RS90GTX RS90GTAX RS90LTX RS90LTGTX - Yamaha · RS90GTX RS90GTAX RS90LTX RS90LTGTX OWNER ’S MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2007 ... manent part

OWNER’S MANUAL

RS90RXRS90GTX

RS90GTAXRS90LTX

RS90LTGTX

8GM-28199-10LIT-12628-02-70

ESU10040

U8GM10E0.book Page 1 Friday, April 27, 2007 6:43 PM

IntroductionESU10120

Congratulations on your purchase of aYamaha snowmobile. This model is the resultof Yamaha’s vast experience in the produc-tion of fine sporting and touring snowmobiles.It represents the high degree of craftsmanshipand reliability that have made Yamaha a lead-er in these fields.This manual will give you an understanding ofthe operation, inspection, and basic mainte-nance of this snowmobile. If you have anyquestions concerning the operation or main-tenance of your snowmobile, please consult aYamaha dealer.To maintain the high quality and performanceof this snowmobile, it is important that you andyour Yamaha dealer pay close attention to therecommended maintenance schedules andoperating instructions contained within thismanual.

RS90RXRS90GTX

RS90GTAXRS90LTX

RS90LTGTXOWNER’S MANUAL

©2007 by Yamaha Motor Corporation, U.S.A.

1st Edition, April 2007All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, U.S.A.is expressly prohibited.

Printed in Japan.P/N LIT-12628-02-70


Important manual informationESU10150

WARNINGEWS00010

PLEASE READ AND UNDERSTAND THISMANUAL COMPLETELY BEFORE OPER-ATING THE SNOWMOBILE.

NOTE:� Yamaha continually seeks advancements

in product design and quality. Therefore,while this manual contains the most currentproduct information available at the time ofprinting, there may be minor discrepanciesbetween your snowmobile and this manual.If there is any question concerning thismanual, please consult a Yamaha dealer.

� This manual should be considered a per-manent part of this snowmobile and shouldremain with the snowmobile when resold.

Particularly important information is distin-guished in this manual by the following nota-tions.

The Safety Alert Symbol means ATTEN-TION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

WARNINGEWS00020

Failure to follow WARNING instructionscould result in severe injury or death to thesnowmobile operator, a bystander, or aperson inspecting or repairing the snow-mobile.

CAUTION:ECS00010

A CAUTION indicates special precautionsthat must be taken to avoid damage to thesnowmobile.

NOTE:A NOTE provides key information to makeprocedures easier or clearer.


Contents

Safety information ............................1Location of the important labels ..... 4

Description ........................................7

Control functions ..............................9Main switch .................................... 9Starter (choke) lever ....................... 9Throttle lever .................................. 9Engine overheating prevention

system ....................................... 10Throttle override system

(T.O.R.S.) .................................. 10Speedometer unit ......................... 11High beam indicator light .............. 12Low coolant temperature

indicator light ............................. 12Fuel meter and grip/

thumb warmer level indicator .... 13Fuel level warning indicator .......... 14Oil level warning indicator ............ 14Coolant temperature warning

indicator ..................................... 15Self-diagnosis device ................... 15Engine stop switch ....................... 15Headlight beam switch

“LIGHTS” ................................... 16Grip/thumb warmer

adjustment switch ...................... 16Auxiliary DC jack (RS90GT /

RS90GTA / RS90LTGT) ........... 16Brake lever ................................... 17Parking brake lever ...................... 18Shift lever ..................................... 18Rear suspension damping force

remote adjustment dial .............. 19Shroud and covers ....................... 19Drive guard ................................... 20V-belt holders ............................... 20Storage compartment ................... 20Fuel .............................................. 20Suspension .................................. 21

Pre-operation checks ..................... 26Pre-operation check list ............... 26

Operation ......................................... 28Starting the engine ....................... 28Break-in ........................................ 28Riding your snowmobile ............... 29Maximizing drive track life ............ 32Driving .......................................... 33Stopping the engine ..................... 34Transporting ................................. 34

Periodic maintenance..................... 36Periodic maintenance chart for

the emission control system ..... 36General maintenance and

lubrication chart ........................ 38Tool kit ......................................... 40Removing and installing

the shroud and covers .............. 40Checking the spark plugs ............. 42Adjusting the engine

idling speed ............................... 43Adjusting the throttle cable

free play .................................... 43Checking the throttle override

system (T.O.R.S.) ..................... 44Checking the air filter ................... 44Carburetors .................................. 46High-altitude settings ................... 46Valve clearance ........................... 46Engine oil and oil filter cartridge ... 47Cooling system ............................ 50V-belt ............................................ 52Drive chain housing ..................... 55Brake and parking brake .............. 56Skis and ski runners ..................... 58Steering system ........................... 59Drive track and slide runners ....... 59Lubrication ................................... 62Replacing a headlight bulb ........... 63Adjusting the headlight beams ..... 64


Contents

Fittings and fasteners ................... 64Battery .......................................... 64Replacing a fuse .......................... 65

Troubleshooting ............................. 68

Storage ............................................ 72

Specifications ................................. 74

Consumer information.................... 76Identification number records ....... 76YAMAHA MOTOR

CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTY ............... 77

YAMAHA EXTENDED SERVICE (Y.E.S.)....................................... 80


Safety information

1

ESU10181

When you ride your snowmobile, you mustknow and use the following for your safety.Severe injury or death may result if you ignoreany of the following.Before operating1. Read the Owner’s Manual and all labels

before operating this snowmobile. Be-come familiar with all of the operatingcontrols and their function. Consult aYamaha dealer about any control or func-tion you do not understand.

2. This snowmobile was not manufacturedfor use on public streets, roads, or high-ways. Such use is prohibited by law, andyou could collide with another vehicle.

3. This snowmobile is designed to carry theOPERATOR ONLY.Passengers are prohibited. Carrying apassenger can cause loss of control.

4. Do not operate the snowmobile afterdrinking alcohol or taking drugs. Yourability to operate the snowmobile is re-duced by the influence of alcohol ordrugs.

5. For safety and proper care of the snow-mobile, always perform the pre-operationchecks on page 26 before starting the en-gine. Check the throttle, brake, and steer-ing for proper operation every time beforestarting the engine. Make sure that thethrottle lever moves freely and it returnsto the home position when it is released.

6. Apply the parking brake before startingthe engine. Never drive the snowmobilewith the parking brake applied. This mayoverheat the brake disc and reduce brak-ing ability.

7. Do not allow anyone to stand behind thesnowmobile when starting, inspecting, oradjusting the snowmobile. A brokentrack, track fittings, or debris thrown bythe track could be dangerous to the oper-ator or bystanders.

8. Handle fuel with care; it is HIGHLYFLAMMABLE.� Never add fuel when the engine is run-

ning or hot. Allow the engine to cool forseveral minutes after running.

� Use an approved fuel container.


Safety information

2

� Fill the fuel tank outdoors with extremecare. Never remove the fuel cap in-doors. Never fill the fuel tank indoors.

� Never refuel while smoking or in the vi-cinity of an open flame.

� Make sure that the fuel tank cap isclosed securely after refueling. Wipeup any spilled fuel immediately.

9. If you swallow some gasoline, inhale a lotof gasoline vapor, or get some gasolineinto your eyes, see your doctor immedi-ately. If any gasoline spills on your skin orclothing, immediately wash your skin withsoap and water, and change yourclothes.

10. Wear protective clothing. Wear an ap-proved helmet, and a face shield or gog-gles. Also, wear a good qualitysnowmobile suit, boots, and a pair ofgloves or mittens that will permit use ofyour thumbs and fingers for operation ofthe controls.

Operation1. Do not run the engine indoors, except

when starting the engine to transport thesnowmobile in or out of the building.Open the outside doors; exhaust fumesare dangerous.

2. Be careful where you ride. There may beobstacles hidden beneath the snow. Stayon established trails to minimize your ex-posure to hazards. Ride slowly and cau-tiously when you ride off of establishedtrails. Hitting a rock or stump, or runninginto wires could cause an accident andinjury.

3. This snowmobile is not designed for useon surfaces other than snow or ice. Useon dirt, sand, grass, rocks, or bare pave-ment may cause loss of control and maydamage the snowmobile.

4. Avoid operating on glare ice, or on snowwhich has a lot of dirt or sand mixed in.Operation under such conditions willdamage or result in rapid wear of ski run-ners, drive track, slide runners, and drivesprockets.

5. Always ride with other snowmobilerswhen going on a ride. You may need helpif you run out of fuel, have an accident, ordamage your snowmobile.

6. Many surfaces such as ice and hard-packed snow require much longer stop-ping distances. Be alert, plan ahead and


Safety information

3

begin decelerating early. The best brak-ing method on most surfaces is to releasethe throttle and apply the brake gently—not suddenly.

Maintenance and storage1. When laying the snowmobile on its side

for maintenance, use a suitable stand tokeep it level.

2. Do not leave the snowmobile on its leftside for an extended period of time. Fuelmay leak out from the fuel breather hose.

3. Modifications made to the snowmobilenot approved by Yamaha, or the removalof original equipment may render yoursnowmobile unsafe for use that maycause severe personal injury. Modifica-tions may also make the snowmobile ille-gal to use.

4. Never store the snowmobile with fuel inthe fuel tank inside a building where igni-tion sources are present such as hot wa-ter and space heaters, an open flame,sparks, clothes dryers, and the like. Allowthe engine to cool off before storing thesnowmobile in an enclosed space.

5. Always refer to the “STORAGE” sectionon page 72 if the snowmobile is to bestored for an extended period.

6. Maintain or replace safety and instructionlabels, as necessary.


Safety information

4

ESU10231

Location of the important labels Please read the following labels carefully before operating this snowmobile.

NOTE:Maintain or replace safety and instruction labels, as necessary.


Safety information

5


Safety information

6

NOTE:The following suspension adjustment charts are included with the Owner’s Manual.


Description

7

ESU10260

1. Battery2. Main fuse3. Air filter4. Oil filler cap5. Throttle stop screw6. Fuse box7. Coolant reservoir8. Tool kit9. Storage compartment10. Tail/brake lights11. Slide rail suspension12. Rear suspension damping force remote ad-

justment dial13. Drive track

14. V-belt holder


Description

8

NOTE:� The snowmobile you have purchased may differ slightly from those shown in the figures of

this manual.� Design and specifications are subjected to change without notice.

1. Brake lever2. Parking brake lever3. Grip warmer adjustment switch4. Headlight beam switch5. Engine stop switch6. Thumb warmer adjustment switch7. Throttle lever8. Shift lever9. Main switch10. Auxiliary DC jack (RS90GT / RS90GTA /

RS90LTGT)11. Starter (choke) lever12. Tachometer13. Low coolant temperature indicator light

14. High beam indicator light15. Warning light16. Self-diagnosis warning indicator17. Coolant temperature warning indicator18. Fuel level warning indicator19. Oil level warning indicator20. Speedometer21. Grip warmer indicator22. Select/reset button23. Thumb warmer indicator24. Fuel meter and grip/thumb warmer level in-

dicator25. Odometer/tripmeter


Control functions

9

ESU10281

Main switch The main switch controls the ignition andlighting systems. The various positions aredescribed below.

OffThe ignition circuit is switched off.The key can be removed only in this position.OnThe ignition circuit is switched on.StartThe starting circuit is switched on.The starter motor cranks the engine.

CAUTION:ECS00020

Release the switch immediately after theengine starts.

NOTE:The headlights, meter lighting, and taillightscome on after the engine is started.

ESU10300

Starter (choke) lever Use the starter (choke) lever when startingand warming up a cold engine.

NOTE:Refer to the “Starting the engine” section onpage 28 for proper operation.

ESU10310

Throttle lever Once the engine is running cleanly, squeez-ing the throttle lever will increase the enginespeed and cause engagement of the drivesystem. Regulate the speed of the snowmo-bile by varying the throttle position. Becausethe throttle is spring-loaded, the snowmobilewill decelerate, and the engine will return toidle when it is released.

1. Off2. On3. Start

1. Starter (choke) lever

1. Warming up2. When starting a cold engine.3. When the engine is warm.


Control functions

10

WARNINGEWS00030

Check the throttle, brake, and steering forproper operation before starting the en-gine. (See page 26.)

ESU10321

Engine overheating prevention system

This model is equipped with a system, whichprevents overheating when the engine isidling.When the engine has been idling for 3 min-utes or longer and the coolant temperaturehas risen above 100 °C (212 °F), the engineautomatically stops to prevent overheating.

NOTE:The engine can be started after it stops.

ESU10331

Throttle override system (T.O.R.S.)

WARNINGEWS00040

� If the T.O.R.S. is activated, make surethat the cause of the malfunction hasbeen corrected and that the engine canbe operated without a problem beforerestarting the engine.

� Be sure to use the specified spark plugand spark plug cap. Otherwise, theT.O.R.S. will not work properly.

If the carburetors or throttle cable malfunc-tions during operation, the T.O.R.S. will oper-ate when the throttle lever is released.The T.O.R.S. is designed to override the igni-tion and limit the engine speed to less than theclutch engagement speed if the carburetorsfail to return to the idle position when the throt-tle lever is released. (See page 74 for theclutch engagement speed.)

Idling / starting

1. Throttle leverIdling / starting Running Trouble

Throttle switch Off On Off

Throttle position sensor

Closed Open Open

Engine Run RunT.O.R.S. will oper-

ate.

1. Throttle position sensor (throttle valve closed position)

2. Throttle cable3. Throttle switch (off)


Control functions

11

Running

Trouble

NOTE:� When the T.O.R.S. is activated, the warn-

ing light and self-diagnosis warning indica-tor will flash, and the two-digit code “84” willflash in the tripmeter/odometer display.

� The T.O.R.S. monitors the condition of thethrottle position sensor, speedometer as-sembly, and speed sensor, and will operateif any of the monitored items is disconnect-ed or is malfunctioning.

ESU10351

Speedometer unit The speedometer unit is equipped with thefollowing:� a digital speedometer (which shows the

riding speed)� an odometer (which shows the total dis-

tance traveled)� a tripmeter (which shows the distance trav-

eled since it was last set to zero)� warning indicators (which show self-diag-

nosis, coolant temperature, fuel level, andoil level warnings)

� a fuel meter (which shows the fuel remain-ing in the fuel tank)

� a grip/thumb warmer level indicator (whichshows the grip warmer level or the thumbwarmer level)

After the engine is started, the tachometermakes one sweep, and the low coolant tem-perature indicator light, the warning light, andall segments of the meter display turn on andoff once.

1. Throttle position sensor (throttle valve open position)

2. Throttle switch (on)

1. Throttle position sensor (throttle valve open position)

2. Throttle switch (off)

1. Warning light “ ”2. Self-diagnosis warning indicator “ ”3. Two-digit code “84”


Control functions

12

The grip warmer level is initially displayed for5 seconds, then the display switches to thefuel meter.Odometer and tripmeter modesPushing the select/reset button switches thedisplay between the odometer mode “ODO”and the tripmeter mode “TRIP”.To reset the tripmeter, push the select/resetbutton for at least one second while the trip-meter is displayed.

NOTE:To switch the speedometer, odometer, andtripmeter displays between kilometers andmiles, select the odometer mode “ODO”, andthen push the select/reset button for at least10 seconds while the snowmobile is stopped.

ESU10410

High beam indicator light “ ” The high beam indicator light comes on whenthe high beams of the headlights are switchedon. (See page 16 for headlight beam switchoperation.)

ESU10481

Low coolant temperature indi-cator light “ ”

The low coolant temperature indicator lightcomes on when the coolant temperature islow and informs the rider that the snowmobileshould be warmed up. After the engine isstarted, warm it up until the indicator lightgoes off.

The snowmobile can be operated normally af-ter the indicator light goes off.

NOTE:Operate the snowmobile at low speeds whenthe low coolant temperature indicator light ison. If the engine speed is too high, the warn-ing light and self-diagnosis warning indicatorwill flash and the two-digit code “86” will flash

1. Tachometer2. Low coolant temperature indicator light

“ ”3. Warning light “ ”4. Meter display5. Select/reset button

1. High beam indicator light “ ”

1. Low coolant temperature indicator light “ ”

2. Warning light “ ”3. Self-diagnosis warning indicator “ ”4. Two-digit code “86”


Control functions

13

in the tripmeter/odometer display. When thisoccurs, maximum engine speed is reduced toprotect the engine.

ESU10421

Fuel meter and grip/thumb warmer level indicator

The fuel meter and grip/thumb warmer levelindicator have eight segments which showthe amount of fuel remaining in the fuel tank,the grip warmer level, or the thumb warmerlevel.

Fuel meterThe display segments of the fuel meter disap-pear towards “E” (Empty) as the fuel level de-creases. When only one segment is left near“E”, the fuel level warning indicator and thewarning light come on.

If the fuel level warning indicator and thewarning light come on, refuel as soon as pos-sible.

NOTE:The snowmobile must be stopped on a levelsurface to obtain an accurate fuel meter read-ing, since the reading changes according tothe movement and inclination of the snowmo-bile.

Grip/thumb warmer level indicatorWhen the grip warmer adjustment switch ispressed, the grip warmer indicator comes onand the display switches to the grip warmerlevel.When the thumb warmer adjustment switch ispressed, the thumb warmer indicator comeson and the display switches to the thumbwarmer level.

1. Fuel meter and grip/thumb warmer level in-dicator

1. Warning light “ ”2. Fuel level warning indicator “ ”

1. Grip warmer indicator “ ”2. Thumb warmer indicator “ ”

1. Grip warmer adjustment switch


Control functions

14

NOTE:� The grip/thumb warmer level is displayed

for 5 seconds after releasing the grip/thumbwarmer adjustment switch, then the displayswitches to the fuel meter.

� The top segment of the grip/thumb warmerlevel indicator flashes once when thegrip/thumb warmer adjustment reaches themaximum level. The bottom segment of thegrip/thumb warmer level indicator flashesonce when the grip/thumb warmer adjust-ment reaches the minimum level.

� When the engine is started, the grip/thumbwarmer levels are set to the levels selectedwhen the engine is stopped.

ESU10450

Fuel level warning indicator “ ” The fuel level warning indicator indicates amalfunctioning sensor, disconnected coupler,broken lead, or short circuit when detected bythe self-diagnosis device of the snowmobile.The fuel level warning indicator, warning light,and all segments of the fuel meter warn therider of the above problems by flashing con-tinuously.When this occurs, have a Yamaha dealer in-spect the snowmobile as soon as possible.

ESU10460

Oil level warning indicator “ ” The oil level warning indicator and the warn-ing light come on when the engine oil level islow.

If the oil level warning indicator and the warn-ing light come on, place the snowmobile on alevel surface and allow it to idle for oneminute.If the oil level warning indicator and the warn-ing light go off, the engine oil level is sufficient,however it is getting low. Add engine oil assoon as possible.If the oil level warning indicator and the warn-ing light do not go off, check the engine oil lev-el in the oil tank (see page 47 for engine oillevel checking procedures), and add engineoil if necessary.

1. Thumb warmer adjustment switch 1. Fuel level warning indicator “ ”2. Warning light “ ”3. Fuel meter

1. Oil level warning indicator “ ”2. Warning light “ ”


Control functions

15

ESU10511

Coolant temperature warning indicator “ ”

If the engine overheats, the coolant tempera-ture warning indicator and the warning lightcome on. When this occurs, stop the engineimmediately and allow the engine to cooldown, and then check the coolant level in thecoolant reservoir. (See page 50 for checkingprocedures.)

CAUTION:ECS00040

Do not operate the engine if it overheats.

ESU10522

Self-diagnosis device This model is equipped with a self-diagnosisdevice for various electrical circuits.If any of those circuits are defective, the warn-ing light and the self-diagnosis warning indi-cator will flash, and a two-digit error code willflash slowly in the tripmeter/odometer display.

WARNINGEWS00052

� If the self-diagnosis warning indicatorand warning light flash continuously,and an error code is displayed duringoperation, there may be some problemwith an electrical circuit, couplers, etc.

� Stop the engine and allow it to cool off.Then, check that the electrical circuits,couplers, etc. in the engine compart-ment are connected properly.

� If the self-diagnosis warning indicator,warning light, and an error code flash af-ter the engine has been restarted, notethe error code, and then have a Yamahadealer inspect the snowmobile as soonas possible.

ESU10530

Engine stop switch “ ” The engine stop switch is used to stop the en-gine in an emergency. Simply push the stopswitch to stop the engine. To start the engine,pull the stop switch and proceed with startingthe engine. (See pages 28 for engine startingprocedures.)

1. Coolant temperature warning indicator “ ”2. Warning light “ ”

1. Warning light “ ”2. Self-diagnosis warning indicator “ ”3. Two-digit error code


Control functions

16

During the first few rides, practice using thestop switch so that you can react quickly in anemergency.ESU10661

Headlight beam switch “LIGHTS”

Push the headlight beam switch to change theheadlight to high beam “HI” or to low beam“LO”.

ESU12650

Grip/thumb warmer adjustment switch

The grip warmer adjustment switch and thethumb warmer adjustment switch control theelectrically heated handlebar grips and throt-tle lever respectively.

To raise the temperature, press the respec-tive switch to “HI”. To lower the temperature,press the switch to “LO”.ESU10690

Auxiliary DC jack (RS90GT / RS90GTA / RS90LTGT)

The auxiliary DC jack is located in the frontpanel and can be used for accessories.

NOTE:The auxiliary DC jack cannot be used if theengine is not running.

To use the auxiliary DC jack1. Start the engine.2. Open the auxiliary DC jack cap, and then

insert the accessory power plug into thejack.

1. Engine stop switch“ ”

1. Headlight beam switch “LIGHTS”2. High beam “HI”3. Low beam “LO”

1. Grip warmer adjustment switch

1. Thumb warmer adjustment switch


Control functions

17

NOTE:After using the auxiliary DC jack, be sure toremove the accessory power plug from thejack and close the auxiliary DC jack cap.

CAUTION:ECS00120

� Do not use accessories requiring morethan the maximum rated capacity for theauxiliary DC jack. This may overload thecircuit and cause the fuse to blow. (Seepage 65 for the specified amperage.)

� Do not use an automotive cigarette light-er or other accessory with a plug thatgets hot because the jack can be dam-aged.

ESU10570

Brake lever The snowmobile is stopped by braking the en-tire drive system.Squeeze the brake lever towards the handle-bar grip to stop the snowmobile.

NOTE:When the brake lever is operated, the brakelight will illuminate.

CAUTION:ECS00060

Make sure that the brake lever end doesnot project out over the handlebar end.This will help prevent brake lever damagewhen the snowmobile is placed on its sidefor service.

RS90GT / RS90GTA / RS90LTGTThe brake lever is equipped with a positionadjuster.To adjust the brake lever position:1. Loosen the locknut.2. While lightly pushing the brake lever in di-

rection (a), finger tighten the adjustingbolt to set the brake lever to the desiredposition.

1. Auxiliary DC jack cap2. Auxiliary DC jack

Maximum rated capacity:DC 12 V, 2.5 A (30 W)

1. Brake lever


Control functions

18

3. Tighten the locknut securely after adjust-ing the brake lever.

ESU10580

Parking brake lever When parking the snowmobile or starting theengine, apply the parking brake by moving theparking brake lever to the left.

To release the parking brake, move the park-ing brake lever to the right.

WARNINGEWS00060

� Always set the parking brake before at-tempting to start the engine.

� Never run the snowmobile with the park-ing brake applied. This may overheat thebrake disc and reduce braking ability.

ESU10590

Shift lever The shift lever is used to put the snowmobileinto forward or reverse. After coming to acomplete stop, pull the shift lever out, slide itto “FWD” or to “REV” until it stops, and thenrelease it.

1. Locknut2. Adjusting bolt

1. Parking brake lever

1. Shift lever

1. Pull out.2. Slide to “FWD” (forward).3. Release.


Control functions

19

CAUTION:ECS00070

Do not shift from “FWD” to “REV” or from“REV” to “FWD” while the snowmobile ismoving. Otherwise, the drive systemcould be damaged.

ESU12530

Rear suspension damping force remote adjustment dial

Turn the remote adjustment dial to adjust therear suspension damping force. (See page 24for adjustment procedures.)

ESU10720

Shroud and covers Securely fasten the shroud and covers beforeoperating the snowmobile. (See page 40 forremoval and installation procedures.)

WARNINGEWS00090

� Do not drive the snowmobile with theshroud or covers unfastened or re-moved.

1. Pull out.2. Slide to “REV” (reverse).3. Release.

1. Rear suspension damping force remote ad-justment dial

1. Shroud2. Right side cover

1. Left side cover

1. Top cover


Control functions

20

� Keep your body and clothing away fromrotating parts when servicing the snow-mobile with the shroud or covers re-moved.

� Do not touch the hot muffler and engineduring or immediately after operation.

CAUTION:ECS00370

Make sure that all cables, leads, etc., arerouted properly before installing theshroud and covers.

ESU10750

Drive guard The drive guard is designed to cover the V-belt clutch and V-belt in case parts break orcome loose.

WARNINGEWS00400

� Make sure that the drive guard is tight-ened securely before operating thesnowmobile.

� Never run the engine with the V-belt ordrive guard removed.

ESU10760

V-belt holders Keep a spare V-belt for emergency use byplacing it into the V-belt holders provided.

CAUTION:ECS00180

Make sure that the V-belt is installed se-curely in the holders.

ESU10810

Storage compartment Open the storage compartment to store thetool kit, spare parts, or other small items.

ESU10600

Fuel Make sure that there is sufficient fuel in thefuel tank.

WARNINGEWS00070

� Fuel is HIGHLY FLAMMABLE and poi-sonous. Check the “SAFETY INFORMA-TION” section carefully before refueling.(See page 1.)

1. Drive guard

1. V-belt holder

1. Storage compartment


Control functions

21

� Do not fill the fuel tank above the bottomof the filler tube. Fuel could overflow ifthe snowmobile is tilted or if the ambienttemperature rises, causing the fuel towarm up and expand.

� Make sure that the fuel tank cap isclosed securely after refueling. Leakingfuel can catch fire.

Your Yamaha engine has been designed touse regular unleaded gasoline with a pumpoctane number [(R+M)/2] of 86 or higher, or aresearch octane number of 91 or higher.

CAUTION:ECS00080

� Oxygenated fuels (gasohol) containinga maximum 5% of ethanol can be used,although richer jetting may be requiredto prevent engine damage. Consult aYamaha dealer. Gasohol containingmethanol is not recommended.

� Make sure that snow or ice does not en-ter the fuel tank when refueling.

� Do not use alcohol deicers or water ab-sorbing additives with oxygenated fuel.

� The fuel tank should be filled withstraight gasoline as specified.

ESU10870

Suspension The suspension can be adjusted to suit riderpreference. A softer setting, for example, mayprovide greater rider comfort, while a hardersetting may allow more precise handling andcontrol over certain types of terrain or ridingconditions.

WARNINGEWS00150

Be sure to have a Yamaha dealer make thisadjustment.This shock absorber contains highly pres-surized nitrogen gas. It could explode byimproper handling, causing injury, orproperty damage.� Do not tamper with or attempt to open

the shock absorber.

1. Filler tube2. Fuel level

Recommended fuel:REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity:36.2 L (9.64 US gal) (8.03 Imp.gal)


Control functions

22

� Do not subject the shock absorber to anopen flame or other high heat source,which could cause it to explode.

� Do not deform or damage the shock ab-sorber in any way.

� Do not dispose of a worn or damagedshock absorber by yourself. Take theunit to a Yamaha dealer.

ESU10900

Adjusting the ski spring preload

CAUTION:ECS00250

The left and right ski spring preload mustbe set to the same setting. Uneven set-tings can cause poor handling and loss ofstability.

The spring preload can be adjusted by turningthe spring preload adjusting ring.

ESU10921

Adjusting the ski damping force (RS90GT / RS90GTA / RS90LTGT)

CAUTION:ECS00260

The damping forces for the left and rightski shock absorbers must be adjusted tothe same settings. Uneven settings cancause poor handling and loss of stability.

Compression damping forceThe compression damping force of each skishock absorber can be adjusted by turningthe compression damping force adjustingknob.To increase the compression damping force,turn the adjusting knob in direction (a). To de-crease the compression damping force, turnthe adjusting knob in direction (b).

1. Spring preload adjusting ring2. Spring seat length

Spring preload setting (spring seat length or spring preload adjusting ring position):

Minimum (soft):RS90R / RS90LT 161.0 mm (6.34 in)RS90GT / RS90GTA / RS90LTGT 119.0 mm (4.69 in)

Standard:RS90R / RS90LT 162.0 mm (6.38 in)RS90GT / RS90GTA / RS90LTGT 119.0 mm (4.69 in)

Maximum (hard):RS90R / RS90LT 172.0 mm (6.77 in)RS90GT / RS90GTA / RS90LTGT 129.0 mm (5.08 in)

* The spring seat length changes ap-proximately 1.5 mm (0.06 in) with each full turn of the adjusting ring.


Control functions

23

Rebound damping forceThe rebound damping force of each ski shockabsorber can be adjusted by turning the re-bound damping force adjusting knob.To increase the rebound damping force, turnthe adjusting knob in direction (a). To de-crease the rebound damping force, turn theadjusting knob in direction (b).

NOTE:The damping forces will not decrease past theminimum levels even if the adjusting knobsare turned out more than the minimum set-tings.

ESU10980

Adjusting the rear suspension spring preload The rear suspension spring preload can beadjusted by turning the spring preload adjust-ing ring on the shock absorber.

1. Compression damping force adjusting knob

Compression damping setting:Minimum (soft):

12 click(s) in direction (b)*Standard:

7 click(s) in direction (b)*Maximum (hard):

2 click(s) in direction (b)** With the adjusting knob fully turned in

direction (a)

1. Rebound damping force adjusting knob

Rebound damping setting:Minimum (soft):

20 click(s) in direction (b)*Standard:

12 click(s) in direction (b)*Maximum (hard):

3 click(s) in direction (b)** With the adjusting knob fully turned in

direction (a)

1. Spring preload adjusting ring

Spring preload setting (spring seat length or spring preload adjusting ring position):

Minimum (soft):1

Standard:4

Maximum (hard):7

* The spring seat length changes ap-proximately 1.5 mm (0.06 in) with each full turn of the adjusting ring.


Control functions

24

NOTE:The rear suspension spring preload can befurther adjusted by changing the position ofthe spring seat.Have a Yamaha dealer make this adjustmentas it requires special tools.

ESU10991

Adjusting the rear suspension damp-ing force

WARNINGEWS00160

Do not turn the remote adjustment dialwhile the snowmobile is moving as thiscould cause loss of control, an accident,and injury.

CAUTION:ECS00290

Be sure to stop the remote adjustment dialat a marked position around the dial wherethere is a click.

The rebound damping force can be adjustedby turning the rear suspension damping forceremote adjustment dial.To increase the rebound damping force, turnthe adjusting dial in direction (a). To decreasethe rebound damping force, turn the adjustingdial in direction (b).

ESU11050

Adjusting the control rod The weight transfer can be adjusted by turn-ing the control rod adjuster or adjusting nut.1. Loosen the locknut.2. Turn the control rod adjuster in direction

(a) to increase weight transfer or direction(b) to decrease weight transfer.

WARNINGEWS00180

Never adjust the control rod beyond therange of the scale on the special wrench.

3. Check the control rod adjuster length us-ing the scale on the special wrench in-cluded in the owner’s tool kit as shown.Make sure that the rim of the control rodbody is within the range of the scale.

1. Rear suspension damping force remote ad-justment dial

2. Standard position

Rebound damping setting:Minimum (soft):

22 click(s) in direction (a)*Maximum (hard):

0 click(s) in direction (b)** With the adjustment dial in the stan-

dard position

1. Locknut2. Control rod adjuster


Control functions

25

4. Tighten the locknut while holding the con-trol rod adjuster in place.

CAUTION:ECS00320

When using the special wrench, makesure that it is situated at a right angle tothe control rod, and that it is tightly fittedto the locknut or the control rod adjuster.

1. Special wrench2. Adjuster length3. Rim4. Scale range

Locknut tightening torque:35 Nm (3.5 m·kgf, 25 ft·lb)


Pre-operation checks

26

ESU11070

The condition of a snowmobile is the owner’s responsibility. Vital components can start to de-teriorate quickly and unexpectedly, even if the snowmobile remains unused (for example, as aresult of exposure to the elements). Any damage or fluid leakage could have serious conse-quences. Therefore, it is very important, in addition to a thorough visual inspection, to checkthe following points before each ride.

NOTE:Pre-operation checks should be made each time the snowmobile is used. Such an inspectioncan be accomplished in a very short time; and the added safety it assures is more than worththe time involved.

WARNINGEWS00190

If any item in the pre-operation check list is not working properly, have it inspected andrepaired before operating the snowmobile.

ESU11080

Pre-operation check list ITEM CHECKS PAGE

Fuel• Check fuel level.• Refuel if necessary.• Check fuel line for leakage.

20

Engine oil

• Check oil level in engine.• If necessary, add recommended oil to specified

level.• Check vehicle for oil leakage.

47

Coolant • Check coolant level.• Add if necessary. 50

V-belt • Check for wear and damage.• Replace if necessary. 52

Drive guard• Make sure that drive guard is tightened securely.• Check the drive guard mounts for damage.• Make sure that the drive guard is firmly in place.

20

Brake

• Check operation.• If soft or spongy, have Yamaha dealer bleed hy-

draulic system.• Check brake pads for wear.• Replace if necessary.• Check fluid level in master cylinder.• If necessary, add recommended brake fluid to

specified level.• Check hydraulic system for leakage.

56

Air filter• Check that there is no snow under the air filter ele-

ment.• If necessary, brush off the snow.

44


Pre-operation checks

27

Tool kit and recommended equipment • Check for proper placement. 40

Shroud and covers • Make sure that the shroud and covers are securely fastened. 19

Skis and ski runners• Check for wear and damage.• If necessary, have Yamaha dealer replace skis or

ski runners.58

Drive track • Check for deflection, wear and damage.• If necessary, have Yamaha dealer replace track. 59

Slide runners• Check for wear and damage.• If necessary, have Yamaha dealer replace slide

runners.59

Steering • Check for excessive free play. 59

Lights, signals and switch-es

• Check operation.• Correct if necessary. 16, 15, 63, 64

Throttle lever • Make sure that operation is smooth and spring back to its home position when released. 9

Throttle override system (T.O.R.S.)

• Check the T.O.R.S. for proper operation.• If system is defective, have Yamaha dealer check

vehicle.44

ITEM CHECKS PAGE


Operation

28

ESU11290

Starting the engine

WARNINGEWS00200

� Be sure to check the “SAFETY INFOR-MATION” section carefully before start-ing the engine.

� Make sure that the parking brake is ap-plied.

NOTE:Make sure that the engine stop switch is in theon position. The starter motor cannot be oper-ated when the engine stop switch is in the offposition.

1. Fully open the starter (choke) lever.

NOTE:The starter (choke) lever is not required whenthe engine is warm. Put the starter (choke) le-ver in the closed position.

2. Turn the main switch to the start position.After the engine starts, put the starter(choke) lever in the half-open position.Warm up the engine until it does not runroughly or begin to stall when the starter(choke) lever is returned to the closed po-sition.

CAUTION:ECS00330

� Release the switch immediately after theengine starts.

� If the engine fails to start, release theswitch, wait a few seconds, then tryagain. Each attempt should be as shortas possible to preserve the battery. Donot crank the engine more than 10 sec-onds on any one attempt.

ESU11310

Break-in There is never a more important period in thelife of your engine than the period between 0and 500 km (300 mi). For this reason, youshould read the following material carefully.Since the engine is brand new, do not put anexcessive load on it for the first 500 km (300mi). The various parts in the engine wear andpolish themselves to the correct operatingclearances. During this period, prolonged full-throttle operation or any condition that mightresult in engine overheating must be avoided.

1. Start


Operation

29

Operating your snowmobile for the first timeStart the engine and let it idle for 15 minutes.0–160 km (0–100 mi)Avoid prolonged operation above 6000 r/min.160–500 km (100–300 mi)Avoid prolonged operation above 8000 r/min.500 km (300 mi) and beyondThe snowmobile can now be operated nor-mally.

CAUTION:ECS00340

� After 800 km (500 mi) of operation, theengine oil must be changed and the oilfilter cartridge replaced.

� If any engine trouble should occur dur-ing the engine break-in period, immedi-ately have a Yamaha dealer check thesnowmobile.

ESU11331

Riding your snowmobile Getting to know your snowmobileA snowmobile is a rider active vehicle, andyour riding position and your balance are thetwo basic factors of maneuvering your snow-mobile.Riding your snowmobile requires skills ac-quired through practice over a period of time.Take the time to learn the basic techniqueswell before attempting more difficult maneu-vers.Riding your new snowmobile can be a veryenjoyable activity, providing you with hours ofpleasure. However, it is essential to familiar-ize yourself with the operation of the snowmo-bile to achieve the skill necessary to enjoyriding safely. Before operating the snowmo-bile, read this Owner’s Manual completelyand understand the operation of the controls.Pay particular attention to the safety informa-tion on page 1.

Please read all warning and caution labels onyour snowmobile. Also, read the Snowmobil-er’s Safety Handbook that is supplied withyour snowmobile.Learning to ride your snowmobileBefore you ride, always perform the pre-oper-ation checks listed on page 26. The short timespent checking the condition of the snowmo-bile will be rewarded with added safety and amore reliable snowmobile. Always wear theproper clothing for both warmth and to helpprotect you from injury if an accident occurs.Become familiar with operating your snowmo-bile at low speeds, even if you are an experi-enced rider. Do not attempt to operate atmaximum performance until you are totally fa-miliar with the snowmobile’s handling andperformance characteristics.The beginning operator should select a largeflat area to become familiar with the snowmo-bile. Make sure that this area is free of obsta-cles and other traffic. You should practicecontrol of the throttle and brake, and masterturning techniques in this area before tryingmore difficult terrain.Set the parking brake and follow the instruc-tions on page 28 to start the engine. Once theengine has warmed up, you are ready to be-gin riding your snowmobile.To start out and accelerate1. With the engine idling, release the park-

ing brake.2. Apply the throttle slowly and smoothly.

The V-belt clutch will engage and you willstart to accelerate.

WARNINGEWS00210

The operator should always keep bothhands on the handlebar. Never put yourfeet outside the running boards. Avoid


Operation

30

high speeds until you have become thor-oughly familiar with your snowmobile andall of its controls.

BrakingWhen slowing down or stopping, release thethrottle and apply the brake gently—not sud-denly.

WARNINGEWS00220

� Many surfaces such as ice and hard-packed snow require much longer stop-ping distances. Be alert, plan ahead, andbegin decelerating early.

� Improper use of the brake can cause thedrive track to lose traction, reduce con-trol, and increase the possibility of anaccident.

TurningFor most snow surfaces, “body English” is thekey to turning.As you approach a curve, slow down and be-gin to turn the handlebar in the desired direc-tion. As you do so, put your weight on therunning board to the inside of the turn andlean your upper body into the turn.

This procedure should be practiced at lowspeeds many times, in a large flat area with noobstacles. Once you have learned this tech-nique, you should be able to perform it at high-

er speeds or in tighter curves. Lean more asthe turn gets sharper or is made at higherspeeds.Improper riding techniques such as abruptthrottle changes, excessive braking, incorrectbody movements, or too much speed for thesharpness of the turn may cause the snow-mobile to tip.If your snowmobile begins to tip while turning,lean more into the turn to regain balance. Ifnecessary, gradually let off on the throttle orsteer to the outside of the turn.Remember:Avoid higher speeds until you are thoroughlyfamiliar with the operation of your snowmo-bile.Riding uphillYou should practice first on gentle slopes. Trymore difficult climbs only after you have de-veloped your skill. As you approach a hill, ac-celerate before you start the climb, and thenreduce the throttle to prevent track slippage. Itis also important to keep your weight on theuphill side at all times. On climbs straight upthe hill, this can be accomplished by leaningforward and, on steeper inclines, standing onthe running boards and leaning forward overthe handlebar. (Also see “Traversing aslope”.)

Slow down as you reach the crest of the hill,and be prepared to react to obstacles, sharpdrops, or other vehicles or people which may


Operation

31

be on the other side. If you are unable to con-tinue up a hill, do not spin the track. Stop theengine and set the parking brake. Then pullthe rear of the snowmobile around to point thesnowmobile back down the hill. When thesnowmobile is pointed downhill, mount yoursnowmobile from the uphill side. Restart theengine, release the parking brake, and de-scend the hill.

WARNINGEWS00230

Side hills and steep slopes are not recom-mended for a novice snowmobiler.

Riding downhillWhen riding downhill, keep speed to a mini-mum. It is important to apply just enoughthrottle to keep the clutch engaged while de-scending the hill. This will allow you to use en-gine compression to help slow thesnowmobile, and to keep the snowmobilefrom rolling freely down the hill. Also apply thebrake frequently, with light pressure.

WARNINGEWS00240

Use extra caution when applying the brakeduring a descent. Excessive braking willcause the drive track to lock, causing aloss of control.

Traversing a slope

WARNINGEWS00250

Traversing slopes is not recommended fora novice snowmobiler.

Traversing a slope requires you to properlyposition your weight to maintain proper bal-ance. As you travel across the slope, leanyour body to position your weight towards theuphill side. A recommended riding position isto kneel with the knee of your downhill leg onthe seat and the foot of your uphill leg on therunning board. This position will make it easi-er for you to shift your body weight as needed.

Snow and ice are slippery, so be prepared forthe possibility that your snowmobile could be-gin to slip sideways on the slope. If this hap-pens, steer in the direction of the slide if thereare no obstacles in your path. As you regainproper balance, gradually steer again in thedirection you wish to travel.If your snowmobile starts to tip, steer downthe hill to regain balance.

WARNINGEWS00260

If you are unable to maintain correct bal-ance, and your snowmobile is going to tipover, dismount your snowmobile immedi-ately on the uphill side.


Operation

32

Ice or icy surfaceOperating on ice or icy surfaces can be verydangerous. Traction for turning, stopping, andstarting is much less than that on snow.

WARNINGEWS00270

When you have to operate on ice or icysurfaces, drive slowly and cautiously.Avoid accelerating, turning, and brakingrapidly. Steering is minimal and uncon-trolled spins are an ever-present danger.

Hard-packed snowIt can be more difficult to negotiate on hard-packed snow as both the skis and drive trackdo not have as much traction as when thesnowmobile is operated on fresh snow. Avoidrapid acceleration, turning, and braking.Operation on surfaces other than snow or iceOperation of your snowmobile on surfacesother than snow or ice should be avoided. Op-eration under such conditions will damage orresult in rapid wear of the ski runners, drivetrack, slide runners, and drive sprockets. Op-eration of the snowmobile on the followingsurfaces should be avoided at all times:� Dirt� Sand� Rocks� Grass� Bare pavementOther surfaces that should be avoided for thesake of drive track and slide runner life are:� Glare ice surfaces� Snow mixed with a lot of dirt and sandAll of the above surfaces have one thing incommon in regard to drive track and slide run-ners: little or no lubricating ability. Drive trackand all slide rail systems require lubrication(snow or water) between the slide runnersand the slide metal. In the absence of lubrica-

tion, the slide runners will rapidly wear and insevere cases, literally melt away, and thedrive track will be subject to damage or failure.Also traction aids such as studs, cleats, etc.,may cause further track damage or failure.

WARNINGEWS00280

Drive track damage or failure could resultin loss of braking ability and snowmobilecontrol, which could cause an accident.� Always check the drive track for damage

or maladjustment before operating thesnowmobile.

� Do not operate the snowmobile if youfind damage to the drive track.

CAUTION:ECS00350

Ride on fresh snow frequently. Operatingon ice or hard-packed snow will rapidlywear the slide runners.

ESU11350

Maximizing drive track life RecommendationsTrack tensionDuring initial break-in, the new drive track willtend to stretch quickly as the track settles. Besure to correct the track tension and align-ment frequently. (See page 59 for adjustmentprocedures.) A loose track can slip (ratchet),derail or catch on suspension parts causingsevere damage. Do not overtighten the drivetrack, otherwise it may increase the frictionbetween the track and the slide runners, re-sulting in the rapid wear of both components.Also, this may put an excessive load on thesuspension components, resulting in compo-nent failure.Marginal snowThe drive track and the slide runners are lubri-cated and cooled by snow and water. To pre-vent the drive track and slide runners fromoverheating, avoid sustained high-speed us-


Operation

33

age in areas such as icy trails, frozen lakesand rivers that have minimal snow coverage.An overheated track will be weakened inter-nally, which may cause failure or damage.Off-trail ridingAvoid off-trail riding until there is sufficientsnow coverage. It generally takes several feetof snow to provide a good overall base toproperly cover debris, such as rocks, logs,etc. If snow coverage is not sufficient, stay ontrails to avoid impact damage to the drivetrack.Studded trackIn general, track life will be shortened whenstuds are installed. Drilling stud holes into thedrive track will cut the internal fibers, whichweakens the track. Avoid spinning the drivetrack. Studs may catch on an object and pullout of the track, leaving tears and damagearound the already weakened area. To mini-mize possible damage, consult your studmanufacturer for installation and stud patternrecommendations.Yamaha does not recommend track stud-ding.ESU11390

Driving

WARNINGEWS00300

Be sure to read the “SAFETY INFORMA-TION” section on page 1 and the “Ridingyour snowmobile” section on page 29carefully before operating the snowmo-bile.

NOTE:Make sure that the engine is warmed upenough before riding.

WARNINGEWS00310

� Make sure that the throttle lever is fullyreleased and the snowmobile is at a fullstop before shifting.

� Be sure to slide the shift lever to “FWD”or “REV” until it stops completely andonly while the engine is idling.

� Make sure that the area behind thesnowmobile is clear before reversing.Watch behind.

� Reduce speed and avoid sharp turningwhen operating the snowmobile in re-verse.

1. To select the desired operating position,pull the shift lever out, slide it to “FWD” orto “REV” until it stops, and then release it.

1. Pull out.2. Slide to “FWD” (forward).3. Release.


Operation

34

CAUTION:ECS00070

Do not shift from “FWD” to “REV” or from“REV” to “FWD” while the snowmobile ismoving. Otherwise, the drive systemcould be damaged.

NOTE:The reverse buzzer beeps while the shift leveris in reverse.

2. Release the parking brake by moving theparking brake lever to the right.

3. Press the throttle lever slowly to move thesnowmobile.

4. Turn the handlebar in the desired direc-tion.

5. Squeeze the brake lever to stop thesnowmobile.

6. Apply the parking brake by moving theparking brake lever to the left.

ESU11410

Stopping the engine Turn the main switch to the off position to stopthe engine.

WARNINGEWS00330

� Push down the engine stop switch tostop the engine in an emergency.

� Make sure that the key is removed fromthe main switch whenever the operatorleaves the snowmobile, to prevent acci-dental starting.

ESU11420

Transporting When transporting your snowmobile on a trail-er or in a truck, observe the following recom-mendations to help protect it from damage:

1. Pull out.2. Slide to “REV” (reverse).3. Release.

1. Off


Operation

35

� Make sure that the fuel level in the fuel tankis lower than the bottom of the carburetors.Otherwise, the vibration and bumps fromthe road surface could make it possible forfuel to flow through the carburetors into thecylinders. This can result in “hydrostaticlock,” a condition where the engine cannotrotate because of fuel accumulated in theengine. Severe engine damage can resultfrom hydrostatic lock. When possible, thefuel tank should be empty during transpor-tation, especially if the trip takes longer than30 minutes.

� If transporting the snowmobile in an opentrailer or truck, put a tight fitting cover on thesnowmobile. A cover specifically designedfor your snowmobile is best. This will helpkeep foreign objects out of the cooling ventsin the shroud, and also help protect thesnowmobile against damage from debris onthe road.

� If transporting the snowmobile in an opentrailer or truck in areas where road salt isused, coat metal suspension surfaces light-ly with oil or another protectant. This willhelp protect against corrosion. Be sure toclean the snowmobile when you get to yourdestination to remove any corrosive salts.


Periodic maintenance

36

ESU11450

Safety is an obligation of the owner. Periodic inspection, adjustment, and lubrication will keepyour snowmobile in the safest and most efficient condition possible. The most important pointsof snowmobile inspection, adjustment, and lubrication are explained on the following pages.Maintenance, replacement, or repair of the emission control devices and systems maybe performed by any repair establishment or individual that is certified (if applicable).

WARNINGEWS00340

If you are not familiar with maintenance work, have a Yamaha dealer do it for you.

PROPER PERIODIC MAINTENANCE OF YOUR SNOWMOBILE IS IMPORTANT IN ORDERTO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAIN-TENANCE SERVICES RELATED TO EMISSION CONTROL. THESE CONTROLS NOTONLY FUNCTION TO ENSURE CLEANER AIR, BUT ARE ALSO VITAL TO PROPER EN-GINE OPERATION AND MAXIMUM PERFORMANCE. IN THE FOLLOWING PERIODICMAINTENANCE CHARTS, THE SERVICES RELATED TO EMISSION CONTROL AREGROUPED SEPARATELY. THESE SERVICES REQUIRE SPECIALIZED DATA, KNOWL-EDGE, AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER-FORM THESE PARTICULAR SERVICES.ESU11460

Periodic maintenance chart for the emission control system

ITEM REMARKS

INITIAL EVERY

PAGE1 month

or 800 km (500 mi) (40 hr)

Seasonally or

4000 km (2500 mi) (200 hr)

Spark plugs• Check condition.• Adjust gap and clean.• Replace if necessary.

42

* Valve clearance • Check and adjust valve clear-ance when engine is cold.

Every 40000 km (25000 mi) 46

* Crankcase breather system

• Check breather hose for cracks or damage.

• Replace if necessary.—

* Fuel filter • Check condition.• Replace if necessary. —

* Fuel line• Check fuel hose for cracks or

damage.• Replace if necessary.

—

* Idle speed • Check and adjust idle speed. 43



37

* It is recommended that these items be serviced by a Yamaha dealer.

* Carburetors

• Adjust synchronization. —

• Adjust the jets.Whenever operating

condition (elevation/tem-perature) is changed.

46

* Exhaust system• Check for leakage.• Tighten or replace gasket if

necessary.—

ITEM REMARKS

INITIAL EVERY

PAGE1 month

or 800 km (500 mi) (40 hr)

Seasonally or

4000 km (2500 mi) (200 hr)



38

ESU11560

General maintenance and lubrication chart

ITEM REMARKS

INITIAL EVERY

PAGE1 month

or 800 km (500 mi) (40 hr)

Seasonally or

4000 km (2500 mi) (200 hr)

Engine oil • Change (warm engine before draining) 47

* Engine oil filter car-tridge • Replace.

Every 20000 km (12000 mi)

47

* Cooling system• Check coolant level.• Air bleed the cooling system if

necessary.50

* Primary and sec-ondary clutches

• Check engagement and shift speed.

• Adjust if necessary.

—

Whenever operating ele-vation is changed. —

• Inspect sheaves for wear and damage.

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

• Inspect ramp shoes/bushings for wear for secondary.

• Replace if necessary.

—

• Lubricate with specified grease. —

* Drive chain • Check chain slack.• Adjust if necessary.

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

mi) thereafter.55

* Drive chain oil• Check oil level. 55

• Change. 55

* Brake and parking brake

• Adjust free play and/or replace pads if necessary. 56

• Change brake fluid. See NOTE following this chart. 56

Control cables• Make sure that operation is

smooth.• Lubricate if necessary.

62

* Disc brake installa-tion

• Check for slight free play.• Lubricate shaft with specified

grease as required.

Every 1600 km (1000 mi) —

* Slide runners • Check for wear and damage.• Replace if necessary. 59

* Skis and ski run-ners

• Check for wear and damage.• Replace if necessary. 58



39

* 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.� Replace the oil seals of the master cylinder and caliper cylinder every two years.� Replace the brake hose every four years, or if cracked or damaged.

* Steering system • Check toe-out.• Adjust if necessary. 59

* Steering bearings

• Check bearing assemblies for looseness.

• Lubricate with specified grease.

—

* Ski and front sus-pension

• Lubricate with specified grease. 62

* Suspension compo-nent

• Lubricate with specified grease. 62

Fittings and fasten-ers

• Make sure that all nuts, bolts and screws are properly tight-ened.

• Tighten if necessary.

64

* Battery • Check condition.• Charge if necessary. 64

ITEM REMARKS

INITIAL EVERY

PAGE1 month

or 800 km (500 mi) (40 hr)

Seasonally or

4000 km (2500 mi) (200 hr)



40

ESU11740

Tool kit The owner’s tool kit has the tools which aresufficient for most periodic maintenance andminor repairs. A torque wrench is also neces-sary to properly tighten nuts and bolts.

CAUTION:ECS00360

Before starting the engine, make sure thatthe tool kit is properly seated in its holderand is securely fastened.

NOTE:If you do not have a torque wrench availableduring a service operation requiring one, takeyour snowmobile to a Yamaha dealer tocheck the torque settings and adjust them ifnecessary.

ESU12891

Removing and installing the shroud and covers

ShroudTo remove the shroudLoosen the fasteners, slowly raise the shroud,and then unhook the shroud from the shroudstay.

To install the shroudHook the end of the shroud onto the shroudstay, slowly lower it to the original position,and then tighten the fasteners.

Left and right side coversTo remove a side cover1. Remove the shroud. (See the above pro-

cedure.)2. Loosen the fasteners, and then remove

the side cover.

1. Tool kit

1. Fastener2. Shroud

1. Shroud stay



41

To install a side cover1. Place the side cover in the original posi-

tion, and then tighten the fasteners.2. Install the shroud.

NOTE:Be sure to fit the projection on the rear of theside cover into the hole in the lower side cov-er.

Top coverTo remove the top cover1. Remove the shroud. (See the above pro-

cedure.)2. Remove the screws, and then remove

the cable guide.

3. Loosen the quick fastener screws, dis-connect the main switch coupler and aux-iliary DC jack coupler (RS90GT /RS90GTA / RS90LTGT), and then re-move the top cover.

To install the top cover1. Connect the main switch coupler and

auxiliary DC jack coupler (RS90GT /RS90GTA / RS90LTGT), place the topcover in the original position, and thentighten the quick fastener screws.

2. Pass all of the cables, etc., through thecable guide, place the cable guide in theoriginal position, and then install thescrews.

3. Install the shroud.

1. Fastener2. Right side cover

1. Fastener2. Left side cover

1. Screw2. Cable guide

1. Quick fastener screw2. Top cover



42

WARNINGEWS00090

� Do not drive the snowmobile with theshroud or covers unfastened or re-moved.

� Keep your body and clothing away fromrotating parts when servicing the snow-mobile with the shroud or covers re-moved.

� Do not touch the hot muffler and engineduring or immediately after operation.

CAUTION:ECS00370

Make sure that all cables, leads, etc., arerouted properly before installing theshroud and covers.

NOTE:When installing the shroud and covers, besure to tighten all fasteners securely.

ESU11780

Checking the spark plugs The spark plug is an important engine compo-nent and is easy to inspect. The condition ofthe spark plug can indicate the condition ofthe engine.Check the coloration on the white porcelaininsulator around the center electrode. Theideal coloration at this point is a medium to alight tan color for a snowmobile that is beingridden normally. If a spark plug shows a dis-tinctly different color, there could be some-thing wrong with the engine. For example, avery white center electrode porcelain colorcould indicate an intake track air leak or car-buretion problem for that cylinder. Do not at-tempt to diagnose such problems yourself.Instead, take the snowmobile to a Yamahadealer for inspection and possible repairs.

You should periodically remove and inspectthe spark plug because heat and deposits willcause a spark plug to slowly break down anderode. Consult a Yamaha dealer beforechanging to a different type of spark plug.

Spark plugs are produced in several differentthread lengths. The thread length or reach isthe distance from the spark plug gasket seatto the end of the threaded portion. If the reachis too long, overheating and engine damagemay result. If the reach is too short, spark plugfouling and poor performance may result. Al-so, if the reach is too short, carbon will form onthe exposed threads resulting in combustionchamber hot spots and thread damage. Al-ways use a spark plug with the specifiedreach.

Before installing any spark plug, measure theelectrode gap with a wire thickness gaugeand adjust to specification.

Specified spark plug:Manufacturer:

NGKModel:

CR8E

Spark plug reach:19.0 mm (0.75 in)

1. Spark plug gap2. Spark plug reach



43

When installing the spark plug, always cleanthe gasket surface. Wipe off any grime fromthe threads and tighten the spark plug to thespecified torque.

CAUTION:ECS00380

Make sure that the spark plug caps are se-curely installed. Otherwise the spark plugcaps could be damaged due to engine vi-bration.

ESU12900

Adjusting the engine idling speed

CAUTION:ECS00390

� Be sure to have a Yamaha dealer makethis adjustment.

� Make sure that the throttle lever movessmoothly.

� Make sure that the carburetor is syn-chronized first.

1. Remove the shroud. (See page 40 for re-moval procedures.)

2. Start the engine and warm it up.3. Turn the throttle stop screw in or out to

adjust the engine idling speed.

4. Install the shroud.ESU12910

Adjusting the throttle cable free play

CAUTION:ECS00410

Be sure to adjust the engine idling speedfirst.

1. Remove the shroud and the right sidecover. (See page 40 for removal proce-dures.)

2. Loosen the locknut.3. Turn the adjusting bolt in or out until the

specified throttle cable free play is ob-tained.

Spark plug gap:0.7–0.8 mm (0.028–0.031 in)

Spark plug tightening torque:12.5 Nm (1.25 m·kgf, 9 ft·lb)

1. Throttle stop screw

Standard engine idling speed:1300–1500 r/min

1. Locknut2. Throttle cable free play adjusting bolt3. Throttle cable free play



44

4. Tighten the locknut.5. Install the right side cover and the shroud.ESU11861

Checking the throttle override system (T.O.R.S.)

Check the T.O.R.S. for proper operation.

WARNINGEWS00351

When checking the T.O.R.S.:� Make sure that the parking brake is ap-

plied.� Make sure that the throttle lever moves

smoothly.� Do not rev the engine to the point that

the clutch engages, otherwise the snow-mobile could start moving, which couldcause an accident.

1. Start the engine.

NOTE:Refer to the “Starting the engine” section onpage 28.

2. Hold the pivot point of the throttle leveraway from the throttle switch by puttingyour thumb (above) and forefinger (be-low) between the throttle lever pivot andthe engine stop switch housing.While holding the pivot point as describedabove, press the throttle lever gradually.

The T.O.R.S. will be activated and theengine speed will be limited to less thanthe clutch engagement speed. (See page74 for the clutch engagement speed.)

WARNINGEWS00361

If the engine speed does not decrease toless than the clutch engagement speed,stop the engine by turning the main switchto the off position and consult a Yamahadealer.

ESU12920

Checking the air filter Always check that there is no snow under theair filter element frame.1. Remove the shroud, the left side cover,

the right side cover, and the top cover.(See page 40 for removal procedures.)

Throttle cable free play:2.0–3.0 mm (0.08–0.12 in)

1. Throttle lever pivot2. Engine stop switch housing3. Throttle lever



45

2. Remove the headlight unit bolt on eachside of the snowmobile.

3. Unfasten the plastic band around the wireharness.

4. Disconnect the cylinder head breatherhose.

5. Unhook the air filter case cover fasteners.

6. Slightly lift up the headlight unit, and thenremove the air filter case cover.

7. Lift up the air filter element frame andcheck the air filter element. If there is anysnow on the air filter element, remove theelement, brush off the snow, and then in-stall the air filter element.

8. Place the air filter element frame in theoriginal position, and then install the airfilter case cover.

9. Hook the fasteners onto the air filter casecover.

10. Connect the cylinder head breather hose.11. Install the headlight unit, making sure to

insert the projections on the headlightunit stay into the slots on the bottom ofthe headlight unit.

1. Headlight unit bolt

1. Plastic band

1. Cylinder head breather hose



46

12. Install the headlight unit bolts, and thentighten them to the specified torque.

13. Place the wire harness in the original po-sition, and then fasten the plastic bandaround it.

14. Install the top cover, the right side cover,the left side cover, and the shroud.

NOTE:After riding the snowmobile, make sure thatthere is no snow under the air filter elementframe.

ESU11910

Carburetors The carburetors are an important part of theengine and its emission control system, whichrequire very sophisticated adjustment. There-fore, carburetor adjustments should be left toa Yamaha dealer, who has the necessary pro-fessional knowledge and experience.ESU11940

High-altitude settings Operating at high altitude reduces the perfor-mance of a gasoline engine about 3% for ev-ery 305 m (1000 ft) of elevation. This isbecause there is less air as altitude increases.Less air means less oxygen available forcombustion.

Your snowmobile can be adjusted to over-come most of the problems found in high-alti-tude riding. Carburetor adjustments are themost important. Less air at high altitudemakes the air/fuel ratio too rich, which cancause poor performance. Common problemsare hard starting, bogging, and plug fouling.Proper carburetion adjustments will correctthe air/fuel ratio. Be sure to have a Yamahadealer make these adjustments.Remember:Less air at higher altitude means there is lesshorsepower available, even with proper car-buretion. Expect acceleration and top speedto be reduced at higher altitudes.To overcome operating with less power athigh altitudes, your snowmobile may also re-quire different settings for the drive chaingears and V-belt clutch to avoid poor perfor-mance and rapid wear. If you plan to operateyour snowmobile at an altitude different fromthe area where you bought it, be sure to con-sult a Yamaha dealer. The dealer can tell youif there are any changes necessary for the al-titude where you plan to ride.

CAUTION:ECS00430

The drive chain gears and V-belt clutchshould be adjusted when operating abovea high altitude of 900 m (3000 ft). Consult aYamaha dealer.

ESU11950

Valve clearance The valve clearance changes with use, result-ing in improper air-fuel mixture and/or enginenoise. To prevent this from occurring, thevalve clearance must be adjusted by aYamaha dealer at the intervals specified inthe periodic maintenance chart.

Headlight unit bolt tightening torque:3 Nm (0.3 m·kgf, 2.2 ft·lb)



47

ESU12930

Engine oil and oil filter cartridge The engine oil level should be checked beforeeach use. In addition, the oil must be changedand the oil filter cartridge replaced at the inter-vals specified in the periodic maintenanceand lubrication chart.

WARNINGEWS00370

Engine oil is extremely hot immediately af-ter the engine is turned off. Coming intocontact with or getting any engine oil onyour clothes could result in burns.

CAUTION:ECS00480

� Do not run the engine with too much ornot enough oil in the oil tank. Oil couldspray out or the engine could be dam-aged.

� Be sure to change the engine oil afterthe first 800 km (500 mi) of operation,and every 4000 km (2500 mi) thereafteror at the start of a new season, other-wise the engine will wear quickly.

� The oil filter cartridge should be re-placed every 20000 km (12000 mi) of op-eration.

To check the engine oil level1. Place the snowmobile on a level surface

and apply the parking brake.

2. Start the engine, warm it up for 10–15minutes, and then turn it off.

NOTE:� The engine can also be warmed up by op-

erating the snowmobile for 10–15 minutes.� After operating the snowmobile, allow the

engine to idle for at least 10 seconds beforeturning it off.


4. Disconnect the oil level gauge coupler.

CAUTION:ECS00451

Disconnect the oil level gauge coupler be-fore removing the oil filler cap, otherwisethe cable could twist and break.

5. Remove the oil filler cap, wipe the dipstickclean, insert it back into the oil filler hole(without screwing it in), and then removeit again to check the oil level.

1. Oil level gauge coupler2. Oil filler cap



48

NOTE:The engine oil should be between the “H” and“L” level marks on the dipstick.

6. If the engine oil is below the “L” levelmark, add sufficient oil of the recom-mended type to raise it to the “H” levelmark. (See page 74 for the recommend-ed oil.)

CAUTION:ECS00461

� When adding the engine oil, be carefulnot to fill above the “H” level mark on thedipstick.

� Use only 4-stroke engine oil.� Make sure that no foreign material en-

ters the engine oil tank.

7. Insert the dipstick into the oil filler hole,and then tighten the oil filler cap.

8. Connect the oil level gauge coupler.9. Install the right side cover and the shroud.To change the engine oil (with or without oil fil-ter cartridge replacement)1. Place the snowmobile on a level surface

and apply the parking brake.2. Start the engine, warm it up for several

minutes, and then turn it off.3. Remove the shroud, the right side cover,

and the top cover. (See page 40 for re-moval procedures.)

4. Remove the right lower cover and thebottom panel.

5. Place an oil pan under the oil tank to col-lect the used oil.

6. Disconnect the oil level gauge coupler.

1. Oil filler cap2. Dipstick

1. “H” level mark2. “L” level mark

1. Bottom panel

1. Right lower cover



49

7. Remove the oil filler cap, the cylinderhead cap, and the engine oil drain bolt todrain the oil from the oil tank.

8. Place an oil pan under the engine to col-lect the used oil.

9. Remove the engine oil drain bolt to drainthe oil from the crankcase.

NOTE:� A “ ” mark is stamped on the crankcase

near the engine oil drain bolt.� Dispose of used oil according to local regu-

lations.� Skip steps 10–12 if the oil filter cartridge is

not being replaced.

10. Remove the oil filter cartridge with an oilfilter wrench.

NOTE:An oil filter wrench is available at a Yamahadealer.

11. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.

12. Install the new oil filter cartridge with anoil filter wrench, and then tighten it to thespecified torque.

1. Oil level gauge coupler2. Oil filler cap

1. Cylinder head cap

1. Engine oil drain bolt (oil tank)

1. Engine oil drain bolt (crankcase)2. “ ” mark

1. Oil filter cartridge



50

13. Install the engine oil drain bolts, and thentighten them to the specified torques.

14. Add 1.5 L (1.6 US qt) (1.3 Imp. qt) of therecommended engine oil to the oil tank,and then install and tighten the oil fillercap and the cylinder head cap.

15. Start the engine, warm it up for severalminutes, and then turn it off.

16. Add sufficient oil of the recommendedtype to raise it to the “H” level mark on thedipstick. (See above for the checking pro-cedure.)

CAUTION:ECS00461

� When adding the engine oil, be carefulnot to fill above the “H” level mark on thedipstick.

� Use only 4-stroke engine oil.� Make sure that no foreign material en-

ters the engine oil tank.

17. Start the engine, and then let it idle forseveral minutes while checking it for oilleakage. If oil is leaking, immediately turnthe engine off and make sure that the en-gine oil drain bolts, the cylinder head cap,and the oil filler cap are installed correct-ly.

18. Turn the engine off, and then connect theoil level gauge coupler.

CAUTION:ECS00470

If oil is leaking or the oil level warning indi-cator comes on when the engine is run-ning, immediately turn the engine off andhave a Yamaha dealer check the snowmo-bile. Continuing to operate the engine un-der such conditions could cause severeengine damage.

19. Install the bottom panel and the right low-er cover.

20. Install the top cover, the right side cover,and the shroud.

ESU12940

Cooling system The coolant level should be checked beforeeach ride. In addition, the cooling systemmust be bled of air at the intervals specified inthe periodic maintenance and lubricationchart.

Tightening torque:Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lb)

Tightening torques:Engine oil drain bolt (crankcase):

10 Nm (1.0 m·kgf, 7.2 ft·lb)Engine oil drain bolt (oil tank):

16 Nm (1.6 m·kgf, 11 ft·lb)

Recommended engine oil:See page 74.

Oil quantity:With oil filter cartridge replacement:

2.5 L (2.64 US qt) (2.20 Imp.qt)Without oil filter cartridge replacement:

2.3 L (2.43 US qt) (2.02 Imp.qt)Total amount:

3.2 L (3.38 US qt) (2.82 Imp.qt)



51

WARNINGEWS00380

Do not remove the coolant reservoir capwhen the engine is hot. Scalding hot fluidand steam may be blown out under pres-sure, which could cause serious injury.When the engine has cooled, place a thickrag or towel over the coolant reservoircap, and slowly rotate the cap counter-clockwise to the detent. This procedure al-lows any residual pressure to escape.When the hissing sound has stopped,press down on the cap while turning coun-terclockwise and remove it.

To check the coolant level1. Remove the shroud and the right side

cover. (See page 40 for removal proce-dures.)

2. Check the coolant level in the coolantreservoir when the engine is cold. If thecoolant level is below the “COLD LEVEL”mark, add coolant until it reaches the“COLD LEVEL” mark. (See the followingsection “Replenishing the coolant” formore details.)

CAUTION:ECS00490

� Hard water or salt water is harmful to theengine parts. You may use boiled or dis-tilled water, if soft water is not available.

� Tap water can be used temporarily in anemergency.

3. Install the right side cover and the shroud.Bleeding the cooling systemThe cooling system must be bled of air if thecoolant reservoir becomes empty, if air can beseen in the cooling system, or if there is acooling system leak. Consult a Yamaha deal-er.

CAUTION:ECS00500

Operating the engine with an improperlybled cooling system can cause overheat-ing and severe engine damage.

Replenishing the coolant1. Remove the shroud, the right side cover,

and the top cover. (See page 40 for re-moval procedures.)

2. Remove the coolant reservoir cap andadd coolant until it reaches the “COLDLEVEL” mark.

1. Coolant reservoir cap

1. “COLD LEVEL” mark



52

3. Start the engine and add coolant until thecoolant level stabilizes, and then stop theengine.

4. Fill the coolant reservoir with coolant untilit reaches the “COLD LEVEL” mark.

5. Install the coolant reservoir cap.6. Check for any coolant leakage.

NOTE:If you find any leaks, consult a Yamaha deal-er.

7. Install the top cover, the right side cover,and the shroud.

ESU12060

V-belt

WARNINGEWS00400

� Make sure that the drive guard is tight-ened securely before operating thesnowmobile.


The V-belt should be checked before eachride.To check the V-belt1. Remove the shroud and the left side cov-

er, and then remove the drive guard.(See page 40 for removal procedures.)

2. Check the V-belt for wear and damage.Replace if necessary.

3. Install the drive guard, and then install theleft side cover and the shroud.

To replace and adjust the V-belt

WARNINGEWS00410


Recommended antifreeze:High-quality ethylene glycol antifreeze containing corrosion inhibitors

Antifreeze and water mixing ratio:3:2

Total amount:RS90GT 4.80 L (5.07 US qt) (4.22 Imp.qt)RS90GTA 4.80 L (5.07 US qt) (4.22 Imp.qt)RS90LT 5.60 L (5.92 US qt) (4.93 Imp.qt)RS90LTGT 5.60 L (5.92 US qt) (4.93 Imp.qt)RS90R 4.80 L (5.07 US qt) (4.22 Imp.qt)

1. V-belt wear limit

New V-belt width:34.1 mm (1.34 in)

V-belt wear limit width:32.5 mm (1.28 in)



53

� When installing the new V-belt, makesure that it is positioned properly. Other-wise, the V-belt clutch engagementspeed will be changed and the snowmo-bile may move unexpectedly when theengine is started, which could cause anaccident.

� Have a Yamaha dealer make this adjust-ment.

CAUTION:ECS00510

As the V-belt wears, adjustment may benecessary. To ensure proper clutch per-formance, the V-belt position should beadjusted by adding a spacer on each ad-justing bolt when the V-belt positionreaches 1.5 mm (0.06 in) below the edge ofthe secondary sheave assembly.

Have a Yamaha dealer make this adjust-ment.

NOTE:Apply the parking brake before replacing theV-belt.

1. Remove the shroud and the left side cov-er, and then remove the drive guard.(See page 40 for removal procedures.)

2. Rotate the secondary sliding sheaveclockwise and push it so that it separatesfrom the secondary fixed sheave.

3. Pull the V-belt up over the secondaryfixed sheave.

4. Remove the V-belt from the secondarysheave assembly and primary sheaveassembly.

1. Edge of the secondary sheave assembly2. Spacer

1. Secondary sliding sheave2. Secondary fixed sheave

1. V-belt



54

5. Temporarily install the new V-belt on thesecondary sheave assembly only, andthen measure the V-belt position. Do notforce the V-belt between the sheaves; thesecondary sliding and fixed sheavesmust touch each other.

6. If the V-belt position is incorrect, adjust itby removing or adding a spacer on eachV-belt position adjusting bolt.

7. Tighten the V-belt position adjustingbolts.

8. Install the V-belt over the primary sheaveassembly.

1. Edge of the secondary sheave assembly2. V-belt position

Standard V-belt position:From 1.5 mm (0.06 in) above the edge of the secondary sheave assembly to 0.5 mm (0.02 in) below the edge.

1. V-belt position adjusting bolt2. Spacer

V-belt position Adjustment

More than 1.5 mm (0.06 in) above the edge

Remove spacer

From 1.5 mm (0.06 in) above the edge to 0.5 mm (0.02 in) below the edge

Not necessary (It is correct.)

More than 0.5 mm (0.02 in) below the edge

Add spacer

V-belt position adjusting bolt tightening torque:

10 Nm (1.0 m·kgf, 7.2 ft·lb)



55

9. Rotate the secondary sliding sheaveclockwise and push it so that it separatesfrom the secondary fixed sheave.

10. Install the V-belt between the secondarysliding and fixed sheaves.

11. Install the drive guard, and then install theleft side cover and the shroud.

ESU12100

Drive chain housing

WARNINGEWS00430

The engine, oil tank, brake disc, and cool-ant hoses will be very hot after the enginehas been run. Avoid contact while they arestill hot with any part of your body or cloth-ing during inspection or repair.

To check the drive chain housing oil level1. Place the snowmobile on a level surface.


3. Remove the dipstick, wipe it off with aclean rag, and then insert it back into thefiller hole.

4. Remove the dipstick and check that theoil is between the maximum and mini-mum level marks. If the oil is below theminimum level mark, add sufficient oil ofthe recommended type to raise it to themaximum level mark.

1. Secondary sliding sheave2. Secondary fixed sheave

1. V-belt

1. Dipstick

1. Maximum level mark2. Minimum level mark



56

CAUTION:ECS00530

Make sure that no foreign material entersthe drive chain housing.

5. Install the dipstick, making sure to alignthe notch in the dipstick handle with theprojection on the drive chain housing.

6. Install the right side cover and the shroud.To adjust the chain tension1. Remove the shroud and the right side


2. Loosen the locknut.3. Turn the chain tension adjusting bolt

clockwise until it is finger tight, and thenloosen it 1/4 turn.

4. Hold the chain tension adjusting bolt inplace while tightening the locknut.

5. Install the right side cover and the shroud.ESU12130

Brake and parking brake

WARNINGEWS00440

� A soft, spongy feeling in the brake leverindicates a failure in the brake system.

� Do not operate the snowmobile if youfind any problems in the brake system.You could lose braking ability, whichcould lead to an accident. Ask a Yamahadealer to inspect and repair the brakesystem.

CAUTION:ECS00060

Make sure that the brake lever end doesnot project out over the handlebar end.This will help prevent brake lever damagewhen the snowmobile is placed on its sidefor service.

Test the brake at a low speed when startingout to make sure that it is working properly. Ifthe brake does not provide proper brakingperformance, inspect the brake for wear orbrake fluid leakage. (See the following sectionfor more details.)Checking the brake padsCheck the brake pads for wear.If the brake pads reach the wear limit, ask aYamaha dealer to replace them.

Recommended drive chain oil:SAE 75W or 80W API GL-4 Gear oil

1. Notch2. Projection

1. Locknut2. Chain tension adjusting bolt



57

Checking the parking brake padsCheck the parking brake pads for wear bymeasuring the thickness of the pads. If theparking brake pads reach the wear limit, ask aYamaha dealer to replace them.

To adjust the parking brakeAs the parking brake pads wear, adjustmentmay be necessary to ensure proper brakeperformance.

WARNINGEWS00450

Be sure to have a Yamaha dealer make thisadjustment.

1. Loosen the parking brake pad locknutand the parking brake pad adjusting bolt.

2. Loosen the parking brake cable locknut.3. Turn the parking brake cable adjusting

bolt in or out to adjust the cable length.

4. Tighten the parking brake cable locknut.5. Turn the parking brake pad adjusting bolt

in or out to adjust the clearance betweenthe parking brake pads and the brakedisc.

1. Brake pad wear indicator2. Brake pad wear limit

Brake pad wear limit:7.5 mm (0.30 in)

1. Parking brake pad wear limit

Parking brake pad wear limit:1.2 mm (0.047 in)

1. Parking brake pad locknut2. Parking brake pad adjusting bolt3. Parking brake cable locknut4. Parking brake cable adjusting bolt5. Parking brake cable length

Parking brake cable length:43.5–46.5 mm (1.713–1.831 in)

1. Parking brake pad2. Brake disc



58

6. Tighten the parking brake pad locknut.Checking the brake fluid level

WARNINGEWS00460

Be careful that water does not enter themaster cylinder when refilling. Water willsignificantly lower the boiling point of thefluid and may result in vapor lock.If the brake fluid level goes down, consulta Yamaha dealer.

CAUTION:ECS00550

Brake fluid may deteriorate painted sur-faces or plastic parts. Never spill any fluid.If any is spilled, clean it up immediately.

Place the snowmobile on a level surface.Check that the brake fluid is above the lowerlevel and replenish when necessary.

Changing the brake fluid

WARNINGEWS00470

Make sure that the brake fluid and theabove parts are replaced by a Yamahadealer.

Brake fluid replacement is necessary whenthe following components are replaced duringthe periodic maintenance or if they are dam-aged or leaking.� All oil seals of the master cylinder and cali-

per cylinder� The brake hoseESU12141

Skis and ski runners Check the skis and ski runners for wear anddamage. Replace if necessary.

Parking brake pad to brake disc clear-ance (a) + (b):

1.5–2.0 mm (0.059–0.079 in)

1. Lower level

Specified brake fluid:DOT 4

1. Ski runner wear limit

1. Ski wear limit



59

CAUTION:ECS00560

Avoid scratching the skis when loadingand unloading the snowmobile, whenriding in areas with little or no snow, or onsharp edges such as concrete, curbs, etc.This will wear or damage the skis.

To align the skis1. Turn the handlebar so the skis face

straight ahead.2. Check the following for ski alignment:

� Skis are facing forward.� Ski toe-out (distance A – distance B) is

within specification.

3. If the alignment is not correct, consult aYamaha dealer.

ESU12151

Steering system Check the handlebar for excessive free play.To check the handlebar1. Push the handlebar up and down and

back and forth.

2. Turn the handlebar slightly to the rightand left.

If excessive free play is felt, consult a Yamahadealer.ESU12171

Drive track and slide runners Drive track

WARNINGEWS00480

A broken track, track fittings or debristhrown by the drive track could be danger-ous to an operator or bystanders. Observethe following precautions:� Do not allow anyone to stand behind the

snowmobile when the engine is running.� When the rear of the snowmobile is

raised to allow the drive track to spin, asuitable stand must be used to supportthe rear of the snowmobile. Never allowanyone to hold the rear of the snowmo-bile off the ground to allow the drivetrack to spin. Never allow anyone near arotating drive track.

� Inspect the drive track condition fre-quently. Replace damaged slide metal.Replace the drive track if it is damagedto the depth where fabric reinforcementmaterial is visible or support rods arebroken. Otherwise, track damage or fail-ure could result in loss of braking abilityand snowmobile control, which couldcause an accident.

Ski runner wear limit:8 mm (0.31 in)

Ski wear limit:12 mm (0.47 in)

1. Distance A2. Distance B

Ski toe-out (distance A – distance B):0.0–15.0 mm (0.00–0.59 in)



60

Checking the drive track

WARNINGEWS00490

Do not operate the snowmobile if you finddamage to the drive track, or if it has beenmaladjusted. Drive track damage or failurecould result in loss of braking ability andsnowmobile control, which could causean accident.

Check the drive track for deflection, wear, anddamage.Adjust or replace if necessary. (See the fol-lowing section for more details.)

Measuring the drive track deflection1. Lay the snowmobile on its side.2. Measure the drive track deflection with a

spring scale. Pull at the center of the drivetrack with a force of 100 N (10 kg, 22 lb).

NOTE:Measure the gap between the slide runnerand the edge of the track window. Measureboth sides.

3. If the deflection is incorrect, adjust thedrive track.

Adjusting the drive track

WARNINGEWS00500

� Be sure to have a Yamaha dealer makethis adjustment.

� Support the snowmobile securely on asuitable stand before working under-neath the snowmobile.

� Operate the engine in a well-ventilatedarea.

1. Lift the rear of the snowmobile onto a suit-able stand to raise the drive track off theground.

2. Loosen the rear axle nut.

1. Spring scale

1. Drive track deflection

Standard drive track deflection:RS90GT 30.0–35.0 mm (1.18–1.38 in)RS90GTA 30.0–35.0 mm (1.18–1.38 in)RS90LT 25.0–30.0 mm (0.98–1.18 in)RS90LTGT 25.0–30.0 mm (0.98–1.18 in)RS90R 30.0–35.0 mm (1.18–1.38 in)



61

3. Start the engine and rotate the drive trackone or two turns. Stop the engine.

4. Check the drive track alignment with theslide runners. If the alignment is incorrect,align the drive track by turning the left andright adjusting nuts.

Shifted to right

Shifted to left

1. Rear axle nut

1. Slide runner

Drive track alignment

Shifted to right Shifted to left

Left adjusting nut Turn out Turn in

Right adjust-ing nut Turn in Turn out

1. Left adjusting nut2. Right adjusting nut

1. Forward2. Gap3. Slide runner4. Drive track5. Slide metal

1. Forward2. Gap3. Slide runner4. Drive track5. Slide metal



62

5. Adjust the drive track deflection to speci-fication.

CAUTION:ECS00591

The right and left adjusting nuts should beturned an equal amount.

6. Recheck alignment and deflection. If nec-essary, repeat steps 3 to 5 until the prop-er adjustment is achieved.

7. Tighten the rear axle nut.

Slide runnersCheck the slide runners for wear and dam-age.If the slide runners reach the wear limit, theyshould be replaced.

CAUTION:ECS00350

Ride on fresh snow frequently. Operatingon ice or hard-packed snow will rapidlywear the slide runners.

ESU12190

Lubrication Lubricate the following points with the speci-fied grease.

WARNINGEWS00510

� Apply a dab of grease onto the cable endonly. Do not grease the throttle cable be-cause it could become frozen, whichcould cause loss of control.

� Be sure to have a Yamaha dealer lubri-cate the front and rear suspensions.

Drive track deflection

More than specified

Less than specified

Left adjusting nut Turn in Turn out

Right adjust-ing nut Turn in Turn out

Rear axle nut tightening torque:75 Nm (7.5 m·kgf, 54 ft·lb)

1. Slide runner2. Wear limit height

Slide runner wear limit height:10.5 mm (0.41 in)

Lubricant:Low-temperature grease

1. Throttle cable end



63

ESU12220

Replacing a headlight bulb

WARNINGEWS00530

Keep flammable products and your handsaway from the hot bulb until it has cooleddown.

1. Remove the top cover. (See page 40 forremoval procedures.)

2. Remove the screws, and then removethe headlight access panel.

3. Disconnect the headlight coupler.4. Remove the bulb holder cover.

5. Unhook the bulb holder by pushing it in,then clockwise.

1. Lubrication point

1. Lubrication point

1. Screw

1. Screw2. Headlight access panel

1. Headlight coupler2. Bulb holder cover



64

6. Remove the bulb.7. Install the new bulb, and then hook the

bulb holder onto the headlight unit.

CAUTION:ECS00620

Keep oil and your hands away from theglass part of the bulb or its life and illumi-nation will be affected.If the glass is oil stained, thoroughly cleanit with a cloth moistened with alcohol orlacquer thinner.

8. Install the bulb holder cover, and thenconnect the headlight coupler.

9. Install the headlight access panel and thetop cover.

ESU12270

Adjusting the headlight beams 1. Remove the top cover. (See page 40 for

removal procedures.)2. Use a Phillips screwdriver to turn the

headlight beam adjusting screw and ad-just the headlight beams. To lower theheadlight beams, turn the headlightbeam adjusting screw in direction (a). Toraise the headlight beams, turn the head-light beam adjusting screw in direction(b).

3. Install the top cover.ESU12290

Fittings and fasteners Check the tightness of the fittings and fasten-ers.Tighten in proper sequence and torque if nec-essary.ESU12300

Battery This snowmobile is equipped with a sealed-type (MF) battery, which does not require anymaintenance. There is no need to check theelectrolyte or to add distilled water.To charge the batteryHave a Yamaha dealer charge the battery assoon as possible if it seems to have dis-charged. Keep in mind that the battery tendsto discharge more quickly if the snowmobile isequipped with electrical accessories.

1. Bulb holder

Bulb type:Halogen bulb

1. Do not touch the glass part of the bulb.

1. Headlight beam adjusting screw



65

WARNINGEWS00540

Battery electrolyte is poisonous and dan-gerous. It contains sulfuric acid and cancause severe burns. Avoid contact withskin, eyes, or clothing.ANTIDOTE:� EXTERNAL: Flush with water.� INTERNAL: Drink large quantities of wa-

ter or milk. Follow with milk of magne-sia, beaten egg, or vegetable oil. Callphysician immediately.

� EYES: Flush with water for 15 minutesand get prompt medical attention.

Batteries produce explosive gases. Keepsparks, flame, cigarettes, etc. away. Venti-late when charging or using in an en-closed space. Always shield your eyeswhen working near batteries.KEEP OUT OF THE REACH OF CHILDREN.

ESU12950

Replacing a fuse

WARNINGEWS00550

Be sure to use the specified fuse. A wrongfuse could cause electrical system dam-age or A FIRE HAZARD.

CAUTION:ECS00631

Be sure to turn the main switch to the offposition and disconnect the negative bat-tery lead to prevent accidental short-cir-cuiting.

1. Remove the shroud, the left side cover,the right side cover, and the top cover.(See page 40 for removal procedures.)

2. Remove the headlight unit bolt on eachside of the snowmobile, disconnect theheadlight couplers and speedometercoupler, and then remove the headlightunit.

3. Disconnect the cylinder head breatherhose and unhook the air filter case fas-tener.

4. Loosen the joint clamp bolts.

1. Headlight unit bolt

1. Cylinder head breather hose2. Fastener

1. Joint clamp bolt



66

5. Lift up the air filter case, slide the oil tankbreather hose clamp down, disconnectthe oil tank breather hose from the air fil-ter case, and then remove the air filtercase.

6. Disconnect the negative battery lead.7. Replace the blown fuse with one of the

proper amperage.

1. Oil tank breather hose clamp2. Oil tank breather hose

1. Main fuse2. Spare main fuse

1. “HEAD” (headlight) fuse2. “SIG” (signal) fuse3. “DC TERM” (auxiliary DC jack) fuse4. “C/W” (carburetor warmer) fuse5. “IGN” (ignition) fuse6. Spare fuse

Specified fuses:Main fuse:

30.0 ASpare main fuse:

30.0 A“HEAD” (headlight) fuse:

20.0 A“SIG” (signal) fuse:

10.0 A“DC TERM” (auxiliary DC jack) fuse:

3.0 A“C/W” (carburetor warmer) fuse:

20.0 A“IGN” (ignition) fuse:

20.0 ASpare fuses:

20.0 A, 10.0 A, 3.0 A



67

8. Connect the negative battery lead.9. Install the air filter case by reversing the

removal steps.

CAUTION:ECS00640

Be sure to connect the breather hoses se-curely when installing the air filter case.

10. Connect the headlight couplers andspeedometer coupler, and then install theheadlight unit, making sure to insert theprojections on the headlight unit stay intothe slots on the bottom of the headlightunit.

11. Install the headlight unit bolts, and thentighten them to the specified torque.

12. Install the top cover, the right side cover,the left side cover, and the shroud.

NOTE:If the fuse immediately blows again, ask aYamaha dealer to inspect the snowmobile.

Headlight unit bolt tightening torque:3 Nm (0.3 m·kgf, 2.2 ft·lb)


Troubleshooting

68

ESU12960

Engine turns over but does not start1. Fuel system

No fuel supplied to combustion chamber• No fuel in tank: Supply fuel.• Clogged fuel line: Clean fuel line.• Clogged carburetor: Clean carburetor.Fuel supplied to combustion chamber• Flooded engine (too much choke): Crank

engine with throttle open or wipe thespark plugs dry.

2. Electrical systemPoor spark or no spark• Spark plugs are dirty with carbon or are

wet: Remove carbon or wipe the sparkplugs dry. Replace if necessary.

• Faulty ignition system: Ask a Yamahadealer to inspect.

• T.O.R.S. malfunction: Disconnect thethrottle switch connectors and connectthe wire harness connectors together tobypass the T.O.R.S.

WARNINGEWS00560

� Before bypassing the T.O.R.S., makesure that the throttle returns properly tothe fully closed position.

� The T.O.R.S. is an important safety de-vice; in the case of a malfunction, takethe snowmobile to a Yamaha dealer im-mediately for repair.

3. CompressionInsufficient• Loose cylinder head nuts: Tighten nuts

properly.• Worn or damaged gasket: Replace gas-

ket.• Worn or damaged piston and cylinder:

Ask a Yamaha dealer to inspect.Discharged batteryIf the battery is discharged, the engine can bestarted using a fully-charged 12-volt batteryand jumper cables. Two connecting leadshave been provided for jump-starting thesnowmobile. Due to the rubber engine mount-ing, the snowmobile frame is not a suitablegrounding point for jump-starting the engine.

WARNINGEWS00570

� Connect the jumper cables only to theconnecting lead terminals. Do not con-nect them to the frame or any wire orother lead.

� When connecting the jumper cables, donot contact the jumper cables or con-necting lead terminals to each other orto the frame or any metal part of thesnowmobile. This can cause electricalsystem damage or A FIRE HAZARD.

� Be sure to pull the lead covers back overthe terminals completely. If the termi-nals are exposed, they could come intocontact with the frame or a metal part ofthe snowmobile and this can cause elec-trical system damage or A FIRE HAZ-ARD.

CAUTION:ECS00650

Use the connecting leads to jump-start thesnowmobile only. Do not use the connect-ing leads for any other purpose.


Troubleshooting

69

To start the engine using the booster battery1. Apply the parking brake and turn the

main switch to the off position.2. Remove the shroud and the right side


3. Remove the red (+) connecting lead fromthe lead holder and move it away fromthe black (–) connecting lead.

CAUTION:ECS00660

Be sure to connect the red (+) jumper ca-ble to the red (+) connecting lead and theblack (–) jumper cable to the black (–) con-necting lead. Do not reverse the connec-tions.

4. Pull the red (+) connecting lead cover toexpose the terminal through the slit in thecover, and then connect the red (+) jump-er cable to the red (+) connecting lead.

5. Connect the other end of the red (+)jumper cable to the positive (+) terminalof the booster battery.

6. Connect the black (–) jumper cable to thenegative (–) terminal of the booster bat-tery.

7. Pull the black (–) connecting lead coverto expose the terminal through the slit inthe cover, and then connect the black (–)jumper cable to the black (–) connectinglead.


Troubleshooting

70

8. Start the engine.9. Disconnect the black (–) jumper cable

from the black (–) connecting lead, andthen pull the cover completely over thelead terminal.

10. Disconnect the black (–) jumper cablefrom the negative (–) terminal of the bat-tery used to jump start the engine.

11. Disconnect the red (+) jumper cable fromthe positive (+) terminal of the batteryused to jump start the engine.

12. Disconnect the red (+) jumper cable fromthe red (+) connecting lead, and then pullthe cover completely over the lead termi-nal.

13. Install the red (+) connecting lead into thelead holder.

14. Install the right side cover and the shroud.

NOTE:Make sure that both the red (+) connectinglead and the black (–) connecting lead areseated securely in the lead holders.

Electric starter does not operate or operates slowly� Engine stop switch is pushed in: Pull it out.� Faulty wire connections: Check connec-

tions or ask a Yamaha dealer to inspect.� Discharged battery: Charge battery or see

“Starting the engine with a discharged bat-tery” above.

� Seized engine: Seizure is caused by poorlubrication, inadequate fuel, or an air leak.Ask a Yamaha dealer to inspect.

� “Hydrostatic lock” occurs when fuel hasfilled the cylinders when the vehicle hasbeen transported: Remove the spark plugsand turn the engine over several times withthe ignition off to expel excess fuel. Ask aYamaha dealer to inspect.

Engine power is low� Low coolant temperature indicator light is

flashing: Warm the engine up.� Faulty spark plugs: Clean or replace the

spark plugs.� Incorrect carburetor jetting for altitude or

temperature: Ask a Yamaha dealer to in-spect.

� Improper fuel flow: See “Engine turns overbut does not start–Fuel system” above.

� Incorrect V-belt clutch settings for altitudeor conditions: Ask a Yamaha dealer to in-spect.

Engine constantly backfires or mis-fires� Faulty spark plugs: Replace the spark

plugs.� Clogged fuel system: See “Engine turns

over but does not start–Fuel system”above.

� Malfunctioning T.O.R.S.: See “Engine turnsover but does not start–Electrical system”above.

Engine overheats� Insufficient coolant: Add coolant.� Air in cooling system: Bleed the cooling sys-

tem or ask a Yamaha dealer to inspect.� Leaking coolant: Ask a Yamaha dealer to

inspect.Snowmobile does not move� Malfunctioning V-belt clutch: Ask a Yamaha

dealer to inspect.� Drive track does not move: Foreign object is

caught in the drive track, or slide runnershave melted to the slide metal due to lack oflubrication.

� Tight, loose, or broken drive chain: Ask aYamaha dealer to inspect.

V-belt twists� Improper V-belt: Replace with the correct V-

belt.


Troubleshooting

71

� Incorrect V-belt clutch offset: Ask a Yamahadealer to inspect.

� Loose or broken engine mount(s): Ask aYamaha dealer to inspect.

V-belt slips or becomes extremely hot� Oily or dirty V-belt or primary and second-

ary sheave assembly surfaces: Clean.� Problem with the driveline: See “V-belt

twists” above.Engine does not upshift or downshift properly or engages harshly� Worn or damaged V-belt: Replace the V-

belt or ask a Yamaha dealer to inspect.� Incorrect V-belt clutch settings for altitude

or conditions: Ask a Yamaha dealer to in-spect.

� Worn or sticking primary sheave assembly:Ask a Yamaha dealer to inspect.

� Worn or sticking secondary sheave assem-bly: Ask a Yamaha dealer to inspect.

Noise or excessive vibration in drive chain and sprockets� Broken V-belt clutch components: Ask a

Yamaha dealer to inspect.� Worn or damaged bearings: Ask a Yamaha

dealer to inspect.� Worn or damaged V-belt with flat spots: Re-

place.� Worn or damaged idler wheels or shafts:

Ask a Yamaha dealer to inspect.� Worn or damaged drive track: Ask a

Yamaha dealer to inspect.


Storage

72

ESU12410

Long-term storage requires some preventiveprocedures to guard against deterioration.CleaningThoroughly clean the snowmobile, inside andout, to remove the corrosive salts and acidsthat can accumulate. Use Yamaha Mud,Grease, and Engine Cleaner, or an equivalentproduct, to loosen mud, grease, and grime.Wash with mild soap, then rinse and dry com-pletely.LubricationLubricate moving parts, suspension linkage,and pivot points. Use the grease or lubricantspecified in the MAINTENANCE section, orYamaha Lube-Zall general-purpose lubricant.Proper lubrication fights corrosion while it re-duces friction.Fuel systemAdd Yamaha Fuel Stabilizer and Conditioner,or an equivalent stabilizer, to the fuel tank tohelp prevent fuel oxidation and gum and var-nish deposits, and to inhibit corrosion in thefuel system and carburetor. In areas whereoxygenated fuel (gasohol) is used, completelydrain the fuel system. Consult a Yamahadealer if further information is needed.EngineProper storage of the engine is essential toprevent costly rust and corrosion damage tointernal engine components. This is more im-portant in areas where oxygenated fuel (gas-ohol) is used, because the alcohol content inthe fuel increases the chance for water to en-ter the engine. Use Yamaha Stor-Rite EngineFogging Oil, or an equivalent fogging oil, toprotect both the combustion chamber andcrankshaft from corrosion. An alternate meth-od is to remove the air filter case and squirt oilinto the carburetor throats while the engine isrunning.

CAUTION:ECS00680

Do not attempt to store the snowmobile bysimply starting the engine occasionallyduring the storage period. This can causemore harm than good! Moisture and acidsform during combustion which can actual-ly increase the chance for corrosion dam-age during the storage period.

Surface protectionApply a coat of wax to painted surfaces. Applysuitable protectants to the exterior of the en-gine, drive track, and to other metal, plastic,and rubber parts.Battery

WARNINGEWS00610

� Never smoke around the battery while itis being charged. Sparks may ignite thehydrogen gas created by the battery.

� Disconnect the negative lead first, thenthe positive lead from the battery.

� Connect the positive lead first, then thenegative lead to the battery when install-ing the battery.

� Never connect the battery to or discon-nect it from the snowmobile while it isbeing charged. Sparks may ignite thehydrogen gas created by the battery.

� Make sure that the battery terminals aretight.

Remove the battery from the snowmobile.Store it in a cool, dry place that is above 0 °C(32 °F), but less than 30 °C (90 °F). Check thecondition of the battery once a month, andcharge it as necessary.

CAUTION:ECS00690

� Always keep the battery charged. Stor-ing a discharged battery can cause per-manent battery damage.


Storage

73

� To charge a sealed-type (MF) battery, aspecial (constant-voltage) batterycharger is required. Using a convention-al battery charger will damage the bat-tery. If you do not have access to asealed-type (MF) battery charger, have aYamaha dealer charge your battery.

� Do not charge the battery quickly.Charge the battery for 10 hours at 1.8amperes.

Drive trackLoosen the drive track and block up the chas-sis so that the track is suspended above theground.V-beltRemove the V-belt and store separately.StorageStore the snowmobile in a dry, well-ventilatedplace out of direct sunlight. Put a fabric coverover the snowmobile, preferably one that isdesigned for it. Do not use a plastic or vinylcover—condensation could be trapped un-derneath which could increase the chances ofrusting.Returning to service after storageWhen returning your snowmobile to service,install the V-belt and battery and adjust thedrive track.Remove the spark plugs and clean or replacethem if necessary. Perform all other pre-oper-ation and seasonal maintenance checks list-ed in the periodic maintenance chart.

NOTE:Before installing the battery, have a Yamahadealer inspect and fully charge it.

For peak performance, it is recommendedthat you have your snowmobile checked andtuned by a Yamaha dealer. The dealer hasthe experience and training to help you getthe maximum performance and use out ofyour Yamaha snowmobile.


Specifications

74

ESU12462

Dimensions:Overall length:

RS90GT 2755 mm (108.5 in)RS90GTA 2755 mm (108.5 in)RS90LT 3000 mm (118.1 in)RS90LTGT 3000 mm (118.1 in)RS90R 2755 mm (108.5 in)

Overall width:1225 mm (48.2 in)

Overall height:1160 mm (45.7 in)

Dry weight:RS90GT 254.0 kg (559 lb)RS90GTA 254.0 kg (559 lb)RS90LT 263.0 kg (577 lb)RS90LTGT 264.0 kg (577 lb)RS90R 253.0 kg (557 lb)

Ski stance:1086 mm (42.8 in)

Engine:Type:

Liquid cooled 4-stroke, 12 valvesCylinder arrangement:

Backward-inclined parallel 3-cylinderDisplacement:

973.0 cm³Bore × stroke:

79.0 × 66.2 mm (3.11 × 2.61 in)Idling speed:

1300–1500 r/minEngine oil:

Recommended grade:API service SG type or higher, JASO standard MA

Type:SAE 0W-30

Carburetor:Manufacturer:

KEIHINModel × quantity:

CVK40 × 3Fuel:

Type:REGULAR UNLEADED GASOLINE ONLY

Minimum pump octane (R+M)/2:86

Starting system:Electric starter

Chassis:Drive track:

Material:Molded rubber, fiberglass-rod reinforced

Type:Internal drive type

Width:381 mm (15.0 in)

Deflection:RS90GT 30.0–35.0 mm (1.18–1.38 in)RS90GTA 30.0–35.0 mm (1.18–1.38 in)RS90LT 25.0–30.0 mm (0.98–1.18 in)RS90LTGT 25.0–30.0 mm (0.98–1.18 in)RS90R 30.0–35.0 mm (1.18–1.38 in)

Length on ground:RS90GT 768 mm (30.2 in)RS90GTA 768 mm (30.2 in)RS90LT 960 mm (37.8 in)RS90LTGT 960 mm (37.8 in)RS90R 768 mm (30.2 in)

Rear suspension:Type:

Slide rail suspensionTrack sprocket wheel:

Material:Polyethylene

Number of teeth:9

Transmission:Clutch type:

Automatic centrifugal engagementRatio range:

3.80–1.00 :1Sheave distance:

267.0–270.0 mm (10.51–10.63 in)Sheave offset:

13.5–16.5 mm (0.53–0.65 in)Engagement speed (Subject to change according to elevation settings.):

RS90GT 3300–3700 r/minRS90GTA 3300–3700 r/minRS90LT 3400–3800 r/minRS90LTGT 3400–3800 r/minRS90R 3300–3700 r/min

Shift speed [Subject to change according to elevation settings. Usually achieved after approximately 800m (0.5 mi) traveled.]:

8250–8750 r/minDrive chain type:

Silent chain enclosed in oil bath


Specifications

75

Reverse system:Yes

Secondary reduction ratio:RS90GT 38/22 (1.73)RS90GTA 38/22 (1.73)RS90LT 39/22 (1.77)RS90LTGT 39/22 (1.77)RS90R 38/22 (1.73)

Secondary reduction ratio [R]:2.27

Fuel tank capacity:36.2 L (9.56 US gal) (7.96 Imp.gal)

Engine oil quantity:With oil filter cartridge replacement:

2.5 L (2.64 US qt) (2.20 Imp.qt)Without oil filter cartridge replacement:

2.3 L (2.43 US qt) (2.02 Imp.qt)Total amount:

3.2 L (3.38 US qt) (2.82 Imp.qt)Brake:

Type:Hydraulic disc type (ventilated disc)

Operation:Handle lever, left-hand operated

Throttle:Operation:

Handle lever, right-hand operatedElectrical system:

Ignition system:T.C.I.

Spark plug:Manufacturer:

NGKModel:

CR8EGap:

0.7–0.8 mm (0.028–0.031 in)Battery:

Model:YTX20L-BS

Voltage, capacity:12 V, 18.0 Ah

Ten-hour rate amperage:1.8 A

Bulb voltage, wattage × quantity:Headlight:

12 V, 60/55 W × 2Headlight bulb type:

Halogen bulbTail/brake light:

12 V, 5/21 W × 2

Meter lighting:14 V, 50 mA × 6

High beam indicator light:14 V, 80 mA × 1

Warning light:14 V, 80 mA × 1

Low coolant temperature indicator light:14 V, 80 mA × 1


Consumer information

76

ESU12480

Identification number records Record the frame serial number, engine serialnumber (Primary ID), and key identificationnumber in the spaces provided for assistancewhen ordering spare parts from a Yamahadealer.Also, record and keep the ID numbers in aseparate place in case the snowmobile is sto-len.Frame serial numberThe frame serial number is the seventeen-digit number stamped on the frame of thesnowmobile.

Engine serial number (Primary ID)The engine serial number is stamped in thelocation as shown.

Key identification numberThe key identification number is stamped inthe location as shown.

1. Frame serial number

1. Engine serial number

1. Key identification number



77

ESU12500

YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMIT-ED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants thatnew Yamaha snowmobiles purchased from an autho-rized Yamaha snowmobile dealer in the continental UnitedStates will be free from defects in material and workman-ship for the period of time stated herein, subject to certainstated limitations.

WARRANTY PERIOD:1. All Yamaha snowmobiles shall be warranted for a

term of one (1) year from the date of purchase, plusa special early-season extension (if applicable).

2. All Yamaha snowmobile clutch components are war-ranted against abnormal wear for one (1) year fromthe date of purchase, plus a special early-seasonextension (if applicable).

DURING THE PERIOD OF WARRANTY any au-thorized Yamaha snowmobile dealer will, free of charge,repair or replace, at Yamaha’s option, any part adjudgeddefective by Yamaha due to faulty workmanship ormaterial from the factory. Parts used in warranty repairswill be warranted for the balance of the snowmobile’swarranty period. All parts replaced under warranty be-come the property of Yamaha Motor Corporation, U.S.A.

GENERAL EXCLUSIONS from this warranty shallinclude any failures to the machine caused by:1. Competition, racing, or non-Yamaha authorized rental

use.2. Operation on surfaces other than snow or ice.3. Installation of parts or accessories that are not qual-

itatively equivalent to genuine Yamaha parts.4. Abnormal strain, neglect, or abuse.5. Lack of proper maintenance.6. Accident or collision damage.7. Modification to original parts.

SPECIFIC EXCLUSIONS from this warranty shallinclude parts replaced due to normal wear or routinemaintenance including oil, spark plugs, clutch drive belts,slide runners, and track.

THE CUSTOMER’S RESPONSIBILITY under thiswarranty shall be to:1. Operate and maintain the snowmobile as specified in

the appropriate Owner’s Manual.

2. Give notice to an authorized Yamaha snowmobiledealer of any and all apparent defects within ten (10)days after discovery, and make the machine avail-able at that time for inspection and repairs at suchdealer’s place of business. You may locate yournearest authorized Yamaha dealer through yourlocal telephone directory.

WARRANTY TRANSFER: To transfer any remain-ing warranty from the original purchaser to any subse-quent purchaser, it is imperative that the machine beinspected and registered for warranty by an authorizedYamaha snowmobile dealer. In order for this warrantyto remain in effect, this inspection and registration musttake place within ten (10) days after ownership transfer.An inspection and registration fee will be charged for thisservice.

EMISSION CONTROL SYSTEM WARRANTYYamaha Motor Corporation, USA also warrants to theultimate purchaser and each subsequent purchaser ofeach 2006 and later model Yamaha snowmobile cov-ered by this warranty that the vehicle is designed, built,and equipped so as to conform at the time of sale withall U.S. emissions standards applicable at the time ofmanufacture and that it is free from defects in materialsand workmanship which would cause it not to meetthese standards within the period listed immediatelybelow. Failures other than those resulting from defectsin material or workmanship which arise solely as aresult of owner abuse and/or lack of proper mainte-nance are not covered by this warranty.

All ModelsThirty (30) months from the original purchase date



78

YAMAHA MOTOR CORPORATION, U.S.A.MAKES NO OTHER WARRANTY OF ANY KIND,EXPRESSED OR IMPLIED. ALL IMPLIED WAR-RANTIES OF MERCHANTABILITY AND FIT-NESS FOR A PARTICULAR PURPOSE WHICHEXCEED THE OBLIGATIONS AND TIME LIM-ITS STATED IN THIS WARRANTY ARE HEREBYDISCLAIMED BY YAMAHA MOTOR CORPO-RATION, U.S.A. AND EXCLUDED FROM THISWARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONSON HOW LONG AN IMPLIED WARRANTYLASTS, SO THE ABOVE LIMITATION MAYNOT APPLY TO YOU. ALSO EXCLUDED FROMTHIS WARRANTY ARE ANY INCIDENTAL ORCONSEQUENTIAL DAMAGES INCLUDINGLOSS OF USE. SOME STATES DO NOT AL-LOW THE EXCLUSION OR LIMITATION OFINCIDENTAL OR CONSEQUENTIAL DAM-AGES, SO THE ABOVE EXCLUSION MAY NOTAPPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LE-GAL RIGHTS, AND YOU MAY ALSO HAVEOTHER RIGHTS WHICH VARY FROM STATETO STATE.

SPECIAL EARLY-SEASON WARRANTY EX-TENSIONA special warranty extension is available for all newYamaha snowmobiles purchased between June 1 andDecember 1.

All new Yamaha snowmobiles purchased between June1 and December 1 will have the warranty extended toNovember 30 of the following year.

YAMAHA MOTOR CORPORATION, U.S.A.Post Office Box 6555

Cypress, California 90630

WARRANTY QUESTIONS ANDANSWERS

Q. What costs are my responsibility during the warrantyperiod?

A. The customer’s responsibility includes all costs ofnormal maintenance services, non-warranty repairs,accident and collision damages, as well as oil, sparkplugs, clutch drive belts, and slide runners.

Q. What are some examples of “abnormal” strain, ne-glect, or abuse?

A. These terms are general and overlap each other inareas. Specific examples include: Running the ma-chine out of oil, hitting an object submerged undersnow, operation on surfaces other than snow or ice,operating the machine with a broken or damagedpart which causes another part to fail, and so on. Ifyou have any specific questions on operation ormaintenance, please contact your dealer for advice.

Q. May I perform any or all of the recommended main-tenance shown in the Owner’s Manual instead ofhaving the dealer do them?

A. Yes, if you are a qualified snowmobile mechanic andfollow the procedures specified in the Owner’s andService Manual. We do recommend, however, thatitems requiring special tools or equipment be done bya Yamaha snowmobile dealer.

Q. Under what conditions is the clutch not covered bywarranty?

A. Clutches as well as clutch components wear withuse. Normal wear is not covered under warranty suchservice is the customer’s responsibility. Abnormalwear is, however, covered for one (1) year from thedate of purchase. Your Yamaha snowmobile dealerpossesses criteria as to what constitutes abnormalwear.

Q. Will the warranty be void or canceled if I do notoperate or maintain my new Yamaha exactly asspecified in the Owner’s Manual?

A. No. The warranty on a new Yamaha cannot be“voided” or “canceled.” However, if a particular failureis caused by operation or maintenance other than asshown in the Owner’s Manual, that failure may not becovered under warranty.



79

Q. What responsibility does my dealer have under thiswarranty?

A. Each Yamaha snowmobile dealer is expected to:1. Completely set up every new machine before sale.2. Explain the operation, maintenance, and warranty

requirements to your satisfaction at the time of sale,and upon your request at any later date.

3. In addition, each Yamaha snowmobile dealer is heldresponsible for his setup, service and warranty repairwork.

Q. Whom should I contact if I have further questionsabout this warranty?

A. Your Yamaha snowmobile dealer has the informa-tion and experience necessary to answer almost anyquestions about this warranty. If the dealer is not ableto do so, he is expected to contact Yamaha MotorCorporation, U.S.A., for clarification or assistance.

CUSTOMER SERVICE

If your machine requires warranty service, you must takeit to any authorized Yamaha snowmobile dealer withinthe continental United States. Be sure to bring yourwarranty identification card or other valid proof of theoriginal date of purchase. If a question or problem arisesregarding warranty, first contact the owner of the dealer-ship. Since all warranty matters are handled at the dealerlevel, this person is in the best position to help you. If youare still not satisfied and require additional assistance,please write:

YAMAHA MOTOR CORPORATION, U.S.A.CUSTOMER RELATIONS

DEPARTMENTP.O. Box 6555

Cypress, California 90630

When contacting Yamaha Motor Corpora-tion, U.S.A. be sure to include the model,serial number, names, dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of amotor vehicle to maintain a complete, up-to-date list of allfirst purchasers against the possibility of a safety-relateddefect and recall. This list is compiled from the purchaseregistrations sent to Yamaha Motor Corporation, U.S.A.by the selling dealer at the time of your purchase.

If you should move after you have purchased your newsnowmobile, please advise us of your new address bysending a postcard listing your snowmobile model name,engine serial number, dealer number (or dealer’s name)as it is shown on your warranty registration identification,your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A.WARRANTY DEPARTMENT

P.O. Box 6555Cypress, California 90630

This will ensure that Yamaha Motor Corporation, U.S.A.has an up-to-date registration record in accordance withfederal law.



80

ESU12510

YAMAHA EXTENDED SERVICE (Y.E.S.)


Index

AAir filter, checking..................................... 44Auxiliary DC jack

(RS90GT / RS90GTA / RS90LTGT)..... 16BBattery...................................................... 64Brake and parking brake .......................... 56Brake lever ............................................... 17Break-in.................................................... 28CCarburetors .............................................. 46Control rod, adjusting ............................... 24Coolant temperature warning indicator .... 15Cooling system......................................... 50DDrive chain housing.................................. 55Drive guard............................................... 20Drive track and slide runners ................... 59Drive track life, maximizing ...................... 32Driving ...................................................... 33EEngine idling speed, adjusting ................. 43Engine oil and oil filter cartridge ............... 47Engine overheating prevention system .... 10Engine stop switch ................................... 15FFittings and fasteners............................... 64Fuel .......................................................... 20Fuel level warning indicator...................... 14Fuel meter and grip/

thumb warmer level indicator................ 13Fuse, replacing......................................... 65GGeneral maintenance and

lubrication chart .................................... 38Grip/thumb warmer adjustment switch..... 16HHeadlight beam switch ............................. 16Headlight beams, adjusting...................... 64Headlight bulb, replacing.......................... 63High beam indicator light.......................... 12High-altitude settings................................ 46IIdentification numbers .............................. 76LLabel locations ........................................... 4

Low coolant temperature indicator light ... 12Lubrication................................................ 62MMain switch ................................................ 9OOil level warning indicator ........................ 14PParking brake lever .................................. 18Part locations ............................................. 7Periodic maintenance chart

for the emission control system ............ 36Pre-operation check list............................ 26RRear suspension damping force,

adjusting ............................................... 24Rear suspension damping force

remote adjustment dial ......................... 19Rear suspension spring preload,

adjusting ............................................... 23Riding your snowmobile ........................... 29SSafety information ...................................... 1Self-diagnosis device ............................... 15Shift lever ................................................. 18Shroud and covers ................................... 19Shroud and covers,

removing and installing ......................... 40Ski damping force, adjusting

(RS90GT / RS90GTA / RS90LTGT) ..... 22Ski spring preload, adjusting .................... 22Skis and ski runners ................................. 58Spark plugs, checking .............................. 42Specifications ........................................... 74Speedometer unit ..................................... 11Starter (choke) lever................................... 9Starting the engine ................................... 28Steering system ....................................... 59Stopping the engine ................................. 34Storage..................................................... 72Storage compartment............................... 20Suspension .............................................. 21TThrottle cable free play, adjusting ............ 43Throttle lever .............................................. 9Throttle override system (T.O.R.S.) ......... 10


Index

Throttle override system (T.O.R.S.), checking................................................ 44

Tool kit...................................................... 40Transporting ............................................. 34Troubleshooting ....................................... 68VValve clearance........................................ 46V-belt........................................................ 52V-belt holders ........................................... 20



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PRINTED ON RECYCLED PAPERPRINTED IN JAPAN2007.05-0.6×1 CR

Documents

RS90GTX RS90GTAX RS90LTX RS90LTGTX - Yamaha · RS90GTX RS90GTAX RS90LTX RS90LTGTX OWNER ’S MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2007 ... manent part