Do not use compressed air to spin the bearings dry. This causes damage to the surface of the bearings. All circlips should be inspected carefully be- fore reassembly.
Always replace piston pin clips after one use. Replace misshapen circlips. See the sectional view. Using the correct special tool will help prevent damage that can be caused by the use ofimpropertools or improvised techniques.
The first part number is for Europe, and the second part is for the U. YSA This tool is used for installing the track clip. YU This instrument is necessary for checking the electrical components. YUA This instrument is invaluable for checking the electrical system. These preventive maintenance procedures, iffollowed, will ensure more reliable machine operation and a longer service life.
In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.
Check oil level. Fuel: Check fuel level. Check coolant level. Check wear and damage. Replace if necessary. Throttle 9verride System: Check operation. Check operation. Drive V-belt: Check wear and damage. Slide Runner Check wear and damage. Adjust if necessary. Check fluid level. Check engagement and shift speed. Wheneveroperatingelevation ischanged.
Lubricate with specified grease. Whenever operating elevation ischanged. Cable End Replace if necessary. Use wire thickness gauge. Spark plug gap: 0. Place a rag under the oil pump assembly to catch oil. Keep the oil running out until air bubbles disappear from the oil hose ill. Keep the oil running out until air bubbles disappear from bleed hole. Recommended replacement interval: Every season 3. Reverse the removal procedure.
Recommended replacement interval: Every season 5. Place the machine on a level surface. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place thick rag like atowel overthe radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.
Drain the coolant. It is harmful or fatal if swallowed. Get immediate medical attention. Call a physician. Remove the reservoir tank CD and drain the coolant.
Fill: Drain bolt: 23 Nm 2. Bleed air from the cooling system. Bleed bolt: 6 Nm 0. Apply and lock the parking brake. Start the engine and run it at approximately The rear heat exchanger will be warm to the touch. The machine could unexpectedly move forward if the clutch engages, ordrive line damage and excessive V-belt wear could occur. Drive belt deflection 8 mm 0. Add shim Tension becomes lower.
Remove shim Tension becomes higher. Shim size Part number Thickness 8CA 0. If out of specification, readjust the drive belt deflec- tion. Tighten: Starter pulley bolt: 23 Nm 2. Turning in Idle speed becomes higher. Turning out Idle speed becomes lower. Throttle cable free play: 1. Turning in Free play is increased. Turning out Free play is decreased. Start the engine. Hold the pivot point ofthe throttle lever away from the throttle switch CD. Press CV the throttle lever gradually.
The T. S warning light should turn on and off and the engine should run between and rpm. Pull the outer tube of starter cable CD upward. Freeplay : 0.
The machine may move unexpectedly when the engine is started. To ensure proper clutch performance, the spacers in the secondary clutch must be repositioned as the V-belt wears. Check the primary and secon- dary sheaves. Drive V-belt length: 1, - 1, mm Place the machine on a level area of hard packed snow. Apply the brake lever. Distance ULU Turning in Distance uLu is increased. Turning out DistanceuLU is decreased. Place a rag under the checking hole CD oil level.
Add oil until oil flows out. Tighten: Checking bolt: 10 Nm 1. Be sure to remove any oil from the heat protec- tor. Observe the following precautions. Never allow anyone to hold the rear of the machine off the ground to allow the track to spin.
Never allow anyone near a rotating track. Replace the track if it is damaged to the depth where fabric reinforcement material is visible. Place the machine with the right side facing down. Track deflection: J a. Starttheengine and rotate the track one or two turns.
Stop the engine. Check the track alignment with the slide runner CID. If the alignment is incorrect. Adjust track deflection to the specified amount. If neces- sary, repeat steps a to c until proper adjust- ment is achieved. Rear axle nut: 75 Nm 7. Ski runner wear limit G : 8 mm 0. Turn the handlebar slightly to the right and left. Locknut rod end : X 25 Nm 2. If not, adjust the direction. Lubricate the brake lever pivot. If the machine has to be operated underconditions otherthanthosespecified above,.
Special care should be taken in carburetor setting so that the piston will not be damaged or seized. In this model, the engine oil is mixed with the fuel just before the fuel enters the carburetors. Therefore, afterthe carburetors have been tuned or maintained, or after the float chamber is removed for cleaning or jet replacement, be sure to idle the engine for about three minutes in order to avoid engine trouble.
Before performing the carburetor tuning, make sure that the following items are set to specification. The engine should never be run without the air intake silencer and air chamber installed; severe engine damage may result. Start the engine and operate the machine under normal conditions to make sure the engine operates smoothly. Then stop the en- gine. The main jet should be adjusted on the basis of the following HMain jet selection chart.
High altitude tuning Use the following guide to select main jets according to variations in elevation and tem- perature. MJ MJ IN:2 Consult the latest technical information from Yamaha to be sure you have the most up-to-date jetting specifications. The Air Silencer Box has no effect on performance characteristics and must be secured to the carburetor during carburetor tuning and adjustment. Also, it must always be in place when the engine is operated. Examine the Silencer regularly for cleanliness and freedom from obstruction.
Tighten the air screw lightly, and back it out from its lightly seated position. Start the engine, and allow it to warm up for a few minutes. Covers the Viking snowmobile model series. Covers the SRV snowmobile model series.
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