Ямаха сайдвиндер руководство

Инструкция Yamaha Sidewinder M-TX SE 162 (2018) доступно в русский?

Page: 1

Read this manual carefully
before operating this vehicle.
OWNER’S MANUAL
SRS10LG
SRS10SG
SRS10XL
SRS10BL53
SRS10ML53
8MF-F8199-S0-E0
U8MFS0E0.book Page 1 Wednesday, July 3, 2019 9:31 AM

Page: 2

Read this manual carefully before operating this vehicle. This manual
should stay with this vehicle if it is sold.
EC Declaration of Conformity
conforming to Directive 2006/42/EC
(Make, model)
2014/30/EU
– – – – – –
General Manager
Recreational Vehicle Development Div.
PF Model Development Section
PF Model Unit
YAMAHA MOTOR CO., LTD.
Signature
Date of Issue
Akihiro Tsuzuki
21, November, 2018
YAMAHA MOTOR EUROPE N.V.
Koolhovenlaan 101, 1119 NC Schiphol-Rijk, The Netherlands
We,YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
declare in sole responsibility, that the product
Authorized Representative
(Title and/or number and date of issue of the other Directives of EEC)
to which this declaration applies, conforms to the essential
health and safety requirements of Directive 2006/42/EC
and to the other relevant Directive of EEC
(If applicable)
To effect correct application of the essential health and safety
requirements stated in the Directives of EEC, the following-
standards and/or technical specifications were consulted:
(If applicable)
(Title and/or number and date of issue of standards and/or specifications)
SRS10ML53 (SRS10ML53) (4UF8MS40 LT000001-)
SRS10BL53 (SRS10BL53) (4UF8MF90 LT000001-)
SRS10XL (SRS10XL) (4UF8NM10 LT000001-)
SRS10SG (SRS10SG) (4UF8NJ20 LT000001-)
SRS10LG (SW1AML53) (4UF8NG20 LT000001-)
U8MFS0E0.book Page 1 Thursday, April 25, 2019 7:15 AM

Page: 3

Table of Contents
Foreword ………………………………………………2
General Information……………………………3-14
Snowmobile Identification……………………….3
Emissions Certification label (for Europe) ….3
Control Locations…………………………………..3
Gasoline—Oil ………………………………………..4
Engine Break-In …………………………………….4
Drive Belt Break-In…………………………………5
Cold Drive-Away Function ………………………5
Speedometer/Tachometer/Digital Gauge ….5
Diagnostic Codes…………………………………..7
Handlebar Tilt………………………………………..8
Exhaust System …………………………………….8
Air-Intake Silencer………………………………….8
Cooling System……………………………………..8
Battery………………………………………………….9
Jump-Starting ……………………………………….9
Drive Clutch and Driven Clutch………………10
Drive Clutch/Driven Clutch Alignment …….10
Fuel Pump…………………………………………..10
Track/Track Studs ………………………………..11
Paddle Track (On Equipped Models) ………11
Reverse Operation ……………………………….11
Access Panels/Hood…………………………….12
Removable Seat…………………………………..12
Heated Seat (if equipped) ……………………..14
Towing………………………………………………..14
Operating Instructions………………………15-19
Pre-Start……………………………………………..15
Starting and Stopping Engine………………..16
Braking……………………………………………….17
Emergency Stopping ……………………………18
Throttle/Ignition Monitor Switch……………..18
Lubrication………………………………………20-22
Chain Case………………………………………….20
Replacing Lubricant……………………………..21
Rear Suspension………………………………….22
Maintenance………………………………….. 23-46
Periodic Maintenance Checklist …………….23
Fuel System ………………………………………..24
Checking Engine Oil Level …………………….24
Changing Engine Oil/Filter …………………….24
Coolant Level ………………………………………26
Air Filter………………………………………………26
Spark Plugs…………………………………………27
Checking/Adjusting Valve Clearance………27
Battery………………………………………………..27
Fuses………………………………………………….30
Brake System………………………………………30
Burnishing Brake Pads …………………………33
Chain Tension………………………………………33
Drive Belt…………………………………………….34
Track Tension ………………………………………35
Track Alignment …………………………………..37
Suspension …………………………………………38
Adjusting Skid Frame Rear Shock (Fox
QS3)………………………………………………..42
QSL Rear Arm Shock……………………………43
Adjusting Rear Spring Pre-Load …………….43
Overload Springs …………………………………43
Lights …………………………………………………44
Ski Wear Bars………………………………………45
Adjusting Ski Stance…………………………….45
Single Wear Bar …………………………………..46
Rail Wear Strips……………………………………46
Performance Tips …………………………… 47-48
Preparation for Storage …………………………49
Preparation after Storage ………………………50
Snowmobile Safety Rules………………………52
U8MFS0E0.book Page 1 Thursday, April 25, 2019 7:15 AM

Page: 4

1
The Safety Alert Symbol means ATTENTION! BE
ALERT! YOUR SAFETY IS INVOLVED.
WARNING WARNING identifies personal safety-related informa-
tion. Follow the directive because it deals with the
possibility of serious personal injury or even death.
CAUTION CAUTION, without the safety alert symbol, identifies
unsafe practices. Follow the directive because it deals
with the possibility of damaging part or parts of the
snowmobile.
 NOTE: A NOTE identifies supplementary information worthy
of particular attention.
WARNING
A snowmobile is a very high performance vehicle. Because it does acceler-
ate rapidly and is capable of very high speeds, it should not be operated by a
novice or an inexperienced operator. Never accelerate rapidly or drive at
high speed beyond the limits of visibility or without being totally familiar with
the terrain and what lies in front of you. Obey speed limits and never operate
at speeds that do not allow adequate maneuvering and stopping distances.
Read and study the entire Owner’s Manual. Failure to follow this warning
could result in personal injury to yourself or others.
Personal Injury
• To avoid injury to yourself and others, NEVER operate the snowmobile with-
out first reading and understanding this manual; then follow the instructions
and heed the warnings given.
• USE COMMON SENSE.
• DON’T DRINK and DRIVE.
• STAY IN CONTROL at ALL TIMES.
• TELL YOUR FRIENDS. If you see a friend operating a snowmobile reck-
lessly, at excessive speeds, while intoxicated, or in other unsafe ways, don’t
wait until it is too late to warn of the consequences of snowmobile misuse.
Such conduct endangers everyone. TAKE AN ACTIVE ROLE IN THE
SAFETY OF YOURSELF AND OTHERS.
U8MFS0E0.book Page 1 Thursday, April 25, 2019 7:15 AM

Page: 5

2
Foreword
Congratulations! You have chosen a quality Yamaha Snowmobile designed and
assembled to give dependable service. Be sure, as the owner/operator of a Yamaha
Snowmobile, to become thoroughly familiar with its basic operation, maintenance,
and off-season storage procedures. Read this manual before operating the snowmo-
bile to learn safe and proper use of your new Yamaha Snowmobile. Always operate
the snowmobile within your level of skill and current terrain conditions.
At the time of publication, all information and illustrations were technically correct.
Some illustrations used in this manual are used for clarity purposes only and are not
designed to depict actual conditions. Because Yamaha constantly refines and
improves its products, no retroactive obligation is incurred. This Owner’s Manual
should be considered a permanent part of the snowmobile and must remain with the
snowmobile at the time of resale.
© 2019 Yamaha
Reference Information
Write the appropriate information for your Yamaha Snowmobile in the spaces below.
Always use these numbers when referring to your snowmobile.
Model: _______________________________________________________
Date of Purchase: _____________________________________________
Vehicle Identification Number: ___________________________________
Engine Serial Number: __________________________________________
Your Yamaha Dealer: __________________________________________
Address: _____________________________________________________
Phone: _______________________________________________________
Parts and Accessories
When in need of replacement parts, oil, or accessories for your Yamaha Snowmo-
bile, be sure to only use GENUINE YAMAHA PARTS, OIL, AND ACCESSO-
RIES. Only genuine Yamaha parts, oil, and accessories are engineered to meet the
standards and requirements of your Yamaha Snowmobile. For a complete list of
accessories, refer to the current Yamaha Accessory Catalog. To aid in service and
maintenance procedures on these snowmobiles, an Illustrated Parts Manual and a
Service Manual are available through your local Yamaha Snowmobile dealer.
U8MFS0E0.book Page 2 Thursday, April 25, 2019 7:15 AM

Page: 6

3
General Information
Snowmobile Identification
The snowmobile has several important
identification numbers. The Vehicle Iden-
tification Number (VIN) is stamped into
the tunnel near the right-side footrest and
below the seat. The rear tunnel decal also
displays pertinent production informa-
tion. The decal also displays pertinent
production information. The Engine
Serial Number (ESN) is stamped into the
crankcase of the engine.
0726-383
These numbers are required by the dealer
to complete warranty claims properly. No
warranty will be allowed by Yamaha Inc.
if the engine serial number or VIN is
removed or mutilated in any way.
Always provide the snowmobile name,
VIN, and ESN when contacting an autho-
rized Yamaha Snowmobile dealer for
parts, service, accessories, or warranty. If
the complete engine must be replaced,
ask the dealer to notify Yamaha for cor-
rect registration information.
Emissions Certification label
(for Europe)
CRJ-8MF
The NRMM (Non-Road Mobile Machin-
ery) regulation limits gaseous and partic-
ulate pollution emissions for internal
combustion engines of non-road mobile
machinery.
Your Yamaha engine was designed and
tested to give an optimal blend of perfor-
mance without excessive emissions.
Therefore, do not attempt to alter the
engine specifications or tamper with the
intake, engine, or exhaust systems.
Control Locations
Shown are the typical control locations
for Yamaha snowmobiles. Location of a
specific control will vary according to
model.
ONS-184
VIN
CAUTION
Tampering with the engine or emis-
sions control system will void the
European Union type-approval of
this engine.
1
Accessory Outlet
Brake Lever Lock
Brake Lever
Headlight Dimmer Switch
Thumb Warmer/
Handlebar Warmer Switches
Seat Warmer Switch (If Equipped)
Emergency Stop Switch
Reverse/Start Switch
Throttle Lever
Ignition Switch
Heated Shield Outlet (If Equipped)
Tether Switch
U8MFS0E0.book Page 3 Thursday, April 25, 2019 7:15 AM

Page: 7

4
Gasoline—Oil
Recommended Gasoline
The recommended gasoline to use is 95
octane premium unleaded. In many areas,
oxygenates are added to the gasoline.
Oxygenated gasolines containing up to
10% ethanol are acceptable gasolines.
NOTE: This mark identifies the
recommended fuel for this vehicle
as specified by European regula-
tion (EN228).
NOTE: Check that gasoline noz-
zle has the same identifier when
fueling.
When using ethanol-blended gasoline, it is
not necessary to add a gasoline antifreeze
since ethanol will prevent the accumula-
tion of moisture in the fuel system.
Recommended Engine Oil
The recommended oil to use is Semi-
Synthetic YAMALUBE 0W-30 oil.
After 800 km (500 miles) of operating,
the engine oil must changed and the oil
filter replaced. The engine oil should be
changed every 4000 km (2500 miles)
before prolonged storage and the oil filter
should be changed every 20,000 km
(12,500 miles).
Filling Gas Tank
Since gasoline expands as its temperature
increases, the gas tank must be filled to
its rated capacity only. Expansion room
must be maintained in the tank particu-
larly if the tank is filled with cold gaso-
line and then moved to a warm area.
Also, if the snowmobile is to remain on a
trailer after filling the gas tank, the bed of
the trailer must be maintained level to
prevent gasoline from draining out
through the gas tank vent hose.
For the snowmobile that features a 16.2 L
(4.3 US gal.) auxiliary gas tank, a sepa-
rate gas tank cap is located beneath the
cowling just behind the passenger seat.
The auxiliary tank is plumbed directly
into the main gas tank.
XM276
To access the spare belt location along
with the tool kit, the storage box lid, aux-
iliary gas tank cap, and storage tray must
be removed.
When installing the storage tray, ensure it
is properly pushed all the way down into
position. If not, the storage box lid will
not sit properly.
Engine Break-In
The engine (when new or rebuilt)
requires a short break-in period before
the engine is subjected to heavy load con-
ditions.
This engine does not require any pre-
mixed fuel during the break-in period.
CAUTION
If a situation arises wherein 95 octane
gasoline is not available, a lower
octane gasoline can be substituted;
however, do not prolong the usage of
lower octane gasoline as it will cause
poor engine performance.
CAUTION
Any oil used in place of the recom-
mended oil could cause serious
engine damage
E5 E10
WARNING
Always fill the gas tank in a well-ven-
tilated area. Never add gasoline to
the snowmobile gas tank near any
open flames or with the engine run-
ning. DO NOT SMOKE while filling
the gas tank. Do not sit on the snow-
mobile without first installing the gas
tank cap.
U8MFS0E0.book Page 4 Thursday, April 25, 2019 7:15 AM

Page: 8

5
There is never a more important period in
the life of the engine than the first 500
km (300 miles).
Since the engine is brand new, do not put
an excessive load on it for the first 500
km (300 miles). The various parts in the
engine wear and polish themselves to the
correct operating clearances. During this
period, prolonged full throttle operation
or any condition that might result in
engine overheating must be avoided.
0-160 km (0–100 miles): Avoid pro-
longed operation above 6000 RPM.
160-500 km (100–300 miles): Avoid pro-
longed operation above 8000 RPM.
500 km (300 miles) and beyond: The
snowmobile can now be operated nor-
mally.
NOTE: After 800 km (500 miles) of
operation, the engine oil must be
changed and the oil filter replaced.
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the snowmobile.
Drive Belt Break-In
Drive belts require a break-in period of
40 km (25 miles). Drive the snowmobile
for 40 km (25 miles) at 3/4 throttle or
less. By revving the engine up and down
(but not exceeding 100 km/h [60 mph]),
the exposed cord on the side of a new belt
will be worn down. This will allow the
drive belt to gain its optimum flexibility
and will extend drive belt life.
NOTE: Before starting the snow-
mobile in extremely cold tempera-
tures, the drive belt should be
removed and warmed up to room
temperature. Once the drive belt is
at room temperature, install the
drive belt.
Cold Drive-Away Function
On these models, there is a “cold drive-
away” function incorporated within the
ECM.
When cold-starting the engine, the cool-
ant temperature warning icon will illumi-
nate and the LOW TEMP display on the
readout screen will begin to flash. With
the engine in this temperature range, the
RPM “limit” of the engine will be below
drive system engagement speed. As the
engine warms, the coolant temperature
warning icon will begin to flash, the
TEMP display will continue to flash, and
the RPM “limit” of the engine will
increase allowing the snowmobile to
move without full-throttle operation.
When the engine reaches proper operat-
ing temperature, the coolant temperature
warning icon and the LOW TEMP dis-
play will go out.
Speedometer/Tachometer/
Digital Gauge
CWI-050A
A. Coolant Temperature Indicator
The indicator and LOW TEMP display
will cease to flash when the engine
reaches proper operating temperature.
CAUTION
Never run the engine with the drive
belt removed. Excessive revving of
the engine could result in serious
engine damage and drive clutch
failure.
CAUTION
It is extremely important that the
engine is properly warmed up before
subjecting the engine to high speed
operation or heavy loads. The engine
should be allowed to idle at least 3-4
minutes before it is operated at more
than 1/2 throttle. In extremely cold
conditions, the warm-up time will be
longer. Cold seizure and piston scuff-
ing caused by insufficient warm-up
will not be covered by warranty. Also,
do not idle the engine for excessively
long periods of time.
Upper Left
Button
Lower Left
Button
Upper Right
Button
Lower Right
Button
U8MFS0E0.book Page 5 Thursday, April 25, 2019 7:15 AM

Page: 9

6
If the coolant temperature rises too far
above proper operating temperature, the
indicator will flash a warning (alert) and
the engine will “surge” to alert the opera-
tor. If the coolant temperature rises to a
critical point above proper operating tem-
perature, the indicator will cease flashing
and will remain constantly illuminated.
NOTE: If the indicator is constantly
on, the engine will shut off if vehicle
speed is reduced to 1.5 km/h (1
mph) or slower.
B. High Beam Indicator
The indicator is on whenever the high
beam mode is selected by the headlight
switch.
C. Oil Pressure Indicator
The indicator relates to engine oil pres-
sure, not the oil level; however, if the oil
level is low, it may affect oil pressure. If
oil pressure is lost, check the oil level
(see page 24).
If the indicator does not go out or if the
engine does not start, take the snowmo-
bile to an authorized Yamaha Snowmo-
bile dealer. If not under warranty, this
service is at the discretion and expense of
the snowmobile owner.
D. Low Fuel Indicator
The indicator illuminates whenever the
gas in the gas tank is low.
E. Coolant Temperature/Battery
Voltage/Intake Air Temperature
This bar display shows coolant tempera-
ture, battery voltage, and intake air tem-
perature. Press the Lower Left Button (or
push the right side of the gauge control
button on the top left side handlebar
switch assembly) to change which
parameter is being displayed. Press and
hold the Lower Left Button to see the
actual values associated with the mode
selected.
F. Fuel Level Display
This display shows the approximate
amount of gas remaining in the gas tank.
G. RPM/Speed/Clock/Altimeter
Press the Upper Left Button (or push the
left side of the gauge control button on
the top left side handlebar switch assem-
bly) to cycle the left screen between
RPM and speed.
ONS-068
NOTE: When RPM is displayed on
the left screen, the right screen will
display speed, clock, or altimeter.
When speed is displayed on the left
screen, the right screen will display
RPM, clock, or altimeter.
Press the Upper Right Button to cycle the
right screen between speed, RPM, clock,
and altimeter.
Press and hold the Upper Button on the
speed-side of the gauge to shift the gauge
between standard (MPH/miles/Fahren-
heit) and metric (km/h/kilometers/Cel-
sius) modes.
Press and hold the Upper Button on the
RPM-side of the gauge to view maxi-
mum RPM. This value is reset each time
the ignition key is turned off.
With the clock mode selected by pressing
the Upper Right Button, press and hold
the Upper Right Button to set the clock.
The option of selecting the 12-hour or
24-hour clock is available; press the
either Left Button to alternate between
the two modes. Next, press the Lower
Right Button to set the clock. Press either
Left Button to set the hours; then press
the Lower Right Button to set the min-
CAUTION
If the indicator is illuminated, stop the
engine immediately and allow it to
cool down. If unable to either deter-
mine or remedy the problem, take the
snowmobile to an authorized Yamaha
Snowmobile dealer for service. If not
under warranty, this service is at the
discretion and expense of the snow-
mobile owner.
Gauge control
U8MFS0E0.book Page 6 Thursday, April 25, 2019 7:15 AM

Page: 10

7
utes. Press either Left Button to set the
minutes. When the proper time has been
set, press the Lower Right Button to
return to the main gauge display.
With the altimeter mode selected by
pressing the Upper Right Button, press
and hold the Upper Right Button to set
the current altitude by using either Left
Button. When the proper altitude has
been set, press the Lower Right Button to
return to the main gauge display.
H. Engine Hour Meter/Odometer/
Trip Meter/Clock
This display shows engine hours, odome-
ter, trip meter, or clock. Press the Lower
Right Button to change which parameter
is being displayed. The Engine Hour
Meter and Odometer cannot be reset. To
reset the trip meter, select the Trip Meter;
then press and hold the Lower Right But-
ton until the trip meter display reads 0.
NOTE: The clock can only be dis-
played in this position if it is not
already being displayed in the main
right screen. To set the clock when
the clock is in this position, press
and hold the Lower Right Button;
then use the procedure found in G.
Diagnostic Codes
Diagnostic codes are activated by the
ECM and may be displayed on the read-
out screen for a number of reasons.
If a code is displayed while the engine is
running, the ECM is receiving input that
is outside of its established parameters. If
a code has been activated, take the snow-
mobile to an authorized Yamaha Snow-
mobile dealer for service. If not under
warranty, this service is at the discretion
and expense of the snowmobile owner.
Refer to the following chart for a list of
possible diagnostic codes.
Code Trouble
8 Shift Switch Abnormality
12 Crank Sensor
13 Manifold Pressure Sensor (PB)
14 Manifold Pressure Sensor (PB)
15 Throttle Position Sensor
19 Wastegate Solenoid
21 Water Temperature Sensor
22 Intake Air Temperature Sensor
23 Atmospheric Pressure Sensor
25 Upstream Pressure Sensor (PC)
26 Upstream Pressure Sensor (PC)
30 Oil Pressure Reduction
33 Ignition Abnormality #1
34 Ignition Abnormality #2
35 Ignition Abnormality #3
37 Idle Speed Control Abnormality
39 Injector Abnormality
42 Vehicle Speed Sensor
43 Monitor Voltage (Fuel System Power)
44 EEPROM Write Error
46 Vehicle System Power Supply Abnor-
mality
50 ECU Internal Failure
65 Knock Sensor
67 Oil Pressure Sensor
69 Air Bypass Solenoid
84 TORS Control
85 Oil Pressure Switch
89 Meter Communication Abnormality
C1500 Right Ski Shock Stepper Motor Stall
Detection
C1505 Left Ski Shock Stepper Motor Stall
Detection
C1510 Front Skid Shock Stepper Motor Stall
Detection
C1515 Rear Skid Shock Stepper Motor Stall
Detection
C1520 Suspension Module Supply Voltage
Low
C1521 Suspension Module Supply Voltage
High
C1522 Suspension Module Checksum Error
C1523 Right Ski Shock Stepper Motor Coil A
Circuit Malfunction
C1524 Right Ski Shock Stepper Motor Coil B
Circuit Malfunction
C1525 Left Ski Shock Stepper Motor Coil A
Circuit Malfunction
C1526 Left Ski Shock Stepper Motor Coil B
Circuit Malfunction
C1529 Rear Skid Shock Stepper Motor Coil
A Circuit Malfunction
C1530 Rear Skid Shock Stepper Motor Coil
B Circuit Malfunction
C1600 Thumb Warmer Open Circuit
C1601 Thumb Warmer Circuit Short to Sys-
tem Ground
C1602 Thumb Warmer Circuit Short to Sys-
tem Power
C1603 Hand Warmer Open Circuit
C1604 Hand Warmer Circuit Short to System
Ground
Code Trouble
U8MFS0E0.book Page 7 Thursday, April 25, 2019 7:15 AM

Page: 11

8
Handlebar Tilt
The handlebar can be adjusted to the
operator’s preference. To adjust the han-
dlebar, use the following procedure:
1. Remove the handlebar cover; then
loosen the eight cap screws securing
the handlebar caps to the riser and the
riser to the steering post.
ONS-065
2. Adjust the handlebar to operator’s
desired position, tighten the cap
screws evenly to 2.0 kg-m (15 ft-lb),
and check steering for maximum
right/left turning capabilities.
Exhaust System
The exhaust system is designed to reduce
noise and to improve the total perfor-
mance of the engine. If any exhaust sys-
tem component is removed from the
engine and the engine is run, severe
engine damage will result.
Air-Intake Silencer
Used in conjunction with the fuel intake
system is a specially designed air-intake
silencer. The purpose of the silencer is to
quiet the intake of fresh air. Since the fuel
intake system is calibrated with the air-
intake silencer in place, the engine must
never be run with the silencer removed.
Performance will not be improved if the
air-intake silencer is removed. In con-
trast, severe engine damage will occur.
Cooling System
These snowmobiles are equipped with a
closed liquid cooling system for engine
cooling. The cooling system should be
inspected daily for leakage and damage.
Also, the coolant level should be checked
daily. If leakage or damage is detected,
take the snowmobile to an authorized
Yamaha Snowmobile dealer for service.
If not under warranty, this service is at
the discretion and expense of the snow-
mobile owner.
When filling the cooling system, use an
ethylene glycol-based coolant/water mix-
ture which will satisfy the coldest antici-
pated weather conditions of your area in
accordance with the coolant manufac-
turer’s recommendations.
NOTE: The gurgling noise heard
when the engine is shut off from
the turbocharger area is normal.
The snowmobile is equipped with a
vapor tank to assist with cooling
the turbocharger after the engine
is off.
NOTE: If operating on ice or hard-
packed snow conditions, it is rec-
ommended that Ice Scratchers be
installed to reduce wear strip wear
and engine overheating.
C1605 Hand Warmer Circuit Short to System
Power
U0132 Lost Communication with Suspen-
sion Control Module
U0155 LCD Gauge Communication Lost
U1212 Lost Communication with Left Han-
dlebar Control
CAUTION
Do not rotate the handlebar to a
position that allows air to enter the
brake system.
WARNING
Tighten cap screws according to
specifications to prevent unex-
pected “movement” of the handle-
bar during operation over rough
terrain. DO NOT position the han-
dlebar so steering (maximum right/
left turning capabilities) or throttle
and brake controls are affected.
Code Trouble
Cap Screws
Cap Screws
CAUTION
These snowmobiles are not
designed to be operated in dusty
conditions. Operating the snowmo-
bile in dusty conditions will result in
severe engine damage.
U8MFS0E0.book Page 8 Thursday, April 25, 2019 7:15 AM

Page: 12

9
For checking/filling cooling system, refer
to Coolant Level sub-section in the Main-
tenance section.
Battery
It is extremely important that the battery
be maintained at full charge at all times
and that the battery connections be clean
and tight. If charging the battery becomes
necessary, refer to Battery sub-section in
the Maintenance section.
Jump-Starting
NOTE: Yamaha does not recom-
mend jump-starting a snowmobile
with a dead battery but rather to
remove the battery, service it, and
correctly charge it; however, in an
emergency, it may be necessary to
jump-start a snowmobile. If so, use
the following procedure to carefully
and safely complete this procedure.
NOTE: To access the battery, the
seat must be removed.
1. For the snowmobile to be jump-
started, slide any terminal boots away.
2. Inspect the battery for any signs of
electrolyte leaks, loose terminals, or
bulging sides. Leaking or bulging
battery cases may indicate a frozen
or shorted battery.
3. Inspect the snowmobile to be used for
jump-starting to determine if voltage
and ground polarity are compatible.
The vehicle must have a 12-volt DC,
negative ground electrical system.
4. Move the vehicle to be used for the
jump-start close enough to ensure
the jumper cables easily reach; then
set and lock the brakes, shut off all
electrical accessories, and turn the
ignition switch OFF.
NOTE: Make sure all switches on
the snowmobile to be jump-started
are turned OFF.
5. Disconnect all external accessories
such as cell phones, GPS units, and
radios on both vehicles.
CAUTION
Always turn the ignition switch key
to the OFF position when the snow-
mobile is not being used. Leaving
the ignition switch in the ON posi-
tion will result in discharging the
battery and possible damage to the
battery.
CAUTION
Jump-starting the vehicle without a
battery is not advisable as it may
cause damage. Additionally, running
the unit without a battery in place or
the use of a “Jumper Pack” could
cause damage to the electrical sys-
tem.
WARNING
Improper handling or connecting of
a battery may result in severe injury
including acid burns, electrical
burns, or blindness as a result of an
explosion. Always remove rings and
watches. Any time service is per-
formed on a battery, the following
must be observed: keep sparks,
open flame, cigarettes, or any other
flame away. Always wear safety
glasses. Protect skin and clothing
when handling a battery. When ser-
vicing a battery in an enclosed
space, keep the area well-ventilated.
WARNING
If any of these conditions exist, DO
NOT attempt to jump-start, boost,
or charge the battery. An explosion
could occur causing serious injury.
CAUTION
Always make sure the electrical sys-
tems are of the same voltage and
ground polarity prior to connecting
jumper cables. If not, severe electri-
cal damage may occur.
CAUTION
Failure to disconnect electronic
accessories during jump-starting
may cause system damage due to
power spikes.
U8MFS0E0.book Page 9 Thursday, April 25, 2019 7:15 AM

Page: 13

10
6. Attach one clamp of the positive
(red) cable to the positive (+) termi-
nal (1) of the dead battery (C) being
careful not to touch any metal with
the other clamp; then attach the
other clamp of the positive (red)
cable to the positive (+) terminal (2)
of the good battery (B).
0744-527
NOTE: Some jumper cables may
be the same color but the clamps
or ends will be color-coded red and
black.
7. Attach one clamp of the negative
jumper cable (black) to the negative
(-) terminal (3) of the good battery
(B); then attach the other clamp of
the negative (black) jumper cable (4)
to an unpainted metal surface (A) on
the engine or frame well away from
the dead battery and fuel system
components.
8. Stand well away from the dead bat-
tery and start the vehicle with the
good battery. Allow the vehicle to
run for several minutes applying
some charge to the dead battery.
9. Start the snowmobile with the dead
battery and allow it to run for several
minutes before disconnecting the
jumper cables.
10. Remove the jumper cables in oppo-
site order of hook-up (4, 3, 2, 1). Be
careful not to short cables against
bare metal.
NOTE: Have the battery and elec-
trical system checked prior to
operating the snowmobile again.
Drive Clutch and Driven
Clutch
The drive clutch and driven clutch do not
require lubrication; therefore, no special
maintenance is required by the snowmo-
bile owner except for periodical cleaning.
However, the drive clutch and driven
clutch should be disassembled, cleaned,
and inspected by an authorized Yamaha
Snowmobile dealer after every 4000 km
(2500 miles) or seasonally, whichever
occurs first. This service is at the discre-
tion and expense of the snowmobile
owner.
When operating the snowmobile at high
altitudes, it may be necessary to change
certain component parts of the drive
clutch and/or the driven clutch. See an
authorized Yamaha Snowmobile dealer
for further information.
Drive Clutch/Driven Clutch
Alignment
The alignment between the drive clutch
and driven clutch is set at the factory.
Normally, no adjustment is necessary as
long as neither the drive clutch nor the
driven clutch is removed or disassem-
bled. However, if premature drive belt
wear is experienced or if the drive belt
turns over, the drive clutch/driven clutch
alignment must be checked. Take the
snowmobile to an authorized Yamaha
Snowmobile dealer for this service. If not
under warranty, this service is at the dis-
cretion and expense of the snowmobile
owner.
Fuel Pump
The fuel pump is designed to provide
adequate amount of gas to the injectors at
all throttle settings. If a fuel delivery
problem is suspected, take the snowmo-
bile to an authorized Yamaha Snowmo-
WARNING
Never make the final connection to
a battery as a spark could ignite
hydrogen gases causing an explo-
sion of the battery resulting in acid
burns or blindness.
A. Unpainted Surface on Engine
with Dead Battery
B. Good Battery
C. Dead Battery
CAUTION
DO NOT attempt to service the
drive clutch and driven clutch. The
drive clutch and driven clutch must
be serviced by an authorized
Yamaha Snowmobile dealer only.
U8MFS0E0.book Page 10 Thursday, April 25, 2019 7:15 AM

Page: 14

11
bile dealer. If not under warranty, this
service is at the discretion and expense of
the snowmobile owner.
Track/Track Studs
Accelerated wear strip and track clip
wear caused by operating on ice or hard-
packed snow conditions is NOT covered
under Yamaha warranty policy.
NOTE: If regularly operating on
ice or hard-packed snow condi-
tions, Performance Wear Strips
may be installed at the expense of
the snowmobile owner.
In general, track life will be shortened
when studs are installed. Drilling stud
holes into the drive track will cut the
internal fibers weakening the track.
Avoid spinning the drive track. Studs
may catch on an object and pull out of the
track leaving tears and damage around
the already weakened area. To minimize
possible damage, consult your stud man-
ufacturer for installation and stud pattern
recommendations. Yamaha does not rec-
ommend studding a track.
Paddle Track (On Equipped
Models)
These models are equipped with a Power
Claw style track which is specially
designed for use in powder snow riding
conditions. When the Power Claw track
is operated in hard-packed snow condi-
tions, it will run slightly slower than a
standard track and it will accelerate wear
strip wear. To decrease the amount of
wear strip wear, slower speeds must be
maintained when operating on hard-
packed trails. Accelerated wear strip
wear caused by operating a Power Claw
track on hard-packed snow conditions is
NOT covered under Yamaha warranty
policy.
NOTE: If operating on ice or hard-
packed snow conditions, it is rec-
ommended that Ice Scratchers be
installed to reduce wear strip wear
and engine overheating.
Reverse Operation
The electrical reverse function offers the
operator the convenience of being able to
back up the snowmobile rather than hav-
ing to turn the snowmobile around by
hand. This feature, under most situations,
should not be used to free a stuck snow-
mobile as it will tend to dig the skis
deeper into the snow. Always use mini-
mal speed when operating in reverse and
come to a complete stop before shifting
from either forward to reverse or reverse
to forward.
Shifting Into Reverse
ONS-170
NOTE: Correct drive belt tension
(deflection) is important for the
reverse function to operate prop-
erly. If the belt is too tight, difficulty
in engaging reverse will be experi-
enced.
1. Always warm up the engine for 2-3
minutes prior to shifting into reverse.
2. With the engine at idle (or under
3000 RPM) and the snowmobile at a
complete stop, press and release the
reverse switch button located on the
left-side handlebar control.
NOTE: The snowmobile must be
at a complete stop and the engine
running under 3000 RPM before
the system will allow shifting.
3. When reverse is engaged, a reverse
icon will illuminate on the deluxe
digital gauge and a reverse alarm
will sound.
CAUTION
Never shift into reverse while the
snowmobile is moving forward as it
is hard on the drive system.
Reverse Switch Button
U8MFS0E0.book Page 11 Thursday, April 25, 2019 7:15 AM

Page: 15

12
Operating in Reverse
1. When shifting into reverse, always
wait for the reverse icon to illumi-
nate and the reverse alarm to sound
before backing up.
NOTE: The reverse function is can-
celled whenever the engine is shut off.
2. After shifting from reverse to for-
ward (or from forward to reverse),
apply the throttle slowly and evenly
to allow the driven pulley to engage
properly.
Access Panels/Hood
To remove the access panel and hood, use
the following procedure:
1. Rotate the two quarter turns to the
vertical position; then pull the top of
the side panel out and up and off the
skid plate.
YM-148A
2. Disconnect the hood harness on the
left-side of the hood; then loosen the
two quarter turns securing the front
of the hood. Pull the hood forward
and remove the hood.
YM-149A
To install the hood and access panels, use
the following procedure:
1. Position the hood onto the snowmo-
bile and connect the hood harness
connector and secure the two front
quarter turns.
2. Install the access panel into the skid
plate; then close the access panel
and secure with the two quarter
turns.
Removable Seat
To remove the seat, remove the Torx-
head screw from the underside of the
seat; then lift on the back of the seat and
move it up and rearward to remove it.
SNO-894A
To install the seat, route the front tabs on
the seat base through the console; then
install the seat and secure using the Torx-
head screw.
WARNING
Use caution and minimal speed
when operating the snowmobile in
reverse. Be sure the button is in the
desired position.
CAUTION
After reversing in deep powder
snow conditions, make sure the
snowflap does not become “caught
up” in the track. Track and/or
snowflap damage may occur.
CAUTION
If the snowmobile is equipped with
ice scratchers, the scratchers must
be disengaged or component dam-
age will occur.
CAUTION
Prior to removing the seat, lift the
rear of the seat and disconnect the
seat heater harness connector.
U8MFS0E0.book Page 12 Thursday, April 25, 2019 7:15 AM

Page: 16

13
SNO-895A
NOTE: Prior to lowering and
securing the seat, connect the seat
heater harness connector.
Removable Seat (S-TX GT)
NOTE: If additional cargo is being
added, maximum weight on the
snowmobile (operator/passenger/
cargo) should not exceed the maxi-
mum limitation set for each snow-
mobile. See the chart in the
Suspension — Overload Springs
sub-section in the Maintenance
section for details. Also, the over-
load springs should be engaged.
To remove the rear seat, lift up both seat
latches and hold them in that position;
then lift and remove the seat. Make sure
to disconnect the accessory harness.
0748-449
Release the lever securing the front seat
assembly; then lift up and remove the
front seat. Make sure to disconnect the
seat heater harness.
0748-419
To install the rear seat base, position the
front of the seat base tabs under the loops
in the seat frame; then press down and
secure using the two seat latches.
SNO-454A
NOTE: On certain models, be
sure to connect the accessory har-
ness.
Adjustable Backrest (S-TX GT)
The backrest is designed for maximum
comfort and safety. When riding double,
the backrest must be in the passenger seat
position.
To change the position of the backrest,
loosen the two adjuster knobs on either
side of the seat and push the backrest for-
ward or backward. Tighten both adjuster
knobs.
0748-418
When riding single, the backrest can be
moved to the forward seat position.
WARNING
Make sure the rear seat is securely
locked in place before carrying a pas-
senger or personal injury may result.
U8MFS0E0.book Page 13 Thursday, April 25, 2019 7:15 AM

Page: 17

14
Heated Seat (if equipped)
Some models are equipped with a heated
seat. Models with this option can be
adjusted with a HIGH and LOW switch
which will be located near the gas tank cap.
SNO-766
Some models are equipped with a pas-
senger heated seat and the switch can be
located on the left-side passenger hand
hold.
ONS-173
Towing
If the snowmobile is to be towed by
another snowmobile, do not tow using
the loops in the skis. The tow rope should
be attached to the lower A-arms.
WARNING
Moving the backrest to the forward
seat position limits the seating
capacity to one person only.
WARNING
People who are unable to feel pain to
the skin because of advanced age,
chronic illness, diabetes, spinal cord
injury, medication, alcohol use,
exhaustion, or other physical condi-
tions, must exercise care when using
the seat heater. The seat heater may
cause burns even at low tempera-
tures, especially if used for long peri-
ods of time. Do not place anything on
the seat that insulates against heat,
such as a blanket or cushion,
because this may cause the seat
heater to overheat. Do not puncture
the seat with pins, needles, or other
pointed objects because this may
damage the heating element which
may cause the seat heater to over-
heat. An overheated seat may cause
serious personal injury.
U8MFS0E0.book Page 14 Thursday, April 25, 2019 7:15 AM

Page: 18

15
Operating Instructions
Pre-Start
It is imperative that the brake system be
checked for wear and proper operation.
After the engine has been started, check
the headlights (high and low beam), tail-
light, and brake light to be sure they are
working properly and adjusted correctly.
Make sure all lights are clean to provide
maximum illumination. The headlight
and taillight must be clean and must be
illuminated whenever the engine is run-
ning.
1. Test the operation of the brake sys-
tem by compressing the brake lever.
The brake lever must feel firm when
compressed; then while holding the
brake lever in the compressed posi-
tion, measure the distance between
the brake lever and the handlebar.
The distance must be greater than
12.8 mm (1/2 in.).
0752-475Y
2. With the brake fluid reservoir in a
level position and the cover
removed, check the fluid level. The
brake fluid level must be at the high
brake fluid mark in the reservoir.
0752-476
3. If the brake fluid is below the high
brake fluid mark, add YAMAHA
approved DOT 4 brake fluid until
the fluid is at the recommended
level. Install and secure the reservoir
cover. Do not allow moisture to con-
taminate the brake system.
4. Test the throttle control lever by
completely compressing and releas-
ing it several times. The lever
MUST return to the idle position
quickly and completely.
5. Make sure the battery is fully
charged to ensure the engine is turn-
ing over at a sufficient RPM to start.
NOTE: Even though the engine
turns over, the engine may not
have sufficient RPM to start.
6. Check the spark plugs and replace as
necessary. Short engine run times
cause carbon buildup on spark plugs.
7. Ensure the gas tank is full of fresh
gas whenever the snowmobile is
removed from storage.
12.8 mm (1/2 in.)
High Brake Fluid Mark
Low Brake Fluid
Mark
CAUTION
Brake fluid is highly corrosive. Do
not spill brake fluid on any surface
of the snowmobile.
WARNING
Do not overfill the brake fluid reser-
voir. Overfilling the reservoir may
cause the brake system to hydrauli-
cally lock. Use only YAMAHA
approved brake fluid.
WARNING
Do not start the engine if the brake
system is not functioning properly.
Service the brake system or have it
properly repaired prior to operating
the snowmobile. Serious personal
injury or even death may occur if the
brake system is not operating prop-
erly.
CAUTION
Always check the coolant level
before starting the engine.
U8MFS0E0.book Page 15 Thursday, April 25, 2019 7:15 AM

Page: 19

16
8. Ensure drive belt tension and deflec-
tion are correct to reduce starter drag.
Starting and Stopping Engine
1. Move the emergency stop switch to
the UP or RUN position.
2. Attach the tether cord to your jacket
or bibs and keep it free from the han-
dlebars so that the engine stops if
you, the operator, separate from the
snowmobile. After riding, remove
the tether cord from the snowmobile
to avoid accidental starting or unau-
thorized use.
3. Insert key into ignition switch; then
rotate key to the RUN position.
NOTE: When a cold engine is
being started, DO NOT COMPRESS
THE THROTTLE CONTROL LEVER.
If the throttle control lever is com-
pressed, the engine will not start
because the fuel/air mixture will be
too lean.
4. Press the start switch button located
on the left-side handlebar control;
then when the engine starts, release
the button.
ONS-070
5. A “cold drive-away” function is
incorporated within the engine. This
function is active until the engine
reaches operating temperature.
6. Flooding — If the engine does not
start but seems ready to start, engage
the brake lever lock; then compress
the throttle control lever fully and
try to start the engine. When the
engine starts, release the throttle
control lever immediately. After the
warm-up, release the brake lever
lock.
NOTE: Spark plugs can be
changed by the snowmobile owner if
qualified to do so. If the owner does
not feel qualified, take the snowmo-
bile to an authorized YAMAHA
Snowmobile dealer for inspection
and service. This service is at the
discretion and expense of the snow-
mobile owner.
7. To shut off the engine, turn the igni-
tion key to the OFF position or push
the emergency stop switch to the
DOWN position.
NOTE: When the engine is turned
off, wait for the gauge to com-
pletely power down before
attempting to start the engine.
CAUTION
Do not continuously run the starter
for more than 5 seconds at a time.
Start Switch Button
CAUTION
It is extremely important that the
engine is properly warmed up before
subjecting the engine to high speed
operation or heavy loads. The
engine should be allowed to idle at
least 3-4 minutes before it is oper-
ated at more than 1/2 throttle. In
extremely cold conditions, the
warm-up time will be longer. Cold
seizure and piston scuffing caused
by insufficient warm-up will not be
covered by warranty. Also, do not
idle the engine for excessively long
periods of time.
CAUTION
Always turn the ignition switch key
to the OFF position when the snow-
mobile is not being used. Leaving
the ignition switch in the ON posi-
tion will result in discharging the
battery and possible damage to the
battery.
U8MFS0E0.book Page 16 Thursday, April 25, 2019 7:15 AM

Page: 20

17
Braking
The following items are items that the
operator must be familiar with when
operating this snowmobile and its
hydraulic brake system. Important addi-
tional information on the proper mainte-
nance of the brake system is found in the
Maintenance section.
1. Use the brakes wisely. Each time the
brakes are applied in all hydraulic
brake systems (including automotive
applications), heat is transferred to
the brake fluid. The amount of heat
transferred during high speed stops
and/or repetitive use may be high
enough to boil the brake fluid and
cause the brakes to either fade or may
cause an unexpected loss of brakes. If
this occurs, the brake fluid requires a
cool-down period before the brakes
will again function properly.
This cool-down period will vary
depending upon the ambient air tem-
perature and the temperature of the
brake fluid. If loss of brakes has
occurred because of high fluid tem-
peratures, do not operate the snow-
mobile until the cool-down period
has expired and brake lever firmness
has returned.
2. Be sure to maintain the brake fluid at
the proper level and take care not to
get any moisture in the system as
moisture in the brake fluid lowers the
boiling point. If the brake fluid is ever
boiled (by high speed stops or repeti-
tive use) or if moisture is allowed to
enter the system, it must be changed.
Never substitute or mix different
types or grades of brake fluid.
3. Never ride the brake. Even main-
taining minimal pressure on the
brake lever will cause the brake pads
to drag on the disc and may overheat
the brake fluid.
4. The brake lever lock is not a parking
brake and should not be applied for
periods exceeding 5 minutes.
NEVER OPERATE THE SNOW-
MOBILE WITH THE BRAKE
LEVER LOCK ENGAGED.
5. Pumping the brake lever is permissi-
ble; however, if pumping the brake
lever more than twice is necessary to
obtain the necessary stopping power,
immediately take the snowmobile to
an authorized Yamaha Snowmobile
dealer for service. If not under war-
ranty, this service is at the discretion
and expense of the snowmobile
owner.
WARNING
Excessive, repetitive use of the
hydraulic brake for high speed
stops will cause overheating of the
brake fluid and premature brake
pad wear which will result in an
unexpected loss of brakes.
WARNING
Use only Yamaha approved DOT 4
brake fluid. Never substitute or mix
different types or grades of brake
fluid. Brake loss can result. Check
brake fluid level and pad wear
before each use. Brake loss can
result in severe injury or even death.
WARNING
The brake lever lock is not a parking
brake and should not be applied for
periods exceeding 5 minutes. The
brake lever lock maintains the brake
lever in the compressed position
and maintains pressure against the
brake disc; however, after a period
of time, the pressure applied to the
brake disc may relax below the
amount required to hold the snow-
mobile stationary.
U8MFS0E0.book Page 17 Thursday, April 25, 2019 7:15 AM

Page: 21

18
6. When new brake pads are installed,
a “burnishing” process is required.
Emergency Stopping
There are several methods of stopping or
slowing the snowmobile under a variety
of situations. Identified in the following
chart are the ways a snowmobile may be
brought to a stop and the effectiveness
under normal conditions.
Throttle/Ignition Monitor
Switch
The throttle control is equipped with a
monitor switch for safety purposes which
will stop the engine when a loss of return
spring force occurs. If ice forms in the
throttle system or if there is some other
malfunction of the throttle system result-
ing in a loss of return spring force, the
monitor switch will stop the engine when
the throttle control lever is released.
If the snowmobile engine stops abruptly
when the throttle control lever is released
and the activation of the monitor switch
is suspected, use the following proce-
dure:
1. Rotate the ignition key to the OFF
position.
2. Remove ice and snow from the
throttle system and wait 5-10 min-
utes for the engine heat to thaw ice
from the throttle system.
3. Test the throttle control lever by
compressing and releasing it several
times. The lever MUST return to the
idle position quickly and completely.
NOTE: If the throttle control lever
operates properly and the engine
does not start, compress the throt-
tle lever slightly (approximately 1/8
throttle) and try starting the engine.
If the engine now starts and stops
when the throttle lever is released,
take the snowmobile to an autho-
rized Yamaha Snowmobile dealer
for service. If not under warranty,
this service is at the discretion and
expense of the snowmobile owner.
4. If the throttle control lever operates
properly, rotate the ignition key to
the RUN position and go through
normal starting procedures.
NOTE: If the throttle control lever
operates properly and the engine
does not start, a malfunctioning
monitor switch may be the prob-
lem. Take the snowmobile to an
authorized Yamaha Snowmobile
dealer for service. If not under war-
ranty, this service is at the discre-
tion and expense of the
snowmobile owner. However, if a
dire emergency exists wherein the
engine must be started, disconnect
the throttle monitor switch located
in the right-side handlebar control.
Item Function
Emergency Stop
Switch
interrupts ignition circuit
Throttle/Ignition
Monitor Switch
interrupts ignition circuit
Ignition Switch interrupts ignition circuit
Brake slows the drive system
Tether interrupts ignition circuit
WARNING
If any malfunction of the throttle
system occurs (such as freezing in
fluffy snow) and the monitor switch
does not shut off the engine, press
down on the emergency stop
switch IMMEDIATELY to stop the
engine. DO NOT start the engine
until the malfunction in the throttle
system has been located and cor-
rected.
WARNING
If the throttle control lever does not
work properly, DO NOT ATTEMPT
TO START THE ENGINE.
U8MFS0E0.book Page 18 Thursday, April 25, 2019 7:15 AM

Page: 22

19
NOTE: If disconnection of the
throttle monitor switch is needed to
start the engine, take the snowmo-
bile to an authorized Yamaha Snow-
mobile dealer for service as soon as
possible. If not under warranty, this
service is at the discretion and
expense of the snowmobile owner.
NOTE: The monitor switch is now
bypassed. All other ignition/electri-
cal features (ignition switch, tether,
emergency stop switch, headlight,
taillight, and brake light) will oper-
ate properly.
WARNING
Under no circumstances should
disconnection of the throttle control
wiring harness be used as a substi-
tute for the monitor switch during
normal operation of the snowmo-
bile. Personal injury and damage
could occur if the throttle system
malfunctions or if the operator is
unable to stop the engine in an
emergency. If the snowmobile must
be operated with a disconnected
throttle control wiring harness,
EXTREME CAUTION MUST BE
TAKEN. NEVER EXCEED 6 KM/H (10
MPH) WITH THE THROTTLE CON-
TROL WIRING HARNESS DISCON-
NECTED.
U8MFS0E0.book Page 19 Thursday, April 25, 2019 7:15 AM

Page: 23

20
Lubrication
Chain Case
Checking Lubricant Level
NOTE: The snowmobile must be
on a level surface for this procedure.
1. Check the lubricant level in the
chain case by using the sight glass.
0746-115
NOTE: The correct level is when
the lubricant is at least halfway up
in the sight glass.
NOTE: Adding lubricant can be
done by the snowmobile owner if
qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized
Yamaha Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner.
2. If the lubricant level is low, remove
the right-side access panel.
3. Remove the three screws securing
the shift actuator to the chain case,
disconnect the actuator wiring har-
ness, and remove the actuator w/
extension, detent, and spring; then
add appropriate amount of Yamaha
Synthetic Chain Lube through the
shift actuator opening.
NOTE: Be sure to add a small
amount of white lithium grease to
the O-rings of the actuator exten-
sion and the shift actuator detent
block before installing.
4. Install the actuator extension and
gently rotate counter clockwise to
make sure the shift fork is in the for-
ward position. When the shift fork is
in the forward position, make sure
the notch in the extension is directed
downward.
YM-101
5. Install spring into the bottom of shift
actuator detent block and install into
the chain case cover. The notch in
the extension should be lined up
with the notch in the block.
YM-102
NOTE: To verify everything is
installed correctly, turn the exten-
sion counterclockwise. The notch
in the extension should not rotate
out of the detent block.
6. Rotate the extension clockwise
approximately 20° making sure not
to pull out the extension when rotat-
ing. This is only to aid in the instal-
lation of the actuator.
Full Level
U8MFS0E0.book Page 20 Thursday, April 25, 2019 7:15 AM

Page: 24

21
SNO-1247A
7. Install the actuator and secure using
the existing three Torx screws.
Tighten to 0.4 kg-m, (36 in-lb).
8. Connect the harness to the gear posi-
tion sensor; then secure the connec-
tor to the main harness using a Cable
Tie.
9. Install the lower console; then install
the seat, hood, and both access pan-
els.
10. Start the engine; then shift the snow-
mobile into and out of reverse three
times.
NOTE: If excessive build-up of
moisture or discolored oil is
detected in the chain case, it may
be necessary to replace the lube.
Replacing Lubricant
NOTE: Replacing the lubricant
can be done by the snowmobile
owner if qualified to do so. If the
owner does not feel qualified, take
the snowmobile to an authorized
Yamaha Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner.
1. Place the snowmobile on a level sur-
face. Remove both access panels
and the hood; then remove the
exhaust resonator.
2. Remove the three screws securing
the shift actuator to the chain case;
then disconnect the actuator wiring
harness and remove the actuator,
extension, detent, and spring.
3. Place a drain pain under the chain
case; then loosen the eleven screws
securing the chain case cover/oil
tank assembly to the chain case
housing starting with the bottom
screws first.
NOTE: Do not remove all eleven
screws completely until the chain
lube has been completely
removed. This will help keep
debris/oil out of the screw holes.
4. Remove all eleven screws; then
swing the chain case out of the way.
Account for a thrust washer on the
countershaft.
YM-128A
5. Inspect all chain case components
along with the cover seal for nicks or
damage.
6. Wipe clean the chain case cover and
housing free of old oil; then install
the cover and secure using the exist-
ing screws. Tighten to 1.65 kg-m (12
ft-lb).
7. Fill the chain case with 355 ml (12
oz) of Yamaha Synthetic Chain
Lube.
NOTE: Be sure to add a small
amount of white lithium grease to
the O-rings of the actuator exten-
sion and the shift actuator detent
block before installing.
8. Install the actuator extension and
gently rotate counter clockwise to
make sure the shift fork is in the for-
ward position. When the shift fork is
in the forward position, make sure
the notch in the extension is directed
downward.
U8MFS0E0.book Page 21 Thursday, April 25, 2019 7:15 AM

Page: 25

22
YM-101
9. Install spring into the bottom of shift
actuator detent block and install into
the chain case cover. The notch in
the extension should be lined up
with the notch in the block.
YM-102
NOTE: To verify everything is
installed correctly, turn the exten-
sion counter clockwise. The notch
in the extension should not rotate
out of the detent block.
10. Rotate the extension clockwise
approximately 20° making sure not
to pull out the extension when rotat-
ing. This is only to aid in the instal-
lation of the actuator.
SNO-1247A
11. Install the actuator and secure using
the existing three Torx screws.
Tighten to 0.4 kg-m, (36 in-lb).
12. Connect the harness to the gear posi-
tion sensor; then secure the connec-
tor to the main harness using a Cable
Tie.
13. Install the resonator and secure
using existing hardware.
14. Install the lower console; then install
the seat, hood, and both access pan-
els.
15. Start the engine; then shift the snow-
mobile into and out of reverse three
times.
Rear Suspension
This procedure should be done every 40
operating hours.
NOTE: Yamaha recommends that
low-temperature grease be used
for this procedure.
1. Using Handlebar Stand or Steering
Post Stand or a suitable substitute,
lay the snowmobile on its left side.
2. Lubricate all grease fittings with
low-temperature grease.
U8MFS0E0.book Page 22 Thursday, April 25, 2019 7:15 AM

Page: 26

23
Maintenance
Periodic Maintenance Checklist
Item Interval Page Remarks
Brake System Daily 30 Check for binding, leakage, and proper operation;
lever firmness, travel, caliper, disc, and pads
Cooling System — Liquid Daily 8,26 Check for leakage, damage, obstructions, cool-
ant level
Engine Oil Daily 24 Check oil level and for signs of leakage
Engine Oil — Initial 800 km (500 Mi) 24 Change oil
Engine Oil — After Initial 4000 km
(2500 Mi)
24 Change oil
Engine Oil Filter — Initial 800 km (500 Mi) 24 Change filter
Engine Oil Filter — After Ini-
tial
20000 km
(12500 Mi)
24 Change filter
Air Filter 4000 km
(2500 Mi)/
Seasonal
26 Check and clean (more frequently if ridden in
heavy snow dust or deep powder conditions).
Change if necessary
Battery Daily 9,27 Check for proper charge and tight connections
Stop Switches (Ignition,
Handlebar and Tether)
Daily — Check for proper operation
Hoses Daily — Check for damage, leakage, and wear
Headlight & Taillight/Brake
Light
Daily 44 Check for proper operation and cleanliness
Steering System Daily — Check for proper operation, tightness of bolts,
and binding
Throttle Control System Daily 18 Check for binding, sticking, proper operation,
throttle cable tension, and wear
Drive Belt Daily
Monthly
34 Check for wear, cracks, and fraying
Check length and width dimensions
Ski Wear Bars Daily 45 Check for wear and damage
Electrical Wiring Weekly — Check for wear, damage, and tight connections
Exhaust System Weekly 8 Check for damage, leakage, and obstructions
Nuts, Bolts, Fasteners Weekly — Check tightness
Shock Absorbers Weekly 38 Check for fluid leakage and damage and air
pressure (Fox Air Shocks)
Spark Plugs 4000 km
(2500 Mi)/
Seasonal
27 Check center electrode insulator color, carbon,
and gap
Valve Clearance 40000 km
(25000 Mi)
27 Check/adjust
Crankcase Breather System Seasonal — Check breather hose for cracks or damage and
replace as necessary
Suspension Weekly 38 Check for damage, loose components, and
proper adjustment
Track Tension/Alignment Weekly 35-37 Check/adjust as necessary
Wear Strips Weekly 46 Check for wear and damage
Wires & Cables Weekly — Check for wear, damage, and fraying
Fuel System — Tank, Pump,
& Vent Hose
Weekly — Check for damage, wear, obstructions, and leak-
age
Chain Case Daily 20 Check lube level and for leakage
Chain Case — Lubricant Seasonal 20 Replace
Drive Chain Tension — Initial 500 km (300 Mi) 33 Check tension and adjust as necessary
Drive Chain Tension — After
Initial
800 km (500 Mi) 33 Check tension and adjust as necessary
Heat Exchangers Monthly — Check for wear, leakage, and damage
Drive Clutch/Driven Clutch 4000 km
(2500 Mi)/
Seasonal
10 Check for damage, binding, and wear/remove
drive belt, clean drive clutch/driven clutch
Rear Suspension Monthly 22 Grease
U8MFS0E0.book Page 23 Thursday, April 25, 2019 7:15 AM

Page: 27

24
The longevity and safety of the snowmo-
bile can be increased by making periodic
checks of the items in the preceding
checklist.
If, at any time, abnormal noises, vibra-
tions, or improper working conditions of
any component of this snowmobile are
detected, DO NOT OPERATE THE
SNOWMOBILE. Take the snowmobile
to an authorized Yamaha Snowmobile
dealer for inspection and adjustment or
repair. If not under warranty, this service
is at the discretion and expense of the
snowmobile owner.
The snowmobile should be taken to an
authorized Yamaha Snowmobile dealer at
the end of each snowmobiling season for
general inspection and for off-season
storage servicing. This inspection and
servicing is at the expense of the snow-
mobile owner.
Fuel System
Gasoline Additives
Fuel de-icer can be used for all models.
Yamaha Fuel Stabilizer should also be
added to the last tank of gasoline before
storage.
Fuel Pickup Valves
If ever there is a restricted fuel flow and a
pickup valve is suspected, take the snow-
mobile to an authorized Yamaha Snowmo-
bile dealer for this service. If not under
warranty, this service is at the discretion
and expense of the snowmobile owner.
0747-833
Checking Engine Oil Level
NOTE: The snowmobile must be
on a level surface for this procedure.
1. Start the engine and let it idle and
warm up until the engine reaches
operating temperature.
2. Shut the engine off. Remove the
right-side access panel; then look at
the oil level tube on the backside of
the oil tank. The oil should be above
the MIN line and below the MAX
line.
XM451
3. If step 1 and 2 was followed and the
oil level is not within the “MAX to
MIN” range, add the recommended
engine oil through the oil tank fill
hole.
NOTE: Care must be taken not to
over-fill the oil tank.
4. Install the oil fill plug.
Changing Engine Oil/Filter
NOTE: Recycle or properly dis-
pose of the used engine oil.
1. Start the engine and let it idle and
warm up until the engine reaches
operating temperature, or if the
snowmobile was operated, allow the
engine to idle for approximately 30
seconds.
WARNING
Whenever any maintenance or
inspection is made on the fuel system
in which there may be fuel leakage,
there should be no welding, smoking,
open flames, etc., in the area.
Fuel Pickup
Valves
CAUTION
If the engine and oil are not at oper-
ating temperature the oil will not
read correctly in the oil level tube.
WARNING
Engine oil is extremely hot immedi-
ately after the engine is turned off.
Burning could occur if oil contacts
skin or clothing.
U8MFS0E0.book Page 24 Thursday, April 25, 2019 7:15 AM

Page: 28

25
2. Shut the engine off. Remove the
access panels and the hood.
3. Remove the Torx-head screws and
the rear access plate from beneath
the snowmobile.
4. Place a drain pan beneath the engine
oil drain screw; then remove the
screw and allow the oil to drain
completely.
YM-152A
5. Using Oil Filter Wrench, loosen (but
do not remove) the oil filter and
allow the oil to drain from the filter
into the drain pan; then remove the
filter.
NOTE: Ensure the O-ring is
removed with the oil filter. If the O-
ring remains attached to the crank-
case, oil leakage may occur.
6. Apply a light coat of fresh engine oil
to the seal of the new oil filter.
7. Install the new oil filter by turning
the oil filter by hand until the seal
has contacted the oil filter mounting
surface; then tighten the oil filter to
1.7 kg-m (12 ft-lb).
8. Install the engine oil drain screw
with a new gasket. Tighten the screw
to 1.0 kg-m (7.2 ft-lb).
9. Install the rear access plate. Tighten
the screws to 1.2 kg-m (9 ft-lb).
10. Remove the four Torx-head screws
securing the right-side footrest to the
tunnel and the support; then with a
drain pan in position, remove the
drain plug from the oil tank.
746-121A
NOTE: To aid in draining the oil
from the tank, position a funnel
between the tank and the opening
of the tunnel running board.
11. After the oil has drained completely,
install the drain plug with a new O-
ring and tighten to 2.2 kg-m (16 ft-lb).
12. Install the four screws securing the
right-side footrest. Tighten the
screws to 0.5 kg-m (44 in.-lb).
13. Pour 2.8 L (3 US quarts) of engine
oil in through oil tank fill hole.
14. Install the oil tank plug then start the
engine and let it idle. The oil pres-
sure light may illuminate briefly
after starting but should go out
within 10 seconds. If the light does
not go out within 10 seconds, the
engine will automatically shut
down. If a shutdown occurs check
that there are no leaks and that oil
has been added to the oil tank before
trying to start the engine again. If the
engine shuts down automatically, the
key will have to be turned off for 5
seconds before the engine can be
restarted. If the light does not stay
off after starting the engine a second
time, take the snowmobile to and
authorized Yamaha Snowmobile
dealer for service.
15. Shut the engine off; then look at the
oil level tube on the backside of the
oil tank. The oil should be above the
MIN line but not above the MAX
line.
Torx-Head Screws
Oil Drain Plug
U8MFS0E0.book Page 25 Thursday, April 25, 2019 7:15 AM

Page: 29

26
XM451
16. If step 13 was followed and the oil
level is not within the “MAX to
MIN” range, add the recommended
engine oil through the oil tank fill
hole.
NOTE: Care must be taken not to
over-fill the oil tank.
17. Install the oil fill plug; then install
the hood and access panels.
Coolant Level
NOTE: Use a good quality, ethyl-
ene glycol-based, automotive-type
coolant.
Locate the filler neck located above the
resonator; then remove the coolant cap
from the filler neck. Verify that the coolant
is at the bottom of the tab in the filler neck.
SNO-867
Locate the coolant tank above the drive
clutch; then remove the plug from the
coolant tank. Add coolant to the full level
on the tank. Install the plug.
YM-147A
Remove the plug in the vapor tank
located above the exhaust. Once the plug
is removed, verify the coolant is just
below the treads. Install the plug.
ZR-296
Air Filter
The air filter inside the air filter housing
must be clean to provide good engine
power and gas mileage.
If operating the snowmobile in heavy
snow dust or deep powder conditions,
the air filter should be inspected for
snow buildup or cleaned.
1. Remove the left-side access panel;
then remove the clips securing the
air filter housing cover.
WARNING
Always check the coolant level with
the engine cold.
Full Level
CAUTION
If the coolant is below the neck and
if coolant has been added, immedi-
ately inspect for leakage and/or
damage. If leakage or damage is
detected, take the snowmobile to
an authorized Yamaha Snowmobile
dealer for service. If not under war-
ranty, this service is at the discre-
tion and expense of the snowmobile
owner.
Full Level
(Cold)
U8MFS0E0.book Page 26 Thursday, April 25, 2019 7:15 AM

Page: 30

27
YM-150A
2. Loosen the two knobs securing the
air filter to the inside of the housing;
then remove the filter.
YM-151A
3. Install the filter and secure using the
two knobs.
4. Install the air filter housing cover
and secure with the clips.
5. Install the left-side access panel.
Spark Plugs
NOTE: Always use the recom-
mended spark plugs in the engine.
See the appropriate specifications
sheet for correct spark plug gap.
1. Disconnect the main harness from the
ignition coils; then remove the ignition
coils from the cylinder head cover.
2. Remove the three spark plugs.
NOTE: Prior to installing the
spark plugs, check the gap
between the electrode and ground
strap. The clearance should be 0.7-
0.8 mm (0.028-0.031 in.).
3. Install new spark plugs. Tighten to
1.3 kg-m (9.4 ft-lb).
4. Install the ignition coils onto the cyl-
inder head cover making sure they
are fully seated. Connect the main
harness to the ignition coils.
5. Install the hood and access panels.
Checking/Adjusting Valve
Clearance
After 40,000 km (25,000 miles), valve
clearance should be checked and adjusted
as necessary.
NOTE: Take the snowmobile to
an authorized Yamaha Snowmobile
dealer for inspection and service.
This service is at the discretion and
expense of the snowmobile owner.
Battery
These sealed batteries, after being in ser-
vice, require regular cleaning and charg-
ing in order to deliver peak performance
and maximum service life. The following
procedure is recommended for cleaning
and maintaining sealed batteries. Always
read and follow instructions provided
with battery chargers and battery prod-
ucts.
NOTE: Battery maintenance may
be done by the snowmobile owner
if qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized
Yamaha Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner.
CAUTION
If adjusting spark plug gap is nec-
essary, do not use the center elec-
trode as a leverage point. Damage
to the plug may occur.
CAUTION
It is critical that the checking/
adjusting valve clearance be done
at the recommended intervals or
severe engine damage may occur.
CAUTION
Jump-starting the vehicle without a
battery is not advisable as it may
cause damage. Additionally, run-
ning the unit without a battery in
place or the use of a “Jumper
Pack” could cause damage to the
electrical system.
U8MFS0E0.book Page 27 Thursday, April 25, 2019 7:15 AM

Page: 31

28
1. Remove the Torx-head screw from
the rear underside of the seat; then
remove the seat. On 2-up models,
remove the passenger and operator
seats.
2. Remove the negative battery cable
and ground wire; then remove the
positive cable.
NOTE: For installing purposes
prior to removing the battery, note
the routing and securing locations
of the cables and harness wires.
3. Remove the two lock nuts securing
the battery bracket/solenoid to the
seat-base; then move the bracket up
and out of the way and remove the
battery.
0747-528
4. Thoroughly wash the battery with soap
and water; then using a wire brush,
clean the battery posts and cable ends
removing all corrosive buildup.
Replace damaged cables or cable ends.
NOTE: If battery posts or cable
ends have a build-up of white/green
powder residue, apply water and
baking soda to neutralize acid; then
flush off with warm soapy water.
5. Using a multimeter, test the battery
voltage. The meter must read no less
than 12.8 DC Volts for a fully
charged battery.
NOTE: At this point if the meter
reads as specified, the battery may
be returned to service (see step 9).
6. If the meter reads less than specified
voltage, charge the battery using the
following guidelines.
A. When using an automatic battery
charger, always follow the char-
ger manufacturer’s instructions.
WARNING
Improper handling or connecting of
a battery may result in severe injury
including acid burns, electrical
burns, or blindness as a result of an
explosion. Always remove rings and
watches. Any time service is per-
formed on a battery, the following
must be observed: keep sparks,
open flame, cigarettes, or any other
flame away. Always wear safety
glasses. Protect skin and clothing
when handling a battery. When ser-
vicing a battery in an enclosed
space, keep the area well-venti-
lated.
WARNING
Battery posts, terminals, and
related accessories contain lead
and lead compounds, chemicals
known to the state of California to
cause cancer and reproductive
harm. Wash hands after handling.
CAUTION
Make sure to disconnect the seat
heater harness connector prior to
removing the seat.
WARNING
Avoid spillage and contact with skin,
eyes, and clothing.
CAUTION
Do not charge the battery while it is
in the snowmobile with the battery
terminals connected.
CAUTION
Do not remove seal strip on a
sealed battery.
WARNING
Battery acid is harmful if it contacts
eyes, skin, or clothing. Care must be
taken whenever handling a battery.
Lock Nuts
Battery Bracket
U8MFS0E0.book Page 28 Thursday, April 25, 2019 7:15 AM

Page: 32

29
B. When using a constant-current
battery charger, use the follow-
ing Battery Charging Chart.
NOTE: If the battery voltage is
11.5 DC Volts or less, some char-
gers may “cut off” and fail to
charge. If this occurs, connect a
fully charged booster battery in
parallel (positive to positive and
negative to negative) for a short
period of time with the charger
connected. After 10-15 minutes,
disconnect the booster battery
leaving the charger connected and
the charger should continue to
charge. If the charger “cuts off,”
replace the battery.
7. After charging the battery for the
specified time, remove the battery
charger and allow the battery to sit
for 1-2 hours.
8. Connect the multimeter and test the
battery voltage. The meter should
read no less than 12.8 DC Volts. If
the voltage is as specified, the bat-
tery is ready for service.
NOTE: If voltage in step 8 is below
specifications, charge the battery
an additional 1-5 hours; then retest.
The battery is ready for service.
9. Place the battery into position in the
snowmobile; then coat the battery
posts and cable ends with a light
coat of multi-purpose grease.
10. Secure the red positive cable to the
positive terminal on the battery
using a cap screw, lock washer, and
a flat washer. Tighten securely.
11. Secure the main black negative
cable and the small black negative
cable to the battery using a cap
screw, lock washer, and a flat
washer. Tighten securely.
NOTE: Ensure the harness wires
and cables are routed properly as
noted during removing battery pro-
cedure.
XM167A
12. Install the battery bracket/solenoid
and tighten the two lock nuts to 1.2
kg-m (105 in.-lb); then install the
seat and secure with the Torx-head
screw. Tighten securely.
NOTE: Prior to lowering and
securing the seat, connect the seat
heater harness connector.
CAUTION
Never exceed the standard charg-
ing rate.
WARNING
An overheated battery could explode
causing severe injury or death.
Always monitor charging times and
charge rates carefully. Stop charging
if the battery becomes very warm to
the touch. Allow it to cool before
resuming charging.
Battery Charging Chart
(Constant-Current Charger)
Battery
Voltage
(DC)
Charge
State
Charge Time
Required (at 1.5-
2.0 Amps)
12.8-13.0 100% None
12.5-12.8 75%-100% 3-6 hours
12.0-12.5 50%-75% 5-11 hours
11.5-12.0 25%-50% 13 hours (minimum)
11.5 or less 0-25% 20 hours (minimum)
CAUTION
Before installing the battery, make
sure the ignition switch is in the
OFF position.
CAUTION
Connecting cables in reverse (pos-
itive to negative and negative to
positive) can cause serious dam-
age to the electrical system.
Cable Tie
U8MFS0E0.book Page 29 Thursday, April 25, 2019 7:15 AM

Page: 33

30
Fuses
Fuses protect the snowmobile electrical
system from overloading. If electrical
parts in the snowmobile are not working,
the system may have been overloaded and
caused a blown fuse. Before repairing or
replacing any electrical part, check the
appropriate fuses. If a fuse blows (opens a
circuit), all the parts of the snowmobile
that use that circuit will not work.
Once which fuse to check has been deter-
mined, perform the following steps:
1. Remove both access panels and the
hood. Locate the fuse block in front
of the engine.
YM146A
NOTE: There are spare fuses
beneath the fuse block cover.
2. Remove the suspected fuse.
NOTE: Fuse function descriptions
are next to the fuse contacts in the
fuse block.
3. Look through the clear side of the
fuse to see if the element inside is
burned or separated. If it is, the fuse is
blown and should be replaced with a
fuse of the correct amperage rating.
4. Install the fuse block cover and
install the hood and access panels.
Even after replacing a fuse, it may con-
tinue to blow if the cause of the overload
is not determined. If the fuse continues to
blow, take the snowmobile to an autho-
rized Yamaha Snowmobile dealer for ser-
vice.
If not under warranty, this service is at
the discretion and expense of the snow-
mobile owner.
Brake System
Yamaha recommends that the brake sys-
tem (brake lever, fluid reservoir, hose,
caliper, pads, and brake disc) be checked
daily for fluid leakage, wear, or damage
and for proper operation. Also, the brake
fluid level must be checked every time
before starting the engine.
Checking/Adding Brake Fluid
1. With the brake fluid reservoir in a
level position and the cover
removed, check the fluid level. The
brake fluid level must be at the high
brake fluid mark in the reservoir.
0752-476
WARNING
Always replace a fuse with one hav-
ing the same specified amperage
rating. Using a fuse with a higher
rating can cause severe wire dam-
age and could start a fire.
WARNING
DO NOT operate the snowmobile
when the brake lever lock is
engaged or when any component in
the brake system is damaged,
worn, or adjusted improperly. If the
snowmobile is operated and the
brake system is not functioning
properly, severe personal injury
could result.
High Brake Fluid Mark
Low Brake Fluid Mark
U8MFS0E0.book Page 30 Thursday, April 25, 2019 7:15 AM

Page: 34

31
2. If the brake fluid is below the high
brake fluid mark, add Yamaha
approved DOT 4 brake fluid until
the fluid is at the recommended
level. Install and secure the reservoir
cover. Do not allow moisture to con-
taminate the brake system.
Changing Brake Fluid
The brake fluid must be changed on a
regular basis and whenever the brake
fluid has been overheated or contami-
nated. The brake fluid should be changed
every 1600 km (1000 miles) or at the end
of the snowmobiling season, whichever
occurs first. Take the snowmobile to an
authorized Yamaha Snowmobile dealer
for this service. This service is at the dis-
cretion and expense of the snowmobile
owner.
Checking Brake Lever Travel
Before each use, check the brake lever
travel using the following procedure:
1. Compress the brake lever fully.
NOTE: Do not pump the brake
lever as it will produce an inaccu-
rate reading.
2. Measure the distance between the
brake lever and the handlebar. The
distance must be greater than 12.8
mm (1/2 in.).
0752-475Y
3. If the resultant distance is less than
specified, take the snowmobile to an
authorized Yamaha Snowmobile
dealer for service. If not under war-
ranty, this service is at the discretion
and expense of the snowmobile owner.
Bleeding Brake System
If the brake lever feels spongy when
applied, the brake system may need to be
bled. To bleed the brake, use the follow-
ing procedure:
NOTE: The brake system may be
bled by the snowmobile owner if
qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized
Yamaha Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner.
1. Remove the reservoir cover and (if
necessary) fill the reservoir to the
high brake fluid mark with Yamaha
approved DOT 4 brake fluid.
CAUTION
Brake fluid is highly corrosive. Do
not spill brake fluid on any surface
of the snowmobile.
WARNING
Do not overfill the brake fluid reser-
voir. Overfilling the reservoir may
cause the brake system to hydrauli-
cally lock. Use only Yamaha
approved DOT 4 brake fluid. Never
substitute or mix different types or
grades of brake fluid. Brake loss
can result. Brake loss can result in
severe injury or even death.
WARNING
Do not operate the snowmobile if
the compressed distance between
the brake lever and the handlebar is
less than 12.8 mm (1/2 in.). Brake
loss may occur. Brake loss can
result in severe personal injury.
CAUTION
Brake fluid is highly corrosive. Do
not spill brake fluid on any surface
of the snowmobile.
WARNING
Use only Yamaha approved DOT 4
brake fluid. Any substitute may
result in a loss of brakes.
12.8 mm (1/2 in.)
U8MFS0E0.book Page 31 Thursday, April 25, 2019 7:15 AM

Page: 35

32
2. Slide a piece of flexible tubing over
the ball of the bleeder valve and
direct the other end into a container.
XM145A
3. Slowly compress the brake lever
until maximum pressure is attained;
then hold the lever in the com-
pressed position to maintain pres-
sure. Open the bleeder valve to
release the fluid and air. When the
fluid stops, close the bleeder valve;
then release the brake lever.
4. Repeat step 3 until the brake fluid
flows free of air bubbles.
NOTE: It may be necessary to
refill the reservoir during the bleed-
ing process. Never allow the brake
fluid to go below the low brake
fluid mark in the reservoir.
5. When the brake fluid is free of all air
and the brake lever feels firm when
compressed, fill the reservoir to the
high brake fluid mark; then install
and secure the cover. Remove the
tube from the bleeder valve.
Checking/Changing Brake Pads
The condition of the brake pads must be
checked daily and changed if worn or
damaged. To check and change the brake
pads, use the following procedure:
NOTE: The brake pads may be
changed by the snowmobile owner
if qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized
Yamaha Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner.
NOTE: When installing new brake
pads, always install them as a set.
Never install just one pad or use
brake pads which have been used
in another snowmobile.
1. Remove the brake fluid reservoir
cover; then remove most of the
brake fluid from the reservoir. Install
the cover.
NOTE: The above procedure will
allow room for the fluid from the
caliper when the pistons are
pushed into the caliper for install-
ing new brake pads. Replacing the
cover will prevent fluid spillage.
2. Open the left-side access panel.
3. Remove the Torx-head screws
securing the brake shield to the belt
guard mount; then remove the cap
screws securing the brake shield to
the brake caliper.
4. Carefully move the shield out of the
way; then remove the hairpin clip
securing the brake pads to the cali-
per assembly.
5. Using a pair of pliers, pull the outer
brake pad out of the caliper assembly.
PC013
NOTE: Changing one pad at a
time will prevent one piston from
pushing out the other piston from
the caliper.
CAUTION
Brake fluid is highly corrosive. Do
not spill brake fluid on any surface
of the snowmobile.
U8MFS0E0.book Page 32 Thursday, April 25, 2019 7:15 AM

Page: 36

33
6. Measure the thickness of the brake
pad. The brake pad thickness must
be greater than 1.0 mm (0.04 in.). If
the brake pad thickness is less than
specified, replacement of both pads
is necessary.
PC011A
7. Using a flat-blade tool, slowly and
carefully push the piston into the
caliper.
8. Position the outer brake pad into the
caliper; then install the hair-pin clip
into the caliper assembly.
9. Repeat steps 5-8 for the inner pad; then
secure the pad with the hairpin clip.
10. Remove the reservoir cover and
remove the remaining fluid; then fill
the reservoir with fresh fluid and
install the cover.
11. Pump the brake lever to ensure cor-
rect positioning of the brake pads
and proper brake lever travel; then
release.
NOTE: If brake lever travel is not
within specification, bleed the
brake system.
12. Remove the reservoir cover and fill
the reservoir (if necessary) to the
proper level with fresh brake fluid;
then install the cover.
13. Secure the brake shield; then close
and secure the left-side access panel.
NOTE: When new brake pads are
installed, a “burnishing” process is
required (see Burnishing Brake
Pads sub-section).
Burnishing Brake Pads
After changing brake pads, the new brake
pads must be burnished to achieve full
braking effectiveness. Braking distance
will be extended until brake pads are
properly burnished.
To properly burnish the brakes, use fol-
lowing procedure:
1. Choose an area sufficiently large to
safely accelerate to 50-65 km/h (30-
40 mph) and to brake to a stop.
NOTE: This procedure can also
be accomplished using a shielded
jack stand.
2. Accelerate to 50-65 km/h (30-40
mph); then compress brake lever to
decelerate to a stop.
NOTE: Lightly apply the brake
lever to come to an easy stop; do
not overapply brakes or “lock up”
the track.
3. Repeat procedure 10-15 times allow-
ing some cooling between stops.
NOTE: Do not repeat too soon or
too aggressively as to get the
brake disc “red hot.”
NOTE: This procedure stabilizes
the pad material and extends the
life of the pads.
Chain Tension
1. Remove both access panels; then
remove the hood.
2. Remove the five Torx screws and
washers securing the turbo heat
shield to the turbo. Remove the
shield.
YM-241
WARNING
Do not attempt sudden stops or put
yourself into a situation where a
sudden stop will be required until the
brake pads are properly burnished.
U8MFS0E0.book Page 33 Thursday, April 25, 2019 7:15 AM

Page: 37

34
3. Remove the six Torx screws secur-
ing the resonator to the turbo; then
remove the spring securing the reso-
nator. Remove the resonator and
account for a gasket.
NOTE: Apply a small amount of
penetrating oil to the Torx screws
before removing the screws. Dis-
assemble with hand tools and T50
ball head Torx bit (p/n 90890-
11148/YS-11148).
XM489
4. Loosen the jam nut.
5. Turn the chain tension adjustment
bolt clockwise until it is finger tight;
then loosen it 1 1/2 turns.
0747-831
6. While holding the bolt with a
wrench, tighten the jam nut to 2.4
kg-m (18 ft-lb).
7. Install the resonator and secure
using the existing gasket, spring, and
cap screws. Tighten the screws to
1.2 kg-m (9 ft-lb) then to 2.4 kg-m
(18 ft-lb) in a crisscross pattern.
NOTE: Apply a small amount of
high temperature (Copper Based)
anti-seize to the threads of the
screws. Assemble with hand tools
and T50 ball head Torx bit (p/n
90890-11148/YS-11148).
8. Install the turbo heat shield and
secure using the existing screws and
washers. Tighten securely.
9. Install the hood and access panels.
Drive Belt
The drive belt transfers power from the
drive clutch to the driven clutch. If the
belt is worn, cracked, or stretched, maxi-
mum power will not be transmitted and
the belt could also fail and therefore must
be replaced. Periodic checks (at least
once a month under normal usage) of two
drive belt specifications are essential.
1. Measure the outside circumference of
the drive belt. The belt should be
within 1118-1126 mm (44.0-44.3 in.).
2. Measure the outside width of the drive
belt. The belt should be at least 34.5
mm (1.36 in.) on a new belt or 32.5
mm (1.28 in.) on a broken in belt.
3. Check the belt for cracking, fraying,
etc.
If any of the specifications or conditions
are unsatisfactory, replace the drive belt.
NOTE: Drive belts should be pur-
chased from an authorized Yamaha
Snowmobile dealer, as Yamaha
drive belts are made to exact spec-
ifications and of quality material.
Belts made by other manufacturers
may not be of the same specifica-
tions or quality and, therefore,
usage could result in poor perfor-
mance and premature belt failure.
NOTE: Before starting the snow-
mobile in extremely cold tempera-
tures, the drive belt should be
removed and warmed up to room
temperature. Once the drive belt is
at room temperature, install the
drive belt.
Also, new drive belts have a break-in
period of 40 km (25 miles). After install-
ing a new drive belt, drive the snowmobile
for 40 km (25 miles) at 3/4 throttle or less.
Jam Nut
Adjustment
Chain Adjuster
U8MFS0E0.book Page 34 Thursday, April 25, 2019 7:15 AM

Page: 38

35
By revving the engine up and down (but
not exceeding 100 km/h [60 mph]), the
exposed cord on the side of a new belt will
be worn down. This allows the drive belt
to gain its optimum flexibility and will
extend drive belt life.
Removing Drive Belt
NOTE: Changing a drive belt can
be done by the snowmobile owner if
qualified to do so. If the owner does
not feel qualified, take the snowmo-
bile to an authorized Yamaha Snow-
mobile dealer for this service. This
service is at the discretion and
expense of the snowmobile owner.
1. Place the snowmobile on a level sur-
face and engage the brake lever
lock.
2. Open the left-side access panel.
3. Rotate the driven clutch sliding
sheave clockwise (1); then push
toward the engine (2) so it will sepa-
rate from the fixed sheave.
4. Remove the drive belt by pulling it
up and over the fixed sheave.
SNO-336
Installing Drive Belt
NOTE: Before installing the drive
belt, use a suitable cleaning sol-
vent to thoroughly clean the
sheaves.
1. Open the left-side access panel.
2. Rotate the driven clutch sliding
sheave clockwise (1); then push
toward the engine (2) so it will sepa-
rate from the fixed sheave.
3. Install the drive belt (3) between the
sheaves.
SNO-326
SNO-327
4. Install the left-side access panel.
Track Tension
Track tension is directly related to the
overall performance of the snowmobile.
If the track is too loose, it may slap
against the tunnel causing wear or it may
“ratchet” on the track drive sprockets. If
extremely loose, the idler wheels may
climb over the track lugs forcing the
track against the tunnel causing the track
to “lock.” Yamaha recommends that the
track tension be checked daily during the
first 500 km (300 miles) of operation and
once a week thereafter and adjusted
according to need. The track will stretch
and take a “set” during break-in. Track
CAUTION
Never run the engine with the drive
belt removed. Excessive revving of the
engine could result in serious engine
damage and drive clutch failure.
WARNING
Never operate the snowmobile with-
out the access panel secured in
place.
U8MFS0E0.book Page 35 Thursday, April 25, 2019 7:15 AM

Page: 39

36
deflection must be maintained within the
recommended range.
Checking Track Tension
1. Remove excess ice and snow buildup
from the track, track drive sprockets,
and the inside of the skid frame.
2. Elevate the snowmobile on a
shielded safety stand high enough to
use a spring scale.
3. At the mid-point of the track (on the
bottom side), hook a spring scale
around a track clip; then pull down
on the scale to 9 kg (20 lb). Measure
the deflection (distance) between the
bottom of the wear strip and the
inside surface of the track clip. Mea-
surement should be 50 mm (2.0 in.).
0752-279
NOTE: Measurement is from the
bottom of the wear strip at the
point of the shock pad on the slide
rail.
NOTE: Only tighten track until the
track does not ratchet. Too tight of
a track will cause the rear suspen-
sion to not work properly.
Adjusting Track Tension
NOTE: To ensure proper track
tension adjustment, perform all
adjustments on both sides of the
snowmobile.
1. Loosen the idler wheel axle cap
screws.
0752-479
0752-481
2. If the deflection (distance between
the bottom of the wear strip and the
inside surface of the track clip)
exceeds specifications, tighten the
adjusting bolts to take up excessive
slack in the track.
3. If the distance between the bottom of
the wear strip and the inside surface
of the track clip is less than specified,
loosen the adjusting bolts to increase
the slack in the track.
4. Check track alignment.
5. After proper track tension is
obtained, tighten the idler wheel
axle cap screws to 4.7 kg-m (34 ft-
lb); then tighten the adjusting bolts
securely against the axle.
WARNING
Track tension must be properly
maintained. Personal injury could
result if a track is allowed to
become excessively loose.
WARNING
DO NOT attempt to check or adjust
track tension with engine running.
Turn ignition key to the OFF posi-
tion. Personal injury could result
from contact with a rotating track.
Deflection
Tension
CAUTION
Always maintain track tension
within recommended specification.
Track Adjuster
Adjusting Bolts
Rear Idler Wheels
Axle Cap Screw
Track Adjuster
Adjusting Bolt
Rear Idler Wheels
Axle Cap
Screw
U8MFS0E0.book Page 36 Thursday, April 25, 2019 7:15 AM

Page: 40

37
NOTE: Since track tension and
track alignment are interrelated,
always check both even if only one
adjustment seems necessary.
Track Alignment
Proper track alignment is obtained when
the rear idler wheels are equal distance
from the inner track drive lugs. Excessive
wear to the idler wheels, drive lugs, and
track will occur if the track is improperly
aligned. Yamaha recommends that the
track alignment be checked once a week
or whenever the track tension is adjusted.
Checking Track Alignment
1. Remove excess ice and snow
buildup from the track, track drive
sprockets, and the inside of the skid
frame.
2. Position the tips of the skis against a
wall; then using a shielded safety
stand, raise the rear of the snowmo-
bile off the floor making sure the
track is free to rotate.
3. Start the engine and accelerate
slightly. Use only enough throttle to
turn the track several revolutions.
SHUT ENGINE OFF.
NOTE: Allow the track to coast to
a stop. DO NOT apply the brake
because it could produce an inac-
curate alignment condition.
4. When the track stops rotating, check
the relationship of the outer track
lugs and the slide rails. If the slide
rails are centered, no adjustment is
necessary.
ONS-062
0752-482
5. If the idler wheels are not centered,
an adjustment is necessary.
Adjusting Track Alignment
1. On the side of the track which has
the inner track drive lugs closer to
the rear idler wheel, loosen the idler
wheel axle cap screw; then rotate the
adjusting bolt clockwise 1 to 1 1/2
turns.
WARNING
Always make sure the adjusting
bolts are snug against the axle and
the idler wheel cap screws are tight-
ened to specifications. Failure to do
so could cause the track to become
extremely loose and, under some
operating conditions, allow the idler
wheels to climb over the track lugs
forcing the track against the tunnel
causing the track to “lock.” If a track
“locks” during operation, severe
personal injury could result.
WARNING
Make sure the ignition key is in the
OFF position and the track is not
rotating before checking or adjust-
ing track alignment. Personal injury
could result if contact is made with a
rotating track.
WARNING
The tips of the skis must be posi-
tioned against a wall or similar
object.
WARNING
DO NOT stand behind the snowmo-
bile or near the rotating track.
NEVER run the track at high speed
when the track is suspended.
Idler Wheel Assembly
Outer Track Lug Outer Track Lug
Idler Wheel Assembly
Outer Track Lug Outer Track Lug
U8MFS0E0.book Page 37 Thursday, April 25, 2019 7:15 AM

Page: 41

38
0752-479
0752-481
2. Check track alignment and continue
adjustment until proper alignment is
obtained.
NOTE: Make sure correct track
tension is maintained after adjust-
ing track alignment.
3. After proper track adjustments are
obtained and the adjusting bolts are
snug against the axle housings,
tighten the idler wheel axle cap
screws to 4.7 kg-m (34 ft-lb).
4. Field test the track under actual con-
ditions.
5. After the field test, check the align-
ment of the track. If additional
adjustment is necessary, repeat
Adjusting Track Alignment proce-
dure.
Suspension
The suspension should be adjusted for
the operational needs and riding prefer-
ence of the operator.
The front shock springs or shock air pres-
sure determines the amount of ski pres-
sure and the reaction of the front
suspension to rough terrain. The amount
of ski pressure can also be changed by
adjusting the length of the skid frame
front arm limiter straps.
The rear arm shock absorber setting or
springs influences the load carrying capa-
bility of the snowmobile and should be
adjusted for the weight and riding prefer-
ence of the operator.
Gas Shocks
Each shock absorber should be visibly
checked weekly for fluid leakage, cracks
or breaks in the body, or a bent shaft. If
any one of these conditions is detected,
replacement is necessary. Take the snow-
mobile to an authorized Yamaha Snow-
mobile dealer for this service. If not
under warranty, this service is at the dis-
cretion and expense of the snowmobile
owner.
WARNING
Always make sure the adjusting
bolts are snug against the axle and
the idler wheel cap screws are tight-
ened to specifications. Failure to do
so could cause the track to become
extremely loose and, under some
operating conditions, allow the idler
wheels to climb over the track lugs
forcing the track against the tunnel
causing the track to “lock.” If a
track “locks” during operation,
severe personal injury could result.
Track Adjuster
Adjusting Bolts
Rear Idler Wheels
Axle Cap Screw
Track Adjuster
Adjusting Bolt
Rear Idler Wheels
Axle Cap
Screw
WARNING
Read a nd understand the following
information before handling shock
absorbers that contain highly pres-
surized nitrogen gas.
• Do not tamper with or attempt
to open the cylinder assemblies.
• Do not subject the shock
absorbers to an open flame or
other high heat source. This
may cause the unit to explode
due to excessive gas pressure.
• Do not deform or damage the
cylinders in any way. Cylinder
damage will result in poor
damping performance.
• Do not dispose of a damaged or
worn out shock absorber your-
self. Take the shock absorber to
a Yamaha dealer for any service.
U8MFS0E0.book Page 38 Thursday, April 25, 2019 7:15 AM

Page: 42

39
FOX Shocks
If service work is needed on any FOX
shocks, the shock must be removed and
sent to FOX or any FOX distributor for
any service work. For FOX shock infor-
mation, log on to www.ridefox.com.
Each shock absorber should be visibly
checked weekly for fluid leakage, cracks
or breaks in the body, or a bent shaft. If
any one of these conditions is detected,
replacement is necessary. Take the snow-
mobile to an authorized Yamaha Snow-
mobile dealer for this service. If not under
warranty, this service is at the discretion
and expense of the snowmobile owner.
Adjusting Front Ski Shock
The front ski shock springs are individually
adjustable for the terrain conditions and
driving style of the operator. The spring
adjuster nut has been set at the factory so the
correct amount of threads are exposed
between the adjuster nut and the threaded
shock body as an initial setting. Additional
ski pressure can be obtained by tightening
the spring tension; ski pressure can be
decreased by relaxing spring tension.
NOTE: Equal adjustments should
be maintained on both sides of the
snowmobile.
Front ski shock spring preload adjust-
ment is accomplished by loosening the
adjuster nut locking collar (B) from the
adjuster nut (A) and using the Spring
Adjuster Tool from the tool kit, rotating
the adjuster nut in whichever direction is
desired. Tighten the locking collar
against the adjuster nut.
0748-941
To adjust the damping, use the adjust-
ment lever located above the EVOL
chamber on the shock. There are three
settings that may be chosen 1, 2, or 3.
Setting #3 is the stiffest and most con-
trolled position.
0745-159
FOX iQS Shocks
(Modifying customized DRIVER 1
and DRIVER 2 settings)
The iQS shocks are adjustable by choos-
ing an overall compression setting (Soft,
Medium or Firm) for both the front and
rear shocks, or two customized driver
profiles that fine tune the ride separately
between the front ski shocks and rear
skid shock. Adjustments may be made
while the snowmobile is in motion using
the gauge control on the handlebar and
the gauge.
To set the customized driver profiles,
press and hold the Lower Left and Lower
Right Buttons on the gauge; then press
the Upper Left Button or Lower Left But-
ton until the Advanced screen appears.
Press the Lower Right Button to select
that screen.
ZR-297
Press the Upper Left or Lower Left But-
ton to select DRIVER 1 or DRIVER 2;
then press the Lower Right Button to
choose that DRIVER.
Threaded
Shock Body
U8MFS0E0.book Page 39 Thursday, April 25, 2019 7:15 AM

Page: 43

40
ZR-298
ZR-299
The compression of the front ski shocks
and rear skid shock are separately adjust-
able to the settings of Soft, Medium or
Firm.
First, the ski setting will blink on the
screen. To adjust the setting, press the
Upper Left or Lower Left Button; then
press the Lower Right Button to save the
setting. Next, the rear track setting will
blink. To adjust the setting, press the
Upper Left or Lower Left Button; then
press the Lower Right Button to save the
setting.
Press the Upper Left or Lower Left But-
ton to select the other DRIVER and
repeat the steps above to adjust and save
the settings.
When the settings in each DRIVER have
been saved, press the Lower Left Button
to choose Exit and then press the Lower
Right Button.
FOX iQS Shocks
(Selecting suspension setting)
With the engine running, press the center
of the gauge control button located on the
left-side handlebar control.
ONS-068
The iQS screen will appear and show the
current suspension setting at the bottom
of the screen.
Press the left or right side of the gauge
control button to select one of the follow-
ing suspension settings:
DRIVER 1 or DRIVER 2 for the custom-
ized driver profile; or
SOFT, MED or FIRM for the overall
shock compression setting.
YM-244
YM-245
Gauge Control
U8MFS0E0.book Page 40 Thursday, April 25, 2019 7:15 AM

Page: 44

41
YM-219
YM-220
YM-221
The suspension setting may be changed
when the snowmobile is in motion and
whenever the iQS screen displays the
suspension setting.
Press the center of the gauge control but-
ton to exit the iQS screen.
Adjusting FOX Air Shocks
NOTE: It is recommended to
monitor the air pressure in the air
shocks once every month.
NOTE: Adjusting air shocks may
be done by the snowmobile owner
if qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized
Yamaha Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner.
The air shocks are individually adjustable
for the terrain conditions and driving
style of the operator. The shocks are pre-
set at the factory (see chart) as an initial
setting; however, it is possible to “fine
tune” the shocks to match the operator’s
weight, riding style, and terrain condi-
tions.
NOTE: Adding air pressure will
increase the air spring force;
reducing air pressure will decrease
air spring force.
NOTE: Shock Pressure should be
checked/added at room tempera-
ture of 18° to 20° C (65° to 70° F).
The following settings are recom-
mended but vary on rider prefer-
ence or style.
NOTE: Care should be taken to
have equal pressure in the front ski
shocks before operating the snow-
mobile.
To increase or decrease air pressure, use
the following procedure.
NOTE: When adjusting air pres-
sure, all weight must be removed
from the suspension, and the
shock absorbers must be fully
extended.
1. Remove the air valve cap from the
shock.
2. Thread the valve of Shock Absorber
Air Pump onto the shock air valve
approximately six rotations.
NOTE: As the pump is being
attached to the shock, the hose will
fill with air. This will result in a lower
gauge pressure of 0.14-0.35 kg/cm2
(2-5 psi).
3. To decrease air pressure in the
shock, press the black bleed valve
button half way down and hold until
desired pressure is attained.
Initial Setting Chart
Model
Front
Shock
(Ski)
Front
Arm
Shock
Rear
Arm
Shock
FOX Float
QS3 models
85 psi 35 psi 165 psi
U8MFS0E0.book Page 41 Thursday, April 25, 2019 7:15 AM

Page: 45

42
NOTE: Pressing the but ton fully
down and releasing it will allow
only a small amount of air to
escape (micro-adjust).
4. To increase air pressure in the shock,
pump until desired pressure is
attained.
5. Remove the pump valve from the
shock air valve.
NOTE: As the pump valve is being
removed from the shock, the sound
of air loss is from the pump hose,
not from the shock.
6. Install the air valve cap onto the
shock.
Rebound Adjustment
The Rebound Adjust feature on certain
shocks gives the ability to externally
adjust the shock rebound damping.
Adjustments are made by turning the
knob or using a small flat-bladed screw-
driver to turn the adjuster on the air
sleeve body cap located on the end of the
shock absorber.
For slower rebound, turn the knob/screw
clockwise. The rebound adjuster has
about 20 clicks of adjustment. The fac-
tory setting is 12 clicks out. The perfor-
mance of the shock at this setting is close
to the performance of the non-adjustable
shock and is a good all-around setting.
The rebound damping affects how
quickly the shock extends (rebounds).
This adjustment affects how quickly the
ski rebounds when traveling through a
series of large bumps and how quickly
the front end responds in the corner.
The optimum rebound setting is usually
found with the minimum damping
required to give acceptable control.
Excessive rebound damping will typi-
cally be felt as the suspension “packing”.
This can often be seen or felt as the vehi-
cle travels through a series of similar-
sized, successive bumps. It works well
for the first two or three bumps and then
bottoms hard on the third or fourth. This
is because the shock has not rebounded
quickly enough, and the shock “packs”
into compression.
Adjusting Skid Frame Front Arm
Spring
The skid frame front arm shock spring
tension and the limiter straps are adjust-
able. However, Yamaha recommends that
the shock spring be maintained at the fac-
tory preset of 3.2-6.4 mm (1/8-1/4 in.)
preload. Tightening the skid frame front
arm shock spring may cause improper
balance and may ruin the handling fea-
tures of the snowmobile.
The length adjustment of the front arm
limiter straps determines the weight dis-
tribution between the front of the skid
frame and the skis. Tightening the limiter
strap (shortening the strap) will pull up
on the front of the skid frame and will
increase ski pressure. Loosening the lim-
iter strap (lengthening the strap) lowers
the front of the skid frame and decreases
ski pressure.
When customizing the amount of ski
pressure, be sure to adjust both straps
equally and do not over-adjust the limiter
straps to adversely affect steering and
operator control of the snowmobile.
Some experimentation may be required
until the proper adjustment for the opera-
tor’s individual style is obtained.
NOTE: If the limiter straps are
adjusted, it is highly recommended
that at least a minimum of 3.2 mm (1/8
in.) preload on the shock spring be
maintained.
Adjusting Skid Frame Rear
Shock (Fox QS3)
To adjust the damping, use the adjust-
ment lever located above the EVOL
chamber on the shock. There are three
settings that may be chosen: 1, 2, or 3.
Setting #3 is the stiffest and most con-
trolled position.
WARNING
Do not adjust the front arm limiter
straps to a point at which steering
and operator control of the snow-
mobile are adversely affected.
U8MFS0E0.book Page 42 Thursday, April 25, 2019 7:15 AM

Page: 46

43
SNO-550
QSL Rear Arm Shock
On mountain models, the rear arm shock
(QSL) has an adjustment lever on the
shock to adjust the damping. There are
three settings that may be chosen: 1, 2, or
3.
0748-940
Choose from three specifically calibrated
ride control settings, with the #3 position
calibrated specifically for technical
mountain riding, allowing increased
climbing capabilities and limited transfer
of the rear suspension.
The #3 setting should only be used when
riding in the back country. This setting is
not designed for trail riding.
Adjusting Rear Spring Pre-
Load
Proper adjustment of rear spring preload
is necessary to get the most desirable
ride. The chart is designed to help in set-
ting up rear spring preload; however, rid-
ing style is the single greatest factor in
determining rear spring requirements.
NOTE: These cam position set-
tings are suggestions only. Personal
riding style will greatly influence
cam position settings. Spend time
to determine setting preferences.
Rear spring preload adjustment is accom-
plished by rotating the adjusting cams.
Position 3 provides the stiffest ride, and
position 1 is for the light driver or slow-
speed trail riding. Position 2 is for the
average operator under normal condi-
tions. Always rotate the cam from the
lighter position to the heavier position.
SNO-595
To rotate an adjusting cam, use the spark
plug wrench from the tool kit. Rotate the
wrench until the cam is in the desired
position. To stiffen the ride, rotate the
cam so as to raise the spring end. Make
the appropriate adjustment on the other
cam.
Overload Springs
When either carrying a heavy load or rid-
ing 2-up, the overload springs should be
engaged by rotating the spring tension
blocks to the UP position. The spring ten-
sion blocks lock in an over-center posi-
tion when engaged.
Rider Weight (lb)
Cam
Position
Up to 80 kg (180 lb) 1
80 kg (180 lb) — 110 kg (240 lb) 2
Over 110 kg (240 lb) 3
CAUTION
Never force the adjustment cams
from the low position to the high
position. Cam damage may occur.
Position 1
Position 2
Position 3 Adjusting Cam
U8MFS0E0.book Page 43 Thursday, April 25, 2019 7:15 AM

Page: 47

44
NOTE: Yamaha recommends that
the overload springs be engaged
whenever a load on the snowmo-
bile (operator/passenger/cargo)
exceeds 136 kg (300 lb).
To either engage or disengage the spring
tension blocks, use a spark plug socket
and a screwdriver to adjust the spring
block to the desired position. Make sure
both spring blocks are in the same posi-
tion (either engaged or disengaged).
744-457A
Lights
For the correct headlight bulb and/or tail-
light/brake light LED, see the appropriate
specifications sheet.
Removing and Installing Taillight/
Brake Light
These models are equipped with an LED
taillight/brake light. If the LED fails, it
must be replaced.
1. Disconnect the taillight harness con-
nector.
2. Remove the two machine screws
securing the taillight to the bracket.
SNO-511
3. Connect the taillight harness con-
nector; then secure the taillight to
the bracket with the two screws.
Adjusting Headlight Aim
The headlight can be adjusted for vertical
aim of the HIGH/LOW beam. The geo-
metric center of HIGH beam zone is to be
used for vertical aiming.
1. Position the snowmobile on a level
floor so the headlight is approxi-
mately 8 m (25 ft) from an aiming
surface (wall or similar surface).
NOTE: There should be an “aver-
age” operating load on the snow-
mobile when adjusting headlight
aim.
2. Measure the distance from the floor
to midpoint of the headlight.
3. Using the measurement obtained in
step 2, make a horizontal mark on
the aiming surface.
4. Make a vertical mark which inter-
sects the horizontal mark on the aim-
ing surface directly in front of the
headlight.
5. Engage the brake lever lock and start
the engine. Move the headlight dim-
mer switch to the HIGH beam posi-
tion. DO NOT USE LOW BEAM.
6. Observe the headlight beam aim.
Proper aim is when the most intense
beam is centered on the vertical mark
50 mm (2 in.) below the horizontal
mark on the aiming surface.
CAUTION
There are weight limitations for
these snowmobiles. If additional
cargo is being added, maximum
weight on the snowmobile (opera-
tor/passenger/cargo) should not
exceed 170 kg (375 lb). Also, the
overload springs should be
engaged.
Machine
Screw
Taillight
U8MFS0E0.book Page 44 Thursday, April 25, 2019 7:15 AM

Page: 48

45
0747-834
7. Remove the vent/goggle bag from
between the two intake vents.
8. Adjust the headlight using the adjust-
ing screw on the backside of the head-
light using a 4 mm swivel socket and
long extension until correct aim is
obtained. Shut the engine off; then
disengage the brake lever lock.
0750-309
9. Reinstall the vent/goggle bag
removed in step 7.
Ski Wear Bars
The ski wear bar is a replaceable bar
attached to the underside of the ski. The
purpose of the wear bar is to assist in turn-
ing the snowmobile, to minimize ski wear,
and to maintain good steering control. If
the snowmobile is operated primarily in
deep snow, ski wear bar wear will be mini-
mal; however, if the snowmobile is oper-
ated on terrain where the snow cover is
minimal, the ski wear bar will wear faster.
To maintain positive steering characteris-
tics, Yamaha recommends that the ski wear
bars be checked before each use and
replaced if worn beyond the wear limits
listed below. Ski wear bars are available
from an authorized Yamaha Snowmobile
dealer.
Removing (Single)
1. Using Front End Lift, elevate the
front of the snowmobile.
2. Remove the lock nuts securing the
wear bar to the ski.
0750-102
3. Remove the wear bar from the ski.
NOTE: When the wear bars are
removed, measure the thickness of
both wear bars to see if they are
within the wear limit of 8.0 mm
(0.31 in.). Replace as necessary.
Installing (Single)
1. Move the wear bar into position on
the bottom of the ski.
2. Align the wear bar studs with the
holes in the ski; then install the lock
nuts. Tighten to 1.4-2.3 kg-m (10-17
ft-lb).
Adjusting Ski Stance
NOTE: Local laws and/or regula-
tions as to maximum width of the
ski stance on these snowmobiles
may be applicable. Always comply
with the maximum width laws and/
or regulations when adjusting ski
stance.
Aiming Surface
Horizontal Mark
Intense Beam
8 m (25 ft)
5 cm (2 in)
Adjusting Screw
WARNING
Operating the snowmobile with
excessively worn ski wear bars may
result in a loss of steering control.
Nut
Washer
Wear Bar
U8MFS0E0.book Page 45 Thursday, April 25, 2019 7:15 AM

Page: 49

46
Single Wear Bar
1. Place the front of the snowmobile on
a support stand.
2. Remove the cotter pin; then remove
the slotted nut and cap screw secur-
ing the ski assembly to the spindle.
Remove the ski. Account for the ski
damper, inserts, spacer and washers.
NOTE: Illustration below shows
the spacer on the inside, narrow
ski stance.
0750-103
3. To increase ski stance, place ski
stance spacer to the outside of the
spindle and adjust the damper.
4. To decrease ski stance, place ski
stance spacer to the inside of the
spindle and adjust the damper.
5. Apply an all-temperature grease to the
non-threaded portion of the cap
screw; then slide the cap screw
through the ski accounting for the rub-
ber damper, inserts, and washers.
NOTE: Install the cap screw so
the nut will be located to the inside
of the ski.
6. Apply Yamabond Red Threadlocker
to the threads of the cap screw; then
tighten the nut to 4.8 kg-m (35 ft-lb).
7. Place the cotter pin into the ski cap
screw and spread the pin.
8. Repeat procedure for the other ski.
Rail Wear Strips
Yamaha recommends that the wear strips
be checked weekly and replaced as nec-
essary. Measure the wear strips at 254
mm (10 in.) intervals. Wear strips must
be 10.7 mm (0.42 in.) thick or thicker.
0745-807
If wear strip measurements are less than
specified, replacement of both wear strips
is necessary to prevent premature track
clip wear and possible track damage.
Take the snowmobile to an authorized
Yamaha Snowmobile dealer for this ser-
vice. This service is at the discretion and
expense of the snowmobile owner.
Each time a new set of wear strips are
installed, they should be tempered. Tem-
per the wear strips by driving the snow-
mobile for approximately a mile on a
hard pack trail; then immediately drive
into deep snow and allow the wear strips
to cool. Repeat the procedure (warming
up the wear strips; then cooling them
down) two or three times.
NOTE: The rail wear strips will
wear rapidly if the snowmobile is
operated on terrain on which the
snow cover is minimal. Loose
snow is required to cool and lubri-
cate the wear strips and prevent
accelerated wear.
NOTE: If operating on ice or hard-
packed snow conditions, it is rec-
ommended that Ice Scratchers be
installed to reduce wear strip wear
and engine overheating.
Spacer
Spindle Axle
Washer
Ski Damper
Insert
Cotter Pin
Cap
Screw
Nut
Washer
Minimum Thickness
10.7 mm (0.42 in.)
U8MFS0E0.book Page 46 Thursday, April 25, 2019 7:15 AM

Page: 50

47
Performance Tips
Operating a high performance snowmo-
bile requires a special attention that is not
required by a low performance snowmo-
bile. Often, a minor adjustment will
result in a large increase in performance.
This section is intended to highlight
minor conditions that adversely affect
performance and the adjustments needed
to correct them. Be sure, however, to
thoroughly read and understand this
entire manual especially the section on
spark plugs, track tension and alignment,
and suspension.
DRIVE CLUTCH/DRIVEN
CLUTCH OFFSET
If premature drive belt wear is experi-
enced or if the drive belt turns over, off-
set must be checked. Also, offset must be
checked whenever either the drive clutch
or driven clutch is serviced.
CHECKING OFFSET AND
DRIVE BELT HEIGHT
1. Remove the left-side access panel.
2. Remove the drive belt.
NOTE: Use a straightedge that is
approximately 470 mm (18.5 in.)
long, 20 mm (0.79 in.) wide, and 4
mm (0.16 in.) thick.
3. Measure the offset (A) between the
drive clutch and the driven clutch.
Clutch offset must be within 58.1-
61.1 mm (2.29-2.41 in.). If adjust-
ment is needed, proceed to step 4.
ONS-048
4. If offset adjustment needs to be
made, remove the driven clutch and
add shims to increase the offset or
remove shims to decrease the offset.
Shim Part Numbers:
8JP-RA448-00: 1.0 mm (0.04 in.)
8JP-RA449-00: 2.0 mm (0.08 in.)
5. Once the correct offset is reached,
install driven clutch and tighten cap
screw to 60 N-m (6.0 kg-m, 44 ft-
lb).
6. Check the secondary clutch sheave
width (a), 45.3-45.8 mm (1.78 in.-
1.80 in.).
ONS-047
7. If required, adjust the sheave width
by removing or adding a spacer (A)
on the mounting bolt.
SNO-775
Spacer Part Numbers:
8KC-RA446-00: 0.5 mm (0.02 in.)
8KC-RA447-00: 1.0 mm (0.04 in.)
8. Once the correct belt position is
reached, tighten cap screw to 60 N-
m (6.1 kg-m, 43 ft-lb).
9. Wrap the drive belt around the sec-
ondary clutch only (do not install
the drive belt on the primary
clutch at this time).
Offset Shim Location
U8MFS0E0.book Page 47 Thursday, April 25, 2019 7:15 AM