Yamaha FX10X 2008 Service Manual

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SERVICE MANUAL

2008

FX10X

FX10RTX

FX10RTRX

FX10RTRAX

FX10MTX

FX10MTRX

FX10MTRAX

LIT-12618-02-69

8GL-28197-10

Table of Contents

Troubleshooting

Summary of Contents for Yamaha FX10X 2008

Page 1 SERVICE MANUAL 2008 FX10X FX10RTX FX10RTRX FX10RTRAX FX10MTX FX10MTRX FX10MTRAX LIT-12618-02-69 8GL-28197-10...
Page 3: How To Use This Manual
NOTICE HOW TO USE THIS MANUAL This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and Particularly important information is distinguished in their qualified mechanics. It is not possible to put an this manual by the following notations: entire mechanic’s education into one manual, so it...
Page 4 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspection and adjustment POWR 3 Chassis CHAS 4 Power train 5 Engine 6 Cooling system 7 Fuel injection system...
Page 5 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTION AND INSP ADJUSTMENT CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM – ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 6: Table Of Contents
CHAPTER 1. THROTTLE BODY JOINTS INSPECTION ..........2-23 GENERAL INFORMATION CHECKING THE AIR FILTER ELEMENT ..........2-23 EXHAUST SYSTEM INSPECTION ..2-25 SNOWMOBILE IDENTIFICATION ....1-1 FRAME SERIAL NUMBER ......1-1 POWER TRAIN..........2-26 ENGINE SERIAL NUMBER......1-1 SHEAVE OFFSET ADJUSTMENT ... 2-26 DRIVE V-BELT..........
Page 7 FX10MT/FX10MTR/FX10MTRA ....3-17 SLIDE RAIL SUSPENSION......4-43 INSPECTION ..........3-18 FX10............4-43 FX10RT/FX10RTR/FX10RTRA ....4-49 FRONT SUSPENSION ........3-19 FX10MT/FX10MTR/FX10MTRA ....4-55 FX10/FX10RT/FX10RTR/FX10RTRA..3-19 HANDLING NOTES ........4-61 FX10MT/FX10MTR/FX10MTRA ....3-21 REMOVAL..........4-61 HANDLING NOTES ........3-23 INSPECTION ..........4-61 INSPECTION ..........
Page 8 OIL PAN AND OIL PUMP ......5-44 ISC (IDLE SPEED CONTROL) UNIT..7-27 REMOVAL ..........5-47 INSPECTION ..........5-47 AIR FILTER CASE ......... 7-28 INSTALLATION ........5-49 THROTTLE BODY.......... 7-29 CRANKCASE ..........5-51 INJECTORS..........7-30 REMOVAL ..........5-53 REMOVAL..........7-32 INSPECTION ..........
Page 9 DC BACK BUZZER (FX10/FX10RTR/ FX10RTRA/FX10MTR/FX10MTRA) ..8-38 COOLANT TEMPERATURE SENSOR ..8-39 OIL LEVEL SWITCH......... 8-40 FUEL SENDER......... 8-40 SPEED SENSOR........8-41 GRIP WARMER SYSTEM ......8-42 CIRCUIT DIAGRAM........8-42 TROUBLESHOOTING......8-44 GRIP WARMER AND THUMB WARMER..........8-45 GRIP/THUMB WARMER ADJUSTMENT SWITCH............
Page 10: Chapter 1. General Information
SNOWMOBILE IDENTIFICATION INFO GENERAL INFORMATION SNOWMOBILE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number 1 is located on the right-hand side of the crank- case.
Page 11: Important Information
ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments.
Page 12: Gaskets, Oil Seals, And O-Rings
IMPORTANT INFORMATION INFO GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
Page 13: Special Tools
SPECIAL TOOLS INFO SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. NOTE: •...
Page 14 SPECIAL TOOLS INFO • Radiator pressure tester P/N: YU-24460-01 • Radiator cap tester P/N: 90890-01325 This tester is used to check the cooling system. • Radiator pressure tester adapter P/N: YU-33984 • Radiator cap tester adapter P/N: 90890-01352 This adapter is used to check the cooling system. •...
Page 15 SPECIAL TOOLS INFO • Bearing driver 40 mm P/N: YM-04058 • Middle driven shaft bearing driver P/N: 90890-04058 • Mechanical seal installer P/N: 90890-04145 These tools are used to install the water pump seal. • Universal magneto & rotor holder P/N: YU-01235 •...
Page 16: For Power Train Service
• Engine mount spacer wrench P/N: YS-01516 90890-01516 Used to turn the engine mounting bolt spacer when removing/installing engine. • Yamaha bond No. 1215 P/N: 90890-85505 ® (Three Bond No.1215 This bond is used to seal two mating surfaces (e.g., crankcase mating sur- faces.)
Page 17: For Fuel Injection Service
SPECIAL TOOLS INFO • Clutch bushing press P/N: YS-42424 90890-01529 This tool is used for removing and installing the post bushings (primary sheave cap bush, sliding sheave bush and torque cam bush). • Track clip installer P/N: YS-91045-C 90890-01721 This tool is used for installing the track clip. FOR FUEL INJECTION SERVICE •...
Page 18: Periodic Inspection And Adjustment
• Replace if necessary. • Check synchronization. ∗ Fuel injection • Adjust if necessary. • Check for leakage. ∗ Exhaust system • Tighten or replace gasket if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer.
Page 19: General Maintenance And Lubrication Chart
• Check condition. ∗ Battery • Charge if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer. NOTE: Brake system: • After disassembling the master cylinder or caliper cylinder, always change the brake fluid. Regularly check the brake fluid level and add fluid if necessary.
Page 20: Engine
INSP SPARK PLUGS/FUEL LINE INSPECTION ENGINE SPARK PLUGS 1. Remove: • Left side cover Refer to “COVERS” in CHAPTER 3. 2. Remove: • Ignition coils • Spark plugs 3. Inspect: • Electrodes 1 Damage/wear → Replace the spark plug. • Insulator color 2 Abnormal color →...
Page 21: Cooling System
INSP COOLING SYSTEM COOLING SYSTEM Coolant replacement NOTE: The coolant should be changed at least every sea- son. 1. Place the snowmobile on a level surface. 2. Remove: • Right lower cover Refer to “COVERS” in CHAPTER 3. 3. Remove: •...
Page 22 INSP COOLING SYSTEM 8. Connect: • Coolant reservoir hose • Thermostat outlet hose 9. Fill: • Cooling system Recommended coolant: High quality ethylene glycol anti- freeze containing corrosion inhibi- tors Coolant mixing ratio (coolant:water): 3:2 (60%:40%) Total amount: FX10/FX10RT/FX10RTR/FX10RTRA 3.40 L (2.99 Imp qt, 3.59 US qt) FX10MT/FX10MTR/FX10MTRA 4.70 L (4.14 Imp qt, 4.97 US qt) CAUTION:...
Page 23 INSP COOLING SYSTEM È Air bleeding steps: NOTE: models other than FX10MT/FX10MTR/ FX10MTRA, skip steps 1–3. • Remove the cap 1 on the heat exchanger pipe. • While slowly adding coolant to the radiator filler, drain the coolant until no more air bubbles appear.
Page 24: Valve Clearance Adjustment
INSP VALVE CLEARANCE ADJUSTMENT VALVE CLEARANCE ADJUSTMENT NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at the top dead cen- ter (TDC) on the compression stroke.
Page 25 INSP VALVE CLEARANCE ADJUSTMENT • Measure the valve clearance with a thickness gauge 1. NOTE: • If the valve clearance is incorrect, record the measured reading. • Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #3 → #2 → #1 È...
Page 26 INSP VALVE CLEARANCE ADJUSTMENT 6. Adjust: • Valve clearance Adjustment steps: • Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3. Valve lapper 90890-04101 Valve lapping tool YM-A8998 NOTE: • Cover the timing chain opening with a rag to pre- vent the valve pad from falling into the crankcase.
Page 27 INSP VALVE CLEARANCE ADJUSTMENT EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) Rounded value = 150 • Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.
Page 28 INSP VALVE CLEARANCE ADJUSTMENT VALVE PAD SELECTION TABLE INTAKE Measured INSTALLED PAD NUMBER clearance ↓ 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.05 ~ 0.09...
Page 29: Throttle Body Synchronization
VALVE CLEARANCE ADJUSTMENT/ INSP THROTTLE BODY SYNCHRONIZATION • Install the new valve pad 1 and the valve lifter NOTE: • Apply molybdenum disulfide oil to the valve pad and the valve lifter. • The valve lifter must turn smoothly when rotated by hand.
Page 30 INSP THROTTLE BODY SYNCHRONIZATION 2. Remove: • Vacuum caps 1 3. Install: • Vacuum gauge 1 Vacuum gauge: 90890-03094 Carburetor synchronizer: YU-44456 4. Install: • Fuel tank Refer to “SEAT AND FUEL TANK” in CHAP- TER 5. 5. Start the engine and let it warm up for several minutes, and then let it run at specified engine idling speed.
Page 31: Throttle Cable Free Play Adjustment
THROTTLE BODY SYNCHRONIZATION INSP THROTTLE CABLE FREE PLAY ADJUSTMENT Adjustment steps: • With throttle body #1 as standard, adjust throttle body #1 and #2 using the synchronizing screws Carburetor angle driver 2: 90890-03173 NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
Page 32 INSP THROTTLE CABLE FREE PLAY ADJUSTMENT 2. Adjust: • Throttle cable free play Throttle body side adjustment steps: • Remove the left side cover. Refer to “COVERS” in CHAPTER 3. • Loosen the locknut 1. • Turn the adjusting nut 2 in direction a or b until the specified free play is obtained.
Page 33: Throttle Override System (T.o.r.s.) Check
INSP THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK WARNING When checking the T.O.R.S.: • Be sure the parking brake is applied. • Be sure the throttle lever moves smoothly. • Do not rev the engine to the point that the clutch engages, otherwise, the snowmobile could start moving forward unexpectedly, which could cause an accident.
Page 34: Compression Pressure Measurement
INSP COMPRESSION PRESSURE MEASUREMENT COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance Out of specification → Adjust. Refer to “VALVE CLEARANCE ADJUST- MENT”. 2. Start the engine, warm it up for several minutes, and then turn it off.
Page 35 INSP COMPRESSION PRESSURE MEASUREMENT 6. Measure: • Compression pressure Above the maximum pressure → Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure → Squirt a few drops of oil into the affected cylinder and measure again.
Page 36: Engine Oil Level Inspection
INSP ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION 1. Inspect: • Engine oil level CAUTION: Do not run the engine with too much or not enough oil in the oil tank. Oil could flow into the air filter and the engine could be damaged. Inspection steps: •...
Page 37: Engine Oil Replacement
ENGINE OIL LEVEL INSPECTION/ INSP ENGINE OIL REPLACEMENT NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. • Start the engine, warm it up for several minutes, and then turn it off. • Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
Page 38 INSP ENGINE OIL REPLACEMENT 9. Remove: • Oil pan engine oil drain bolt 1 NOTE: ” mark a is stamped in the oil pan near the oil A “ pan drain bolt. 10. Remove: • Oil tank engine oil drain bolt 1 11.
Page 39 INSP ENGINE OIL REPLACEMENT 13. Install: • Drain bolts (along with the new gaskets) Oil tank engine oil drain bolt: 16 Nm (1.6 m · kg, 11 ft · lb) Oil pan engine oil drain bolt: 10 Nm (1.0 m · kg, 7.2 ft · lb) 14.
Page 40: Cylinder Head Breather Hose Inspection
CYLINDER HEAD BREATHER HOSE INSPECTION/ INSP THROTTLE BODY JOINTS INSPECTION/ CHECKING THE AIR FILTER ELEMENT CYLINDER HEAD BREATHER HOSE INSPECTION 1. Inspect: • Cylinder head breather hose 1 Cracks/damage → Replace. Loosen connection → Connect properly. CAUTION: Make sure that the cylinder head breather hose is routed correctly.
Page 41: Checking The Air Filter Element
INSP CHECKING THE AIR FILTER ELEMENT 4. Clean: • Air filter element NOTE: Remove the snow. 5. Inspect: • Air filter element Damage/clogs → Replace. 6. Install: • Air filter element • Air filter element frame • Air filter case cover NOTE: Push down on the air filter element frame until a click is heard.
Page 42: Exhaust System Inspection
INSP EXHAUST SYSTEM INSPECTION EXHAUST SYSTEM INSPECTION 1. Remove: • Fuel tank Refer to “SEAT AND FUEL TANK” in CHAP- TER 5. 2. Inspect: • Exhaust pipe joints 1 • Exhaust pipe 2 • Muffler 3 • Exhaust pipe bands 4 •...
Page 43: Power Train
INSP SHEAVE OFFSET ADJUSTMENT POWER TRAIN SHEAVE OFFSET ADJUSTMENT 1. Remove: • Left side cover • Drive guard Refer to “COVERS” in CHAPTER 3. 2. Remove: • Drive V-belt 3. Measure: • Sheave offset a 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.
Page 44 INSP SHEAVE OFFSET ADJUSTMENT • Install secondary sheave, secondary sheave bolt and washer. Secondary sheave bolt: 64 Nm (6.4 m · kg, 46 ft · lb) • Recheck the sheave offset. If out of specifica- tion, repeat the above steps. NOTE: When adjusting the sheave offset, the secondary sheave free play (clearance) should be adjusted.
Page 45: Drive V-Belt
INSP DRIVE V-BELT DRIVE V-BELT WARNING When installing the new V-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to –0.5 mm (–0.02 in) below the edge a. If the V-belt is not positioned correctly, the clutch engagement speed will be changed.
Page 46 INSP DRIVE V-BELT 2. Adjust the position of the V-belt by removing or adding a spacer 1 on each adjusting bolt 2. V-belt position Adjustment More than 1.5 mm (0.06 in) above the Remove a spacer edge From 1.5 mm (0.06 in) above the edge to Not necessary –0.5 mm (–0.02 in)
Page 47: Engagement Speed Check
DRIVE V-BELT/ INSP ENGAGEMENT SPEED CHECK 6. Measure: • Drive V-belt circumference a Out of specification → Replace. V-belt circumference: 1,129 ~ 1,137 mm (44.4 ~ 44.8 in) ENGAGEMENT SPEED CHECK 1. Place the snowmobile on a level surface. 2. Inspect: •...
Page 48: Parking Brake Pad Inspection
PARKING BRAKE PAD INSPECTION/ INSP PARKING BRAKE ADJUSTMENT PARKING BRAKE PAD INSPECTION 1. Remove: • Right side cover Refer to “COVERS” in CHAPTER 3. 2. Inspect: • Parking brake pad Wear limit a reached → Replace the parking brake assembly. Parking brake pad wear limit: 1.2 mm (0.05 in) PARKING BRAKE ADJUSTMENT...
Page 49: Brake Fluid Level Inspection
PARKING BRAKE ADJUSTMENT/ INSP BRAKE FLUID LEVEL INSPECTION 4. Measure: • Brake pad clearance (a + b) Out of specification → Adjust. Brake pad clearance (a + b): 1.5 ~ 2.0 mm (0.059 ~ 0.079 in) 5. Adjust: • Brake pad clearance Adjustment steps: •...
Page 50: Brake Pad Inspection
BRAKE FLUID LEVEL INSPECTION/ INSP BRAKE PAD INSPECTION/BRAKE HOSE INSPECTION WARNING • Use only the designated brake fluid. Other flu- ids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of fluid. Mixing fluids may result in a harmful chemical reaction leading to poor brake performance.
Page 51: Air Bleeding (Hydraulic Brake System)
INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) WARNING Bleed the brake system in the following cases: • The system has been disassembled. • A brake hose is loosened or removed. • The brake fluid has been very low. •...
Page 52: Drive Chain
INSP DRIVE CHAIN DRIVE CHAIN Oil level inspection WARNING The engine and muffler will be very hot after the engine has run. Avoid touching a hot engine and muffler while they are still hot with any part of your body or clothing during inspection or repair.
Page 53 INSP DRIVE CHAIN Oil replacement Oil replacement steps: • Remove the right lower cover. Refer to “COVERS” in CHAPTER 3. • Place the drive chain cover under the drain hole. • Remove the oil drain bolt (along with the gas- ket) 1 and drain the oil.
Page 54: Track Tension Adjustment
INSP TRACK TENSION ADJUSTMENT TRACK TENSION ADJUSTMENT WARNING A broken track or track fittings, and debris thrown by the track could be dangerous to an operator or bystanders. Observe the following precautions. • Do not allow anyone to stand behind the snowmobile when the engine is running.
Page 55 INSP TRACK TENSION ADJUSTMENT 3. Adjust: • Track deflection Adjustment steps: a. Place the snowmobile onto a suitable stand to raise the track off of the ground. b. Loosen the rear axle nut 1. c. Start the engine and rotate the track once or twice.
Page 56: Slide Runner Inspection
SLIDE RUNNER INSPECTION/ INSP MAXIMIZING DRIVE TRACK LIFE SLIDE RUNNER INSPECTION 1. Inspect: • Slide runner 1 Cracks/damage/wear → Replace. 2. Measure: • Slide runner wear limit a Out of specification → Replace. Slide runner wear limit: 10.5 mm (0.41 in) MAXIMIZING DRIVE TRACK LIFE Recommendations Track tension...
Page 57 To minimize possible damage, consult your stud man- ufacturer for installation and stud pattern recom- mendations. Yamaha does not recommend track studding. 2-40...
Page 58: Chassis
INSP SKI/SKI RUNNER/STEERING SYSTEM CHASSIS SKI/SKI RUNNER 1. Inspect: • Ski • Ski runner Damage/wear → Replace. • Ski runner thickness a • Plastic ski thickness b Out of specification → Replace. Ski runner wear limit: FX10/FX10RT/FX10RTR/FX10RTRA 8 mm (0.31 in) FX10MT/FX10MTR/FX10MTRA 6 mm (0.24 in) Plastic ski wear limit:...
Page 59 INSP STEERING SYSTEM Toe-out adjustment 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. Ski toe-out: 0 ~ 15 mm (0 ~ 0.59 in) Ski stance (center to center): FX10/FX10RT/FX10RTR/FX10RTRA 1,050 mm (41.3 in)
Page 60: Brake Lever Adjustment
INSP BRAKE LEVER ADJUSTMENT/LUBRICATION BRAKE LEVER ADJUSTMENT 1. Adjust: • Brake lever position a Adjustment steps: • While pushing the brake lever forward, loosen the locknut 1. • While pushing the brake lever forward, turn the adjusting bolt 2 in direction b or c until the brake lever is in the desired position.
Page 61 INSP LUBRICATION 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...
Page 62: Electrical
INSP HEADLIGHT BULB REPLACEMENT ELECTRICAL HEADLIGHT BULB REPLACEMENT The following procedure applies to both of the headlight bulbs. 1. Remove: • Shroud Refer to “COVERS” in CHAPTER 3. 2. Disconnect: • Headlight coupler 1 3. Remove: • Headlight bulb cover 2 4.
Page 63: Headlight Beam Adjustment
INSP HEADLIGHT BEAM ADJUSTMENT/BATTERY INSPECTION HEADLIGHT BEAM ADJUSTMENT 1. Place the snowmobile on a level surface. 2. Place the snowmobile in front of a wall at the recommended distance D. Refer to the table below. 3. Measure the distance H from the floor to the center of the headlight and place a mark on the wall at that height.
Page 64 INSP BATTERY INSPECTION First aid in case of bodily contact: External • SKIN – Wash with water. • EYES – Flush with water for 15 minutes and get immediate medical attention. Internal • Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil.
Page 65 INSP BATTERY INSPECTION 4. Remove: • Battery 5. Inspect: • Battery charge Inspection steps: • Connect a pocket tester to the battery terminals. Positive tester probe → positive battery terminal Negative tester probe → negative battery terminal NOTE: • The charge state of a MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is discon- nected).
Page 66 INSP BATTERY INSPECTION 6. 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. •...
Page 67 INSP BATTERY INSPECTION 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.
Page 68 INSP BATTERY INSPECTION Charging method using a constant voltage charger NOTE: Voltage should be measured 30 Measure the open-circuit minutes after the snowmobile is voltage prior to charging. stopped. Connect a charger and AMP meter to the battery and start charging. Make sure that the current is higher than the stan- dard charging current writ-...
Page 69 INSP BATTERY INSPECTION/FUSE INSPECTION 7. Install: • Battery 8. Install: • Battery bracket 9. Connect: • Battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, then the negative battery lead 2. 10. Check: • Battery terminals Dirt →...
Page 70: Fuse Inspection
INSP FUSE INSPECTION 3. Replace: • Blown fuse Replacing steps: • Turn the main switch off. • Install a new fuse of the correct amperage. • Turn the main switch on and verify if the electri- cal circuit is operational. •...
Page 71: Tuning
INSP CLUTCH TUNING CLUTCH P Pink S Silver High altitude Y Yellow Specifications Model: FX10/FX10RT/FX10RTR/FX10RTRA ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft)
Page 72 INSP CLUTCH Br Brown G Green L Blue P Pink W White Specifications Model: FX10MT/FX10MTR/FX10MTRA ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft)
Page 73 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the snowmobile will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the snowmobile first begins to move from a complete stop.
Page 74: Gear Selection
INSP GEAR SELECTION 1 Chain and sprocket part number È Parts name É Teeth & links Ê Parts no. Ë Standard 18 teeth 8FA-17682-80 19 teeth 8FA-17682-90 20 teeth 8FA-17682-00 FX10MT/ FX10MTR “USA/Canada”/ FX10MTRA “USA/Canada” Ì Drive sprocket 21 teeth 8FA-17682-10 FX10/FX10RT/FX10RTR/ FX10RTRA...
Page 75 INSP GEAR SELECTION 3 Secondary sheave spring É Spring rate Ê Preload Ï Outside Ì Wire gauge Î Free length È Part No. Ë Color Í No. of coils Ð Standard N · mm/rad N/mm (kg/mm) diameter mm (in) mm (in) (kg ·...
Page 76 INSP GEAR SELECTION 6 Primary spring Ì Spring rate Ð Outside Í Preload Ï Wire gauge Ò Free length Ë Parts No. Î Color Ñ No. of coils Ó Standard N/mm diameter N (kg) mm (in) mm (in) (kg/mm) mm (in) 90501-550A2 19.6 (2.00) 196 (20)
Page 77 INSP GEAR SELECTION 7 Clutch weight É Weight g (oz) È Parts No. Ê Shape & ID mark Ë Standard without bush and rivets 8BU-17605-20 45.41 (1.603) 8DJ-17605-00 37.77 (1.333) 8ES-17605-00 54.63 (1.928) 8FA-17605-10 63.81 (2.252) 8FN-17605-00 75.28 (2.657) 8FP-17605-00 67.81 (2.394) FX10MT/FX10MTR/ 8FS-17605-00...
Page 78 INSP GEAR SELECTION 8 Weight rivets Ê Length Ë Weight È Parts No. É Material Ì Standard Í Effects mm (in) g (oz) IN: FX10/FX10RT/FX10RTR/ FX10RTRA Î Increased force CENTER: FX10/FX10RT/ FX10RTR/FX10RTRA/ 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) FX10MTR “Europe”/ FX10MTRA “Europe”...
Page 79 INSP GEAR SELECTION 9 Rollers I.D. 9 mm (0.354 in) É Outside È Roller with bush- Ê Bushing type Ë Identification mark Ì Standard Í Effects diameter ing part number (P/N) (Width) mm (in) Î Grooved & Machined 8FG-17624-00 14.5 (0.57) VESPEL Ó...
Page 80: Front Suspension
INSP FRONT SUSPENSION FRONT SUSPENSION È Spring preload 1. Adjust: • Spring preload Adjustment steps: • Loosen the locknut 1. • Turn the spring seat 2 in or out. FX10 Standard Spring seat Short ← → Long distance É Hard ← →...
Page 81 INSP FRONT SUSPENSION 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 Direction b* ← → Direction a Rebound Soft ←...
Page 82 INSP FRONT SUSPENSION 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 Direction b* ← → Direction a Compres- Soft ←...
Page 83 INSP FRONT SUSPENSION Adjustment steps: WARNING Support the snowmobile securely on a suitable stand before adjusting the shock absorbers. CAUTION: Make sure that there is no load on the shock absorbers and that they are fully extended before making any air pressure adjustments. •...
Page 84 INSP FRONT SUSPENSION/REAR SUSPENSION Air pressure range: 345 kPa (3.4 kg/cm², 50 psi) to 1,034 kPa (10.3 kg/cm², 150 psi) Recommended air pressure: 517 kPa (5.3 kg/cm², 75 psi) CAUTION: Do not exceed 1,034 kPa (10.3 kg/cm², 150 psi). • Install the air valve cap. NOTE: If the front suspension bottoms too easily or rolls too much during cornering, increase the air pres-...
Page 85: Rear Suspension
INSP REAR SUSPENSION Adjustment steps: È • Remove the stopper band bolts 1, nuts and No.5 washers. No.4 • Adjust the length of the stopper bands 2 by No.3 inserting the bolts in different holes. No.2 Standard setting: No.1 No. 1 hole •...
Page 86 INSP REAR SUSPENSION 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.
Page 87 INSP REAR SUSPENSION • Turn the adjusting ring 3 to the proper position. Ê Spring adjuster position Soft ← → Hard Preload Standard WARNING This shock absorber contains highly pressur- ized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly.
Page 88 INSP REAR SUSPENSION Damping force adjustment Rebound damping force (Front side) (FX10RT/FX10RTR/FX10RTRA) The damping force can be adjusted by turning the adjusting dial 1. 20 clicks out 11 clicks out 3 clicks out Adjusting dial position Minimum Standard Maximum Direction b* ← →...
Page 89 INSP REAR SUSPENSION Rebound damping force (Rear side) (FX10RT/FX10RTR/FX10RTRA) The damping force can be adjusted 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 ←...
Page 90 INSP REAR SUSPENSION Compression damping force (Front side) (FX10RT/FX10RTR/FX10RTRA) The compression damping force can be adjusted by turning the adjusting screw 1. 12 clicks out 6 clicks out 2 clicks out Adjusting screw Minimum Standard Maximum position Direction b* ← →...
Page 91 INSP REAR SUSPENSION Compression damping force (Rear side) È (FX10/FX10RT/FX10RTR/FX10RTRA) The compression damping force can be adjusted by turning the adjusting screw 1. 12 clicks out 6 clicks out 2 clicks out Adjusting screw Minimum Standard Maximum position Direction b* ← →...
Page 92 INSP REAR SUSPENSION Control rod (FX10MT/FX10MTR/FX10MTRA) 1. Adjust: • Control rod stroke a CAUTION: Make sure the adjusting nut ends are set at the same position on each side. Adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 in or out to adjust the control rod stroke.
Page 93: Chapter 3. Chassis
CHAS COVERS CHASSIS COVERS È: kg, 2.9 ft 4 Nm (0.4 m • • FX10RT/FX10RTR/ FX10RTRA È È Q’ty Remarks Order Job name/Part name Covers removal Remove the parts in the order listed below. Windshield Shroud Side cover (left and right) Main switch coupler Disconnect.
Page 94 CHAS COVERS È: kg, 5.1 ft 7 Nm (0.7 m • • É: kg, 17 ft 23 Nm (2.3 m • • È È È È É Q’ty Remarks Order Job name/Part name Drive guard pin Drive guard Lower cover (left and right) Storage pouch Reflector Front cover...
Page 95: Installation
CHAS COVERS INSTALLATION 1. Install: • Headlight assembly 1 Installed position a: 16.0 mm (0.63 in) 2 Headlight stay...
Page 96: Steering
CHAS STEERING STEERING FX10 È: kg, 5.1 ft 7 Nm (0.7 m • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: 23 Nm (2.3 m kg, 17 ft • • Ê É È È Order Job name/Part name Q’ty Remarks Handlebar removal...
Page 97 CHAS STEERING È: 7 Nm (0.7 m kg, 5.1 ft • • É: 10 Nm (1.0 m kg, 7.2 ft • • Ê: kg, 17 ft 23 Nm (2.3 m • • Ê É È È Q’ty Remarks Order Job name/Part name Left handlebar switch Brake master cylinder holder Master cylinder assembly...
Page 98: Fx10Rt/Fx10Rtr/Fx10Rtra
CHAS STEERING FX10RT/FX10RTR/FX10RTRA È: kg, 5.1 ft 7 Nm (0.7 m • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: kg, 17 ft 23 Nm (2.3 m • • Ê É È Ê Ê È Q’ty Remarks Order Job name/Part name...
Page 99 CHAS STEERING È: kg, 5.1 ft 7 Nm (0.7 m • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: kg, 17 ft 23 Nm (2.3 m • • Ê É È Ê Ê È Order Job name/Part name Q’ty Remarks Left handlebar switch...
Page 100: Fx10Mt/Fx10Mtr/Fx10Mtra
CHAS STEERING FX10MT/FX10MTR/FX10MTRA È: kg, 7.2 ft 10 Nm (1.0 m • • É: 23 Nm (2.3 m kg, 17 ft • • É È Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Shroud/Side covers/Speedometer cover Refer to “COVERS”.
Page 101 CHAS STEERING È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 17 ft 23 Nm (2.3 m • • É È Q’ty Remarks Order Job name/Part name Throttle cable holder Throttle cable Disconnect. Right handlebar switch/throttle lever assembly Upper handlebar holder Handlebar...
Page 102 CHAS STEERING È: kg, 17 ft 23 Nm (2.3 m • • É: kg, 18 ft 25 Nm (2.5 m • • Ê: kg, 20 ft 28 Nm (2.8 m • • Ë: kg, 25 ft 35 Nm (3.5 m •...
Page 103: Removal
CHAS STEERING REMOVAL 1. Straighten the lock washer tabs. INSPECTION 1. Inspect: • Handlebar • Steering column Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent column. This may dangerously weaken the column. 2. Inspect: • Bearings (steering column) •...
Page 104: Installation
CHAS STEERING INSTALLATION 1. Install: • Tie rod 1 • Locknuts 2 • Joints 3 È Tie rod part É Set length Ê Tie rod length b number 8GL-23830-00 (FX10/FX10RT/ 544.0 mm 475.5 mm FX10RTR/ (21.42 in) (18.72 in) FX10RTRA) È...
Page 105 CHAS STEERING 4. Install: • Steering shaft 1 • Locknuts 2 • Joints 3 È Steering shaft É Set length Ê Shaft length b part number 8GL-23820-00 232.2 mm 174.2 mm (9.14 in) (6.86 in) CAUTION: Always use new cotter pin. Steering shaft and pivot arm nut: 35 Nm (3.5 m ·...
Page 106 CHAS STEERING • Loosen the steering shaft locknuts 5. • Adjust the steering shaft 6 by turning so that the pivot arm point right under. Turning the steering Turning the ski in shaft in direction a direction c Turning the steering Turning the ski in shaft in direction b direction d...
Page 107 CHAS STEERING 8. Install: • Handlebar 1 • Handlebar holders 2 NOTE: • The handlebar holders should be installed with the punch marks a facing forward. • Align the punch mark b on the handlebar with the upper surface of the lower handlebar holder. (FX10) •...
Page 108: Ski
CHAS FX10/FX10RT/FX10RTR/FX10RTRA È: kg, 8.7 ft 12 Nm (1.2 m • • É: kg, 12 ft 17 Nm (1.7 m • • Ê: 19 Nm (1.9 m kg, 13 ft • • Ë: kg, 35 ft 48 Nm (4.8 m •...
Page 109: Fx10Mt/Fx10Mtr/Fx10Mtra
CHAS FX10MT/FX10MTR/FX10MTRA È: kg, 8.7 ft 12 Nm (1.2 m • • É: kg, 12 ft 17 Nm (1.7 m • • Ê: kg, 13 ft 19 Nm (1.9 m • • Ë: kg, 35 ft 48 Nm (4.8 m •...
Page 110: Inspection
CHAS INSPECTION The following procedure applies of all of the skis and related components. 1. Inspect: • Ski • Ski runner • Ski stopper • Ski handle Wear/cracks/damage → Replace. • Mounting bolt • Collars Wear/damage → Replace. 3-18...
Page 111: Front Suspension
CHAS FRONT SUSPENSION FRONT SUSPENSION FX10/FX10RT/FX10RTR/FX10RTRA È: kg, 20 ft 28 Nm (2.8 m • • Ê É: kg, 24 ft 34 Nm (3.4 m • • Ê: kg, 32 ft 45 Nm (4.5 m • • Ë: kg, 47 ft 65 Nm (6.5 m •...
Page 112 CHAS FRONT SUSPENSION È: kg, 20 ft 28 Nm (2.8 m • • Ê É: 34 Nm (3.4 m kg, 24 ft • • Ê: kg, 32 ft 45 Nm (4.5 m • • Ë: kg, 47 ft 65 Nm (6.5 m •...
Page 113: Fx10Mt/Fx10Mtr/Fx10Mtra
CHAS FRONT SUSPENSION FX10MT/FX10MTR/FX10MTRA È: kg, 20 ft 28 Nm (2.8 m • • Ê É: kg, 24 ft 34 Nm (3.4 m • • Ê: kg, 32 ft 45 Nm (4.5 m • • Ë: kg, 47 ft 65 Nm (6.5 m •...
Page 114 CHAS FRONT SUSPENSION È: kg, 20 ft 28 Nm (2.8 m • • Ê É: kg, 24 ft 34 Nm (3.4 m • • Ê: kg, 32 ft 45 Nm (4.5 m • • Ë: kg, 47 ft 65 Nm (6.5 m •...
Page 115: Handling Notes
CHAS FRONT SUSPENSION HANDLING NOTES WARNING This shock absorber contains highly com- pressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The man- ufacturer cannot be held responsible for prop- erty damage or personal injury that may result from improper handling.
Page 116: Installation
CHAS FRONT SUSPENSION INSTALLATION 1. Install: • Stabilizer 1 • Bushing 2 • Stabilizer holder 3 NOTE: Install the stabilizer holder in the direction shown in the illustration. a Forward 2. Install: • Shock absorber 1 NOTE: • Install the shock absorber with the air valve a facing outward.
Page 117 CHAS FRONT SUSPENSION Ski alignment NOTE: Be sure to verify the spring preload setting before adjusting the ski toe-out since this adjustments may affect the ski toe-out setting. Point the skis straight forward and measure the amount of ski toe-out. Ski toe-out: 0 ~ 15 mm (0 ~ 0.59 in) a –...
Page 118: Chapter 4. Power Train
POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT È: 120 Nm (12.0 m kg, 85 ft • • kg, 43 ft 60 Nm (6.0 m • • È Q’ty Remarks Order Job name/Part name Primary sheave and drive V-belt Remove the parts in the order listed below.
Page 119 POWR PRIMARY SHEAVE AND DRIVE V-BELT Q’ty Remarks Order Job name/Part name Primary sheave disassembly Remove the parts in the order listed below. Primary sheave cap Primary sheave spring Collar Roller Washer Collar Weight Washer Fixed sheave Stopper Sliding sheave Bushing Spider Left-handed thread.
Page 120: Removal
POWR PRIMARY SHEAVE AND DRIVE V-BELT REMOVAL 1. Remove: • Primary sheave assembly 1 NOTE: Use the primary sheave holder 2 and primary sheave puller 3. Sheave holder: 90890-01701 Primary clutch holder: YS-01880-A Primary sheave puller (18 mm): 90890-01898, YS-01881-A, YS-01881-1 DISASSEMBLY 1.
Page 121: Inspection
POWR PRIMARY SHEAVE AND DRIVE V-BELT • Fit the primary sheave assembly onto the adapter and secure the supporting plates 8. NOTE: Securely fit the projections on the adapter into the fixed sheave holes. • Set the bar wrench 9 onto the spider and turn the special tool clockwise to loosen the spider.
Page 122 POWR PRIMARY SHEAVE AND DRIVE V-BELT 2. Inspect: • Primary sheave spring 1 Cracks/damage → Replace. 3. Measure: • Primary sheave spring (standard) free length Out of specification → Replace the primary sheave spring. Primary sheave spring (standard) free length: FX10/FX10RT/FX10RTR/FX10RTRA 87.4 mm (3.44 in) FX10MT “USA/Canada”/FX10MTR...
Page 123: Assembly
POWR PRIMARY SHEAVE AND DRIVE V-BELT Rivet replacement steps: • Remove old rivet with the appropriate drill. • Insert the rivet 1 from the ID mark 2 side. • Press or peen the rivet head so that the diame- ter a of the rivet head measures 8.2 mm (0.32 in) or larger.
Page 124 POWR PRIMARY SHEAVE AND DRIVE V-BELT 2. Install: • Fixed sheave (onto the spider) NOTE: • Clean the threads. ® • Apply LOCTITE #648 to the fixed sheave as shown. CAUTION: ® LOCTITE should be applied only to the speci- fied area.
Page 125 POWR PRIMARY SHEAVE AND DRIVE V-BELT • Tighten the spider to specification using the bar wrench 3. Clutch spider separator (bar wrench): 90890-01711, YS-28890-C Spider: 200 Nm (20.0 m · kg, 145 ft · lb) CAUTION: The spider has a left-handed thread. WARNING •...
Page 126: Installation
POWR PRIMARY SHEAVE AND DRIVE V-BELT 6. Install: • Primary sheave spring 1 • Primary sheave cap 2 NOTE: Be sure the sheave cap match mark (X) is aligned with the spider match mark (X). Primary sheave cap bolt: 14 Nm (1.4 m · kg, 10 ft · lb) INSTALLATION 1.
Page 127 POWR PRIMARY SHEAVE AND DRIVE V-BELT • Loosen the primary sheave bolt completely. • Retighten the primary sheave bolt to specifica- tion. Primary sheave bolt: 2nd: 60 Nm (6.0 m · kg, 43 ft · lb) 4. Adjust: • V-belt position Refer to “DRIVE V-BELT”...
Page 128: Secondary Sheave
POWR SECONDARY SHEAVE SECONDARY SHEAVE È: kg, 46 ft 64 Nm (6.4 m • • È Q’ty Remarks Order Job name/Part name Secondary sheave removal Remove the parts in the order listed below. NOTE: Apply the brake to lock the secondary sheave.
Page 129 POWR SECONDARY SHEAVE Q’ty Remarks Order Job name/Part name Secondary sheave disassembly Remove the parts in the order listed below. Spring seat Secondary sheave spring Fixed sheave Stopper Sliding sheave For assembly, reverse the disassembly pro- cedure. 4-12...
Page 130: Disassembly
POWR SECONDARY SHEAVE DISASSEMBLY WARNING • Use extreme CAUTION when disassembling the secondary sheave since serious injury can occur due to the sudden release of spring tension. Use the sheave compressor to con- tain the spring tension before removing the spring seat nuts.
Page 131: Assembly
POWR SECONDARY SHEAVE 5. Measure: • Ramp shoe thickness a Out of specification → Replace the ramp shoe. Wear limit: 1.0 mm (0.04 in) ASSEMBLY 1. Install: • Secondary sheave spring 1 • Spring seat 2 NOTE: Hook the end of the secondary sheave spring into the spring holes in the fixed sheave.
Page 132 • Install new shims of the proper thickness and reassemble the secondary sheave. • Measure the secondary sheave clearance again. Repeat these steps until the clearance is within specification. NOTE: Yamaha recommends keeping the original shims. Shims: Part number Thickness 90201-061H1 0.5 mm (0.02 in) 90201-06037 1.0 mm (0.04 in)
Page 133: Installation
POWR SECONDARY SHEAVE INSTALLATION 1. Lubricate: • Splines (fixed sheave) Recommended grease: ESSO beacon 325 grease or Aeroshell grease #7A 2. Tighten: • Secondary sheave bolt Secondary sheave bolt: 64 Nm (6.4 m · kg, 46 ft · lb) 3. Adjust: •...
Page 134: Drive Chain
POWR DRIVE CHAIN DRIVE CHAIN WITHOUT REVERSE MODEL È: Ë: kg, 4.3 ft kg, 18 ft 6 Nm (0.6 m 25 Nm (2.5 m • • • • É: Ì: 10 Nm (1.0 m kg, 7.2 ft 28 Nm (2.8 m kg, 20 ft •...
Page 135 POWR DRIVE CHAIN È: Ë: kg, 4.3 ft 6 Nm (0.6 m 25 Nm (2.5 m kg, 18 ft • • • • É: Ì: kg, 7.2 ft kg, 20 ft 10 Nm (1.0 m 28 Nm (2.8 m • •...
Page 136: Removal
POWR DRIVE CHAIN REMOVAL 1. Remove: • Driven sprocket 1 NOTE: While holding the front axle assembly with spanner wrench 2, loosen the driven sprocket nut. INSPECTION 1. Inspect: • Drive chain cover Cracks/damage → Replace. • Oil seals (drive chain cover) Wear/damage →...
Page 137 POWR DRIVE CHAIN 3. Measure: • 14 link section a of the drive chain Using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b. Out of specification → Replace the drive chain. Maximum 14 link drive chain section length: 133.35 mm (5.25 in) Limit: 137.35 mm (5.41 in)
Page 138: Installation
POWR DRIVE CHAIN INSTALLATION 1. During installation, pay attention to the follow- ing. È Make sure that the bearing seals face towards the drive chain as shown. É Properly install the rubber seal onto the drive chain cover, making sure that there are no gaps. É...
Page 139: With Reverse Model
POWR DRIVE CHAIN WITH REVERSE MODEL È: Ë: Î: kg, 4.3 ft kg, 17 ft kg, 40 ft 6 Nm (0.6 m 23 Nm (2.3 m 55 Nm (5.5 m • • • • • • É: Ì: kg, 18 ft kg, 7.2 ft 25 Nm (2.5 m 10 Nm (1.0 m...
Page 140 POWR DRIVE CHAIN È: Ë: Î: kg, 4.3 ft kg, 40 ft 6 Nm (0.6 m 23 Nm (2.3 m kg, 17 ft 55 Nm (5.5 m • • • • • • É: Ì: kg, 7.2 ft kg, 18 ft 10 Nm (1.0 m 25 Nm (2.5 m •...
Page 141 POWR DRIVE CHAIN È: Ë: Î: kg, 4.3 ft kg, 40 ft 6 Nm (0.6 m 23 Nm (2.3 m kg, 17 ft 55 Nm (5.5 m • • • • • • É: Ì: kg, 7.2 ft kg, 18 ft 10 Nm (1.0 m 25 Nm (2.5 m •...
Page 142: Removal
POWR DRIVE CHAIN REMOVAL 1. Remove: • Reverse driven gear 1 NOTE: While holding the front axle assembly with spanner wrench 2, loosen the reverse driven gear bolt. INSPECTION 1. Inspect: • Drive chain cover Cracks/damage → Replace. • Shift fork Pitting/wear/damage →...
Page 143: Installation
POWR DRIVE CHAIN INSTALLATION 1. During installation, pay attention to the follow- ing. È Properly install the rubber seal onto the drive chain cover, making sure that there are no gaps. Be sure to install the collars in their original positions, otherwise the brake disc and sec- ondary shaft will stick.
Page 144 POWR DRIVE CHAIN 2. Install: • Shift rod 1 3. Adjust: • Shift rod length a Adjustment steps: • Move the shift lever to the “FWD.” position. • Loosen the locknuts 2. • Turn the shift rod 1 so that shift rod free play is 0 mm (in direction where a can be shortened appropriately) and then turn back the shift rod 1/2 turns.
Page 145: Secondary Shaft
POWR SECONDARY SHAFT SECONDARY SHAFT È: 30 Nm (3.0 m kg, 22 ft • • È È Q’ty Remarks Order Job name/Part name Secondary shaft removal Remove the parts in the order listed below. Secondary sheave Refer to “SECONDARY SHEAVE”. Drive chain Refer to “DRIVE CHAIN”.
Page 146: Inspection
POWR SECONDARY SHAFT INSPECTION 1. Inspect: • Secondary shaft 1 Scratches (excessive)/damage → Replace. • Splines 2 Wear/damage → Replace the secondary shaft. • Bearing contact surface 3 Scratches/wear/damage → Replace the sec- ondary shaft. 4-29...
Page 147: Secondary Shaft And Drive Chain Cover Installation
POWR SECONDARY SHAFT SECONDARY SHAFT AND DRIVE CHAIN COVER INSTALLATION 1. Install: • Secondary shaft • Drive chain cover È Installation steps: • Install the secondary shaft. • Tighten the bolts 1. Bearing housing bolt: 30 Nm (3.0 m · kg, 22 ft · lb) •...
Page 148 POWR SECONDARY SHAFT 3. Adjust: • Brake disc clearance Adjustment steps: • Remove the circlip 5. • Adjust the brake disc clearance by adding or removing shim(s) 6. Shim size Part number Thickness 90201-222F0 0.5 mm (0.02 in) 90201-225A4 1.0 mm (0.04 in) •...
Page 149: Brake
POWR BRAKE BRAKE BRAKE PAD È: kg, 1.4 ft 2 Nm (0.2 m • • É: kg, 4.3 ft 6 Nm (0.6 m • • Ê: kg, 12 ft 17 Nm (1.7 m • • Ë: kg, 35 ft 48 Nm (4.8 m •...
Page 150: Brake Pad Replacement
POWR BRAKE CAUTION: Disc brake components rarely require disas- sembly. DO NOT: • Do not disassemble components unless absolutely necessary. • Do not use solvents on internal brake compo- nents. • Do not use contaminated brake fluid for cleaning. • Use only clean brake fluid. •...
Page 151 POWR BRAKE 2. Install: • Brake pads • Brake pad spring Installation steps: • Connect suitable hoses 1 tightly to the caliper bleed screws 2. Put the other end of each hose into an open container. • Loosen the caliper bleed screws and push the pistons into the caliper with your finger.
Page 152: Brake Caliper And Parking Brake
POWR BRAKE BRAKE CALIPER AND PARKING BRAKE È: 10 Nm (1.0 m kg, 7.2 ft • • É: 15 Nm (1.5 m kg, 11 ft • • Ê: kg, 22 ft 30 Nm (3.0 m • • Ë: 48 Nm (4.8 m kg, 35 ft •...
Page 153 POWR BRAKE È: kg, 1.4 ft 2 Nm (0.2 m • • É: kg, 4.3 ft 6 Nm (0.6 m • • Ê: kg, 12 ft 17 Nm (1.7 m • • É É Ê È Q’ty Remarks Order Job name/Part name Brake caliper disassembly Remove the parts in the order listed below.
Page 154: Brake Caliper Disassembly
POWR BRAKE BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: • Brake caliper pistons • Brake caliper piston dust seals • Brake caliper piston seals Removal steps: •...
Page 155: Brake Caliper Assembly
POWR BRAKE 1. Inspect: • Brake caliper pistons Scratches/rust/wear → Replace the caliper assembly. • Brake caliper cylinder → Wear/scratches Replace caliper assembly. • Brake caliper body Cracks/damage → Replace. • Brake fluid delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and piston dust seals whenever a caliper is disassembled.
Page 156: Brake Master Cylinder
POWR BRAKE BRAKE MASTER CYLINDER È: kg, 5.1 ft 7 Nm (0.7 m • • É: 10 Nm (1.0 m kg, 7.2 ft • • Ê Ê: kg, 17 ft 23 Nm (2.3 m • • Ë: kg, 22 ft 30 Nm (3.0 m •...
Page 157 POWR BRAKE È: 7 Nm (0.7 m kg, 5.1 ft • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê Ê: kg, 17 ft 23 Nm (2.3 m • • Ë: kg, 22 ft 30 Nm (3.0 m •...
Page 158: Inspection
POWR BRAKE INSPECTION 1. Inspect: • Brake master cylinder 1 Wear/scratches → Replace the master cylin- der assembly. • Brake master cylinder body 2 Cracks/damage → Replace. • Brake fluid delivery passage (master cylinder body) Blow out with compressed air. 2.
Page 159: Installation
POWR BRAKE INSTALLATION 1. Install: • Brake hose CAUTION: When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a as shown. Union bolt (brake hose): 30 Nm (3.0 m · kg, 22 ft · lb) 2.
Page 160: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION FX10 È: kg, 43 ft 60 Nm (6.0 m • • É: 69 Nm (6.9 m kg, 50 ft • • É È Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below.
Page 161 POWR SLIDE RAIL SUSPENSION Ë È: kg, 2.9 ft 4 Nm (0.4 m • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
Page 162 POWR SLIDE RAIL SUSPENSION È: 49 Nm (4.9 m kg, 35 ft • • É: 60 Nm (6.0 m kg, 43 ft • • Ê: kg, 52 ft 72 Nm (7.2 m • • È É Ê Ê Ê É Ê...
Page 163 POWR SLIDE RAIL SUSPENSION È: kg, 2.9 ft 4 Nm (0.4 m • • É: 9 Nm (0.9 m kg, 6.5 ft • • Ê: kg, 43 ft 60 Nm (6.0 m É • • Ë: kg, 52 ft 72 Nm (7.2 m •...
Page 164 POWR SLIDE RAIL SUSPENSION È: kg, 2.9 ft 4 Nm (0.4 m • • É: 9 Nm (0.9 m kg, 6.5 ft • • Ê: kg, 43 ft 60 Nm (6.0 m É • • Ë: kg, 52 ft 72 Nm (7.2 m •...
Page 165 POWR SLIDE RAIL SUSPENSION È: kg, 54 ft 75 Nm (7.5 m • • È Q’ty Remarks Order Job name/Part name Rear axle Guide wheel Guide wheel Collar Tension adjuster Collar Collar Sliding frame For assembly, reverse the disassembly pro- cedure.
Page 166: Fx10Rt/Fx10Rtr/Fx10Rtra
POWR SLIDE RAIL SUSPENSION FX10RT/FX10RTR/FX10RTRA È: 60 Nm (6.0 m kg, 43 ft • • É: 69 Nm (6.9 m kg, 50 ft • • É È Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen.
Page 167 POWR SLIDE RAIL SUSPENSION Ë È: kg, 2.9 ft 4 Nm (0.4 m • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
Page 168 POWR SLIDE RAIL SUSPENSION È: 49 Nm (4.9 m kg, 35 ft • • É: 60 Nm (6.0 m kg, 43 ft • • Ê: kg, 52 ft 72 Nm (7.2 m • • È É Ê Ê Ê É Ê...
Page 169 POWR SLIDE RAIL SUSPENSION È: kg, 2.9 ft 4 Nm (0.4 m • • É: 9 Nm (0.9 m kg, 6.5 ft • • Ê: kg, 43 ft 60 Nm (6.0 m É • • Ë: kg, 52 ft 72 Nm (7.2 m •...
Page 170 POWR SLIDE RAIL SUSPENSION È: 4 Nm (0.4 m kg, 2.9 ft • • É: kg, 6.5 ft 9 Nm (0.9 m • • Ê: kg, 43 ft 60 Nm (6.0 m É • • Ë: 72 Nm (7.2 m kg, 52 ft •...
Page 171 POWR SLIDE RAIL SUSPENSION È: kg, 54 ft 75 Nm (7.5 m • • È Q’ty Remarks Order Job name/Part name Rear axle Guide wheel Guide wheel Collar Tension adjuster Collar Collar Sliding frame For assembly, reverse the disassembly pro- cedure.
Page 172: Fx10Mt/Fx10Mtr/Fx10Mtra
POWR SLIDE RAIL SUSPENSION FX10MT/FX10MTR/FX10MTRA È: 72 Nm (7.2 m kg, 52 ft • • È È Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen.
Page 173 POWR SLIDE RAIL SUSPENSION Ë È: kg, 2.9 ft 4 Nm (0.4 m • • É É: kg, 4.3 ft 6 Nm (0.6 m • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
Page 174 POWR SLIDE RAIL SUSPENSION Ë È: kg, 2.9 ft 4 Nm (0.4 m • • É É: kg, 4.3 ft 6 Nm (0.6 m • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
Page 175 POWR SLIDE RAIL SUSPENSION È: kg, 6.5 ft 9 Nm (0.9 m • • É: kg, 18 ft 25 Nm (2.5 m • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
Page 176 POWR SLIDE RAIL SUSPENSION È: kg, 6.5 ft 9 Nm (0.9 m • • É: kg, 18 ft 25 Nm (2.5 m • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
Page 177 POWR SLIDE RAIL SUSPENSION È: kg, 54 ft 75 Nm (7.5 m • • È Q’ty Remarks Order Job name/Part name Rear axle Guide wheel Guide wheel Collar Tension adjuster Collar Collar Sliding frame For assembly, reverse the disassembly pro- cedure.
Page 178: Handling Notes
POWR SLIDE RAIL SUSPENSION HANDLING NOTES WARNING This shock absorber contains highly com- pressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The man- ufacturer cannot be held responsible for prop- erty damage or personal injury that may result from improper handling.
Page 179: Assembly
POWR SLIDE RAIL SUSPENSION • Suspension wheel bracket • Front suspension bracket • Rear suspension bracket • Connecting arm • Sliding frame Cracks/damage → Replace. • Slide runner Wear/damage → Replace. ASSEMBLY 1. Install: • tension adjusters 1 NOTE: Install the tension adjusters so that they are angled outward as shown in the illustration.
Page 180 POWR SLIDE RAIL SUSPENSION 5. Install: FX10/FX10RT/FX10RTR/FX10RTRA • Pull rods 1 • Collars 2 • Washers 3 NOTE: Be sure not to pinch the washers when installing the pull rods. After installing the pull rods, make sure that the washers rotate. 6.
Page 181 POWR SLIDE RAIL SUSPENSION È 8. Install: • Front shock absorber 1 (FX10/FX10RT/FX10RTR/FX10RTRA) NOTE: • For FX10: Install the front shock absorber with the charging valve a facing downward. • For FX10RT/FX10RTR/FX10RTRA: Install the gas cylinder with the adjuster b facing upward.
Page 182 POWR SLIDE RAIL SUSPENSION 10. Install: È • Stopper band 1 NOTE: • Install the stopper band with a toward the front pivot arm and b toward the shaft. • Install the stopper band with c toward the rear pivot arm and d toward the rear pivot arm bracket.
Page 183: Installation
POWR SLIDE RAIL SUSPENSION INSTALLATION 1. Adjust: • Track tension Refer to “TRACK TENSION ADJUSTMENT” in CHAPTER 2. Control rod part numbers (FX10MT/FX10MTR/FX10MTRA) È Control rod 1 É Length a mm (in) Ê Length b mm (in) Ë Length c mm (in) 2.5P ×...
Page 184: Front Axle And Track
POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK É È: kg, 6.5 ft 9 Nm (0.9 m • • É É: 24 Nm (2.4 m kg, 17 ft • • Ê: 30 Nm (3.0 m kg, 22 ft • •...
Page 185: Inspection
POWR FRONT AXLE AND TRACK INSPECTION 1. Inspect: • Track 1 • Slide metal 2 Wear/cracks/damage → Replace. 2. Inspect: È • Sprocket wheels 1 Wear/break/damage → Replace. • Front axle 2 Bends/scratches (excessive)/damage → Replace. È FX10/FX10RT/FX10RTR/FX10RTRA É FX10MT/FX10MTR/FX10MTRA 3.
Page 186 POWR FRONT AXLE AND TRACK 2. Install: È 102 mm 123 mm 102 mm (4.02 in) (4.84 in) (4.02 in) • Sprocket wheels • Guide wheels 53.8 mm 39 mm 27 mm 39 mm (2.12 in) (1.54 in) (1.06 in) (1.54 in) NOTE: •...
Page 187: Chapter 5. Engine
SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK È: 4 Nm (0.4 m kg, 2.9 ft • • É: kg, 5.1 ft 7 Nm (0.7 m • • Ê: kg, 5.8 ft 8 Nm (0.8 m • • Ë: 10 Nm (1.0 m kg, 7.2 ft •...
Page 188 SEAT AND FUEL TANK È: kg, 2.9 ft 4 Nm (0.4 m • • É: kg, 5.1 ft 7 Nm (0.7 m • • Ê: kg, 5.8 ft 8 Nm (0.8 m • • Ë: 10 Nm (1.0 m kg, 7.2 ft •...
Page 189: Removal
SEAT AND FUEL TANK REMOVAL 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose connector holder • Fuel hose CAUTION: • Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools.
Page 190: Installation
SEAT AND FUEL TANK INSTALLATION 1. Install: • Fuel pump gasket • Fuel pump • Fuel pump bracket Fuel pump nut: 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • Do not damage the installation surface of the fuel tank when installing the fuel pump.
Page 191: Exhaust Pipe And Muffler
EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER Ì È: kg, 4.3 ft 6 Nm (0.6 m • • Í Í Ë È É: kg, 5.1 ft 7 Nm (0.7 m • • Ê: 9 Nm (0.9 m kg, 6.5 ft •...
Page 192 EXHAUST PIPE AND MUFFLER Ì È: kg, 4.3 ft 6 Nm (0.6 m • • Í Í Ë È É: kg, 5.1 ft 7 Nm (0.7 m • • Ê: kg, 6.5 ft 9 Nm (0.9 m • • Ë: 10 Nm (1.0 m kg, 7.2 ft •...
Page 193: Installation
EXHAUST PIPE AND MUFFLER INSTALLATION 1. Install: • Exhaust pipe 1 (temporarily) NOTE: Install the exhaust pipe to the brackets on the frame, making sure to position it as far rearward as possible, and then temporarily tighten the exhaust pipe bolts. 2.
Page 194 EXHAUST PIPE AND MUFFLER 6. Tighten: • Muffler band bolt Muffler band bolt: 20 Nm (2.0 m · kg, 14 ft · lb) 7. Tighten: • Exhaust pipe bolts Exhaust pipe bolt: 23 Nm (2.3 m · kg, 17 ft · lb)
Page 195: Oil Tank
OIL TANK OIL TANK È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 11 ft 16 Nm (1.6 m • • È É Q’ty Remarks Order Job name/Part name Oil tank removal Remove the parts in the order listed below. Lower side cover (left and right) Refer to “COVERS”...
Page 196: Engine Assembly
ENGINE ASSEMBLY ENGINE ASSEMBLY HOSES AND LEADS È: 10 Nm (1.0 m kg, 7.2 ft • • É: 25 Nm (2.5 m kg, 18 ft • • È É Order Job name/Part name Q’ty Remarks Hoses and leads removal Remove the parts in the order listed below. Coolant Drain.
Page 197: Engine Assembly
ENGINE ASSEMBLY È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 18 ft 25 Nm (2.5 m • • È É Q’ty Remarks Order Job name/Part name Fuel tank Refer to “SEAT AND FUEL TANK”. Exhaust pipe/Muffler Refer to “EXHAUST PIPE AND MUFFLER”.
Page 198 ENGINE ASSEMBLY ENGINE ASSEMBLY È: kg, 6.5 ft 9 Nm (0.9 m • • É: kg, 17 ft 23 Nm (2.3 m • • Ê: kg, 18 ft 25 Nm (2.5 m • • Ë: kg, 47 ft 65 Nm (6.5 m •...
Page 199: Removal
ENGINE ASSEMBLY REMOVAL 1. Remove: • Rear engine mounting nut • Front engine mounting nuts • Washers NOTE: Do not remove the engine mounting bolts. 2. Remove: • Engine assembly Removal steps: • Screw in the engine mounting bolt spacers (front and rear) using the engine mount spacer wrench 1 so that there is a gap between each engine mounting bolt spacer 2 and engine...
Page 200 ENGINE ASSEMBLY Installation steps: • Install the engine mounting bolt spacers (right front and rear). • Install the engine assembly and then, install the rear engine mounting bolt, right front engine mounting bolt and washers. • Install the left front engine mounting bolt spacer to engine mounting bracket and then install the engine mounting bracket, left front engine mounting bolt and washer.
Page 201: Camshafts
CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER È: kg, 8.7 ft 12 Nm (1.2 m • • É: kg, 9.4 ft 13 Nm (1.3 m • • È É Q’ty Remarks Order Job name/Part name Cylinder head cover removal Remove the parts in the order listed below. Fuel tank Refer to “SEAT AND FUEL TANK”.
Page 202: Camshafts
CAMSHAFTS CAMSHAFTS È: kg, 7.2 ft 10 Nm (1.0 m • • É: 12 Nm (1.2 m kg, 8.7 ft • • È Ê: kg, 17 ft 24 Nm (2.4 m • • Ê Ê É Q’ty Remarks Order Job name/Part name Camshafts removal Remove the parts in the order listed below.
Page 203: Removal
CAMSHAFTS REMOVAL 1. Remove: • Timing accessing screw • Crankshaft end cover 2. Align: • “I” mark a on the AC magneto rotor (with the stationary pointer b on the AC mag- neto cover) NOTE: • Turn the crankshaft clockwise. •...
Page 204: Inspection
CAMSHAFTS 6. Remove: • Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2 (Use the special tool 3) Rotor holding tool: 90890-01235 Universal magneto & rotor holder: YU-01235 INSPECTION 1. Inspect: • Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2.
Page 205 CAMSHAFTS 3. Measure: • Camshaft runout Out of specification → Replace. Camshaft runout: 0.030 mm (0.0012 in) 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft-cap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) Measurement steps: •...
Page 206 CAMSHAFTS 6. Inspect: • Camshaft sprocket More than 1/4 tooth a wear → Replace the camshaft sprockets, timing chain, and crank- shaft as a set. a 1/4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 7. Inspect: • Timing chain guide (top side) Damage/wear →...
Page 207 CAMSHAFTS Assembly steps: • Install the timing chain tensioner spring and tim- ing chain tensioner rod 1. • Squeeze the timing chain tensioner clip 2, and then push the timing chain tensioner rod 3 into the timing chain tensioner housing. NOTE: Do not release the timing chain tensioner clip while pushing the rod into the housing, otherwise the rod...
Page 208: Installation
CAMSHAFTS INSTALLATION 1. Install: • Intake camshaft sprocket 1 • Exhaust camshaft sprocket 2 (with the special tool 3) Rotor holding tool: 90890-01235 Universal magneto & rotor holder: YU-01235 • Camshaft sprocket bolts Camshaft sprocket bolt: 24 Nm (2.4 m · kg, 17 ft · lb) NOTE: Make sure that the holes a in the cylinder #3 cam and marks b on the camshaft sprockets are in the...
Page 209 CAMSHAFTS 3. Install: • Dowel pins • Intake camshaft caps • Exhaust camshaft caps NOTE: • The “I” mark refers to the intake camshaft caps and the “E” mark refers to the exhaust camshaft caps. • Install the camshaft caps with the arrow mark a pointing towards the right side of the engine.
Page 210 CAMSHAFTS 5. Install: • Timing chain tensioner gasket 1 • Timing chain tensioner 2 Timing chain tensioner bolt: 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: • Be sure to install the timing chain tensioner gas- ket so that its section with the “L” mark a is pro- truding from the lower left side of the timing chain tensioner.
Page 211 • Apply bond TB1541 of the cylinder head cover and cylinder head cover gasket. • Apply Yamaha bond No. 1215 2 onto the mating surfaces of the cylinder head cover gasket. • Tighten the cylinder head cover bolts stages and in a crisscross pattern.
Page 212: Cylinder Head
CYLINDER HEAD CYLINDER HEAD Ê É È È: 12 Nm (1.2 m kg, 8.7 ft • • É: kg, 14 ft 20 Nm (2.0 m • • Ê: 25 Nm (2.5 m kg, 18 ft • • kg, 18 ft 25 Nm (2.5 m •...
Page 213: Removal
CYLINDER HEAD REMOVAL 1. Remove: • Cylinder head bolts NOTE: • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. INSPECTION 1.
Page 214: Installation
CYLINDER HEAD INSTALLATION 1. Install: • Cylinder head NOTE: Pass the timing chain through the timing chain cav- ity. 2. Tighten: • Cylinder head bolts (M10) NOTE: The tightening procedure of the cylinder head bolts is angle controlled, therefore tighten the bolts using the following procedure.
Page 215 CYLINDER HEAD • Tighten the cylinder head bolts further to reach the specified angle 175 ~ 185° in the proper tightening sequence as shown. Cylinder head bolt (M10): Final: Specified angle 175 ~ 185° WARNING When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it.
Page 216 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Q’ty Remarks Order Job name/Part name Valves and valve springs removal Remove the parts in the order listed below. Cylinder head Refer to “CYLINDER HEAD”. Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Intake valve Exhaust valve...
Page 217: Valves And Valve Springs
VALVES AND VALVE SPRINGS REMOVAL The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: •...
Page 218: Inspection
VALVES AND VALVE SPRINGS 4. Remove: • Upper spring seat 1 • Valve spring 2 • Valve 3 • Valve stem seal 4 • Lower spring seat 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. INSPECTION 1.
Page 219 VALVES AND VALVE SPRINGS • After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (ø4.5): 90890-04116 Valve guide remover (4.5 mm): YM-04116...
Page 220 VALVES AND VALVE SPRINGS 6. Measure: • Valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the valve stem seal. Valve stem runout: 0.010 mm (0.0004 in) 7.
Page 221 VALVES AND VALVE SPRINGS 10. Lap: • Valve face • Valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: • Apply a coarse lapping compound a to the valve face.
Page 222: Installation
VALVES AND VALVE SPRINGS 11. Measure: • Valve spring free length a Out of specification → Replace the valve spring. Valve spring free length (intake and exhaust): 39.57 mm (1.56 in) <Limit>: 37.59 mm (1.48 in) 12. Measure: • Compressed valve spring force a Out of specification →...
Page 223 VALVES AND VALVE SPRINGS 2. Lubricate: • Valve stem 1 • Valve stem seal 2 (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide oil 3. Install: • Lower spring seat 1 • Valve stem seal 2 • Valve 3 • Valve spring 4 •...
Page 224 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad •...
Page 225 AC MAGNETO ROTOR AND STARTER CLUTCH AC MAGNETO ROTOR AND STARTER CLUTCH È: 10 Nm (1.0 m kg, 7.2 ft • • É: 12 Nm (1.2 m kg, 8.7 ft • • Ê: 130 Nm (13.0 m kg, 94 ft •...
Page 226: Ac Magneto Rotor And Starter Clutch
AC MAGNETO ROTOR AND STARTER CLUTCH REMOVAL 1. Remove: • AC magneto rotor bolt 1 • Washer NOTE: While holding the AC magneto rotor 2 with the sheave holder 3, loosen the AC magneto rotor bolt. Sheave holder: 90890-01701 Primary clutch holder: YS-01880-A 2.
Page 227: Inspection
AC MAGNETO ROTOR AND STARTER CLUTCH 3. Remove: • Starter clutch NOTE: While holding the AC magneto rotor with the sheave holder, remove the starter clutch bolts 1. Sheave holder: 90890-01701 Primary clutch holder: YS-01880-A INSPECTION 1. Inspect: • Stator coil Damage →...
Page 228: Installation
AC MAGNETO ROTOR AND STARTER CLUTCH 4. Inspect: • Starter clutch operation È Installation steps: • Install the starter clutch gear onto the starter É clutch and hold the AC magneto rotor. • When turning the starter clutch gear clockwise È, it should turn freely, otherwise the starter clutch is faulty and must be replaced.
Page 229 Sheave holder: 90890-01701 Primary clutch holder: YS-01880-A 5. Apply: • Sealant (onto the AC magneto lead grommet) Yamaha bond No. 1215: 90890-85505 ® (Three Bond No.1215 6. Install: • AC magneto rotor cover AC magneto rotor cover bolt: 12 Nm (1.2 m · kg, 8.7 ft · lb) ®...
Page 230 OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP È È (15) É È Ê Ê È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 8.7 ft 12 Nm (1.2 m • • Ê: 15 Nm (1.5 m kg, 11 ft •...
Page 231 OIL PAN AND OIL PUMP È: 4 Nm (0.4 m kg, 2.9 ft • • È È È È Q’ty Remarks Order Job name/Part name Oil pump disassembly Remove the parts in the order listed below. Oil pan divider Oil pump housing cover 1 Oil pump housing cover 2 Oil strainer Washer...
Page 232 OIL PAN AND OIL PUMP È: 4 Nm (0.4 m kg, 2.9 ft • • È È È È Q’ty Remarks Order Job name/Part name Oil pump shaft Oil seal Check ball seat Check ball Spring Spacer Relief valve cover Spring Relief valve Oil pump housing...
Page 233: Oil Pan And Oil Pump
OIL PAN AND OIL PUMP REMOVAL 1. Remove: • Oil pan 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
Page 234 OIL PAN AND OIL PUMP 2. Measure: • Inner-rotor-to-outer-rotor-tip clearance a (between inner rotor 1 and outer rotor 2) • Outer-rotor-to-oil-pump-housing clearance b (between outer rotor 2 and pump housing 3) Out of specifications → Replace oil pump assembly. Inner-rotor-to-outer-rotor-tip clear- ance: 0.090 ~ 0.150 mm (0.0035 ~ 0.0059 in)
Page 235: Installation
OIL PAN AND OIL PUMP 6. Inspect: • Check ball seat 1 • Check ball 2 • Spring 3 • Spacer 4 Damage/wear → Replace the defective part(-s). 7. Inspect: • Oil strainer Damage → Replace. Obstruction → Wash and blow out with com- pressed air.
Page 236 OIL PAN AND OIL PUMP 4. Install: • Oil pump driven gear 1 Oil pump driven gear bolt: 15 Nm (1.5 m · kg, 11 ft · lb) NOTE: • Install the oil pump driven gear with the stamped mark “4XV” facing towards the oil pump assem- bly.
Page 237: Crankcase
• Final Specified angle 65 ~ 70˚ É È É É È Ë È : Yamaha bond No.1215 Ë ® (Three Bond No.1215 Order Job name/Part name Q’ty Remarks Crankcase separate Remove the parts in the order listed below. Engine assembly Refer to “ENGINE ASSEMBLY”.
Page 238 • • Final Specified angle 65 ~ 70˚ É È É É È Ë È : Yamaha bond No.1215 Ë ® (Three Bond No.1215 Order Job name/Part name Q’ty Remarks Primary sheave drive shaft assembly bolt Lower crankcase Dowel pin For installation, reverse the removal proce- dure.
Page 239: Removal
CRANKCASE REMOVAL 1. Remove: • Crankcase bolts NOTE: • Place the engine upside down. • Loosen the bolts in decreasing numerical order of the embossed numbers on the crankcase. • Loosen each bolt 1/4 of a turn at a time. After all of the bolts are fully loosened, remove them.
Page 240: Installation
• Lubricate the bolts 9 ~ E, I ~ N thread part and mating surface with engine oil. • Apply Yamaha bond No. 1215 to the threads of the bolts F ~ H. • Finger tighten the crankcase bolts.
Page 241 CRANKCASE 5. Tighten: • Crankcase bolts (M9 × 105 mm) 1 ~ 8 NOTE: Tighten the bolts in the order of the embossed numbers on the crankcase. • Tighten the crankcase bolts. Crankcase bolt 1 ~ 8: 1st: 15 Nm (1.5 m · kg, 11 ft · lb) •...
Page 242 CRANKCASE 6. Tighten: • Crankcase bolts 9 ~ N NOTE: Tighten the bolts in the order of the embossed numbers on the crankcase. Crankcase bolt 9 ~ B: 24 Nm (2.4 m · kg, 17 ft · lb) Crankcase bolt C ~ N: 12 Nm (1.2 m ·...
Page 243: Connecting Rods And Pistons
CONNECTING RODS AND PISTONS CONNECTING RODS AND PISTONS È È: kg, 14 ft 20 Nm (2.0 m • • Final Specified angle 115 ~ 125˚ Q’ty Remarks Order Job name/Part name Connecting rods and pistons removal Remove the parts in the order listed below. Crankcase Separate.
Page 244: Removal
CONNECTING RODS AND PISTONS REMOVAL 1. Remove: • Connecting rod cap 1 • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place. 2. Remove: • Piston pin clips 1 •...
Page 245: Inspection
CONNECTING RODS AND PISTONS INSPECTION 1. Inspect: • Piston wall • Cylinder wall Vertical scratches → Replace the crankcase, and replace the piston and piston rings as a set. 2. Measure: • Piston-to-cylinder clearance Measurement steps: 1st step: • Measure cylinder bore “C” with the cylinder bore gauge 1.
Page 246 CONNECTING RODS AND PISTONS 2nd step: • Measure piston skirt diameter “P” with the micrometer. a 11.0 mm (0.43 in) from the bottom edge of the piston. Piston size (standard) (P): 81.950 ~ 81.965 mm (3.2264 ~ 3.2270 in) • If out of specification, replace the piston and piston rings as a set.
Page 247 CONNECTING RODS AND PISTONS 4. Install: • Piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown. a 5.0 mm (0.20 in) 5. Measure: • Piston ring end gap Out of specification → Replace the piston rings as a set.
Page 248 CONNECTING RODS AND PISTONS 8. Measure: • Piston pin bore inside diameter Out of specification → Replace the piston. Piston pin bore inside diameter: 19.004 ~ 19.015 mm (0.7482 ~ 0.7486 in) 9. Calculate: • Piston pin to piston pin bore clearance Out of specification →...
Page 249 CONNECTING RODS AND PISTONS Measurement steps: CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crank- shaft-pin-to-big-end-bearing clearance and pre- vent engine damage, the big end bearings must be installed in their original positions. •...
Page 250 CONNECTING RODS AND PISTONS • Tighten the connecting rod nuts. Refer to “INSTALLATION” in “CONNECTING RODS AND PISTONS” on page 5-65. • Remove the connecting rod and big end bear- ings. ® width e • Measure the compressed Plastigauge on the crankshaft pin. If the clearance is out of specification, select replacement big end bearings.
Page 251: Installation
CONNECTING RODS AND PISTONS INSTALLATION 1. Install: • Top ring 1 • 2nd ring 2 • Upper oil ring rail 3 • Oil ring expander 4 • Lower oil ring rail 5 NOTE: Be sure to install the piston rings so that the manu- facturer marks a face up.
Page 252 CONNECTING RODS AND PISTONS 4. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant: Engine oil 5. Lubricate: • Bolt threads • Nut seats (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide grease 6. Lubricate: •...
Page 253 CONNECTING RODS AND PISTONS 8. Align: • Bolt heads (with the connecting rod caps) 9. Tighten: • Connecting rod nuts WARNING Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts.
Page 254: Crankshaft And Balancer Shaft
CRANKSHAFT AND BALANCER SHAFT CRANKSHAFT AND BALANCER SHAFT È: 10 Nm (1.0 m kg, 7.2 ft • • É: kg, 25 ft 35 Nm (3.5 m • • É 10 11 È É Q’ty Remarks Order Job name/Part name Crankshaft and balancer shaft removal Remove the parts in the order listed below.
Page 255 CRANKSHAFT AND BALANCER SHAFT È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 25 ft 35 Nm (3.5 m • • É 10 11 È É Q’ty Remarks Order Job name/Part name Balancer shaft Balancer driven gear Bearing retainer Bearing Circlip...
Page 256: Remove
CRANKSHAFT AND BALANCER SHAFT REMOVE 1. Remove: • Crankshaft journal lower bearings (from the lower crankcase) • Crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its orig- inal place.
Page 257: Inspection
CRANKSHAFT AND BALANCER SHAFT INSPECTION 1. Measure: • Crankshaft runout Use the V-blocks and a dial gauge. Out of specification → Replace the crank- shaft. Dial gauge: 90890-03097 Dial indicator gauge: YU-A8428 Crankshaft runout: 0.03 mm (0.0012 in) 2. Inspect: •...
Page 258 CRANKSHAFT AND BALANCER SHAFT Measurement steps: CAUTION: Do not interchange the crankshaft journal bear- ings. To obtain the correct crankshaft-journal- to-crankshaft-journal-bearing clearance prevent engine damage, the crankshaft journal bearings must be installed in their original posi- tions. • Clean the crankshaft journal bearings, crank- shaft journals, and bearing portions of the crankcase.
Page 259 CRANKSHAFT AND BALANCER SHAFT • Tighten the bolts in the order of the embossed numbers on the crankcase. Refer to “INSTALLATION” in “CRANKCASE” on page 5-54. • Remove the lower crankcase and the crank- shaft journal lower bearings. ® width e •...
Page 260: Installation
CRANKSHAFT AND BALANCER SHAFT INSTALLATION 1. Install: • Balancer driven gear 1 • Balancer shaft 2 NOTE: • Face the punch mark a on the balancer driven gear inward. • Align the projection b on the balancer shaft with the slot c in the balancer driven gear. 2.
Page 261 CRANKSHAFT AND BALANCER SHAFT 4. Tighten: • Balancer weight bolts 1 NOTE: Place a wood a between the balancer weight 2 and crankcase. Balancer weight bolt: 35 Nm (3.5 m · kg, 25 ft · lb) 5. Bend the lock washer tab. 6.
Page 262 CRANKSHAFT AND BALANCER SHAFT 8. Install: • Primary sheave drive shaft assembly 1 (to the crankshaft 2) NOTE: Align the shallow groove a in the primary drive shaft assembly with the low spline b of the crank- shaft. 9. Install: •...
Page 263: Chapter 6. Cooling System
COOL RADIATOR COOLING SYSTEM RADIATOR È È: kg, 5.1 ft 7 Nm (0.7 m • • È È È È Order Job name/Part name Q’ty Remarks Radiator removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAPTER Steering column Refer to “STEERING”...
Page 264 COOL RADIATOR È È: kg, 5.1 ft 7 Nm (0.7 m • • È È È È Q’ty Remarks Order Job name/Part name Radiator Radiator fan motor DC back buzzer coupler Disconnect. Reverse model only DC back buzzer Reverse model only Radiator stay For installation, reverse the removal proce- dure.
Page 265: Inspection
COOL RADIATOR INSPECTION 1. Inspect: • Radiator inlet hose • Radiator outlet hose • Coolant reservoir hose Cracks/damage → Replace. 2. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver.
Page 266: Installation
COOL RADIATOR INSTALLATION 1. Install: • Radiator stay 1 • DC back buzzer 2 (For reverse model) Radiator stay bolt: 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • Hook the hooked portion a of the brake hose holder onto the radiator stay, and then fasten the holder with the bolt.
Page 267: Thermostat
COOL THERMOSTAT THERMOSTAT È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 17 ft 23 Nm (2.3 m • • È É Order Job name/Part name Q’ty Remarks Thermostat removal Remove the parts in the order listed below. Coolant Drain.
Page 268: Inspection
COOL THERMOSTAT INSPECTION 1. Inspect: • Thermostat Does not open at 69.0 ~ 73.0 °C (156.2 ~ 163.4 °F) → Replace. Inspection steps: • Suspend the thermostat 1 in a container 2 filled with water. • Slowly heat the water 3. •...
Page 269: Water Pump
COOL WATER PUMP WATER PUMP È: kg, 8.7 ft 12 Nm (1.2 m • • È Order Job name/Part name Q’ty Remarks Water pump removal Remove the parts in the order listed below. Engine assembly Refer to “ENGINE ASSEMBLY” in CHAPTER Timing mark accessing screw Crankshaft end cover Water pump assembly...
Page 270 COOL WATER PUMP Q’ty Remarks Order Job name/Part name Water pump disassembly Remove the parts in the order listed below. Water pump housing cover Gasket Circlip Impeller shaft gear Impeller shaft assembly Water pump seal Bearing Oil seal Water pump housing For assembly, reverse the disassembly pro- cedure.
Page 271: Removal
COOL WATER PUMP REMOVAL 1. Remove: • Timing mark accessing screw • Crankshaft end cover 2. Align: • “I” mark a on the AC magneto rotor (with the stationary pointer b on the AC mag- neto cover) NOTE: Turn the crankshaft clockwise. 3.
Page 272: Inspection
4 and middle driven shaft bear- ing driver 5. • Before installing the water pump seal, apply ® Yamaha bond No.1215 (Three Bond No.1215 2 to the water pump housing 3. Mechanical seal installer: 90890-04145 Middle driven shaft bearing driver:...
Page 273: Installation
COOL WATER PUMP 4. Install: • Rubber damper holder 1 • Rubber damper 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 5. Measure: • Impeller shaft tilt Out of specification → Repeat steps (4) and (5).
Page 274: Oil Cooler And Heat Exchanger
COOL OIL COOLER AND HEAT EXCHANGER OIL COOLER AND HEAT EXCHANGER È: kg, 7.2 ft 10 Nm (1.0 m • • FX10MT/FX10MTR/FX10MTRA È Q’ty Remarks Order Job name/Part name Oil cooler and heat exchanger removal Remove the parts in the order listed below. Coolant Drain.
Page 275 COOL OIL COOLER AND HEAT EXCHANGER È: kg, 7.2 ft 10 Nm (1.0 m • • FX10MT/FX10MTR/FX10MTRA È Q’ty Remarks Order Job name/Part name Heat exchanger hose 1 Heat exchanger pipe Heat exchanger hose 2 Heat exchanger For installation, reverse the removal proce- dure.
Page 276: Inspection
COOL OIL COOLER AND HEAT EXCHANGER INSPECTION 1. Inspect: • Heat exchanger(s) • Oil cooler • Cylinder head water jacket • Oil cooler hose • Water pump hoses • Heat exchanger hoses • Heat exchanger pipe Cracks/damage → Replace. 6-14...
Page 277: Chapter 7. Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Battery 8 Intake air pressure sen- D Crankshaft position I Injector #2 2 Injector #3 J Coolant temperature sor 1 (cylinders #1, #2, sensor 3 Cylinder-#3 ignition coil E Oil pressure switch and #3) sensor 4 Spark plug...
Page 278 FUEL INJECTION SYSTEM...
Page 279 FUEL INJECTION SYSTEM 3 Crankshaft position sensor 4 Main switch 5 Main fuse 6 Load control relay 7 Battery 0 Fuel injection system fuse B Engine stop switch C Throttle switch D Thumb warmer E Grip warmer F Oil pressure switch G CO adjustment coupler H ECU (engine control unit) I Cylinder-#1 ignition coil...
Page 280: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operat- ing normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and the warning light and self-diagnostic warning indicator on the LCD flash to alert the rider that a malfunction has occurred in the system.
Page 281 FUEL INJECTION SYSTEM Fault code Able/unable Able/unable Item Symptom to start to drive Able ISC (idle speed control) valve (stuck fully Engine speed is high when the engine is (unable if Able open) idling. valve stuck fully closed) Speed sensor No normal signals are received from the Able Able...
Page 282: Troubleshooting Chart
FUEL INJECTION SYSTEM TROUBLESHOOTING CHART Engine operation is not normal or the warning light and self-diagnostic warning indicator on the LCD flash. * The warning light and self-diagnostic warning indicator on the LCD may not flash even if the engine operation is not normal.
Page 283: Diagnostic Mode
FUEL INJECTION SYSTEM DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode 1.
Page 284 FUEL INJECTION SYSTEM 6. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating condi- tions of the sensor appears on the odometer/ tripmeter/engine speed meter LCD. • Actuator operation Push the grip warmer side of the grip/thumb warmer adjustment switch to operate the actuator.
Page 285 FUEL INJECTION SYSTEM Fault code table Fault Symptom Probable cause of malfunction Diagnostic code No. code No. No normal signals are • Open or short circuit in wire harness. received from the crankshaft • Defective crankshaft position sensor. position sensor. •...
Page 286 FUEL INJECTION SYSTEM Fault Symptom Probable cause of malfunction Diagnostic code No. code No. • Open or short circuit in wire harness. • Open or short circuit in fuel injection system sub-wire harness. • Malfunction in throttle body. • Malfunction in throttle cable. Engine speed is high when •...
Page 287 FUEL INJECTION SYSTEM Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAG- NOSTIC MODE”. NOTE: • Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively.
Page 288 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code No. (reference value) Injector #2 If the grip warmer side of the grip/thumb warmer adjust- After pushing the switch, check ment switch is pushed, actuates injector #2 and displays that the injector operates five the self-diagnosis warning indicator (five times at one- times by listening to its operat-...
Page 289: Troubleshooting Details
FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the meter display accord- ing to the reinstatement method.
Page 290 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor 1 (cylinders #1, #2, and #3): open or short circuit detected. Diagnostic code No. 03 (intake air pressure sensor 1 (cylinders #1, #2, and #3)) Order Item/components and probable cause Check or maintenance job Reinstatement method...
Page 291 FUEL INJECTION SYSTEM Intake air pressure sensor 1 (cylinders #1, #2, and #3): hose system mal- Fault code No. Symptom function (clogged or detached hose). Diagnostic code No. 03 (intake air pressure sensor 1 (cylinders #1, #2, and #3)) Order Item/components and probable cause Check or maintenance job Reinstatement...
Page 292 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic code No. 01 (throttle position sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method Installed condition of throttle position Check for looseness or pinching. Starting the sensor.
Page 293 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor 2 (cylinder #1): open or short circuit detected. Diagnostic code No. 04 (intake air pressure sensor 2 (cylinder #1)) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have...
Page 294 FUEL INJECTION SYSTEM Intake air pressure sensor 2 (cylinder #1): hose system malfunction Fault code No. Symptom (clogged or detached hose). Diagnostic code No. 04 (intake air pressure sensor 2 (cylinder #1)) Order Item/components and probable cause Check or maintenance job Reinstatement method Intake air pressure sensor 2 (cylinder #1)
Page 295 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the cylinder-#1 ignition coil. Diagnostic code No. 30 (cylinder-#1 ignition coil) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have Starting the Cylinder-#1 ignition coil coupler pulled out.
Page 296 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the cylinder-#3 ignition coil. Diagnostic code No. 32 (cylinder-#3 ignition coil) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have Starting the Cylinder-#3 ignition coil coupler pulled out.
Page 297 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the speed sensor. Diagnostic code No. 07 (speed sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have Starting the Speed sensor coupler pulled out.
Page 298 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injectors and fuel pump is not normal. Diagnostic code No. 09 (fuel system voltage) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have Starting the Fuel injection system relay coupler pulled out.
Page 299 FUEL INJECTION SYSTEM Error is detected while reading or writing on EEPROM (CO adjustment Fault code No. Symptom value). Diagnostic No. 60 (EEPROM improper cylinder indication) Order Item/components and probable cause Check or maintenance job Reinstatement method Malfunction in ECU. Execute the diagnostic mode (code No.
Page 300 FUEL INJECTION SYSTEM Fault code No. Symptom Grip warmer: open or short circuit detected. Diagnostic code No. 26 (grip warmer operation) Order Item/components and probable cause Check or maintenance job Reinstatement method Open or short circuit in wire harness. Repair or replace if there is an open or short cir- Setting the cuit.
Page 301 FUEL INJECTION SYSTEM Er-1 Symptom No signals are received from the ECU. Er-2 Symptom No signals are received from the ECU within the specified signal time. Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Er-4 Symptom Non-registered data has been received from the meter.
Page 302: Oil Pressure Switch
FUEL INJECTION SYSTEM OIL PRESSURE SWITCH 1. Disconnect: • Oil pressure switch coupler 1 2. Connect: • Pocket tester (between the engine ground and oil pressure switch terminal) 3. Check: • Oil pressure switch continuity No continuity → Replace the oil pressure switch.
Page 303: Isc (Idle Speed Control) Unit
FUEL INJECTION SYSTEM ISC (IDLE SPEED CONTROL) UNIT NOTE: Do not remove the ISC (idle speed control) unit completely from the throttle body. 1. Inspect: • ISC (idle speed control) unit Inspection steps: • Disconnect the ISC (idle speed control) unit coupler from the ISC (idle speed control) unit.
Page 304: Air Filter Case
AIR FILTER CASE AIR FILTER CASE È: kg, 2.2 ft 3 Nm (0.3 m • • É: kg, 5.1 ft 7 Nm (0.7 m • • É È É È É Q’ty Remarks Order Job name/Part name Air filter case removal Remove the parts in the order listed below.
Page 305: Throttle Body
THROTTLE BODY THROTTLE BODY È: 3 Nm (0.3 m kg, 2.2 ft • • È È È È È È Q’ty Remarks Order Job name/Part name Throttle body removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAPTER Steering column Refer to “STEERING”...
Page 306: Injectors
THROTTLE BODY INJECTORS Order Job name/Part name Q’ty Remarks Injectors removal Remove the parts in the order listed below. Throttle position sensor coupler Disconnect. Intake air pressure sensor 2 (cylinder #1) Disconnect. coupler Intake air pressure sensor 1 (cylinders #1, Disconnect.
Page 307 THROTTLE BODY Q’ty Remarks Order Job name/Part name Intake air pressure sensor 1 (cylinders #1, #2, and #3) Fuel rail Injector For installation, reverse the removal proce- dure. 7-31...
Page 308: Removal
THROTTLE BODY REMOVAL 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose CAUTION: • Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools.
Page 309: Fuel Pressure Inspection
THROTTLE BODY FUEL PRESSURE INSPECTION 1. Inspect: • Fuel pressure Measurement steps: • Remove the fuel hose connector holder, and then disconnect the fuel hose. Refer to “SEAT AND FUEL TANK” in CHAP- TER 5. • Connect the fuel pressure adapter 1 between the fuel hose 2 and fuel pump 3.
Page 310: Inspection And Adjustment
THROTTLE BODY INSPECTION AND ADJUSTMENT 1. Inspect: • Throttle position sensor Inspect steps: • Disconnect the throttle position sensor coupler. • Remove the throttle position sensor from the throttle body. • Connect the pocket tester (Ω × 1k) to the throt- tle position sensor.
Page 311 THROTTLE BODY • Measure the throttle position sensor voltage. • Adjust the throttle position sensor angle so the measured voltage is within the specified range. Throttle position sensor voltage: 0.63 ~ 0.73 V (Yellow – Black/Blue) • After adjusting the throttle position sensor angle, tighten the throttle position sensor screws.
Page 312 7-36...
Page 313: Chapter 8. Electrical
– ELEC SWITCH INSPECTION ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for conti- nuity. If the continuity is faulty at any point, replace the switch. Pocket tester: 90890-03112 Analog pocket tester: YU-03112-C NOTE: • Set the pocket tester to “0” before starting a test. •...
Page 314: Ignition System
– ELEC IGNITION SYSTEM...
Page 315: Circuit Diagram
– ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM 3 Crankshaft position sensor 4 Main switch 5 Main fuse 7 Battery B Engine stop switch C Throttle switch H ECU (engine control unit) I Cylinder-#1 ignition coil J Spark plug K Cylinder-#2 ignition coil L Cylinder-#3 ignition coil R Throttle position sensor S Speed sensor...
Page 316: Troubleshooting
– ELEC IGNITION SYSTEM TROUBLESHOOTING NO SPARK OR WEAK SPARK. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace or charge the battery.
Page 317 – ELEC IGNITION SYSTEM T.O.R.S. OPERATES. Is self-diagnosis code 15, 16, or 42 displayed? Check the affected item(s). Has throttle body icing occurred or is foreign material stuck in the throttle body? Perform throttle body maintenance. Is the throttle switch malfunctioning? Repair or replace the right handlebar switch.
Page 318: Ignition Spark Gap
– ELEC IGNITION SYSTEM IGNITION SPARK GAP È The following procedure applies to all of the ignition coils. 1. Measure: • Ignition spark gap Out of specification → Replace the ignition coil(s). Measurement steps: • Disconnect the ignition coil 1 from the spark plug.
Page 319: Crankshaft Position Sensor
– ELEC IGNITION SYSTEM CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor coupler 2. Connect: • Pocket tester (to the crankshaft position sensor coupler) 3. Measure: • Crankshaft position sensor resistance Out of specification → Replace. Crankshaft position sensor resis- tance: 336 ~ 504 Ω...
Page 320: Throttle Override System (T.o.r.s.)
– ELEC IGNITION SYSTEM THROTTLE OVERRIDE SYSTEM (T.O.R.S.) WARNING • If the T.O.R.S. is activated, make sure that the cause of the malfunction has been corrected and that the engine can be operated without a problem before restarting the engine. •...
Page 321: Engine Stop Switch
– ELEC IGNITION SYSTEM NOTE: • When the T.O.R.S. is activated, the warning light 4 and self-diagnosis warning indicator 5 will flash and the two-digit code “84” 6 will flash in the odometer/tripmeter/engine speed meter LCD. • The T.O.R.S. monitors the condition of the throt- tle position sensor, speedometer unit, and speed sensor, and will operate if any of the monitored items is disconnected or malfunctioning.
Page 322: Main Switch
– ELEC IGNITION SYSTEM MAIN SWITCH 1. Disconnect: • Main switch coupler 2. Connect: • Pocket tester (to the main switch coupler) Br/W 3. Check: • Main switch continuity Faulty → Replace. Color code Switch position Br/W START Continuity 8-10...
Page 323: Electrical Starting System
– ELEC ELECTRICAL STARTING SYSTEM 8-11...
Page 324: Troubleshooting
– ELEC ELECTRICAL STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. 1. Connect: • Starter relay terminals (battery side and starter motor side) Check the battery and connectors. Refer to “BATTERY INSPECTION” in CHAPTER Charge or replace the battery. Refer “BATTERY INSPECTION”...
Page 325: Circuit Diagram
– ELEC ELECTRICAL STARTING SYSTEM FAULTY Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the engine stop switch and main switch. Refer to “IGNITION SYSTEM”. Replace the right handlebar switch and/or main switch.
Page 326: Starter Motor
– ELEC ELECTRICAL STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in the order listed below. Engine assembly Refer to “ENGINE ASSEMBLY” in CHAPTER Starter motor lead Starter motor assembly For installation, reverse the removal proce- dure.
Page 327 – ELEC ELECTRICAL STARTING SYSTEM Q’ty Remarks Order Job name/Part name Brush holder Bearing Armature assembly Starter motor yoke For assembly, reverse the disassembly pro- cedure. 8-15...
Page 328 – ELEC ELECTRICAL STARTING SYSTEM Inspection 1. Inspect: • Commutator (outer surface) Dirty → Clean with #600 grit sandpaper 1. Hold the armature in a vise 2 and copper or aluminium plate 3. CAUTION: Lightly grip the armature with a vise. 2.
Page 329 – ELEC ELECTRICAL STARTING SYSTEM 5. Measure: • Brush length a Out of specification → Replace the brushes as a set. Brush length wear limit: 4.4 mm (0.17 in) 6. Measure: • Brush spring pressure Fatigue/out of specification → Replace the brush spring as a set.
Page 330: Charging System
– ELEC CHARGING SYSTEM 8-18...
Page 331: Troubleshooting
– ELEC CHARGING SYSTEM TROUBLESHOOTING BATTERY IS NOT CHARGED. 1. Connect: • Pocket tester (to the battery terminals) 2. Measure: OUT OF SPECIFICATION • Battery voltage Battery voltage: More than 12 V at 20 °C (68 °F) • Check the battery. •...
Page 332: Battery
– ELEC CHARGING SYSTEM BATTERY Inspection 1. Inspect: • Battery condition Refer to “BATTERY INSPECTION” in CHAP- TER 2. Battery Storage The battery should be stored if the snowmobile is not going to be used for a long period. 1. Remove: •...
Page 333 – ELEC CHARGING SYSTEM 8-21...
Page 334: Lighting System
– ELEC LIGHTING SYSTEM 8-22...
Page 335: Circuit Diagram
– ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 1 Rectifier/regulator 2 AC magneto 4 Main switch 5 Main fuse 6 Load control relay 7 Battery B Engine stop switch H ECU (engine control unit) Z Frame ground _ Tail/brake light d Multi-function meter g High beam indicator light h Headlight...
Page 336: Troubleshooting
– ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT DO NOT COME ON. Check the headlight bulb(s). NO CONTINUITY Replace the bulb(s). Check the main fuse, ignition fuse, and headlight fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse, and/or head- light fuse.
Page 337 – ELEC LIGHTING SYSTEM METER LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace or charge the battery.
Page 338 – ELEC LIGHTING SYSTEM TAIL LIGHT DOES NOT COME ON. Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse, ignition fuse, and/or signal FAULTY fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace or charge the battery.
Page 339: Bulb(S)
– ELEC LIGHTING SYSTEM BULB(S) NOTE: Do not check any of the lights that use LEDs. 1. Remove: • Headlight bulb 2. Connect: • Pocket tester (to the bulb terminals) WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot. Do not touch the bulb until it cools down.
Page 340: Headlight Relay
– ELEC LIGHTING SYSTEM HEADLIGHT RELAY 1. Remove: • Headlight relay (with the black coupler) Inspection steps: • Connect the pocket tester (Ω × 1) to the head- light relay terminals as shown. Positive tester probe → Blue/White 1 Negative tester probe → Green 2 •...
Page 341 – ELEC LIGHTING SYSTEM 8-29...
Page 342: Signal System
– ELEC SIGNAL SYSTEM 8-30...
Page 343: Circuit Diagram
– ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 1 Rectifier/regulator 2 AC magneto 4 Main switch 5 Main fuse 6 Load control relay 7 Battery B Engine stop switch H ECU (engine control unit) S Speed sensor W Coolant temperature sensor Z Frame ground [ DC back buzzer \ Gear position switch...
Page 344: Troubleshooting
– ELEC SIGNAL SYSTEM TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse, and/or signal fuse. Check the battery. Refer to “BATTERY INSPECTION”...
Page 345 – ELEC SIGNAL SYSTEM LOW COOLANT TEMPERATURE INDICATOR LIGHT, COOLANT TEMPERATURE WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery.
Page 346 – ELEC SIGNAL SYSTEM FUEL METER AND/OR FUEL LEVEL WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery.
Page 347 – ELEC SIGNAL SYSTEM OIL LEVEL WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION”...
Page 348 – ELEC SIGNAL SYSTEM SPEEDOMETER DOES NOT OPERATE. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace or charge the battery.
Page 349 – ELEC SIGNAL SYSTEM BACK BUZZER DOES NOT SOUND. (FX10/FX10RTR/FX10RTRA/FX10MTR/FX10MTRA) Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse, ignition fuse, and/or signal FAULTY fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace or charge the battery.
Page 350: Brake Light Switch
– ELEC SIGNAL SYSTEM BRAKE LIGHT SWITCH 1. Disconnect: • Brake light switch coupler 2. Connect: • Pocket tester (to the brake light switch coupler) 3. Check: • Brake light switch continuity Faulty → Replace. Switch position Continuity Brake lever operates Brake lever does not operate DC BACK BUZZER (FX10/FX10RTR/...
Page 351: Coolant Temperature Sensor
– ELEC SIGNAL SYSTEM COOLANT TEMPERATURE SENSOR 1. Remove the coolant temperature sensor. CAUTION: Handle the coolant temperature sensor with special care. Never subject it to shock or allow it to be dropped. If it is dropped, it must be replaced.
Page 352: Oil Level Switch
– ELEC SIGNAL SYSTEM OIL LEVEL SWITCH 1. Remove: • Oil level switch Ch R/B 2. Connect: • Pocket tester (to the oil level switch coupler) 3. Check: • Oil level switch continuity É Faulty → Replace. È Good Switch position Bad condition condition Down...
Page 353: Speed Sensor
– ELEC SIGNAL SYSTEM SPEED SENSOR 1. Inspect: • Speed sensor Inspection steps: • Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown. Positive tester probe → White Negative tester probe → Black/Blue Positive battery terminal →...
Page 354: Grip Warmer System
– ELEC GRIP WARMER SYSTEM 8-42...
Page 355: Circuit Diagram
– ELEC GRIP WARMER SYSTEM GRIP WARMER SYSTEM CIRCUIT DIAGRAM 4 Main switch 5 Main fuse 7 Battery B Engine stop switch D Thumb warmer E Grip warmer H ECU (engine control unit) Y Grip/thumb warmer adjust- ment switch Z Frame ground d Multi-function meter n Ignition fuse 8-43...
Page 356: Troubleshooting
– ELEC GRIP WARMER SYSTEM TROUBLESHOOTING GRIP WARMER AND THUMB WARMER DO NOT OPERATE. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace or charge the battery.
Page 357: Grip Warmer And Thumb Warmer
– ELEC GRIP WARMER SYSTEM GRIP WARMER AND THUMB WARMER 1. Disconnect: • Grip warmer couplers • Thumb warmer coupler 2. Connect: • Pocket tester Ω × 1 (to the grip warmer couplers and/or thumb – warmer coupler) 3. Measure: •...
Page 358: Cooling System
– ELEC COOLING SYSTEM 8-46...
Page 359: Circuit Diagram
– ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 4 Main switch 5 Main fuse 7 Battery B Engine stop switch H ECU (engine control unit) W Coolant temperature sensor Z Frame ground k Radiator fan motor l Radiator fan motor relay n Ignition fuse o Radiator fan motor fuse 8-47...
Page 360: Troubleshooting
– ELEC COOLING SYSTEM TROUBLESHOOTING THE RADIATOR FAN MOTOR DOES NOT MOVE Check the main fuse, ignition fuse, and radiator fan motor fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse, and/or radia- tor fan motor fuse. Check the battery.
Page 361: Radiator Fan Motor
– ELEC COOLING SYSTEM RADIATOR FAN MOTOR 1. Disconnect: • Radiator fan motor coupler 2. Connect: • Battery (to the radiator fan motor coupler) 3. Inspect: • Radiator fan motor Positive battery terminal → Blue 1 Negative battery terminal → Black 2 Does not move →...
Page 362: Chapter 9. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Model code number: 8GL1 (FX10 “USA/Canada”) 8GL2 (FX10 “Europe”) 8HJ1 (FX10RT “USA/Canada”) 8HB1 (FX10RTR “USA/Canada”) 8HB2 (FX10RTR “Europe”) 8HB3 (FX10RTRA “USA/Canada”) 8HB4 (FX10RTRA “Europe”) 8HA1 (FX10MT “USA”) 8HA5 (FX10MTR “USA/Canada”) 8HA6 (FX10MTR “Europe”) 8HA7 (FX10MTRA “USA/Canada”) 8HA8 (FX10MTRA “Europe”) Dimensions:...
Page 363 SPEC GENERAL SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Engine: Engine type Liquid-cooled, 4-stroke, DOHC Cylinder arrangement Backward-inclined parallel 3-cylinder Displacement 1,049.0 cm Bore × stroke 82.0 × 66.2 mm (3.23 × 2.61 in) Compression ratio 11.0 : 1 Maximum hose power r/min 8,750 r/min Maximum torque r/min 7,000 r/min...
Page 364 SPEC GENERAL SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Transmission: Primary reduction system V-Belt Primary reduction ratio 3.80 ~ 1.00 : 1 Clutch type Automatic centrifugal engagement Secondary reduction system Chain Secondary reduction ratio 1.86 (39/21) (FX10/FX10RT/FX10RTR/FX10RTRA) 1.82 (40/22) (FX10MTR “Europe”/FX10MTRA “Europe”) 2.00 (40/20) (FX10MT/FX10MTR “USA/Canada”/ FX10MTRA “USA/Canada”) Reverse system No (FX10RT/FX10MT)
Page 365 SPEC GENERAL SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Headlight bulb type: Halogen bulb Bulb wattage × Quantity: 12 V, 60/55 W × 2 Headlight Tail/brake light Meter light Warning light High beam indicator light Low coolant temperature indicator light...
Page 366: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Cylinder head: Volume (with spark plug) 25.21 ~ 26.01 cm (1.54 ~ 1.59 cu.in) <Warpage limit> 0.10 mm (0.0039 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating Bore size 82.000 ~ 82.010 mm (3.2283 ~ 3.2287 in) <Taper limit>...
Page 367 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Valves, valve seats, valve guides: Valve clearance (cold) Intake 0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) Exhaust 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Valve dimensions Valve head diameter A Intake 30.90 ~ 31.10 mm (1.2165 ~ 1.2244 in) Exhaust 25.90 ~ 26.10 mm (1.0197 ~ 1.0276 in) Valve face width B...
Page 368 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Valve spring: Free length Intake 39.57 mm (1.56 in) <Limit> 37.59 mm (1.48 in) Exhaust 39.57 mm (1.56 in) <Limit> 37.59 mm (1.48 in) Installed length (valve closed) Intake 34.60 mm (1.36 in) Exhaust 34.60 mm (1.36 in) Compressed spring force (installed) Intake...
Page 369 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Piston ring: Top ring Ring type Barrel Dimensions (B × T) 1.00 × 2.80 mm (0.039 × 0.110 in) 2nd ring Top ring (same or no) Ring type Taper Dimensions (B × T) 1.00 × 2.90 mm (0.039 × 0.114 in) Oil ring Dimensions (B ×...
Page 370 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Throttle body: Type × Quantity 41EIDW × 2 Manufacturer MIKUNI I.D. mark 8GL1 00 Throttle valve (Th.V) 818-41005-100 (θ = 10°) Throttle cable free play 3.0 ~ 4.0 mm (0.12 ~ 0.16 in) Engine idle speed 1,450 ~ 1,550 r/min Fuel pump: Type...
Page 371: Power Train
SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Transmission: Type V-belt automatic Range of ratio 3.80 ~ 1.00 : 1 Engagement speed r/min 3,550 ~ 3,950 r/min (FX10/FX10RT/FX10RTR/FX10RTRA) 3,300 ~ 3,700 r/min (FX10MT/FX10MTR “USA/Canada”/ FX10MTRA “USA/Canada”) 3,100 ~ 3,500 r/min (FX10MTR “Europe”/FX10MTRA “Europe”) Shift r/min 8,500 ~ 9,000 r/min...
Page 372 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Number of coils 4.92 (FX10/FX10RT/FX10RTR/FX10RTRA) 5.08 (FX10MT/FX10MTR “USA/Canada”/FX10MTRA “USA/Canada”) 5.64 (FX10MTR “Europe”/FX10MTRA “Europe”) Free length 87.4 mm (3.44 in) (FX10/FX10RT/FX10RTR/FX10RTRA) 89.8 mm (3.54 in) (FX10MT/FX10MTR “USA/Canada”/ FX10MTRA “USA/Canada”) 98.4 mm (3.87 in) (FX10MTR “Europe”/FX10MTRA “Europe”) Set length 73.4 mm (2.89 in) Primary sheave weight arm:...
Page 373 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Secondary sheave spring: Part number 90508-60012 Color code Pink Outside diameter 69.5 mm (2.74 in) Wire diameter 6.0 mm (0.236 in) Hole position Sheave side-spring seat side (twist angle) 2-6 (80°) (FX10/FX10RT/FX10RTR/FX10RTRA) 1-6 (70°) (FX10MT/FX10MTR/FX10MTRA) Spring rate Compression 12.3 N/mm (1.25 kg/mm, 70.23 lb/in)
Page 374 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Track: Part number 8FA-47110-00 (FX10/FX10RT/FX10RTR/FX10RTRA) 8HA-47110-00 (FX10MT/FX10MTR/FX10MTRA) Width 381.0 mm (15.0 in) Length 3,072.4 mm (120.96 in) (FX10/FX10RT/FX10RTR/FX10RTRA) 3,886.2 mm (153.00 in) (FX10MT/FX10MTR/FX10MTRA) Pitch 64.0 mm (2.52 in) (FX10/FX10RT/FX10RTR/FX10RTRA) 76.2 mm (3.00 in) (FX10MT/FX10MTR/FX10MTRA) Number of links 48 (FX10/FX10RT/FX10RTR/FX10RTRA) 51 (FX10MT/FX10MTR/FX10MTRA)
Page 375 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Shock absorber: Damping force Front Extension 1,373 N/0.3 m/s (140.0 kg/0.3 m/s, 308.6 lb/0.3 m/s) (FX10 “USA/Canada”) 1,359 N/0.3 m/s (138.6 kg/0.3 m/s, 305.5 lb/0.3 m/s) (FX10 “Europe”) 1,346 N/0.3 m/s (137.2 kg/0.3 m/s, 302.6 lb/0.3 m/s) (FX10RT/FX10RTR/FX10RTRA) 620 N/0.3 m/s (63.2 kg/0.3 m/s, 139.4 lb/0.3 m/s) (FX10MT/FX10MTR/FX10MTRA)
Page 376 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Slide runner: Thickness 18.3 mm (0.72 in) Wear limit 10.5 mm (0.41 in) Track sprocket wheel: Material Ultra high molecular weight polyethylene Number of teeth 9 T (FX10/FX10RT/FX10RTR/FX10RTRA) 7 T (FX10MT/FX10MTR/FX10MTRA) Rear guide wheel: Material High molecular weight polyethylene with rubber Outside diameter...
Page 377: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Frame: Frame material Aluminum and Steel Seat height 770.0 mm (30.31 in) Luggage box location Front Steering: Lock-to-lock angle (left) 29.6° (R ski) 35.6° (L ski) (right) 35.6° (R ski) 29.6° (L ski) Ski alignment Toe-out Toe-out size...
Page 378 SPEC MAINTENANCE SPECIFICATIONS FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ Model FX10MTRA Shock absorber: Damping force Extension 1,371 N/0.3 m/s (139.8 kg/0.3 m/s, 308.2 lb/0.3 m/s) (FX10 “USA/Canada”) 1,334 N/0.3 m/s (137.1 kg/0.3 m/s, 302.1 lb/0.3 m/s) (FX10 “Europe”) 1,290 N/0.3 m/s (131.5 kg/0.3 m/s, 290.0 lb/0.3 m/s) (FX10RT/FX10RTR/FX10RTRA) 1,704 N/0.3 m/s (173.8 kg/0.3 m/s, 383.1 lb/0.3 m/s) (FX10MT/FX10MTR/FX10MTRA)
Page 379: Electrical
Ten hour rate amperage 1.8 A Electric starter system: Type Constant mesh type Starter motor: Model/Manufacturer 8GL/YAMAHA Output 0.95 kW Armature coil resistance 0.0081 ~ 0.0099 Ω at 20 °C (68 °F) Continuity check Insulation check Above 1 MΩ at 20 °C (68 °F)
Page 380 0.290 ~ 0.354 kΩ at 80 °C (176 °F) Speed sensor: Model/Manufacture 8FP/NIPPON SEIKI Crankshaft position sensor: Model/Manufacture 8GL/YAMAHA 336 ~ 504 Ω at 20 °C (68 °F) (Gray – Black) Resistance Intake air pressure sensor: Model/Manufacture 2CO/DENSO Intake air temperature sensor:...
Page 381: Tightening Torque
SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m · kg ft · lb Spark plug Cylinder head bolt (M10 × 1.25) See NOTE. Apply the engine oil. Cylinder head bolt Cylinder head cover bolt Camshaft cap bolt Apply the engine oil.
Page 382 Apply the engine oil. Crankcase bolt (M6 × 1.0) Apply the engine oil. Crankcase bolt (M6 × 1.0) Black bolt Apply Yamaha bond No. 1215 ® (Three Bond No.1215 Primary sheave drive shaft assembly bolt Connecting rod nut See NOTE.
Page 383: Power Train
SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Remarks m · kg ft · lb Primary sheave bolt See NOTE. Spider and sliding sheave 20.0 Left-hand thread. ® Apply LOCTITE Primary sheave cap and sliding sheave bolt Roller and weight nut (primary sheave) ®...
Page 384 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Slide runner and front pivot arm (FX10/FX10RT/FX10RTR/ ® FX10RTRA) Apply LOCTITE Shaft and sliding frame bolt (FX10/FX10RT/FX10RTR/ ® FX10RTRA) Apply LOCTITE Shaft and sliding frame bolt (FX10MT/FX10MTR/FX10MTRA) Shock absorber and front pivot arm nut Shock absorber and front suspension bracket nut...
Page 385 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Control rod shaft and sliding frame (FX10MT/FX10MTR/FX10MTRA) Rear axle nut ® Set bolt (front axle) Apply LOCTITE Speed sensor Bearing holder (front axle) Bearing housing bolt Left side Bearing housing bolt Right side...
Page 386: Chassis
SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Remarks m · kg ft · lb Headlight stay nut Front cover screw Lower cover bolt Front bumper bolt Seat bolt Rear upper cover screw Rear side cover bolt Tail/brake light assembly bolt ®...
Page 387: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (bolt) This chart specifies torque for standard fasteners m · kg ft · lb with standard I.S.O. pitch threads. Torque specifi- 10 mm 6 mm cations for special components or assemblies are 12 mm 8 mm included in the applicable sections of this book.
Page 388: Cable Routing
SPEC CABLE ROUTING 9-27...
Page 389 SPEC CABLE ROUTING CABLE ROUTING 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.
Page 390 SPEC CABLE ROUTING 9-29...
Page 391 SPEC CABLE ROUTING 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...
Page 392 SPEC CABLE ROUTING 9-31...
Page 393 SPEC CABLE ROUTING 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.
Page 394 SPEC CABLE ROUTING 9-33...
Page 395 SPEC CABLE ROUTING 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.
Page 396 SPEC CABLE ROUTING 2 3 4 5 b c d 9-35...
Page 397 SPEC CABLE ROUTING 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...
Page 398 SPEC CABLE ROUTING 2 3 4 5 b c d 9-37...
Page 399 SPEC CABLE ROUTING 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.
Page 400 SPEC CABLE ROUTING 9-39...
Page 401 SPEC CABLE ROUTING 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...
Page 402 SPEC CABLE ROUTING 9-41...
Page 403 SPEC CABLE ROUTING N Fasten the corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead), cor- rugated tube (engine stop switch lead, throttle switch leads, right grip warmer lead, and thumb warmer lead), and brake hose with the plastic band (FX10MT/ FX10MTR/FX10MTRA).
Page 404 SPEC CABLE ROUTING 9-43...
Page 405 SPEC CABLE ROUTING 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.
Page 408 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN U.S.A. 2007.07 CR...
Page 409 WIRING DIAGRAM FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/ FX10MTRA 2008 8GL-0F001-00/8HA-0F001-00 1 Rectifier/regulator X Intake air temper- COLOR CODE 2 AC magneto ature sensor B ....Black 3 Crankshaft posi- Y Grip/thumb Br.....Brown Ch....Chocolate tion sensor warmer adjust- Dg....Dark green 4 Main switch ment switch G....Green 5 Main fuse Z Frame ground Gy....Gray...
Page 410 WIRING DIAGRAM FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/FX10MTRA 2008 8GL-0F001-00/8HA-0F001-00 È É L/B G/B R/B R/L Y B/L L G L/R L/R G R/Y W/G Br/L Br/L (BLACK) (BLACK) (GRAY) (GRAY) OIL PRESSURE TAIL/BRAKE COOLANT FUEL INJECTION SYSTEM WIRE WIRE WIRE SPEEDOMETER WIRE REVERSE SWITCH WIRE WIRE HARNESS SWITCH...
Page 411 WIRING DIAGRAM FX10/FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/FX10MTRA 2008 8GL-0F001-00/8HA-0F001-00 È É (BLACK) (BLACK) (GRAY) (GRAY) OIL PRESSURE TAIL/BRAKE COOLANT FUEL INJECTION SYSTEM WIRE WIRE WIRE SPEEDOMETER WIRE REVERSE SWITCH WIRE TEMPERATURE WIRE HARNESS SWITCH LIGHT SUB-WIRE HARNESS HARNESS HARNESS HARNESS UNIT SUB-LEAD HARNESS SUB-WIRE HARNESS HARNESS SUB-LEAD SUB-LEAD...

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Yamaha FX10X 2008 Service Manual

Chapter 1. General Information

Snowmobile Identification

Important Information

Special Tools

Chapter 2

Periodic Inspection and Adjustment

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Engine

Power Train

Chassis

Electrical

Tuning

Chapter 3. Chassis

Covers

Steering

Ski

Front Suspension

Chapter 4. Power Train

Primary Sheave and Drive V-Belt

Secondary Sheave

Drive Chain

Secondary Shaft

Brake

Slide Rail Suspension

Front Axle and Track

Chapter 5. Engine

Seat and Fuel Tank

Exhaust Pipe and Muffler

Oil Tank

Engine Assembly

Camshafts

Cylinder Head

Valves and Valve Springs

Ac Magneto Rotor and Starter Clutch

Oil Pan and Oil Pump

Crankcase

Connecting Rods and Pistons

Crankshaft and Balancer Shaft

Chapter 6. Cooling System

Radiator

Thermostat

Water Pump

Oil Cooler and Heat Exchanger

Chapter 7. Fuel Injection System

Fuel Injection System

Air Filter Case

Throttle Body

Chapter 8. Electrical

Switch Inspection

Ignition System

Electrical Starting System

Charging System

Lighting System

Signal System

Grip Warmer System

Cooling System

Chapter 9. Specifications

General Specifications

Maintenance Specifications

Tightening Torque

Chassis

General Torque Specifications

Definition of Units

Cable Routing

Quick Links

Troubleshooting

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Summary of Contents for Yamaha FX10X 2008