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Yamaha RX10K Assembly Manual
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Yamaha RX10K Assembly Manual

Yamaha RX10K Assembly Manual

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ASSEMBLY MANUAL
RX10K
RX10RK/RX10RSK
RXW10K/RXW10SK
RX10MK/RX10MSK
LIT-12668-02-39
8FV-28107-10
981094

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Summary of Contents for Yamaha RX10K

  • Page 1 ASSEMBLY MANUAL RX10K RX10RK/RX10RSK RXW10K/RXW10SK RX10MK/RX10MSK LIT-12668-02-39 8FV-28107-10 981094...
  • Page 2 Supplies er. Since some external parts of the machine Oils, greases, shop rags. have been removed at the Yamaha factory for convenience of packing, assembly by the Ya- Workshop maha dealer is required. It should be noted that...
  • Page 3 PREPARATION To assemble the snowmobile correctly, supplies (i.e., greases, shop rags, etc.) and working space are required. Workshop The workshop where the snowmobile is assembled, should be clean and large. The floor should be level. Self-protection Protect your eyes with suitable safety glasses or goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off.

  • Page 4: Table Of Contents

    ..STEERING ASSEMBLY (For RX10MK, RX10MSK) ... . REAR BUMPER (For RX10K, RX10RK, RX10RSK) ... . 2-11 REAR BUMPER (For RXW10K, RXW10SK) .
  • Page 5 ....3-25 CONTROL ROD ADJUSTMENT (RX10K, RX10RK, RX10RSK) ....... 3-26 CONTROL ROD ADJUSTMENT (RXW10K, RXW10SK) .

  • Page 6: Parts Location

    PARTS LOCATION PARTS LOCATION A Carton box (The items H , I , J , and K are packaged in the carton box A for shipment.) B Carton box C Carton box D Vinyl bag E Vinyl bag (For RX10MK, RX10MSK) F Windshield G Flap H Tool box...
  • Page 7 (Except for RX10MK, Left Right (For RX10MK, RX10MSK) RX10MSK) Rear bumper Rear bumper bracket Rear bumper bracket Rear bumper bracket (For RX10MK, (For RX10K, RX10RK, (For RXW10K, RX10MSK) RX10RSK) RXW10SK) Stopper flap Side cover (For RX10K, (For RX10MK, RX10RK, RX10RSK) RX10MSK)
  • Page 8 (16) Spanner (10-12) Screw driver bit + – 2 pcs Box wrench (14) Wrench (3) Spanner (19-22) For RX10K, RX10RK, RX10RSK Spanner (14-17) For RXW10K, RXW10SK For RX10MK, RX10MSK 2 pcs Spanner (14-17) Spanner (14-17) 2 pcs Spanner...
  • Page 9 Owner’s manual Safety hand book Suspension setting card (Except for RXW10K, RXW10SK)

  • Page 10: Removal From Crate

    REMOVAL FROM CRATE 1. Open the fastener of plastic cover. (One side fastener) 2. Remove the plastic cover 1 . 3. Remove the bolts 2 and then remove the top of the crate 3 . 4. Remove the bolts 4 and then remove the sides of the crate.
  • Page 11 8. Remove the hook 8 . (Left side) 9. Remove the steel band 9 . (Right side) 10. Remove the steel band (Left side) 11. Remove the bolt and nut (Right side) The bolt and nut installed on the right side are not used for installation.

  • Page 12: Set Up Procedure

    SET UP PROCEDURE WINDSHIELD, FAIRING, HEADLIGHT 3 Nm (0.3 mSkg, 2.2 ftSlb) 1 Nm (0.1 mSkg, 0.7 ftSlb) Parts List Parts Name Location Remark Windshield on the shroud Fairing assembly in the carton box “ ” Headlight unit in the carton box “ ”...

  • Page 13: Fairing Assembly

    FAIRING ASSEMBLY 1 Nm (0.1 mSkg, 0.7 ftSlb) 3 Nm (0.3 mSkg, 2.2 ftSlb) 1 Nm (0.1 mSkg, 0.7 ftSlb) 3 Nm (0.3 mSkg, 2.2 ftSlb) 3 Nm (0.3 mSkg, 2.2 ftSlb) Parts List Parts Name Location Remark Nut spring in the vinyl bag “4”...

  • Page 14: Ski Assembly (Except For Rx10Mk, Rx10Msk)

    Parts List Parts Name Location Remark Ski assembly in the carton box “ ” for RX10K, RX10RK, RX10RSK 1.25 L = 130 mm (5.12 in) Bolt in the vinyl bag “2” Bolt in the vinyl bag 2 for RXW10K, RXW10SK 1.25 L = 115 mm (4.53 in)

  • Page 15: Ski Assembly (For Rx10Mk, Rx10Msk)

    SKI ASSEMBLY (For RX10MK, RX10MSK) 48 Nm (4.8 mSkg, 35 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Parts List Parts Name Location Remark Ski assembly in the carton box “ ” Bolt in the vinyl bag “2” 1.25 L = 153 mm (6.02 in) in the vinyl bag “2”...

  • Page 16: Front Suspension

    FRONT SUSPENSION 45 Nm (4.5 mSkg, 33 ftSlb) 45 Nm (4.5 mSkg, 33 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Parts List Parts Name Location Remark Shock absorber in the carton box “ ” in the vinyl bag “2” 1.25 Washer, plate in the vinyl bag “2”...

  • Page 17: Front Bumper, Under Cover

    FRONT BUMPER, UNDER COVER 17 Nm (1.7 mSkg, 12 ftSlb) 3 Nm (0.3 mSkg, 2.2 ftSlb) Parts List Parts Name Location Remark Under cover in the carton box “ ” Bolt in the vinyl bag “1” 1.0 L = 18 mm (0.71 in) Nut spring in the vinyl bag “1”...

  • Page 18: Side Cover (For Rx10Mk, Rx10Msk)

    SIDE COVER (For RX10MK, RX10MSK) 0.4 Nm (0.04 mSkg, 0.3 ftSlb) Parts List Parts Name Location Remark Side cover in the carton box “ ” Screw in the vinyl bag “1” in the vinyl bag “1”...

  • Page 19: Steering Assembly (Except For Rx10Mk, Rx10Msk)

    STEERING ASSEMBLY (Except for RX10MK, RX10MSK) 15 Nm (1.5 mSkg, 11 ftSlb) Parts List Parts Name Location Remark Handle assembly on the fuel tank Lower handle holder in the vinyl bag “ ” Upper handle holder in the vinyl bag “ ”...

  • Page 20: Steering Assembly (For Rx10Mk, Rx10Msk)

    STEERING ASSEMBLY (For RX10MK, RX10MSK) 15 Nm (1.5 mSkg, 11 ftSlb) Parts List Parts Name Location Remark Handle assembly on the fuel tank Lower handle holder in the vinyl bag “ ” Handlebar joint in the vinyl bag “ ” Upper handle holder in the vinyl bag “...
  • Page 21 Set up point 1. Check the handlebar assembly 1 . CAUTION: D Be sure the small gap A side of the holder faces forward B . “a” = 0 mm (0 in) D Center the match mark 1 on the handle- bar C between the lower handlebar hold- ers D .

  • Page 22: Rear Bumper (For Rx10K, Rx10Rk, Rx10Rsk)

    REAR BUMPER (For RX10K, RX10RK, RX10RSK) 26 Nm (2.6 mSkg, 19 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) Parts List Parts Name Location Remark Stopper flap in the carton box  " Rivet in the vinyl bag 3" Flap on the seat Rivet in the vinyl bag “3”...

  • Page 23: Rear Bumper (For Rxw10K, Rxw10Sk)

    REAR BUMPER (For RXW10K, RXW10SK) 4 Nm (0.4 mSkg, 2.9 ftSlb) 26 Nm (2.6 mSkg, 19 ftSlb) Parts List Parts Name Location Remark Rear bumper in the carton box “ ” Grommet (Right) in the vinyl bag “6” Grommet (Left) in the vinyl bag “6”...

  • Page 24: Rear Bumper (For Rx10Mk, Rx10Msk)

    REAR BUMPER (For RX10MK, RX10MSK) 4 Nm (0.4 mSkg, 2.9 ftSlb) 26 Nm (2.6 mSkg, 19 ftSlb) Parts List Parts Name Location Remark Rear bumper in the carton box “ ” Grommet (Right) in the vinyl bag “3” Grommet (Left) in the vinyl bag “3”...
  • Page 25 2-14...

  • Page 26: Adjustments And Predelivery Service

    ADJUSTMENTS AND PREDELIVERY SERVICE The following adjustments and pre-delivery ser- vice must be made before delivery of the ma- chine to a customer. SHEAVE OFFSET ADJUSTMENT 1. Open the shroud: 2. Remove: S Drive V-belt guard S Drive V-belt 3. Measure: S Sheave offset a Use the sheave gauge.
  • Page 27 4. Adjust: S Sheave offset Adjustment steps: S Apply the brake to lock the secondary sheave. S Remove the bolt (Secondary sheave) 1 , washer 2 and secondary sheave 3 . S Adjust the sheave offset by adding or remov- ing shim(s) 4 .

  • Page 28: Drive V-Belt Height And Installation

    DRIVE V-BELT HEIGHT AND INSTALLATION NOTE: Apply the parking brake before installing the drive V-belt. 1. Check clutch center-to-center and offset specification. Adjust as necessary. 2. Clean sheave surface of primary and sec- ondary clutches. 3. Install the drive belt over the primary sheave, noting the direction of the arrows on the belt.

  • Page 29: Engine Oil

    ENGINE OIL Use a combination of the recommended SAE and API oil classifications shown in the chart be- low. CAUTION: D Use only 4-stroke engine oil. D Engine oil also lubricates the starter clutch. In order to prevent clutch slip- page, do not mix any chemical additives with the oil or use oils of a higher grade than “CD”.

  • Page 30: Break-In

    NOTE: The engine oil should be between the “F” 3 and “E” 4 level marks on the oil level gauge/dip- stick. 5. If the engine oil is below the “E” level mark, add sufficient oil of the recommended type to raise it to the “F” level mark. CAUTION: D When adding the engine oil, be careful not to fill above the “F”...

  • Page 31: Coolant Level

    COOLANT LEVEL WARNING D Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious inju- ry. When the engine has cooled, place a thick rag or towel over the radiator cap, slowly rotate the cap counterclockwise to the detent.

  • Page 32: Drive Chain Housing Oil Level Inspection

    DRIVE CHAIN HOUSING OIL LEVEL INSPECTION 1. Place the machine on a level surface. NOTE: Be sure the machine is positioned straight up when checking the oil level. 2. Remove the oil level gauge 1 . 3. Check the oil level gauge. If not, add oil until upper level.

  • Page 33: Drive Chain Tension Adjustment

    DRIVE CHAIN TENSION ADJUSTMENT 1. Loosen the locknut 1 . 2. Turn the adjuster bolt 2 clockwise until it is finger-tight. 3. Hold the adjuster bolt 2 in place while tight- ening the chain adjuster locknut 1 .

  • Page 34: Throttle Cable Adjustment

    THROTTLE CABLE ADJUSTMENT NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. 1. Measure the throttle cable free play a . Throttle cable free play: 2.0 X 3.0 mm (0.08 X 0.12 in) Adjust if out of specification. 2.

  • Page 35: Battery Installation

    BATTERY INSTALLATION WARNING Battery – electrolyte is poisonous and dan- gerous, causes severe burns, etc. Contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL – Flush with water. INTERNAL – Drink large quantities of water or milk. Follow with milk of magnesia, beat- en egg or vegetable oil.
  • Page 36 (–) cable 2 (black cable) to the battery as shown. A For RX10K, RX10MK, RX10MSK B Except for RX10K, RX10MK, RX10MSK CAUTION: D Avoid touching wrenches to the ground of the insulator plate on the muffler when...

  • Page 37: Track Tension Adjustment

    TRACK TENSION ADJUSTMENT WARNING A broken track, track fittings, or debris thrown by the track could be dangerous to an operator or bystanders. Observe the fol- lowing precautions. D Do not allow anyone to stand behind the machine when the engine is running. D When the rear of the machine is raised to allow the track to spin, a suitable stand must be used to support the rear of the...
  • Page 38 3. Adjust: S Track deflection Adjustment steps: Lift the rear of the machine onto a suitable stand to raise the track off the ground. Loosen the rear axle nut 1 . a. Start the engine and rotate the track one or two turns.

  • Page 39: Headlight Beam Adjustment

    HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Place the machine from the wall at a dis- tance D indicated by the chart below. 3. Measure the distance from the floor to the center of the headlight H and place a mark on the wall equal to distance D from the floor.

  • Page 40: Parking Brake Adjustment

    PARKING BRAKE ADJUSTMENT 1. Measure: S Brake pad clearance a Out of specification ! Adjust. Brake pad clearance: 1.5 X 2.0 mm (0.059 X 0.079 in) 2. Adjust: S Brake pad clearance Adjustment steps: S Loosen the locknut 1 S Turn the adjuster 2 in or out to until the speci- fied clearance between the brake pad 3 and brake disc 4 is obtained.

  • Page 41: Ski Adjustment

    SKI ADJUSTMENT Toe-out 1. Measure the ski toe-out. S Ski toe-out ( a – c ) S Ski stance b Point the skis forward. Out of specification ! Adjust. NOTE: Point the skis in parallel to the direction of move- ment.

  • Page 42: Front Suspension Spring Preload

    1. Loosen the lock nut 1 . 2. Adjust the spring preload by turning the spring seat 2 . Check the rear suspension spring preload and adjust if needed. RX10K, RX10RK, RX10RSK, RXW10K, RXW10SK Spring seat Standard Shorter z ! Longer...

  • Page 43: Rear Suspension Stopper Band Tension (Rx10K, Rx10Rk, Rx10Rsk, Rx10Mk, Rx10Msk)

    REAR SUSPENSION STOPPER BAND TENSION (RX10K, RX10RK, RX10RSK, RX10MK, RX10MSK) Adjust the stopper band tension by changing the position of the hole of a X e or f . CAUTION: Make sure the left and right sides of the rear suspension stopper band are adjusted evenly.

  • Page 44: Rear Suspension Stopper Band Tension (Rxw10K, Rxw10Sk)

    REAR SUSPENSION STOPPER BAND TENSION (RXW10K, RXW10SK) Adjust the stopper band tension by turning the adjusting nut 2 . CAUTION: Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. NOTE: This adjustment affects the handling character- istics of the machine.

  • Page 45: Rear Suspension Spring Preload (Rx10K, Rx10Rk, Rx10Rsk)

    REAR SUSPENSION SPRING PRELOAD (RX10K, RX10RK, RX10RSK) WARNING This shock absorber contains highly pres- surized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assem- bly to flames or high heat, which could cause it to explode.

  • Page 46: Rear Suspension Spring Preload (Rxw10K, Rxw10Sk)

    REAR SUSPENSION SPRING PRELOAD (RXW10K, RXW10SK) WARNING This shock absorber contains highly pres- surized nitrogen gas. Do not tamper with or attempt to open the shock absorber assem- bly. Do not subject the shock absorber assem- bly to open flame or high heat, which could cause it to explode.

  • Page 47: Rear Suspension Spring Preload (Rx10Mk, Rx10Msk)

    REAR SUSPENSION SPRING PRELOAD (RX10MK, RX10MSK) Front shock absorber Turn the adjusting ring 1 to the proper position. Spring adjuster position Softer z ! Harder Preload Front Standard Rear shock absorber Turn the adjusting hook 2 to the proper posi- tion.

  • Page 48: Rear Suspension Damping Force (Rx10K, Rx10Rk, Rx10Rsk)

    REAR SUSPENSION DAMPING FORCE (RX10K, RX10RK, RX10RSK) CAUTION: Never go beyond the maximum or minimum adjustment positions. Turn the adjusting handle 1 in direction a or b . (Maximum: 11 clicks) Adjustment dial turning direction Softer z ! Harder Damping force...

  • Page 49: Rear Suspension Damping Force (Rxw10K, Rxw10Sk)

    REAR SUSPENSION DAMPING FORCE (RXW10K, RXW10SK) WARNING This shock absorber contains highly pres- surized nitrogen gas. Do not tamper with or attempt to open the shock absorber assem- bly. Do not subject the shock absorber assem- bly to open flame or high heat, which could cause it to explode.

  • Page 50: Full Rate Adjuster (Rxw10K, Rxw10Sk)

    FULL RATE ADJUSTER (RXW10K, RXW10SK) The total suspension spring rate and damping characteristics can be adjusted by changing the installed position of the shock-absorber assem- bly. Installation Position Spring rate and Soft Medium Hard Damping Standard 1. Loosen the nut 1 (turns out 1/2 X 3/4). 2.
  • Page 51 CONTROL ROD ADJUSTMENT (RX10K, RX10RK, RX10RSK) Control rod stroke a 1. Loosen the locknut 1 . 2. Check the adjusting rod length using the scale on the special wrench 2 included in the owner’s tool kit. 3. Turn the adjusting rod 3 in direction a or b to adjust the control rod stroke.

  • Page 52: Control Rod Adjustment (Rxw10K, Rxw10Sk)

    CONTROL ROD ADJUSTMENT (RXW10K, RXW10SK) The weight transfer can be adjusted by turning the control rod adjusting nut 1 . 1. Loosen the locknut 2 while holding the control rod adjusting nut 1 . 2. To increase weight transfer, turn the adjusting nut in direction a .

  • Page 53: Control Rod Adjustment (Rx10Mk, Rx10Msk)

    CONTROL ROD ADJUSTMENT (RX10MK, RX10MSK) Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. 1. Loosen the lock nut 1 . 2. Turn the adjusting nut 2 in or out to adjust the control rod stroke.

  • Page 54: Brake Fluid Level

    All rubber seals of the master cylinder and caliper cylinder b. The brake system hose WARNING Be sure the brake fluid and the above parts are replaced by a Yamaha dealer. 3-29...

  • Page 55: Hydraulic Brake Air Bleeding

    HYDRAULIC BRAKE AIR BLEEDING WARNING Bleed the brake system if: D The system has been disassembled. D A brake hose has been loosened or re- moved. D The brake fluid has been very low. D The brake operation has been faulty. D During predelivery set up.

  • Page 56: Battery Inspection

    BATTERY INSPECTION 1. Fill: CAUTION: S Never remove the sealing sheet (alumini- um seal) from the battery until the battery is filled with electrolyte. If battery plates are exposed to air, they will oxidize. As a result, power will not be gen- erated as specified.
  • Page 57 e. Turn the electrolyte container upside-down with the six sealed areas in line with the six filler ports of the battery. Push the container down strongly enough to break the seals. The electrolyte will start to flow into the battery. CAUTION: S Do not tilt the container as the electrolyte may stop flowing.
  • Page 58 WARNING S Do not attempt boost charging under any circumstances. S Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. Contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: External – Flush with water. Inter- nal – Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 59 3. Charge: Charging Ambient temperature 20_C S battery (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Make sure that the battery vent is free of obstructions.
  • Page 60 Charging method using a variable voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V. and start charging.
  • Page 61 Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery.

  • Page 63: Lubrication Point And Grade Of Lubricant

    LUBRICATION POINT AND GRADE OF LUBRICANT Front and rear suspension 1. Use a grease gun to inject grease into the nipples 1 . 2. Apply grease 2 . Recommended lubricant: Esso Beacon 325 Grease or Aeroshell Grease #7A A Front B Rear (RXW10K, RXW10SK) C Rear (RX10MK, RX10MSK)

  • Page 64: Cable Routing

    CABLE ROUTING (for RX10K, RX10MK, RX10MSK)
  • Page 65 To the headlight and meter as- sembly Clamp the lead at the position of white tape. Clamp the wire harness and A.C.magneto lead. Battery negative lead Battery positive lead Main harness Negative lead connector Carburetor heater lead coupler Oil level switch lead coupler Oil level switch Starter motor positive lead (un- der the battery bracket)
  • Page 67 Route the coolant hose be- tween the upper vacuum hose and lower vacuum hose. Route the vacuum hose under the coolant hose. Route the vacuum hose over the coolant hose. Clamp the coolant hose and vacuum hose. Clamp the coolant hose and vacuum hose 2.
  • Page 69 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securely fit in the rubber cover) Put the boots of the meter cou- pler in the boss root on the side of the meter.
  • Page 71 1 Clamp the grip warmer lead and the right handlebar switch lead. Clamp the main harness, main switch and harness. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Ex- cept for brake hose and parking brake cable.) Pass the brake hose and the parking brake cable through...
  • Page 73 Clamp the wire harness and fuel tank breather hose from the top. Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side. Right handlebar switch Push into the end of clamp be- tween frame cross member and fuel tank.
  • Page 74 6-11...
  • Page 75 Headlight wire harness Tighten the frame ground and voltage regulator upper bolt to- gether. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through be- tween engine and heat ex- changer.
  • Page 76 6-13...
  • Page 77 1 Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the up- ward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross mem- ber and frame. Wire harness clamp Rivets Speed sensor Nylon nuts Point the pawl of clip to the downward.
  • Page 78 6-15...
  • Page 79 1 Battery positive lead CDI unit Battery negative lead Air box drain hose Starter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat CDI unit bracket Latch Battery band Battery cover To the carburetor.
  • Page 80 CABLE ROUTING (for RX10RK, RX10RSK, RXW10K, RXW10SK) 6-17...
  • Page 81 To the headlight and meter as- sembly Clamp the lead at the position of white tape. Clamp the wire harness and A.C.magneto lead. Battery positivee lead Battery negative lead Main harness Negative lead connector Carburetor heater lead coupler Oil level switch lead coupler Oil level switch Starter motor positive lead (un- der the battery bracket)
  • Page 82 6-19...
  • Page 83 Route the coolant hose be- tween the upper vacuum hose and lower vacuum hose. Route the vacuum hose under the coolant hose. Route the vacuum hose over the coolant hose. Clamp the coolant hose and vacuum hose. Clamp the coolant hose and vacuum hose 2.
  • Page 84 6-21...
  • Page 85 1 Headlight wire harness Align it with the positioning tape of the headlight wire harness Meter coupler (Securely fit in the rubber cover) Put the boots of the meter cou- pler in the boss root on the side of the meter. 6-22...
  • Page 86 6-23...
  • Page 87 1 Clamp the grip warmer lead and the right handlebar switch lead. Clamp the main harness, main switch and harness. Throttle cable Handlebar holder Pass all leads and cables through the cable holder. (Ex- cept for brake hose and parking brake cable.) Pass the brake hose and the parking brake cable through...
  • Page 88 6-25...
  • Page 89 Clamp the wire harness and fuel tank breather hose from the top. Clamp the wire harness. Fuel hose Clamp the wire harness and fuel tank breather hose from the lower side. Right handlebar switch Push into the end of clamp be- tween frame cross member and fuel tank.
  • Page 90 6-27...
  • Page 91 Headlight wire harness Tighten the frame ground and voltage regulator upper bolt to- gether. Engine oil tank hose Point the clamp tightening direction to the downward. Drain hose Less than 30 mm (1.2 in). Pass the coolant reservoir tank breather hose through be- tween engine and heat ex- changer.
  • Page 92 6-29...
  • Page 93 1 Fuel pump Fuel hoses Coolant reservoir tank Point the pawl of clip to the up- ward. Clamp the fuel tank breather hose and speed sensor lead. Tighten the frame cross mem- ber and frame. Wire harness clamp Rivets Speed sensor Nylon nuts Point the pawl of clip to the downward.
  • Page 94 6-31...
  • Page 95 1 Battery negative lead CDI unit Battery positive lead Air box drain hose Starter motor Plate cover Wire harness Clip it to the frame cross member Wire harness holder Battery bracket Battery Battery seat CDI unit bracket Latch Battery band Battery cover To the carburetor.
  • Page 98 PRINTED IN U.S.A. 2004.06.ITP (E) PRINTED ON RECYCLED PAPER...

This manual is also suitable for:

Rx10rkRx10rskRxw10kRxw10skRx10mkRx10msk

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