................................................... 2-27 HEADLIGHT BULB REPLACEMENT ......... 2-27 HEADLIGHT BEAM ADJUSTMENT ......... 2-28 TAIL/BRAKE LIGHT BULB REPLACEMENT ....................................... 2-28 BATTERY INSPECTION ............................ 2-28 FUSE INSPECTION ................................... 2-30 TUNING ........................................................... 2-32 CARBURETOR TUNING ............................ 2-32 CLUTCH TUNING ...................................... 2-40 GEARING SELECTION .............................. 2-41 HIGH ALTITUDE TUNING ......................... 2-43 SLIDE RAIL SUSPENSION TURNING ...... 2-44

1991-1997 Yamaha Venture XL GT & TF Snowmobile Service & Repair Manual

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