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Supplies Since some external parts of the snowmobile have Oils, greases, shop rags. been removed at the Yamaha factory for conve- Workshop nience of packing, assembly by the Yamaha dealer The workshop where the snowmobile is assembled is required.
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SYMBOLS USED IN THE ASSEMBLY MANUAL In order to simplify descriptions in this assembly manual, the follow- ing symbols are used: (1): Filling fluid (2): Lubricant (3): Special tool (4): Tightening torque (5): Wear limit, clearance (6): ESSO beacon 325 grease or Aeroshell grease #7A ®...
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PREPARATION To assemble the snowmobile correctly, supplies (i.e., oils, 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.
PARTS LOCATION PARTS LOCATION A Carton box B Carton box C Carton box D Vinyl bag E Carton box F Shroud (For FX10/FX10RT/FX10RTR/ FX10RTRA) A Carton box 1 Windshield (For FX10/FX10MT/FX10MTR/ FX10MTRA) 2 Windshield (For FX10RT/FX10RTR/ FX10RTRA) 3 Front cover 4 Front bumper 5 Flap 6 Flap stopper (For FX10/FX10RT/FX10RTR/...
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B Carton box 1 Rear bumper 2 Flange bolt M8 L = 20 mm (0.79 in) 3 Vinyl bag 1 ~ 4 4 Ski stopper (For FX10/FX10RT/FX10RTR/ FX10RTRA) 5 Ski stopper (For FX10MT/FX10MTR/ FX10MTRA) 6 Handlebar holder (For FX10RT/FX10RTR/ FX10RTRA/FX10MT/FX10MTR/FX10MTRA) 7 Flange bolt M8 L = 35 mm (1.38 in) (For FX10RT/FX10RTR/FX10RTRA) 8 Flange bolt M8 L = 185 mm (7.28 in) (For...
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G Owner’s tool kit a Open ended wrench (8-10) b Open ended wrench (10-12) 2 pcs c Open ended wrench (14-17) d Box-end wrench (19-22) e Grip f Screwdriver bit (+ -) g Socket wrench (14) h Spark plug box wrench (16) i Special wrench j Combination wrench (19-30) (For FX10MT/ FX10MTR/FX10MTRA)
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D Vinyl bag 1 Key E Carton box 1 Ski assemblies (For FX10/FX10RT/FX10RTR/ FX10RTRA) 2 Ski assemblies (For FX10MT/FX10MTR/ FX10MTRA) F Shroud (For FX10/FX10RT/FX10RTR/ FX10RTRA) 1 Shroud...
REMOVAL FROM CRATE 1. Open the fastener of plastic cover. (One side fastener) 2. Remove the crate cover 1. 3. Remove the bolts 2 and then remove the top of the crate 4. Remove the bolts 4 and then remove the sides of the crate.
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7. Remove the bolts 7, collars 8, and nuts 9. (Left and right side) NOTE: The bolts, collars, and nuts installed are not used for installa- tion. 8. Remove the PPband 0. 9. Remove the clips A and pins B and then remove the brackets C.
SET UP PROCEDURE FRONT BUMPER kg, 5.1 ft 7 Nm (0.7 m • • kg, 1.4 ft 2 Nm (0.2 m • • kg, 17 ft 23 Nm (2.3 m • • kg, 5.1 ft 7 Nm (0.7 m • •...
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Set up point 1. Fit the front cover 1 onto the front bumper 2, and then install the bumper to the snowmobile using the flange bolts 3. Then, install the front cover using the screws 4. 2. Install the reflectors 5 using the nuts 6.
WINDSHIELD kg, 0.29 ft kg, 0.29 ft 0.4 Nm (0.04 m 0.4 Nm (0.04 m • • • • kg, 0.29 ft 0.4 Nm (0.04 m • • Parts List Location Remark Parts name 1 Nut in the vinyl bag “3” d = 5 mm (0.20 in) 2 Windshield in the carton box “A”...
FRONT SUSPENSION 45 Nm (4.5 m kg, 33 ft • • Valve face Valve face kg, 33 ft 45 Nm (4.5 m • • Parts List Location Remark Parts name 1 Front shock absorber in the carton box “c” (For FX10) 2 Front shock absorber in the carton box “c”...
SKI ASSEMBLY È Parts List Location Remark Parts name 1 Collar in the carton box “B” L = 76.2 mm (3.00 in) (For FX10/FX10RT/ FX10RTR/FX10RTRA) L = 101.6 mm (4.00 in) (For FX10MT/ FX10MTR/FX10MTRA) 2 Washer in the vinyl bag “2” d = 16 mm (0.63 in) D = 25 mm (0.98 in) 3 Collar...
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È Parts List Parts name Location Remark 5 Ski stopper in the carton box “B” (For FX10/FX10RT/FX10RTR/ FX10RTRA) 6 Ski assembly in the carton box “E” (For FX10/FX10RT/FX10RTR/ FX10RTRA) 7 Ski stopper in the carton box “B” (For FX10MT/FX10MTR/FX10MTRA) 8 Ski assembly in the carton box “E”...
STEERING ASSEMBLY (For FX10/FX10RT/FX10RTR/FX10RTRA) kg, 17 ft kg, 2.9 ft 23 Nm (2.3 m 4 Nm (0.4 m • • • • 4 Nm (0.4 m kg, 2.9 ft • • kg, 5.1 ft 7 Nm (0.7 m • • kg, 5.1 ft 7 Nm (0.7 m •...
STEERING ASSEMBLY (For FX10MT/FX10MTR/FX10MTRA) kg, 17 ft 23 Nm (2.3 m • • Parts List Location Remark Parts name 1 Steering joint in the carton box “B” 2 Handlebar assembly on the snowmobile 3 Steering joint holder in the carton box “B” 4 Flange bolt in the carton box “B”...
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Set up point • Handlebar (For FX10) 1. Loosen the bolts 1. 2. Raise the handlebar 2 as shown in the illustration and align the punch mark a on the handlebar with the upper surface of the lower handlebar holder. 3.
FLAP (For FX10/FX10RT/FX10RTR/FX10RTRA) 26 Nm (2.6 m kg, 19 ft • • Parts List Location Remark Parts name 1 Flap stopper in the carton box “A” 2 Rivet in the vinyl bag “1” 3 Flap in the carton box “A” 4 Rivet in the vinyl bag “1”...
FLAP (For FX10MT/FX10MTR/FX10MTRA) kg, 19 ft 26 Nm (2.6 m • • Parts List Location Remark Parts name 1 Flap in the carton box “A” 2 Rivet in the vinyl bag “1” 3 Rear bumper in the carton box “B” 4 Flange bolt in the carton box “B”...
ADJUSTMENTS AND PREDELIVERY SERVICE The following adjustments and pre-delivery service must be made before delivery of the snowmobile to a customer. SHROUD AND COVERS NOTE: Use the following procedure to remove the shroud, left side cover, and right side cover in order to per- form the adjustments and predelivery service.
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2. Measure: • Sheave offset a Use a straightedge that is approximately 500 mm (19.7 in) long, 20 mm (0.79 in) wide, and 4 mm (0.16 in) thick. Out of specification → Adjust. Sheave offset: 13.5 ~ 16.5 mm (0.53 ~ 0.65 in) NOTE: Push the secondary sheave inward towards the frame, and then measure the sheave offset.
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NOTE: When adjusting the sheave offset, the secondary sheave free play (clearance) should be adjusted. 4. Measure: • Secondary sheave free play (clearance) a • Use a feeler gauge. Out of specification → Adjust. Secondary sheave free play (clear- ance): 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) 5.
DRIVE V-BELT HEIGHT AND INSTALLATION NOTE: Apply the parking brake before installing the V-belt. 1. Check clutch center-to-center and offset specifi- cation. Adjust as necessary. 2. Clean sheave surface of primary and secondary clutches. 3. Install the V-belt over the primary sheave, noting the direction of the arrows on the V-belt.
ENGINE OIL È Use a combination of the recommended SAE and API oil classifications shown in the chart on the left. -40˚ -20˚ 0˚ 20˚ 40˚ 60˚F CAUTION: • Use only 4-stroke engine oil. YAMALUBE 4-S (0W-30) or SAE 0W-30 •...
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CAUTION: Disconnect the oil level switch coupler before removing the oil level gauge. Otherwise the lead can twist and become severed. 5. Remove the oil level gauge 2, wipe it clean, insert it back into the filler hole (without screw- ing it in), and then remove it again to check the oil level.
BREAK-IN There is never a more important period in the life of your engine than the period between 0 and 500 km (300 mi). For this reason, you should read the fol- lowing material carefully. Since the engine is brand new, do not put an excessive load on it for the first 500 km (300 mi).
COOLANT LEVEL WARNING • 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 injury. When the engine has cooled, place a thick rag or towel over the radiator cap, slowly rotate the cap counterclockwise to the detent.
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Air bleeding steps: È NOTE: models other than FX10MT/FX10MTR/ FX10MTRA, skip the first three steps. • Remove the cap 1 on the heat exchanger joint pipe. • While slowly adding coolant to the radiator filler, drain the coolant until no more air bubbles appear.
DRIVE CHAIN HOUSING OIL LEVEL CHECK 1. Remove the shroud and the right side cover. Refer to “SHROUD AND COVERS” 2. Place the snowmobile on a level surface. NOTE: Be sure the snowmobile is positioned straight up when checking the oil level. 3.
DRIVE CHAIN TENSION ADJUSTMENT 1. Loosen the locknut 1. 2. Turn the adjusting bolt 2 clockwise until it is fin- ger tight, and then loosen it 1/4 turn. 3. Hold the adjusting bolt 2 in place while tighten- ing the chain adjusting locknut 1. Drive chain adjusting locknut: 25 Nm (2.5 m ·...
Handlebar side adjustment steps: • Slide back the rubber cover. • Loosen the locknut 1. • Turn the adjusting nut 2 in direction a or b until the specified free play is obtained. Direction a Free play is increased. Direction b Free play is decreased.
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1. Remove the shroud. Refer to “SHROUD AND COVERS” 2. Remove the right side cover. Refer to “SHROUD AND COVERS” 3. Add electrolyte to the battery. (See pages 3-35 ~ 3-37) WARNING Do not overfill! 4. Charge the battery at the rate of 1.8 A for 10 hours.
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 following precau- tions. • Do not allow anyone to stand behind the snowmobile when the engine is running. •...
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3. Adjust: • Track deflection Adjustment steps: • Lift the rear of the snowmobile 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.
HEADLIGHT BEAM ADJUSTMENT 1. Place the snowmobile on a level surface. 2. Place the snowmobile from the wall at a dis- tance D indicated by the chart below. 3. Measure the distance from the floor to the cen- ter of the headlight H and place a mark on the wall equal to height H from the floor.
SKI ADJUSTMENT Toe-out 1. Place the snowmobile on a level surface. 2. Measure: • Ski toe-out (a - c) • Ski stance b Point the skis forward. Out of specification → Adjust. NOTE: Point the skis in parallel to the direction of move- ment.
FRONT SUSPENSION SPRING PRELOAD WARNING These shock absorbers contain highly pressur- ized nitrogen gas. Do not tamper with or attempt to open the shock absorber assem- blies. Do not subject the shock absorber assemblies to open flame or high heat, which could cause them to explode.
REBOUND DAMPING FORCE ADJUSTMENT (FX10) The rebound damping force can be adjusted by turning the adjusting knob 1. 20 clicks out 11 clicks out 3 clicks out Adjusting knob Minimum Standard Maximum position Turns out b* ← → Turns in a Rebound Soft ←...
COMPRESSION DAMPING FORCE ADJUSTMENT (FX10) The compression damping force can be adjusted by turning the adjusting knob 1. 12 clicks out 6 clicks out 2 clicks out Adjusting knob Minimum Standard Maximum position Turns out b* ← → Turns in a Compres- Soft ←...
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This snowmobile is equipped with FOX shock absorbers as standard equipment. The air pressure of the shock absorbers can be adjusted using the shock absorber pump 1 included with your snowmobile. Adjustment steps: WARNING Support the snowmobile securely on a suitable stand before adjusting the shock absorbers.
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• Remove the hose connector from the air valve. NOTE: When removing the connector, the sound of air escaping may be heard, but this is from the pump hose, not the shock absorber. Air pressure range: 345 kPa (3.4 kgf/cm², 50 psi) to 1,034 kPa (10.3 kgf/cm², 150 psi) Recommended air pressure: 517 kPa (5.3 kgf/cm², 75 psi)
REAR SUSPENSION STOPPER BAND LENGTH Adjust the stopper band length by fastening it with a different band hole. CAUTION: Make sure the left and right rear suspension stopper bands are adjusted evenly. (FX10MT/ FX10MTR/FX10MTRA) NOTE: È This adjustment affects the handling characteristics of the snowmobile.
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Choosing other settings: CAUTION: The standard settings work well under most general riding conditions. The suspension can be adjusted to work better in one condition, but only at the expense of another. Keep this in mind when you adjust the suspension. È: No.
REAR SUSPENSION SPRING PRELOAD WARNING This shock absorber contains highly pressur- ized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to open flame or high heat, which could cause it to explode.
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Rear side È • Turn the spring preload adjuster 1 to proper position. Spring preload adjuster position Spring preload Soft Medium Hard Standard WARNING Always adjust both spring preloads (left and É right) to the same setting. Uneven adjustment can cause poor handling and loss of stability. È...
REAR SUSPENSION DAMPING FORCE WARNING This shock absorber contains highly pressur- ized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to open flame or high heat, which could cause it to explode.
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Rebound damping force (Rear side) (FX10RT/FX10RTR/FX10RTRA) Adjust the damping force by turning the adjusting dial 1. 20 clicks out 11 clicks out 3 clicks out Adjusting dial position Minimum Standard Maximum Direction b* ← → Direction a Rebound Soft ← →...
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Compression damping force (Front side) (FX10RT/FX10RTR/FX10RTRA) Adjust the damping force by turning the adjusting screw 1. 12 clicks out 6 clicks out 2 clicks out Adjusting screw Minimum Standard Maximum position Direction b* ← → Direction a Compres- Soft ← →...
Compression damping force (Rear side) È (FX10/FX10RT/FX10RTR/FX10RTRA) Adjust the damping force by turning the adjusting screw 1. 12 clicks out 6 clicks out 2 clicks out Adjusting screw Minimum Standard Maximum position Direction b* ← → Direction a Compres- Soft ← →...
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3. Tighten the locknut. Locknut: 25 Nm (2.5 m · kg, 18 ft · lb) CAUTION: The left and right adjusting nut must be set to the same position. Uneven settings can cause poor handling and loss of stability. WARNING Never adjust the control rod beyond the maxi- mum range indicated on the rod with red paint 3-32...
All rubber seals of the master cylinder and cali- per cylinder. b. The brake system hose. WARNING Be sure the brake fluid and the above parts are replaced by a Yamaha dealer. 3-33...
HYDRAULIC BRAKE AIR BLEEDING WARNING Bleed the brake system if: • The system has been disassembled. • A brake hose has been loosened or removed. • The brake fluid has been very low. • The brake operation has been faulty. •...
BATTERY INSPECTION 1. Fill: CAUTION: • Never remove the sealing sheet (aluminium 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 gener- ated as specified.
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NOTE: Do not lose the strip of caps because it will be used as battery plugs. CAUTION: Do not peel or pierce the sealed areas. e. Turn the electrolyte container upside-down with the six sealed areas in line with the six filler ports of the battery.
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WARNING • Do not attempt boost charging under any cir- cumstances. • Battery electrolyte is poisonous and danger- ous, causing severe burns, etc. Contains sul- furic acid. Avoid contact with skin, eyes or clothing. Antidote: External – Flush with water. Internal - Drink large quantities of water or milk.
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3. Charge: • Battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. CAUTION: • Make sure that the battery vent is free of obstructions. • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
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Charging method using a variable voltage charger Charger AMP meter NOTE: Measure the open-circuit Voltage should be measured 30 voltage prior to charging. minutes after the snowmobile is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 ~ 17 V.
LUBRICATION POINT AND GRADE OF LUBRICANT Rear suspension 1. Use a grease gun to inject grease into the nip- ples. 2. Apply grease to the pivoting parts. Recommended lubricant: ESSO Beacon 325 Grease or Aeroshell Grease #7A È FX10/FX10RT/FX10RTR/FX10RTRA É FX10MT/FX10MTR/FX10MTRA 1 Nipple 2 Nipple (both sides) È...
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1 ECU (engine control unit) 2 Load control relay 3 Headlight relay 4 Fuel injection system relay 5 Radiator fan motor relay 6 Fasten the wire harness and sta- tor coil lead to the front frame with the plastic band. 7 To the left handlebar switch 8 To the AC magneto 9 To the radiator...
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R Face the ends of each hose clamp toward the fuel tank. S Fuel sender coupler T Fasten the tail/brake light lead (wire harness side) to the frame rear cross member with the plas- tic band. U Tail/brake light coupler V Fuel pump lead W Fasten the tail/brake light lead with the holders, making sure to...
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1 To the auxiliary DC jack (FX10MT/FX10MTR/ FX10MTRA) 2 Throttle cable 3 Radiator fan motor coupler 4 Wire harness 5 Fuel injection system sub-wire harness coupler 6 Speed sensor coupler 7 To the radiator fan motor 8 Fasten the speed sensor lead to the frame rear cross member with the plastic band.
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P Rectifier/regulator lead Q Rectifier/regulator R Route the coolant reservoir breather hose above the coolant reservoir check window. S ECU (engine control unit) T Fasten the coolant reservoir breather hose to the front frame with the plastic band, making sure not to pinch the hose. U Intake air temperature sensor V Route the wire harness above the intake air temperature sen-...
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1 Fasten the wire harness to the frame rear cross member with the plastic band. Face the end of the plastic band downward. 2 Positive battery lead 3 Coolant reservoir hose 4 To the main switch 5 To the brake master cylinder 6 Brake hose 7 To the parking brake lever 8 Parking brake cable...
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R Make sure that the catch of the holder is facing downward. (FX10/FX10RTR/FX10RTRA/ FX10MTR/FX10MTRA) S DC back buzzer (FX10/ FX10RTR/FX10RTRA/ FX10MTR/FX10MTRA) T Fuse box U Pass the wire harness and DC back buzzer lead through the guide, making sure that the guide is positioned to the front of the bolt.
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1 Corrugated tube (left grip warmer lead, grip/thumb warmer adjust- ment switch lead, brake light switch lead, and headlight beam switch lead) 2 Parking brake cable 3 Brake master cylinder 4 Left handlebar switch 5 Left grip warmer lead 6 Brake hose 7 Route the brake hose behind the throttle cable and in front of the corrugated tubes.
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1 Fasten the tail/brake light lead with the holder, making sure to push the lead against the fuel tank. 2 Fasten the tail/brake light lead with the holder. 3 Tail/brake light lead 4 After routing the tail/brake light lead, bend the holder around the lead to fasten it.
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN U.S.A. 2007.06 CR...