Сервис мануал ямаха профессионал

• #1

На этом сайте наконец то нашел руководство по ремонту Ямаха профессионал. www.moto-m0t0.ru .Там Ямахи за 2014 и 2016 год, но мне на ямаху 2012 года подошла. Могу отправить на электронную почту , Бесплатно!

• #2

На проф 2 скинь если не сложно

• #3

На проф 2 скинь если не сложно

К сожалению на профиль 2 не получается скачать

• #4

На этом сайте наконец то нашел руководство по ремонту Ямаха профессионал. www.moto-m0t0.ru .Там Ямахи за 2014 и 2016 год, но мне на ямаху 2012 года подошла. Могу отправить на электронную почту , Бесплатно!

Доброго времени суток! Вы бы не могли мне помочь скинуть монуал по ремонту ямахи на мой ник? Буду очень Вам признателен!!!

• #5

Доброго времени суток! Вы бы не могли мне помочь скинуть монуал по ремонту ямахи на мой ник? Буду очень Вам признателен!!!

На проф 2 скинь если не сложно

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• #6

На этом сайте наконец то нашел руководство по ремонту Ямаха профессионал. www.moto-m0t0.ru .Там Ямахи за 2014 и 2016 год, но мне на ямаху 2012 года подошла. Могу отправить на электронную почту , Бесплатно!

Скинь и мне пожалуйста setnorm@mail.ru

• #7

Здра

На этом сайте наконец то нашел руководство по ремонту Ямаха профессионал. www.moto-m0t0.ru .Там Ямахи за 2014 и 2016 год, но мне на ямаху 2012 года подошла. Могу отправить на электронную почту , Бесплатно!

Здравствуйте, скиньте мне на электронку, если не сложно. Буду очень благодарен

• #8

Здравствуйте, скиньте мне на электронку, если не сложно. Буду очень благодарен[/QUOTE]
Привет,пришли адрес электронной почты на этот номер,89140819413,я с Анадыря.

• #9

Ватсап,Канчаланская группа,скинул туда.

• #10

Огромное с

Ватсап,Канчаланская группа,скинул туда.

Огромное спасибо, как раз я там и живу. Как только появится интернет нормальный я сразу же скачаю

Related Manuals for Yamaha VK10W

Cover_SMB.fm Page 1 Thursday, June 29, 2006 2:03 PM

SUPPLEMENTARY SERVICE MANUAL

VK10W

YAMAHA MOTOR CO., LTD.

PRINTED IN U.S.A.

2006.07 CR

(E)

LIT-12618-02-57 8GS-28197-10

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and new data for the VK10W. For complete information, on service procedures, it is necessary to use this Supplementary Service Manual together with following manual:

RS90K, RS90RK, RSG90K, RS90MK, RST90K, RST90TFK SERVICE MANUAL:

8FJ-28197-10 (981096) (LIT-12618-02-38)

VK10L SUPPLEMENTARY SERVICE MANUAL:

8FN-28197-10 (LIT-12618-02-42)

VK10W

SUPPLEMENTARY SERVICE MANUAL

©2006 by Yamaha Motor

Corporation, U.S.A.

1st Edition, July 2006

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N.LIT-12618-02-57

NOTICE

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understanding of the mechanical concepts and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to this model may render it unfit and/or unsafe to use.

This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by

Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

HOW TO USE THIS MANUAL

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS

INVOLVED!

WARNING

CAUTION:

Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snowmobile.

A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile.

NOTE:

A NOTE provides key information that can make procedures easier or clearer.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g.,

• Bearings

Pitting/damage

→ Replace.

EXPLODED DIAGRAM

Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.

1

GEN

INFO

3

CHAS

5

7

ENG

CARB

9

0

SPEC

A

2

INSP

ADJ

4

POWR

TR

6

COOL

8

ELEC

– +

B

.

T

R

.

C D E

F G

LT

I

E

L

B

O

New

J

M

LS

G

H

5

K

M

N

M

ILLUSTRATED SYMBOLS

(Refer to the illustration)

Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content.

1 General information

2 Periodic inspection and adjustment

3 Chassis

4 Power train

5 Engine

6 Cooling system

7 Carburetion

8 Electrical

9 Specifications

Illustrated symbols 0 to F are used to identify the specifications which appear.

0 Filling fluid

A Lubricant

B Tightening

C Wear limit, clearance

D Engine speed

E Special tool

F

Ω, V, A

Illustrated symbols G to O in the exploded diagram indicate grade of lubricant and location of lubrication point.

G Apply locking agent (LOCTITE

®

)

H Apply Yamabond No.5

®

I Apply engine oil

J Apply gear oil

K Apply molybdenum disulfide oil

L Apply wheel bearing grease

M Apply low-temperature lithium-soap base grease

N Apply molybdenum disulfide grease

O Use new one

INDEX

GENERAL INFORMATION

PERIODIC INSPECTION AND

ADJUSTMENT

CHASSIS

POWER TRAIN

ENGINE

COOLING SYSTEM

CARBURETION

ELECTRICAL

SPECIFICATIONS

GEN

INFO

1

INSP

ADJ

2

CHAS

3

POWR

TR

4

ENG

5

COOL

6

CARB

+

7

–

ELEC

8

SPEC

9

GENERAL INFORMATION

SPECIAL TOOLS ………………………………………….1

FOR ELECTRICAL SERVICE ……………………1

PERIODIC INSPECTION AND

ADJUSTMENT

INTRODUCTION……………………………………………2

PERIODIC MAINTENANCE CHART FOR

THE EMISSION CONTROL SYSTEM………………2

GENERAL MAINTENANCE AND

LUBRICATION CHART………………………………….3

POWER TRAIN……………………………………………..5

DRIVE V-BELT ………………………………………..5

BRAKE PAD INSPECTION ……………………….7

AIR BLEEDING (HYDRAULIC BRAKE

SYSTEM) ………………………………………………..7

DRIVE CHAIN………………………………………….8

TUNING ……………………………………………………..11

CLUTCH ……………………………………………….11

GEAR SELECTION ………………………………..12

HIGH ALTITUDE TUNING……………………….18

POWER TRAIN

SHIFT LEVER……………………………………………..19

INSTALLATION ……………………………………..21

DRIVE CHAIN HOUSING ……………………………..22

REMOVAL …………………………………………….25

INSPECTION …………………………………………25

INSTALLATION ……………………………………..27

SECONDARY SHAFT ………………………………….29

SECONDARY SHAFT AND DRIVE CHAIN

HOUSING INSTALLATION………………………29

BRAKE ………………………………………………………31

BRAKE PAD REPLACEMENT …………………32

BRAKE CALIPER DISASSEMBLY ……………36

BRAKE CALIPER INSTALLATION……………36

FRONT AXLE AND TRACK………………………….37

INSTALLATION ……………………………………..37

ENGINE

CAMSHAFTS…………………………………………….. 38

INSTALLATION…………………………………….. 38

CARBURETION

CARBURETORS ……………………………………….. 43

THROTTLE POSITION SENSOR (T.P.S.)

INSPECTION AND ADJUSTMENT …………. 44

ELECTRICAL

SIGNAL SYSTEM ………………………………………. 46

CIRCUIT DIAGRAM………………………………. 46

TROUBLESHOOTING …………………………… 48

GEAR POSITION SWITCH…………………….. 49

GEAR POSITION SWITCH RELAY…………. 49

SPECIFICATIONS

GENERAL SPECIFICATIONS……………………… 50

MAINTENANCE SPECIFICATIONS……………… 52

ENGINE ………………………………………………. 52

POWER TRAIN…………………………………….. 57

CHASSIS …………………………………………….. 60

ELECTRICAL ……………………………………….. 61

HIGH ALTITUDE SETTINGS………………….. 64

TIGHTENING TORQUE………………………………. 66

ENGINE ………………………………………………. 66

POWER TRAIN…………………………………….. 68

CHASSIS …………………………………………….. 70

GENERAL TORQUE SPECIFICATIONS ………. 71

DEFINITION OF UNITS ………………………………. 71

CABLE ROUTING ……………………………………… 72

SPECIAL TOOLS

GEN

INFO

GENERAL INFORMATION

SPECIAL TOOLS

Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques.

NOTE:

• Be sure to use the correct part number when ordering the tool, since the part number may differ according to country.

• For USA and Canada, use part number starting with “YB-”, “YM-”, “YU-” or “YS-”, “ACC-”.

• For others, use part number starting with “90890-”.

FOR ELECTRICAL SERVICE

• Pocket tester

P/N: YU-03112-C

90890-03112

This instrument is necessary for checking the electrical components.

1

1

INTRODUCTION/PERIODIC MAINTENANCE CHART FOR

THE EMISSION CONTROL SYSTEM

INSP

ADJ

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION

This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, 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.

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

Item Remarks

Pre-operation check

(Daily)

Initial

1 month or

800 km

(500 mi)

(40 hr)

Every

Seasonally or 4,000 km

(2,500 mi)

(200 hr)

Spark plugs

Valve clearance

Crankcase breather system

Fuel filter

Fuel line

Idle speed

Check condition.

Adjust gap and clean.

Replace if necessary.

Check clearance.

Adjust clearance when engine is cold.

Check breather hose for cracks or damage.

Replace if necessary.

Check condition.

Replace if necessary.

Check fuel hose for cracks or damage.

Replace if necessary.

Check and adjust engine idle speed.

Adjust synchronization of carburetors.

Carburetors

Exhaust system

Adjust the jets.

Check for leakage.

Tighten or replace gasket if necessary.

Every 40,000 km (25,000 mi)

Whenever operating condition (elevation/ temperature) is changed.

2

GENERAL MAINTENANCE AND LUBRICATION CHART

INSP

ADJ

GENERAL MAINTENANCE AND LUBRICATION CHART

Item Remarks

Pre-operation check

(Daily)

Initial

1 month or

800 km

(500 mi)

(40 hr)

Every

Seasonally or 4,000 km

(2,500 mi)

(200 hr)

Engine oil

Check oil level.

Replace.

Engine oil filter cartridge Replace.

Every

20,000 km

(12,000 mi)

Fuel

Engine coolant

Louvers

Check fuel level.

Check coolant level.

Air bleed the cooling system if necessary.

Check condition.

Remove snow if necessary.

Check throttle lever operation.

Throttle lever (carburetor side)

Throttle lever (handlebar side)

Throttle override system

(T.O.R.S.)

Engine stop switch

Drive guard

V-belt

Drive track and idler wheels

Slide runners

Brake and parking brake

Disc brake installation

Check operation.

Repair if necessary.

Check operation.

Repair if necessary.

Check operation.

Repair if necessary.

Check for cracks, bends or damage.

Replace if necessary.

Check for wear and damage.

Replace if necessary.

Check deflection, and for wear and damage.

Adjust/replace if necessary.

Check for wear and damage.

Replace if necessary.

Check operation and fluid leakage.

Adjust free play and/or replace pads if necessary.

Replace brake fluid.

Check for slight free play.

Lubricate shaft with specified grease as required.

Drive chain oil

Drive chain

Skis and ski runners

Steering system

Strap

Lights

Battery

Primary and secondary clutches

Check oil level.

Replace.

Check deflection.

Adjust if necessary.

Check for wear and damage.

Replace if necessary.

Check operation.

Adjust toe-out if necessary.

Check for damage.

Replace if necessary.

Check operation.

Replace bulbs if necessary.

Check condition.

Charge if necessary.

Check engagement and shift speed.

Adjust if necessary.

Inspect sheaves for wear/damage.

Inspect weights/rollers and bushings for wear-for primary.

Inspect ramp shoes/bushings for wear-for secondary.

Replace if necessary.

Lubricate with specified grease.

See NOTE on page 4.

Every

1,600 km

(1,000 mi)

Initial at 500 km (300 mi) and every 800 km

(500 mi) thereafter.

Whenever operating elevation is changed.

3

2

GENERAL MAINTENANCE AND LUBRICATION CHART

Item Remarks

Pre-operation check

(Daily)

INSP

ADJ

Initial

1 month or

800 km

(500 mi)

(40 hr)

Every

Seasonally or 4,000 km

(2,500 mi)

(200 hr)

Steering column bearing

Ski and front suspension

Lubricate with specified grease.

Lubricate with specified grease.

Suspension component Lubricate with specified grease.

Parking brake cable end and lever end/throttle cable end

Lubricate with specified grease.

Check cable damage.

Replace if necessary.

Shroud latches

Fittings and fasteners

Make sure that the shroud latches are hooked.

Check tightness.

Repair if necessary.

Tool kit and recommended equipment

Check for proper placement.

NOTE:

Brake system:

• After disassembling the master cylinder or caliper cylinder, always change the brake fluid. Regularly check the brake fluid level and add fluid if necessary.

• Replace the oil seals of the master cylinder and caliper cylinder every two years.

• Replace the brake hose every four years, or if cracked or damaged.

4

5

DRIVE V-BELT

INSP

ADJ

POWER TRAIN

DRIVE V-BELT

WARNING

When installing the new V-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to –0.5 mm

(–0.02 in) below the edge

a.

If the V-belt is not positioned correctly, the clutch engagement speed will be changed. The machine may move unexpectedly when the engine is started.

Adjust the V-belt position by removing or add-

ing a spacer 1 on each adjusting bolt 2.

CAUTION:

As the V-belt wears, adjustment may be necessary. To ensure proper clutch performance, the

V-belt position should be adjusted by adding a spacer on each adjusting bolt when the V-belt position reaches 1.5 mm (0.06 in) below the edge.

New belt width:

34.1 mm (1.34 in)

Belt wear limit width:

32.1 mm (1.26 in)

1. Measure:

• V-belt position a

NOTE:

Install the new V-belt onto the secondary sheave only. Do not force the V-belt between the sheaves; the sliding and fixed sheaves must touch each other.

Standard V-belt height:

–0.5 ~ 1.5 mm (–0.02 ~ 0.06 in)

DRIVE V-BELT

INSP

ADJ

2. Adjust the position of the V-belt by removing or adding a spacer 1 on each adjusting bolt 2.

V-belt position

More than 1.5 mm

(0.06 in) above the edge

From 1.5 mm (0.06 in) above the edge to

–0.5 mm (–0.02 in) below the edge

More than –0.5 mm

(–0.02 in) below the edge

Adjustment

Remove a spacer

Not necessary

(It is correct.)

Add spacer

Part number

90201-061H1

90201-06037

3. Tighten:

• Adjusting bolt 2

T

.

R

.

Thickness

0.5 mm (0.02 in)

1.0 mm (0.04 in)

Adjusting bolt:

10 Nm (1.0 m · kg, 7.2 ft · lb)

4. Inspect:

• Drive V-belt

Cracks/damage/wear

→ Replace.

Oil or grease on the V-belt

→ Check the primary and secondary sheaves.

6

5. Inspect:

• Primary sheave

• Secondary sheave

Oil or grease on the primary and secondary sheaves

→ Use a rag soaked in lacquer thinner or solvent to remove the oil or grease.

Check the primary and secondary sheaves.

DRIVE V-BELT/BRAKE PAD INSPECTION/

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

INSP

ADJ

6. Measure:

• Drive V-belt circumference a

Out of specification

→ Replace.

V-belt circumference:

1,132 ~ 1,138 mm (44.6 ~ 44.8 in)

1

2

1 a a

1

2

BRAKE PAD INSPECTION

1. Apply the brake lever.

2. Inspect:

• Brake pad wear a

Wear indicator 1 nearly contacts the brake disc

→ Replace as a set.

Wear limit:

4.7 mm (0.19 in)

AIR BLEEDING (HYDRAULIC BRAKE

SYSTEM)

WARNING

Bleed the brake system in the following cases:

• The system has been disassembled.

• A brake hose is loosened or removed.

• The brake fluid has been very low.

• Brake operation is faulty.

If the brake system is not properly bled a loss of braking performance may occur.

1. Bleed:

• Brake system

Air bleeding steps:

a. Fill the brake master cylinder reservoir with the proper brake fluid.

b. Install the diaphragm. Be careful not to spill any fluid or allow the brake master cylinder reservoir to overflow.

c. Connect clear plastic hoses 1 tightly to the brake caliper bleed screws 2.

d. Place the other ends of the hoses in a container.

e. Slowly apply the brake lever several times.

f. Pull the lever in, then hold the lever in position.

g. Loosen the bleed screws and allow the brake lever to travel towards its limit.

h. Tighten the bleed screws when the brake lever limit has been reached, then release the lever.

7

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/

DRIVE CHAIN

INSP

ADJ

i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the fluid.

j. Tighten the bleed screws.

.

T

R

.

Bleed screw:

6 Nm (0.6 m · kg, 4.3 ft · lb)

NOTE:

If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours.

Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.

k. Add brake fluid to the proper level.

WARNING

After bleeding the brake system, check the brake operation.

DRIVE CHAIN

Oil level inspection

WARNING

The engine and muffler will be very hot after the engine has run. Avoid touching a hot engine and muffler while they are still hot with any part of your body or clothing during inspection or repair.

1. Place the machine on a level surface.

2. Check:

• Oil level

8

1

2 b a

DRIVE CHAIN

INSP

ADJ

Checking steps:

• Remove the rubber cap 1.

• Check the oil level through the check window 2 located on the drive chain housing.

• If the oil is below the minimum level mark a, remove the dipstick 3 and add sufficient oil to the maximum level mark b.

Recommended oil:

Gear oil “GL-3”

75W or 80W

CAUTION:

Make sure that no foreign material enters the drive chain housing.

3

9

• Reinstall the dipstick 3.

NOTE:

Align the notch c of the dipstick handle with the projection d of the drive chain housing.

• Install the rubber cap.

1

DRIVE CHAIN

INSP

ADJ

Oil replacement

Oil replacement steps:

• Place the oil pan under the drain hole.

• Remove the oil drain bolt (along with the gasket) 1 and drain the oil.

CAUTION:

Be sure to remove any oil from the heat protector.

• Install the new gasket and oil drain bolt 1.

T

.

R

.

Oil drain bolt:

16 Nm (1.6 m · kg, 11 ft · lb)

Recommended oil:

Gear oil “GL-3”

75W or 80W

Oil capacity:

0.35 L (0.31 Imp qt, 0.37 US qt)

Chain slack adjustment

1. Adjust:

• Drive chain slack

Adjustment steps:

• Loosen the locknut 1.

• Turn the adjusting bolt 2 clockwise until it is finger tight, and then loosen it 1/4 turn.

• Hold the adjusting bolt 2 in place while tightening the chain adjusting locknut 1.

T

.

R

.

Drive chain adjusting locknut:

25 Nm (2.5 m · kg, 18 ft · lb)

10

CLUTCH

INSP

ADJ

TUNING

CLUTCH

High altitude

L Blue

W White

P Pink

Y Yellow

Specifications

È Elevation

~ 800 m

(~ 2,500 ft)

600 ~ 1,400 m

(2,000 ~ 4,500 ft)

1,200 ~ 2,000 m

(4,000 ~ 6,500 ft)

1,800 ~ 2,600 m

(6,000 ~ 8,500 ft)

É Engine idle speed

1,400 ± 100 r/min

Ê Engagement r/min Approx. 2,400 r/min

Ë Shift r/min

Ì Main jet

Approx. 8,500 r/min

←

←

←

←

Approx. 2,500 r/min

←

←

←

←

, Refer to “HIGH ALTITUDE SETTINGS” in “MAINTENANCE SPECIFICATIONS”.

Í Pilot jet

Î Pilot screw

Ï Secondary reduction ratio (number of links)

20/39 (68 L)

←

19/39 (68 L)

←

Ð Primary sheave spring

Ñ Color

Ò Free length

Ó Preload

90501-550A2

W-L-W

82.3 mm (3.24 in)

196 N (20 kg, 44 lb)

←

←

←

←

←

←

←

←

←

←

←

←

Ô Spring rate

22.1 N/mm

(2.25 kg/mm,

126 lb/in)

← ← ←

Õ Wire diameter

Ö Outside diameter

5.5 mm (0.217 in)

59.5 mm (2.34 in)

←

←

←

←

←

←

× Weight (ID)

8FN-17605-00

(8FN00)

← ← ←

Ø Weight rivet

Steel 17.2 with hole

(IN)

Ù Weight bushing

Ú Roller outer dia.

Û Roller bushing

Ü Pri. clutch shim

Ý Secondary sheave spring

Þ Color

ß Free length

VESPEL TP-8549

15.6 mm (0.61 in)

VESPEL TP-8549

None

90508-60012

P

75 mm (2.95 in)

À Preload rate

Á Wire diameter

+ Outside diameter

, Sec. torque cam angle

— Sec. clutch shim

Steel 17.2 (OUT)

60° (3-3)

1,211 kg · mm/rad

6.0 mm (0.236 in)

69.5 mm (2.74 in)

39°

1.0 mm (0.04 in)

Steel 17.2 with hole

(OUT)

Steel 17.2 with hole

(IN)

←

←

←

←

←

←

←

←

←

←

←

←

Steel 13.3 with hole

(OUT)

Steel 13.3 with hole

(IN)

←

←

←

←

←

←

←

←

←

←

←

←

Aluminum 13.3 with hole (OUT)

Aluminum 13.3 with hole (IN)

←

←

←

←

←

←

←

←

←

←

←

←

2,400 ~ 3,000 m

(8,000 ~ 10,000 ft)

←

Approx. 2,600 r/min

←

90501-580A1

L-Y-L

←

81.4 mm (3.20 in)

←

24.5 N/mm

(2.5 kg/mm,

140 lb/in)

5.8 mm (0.228 in)

←

←

None (OUT)

None (IN)

←

←

←

←

←

←

←

←

←

←

←

←

11

CLUTCH/GEAR SELECTION

INSP

ADJ

The clutch may require tuning depending upon where the machine 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 machine first begins to move from a complete stop.

Clutch shifting speed is defined as the engine speed reached when the machine has travelled

800 m (2,500 ft) after being started at full-throttle from a dead stop.

Normally, when a machine reaches shifting speed, the vehicle 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 has been reached.

È Engine speed

É Good condition

Ê Clutch shifting speed

Ë Clutch engagement speed

Ì Starting position

Í Distance travelled 800 m (2,500 ft)

12

GEAR SELECTION

The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions.

If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions exist, decrease the ratio.

Gear ratio chart

The drive and driven gears and the chains shown in the gear ratio chart are available as options. The figures containing a decimal point represent the drive/driven gear ratios, while the bottom numbers designate the number of links in the chain.

GEAR SELECTION

INSP

ADJ

1 Chain and sprocket part number

È Parts name

Ì Drive sprocket

Í Driven sprocket

Î Chain

É Teeth & links

19 teeth

20 teeth

21 teeth

22 teeth

23 teeth

24 teeth

38 teeth

39 teeth

40 teeth

68 links

70 links

2 Gear ratio

È Drive gear

É Driven gear

38 teeth

19 teeth

39 teeth

40 teeth

2.05

68 links

2.11

68 links

20 teeth

1.90

68 links

1.95

68 links

2.00

68 links

Ê Parts no.

8FA-17682-90

8FA-17682-00

8FA-17682-10

8FA-17682-20

8FA-17682-30

8FA-17682-40

8FB-47587-80

8FB-47587-90

8FB-47587-00

94890-09068

94890-09070

21 teeth

1.81

68 links

1.86

68 links

1.91

70 links

22 teeth

1.73

68 links

1.77

70 links

1.82

70 links

Ë Standard

√

√

23 teeth

1.65

70 links

1.70

70 links

1.74

70 links

3 Secondary sheave spring

È Part No.

90508-500B1

90508-536A9

90508-556A2

90508-556A7

90508-60012

90508-60007

É Spring rate

N · mm/rad

(kg · mm/rad)

6003 (613)

Ê Preload

N/mm (kg/mm)

(lb/in)

6.2 (0.63), 35.28

7147 (729)

8314 (848)

7.3 (0.74), 41.44

8.5 (0.87), 48.72

9460 (965) 10.2 (1.04), 58.24

11876 (1211) 12.3 (1.26), 70.56

12654 (1290) 13.5 (1.37) 76.72

Ë Color

Brown

Red

Green

Silver

Pink

White

Ì Wire gauge mm (in)

Í No. of coils Î

Free length mm (in)

5.0 (0.196)

5.3 (0.209)

5.5 (0.217)

5.5 (0.217)

6.0 (0.236)

6.0 (0.236)

5.19

5.53

5.53

4.86

5.53

5.19

75 (2.95)

75 (2.95)

75 (2.95)

75 (2.95)

75 (2.95)

75 (2.95)

Ï Outside diameter mm (in)

69.5 (2.736)

69.5 (2.736)

69.5 (2.736)

69.5 (2.736)

69.5 (2.736)

69.5 (2.736)

24 teeth

1.58

70 links

1.63

70 links

1.67

70 links

Ð Standard

√

13

4 Secondary spring twist angle

È Seat

É Sheave

1

2

3

5 Torque cam (secondary spring seat)

0

10°

20°

30°

GEAR SELECTION

INSP

ADJ

3

40°

50°

60°

6

70°

80°

90°

9

100°

110°

120°

É Effects

Î Quicker upshifting during acceleration

Ï Quicker backshifting under load

Ê Part no.

8FA-17604-00

8BV-17604-71

8BV-17604-51

8BV-17604-31

8BV-17604-11

8BV-17604-91

Ë Cam angle Ì Identification mark

51-43° 8BVFA

47°

45°

8BV71

8BV51

43°

41°

39°

8BV31

8BV11

8BV91

Í Standard

√

14

GEAR SELECTION

INSP

ADJ

6 Primary spring

Ë Parts No.

Ì Spring rate

N/mm

(kg/mm)

Í Preload

N (kg)

90501-550A2 19.6 (2.00)

90501-550A3 22.1 (2.25)

90501-551L3 19.6 (2.00)

90501-551L9 19.6 (2.00)

196 (20)

196 (20)

294 (30)

343 (35)

90501-552L5 19.6 (2.00)

90501-580A1 24.5 (2.50)

90501-581L5 24.5 (2.50)

90501-581L6 27.0 (2.75)

90501-582L1 24.5 (2.50)

90501-582L2 27.0 (2.75)

90501-582L6 22.1 (2.25)

90501-582L7 24.5 (2.50)

392 (40)

196 (20)

294 (30)

294 (30)

343 (35)

343 (35)

392 (40)

392 (40)

90501-583L0 19.6 (2.00)

90501-583L1 22.1 (2.25)

90501-583L4 22.1 (2.25)

90501-583L5 22.1 (2.25)

90501-600A1 29.4 (3.00)

90501-601L7 29.4 (3.00)

90501-601L8 31.9 (3.25)

90501-602L3 29.4 (3.00)

90501-602L8 27.0 (2.75)

90501-602L9 29.4 (3.00)

90501-603L2 24.5 (2.50)

90501-603L3 27.0 (2.75)

90501-624L8 31.9 (3.25)

441 (45)

441 (45)

343 (35)

294 (30)

196 (20)

294 (30)

294 (30)

343 (35)

392 (40)

392 (40)

441 (45)

441 (45)

343 (35)

Î Color

Blue-Blue-Blue

White-Blue-White

Blue-Pink-Blue

Blue-Silver-Blue

Blue-Green-Blue

Yellow-Blue-Yellow

Yellow-Pink-Yellow

Green-Pink-Green

Yellow-Silver-Yellow

Green-Silver-Green

White-Green-White

Yellow-Green-Yellow

Blue-White-Blue

White-White-White

White-Silver-White

White-Pink-White

Pink-Blue-Pink

Pink-Pink-Pink

Orange-Pink-Orange

Pink-Silver-Pink

Green-Green-Green

Pink-Green-Pink

Yellow-White-Yellow

Green-White-Green

Orange-Silver-Orange

5.5 (0.217)

5.5 (0.217)

5.5 (0.217)

5.5 (0.217)

5.5 (0.217)

5.8 (0.228)

5.8 (0.228)

5.8 (0.228)

5.8 (0.228)

5.8 (0.228)

5.8 (0.228)

5.8 (0.228)

5.8 (0.228)

5.8 (0.228)

5.8 (0.228)

5.8 (0.228)

6.0 (0.236)

6.0 (0.236)

6.0 (0.236)

6.0 (0.236)

6.0 (0.236)

6.0 (0.236)

6.0 (0.236)

6.0 (0.236)

6.2 (0.244)

Ï Wire gauge mm (in)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

Ð Outside diameter mm (in)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

59.5 (2.34)

Ñ No. of coils Ò

Free length mm (in)

5.65

5.25

5.25

5.25

4.92

4.66

5.25

4.92

4.89

4.56

4.91

4.91

4.91

4.91

4.92

4.66

5.08

4.82

5.39

5.08

5.00

4.81

4.82

4.60

4.82

83.4 (3.28)

82.3 (3.24)

88.4 (3.48)

90.9 (3.58)

93.4 (3.68)

81.4 (3.20)

85.4 (3.36)

84.3 (3.32)

87.4 (3.44)

86.1 (3.39)

91.2 (3.59)

89.4 (3.52)

95.9 (3.78)

93.4 (3.68)

89.0 (3.50)

86.7 (3.41)

80.1 (3.15)

83.4 (3.28)

82.6 (3.25)

85.1 (3.35)

87.9 (3.46)

86.7 (3.41)

91.4 (3.60)

89.8 (3.54)

84.2 (3.31)

Ó Standard

√

15

7 Clutch weight

È Parts No.

É Weight g (oz) without bush and rivets

8BU-17605-20 45.41 (1.603)

GEAR SELECTION

INSP

ADJ

Ê Shape & ID mark Ë Standard

8CH-17605-10 35.32 (1.246)

8DG-17605-00 34.26 (1.208)

8DJ-17605-00 37.77 (1.332)

8DN-17605-10 39.76 (1.402)

8ES-17605-00 54.63 (1.928)

8FA-17605-10 63.81 (2.251)

8FN-17605-00 75.28 (2.657)

√

16

GEAR SELECTION

8 Weight rivets

È Parts No.

90261-06033

90261-06034

90269-06006

90261-06019

90261-06015

90266-06002

90261-06028

90266-06001

É Material

Steel

Steel

Steel

Steel

Steel

Steel

Aluminum

Aluminum

9 Rollers

I.D. 9 mm (0.354 in)

È Roller with bushing part number

8FG-17624-00

É Outside diameter mm (in)

14.5 (0.57)

Ê Length mm (in)

17.2 (0.677)

13.9 (0.547)

17.2 (0.677)

13.3 (0.524)

10.3 (0.406)

13.3 (0.524)

10.3 (0.406)

13.3 (0.524)

Ë Weight g (oz)

4.5 (0.159)

3.6 (0.127)

3.6 (0.127)

3.1 (0.109)

2.44 (0.086)

2.44 (0.086)

0.85 (0.030)

0.85 (0.030)

√ (OUT)

√ (IN)

Ì Standard

Ê Bushing type

(P/N)

VESPEL

TP-8549

Ë Identification mark

(Width)

Î Grooved & Machined

Ì Standard

INSP

ADJ

Í Effects

Î Increased force

Ï Decreased force

Í Effects

Ó Increased force

8FG-17624-10 15.0 (0.59)

90386-09001

VESPEL

TP-8549

(14.6 mm)

Ï Grooved

8FG-17624-20 15.6 (0.61)

90386-09001

VESPEL

TP-8549

(14.6 mm)

Ð No Mark

8FG-17624-30 16.0 (0.63)

90386-09001

VESPEL

TP-8549

(14.6 mm)

Ñ Grooved & Grooved

8FG-17624-40 16.5 (0.65)

90386-09001

VESPEL

TP-8549

(14.6 mm)

Ò Machined

√

Ô Decreased force

90386-09001 (14.6 mm)

17

HIGH ALTITUDE TUNING

INSP

ADJ

HIGH ALTITUDE TUNING

To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below.

Check STD settings

• Carburetors

• Spark plugs

Adjust the main jet size according to the chart

Test the main jet

(performance & plug color)

OK

Test the low speed setting

OK

Not OK

Try high altitude settings

Not OK

OK

Not OK

Adjust the size of the main jet

Re-test

OK Not OK

Adjust the engine idle speed by turning the stop screw of carburetor.

Check to see if the gearing is too high or low

OK

Adjust the engine idle speed by turning the stop screw of carburetor.

Decide if the problem is with the pilot jet and adjust accordingly

Not OK

OK

Check the engagement speed and shift performance

Not OK OK

Not OK

Adjust the primary clutch as required

Not OK

Adjust the secondary clutch as required

High altitude tuning OK

OK

OK

18

SHIFT LEVER

POWER TRAIN

POWR

TR

SHIFT LEVER

É

4

2

É

È

È:

10 Nm (1.0 m

•

kg, 7.2 ft

•

lb)

É:

23 Nm (2.3 m

•

kg, 17 ft

•

lb)

3

É

1

Order Job name/Part name

Shift lever assembly removal

Right side cover

2 Bracket

Q’ty Remarks

Remove the parts in the order listed below.

1

1

1 Disconnect.

1

For installation, reverse the removal procedure.

4

19

7

0

SHIFT LEVER

POWR

TR

È:

23 Nm (2.3 m

•

kg, 17 ft

•

lb)

É:

59 Nm (5.9 m

•

kg, 43 ft

•

lb)

È

LS

È

8

New

4

New

LS

New

6

5

4

Order

1

2

Job name/Part name

Shift lever disassembly

Shift lever stay

Circlip

3 Bearing

4 Circlip

5

6

7

8

9

0

Collar

Shift lever pin

Shift lever

Shift lever guide

Spring

Shift lever stopper

9

2

3

1

É

Q’ty Remarks

Remove the parts in the order listed below.

1

1

1

1

1

1

1

2

1

1

For assembly, reverse the disassembly procedure.

20

3

2

4

6

2

5

1

SHIFT LEVER

INSTALLATION

1. Install:

• Shift lever 1

• Shift lever stopper 2

• Shift guide 3

• Shift lever pin 4

• Spring

POWR

TR

4

1

3

Installation steps:

• Install the shift lever 1 onto the shift lever stopper 2.

• Install the shift lever guide 3 and spring 5 onto the shift lever, position the shift lever and shift lever guide as shown, and then install the shift lever pin 4.

NOTE:

Make sure that the end of the spring 5 is installed between the washer 6 and the shift lever guide 3.

21

DRIVE CHAIN HOUSING

POWR

TR

DRIVE CHAIN HOUSING

È:

É:

Ê:

6 Nm (0.6 m

•

kg, 4.3 ft

•

lb)

10 Nm (1.0 m

•

kg, 7.2 ft

•

lb)

14 Nm (1.4 m

•

kg, 10 ft

•

lb)

Ë:

16 Nm (1.6 m

•

kg, 11 ft

•

lb)

1

4

New

2

New

3

14

Ð

5

G

New

13

6

È

New

LT

11

Í

Ì

Ì:

18 Nm (1.8 m

•

kg, 13 ft

•

lb)

Í:

20 Nm (2.0 m

•

kg, 14 ft

•

lb)

Î:

24 Nm (2.4 m

•

kg, 17 ft

•

lb)

9

New

G

10

New

27

28

32

37

Ï:

43 Nm (4.3 m

•

kg, 31 ft

•

lb)

Ð:

55 Nm (5.5 m

•

kg, 40 ft

•

lb)

7

Ê

New

É

É

Î

(3)

(2)

É

Ï

15

LT

16

17

19

29

New

12

30

39

38

É

New

Ì

LT

G

20

21

22

23

New

33

34

31

43

É

LT

36

16

18

19

35

New

42

26

41

40

24

25

Ï

(2)

New

44

8

Ë

New

New

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

7

8

5

6

3

4

1

2

9

10

11

12

13

Order Job name/Part name

Drive chain housing removal

Right side cover/shift lever/parking brake/ brake caliper

Shim

Washer

Collar

Brake disc

Straight key

Collar

Shift rod

Chain tension adjusting bolt

Spring

Ball

Gear position switch

Drive chain housing cover

Shift drum

Q’ty Remarks

Remove the parts in the order listed below.

Refer to “SHIFT LEVER” and “BRAKE”.

1

1

1

1

1

— t = 0.5

1 t = 1.0

1

1

1

1

1

1 Loosen.

22

DRIVE CHAIN HOUSING

POWR

TR

È:

É:

Ê:

6 Nm (0.6 m

•

kg, 4.3 ft

•

lb)

10 Nm (1.0 m

•

kg, 7.2 ft

•

lb)

14 Nm (1.4 m

•

kg, 10 ft

•

lb)

Ë:

16 Nm (1.6 m

•

kg, 11 ft

•

lb)

1

4

New

2

New

3

14

Ð

5

G

New

13

6

È

New

LT

11

Í

Ì

Ì:

18 Nm (1.8 m

•

kg, 13 ft

•

lb)

Í:

20 Nm (2.0 m

•

kg, 14 ft

•

lb)

Î:

24 Nm (2.4 m

•

kg, 17 ft

•

lb)

9

New

G

10

New

27

28

32

37

Ï:

43 Nm (4.3 m

•

kg, 31 ft

•

lb)

Ð:

55 Nm (5.5 m

•

kg, 40 ft

•

lb)

7

Ê

New

É

É

Î

(3)

(2)

É

Ï

15

LT

16

17

19

29

New

12

30

39

38

É

New

Ì

LT

G

20

21

22

23

New

33

34

31

43

É

LT

36

16

18

19

35

New

42

26

41

40

24

25

Ï

(2)

New

44

8

Ë

New

New

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

25

26

27

28

29

21

22

23

24

Order

14

15

16

17

18

19

20

Job name/Part name

Shift fork guide bar

Shift fork

Washer

Counter gear

Low pinion gear

Spring

Collar

Driven gear

Journal

Washer

Chain tensioner

Washer

Collar

Collar

Washer

Reverse drive gear

1

1

1

1

1

1

1

1

1

2

1

1

1

Q’ty

1

1

2

Remarks

23

DRIVE CHAIN HOUSING

POWR

TR

È:

É:

Ê:

6 Nm (0.6 m

•

kg, 4.3 ft

•

lb)

10 Nm (1.0 m

•

kg, 7.2 ft

•

lb)

14 Nm (1.4 m

•

kg, 10 ft

•

lb)

Ë:

16 Nm (1.6 m

•

kg, 11 ft

•

lb)

1

4

New

2

New

3

14

Ð

5

G

New

13

6

È

New

LT

11

Í

Ì

Ì:

18 Nm (1.8 m

•

kg, 13 ft

•

lb)

Í:

20 Nm (2.0 m

•

kg, 14 ft

•

lb)

Î:

24 Nm (2.4 m

•

kg, 17 ft

•

lb)

9

New

G

10

New

27

28

32

37

Ï:

43 Nm (4.3 m

•

kg, 31 ft

•

lb)

Ð:

55 Nm (5.5 m

•

kg, 40 ft

•

lb)

7

Ê

New

É

É

Î

(3)

(2)

É

Ï

15

LT

16

17

19

29

New

12

30

39

38

É

New

Ì

LT

G

20

21

22

23

New

33

34

31

43

É

LT

36

16

18

19

35

New

42

26

41

40

24

25

Ï

(2)

New

44

8

Ë

New

New

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

41

42

43

44

37

38

39

40

Order

30

31

32

33

34

35

36

Job name/Part name

Washer

Low drive gear

Drive sprocket

Drive chain

Driven sprocket

Low wheel gear

Washer

Collar

Plate

Shaft

Plate

Shaft

Rubber seal

Washer

Drive chain housing

1

1

1

1

1

1

1

1

1

1

1

1

Q’ty

1

1

1

Remarks

For installation, reverse the removal procedure.

24

1

2

DRIVE CHAIN HOUSING

POWR

TR

REMOVAL

1. Remove:

• Driven gear 1

NOTE:

While holding the front axle assembly with spanner wrench 2, loosen the reverse driven gear bolt.

INSPECTION

1. Inspect:

• Drive chain housing

• Drive chain housing cover

Cracks/damage

→ Replace.

• Shift fork

Pitting/wear/damage

→ Replace.

• Oil seals (drive chain housing and cover)

Wear/damage

→ Replace.

• Bearings (drive chain housing and cover)

Pitting/damage

→ Replace.

Replacement steps:

• Remove the circlip (drive chain housing and cover).

• Remove the bearing(s) using a general bearing puller.

• Install the new bearing(s).

NOTE:

Use a socket 1 that is the same size as the outside diameter of the bearing race.

CAUTION:

Do not strike the inner race 2 or ball bearings

3.

Contact only the outer race 4.

• Install a new circlip (drive chain housing and cover).

CAUTION:

Always use new circlips.

25

DRIVE CHAIN HOUSING

POWR

TR

2. Inspect:

• Drive sprocket

• Driven sprocket

• Driven gear

• Reverse drive gear

• Counter gear

• Low pinion gear

• Low wheel gear

• Low drive gear

• Journal

• Chain tensioner

Pitting/wear/damage

→ Replace.

• Drive chain

Wear/damage

→ Replace.

Shift

→ Clean or replace.

• Shift lever assembly

• Bearing (chain tensioner)

Pitting/damage

→ Replace the bearing and the inner race holder as a set.

3. Measure:

• 14 link section a of the drive chain

Using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b.

Out of specification

→ Replace the drive chain.

Maximum 14 link drive chain section length:

133.35 mm (5.25 in)

Limit: 137.35 mm (5.41 in)

NOTE:

• Measure the length between drive chain pin 1 and E as shown.

• Perform this measurement at two or three different places.

If replacement is necessary, always replace the chain and the sprockets as a set.

4. Inspect:

• Drive chain 1

Stiffness

→ Clean and lubricate or replace.

• Drive chain plates 2

Damage/wear

→ Replace the drive chain.

Cracks

→ Replace the drive chain.

26

É

Ê

Î

1

Ò

Ð

Ï

Í

È

2

Ë

Ì

Ñ

Í

Ð

G

É

DRIVE CHAIN HOUSING

POWR

TR

5. Measure:

• Brake disc thickness a

Measure the brake disc thickness 1 ~ 3 mm

(0.04 ~ 0.12 in) from the edge of the brake disc.

Out of specification

→ Replace.

Minimum thickness:

3.5 mm (0.14 in)

INSTALLATION

1. Install:

• Shift drum

NOTE:

Make sure that the projection 1 on the shift fork is properly seated in the shift drum groove 2.

2. During installation, pay attention to the following.

È Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps.

É Make sure that the bearing seals face towards the drive chain as shown.

Ê Install the washer as shown.

Ë Be sure to install the spacers in their original positions, otherwise the brake disc and shaft will stick.

Ì 0.2 ~ 0.7 mm (0.008 ~ 0.028 in)

Í Make sure that the bearing does not protrude past the end of the counter gear.

Î 1.8 ± 0.5 mm (0.071 ± 0.020 in)

Ï 6 ± 0.5 mm (0.236 ± 0.020 in)

Ð Stamp side

Ñ 1.8 ± 0.5 mm (0.071 ± 0.020 in)

Ò 5 ± 0.5 mm (0.197 ± 0.020 in)

: ESSO beacon 325 grease or Aeroshell grease

#7A

For the shaft and drive chain housing installation,

refer to “SECONDARY SHAFT”.

27

a

Ó

G

G

G

DRIVE CHAIN HOUSING

Ó 0 ~ 1 mm (0 ~ 0.039 in)

POWR

TR

3. Install:

• Shift rod lock washer 1

NOTE:

Bend a lock washer tab along a flat side of the bolt.

4. Adjust:

• Shift rod length a

Adjustment steps:

• Adjust the shift rod length.

Shift rod length:

236 mm (9.29 in)

• Check that the shift lever pin moves smoothly when the shift lever is pulled out 21 mm

(0.83 in) to the position b shown. Also, check that the shift lever pin returns to its original position by the force of the spring when the shift lever is released. If the pin moves to a different position, adjust the shift rod length.

5. Fill:

• Drive chain housing oil

Refer to “DRIVE CHAIN” in CHAPTER 2.

6. Adjust:

• Drive chain slack

Refer to “DRIVE CHAIN” in CHAPTER 2.

1 b

28

6

2

5

1

4

È

7

5

2 a

5

9

6

3

6

2

4

8

SECONDARY SHAFT

POWR

TR

SECONDARY SHAFT

SECONDARY SHAFT AND DRIVE CHAIN

HOUSING INSTALLATION

1. Install:

• Secondary shaft

• Drive chain housing

Installation steps:

• Install the secondary shaft.

• Tighten the bolt.

.

T

R

.

Secondary shaft bolt:

30 Nm (3.0 m · kg, 22 ft · lb)

• Install the drive chain housing 1.

• Tighten the bolts and nut 2.

.

T

R

.

Drive chain housing bolt and nut:

43 Nm (4.3 m · kg, 31 ft · lb)

• Install the drive chain, drive sprocket and reverse drive gear.

• Install the drive chain housing cover 3.

È Properly install the rubber seal onto the drive chain housing, making sure that these are no gaps.

• Tighten the bolts 4.

.

T

R

.

Drive chain housing cover bolt:

43 Nm (4.3 m · kg, 31 ft · lb)

• Tighten the bolts 5.

.

T

R

.

Drive chain housing cover bolt:

24 Nm (2.4 m · kg, 17 ft · lb)

• Tighten the bolt 6.

.

T

R

.

Drive chain housing cover bolt:

10 Nm (1.0 m · kg, 7.2 ft · lb)

• Install the collar.

• Tighten the collar set screw 7.

.

T

R

.

Collar set screw:

6 Nm (0.6 m · kg, 4.3 ft · lb)

LOCTITE

®

• Install the brake disc.

• Adjust the brake disc clearance.

• Adjust the drive chain slack.

29

SECONDARY SHAFT

POWR

TR

2. Measure:

• Brake disc clearance a

Out of the specification

→ Adjust.

Brake disc clearance:

0.2 ~ 0.7 mm (0.008 ~ 0.028 in)

3. Adjust:

• Brake disc clearance

Adjustment steps:

• Remove the circlip 8.

• Adjust the brake disc clearance by adding or removing shim(s) 9.

Part number

90201-252F1

Shim size

Thickness

0.5 mm (0.02 in)

• Install the new circlip.

30

BRAKE

5

4

È

È

2 3

1

É

6

Ê

BRAKE

POWR

TR

È:

6 Nm (0.6 m

•

kg, 4.3 ft

•

lb)

É:

18 Nm (1.8 m

•

kg, 13 ft

•

lb)

Ê:

48 Nm (4.8 m

•

kg, 35 ft

•

lb)

3

4

1

2

5

6

Order Job name/Part name

Brake pad removal

Right side cover

Cap bolt

Retaining pin

Pad spring

Brake pad

Brake caliper assembly

Q’ty Remarks

Remove the parts in the order listed below.

1

1

1

1

2

1

For installation, reverse the removal procedure.

31

32

BRAKE

POWR

TR

CAUTION:

Disc brake components rarely require disassembly. DO NOT:

• Do not disassemble components unless absolutely necessary.

• Do not use solvents on internal brake components.

• Do not use contaminated brake fluid for cleaning.

• Use only clean brake fluid.

• Do not allow brake fluid to contact the eyes, otherwise eye injury may occur.

• Do not allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur.

• Do not disconnect any hydraulic connection, otherwise the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly.

BRAKE PAD REPLACEMENT

NOTE:

It is not necessary to disassemble the brake caliper and brake hose in order to replace the brake pads.

1. Remove:

• Brake pads

NOTE:

• Do not depress the brake lever when the caliper or disc is off the machine otherwise the brake pads will be forced shut.

• Install a new brake pad spring and shims when the brake pads are replaced.

• Replace the pads as a set if either one is found to be worn to the wear limit a.

Wear limit:

4.7 mm (0.19 in)

1

2

2

1

BRAKE

2. Install:

• Brake pads

• Pad spring

POWR

TR

Installation steps:

• Connect a suitable hoses 1 tightly to the caliper bleed screws 2. Put the other end of this hose into an open container.

• Loosen the caliper bleed screws and push the pistons into the caliper with your finger.

• Tighten the caliper bleed screws 2.

.

T

R

.

Bleed screw:

6 Nm (0.6 m · kg, 4.3 ft · lb)

• Install the brake pads and pad spring.

3. Check:

• Brake fluid level

4. Check:

• Brake lever operation

A soft or spongy feeling

→ Bleed brake system.

Refer to “AIR BLEEDING (HYDRAULIC

BRAKE SYSTEM)” in CHAPTER 2.

33

BRAKE

POWR

TR

3

4

1

2

5

6

Order Job name/Part name

Brake caliper and parking brake removal

Brake fluid

Brake hose

Brake caliper assembly

Parking brake cable

Spring

Parking brake assembly

Collar

1

1

1

1

1

2

Q’ty Remarks

Remove the parts in the order listed below.

Drain.

For installation, reverse the removal procedure.

34

3

È

BRAKE

POWR

TR

È:

6 Nm (0.6 m

•

kg, 4.3 ft

•

lb)

É:

18 Nm (1.8 m

•

kg, 13 ft

•

lb)

7

New

6

5

New

6

È

5

7

2

1

É

Order Job name/Part name

Brake caliper disassembly

5 Brake caliper piston

6 Brake caliper piston seal

5

6

New

4

5

6

New

Q’ty Remarks

Remove the parts in the order listed below.

4

8

2

1

2

1

1

For assembly, reverse the disassembly procedure.

35

3 a

2

1

BRAKE

POWR

TR

BRAKE CALIPER DISASSEMBLY

NOTE:

Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid.

1. Remove:

• Pistons

• Piston seals 1

Removal steps:

• Using a wood of piece 2, lock the right piston.

• Blow compressed air into the hose joint opening a to force out the left piston from the caliper body.

• Remove the piston seals and reinstall the piston.

• Repeat the previous steps to force out the right piston from the caliper body.

WARNING

• Never try to pry out the pistons.

• Do not loosen the retaining pins 3.

3

BRAKE CALIPER INSTALLATION

1. Install:

• Brake hose 1

CAUTION:

When installing the brake hose 1 onto the

brake caliper 2, make sure that the brake pipe

touches the projection

a on the brake caliper.

.

T

R

.

Union bolt (brake hose):

30 Nm (3.0 m · kg, 22 ft · lb)

36

103.5 mm

(4.07 in)

121.5 mm

(4.78 in)

32.5 mm

(1.28 in)

42 mm

(1.65 in)

125 mm

(4.92 in)

246.5 mm

(9.70 in)

58.5 mm

(2.30 in)

121.5 mm

(4.78 in)

58.5 mm

(2.30 in)

103.5 mm

(4.07 in)

39 mm

(1.54 in)

182 mm

(7.17 in)

92.5 mm

(3.64 in)

FRONT AXLE AND TRACK

POWR

TR

FRONT AXLE AND TRACK

INSTALLATION

1. Install:

• Sprocket wheels

• Guide wheels

NOTE:

• When pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel.

• Position each sprocket wheel on the axle as shown in the illustration.

1 a

2 a

2. Place the track in the chassis.

NOTE:

For track with a direction of rotation mark a:

Install the track with the mark pointing in the direction of track rotation.

3. Install:

• Bearing holder 1

NOTE:

Align the punch mark a on the bearing holder 1 with the rivet 2.

37

b

1 a b c a

2 c d d

CAMSHAFTS

ENG

ENGINE

CAMSHAFTS

INSTALLATION

1. Install:

• Exhaust camshaft sprocket 1

• Intake camshaft sprocket 2

(with the special tool 3)

Rotor holding tool:

90890-01235, YU-01235

• Camshaft sprocket bolts

T

.

R

.

Camshaft sprocket bolt:

24 Nm (2.4 m · kg, 17 ft · lb)

NOTE:

Make sure that the holes a in the cylinder #3 cam and marks b and c on the camshaft sprockets are in the position shown in the illustration.

b: Exhaust side “→” c: Intake side “—” d: Cylinder #3 — cam

38

b a

1

2 c d e

2

1 e

CAMSHAFTS

ENG

2. Install:

• Exhaust camshaft 1

• Intake camshaft 2

(with the camshaft sprockets)

Installation steps:

• Turn the crankshaft clockwise.

• When piston #3 is at TDC on the compression stroke, align the “I” mark a on the A.C. magneto rotor with the stationary pointer b on the

A.C. magneto cover.

• Install the timing chain onto both camshaft sprockets, and then install the camshafts.

NOTE:

• Install the camshafts with the hole c in the cylinder #3 — cam facing up.

• When installing the timing chain, start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side.

• Make sure the marks d and e on the timing chain sprockets are parallel with the edge of the cylinder head. d: Exhaust side “→” e: Intake side “—” f: Cylinder #3 — cam f d f

5

39

a b b a

CAMSHAFTS

ENG

3. Install:

• Dowel pins

• Intake camshaft caps

• Exhaust camshaft caps

NOTE:

• The “I” mark refers to the intake camshaft caps and the “E” mark refers to the exhaust camshaft cap.

• Install the camshaft caps with the arrow mark a pointing towards the right side of the engine.

• Make sure the punch marks b in the camshaft are aligned with the arrow mark a on the camshaft caps.

4. Install:

• Camshaft cap bolts

T

.

R

.

Camshaft cap bolt:

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.

CAUTION:

• Lubricate the camshaft cap bolts with the engine oil.

• The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result.

• Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing.

40

b a

1 d c

3

3

2 c

CAMSHAFTS

5. Install:

• Timing chain tensioner

ENG

Installation steps:

• While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1.

NOTE:

Make sure that the tensioner rod has been fully set clockwise.

• With the timing chain tensioner rod turned all the way into the timing chain tensioner housing

(with the thin screwdriver still installed), install the gasket and the timing chain tensioner 2 onto the cylinder block.

WARNING

Always use a new gasket.

• Tighten the timing chain tensioner bolts 3 to the specified torque.

.

T

R

.

Timing chain tensioner bolt:

10 Nm (1.0 m · kg, 7.2 ft · lb)

• Remove the screwdriver, make sure the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque.

T

.

R

.

Cap bolt:

7 Nm (0.7 m · kg, 5.1 ft · lb)

6. Turn:

• Crankshaft

(several turns clockwise)

7. Inspect:

• “I” mark a

Make sure the “I” mark a on the A.C. magneto rotor is aligned with the stationary pointer b on the A.C. magneto cover.

• Camshaft punch marks c

Make sure the punch marks c in the cylinder

#3 — cam are aligned with the arrow marks d on the camshaft caps.

Out of alignment

→ Adjust.

Refer to the installation steps above.

d

41

1

2

CAMSHAFTS

ENG

8. Measure:

• Valve clearance

Out of specification

→ Adjust.

9. Install

• Cylinder head cover gasket

• Cylinder head cover

New

.

T

R

.

Cylinder head cover bolt:

12 Nm (1.2 m · kg, 8.7 ft · lb)

NOTE:

• Apply bond TB1541 1 onto the mating surfaces of the cylinder head cover and cylinder head cover gasket.

• Apply Sealant (Quick Gasket

®

) or Yamaha bond

No. 1215 2 onto the mating surfaces of the cylinder head cover gasket and cylinder head.

• Tighten the cylinder head cover bolts stages and in a crisscross pattern.

42

CARBURETORS

2

0

CARBURETORS

CARBURETION

CARB

8

6

7

5

0

5

1

4

4

Order Job name/Part name

Carburetor separation

2

Carburetor heating hose

4

Float chamber air vent hose

6 Spring

7

Starter plunger link

9

Throttle position sensor

0 Carburetor

3

9

3

0

Q’ty Remarks

Remove the parts in the order listed below.

1

2

2

1

1

3

2

2

1

1

For installation, reverse the removal procedure.

7

43

44

CARBURETORS

CARB

THROTTLE POSITION SENSOR (T.P.S.)

INSPECTION AND ADJUSTMENT

NOTE:

Before adjusting the throttle position sensor, properly adjust the idle speed.

1. Inspect:

• Throttle position sensor

Inspection steps:

• Disconnect the throttle position sensor coupler.

• Connect the pocket tester (

Ω × 1k) to the throttle position sensor coupler.

Positive tester probe

→ Blue 1

Negative tester probe

→ Black 2

• Check the throttle position sensor resistance.

Throttle position sensor resistance

“R

1

”:

4 ~ 6 k

Ω at 20 °C (68 °F)

(Blue – Black)

Out of specification

→ Replace the throttle position sensor.

• Connect the pocket tester (

Ω × 1k) to the throttle position sensor coupler.

Positive tester probe

→ Yellow 3

Negative tester probe

→ Black 2

• While slowly pushing the throttle check the throttle position sensor resistance.

Throttle position sensor resistance

“R

2

”:

0 ~ 4 k

Ω at 20 °C (68 °F)

(Yellow – Black)

Out of specification

→ Replace the throttle position sensor.

4

CARBURETORS

CARB

2. Adjust:

• Throttle position sensor angle

Adjustment steps:

• Disconnect the throttle position sensor coupler.

• Connect the test coupler to the throttle position sensor.

• Connect three dry cells (1.5 V

× 3 pcs.) in series to the test coupler.

Dry cells negative end

→ 1

Dry cells positive end

→ 2

• Connect the digital multi meter to the test coupler.

Digital multi meter negative lead

→ 1

Digital multi meter positive lead

→ 3

• Measure the voltage

A.

NOTE:

When measuring the voltage

A be sure that the test coupler is connected to the throttle position sensor.

• Calculate the specified voltage

B.

Specified voltage

B = Voltage A × (0.136)

• Loosen the throttle position sensor bolt 4.

• Connect the digital multi meter to the test coupler.

Digital multi meter negative lead

→ 1

Digital multi meter positive lead

→ 3

• Adjust the throttle position sensor position to obtain the specified voltage

B.

• Tighten the throttle position sensor bolt 4.

• Disconnect the test coupler and connect the throttle position sensor coupler.

45

SIGNAL SYSTEM

ELECTRICAL

ELEC

– +

46

SIGNAL SYSTEM

CIRCUIT DIAGRAM

2 A.C. magneto

3 Rectifier/regulator

4 Main switch

5 Load control relay

6 Main fuse

9 Battery

I Ignitor unit

M Coolant temperature sensor

P Frame ground

T DC back buzzer

U Gear position switch relay

V Gear position switch

W Brake light switch

X Tail/brake light

Y Speed sensor

Z Fuel sender

[ Oil level switch

] Multi-function meter

_ Warning light a Low coolant temperature indicator light f Signal fuse i Ignition fuse

SIGNAL SYSTEM

ELEC

– +

8

47

SIGNAL SYSTEM

ELEC

– +

TROUBLESHOOTING

BACK BUZZER DOES NOT SOUND.

Check the signal fuse.

OK

FAULTY

Check the battery.

OK

OUT OF SPECIFICATION

Check the stator coil.

OK

OUT OF SPECIFICATION

Check the main switch.

OK

FAULTY

Check the gear position switch.

OK

FAULTY

Check the gear position switch relay.

OK

FAULTY

Check the load control relay.

OK

FAULTY

Check the DC back buzzer.

OK

DOES NOT SOUND

Check the signal system’s wiring.

OK

FAULTY

Correct the connection and/or replace the rectifier/ regulator and/or ignitor unit.

Replace the signal fuse.

Replace and/or charge the battery.

Replace the stator coil assembly.

Replace the main switch.

Replace the gear position switch.

Replace the gear position switch relay.

Replace the load control relay.

Replace the DC back buzzer.

Properly connect or repair the signal system’s wiring.

48

+ –

1

ELEC

–

SIGNAL SYSTEM

GEAR POSITION SWITCH

1. Check:

• Gear position switch 1 continuity

Faulty

→ Replace.

Shift lever position

DRIVE (D) or LOW (L)

REVERSE

Continuity

Yes

No

+

1

2

3

P

L/R B B/R

4 1

GEAR POSITION SWITCH RELAY

1. Inspect:

• Gear position switch relay 1

Inspection steps:

• Disconnect the gear position switch relay from the coupler.

• Connect the pocket tester (

Ω × 1) and battery

(12 V) to the gear position switch relay terminals as shown.

Positive battery terminal

→ Blue/Red 1

Negative battery terminal

→ Black/Red 2

Positive tester probe

→ Pink 3

Negative tester probe

→ Black 4

• If gear position switch relay does not have continuity between the pink and black terminals, replace it.

49

GENERAL SPECIFICATIONS

SPEC

GENERAL SPECIFICATIONS

SPECIFICATIONS

Model code number:

Model

8GS1 (USA/Canada)

8GS2 (Europe)

Dimensions:

Overall length

Overall width

Overall height

Weight:

Dry weight

Minimum turning radius:

Clockwise

Counterclockwise

Engine:

Engine type

Cylinder type

Displacement

Bore

× stroke

Compression ratio

Maximum hose power r/min

Maximum torque r/min

Vacuum pressure at engine idling speed

Standard compression pressure (at sea level)

Starting system

Lubrication system:

Engine oil:

Type

Oil capacity

Periodic oil change

With oil filter replacement

Total amount

Oil filter:

Oil filter type

Drive chain housing oil:

Type

Capacity

Coolant:

Filler cap opening pressure

Capacity

Fuel:

Type

3,270 mm (128.7 in)

1,200 mm (47.2 in)

1,380 mm (54.3 in)

360 kg (794 lb)

4.7 m (15.4 ft)

4.7 m (15.4 ft)

Liquid-cooled, 4-stroke, DOHC

Backward-inclined parallel 3-cylinder

973 cm

3

(59.37 cu.in)

79.0

× 66.2 mm (3.11 × 2.61 in)

11.3 : 1

84.7 kw (115.2 PS)/8,500 r/min

101.6 Nm (10.4 kgf)/7,000 r/min

24.0 kPa (0.24 kg/cm

2

, 3.41 psi)

1,450 kPa (14.5 kg/cm

2

, 206 psi) at 400 r/min

Electric starter

Dry sump

VK10W

API SE, SF, SG or higher SAE 0W-30

2.8 L (2.5 Imp qt, 3.0 US qt)

3.0 L (2.6 Imp qt, 3.2 US qt)

3.7 L (3.3 Imp qt, 3.9 US qt)

Cartridge (paper)

Gear oil “GL-3” 75W or 80W

0.35 L (0.31 Imp qt, 0.37 US qt)

93.3 ~ 122.7 kPa (0.93 ~ 1.23 kg/cm

2

, 13.2 ~ 17.5 psi)

4.7 L (4.14 Imp qt, 4.97 US qt)

Regular unleaded gasoline

Pump Octane

R + M

2

; 86 or higher (For USA/Canada)

Research Octane; 91 or higher (For Europe)

42 L (9.24 Imp gal, 11.10 US gal) Tank capacity

Carburetors:

Type/Quantity

Manufacture

CVK40/3

KEIHIN

50

Model

Spark plug:

Type

Manufacture

Gap

Transmission:

Primary reduction system

Primary reduction ratio

Clutch type

Secondary reduction system

Secondary reduction ratio

Reverse system

Chassis:

Frame type

Caster

Ski stance (center to center)

Suspension:

Front suspension type

Rear suspension type

Track:

Track type

Track width

Length on ground

Track deflection mm/100 N (10 kg, 22 lb)

Brake:

Brake type

Operation method

Electrical:

Ignition system

Generator system

Headlight bulb type:

Bulb wattage

× Quantity:

Headlight

Tail/Brake light

Meter light

High beam indicator light

Information indicator light

Low coolant temperature light

GENERAL SPECIFICATIONS

SPEC

VK10W

NGK R CR8E

NGK

0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

V-Belt

3.8 ~ 1 : 1

Automatic centrifugal engagement

Chain

1.95 (39/20)

Yes

Monocoque

23.0°

1,020 mm (40.2 in)

Double wishbone

Slide rail suspension

Internal drive type

500 mm (19.69 in)

1,204 mm (47.40 in)

35 ~ 45 mm (1.38 ~ 1.78 in)

Caliper type disc brake

Handlebar, left hand operated

Transistorized coil ignition

A.C. magneto

Halogen bulb

12 V, 60 W/55 W

× 2

12 V, 5 W/21 W

14 V, 50 mA

× 6

14 V, 80 mA

14 V, 80 mA

14 V, 80 mA

51

9

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Model

Cylinder head:

Volume (with spark plug)

<Warpage limit>

VK10W

22.82 ~ 23.62 cm

3

(1.39 ~ 1.44 cu.in)

0.10 mm (0.0039 in)

Lines indicate straight edge measurement.

Cylinder:

Material

Bore size

<Taper limit>

<Out of round>

Camshaft:

Drive system

Camshaft cap inside diameter

Camshaft journal diameter

Camshaft-journal-to-camshaft-cap clearance

Camshaft dimensions

Intake “A”

<Limit>

“B”

<Limit>

Exhaust “A”

<Limit>

“B”

<Limit>

Camshaft runout

B

A

Aluminum alloy with dispersion coating

79.000 ~ 79.010 mm (3.1102 ~ 3.1106 in)

0.050 mm (0.0020 in)

0.050 mm (0.0020 in)

Chain drive (right)

24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in)

24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in)

0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in)

33.75 ~ 33.85 mm (1.3287 ~ 1.3327 in)

33.65 mm (1.3248 in)

24.95 ~ 25.05 mm (0.9823 ~ 0.9862 in)

24.85 mm (0.9783 in)

33.75 ~ 33.85 mm (1.3287 ~ 1.3327 in)

33.65 mm (1.3248 in)

24.95 ~ 25.05 mm (0.9823 ~ 0.9862 in)

24.85 mm (0.9783 in)

0.03 mm (0.0012 in)

Timing chain:

Model/Number of links

Tensioning system

98XTRH2005/140

Automatic

52

MAINTENANCE SPECIFICATIONS

SPEC

Model

Valves, valve seats, valve guides:

Valve clearance (cold)

Intake

Exhaust

Valve dimensions

Valve head diameter A

Intake

Exhaust

Valve face width B

Intake

Exhaust

Valve seat width C

Intake

Exhaust

Valve margin thickness D

Intake

Exhaust

Valve stem diameter

Intake

<Limit>

Exhaust

<Limit>

Valve guide inside diameter

Intake

<Limit>

Exhaust

<Limit>

Valve-stem-to-valve-guide clearance

Intake

<Limit>

Exhaust

<Limit>

Valve stem runout limit

A

B

C

D

4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in)

4.945 mm (0.1947 in)

4.965 ~ 4.980 mm (0.1955 ~ 0.1961 in)

4.935 mm (0.1943 in)

5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in)

5.05 mm (0.199 in)

5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in)

5.05 mm (0.199 in)

0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)

0.08 mm (0.0031 in)

0.020 ~ 0.047 mm (0.0008 ~ 0.0019 in)

0.10 mm (0.0039 in)

0.01 mm (0.0004 in)

VK10W

0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in)

0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in)

29.9 ~ 30.1 mm (1.1771 ~ 1.1850 in)

25.9 ~ 26.1 mm (1.0197 ~ 1.0276 in)

1.90 ~ 2.62 mm (0.0748 ~ 0.1031 in)

1.90 ~ 2.62 mm (0.0748 ~ 0.1031 in)

0.9 ~ 1.1 mm (0.035 ~ 0.043 in)

0.9 ~ 1.1 mm (0.035 ~ 0.043 in)

0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in)

0.5 ~ 0.9 mm (0.0197 ~ 0.0354 in)

Valve seat width

Intake

<Limit>

Exhaust

<Limit>

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

1.6 mm (0.0630 in)

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

1.6 mm (0.0630 in)

53

MAINTENANCE SPECIFICATIONS

SPEC

Model

Valve spring:

Free length

Intake

<Limit>

Exhaust

<Limit>

Installed length (valve closed)

Intake

Exhaust

Compressed spring force (installed)

Intake

Exhaust

Spring tilt

Intake

Exhaust

Winding direction (top view)

Intake

Exhaust

Valve lifter:

Valve lifter outside diameter

Intake

<Limit>

Exhaust

<Limit>

Valve lifter hole inside diameter

Intake

<Limit>

Exhaust

<Limit>

Piston:

Piston size (D)

Measuring point (H)

Piston to-cylinder clearance

<Limit>

Piston pin bore off set

Off-set direction

Piston pin bore inside diameter

<Limit>

Piston pin:

D

Piston pin outside diameter

<Limit>

Piston pin length

Piston pin to piston pin bore clearance

<Limit>

VK10W

39.73 mm (1.56 in)

37.74 mm (1.48 in)

39.73 mm (1.56 in)

37.74 mm (1.48 in)

33.0 mm (1.30 in)

33.0 mm (1.30 in)

136 ~ 158 N (13.9 ~ 16.1 kg, 30.6 ~ 35.5 lb)

136 ~ 158 N (13.9 ~ 16.1 kg, 30.6 ~ 35.5 lb)

2.5°/1.7 mm (0.07 in)

2.5°/1.7 mm (0.07 in)

Clockwise

Clockwise

24.482 ~ 24.488 mm (0.9639 ~ 0.9641 in)

24.457 mm (0.9629 in)

24.482 ~ 24.488 mm (0.9639 ~ 0.9641 in)

24.457 mm (0.9629 in)

24.500 ~ 24.518 mm (0.9646 ~ 0.9653 in)

24.548 mm (0.9665 in)

24.500 ~ 24.518 mm (0.9646 ~ 0.9653 in)

24.548 mm (0.9665 in)

H

78.935 ~ 78.950 mm (3.1077 ~ 3.1083 in)

5.0 mm (0.20 in)

0.050 ~ 0.075 mm (0.0020 ~ 0.0030 in)

0.120 mm (0.0047 in)

0.5 mm (0.0197 in)

Exhaust side

19.004 ~ 19.015 mm (0.7482 ~ 0.7486 in)

19.045 mm (0.7498 in)

18.991 ~ 19.000 mm (0.7477 ~ 0.7480 in)

18.971 mm (0.7469 in)

52.9 ~ 53.0 mm (2.083 ~ 2.087 in)

0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in)

0.074 mm (0.0029 in)

54

MAINTENANCE SPECIFICATIONS

SPEC

Model VK10W

Piston ring:

Sectional sketch

Top ring

Ring type

Dimensions (B

× T)

2nd ring

Ring type

Dimensions (B

× T)

Oil ring

Dimensions (B

× T)

End gap (installed)

Top ring

2nd ring

Oil ring

Side clearance (installed)

Top ring

2nd ring

Oil ring

Plating/coating

T

T

T

B

B

B

Barrel

1.00

Taper

1.00

2.00

× 2.80 mm (0.039 × 0.110 in)

× 2.90 mm (0.039 × 0.114 in)

× 2.50 mm (0.079 × 0.098 in)

0.35 ~ 0.45 mm (0.014 ~ 0.018 in)

0.75 ~ 0.85 mm (0.030 ~ 0.033 in)

0.20 ~ 0.60 mm (0.008 ~ 0.024 in)

0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in)

0.020 ~ 0.060 mm (0.0008 ~ 0.0024 in)

0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in)

Top ring

2nd ring

Connecting rod:

Small end diameter

Chrome plated/parkerizing

Parkerizing

Bearing color code

19.005 ~ 19.018 mm (0.7482 ~ 0.7487 in)

Big end diameter 41.000 ~ 41.018 mm (1.6142 ~ 1.6149 in)

Crankshaft-pin-to-big-end-bearing clearance 0.033 ~ 0.050 mm (0.0013 ~ 0.0020 in)

0 = White-White 1 = Blue-Blue 2 = Black-Black

3 = Brown-Brown 4 = Green-Green 5 = Yellow-Yellow

Crank pin:

Crank pin outside diameter

Crankshaft:

37.976 ~ 38.000 mm (1.4951 ~ 1.4961 in)

C C

1 2

A D

B

Measuring point 1

Measuring point 2

Width A

Width B

Crankshaft runout C

Big end side clearance D

Crankshaft-journal-to-crankshaft-journalbearing clearance

Bearing color code

62.0 mm (2.44 in)

100.0 mm (3.94 in)

62.25 ~ 62.65 mm (2.451 ~ 2.467 in)

234.65 ~ 235.65 mm (9.24 ~ 9.28 in)

0.03 mm (0.0012 in)

0.160 ~ 0.262 mm (0.0063 ~ 0.0103 in)

0.027 ~ 0.045 mm (0.0011 ~ 0.0018 in)

2 = Black 3 = Brown 4 = Green 5 = Yellow

6 = Pink 7 = Red 8 = White

55

MAINTENANCE SPECIFICATIONS

SPEC

Model

Carburetor:

Type/Quantity

Manufacturer

I.D. mark

Main jet

Main air jet

Jet needle

Needle jet

Pilot jet

Pilot air jet

Pilot outlet

Bypass 1

(M.J)

(M.A.J)

(J.N)

(N.J)

(P.J)

(P.A.J)

(P.O)

Throttle valve

Valve seat size

Starter jet

(B.P.1)

(B.P.2)

(B.P.3)

(B.P.4)

(B.P.5)

(Th.V)

(V.S)

(G.S)

Float height (F.H)

Fuel level (below the line on the float chamber)

Throttle cable free play

Engine idle speed

Fuel pump:

Type

Manufacturer

Oil filter:

Oil filter type

Bypass valve opening pressure

Oil pump:

Oil pump type

Inner-rotor-to-outer-rotor-tip clearance

Outer-rotor-to-oil-pump-housing clearance

Relief valve operating pressure

Oil pressure (hot)

Cooling system:

Filler cap opening pressure

Thermostat opening temperature

Valve lift

Water pump type

Reduction ratio

Coolant type

Coolant mixing ratio (coolant: water)

Capacity

Max. impeller shaft tilt

<Limit>

CVK40/3

KEIHIN

8ES1 02

#148

#70

N425-BSJ00

W9554-26538#6

#45

#120

0.9

0.8

0.8

0.8

0.8

0.8

1020-B70-80 (

θ = 10°)

1.2

#70

16 mm (0.630 in)

0.2 ~ 2.2 mm (0.008 ~ 0.087 in)

2.0 ~ 3.0 mm (0.08 ~ 0.12 in)

1,300 ~ 1,500 r/min

Diaphragm

8FA (MIKUNI)

Cartridge (paper)

VK10W

78 ~ 118 kPa (0.78 ~ 1.18 kg/cm

2

, 11.1 ~ 16.8 psi)

Trochoidal

0.09 ~ 0.15 mm (0.004 ~ 0.006 in)

0.03 ~ 0.08 mm (0.001 ~ 0.003 in)

440 ~ 560 kPa (4.4 ~ 5.6 kg/cm

2

, 62.6 ~ 79.6 psi)

45 kPa (0.45 kg/cm

2

, 6.40 psi) at 1,400 r/min

93.3 ~ 122.7 kPa (0.93 ~ 1.23 kg/cm

2

, 13.2 ~ 17.5 psi)

80 ~ 84 °C (176 ~ 183 °F)

7.0 mm (0.28 in) at 95 °C (203 °F)

Single-suction centrifugal pump (Impeller type)

22/28 (0.786)

High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors

3 : 2 (60% : 40%)

4.7 L (4.14 Imp qt, 4.97 US qt)

0.15 mm (0.0059 in)

0.072 mm (0.0028 in)

56

MAINTENANCE SPECIFICATIONS

POWER TRAIN

Model

Transmission:

Type

Range of ratio

Engagement speed r/min

Shift r/min

Sheave distance

Sheave offset

Secondary sheave free play (clearance)

Secondary sheave clearance

V-belt height (standard)

V-belt:

Part number/Manufacturer

Circumference

Width “A”

Wear limit “B”

Primary sheave spring:

Part number

Color code

Diameter

Wire diameter

Preload

Spring rate

Number of coils

Free length

Set length

Primary sheave weight arm:

Part number (with bush)

Weight (without bush and rivets)

Rivet:

Outer

Part number

Material

Size

Quantity

Hole quantity

Inner

Part number

Material

Size

Quantity

Hole quantity

None (outer and inner)

Secondary sheave spring:

Part number

Color code

Outside diameter

Wire diameter

V-belt automatic

3.8 ~ 1.0 : 1

2,200 ~ 2,600 r/min

8,250 ~ 8,750 r/min

267 ~ 270 mm (10.51 ~ 10.63 in)

13.5 ~ 16.5 mm (0.53 ~ 0.65 in)

1.0 ~ 2.0 mm (0.04 ~ 0.08 in)

35.0 ~ 35.8 mm (1.38 ~ 1.41 in)

–0.5 ~ 1.5 mm (–0.02 ~ 0.06 in)

8GS-17641-00/MITSUBOSHI

1,132 ~ 1,138 mm (44.6 ~ 44.8 in)

34.1 mm (1.34 in)

32.1 mm (1.26 in)

90501-550A3

White-Blue-White

59.5 mm (2.34 in)

5.5 mm (0.217 in)

196 N (20.0 kg, 44.1 lb)

22.1 N/mm (2.25 kg/mm, 126 lb/in)

4.56

82.3 mm (3.24 in)

73.4 mm (2.89 in)

8FN-17605-00

75.28 g (2.657 oz)

90261-06033

Steel

17.2 mm (0.677 in)

3

3

90269-06006

Steel

17.2 mm (0.677 in)

3

3

Nothing

90508-60012

Pink

69.5 mm (2.736 in)

6.0 mm (0.236 in)

VK10W

SPEC

57

MAINTENANCE SPECIFICATIONS

SPEC

Model

Hole position

Sheave side-spring side (twist angle) 3-3 (60°)

VK10W

Spring rate

Number of coils

Free length

12.3 N/mm (1.25 kg/mm, 70.23 lb/in)

5.53

75 mm (2.95 in)

39° Torque cam angle

Drive chain:

Type Borg Warner Automotive 23RH303-68ASM

Number of links

Secondary reduction ratio

68L

1.95 (39/20)

Maximum 14 link drive chain section length 133.35 mm (5.25 in)

137.35 mm (5.41 in) <Limit>

Track:

Part number 8FN-47110-00

Width

Length

Pitch

Number of links

Thickness “A”

Height “B”

500 mm (19.69 in)

3,969 mm (156.24 in)

64 mm (2.52 in)

42

5.1 mm (0.20 in)

31.8 mm (1.25 in)

Track deflection at 100 N (10 kg, 22 lb)

Slide rail suspension (rear suspension):

Front travel

Rear travel

Suspension spring rate

Front

Rear

Suspension wire diameter

Front

Rear

Suspension setting position:

Hook setting length *

(Standard)

(Maximum)

(Minimum)

Full rate adjusting position **

35 ~ 45 mm (1.38 ~ 1.77 in)

212 mm (8.3 in)

262 mm (10.31 in)

12.7 N/mm (1.29 kg/mm, 72.5 lb/in)

68.6 N/mm (7.00 kg/mm, 391.7 lb/in)

6.8 mm (0.268 in)

13.3 mm (0.524 in)

14.5 ~ 15.5 mm (0.571 ~ 0.610 in)

35 mm (1.37 in)

10 mm (0.40 in)

A

58

Model

Shock absorber: Damping force

Front

Extension

Compression

Rear

Extension

Compression

Slide runner:

Thickness

Wear limit

Track sprocket wheel:

Material

Number of teeth

Rear guide wheel:

Material

Outside diameter

Brake:

Recommended brake fluid

Pad thickness

Pad wear limit

Parking brake pad clearance

Parking brake cable distance

Disc outside diameter

Disc minimum thickness

MAINTENANCE SPECIFICATIONS

SPEC

VK10W

540 N/0.3 m/s (55.1 kg/0.3 m/s, 121.4 lb/0.3 m/s)

1,130 N/0.3 m/s (115.2 kg/0.3 m/s, 254.0 lb/0.3 m/s)

2,530 N/0.3 m/s (258.0 kg/0.3 m/s, 568.7 lb/0.3 m/s)

690 N/0.3 m/s (70.4 kg/0.3 m/s, 155.1 lb/0.3 m/s)

17.8 mm (0.70 in)

10 mm (0.39 in)

Ultra high molecular weight polyethylene

8 T

High molecular weight polyethylene with rubber

178 mm (7.01 in)

DOT 4

10.2 mm (0.40 in)

4.7 mm (0.19 in)

1.5 ~ 2.0 mm (0.059 ~ 0.079 in)

43.5 ~ 46.5 mm (1.713 ~ 1.831 in)

200 mm (7.87 in)

3.5 mm (0.14 in)

59

MAINTENANCE SPECIFICATIONS

CHASSIS

Model

Frame:

Frame material

Seat height

Luggage box location

Steering:

Lock-to-lock angle

Ski alignment

Toe-out size

Caster angle

Ski:

Ski stance (center to center)

Ski material

Length

(left)

(right)

Width

Ski runner material

Ski cover

Ski runner wear limit

Plastic ski wear limit

Ski suspension (front suspension):

Type

Travel

Spring type

Spring rate

Wire diameter

Shock absorber: Damping force

Extension

Compression

Monocoque (Aluminum & Steel)

716 mm (28.2 in)

Under seat

29.7° (R ski) 34.4° (L ski)

34.4° (R ski) 29.7° (L ski)

Toe-out

0 ~ 15 mm (0 ~ 0.59 in)

23°

1,020 mm (40.2 in)

Plastic

1,073 mm (42.24 in)

180 mm (7.09 in)

Steel

No

8 mm (0.31 in)

25 mm (0.98 in)

VK10W

Independent wishbone

175.0 mm (6.89 in)

Coil spring

42.2 N/mm (4.30 kg/mm, 24.0 lb/in)

10.0 mm (0.394 in)

SPEC

1,010 N/0.3 m/s (103.0 kg/0.3 m/s, 227.0 lb/0.3 m/s)

460 N/0.3 m/s (46.9 kg/0.3 m/s, 103.4 lb/0.3 m/s)

60

ELECTRICAL

Model

Voltage

Ignition system:

Ignition timing (B.T.D.C.)

Advanced type

Ignition coil:

Model/Manufacturer

Ignition spark gap

Primary coil resistance

Secondary coil resistance

Charging system:

Type

Nominal output

DC-C.D.I.:

Magneto model/Manufacturer

Standard

Pickup coil resistance (color code)

Stator coil resistance (color code)

Ignitor unit model/Manufacturer

Rectifier/regulator:

Type

Model/Manufacturer

No load regulated voltage (DC)

Capacity (DC)

Withstand voltage

Battery:

Specific gravity

Manufacturer

Type

Ten hour rate amperage

Electric starter system:

Type

Starter motor:

Model/Manufacturer

Output

Armature coil resistance

Continuity check

Insulation check

Brush

Overall length

<Wear limit>

Spring pressure

Commutator diameter

<Wear limit>

Mica undercut

Starter relay:

Model/Manufacturer

Amperage rating

Coil resistance

MAINTENANCE SPECIFICATIONS

12 V

5° at 1,400 r/min

Digital type

F6T558/MITSUBISHI

6.0 mm (0.24 in)

1.19 ~ 1.61

Ω at 20 °C (68 °F)

8.5 ~ 11.5 k

Ω at 20 °C (68 °F)

A.C. magneto

14 V/less than 35 A at 5,000 r/min

SPEC

F074T38571/MITSUBISHI

14 V 30 A, 420 W at 5,000 r/min

189 ~ 231

Ω at 20 °C (68 °F) (Gray – Black)

0.22 ~ 0.26

Ω at 20 °C (68 °F) (White – White)

J4T16271/MITSUBISHI

Short circuit type

FH001/SHINDENGEN

14.1 ~ 14.9 V

35 A

40 V

1.32

YUASA

YTX20L-BS 12V-18Ah

18 A

Constant mesh type

8ES1/MORIC

12 V – 0.95 kW

VK10W

0.008 ~ 0.010

Ω at 20 °C (68 °F)

More than 100 k

Ω at 20 °C (68 °F)

9.8 mm (0.39 in)

5.0 mm (0.20 in)

7.36 ~ 11.04 N (750 ~ 1,126 g, 26.5 ~ 39.7 oz)

28.5 mm (1.12 in)

27.5 mm (1.08 in)

1.5 mm (0.059 in)

MS5F-421/JIDECO

180 A

4.18 ~ 4.62

Ω at 20 °C (68 °F)

61

MAINTENANCE SPECIFICATIONS

SPEC

Model

T.P.S. (throttle position sensor):

Manufacturer

Resistance

Oil level switch:

Model/Manufacturer

Fuel sender:

Model/Manufacturer

Sender resistance Full

Empty

Starting circuit cut-off relay, passenger grip warmer relay, radiator fan motor relay:

Model/Manufacturer

Coil resistance

Headlight relay, gear position switch relay:

Model/Manufacturer

Coil resistance

Grip warmer:

Heater resistance (left)

(right)

Thumb warmer:

Heater resistance

Passenger grip warmer:

Heater resistance (high)

Heater resistance (low)

Circuit breaker:

Type

Amperage for individual circuit

Main fuse

Headlight fuse

Signal fuse

Ignition fuse

Carburetor heater fuse

DC terminal fuse

Radiator fan fuse

Reserve fuse

Reserve fuse

Reserve fuse

Reserve fuse

Reserve fuse

Coolant temperature sensor:

Model/Manufacturer

Resistance

Indicator light

Radiator fan:

ON

OFF

(ON)

(OFF)

VK10W

KEIHIN

4 ~ 6 k

Ω at 20 °C (68 °F) (Blue – Black)

0 ~ 4 k

Ω at 20 °C (68 °F) (Yellow – Black)

8FA/ASTI

8FN/NIPPON SEIKI

10 ~ 12

Ω at 20 °C (68 °F)

179 ~ 185

Ω at 20 °C (68 °F)

8DM/MATSUSHITA

75.7 ~ 92.5

Ω at 20 °C (68 °F)

Fuse

30 A

× 1

20 A

× 1

10 A

× 1

15 A

× 1

20 A

× 1

3 A

× 1

15 A

× 1

30 A

× 1

20 A

× 1

15 A

× 1

10 A

× 1

3 A

× 1

5DM/OMRON

94.5 ~ 115.5

Ω at 20 °C (68 °F)

1.53 ~ 1.87

Ω at 20 °C (68 °F)

1.53 ~ 1.87

Ω at 20 °C (68 °F)

37.0 ~ 45.2

Ω at 20 °C (68 °F)

8.82 ~ 10.78

Ω (Green – Black)

14.67 ~ 17.93

Ω (Yellow – Black)

8CC/MITSUBISHI

5.21 ~ 6.37 k

Ω at 0 °C (32 °F)

0.290 ~ 0.354 k

Ω at 80 °C (176 °F)

0.170 ~ 0.208 k

Ω at 100 °C (212 °F)

95 ~ 116 °C (203 ~ 241 °F)

90 ~ 110 °C (194 ~ 230 °F)

86 ~ 105 °C (187 ~ 221 °F)

79 ~ 97 °C (174 ~ 207 °F)

62

Model

Speed sensor:

Model/Manufacture

Carburetor heater:

Model/Manufacture

Wattage

Resistance

MAINTENANCE SPECIFICATIONS

SPEC

VK10W

8EK/NIPPON SEIKI

5FU/NIPPON THERMOSTAT

30 W

6 ~ 10

Ω at 20 °C (68 °F)

63

MAINTENANCE SPECIFICATIONS

HIGH ALTITUDE SETTINGS

Temperature

Altitude

0 ~ 200 m

(0 ~ 700 ft)

200 ~ 1,500 m

(700 ~ 5,000 ft)

MJ

PJ

MJ

PJ

–30 °C

(–22 °F)

#150

#50

#148

#48

1,500 ~ 3,000 m

(5,000 ~ 10,000 ft)

[Production spec]

MJ

PJ

#148

#45

MJ#1, 2, 3: #148

MJ

PJ

MJ

PJ

MJ

PJ

PJ: #45

–10 °C

(–14 °F)

#148

#48

#148

#45

#145

#45

MJ

PJ

MJ

PJ

MJ

PJ

10 °C

(50 °F)

#148

#45

#145

#45

#145

#40

SPEC

Idling speed (r/min)

1,400

1,400

1,400

64

MAINTENANCE SPECIFICATIONS

SPEC

65

TIGHTENING TORQUE

ENGINE

Parts to be tightened

Spark plug

Cylinder head bolt (M10

× 1.25)

Cylinder head bolt

Camshaft cap and cylinder head

Cylinder head cover

Camshaft and camshaft sprocket

Timing chain tensioner

Timing chain tensioner cap

Timing chain guide (exhaust and intake)

Cylinder head water jacket

Thermostat housing cover

Coolant temperature sensor

Hose band

Water pump

Coolant reservoir

Coolant hose joint

Carburetor coolant shut-off assembly

Oil cooler

Engine mounting adjust bolt

Engine mounting nut

Engine mounting bracket

Oil pan

Oil pan drain bolt

Oil filter cartridge

Oil pump

Oil pump drive chain guide

Oil pump housing cover

Oil pump driven gear

Oil tank drain bolt

Oil tank and frame (bolt)

Oil tank and frame (nut)

Oil gallery bolt

Oil cooler outlet pipe

Check valve

Exhaust pipe joint

Muffler band

Exhaust pipe

Exhaust pipe joint band

Muffler

Muffler cover

Muffler cover plate

Exhaust pipe joint cover

Crankcase (M9

× 1.25)

Crankcase (M8

× 1.25)

Crankcase (M6

× 1.0)

TIGHTENING TORQUE

SPEC

Tightening torque

Nm m · kg ft · lb

Remarks

10

19

20

10

10

25

20

17

12

10

3

15

16

1.0

1.9

2.0

1.0

1.0

2.5

2.0

1.7

1.2

1.0

0.3

1.5

1.6

10

9

65

25

10

10

23

2

12

10

10

5

24

10

7

10

10

10

13 1.3

See NOTE.

*1

9.4

12

10

12

1.2

1.0

1.2

8.7

7.2

8.7

Apply the engine oil.

2.4

1.0

0.7

1.0

1.0

1.0

17

7.2

5.1

7.2

Apply LOCTITE

®

7.2

7.2

2.3

0.2

1.2

1.0

1.0

0.5

1.0

0.9

6.5

2.5

1.0

1.0

17

1.4

8.7

7.2

7.2

3.6

7.2

Apply LOCTITE

®

6.5

47

7.2

14

14

7.2

7.2

18

14

18

7.2

7.2

12

8.7

7.2

2.2

11

11

25

9

16

11

2.5

0.9

1.6

1.1

18

6.5

11

8

11 1.1

8

7

24

0.7

See NOTE.

*2

2.4

5.1

Apply the engine oil.

17 Apply the engine oil.

12 1.2

8.7

Apply the engine oil.

66

TIGHTENING TORQUE

SPEC

Parts to be tightened

Primary sheave drive shaft assembly bolt

Connecting rod and cap

Balancer

Balancer shaft bearing retainer

A.C. magneto rotor

A.C. magneto rotor cover bolt (M6

× 1.0) × 11

A.C. magneto rotor cover bolt (M6

× 1.0) × 1

Starter clutch

Stator coil

Pickup coil

A.C. magneto lead holder

Carburetor joint

Air filter case joint clamp screw

Starter motor

Fuel pump

Fuel pump stay

Fuel tank

Starter motor lead

Throttle cable locknut

Rectifier/regulator

Ground earth lead (engine mounting bracket)

Ground earth lead (Ignitor unit)

Frame cross member (front)

Frame cross member (side [front])

Frame cross member (side [rear])

Frame cross member (under side [rear])

Tightening torque

Remarks

Nm m · kg ft · lb

25

7

23

45

23

20

10

10

10

7

6

7

12 1.2

See NOTE.

*3

8.7

35 3.5

10

130

1.0

13

25

7.2

Apply LOCTITE

®

94 Apply the engine oil.

12

12

12

10

6

10

10

3

27

1.2

1.2

1.2

1.0

0.6

1.0

1.0

0.3

2.7

8.7

8.7

Apply LOCTITE

8.7

Apply LOCTITE

7.2

Apply LOCTITE

®

4.3

Apply LOCTITE

®

7.2

Apply LOCTITE

®

7.2

2.2

20

®

®

1.0

1.0

1.0

0.7

0.6

0.7

7.2

7.2

7.2

5.1

4.3

5.1

2.5

0.7

2.3

4.5

2.3

2.0

18

5.1

17

32

17

14

NOTE:

*1: Tighten the cylinder head bolts to 25 Nm (2.5 m · kg, 18 ft · lb) in the proper tightening sequence, loosen and retighten the cylinder head bolts to 25 Nm (2.5 m · kg, 18 ft · lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence.

*2: Tighten the crankcase bolts to 15 Nm (1.5 m · kg, 11 ft · lb) in the proper tightening sequence, loosen and retighten the crankcase bolts to 15 Nm (1.5 m · kg, 11 ft · lb) in the proper tightening sequence, and then tighten the crankcase bolts further to reach the specified angle 65 ~ 70° in the proper tightening sequence.

*3: Tighten the connecting rod nuts to 20 Nm (2.0 m · kg, 14 ft · lb), and then tighten the connecting rod nuts further to reach the specified angle 120°.

67

TIGHTENING TORQUE

SPEC

POWER TRAIN

Tightening torque

Parts to be tightened Remarks

Nm m · kg ft · lb

Primary sheave

Spider and sliding sheave

Primary sheave cap and sliding sheave

Roller and weight (primary sheave)

Set bolt (primary sheave collar)

Secondary sheave

Stopper (secondary sheave)

Spring seat (secondary sheave)

Secondary sheave adjusting bolt

Secondary shaft bolt

Drive chain adjusting locknut

Drive chain housing and frame

Drive chain housing cover, chain housing and frame

Shift cam bolt

Gear position switch

Drive chain housing oil drain bolt

Drive chain housing cover (M8)

Drive chain housing cover (M6)

Set bolt (secondary shaft)

Shift lever assembly

Shift lever stay and shift lever stopper

Shift lever stay and shift lever guide

Shift lever assembly and lever rod

Lever and drive chain housing

Low wheel gear shaft

Low pinion gear

Reverse drive gear shaft

Driven gear

Counter gear

Driven sprocket and low drive gear

Drive chain housing and brake caliper

Brake caliper bleed screw

Brake caliper retaining pin

Brake hose union bolt (caliper side)

6

18

30

Parking brake assembly and drive chain housing

Lever and parking brake assembly

10

16

Brake hose union bolt (brake master cylinder side) 30

Parking brake cable and parking brake lever 10

Parking brake cable locknut

Brake master cylinder

Brake master cylinder holder and parking brake lever

Slide rail suspension mounting bolt (M10)

Stopper band

Hook and front pivot arm

Front suspension bracket and sliding frame

Bracket bolt (rear)

10

10

55

10

18

48

6

10

23

72

4

16

72

30

23

23

59

10

14

10

18

20

16

24

10

6

10

30

25

43

43

200

See NOTE.

20 145 Left-hand thread.

Apply LOCTITE

®

14 1.4

6

4

0.6

0.4

10

4.3

2.9

Apply LOCTITE

®

64

7

23

6.4

0.7

2.3

46

5.1

17

1.0

3.0

2.5

4.3

4.3

7.2

22

18

31

31

1.8

2.0

1.6

2.4

1.0

0.6

2.3

2.3

5.9

1.0

1.4

1.0

1.0

1.0

5.5

1.0

1.8

4.8

0.6

1.8

3.0

1.0

1.6

3.0

1.0

0.6

1.0

2.3

7.2

0.4

1.6

7.2

3.0

13

14

12

17

7.2

4.3

Apply LOCTITE

®

17

17

43

7.2

10 Apply LOCTITE

®

7.2

Apply LOCTITE

®

7.2

Apply LOCTITE

®

7.2

Apply LOCTITE

®

40 Apply LOCTITE

®

7.2

Apply LOCTITE

®

13 Apply LOCTITE

®

35

4.3

13

22

7.2

11

22

7.2

4.3

7.2

17

52

2.9

11

Apply LOCTITE

®

52 Apply LOCTITE

®

22 Apply LOCTITE

®

68

TIGHTENING TORQUE

SPEC

Parts to be tightened

Shaft and sliding frame

Shock absorber and front pivot arm

Shock absorber and front suspension bracket

Front pivot arm and sliding frame

Suspension wheel (front, center and rear)

Wheel bracket and sliding frame

Shock absorber and rear suspension bracket

Rear pivot arm and pull rod

Rear suspension bracket and pull rod

Shock absorber and rear pivot arm

Rear pivot arm and rear pivot arm bracket

Control rod and sliding frame

Control rod bolt

Rear pivot arm bracket

Wheel bracket shaft and sliding frame

Pivot bracket and sliding bracket

Pivot bracket and rear sliding frame

Pivot bracket and spring hook

Rear axle

Set bolt (front axle)

Speed sensor

Bearing holder

Gear unit (speed sensor)

*: ESSO beacon 325 grease or Aeroshell grease #7A

28

80

9

20

20

40

72

80

69

34

49

24

72

32

49

72

72

24

49

49

49

Tightening torque

Remarks

Nm m · kg ft · lb

72 7.2

52 Apply LOCTITE

®

49 4.9

35

4.9

7.2

7.2

2.4

4.9

4.9

4.9

35

52 Apply LOCTITE

52

Apply LOCTITE

®

®

17

35

35 Apply LOCTITE

®

35 Apply LOCTITE

®

4.9

2.4

7.2

3.2

7.2

8.0

6.9

3.4

2.8

8.0

0.9

2.0

2.0

4.0

35

17

52 Apply LOCTITE

®

23

52 Apply LOCTITE

®

58

50

24

20 Apply grease*

58

6.5

Apply LOCTITE

®

14

14

29

NOTE:

Tightening steps:

1. Tighten the bolt to a torque at 120 Nm (12.0 m · kg, 85 ft · lb).

2. Loosen the bolt completely.

3. Retighten the bolt to a torque of 60 Nm (6.0 m · kg, 43 ft · lb).

69

CHASSIS

Parts to be tightened

Handlebar holder

Steering column 1 (front)

Steering column 1 (rear upper)

Steering column 1 (rear lower)

Steering column 2 (upper)

Steering column 2 (lower)

Steering column 2 and steering shaft

Steering shaft end locknut

Steering shaft and steering column 1

Steering column 1 and relay rod

Relay rod and idler arm

Relay arm and idler arm

Idler arm and tie rod

Tie rod and steering arm

Relay arm

Tie rod end locknut

Ski

Ski runner

Ski and ski handle (M8

× 55)

Ski and ski handle (M8

× 100)

Shock absorber (upper)

Shock absorber (lower)

Steering arm and ski column

Upper arm and frame

Upper arm and steering knuckle

Lower arm and frame

Lower arm and steering knuckle

Front bumper

Rider seat

Rear carrier and frame

Rear carrier and tail/brake light bracket

Tail/brake light bracket and frame (front)

Tail/brake light bracket and frame (rear)

Rear carrier seat

Tail brake light cover

Passenger assist grip

Passenger assist grip bracket

Tail/brake light assembly

Battery bracket

Main switch

Shroud

TIGHTENING TORQUE

SPEC

Tightening torque

Remarks

Nm m · kg ft · lb

45

35

37

40

37

65

25

48

19

11

17

45

35

30

35

30

35

53

15

23

23

35

23

23

35

25

35

7

7

48

21

7

18

2

13

27

10

48

23

18

30

4.5

3.5

3.7

4.0

3.7

6.5

2.5

4.8

1.9

1.1

1.7

4.5

3.5

3.0

3.5

3.0

3.5

5.3

1.5

2.3

2.3

3.5

2.3

2.3

3.5

2.5

3.5

0.7

0.7

4.8

2.1

0.7

1.8

0.2

1.3

2.7

1.0

4.8

2.3

1.8

3.0

19

7.2

35

17

13

22

8

12

33

33

25

27

29

27

47

5.1

5.1

35

15

5.1

13

1.4

9.4

11

17

17

25

17

17

25

18 Apply LOCTITE

®

25

25

22

25

22

25

38

18 Apply LOCTITE

®

35

14

70

GENERAL TORQUE SPECIFICATIONS/

DEFINITION OF UNITS

GENERAL TORQUE

SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads.

Components should be at room temperature.

A

(nut)

10 mm

12 mm

14 mm

17 mm

19 mm

22 mm

B

(bolt)

6 mm

8 mm

10 mm

12 mm

14 mm

16 mm

SPEC

General torque specifications

Nm m · kg ft · lb

6

15

30

55

85

130

0.6

1.5

3.0

5.5

8.5

13.0

4.3

11

22

40

61

94

A: Distance across flats

B: Outside thread diameter mm cm kg

N

Nm m · kg

Pa

N/mm

L cm

3 r/min

DEFINITION OF UNITS

Unit Read

Millimeter

Centimeter

Kilogram

Newton

Newton meter

Meter kilogram

Pascal

Newtons per millimeter

Liter

Cubic centimeter

Rotations per minute

Definition

10

-3

meter

10

-2

meter

10

3

gram

1 kg

× m/sec 2

N

× m m

× kg

N/m

2

N/mm

—

—

Measurement

Length

Length

Weight

Force

Torque

Torque

Pressure

Spring rate

Volume or capacity

Engine speed

71

CABLE ROUTING

SPEC

D-D

w d y

E

e c a b

^

]

[

x f

Z

Y

X g h

D

D

W i j

1

2 3 k

U

A

V

T

4 5 l m

6

7

8

A

E

J

9

0

A

B

C

D

G

F

E

H

I

K

L

M

N u v

Q

S

B

R n

O

P

C-C

o p q

C

r

C

t s

B

72

CABLE ROUTING

1 Positive battery lead

2 Negative battery lead

3 Pass the wire harness (two leads) through the hole in the cover.

4 Wire harness

5 A.C. magneto lead

6 Negative battery lead coupler

7 Positive starter motor lead

8 Fasten the A.C. magneto lead and wire harness with the plastic band.

9 Negative battery lead terminal

0 Positive battery lead terminal

A Oil level switch lead coupler

B Oil level gauge/dipstick

C Route the oil level switch lead behind the battery bracket.

D Carburetor heater coupler

E Fasten the positive starter motor lead and oil tank inlet hose with the plastic band. Face the end of the plastic band towards the battery bracket.

F Pass the carburetor heater lead over the oil cooler outlet hose.

G Fasten the wire harness and coolant hose with the plastic band, making sure that the wire harness is not routed under the hose.

H Starter motor

I Coolant temperature sensor coupler

J 45 ± 5 mm (1.77 ± 0.20 in)

K To the brake caliper

L Pass the coolant temperature sensor lead over the coolant hose.

M Less than 145 mm (5.71 in)

N Fasten the ignition coil lead and wire harness to the frame cross member with the plastic band, making sure to face the end of the band rearward.

O Place the main switch lead coupler underneath the fuel tank cover.

P Main switch

Q Handlebar switch lead couplers

R Tail/brake light sub-wire harness coupler

S Throttle cable

T To the tail/brake light

U Thumb warmer switch lead couplers

V Grip warmer connectors

W Headlight beam switch coupler

X Grip warmer adjustment switch lead coupler

Y Brake light switch coupler

73

CABLE ROUTING

SPEC

CABLE ROUTING

SPEC

D-D

w d y

E

e c a b

^

]

[

x f

Z

Y

X g h

D

D

W i j

1

2 3 k

U

A

V

T

4 5 l m

6

7

8

A

E

J

9

0

A

B

C

D

G

F

E

H

I

K

L

M

N u v

Q

S

B

R n

O

P

C-C

o p q

C

r

C

t s

B

74

Z Starter cable

[ Brake hose

Fuel sender lead coupler

] Fasten the ignition coil lead to the frame cross member with the plastic band, making sure to fasten the lead under the fuel hoses and to face the end of the band rearward.

^ Fasten the fuel hoses with the holders.

a Fasten the coolant hoses with plastic band, making sure that the end of the band is to the rear of the hose, facing downward.

b Fasten the coolant hose and throttle position sensor coupler with the plastic band, making sure that the end of the band is to the rear of the hose, facing downward.

c Slide the boot completely over the throttle position sensor coupler, and then fasten the coupler to the coolant hose with the plastic band.

d Air duct e When installing the air duct, make sure that it contacts the bulkhead.

f Install the ground lead terminal and the rectifier/regulator using the same bolt.

g Rectifier/regulator h Insert the front section of the cover into the frame.

i Fasten the wire harness at the white tape with the plastic band.

j To the headlight and meter assembly k Install the starter motor lead terminal so that the bent section of the terminal is facing upward.

l Up m Front n Load control relay o Headlight relay p Fasten the gear position switch lead at the positioning tape with the plastic locking tie.

q Carburetor heater relay r Back buzzer s When installing the back buzzer, make sure that it contacts the rivet.

t To the tail/brake light u Nut v Bolt w Pass the negative battery leads under the starter relay.

CABLE ROUTING

SPEC

75

CABLE ROUTING

SPEC

D-D

w d y

E

e c a b

^

]

[

x f

Z

Y

X g h

D

D

W i j

1

2 3 k

U

A

V

T

4 5 l m

6

7

8

A

E

J

9

0

A

B

C

D

G

F

E

H

I

K

L

M

N u v

Q

S

B

R n

O

P

C-C

o p q

C

r

C

t s

B

76

x Pass the carburetor heater lead under the positive starter motor lead.

y Be sure to install the positive battery lead terminal so that it is facing rearward.

CABLE ROUTING

SPEC

77

2

3

1

CABLE ROUTING

SPEC

A-A

7

4

5

6

A

A

78

1 Headlight sub-wire harness

2 Fasten the headlight sub-wire harness at the white tape with the holder on the shroud.

3 Fasten the headlight sub-wire harness with the holder.

4 Shroud stopper

5 Pass the headlight sub-wire harness inside of the shroud stopper.

6 Fasten the headlight sub-wire harness and lead at the tape with the plastic band. After connecting the coupler, install the rubber cover securely.

7 Install the meter assembly coupler rubber cover until it contacts the meter assembly.

CABLE ROUTING

SPEC

79

CABLE ROUTING

SPEC

Z

N

O

Q

P

S

T

R

1

2

3

4

5

6

7

8

U

V

W

X

Y W

A-A

A

9

0

A

B

C

D

E

A

F

G

H

I

L

J

K

M

80

1 Right handlebar switch

2 Handlebar holder

3 Throttle cable

4 Pass all of the leads and cables through the guide, except the parking brake cable. Do not pass the brake hose through the guide.

5 Fasten the wire harness with the plastic band.

6 Parking brake cable

7 Left handlebar switch

8 Starter cable. Pass the starter cable over the left handle leads.

9 Speed sensor coupler

0 Lead cover

A Route the fuel tank breather hose along the frame cross member.

B Radiator fan motor coupler

C Fuel sender coupler

D There should be no slack in the radiator fan motor lead.

E Fasten the relay lead, speed sensor lead, and radiator fan motor lead with the plastic band.

F Fasten the compression spring section of the fuel tank breather hose with the holder.

G Route the float chamber air vent hoses behind the battery bracket.

H Face the ends of the clamp upward.

I Install the fuel tank breather hose onto the breather pipe, making sure that it contacts the running board support.

J Back buzzer relay

K Passenger grip warmer relay

L Radiator fan motor relay

M To the speed sensor

N To the oil tank

O Negative battery lead

P To the parking brake

Q To the brake caliper

R Brake hose

S Fasten the wire harness with the plastic band.

T Fasten the coolant hose with the clamp.

U Fuel hoses

V Fasten the wire harness and the fuel tank breather hose next to the rubber damper on the frame cross member with the holder, making sure that the ends of the holder are facing up.

W Fasten the fuel tank breather hose with the holder.

X Fasten the wire harness with the plastic band.

81

CABLE ROUTING

SPEC

CABLE ROUTING

SPEC

Z

N

O

Q

P

S

T

R

1

2

3

4

5

6

7

8

U

V

W

X

Y W

A-A

A

9

0

A

B

C

D

E

A

F

G

H

I

L

J

K

M

82

Y Pass the wire harness, brake hose, and parking brake cable through the guide. Do not pass the throttle cable and starter cable through the guide.

Z Place the end of the plastic band between the frame cross member and the fuel tank.

CABLE ROUTING

SPEC

83

1

B

C

D

E

F

G

A

0

9

8

7

6

CABLE ROUTING

SPEC

2

3

5

4

84

1 Headlight sub-wire harness

2 Oil tank outlet hose

3 Starter motor positive lead

4 Pass the starter motor positive lead behind the engine.

5 Gear position switch lead

6 To the tail/brake light

7 Route the wire harness to the front of the frame cross member bolts, making sure that the harness is not on the bolts.

8 Fasten the wire harness with the holder. Secure the frame cross member and the holder to the frame with the nut and bolt.

9 Gear position switch lead

0 Fuse box

A Wire harness

B Conduction assembly

C Brake hose

D Parking brake cable

E Coolant reservoir

F Route the parking brake cable so that it is not caught on the check valve hose clamp.

G Fasten the positive battery lead terminal and negative battery lead terminal with the holder.

CABLE ROUTING

SPEC

85

CABLE ROUTING

SPEC

1

2 3

4

5

A

A

B

A

9

B

0

B

E

D

A-A

C

6

7

8

9

0

86

1 Fuel pumps

2 Face the ends of each clamp outward.

3 Fuel hoses

4 Coolant reservoir

5 Fasten the fuel tank breather hose, speed sensor lead and relay leads with the holder.

Secure the frame cross member and the holder to the frame with the nut and bolt.

6 Speed sensor lead holder

7 Rivet (quantity: 4)

8 Align the punch mark on the bearing holder with the rivet.

9 Bearing holder

0 Speed sensor

A Front axle

B Primary sheave

C Water pump inlet hose

D More than 5 mm (0.2 in)

E Water pump

CABLE ROUTING

SPEC

87

CABLE ROUTING

SPEC

2 3

5

6

1

5

A

7

8

4

9

A

B

A

0

A-A

88

1 To the starter motor

2 Starter motor positive lead

3 Negative battery lead

4 Positive battery lead

5 Ignitor unit

6 Ignitor unit bracket

7 Air filter case latch

8 Battery band

9 Battery cover

0 To the carburetor

A Wire harness

B Battery bracket

CABLE ROUTING

SPEC

89

CABLE ROUTING

SPEC

7

8

A

6

1

2 3

4

5

A

90

1 Forward

2 Wire harness

3 Battery bracket

4 To the air filter case

5 A.C. magneto lead

6 Route the crankcase breather hose inside of the wire harness, and then over the starter motor positive lead, and under the battery bracket.

7 Crankcase breather hose

8 Face the paint mark towards vehicle outside.

CABLE ROUTING

SPEC

91

1

2

3

4

5

6

CABLE ROUTING

SPEC

7

8

3

4

9

0

92

1 Fasten the passenger grip warmer lead with the plastic band, making sure that the end of the band is on top of the pipe and facing rearward. The plastic band should not be visible when the passenger seat is installed.

2 Route the passenger grip warmer lead along the groove in the storage compartment. Route the passenger grip warmer lead along the groove in the storage compartment, making sure that there is not excessive slack in the lead.

3 Be sure to install the passenger grip warmer switch with the “HI” side up.

4 Position the coupler on the inside of the storage compartment.

5 Fasten the tail/brake light subwire harness with the plastic band. (quantity: 7)

6 Pass the passenger grip warmer lead through the hole in the frame, routing it towards the inside of the snowmobile, and then pass the lead through the hole in the storage compartment before connecting it.

7 Connect the tail/brake light subwire harness coupler on the outside of the storage compartment.

8 Tail/brake light sub-wire harness

9 Route the handlebar switch lead on top of the sponge cushion that is affixed to the frame.

0 Position the tail/brake light subwire harness coupler in the location shown in the illustration.

CABLE ROUTING

SPEC

93

WIRING DIAGRAM

VK10W 2007

8GS-0F001-00

1 Pickup coil

2 A.C. magneto

3 Rectifier/regulator

4 Main switch

5 Load control relay

6 Main fuse

7 Starter relay

8 Starter motor

9 Battery

0 Engine stop switch

A Throttle switch

B Carburetor heater relay

C Carburetor ground

D Carburetor heater

E Radiator fan motor relay

F Radiator fan motor

G Grip warmer

H Thumb warmer

I Ignitor unit

J Ignition coil

K Spark plug

L Throttle position sensor

M Coolant temperature sensor

N Grip warmer adjustment switch

O Thumb warmer adjustment switch

P Frame ground

Q Passenger grip warmer relay

R Passenger grip warmer switch

S Passenger grip warmer

T DC back buzzer

U Gear position switch relay

V Gear position switch

W Brake light switch

X Tail/brake light

Y Speed sensor

Z Fuel sender

[ Oil level switch

Meter assembly

] Multi-function meter

_ Warning light a Low coolant temperature indicator light b Meter light c High beam indicator light d Auxiliary DC jack fuse e Headlight fuse f Signal fuse g Cooling fan motor fuse h Carburetor heater fuse i Ignition fuse j Auxiliary DC jack k Headlight beam switch l Headlight relay m Headlight

COLOR CODE

B …………. Black

Br ………… Brown

Dg ……….. Dark green

G …………. Green

Gy ……….. Gray

L………….. Blue

Lg………… Light green

O …………. Orange

P …………. Pink

R …………. Red

W ………… White

Y …………. Yellow

B/L ………. Black/Blue

B/G………. Black/Green

B/W ……… Black/White

B/Y ………. Black/Yellow

Br/B……… Brown/Black

Br/G …….. Brown/Green

Br/L ……… Brown/Blue

Br/R……… Brown/Red

Br/W…….. Brown/White

Br/Y……… Brown/Yellow

G/B………. Green/Black

G/R ……… Green/Red

G/W……… Green/White

G/Y………. Green/Yellow

L/G ………. Blue/Green

L/R ………. Blue/Red

L/Y ………. Blue/Yellow

Lg/L……… Light green/Blue

Lg/W ……. Light green/White

O/B………. Orange/Black

O/R ……… Orange/Red

R/B………. Red/Black

R/L ………. Red/Blue

R/W……… Red/White

R/Y………. Red/Yellow

W/B ……… White/Black

W/G……… White/Green

W/R……… White/Red

W/Y ……… White/Yellow

Y/B ………. Yellow/Black

Y/L ………. Yellow/Blue

Y/R………. Yellow/Red

Cover_SMB.fm Page 1 Thursday, June 29, 2006 2:03 PM

SUPPLEMENTARY SERVICE MANUAL

VK10W

YAMAHA MOTOR CO., LTD.

PRINTED IN U.S.A.

2006.07 CR

(E)

LIT-12618-02-57 8GS-28197-10

WIRING DIAGRAM

VK10W 2007

8GS-0F001-00

A B C D

WIRE HARNESS

SUB-WIRE

HARNESS 3

B/Y

L/G

W/G R/W B/W

G R/L W/Y

Br/B

O/R

B/L Br/R

W/R G/Y L

Lg Br/Y Y/R

Y/B Br/L B Y G/W

(BLACK)

Br

O

Br

Gy

K

J

O Br

(BLACK)

G/B B/Y L/Y

B R/B

L/Y B/Y G/B

R/B B

WIRE HARNESS

HEADLIGHT

SUB-WIRE

HARNESS 1

W/R W/G

B R

L/Y j

G W/B

L/Y B

B

Gy B

1

W W W

(GLAY)

L/Y

W

G

Y

Y/B

L/R

(BLACK)

Y/B

L/R

G L/Y

Y W

(BLACK)

WIRE HARNESS

HEADLIGHT

SUB-WIRE

HARNESS 2

2

W W W

W W W

3

B

(3A)

L

(20A)

L

(10A)

L

(15A)

R

W/G

W/R

R

R

(15A)

R d e f g h i

L/Y

L/Y

A

L/Y

L/W L/R Br/G R/W R/Y k

L/W

Lg

Lg L/W

O/B L/R

B G

L/R O/B

G B

WIRE HARNESS

TAIL/BRAKE LIGHT

SUB-WIRE

HARNESS

B B/G Dg B

4

Br

R

L

Br/L

OFF

ON

START

Br Br/R

R Br

R/Y R/W

5

Br

Br/R

O/R

R R/W

Br Br/W

R/W

Br/R

R/Y

Br

0

RUN

STOP

A

CLOSE

OPEN

B/Y

Br Br/W

(BLACK)

B/Y

R

R

7

R

(30A)

6

R/W

B

B

R

R/W

Br/R Br

(BLACK)

L/R

R/W

B/G

Br/Y

L/R

R/W

B

B/L

(BLACK)

L

Br/L

B

9

B

B B

8

Br/Y

B/G

B/G D Dg

B

D B

O/R

B/Y

(BLACK)

Dg Dg

D D D

B B

C

Dg

L/R

Br/G

L

G/W

L/R

Br/G

E

L

G/W

L

F

B

B

L

B

L

(BLACK) (BLACK)

Y/R

B

G

G

HI

LO

L/W

Lg m

Y G

G

B

G

Lg

L/W

G

Y B

(BLACK) l

L/W

G

Lg

Y

G

B m

Y

B

Y

B

Y

L/R B L/R

Y G

Y

G

B

L/R

^

L/R

B/Y R/B G/B Y/B

(BLACK)

Y

L/Y

W

]

Y/B

L/Y

W

Y a b c

Y/B B Y/B

L/Y

W

B

B

L/Y

W

G/B

R/B

R/B

A

R/B

R/B

G/B A G/B

[

B/Y

B/Y R/B

B/Y

A

B/Y

B/Y

(GRAY)

B

B

A

B

B

G/B

B/Y

L/Y

W

B/Y

G B

Z

Y

P O/R

B/W

L/Y W

B/Y

B/Y

G/B

W

OFF

ON

L/R

G

G/Y

L

G

L/R

L/R G

C C

L/R G

L/R G

G L/R B

B L Y

B

B

C

B

X

Lg

H

B

W/G

W/R

Br/R

O/R

B

Br/Y

Br/L

G/W

Y/B

Y/R

Lg

G

Y

I

B/Y

Gy

O

Gy

W

L

W/Y

B/L

L/G

B/W

Br/B

G/Y

R/W

R/L

O

W

Br

W

K

J

Gy

Br

(BLACK)

K

J

W Br

(BLACK)

L

W/Y

B/L

L

L/G

M

B/W

B

W

B

Lg

L/R

P

T

Br

P

U

P

P

L/R

Q

Br/B

B/Y

G/Y

G/Y Br/B

B/Y

Y/W Y/L

N

B/L

P

B

Y

O/B O/B C O/B

O/B

R/W

B/Y

R/L

R/L R/W

B/Y

Lg/W Lg/L

O

B/L

(BLACK)

(BLACK)

L/R

L/R

O/B

Y

R

LO

OFF

HI

L/R

L/R

Y/L O/B G/R

(BLACK)

G/R O/B Y/L

(BLACK)

Y/L G/R

Y/L B G/R

(BLACK)

S

G

B Y

(BLACK)

G/R

Y/L

B

Y/L B G/R

(BLACK)

S

G B Y

(BLACK)

G/R

B

L/R

B

B/R

B/R

P

L/R

B B/R

(BLACK)

V

W/Y L

B/L

(BLACK)

L

B

Y

(BLACK)

L/G B/W

(DARK GREEN)

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