1988-2005 Yamaha Viking VK 540 Series Snowmobile Service Repair Factory Manual INSTANT

® ® (j) ® ICHASI...# IIELECI iii I ([j) ~ @ ~ ® ~ @§ @ mID @ & @l @l @l tTl Gl a ® ® @ ~ ~~ ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to @ are designed as thumb tabs to indicate the chapter's number and content. CDGeneral information ® Periodic inspection and adjustment @Engine (!)Cooling system ® Carburetion ® Power train (j)Chassis ® Electrical @Appendices Illustrated symbols @ to @ are used to iden- tify the specifications appearing. @Filling fluid ([j) Lubricant @Tightening ®Wear limit, clearance @Engine speed @Q,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 POWER TRAIN CHASSIS ELECTRICAL APPENDICES ~- ENG ~ ~- iii ELEC ~,

CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ..................................... 1-1 FRAME SERIAL NUMBER .................................... 1-1 ENGINE SERIAL NUMBER .................................... 1-1 D STORAGE .................................................... 1-2 PRE-SEASON PREPARATION .................................... 1-2 IMPORTANT INFORMATION ..................................... 1-3 NO FLAME SOURCES ........................................ 1-3 WASHING AND CLEANING ................................... 1-3 RIGHT TOOLS .............................................. 1-3 MAKING IT NEAT . .......................................... 1-3 TIGHTENING TORQUE ....................... .... ........... 1-3 ALL REPLACEMENT PARTS .................................. 1-4 GASKETS, OIL SEALS, AND O-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 TUNE UP ........ . ......... ... ......................... 1-5 FOR ENGINE SERVICE ...................................... 1-6 FOR POWE R TRAI N SERVICE ............................... .. 1-6 FOR ELECTRICAL SERVICE .................. . ............... 1-7 SPECIAL TOOLS CROSS REFERENCE LIST ......................... 1-9

1~1~1- I MACHINE IDENTIFICATION 1-1 GENERAL 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 The engine serial number CD· is located on thp right-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: For (OK, N, NL, S, SF): 83R-00010l For (CON): 84R-00010l NOTE: ________________________ __ Designs and specifications are subject to change without notiCe.

_______________ ST_O_R_A_G_E_/P_R_E_-S_E_A_S_O_N_P_R_E_PA __ RA_T _1_o __ N~I~ __ ~_~~I-- __ ~ STORAGE If a snowmobile will not be used for severa l months, it should be stored in a proper pl ace 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 reassemb Ie 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.) 1-2

'-3 IMPORTANT INFORMATION c~ ( · c U ,~~,' ~ .. = . -. ':.. ~ . ~I , .. '. '::....,..:; i' -" ~. ~ IMPORTANT IN FORMATION 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 I ~~'l>I- 300- 002 300- 003 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 O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil sea l lips, and O-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 OIL SEALS 1. Install the bearing(s) CD and oil seal(s) ® with their manufacturer's marks or numbers facing outward. (I n 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. 1-"

I SPECIAL TOOLS 300-001 1-5 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 TUNE UP 1. Sheave Gauge PIN YS-91047 This gauge is used for sheave distance and offset adjustment. 2. Dial Gauge PIN YU-03097 This gauge is used for ignition timing adjustment. 3. Dial Gauge Stand Set PIN YU-01256 These tools are used for ignition timing adjustment.

SPECIAL TOOLS 1~1-~I- FOR ENGINE SERVICE 1. Universal Rotor Holder PIN YU-01235 This tool is used to hold starter pulley and COl magneto. 2. Piston Pin Puller PIN YU-01304 This tool is used to remove piston pin. 3. Rotor Puller PIN Y U-33270 This tool is used to remove COl magneto. FOR POWER TRAIN SERVICE 1. Primary Sheave Holder PIN YS-01880 This tool is used to hold primary sheave. 2. Primary Sheave Pu lIer PIN YS-01882-A This tool is used for removing primary sheave. 1-6

SPECIAL TOOLS 1-7 3. Sheave Compressor PIN YS-28891 This tool is used for disassembling and assembling sheave. 4. Clutch Spider Separator PIN YS-28890-A These tools are used for disassembling and assembling primary sheave. 5. Clutch Separator Adapter PIN YS-34480 This tool is used for disassembling and assembling primary sheave. 6. Track Clip Installer PIN YS-91 045 This tool is used for installing the track clip. FOR ELECTRICAL SERVICE 1. Pocket Tester PIN Y U-0311 2 This instrument is necessary for checking the electrical components.

1988-2005 Yamaha Viking VK 540 Series Snowmobile Service Repair Factory Manual INSTANT

You're Reading a Preview

Recently Viewed