Yamaha RSG90W Owner's Manual

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OWNER’S MANUAL
SNOWMOBILE
RS90NW
RS90RW/RS90NRW
RS90MW/RS90MSW
RS90GTW
RSG90W/RSG90GTW
8GG-28199-12
LIT-12628-02-55
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2006.04
-
1.6×2 CR
(E)
YAMAHA MOTOR CO., LTD.
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Summary of Contents

Page 1 - RSG90W/RSG90GTW

OWNER’S MANUALSNOWMOBILERS90NWRS90RW/RS90NRWRS90MW/RS90MSWRS90GTWRSG90W/RSG90GTW8GG-28199-12LIT-12628-02-55PRINTED ON RECYCLED PAPERPRINTED IN JAPAN20

Page 2

1-3CW-09EQ. What responsibility does my dealer have under thiswarranty?A. Each Yamaha snowmobile dealer is expected to:1. Completely set up every new

Page 3 - MACHINE IDENTIFICATION

10-2CAUTION:@ ●Always keep the battery charged.Storing a discharged battery cancause permanent battery damage. ●To charge a sealed-type (MF) battery,a

Page 4 - INTRODUCTION

11-1ESU00228 11-SPECIFICATIONSESU00229 Dimensions CS-01EESU00230 EngineCS-02ERS90N/RS90R/RS90NR/RS90M/RS90MSRS90GT/RSG90/RSG90GTOverall length 2,755 m

Page 5

11-2ESU00231 ChassisCS-03ECarburetor type KEIHIN, CVK40 × 3Fuel Unleaded gasolinePump octane (R+M)/2; 86 or higherStarting system Electric starterRS90

Page 6 - CONTENTS

11-3Transmission:Type Automatic centrifugal engagement, infinite-ly variable 3.8:1–1:1Sheave distance Approx. 268.5 mm (10.57 in)Sheave offset Approx.

Page 7

11-4ESU00232 ElectricCS-04ERS90N/RS90R/RS90NR/RS90M/RS90MSRS90GT/RSG90/RSG90GTIgnition system TCISpark plug Type · R · CR8E (NGK)Gap 0.7–0.8 mm (0.028

Page 8 - SNOWMOBILE LIMITED WARRANTY

–MEMO–E_8gg.book Page 5 Thursday, March 16, 2006 4:23 PM

Page 9 - WARRANTY QUESTIONS AND

12-1ESU00233 1-WIRING DIAGRAMOFFONHILOOFFONSTARTRUNSTOPCLOSEOPENG/BChBGL/RGGL/RBWLgBDgBL/ WGLgBY(3A) (20A) (10A) (20A)(20A) (15A)(BLACK)PO/RB/WL/ YWCh

Page 10 - CHANGE OF ADDRESS

12-21Crankshaft position sensor2AC magneto3Rectifier/regulator4Main switch5Load control relay6Main fuse7Starter relay8Starter motor9Battery0Engine sto

Page 11 - ESU04280

–MEMO–E_8gg.book Page 3 Thursday, March 16, 2006 4:23 PM

Page 13 - CAUTION ATTENTION

1-4ESU04280 YAMAHA EXTENDED SERVICE (Y.E.S.)CW-06EE_8gg.book Page 4 Thursday, March 16, 2006 4:23 PM

Page 14 - 8FS-24875-E0

OWNER’S MANUALSNOWMOBILERS90NWRS90RW/RS90NRWRS90MW/RS90MSWRS90GTWRSG90W/RSG90GTW8GG-28199-12LIT-12628-02-55PRINTED ON RECYCLED PAPERPRINTED IN JAPAN20

Page 15 - RS90R/RS90GT/RSG90/RSG90GT

2-1ESU04050 2-LOCATION OF THE IMPORTANT LABELSPlease read the following labels carefully before operat-ing this snowmobile.NOTE:@ Maintain or replace

Page 16 - SAFETY INFORMATION

2-23455RS90GT/RSG90GT6 RS90M/RS90MS7 RS90M/RS90MS8ES-14488-00CAUTION ATTENTIONSevere engine damage can result from oil loss if crankcase breather hose

Page 17

2-38 RS90M/RS90MS/RSG90/RSG90GT9 RS90MS 8FS-24875-E0Do not use the carrierto lift the snowmobile.Ne pas soulever la motoneigeen tirant sur le porte-ba

Page 18

2-4NOTE:@ The following suspension adjustment charts are includedwith the Owner’s Manual. @ RS90N/RS90NR/RS90M/RS90MSRS90R/RS90GT/RSG90/RSG90GTE_8gg.b

Page 19 - DESCRIPTION

3-1ESU00008 3-SAFETY INFORMATIONWhen you ride your snowmobile, you must know and usethe following for your safety. Severe injury or death mayresult if

Page 20

3-27. Do not allow anyone to stand behind the snowmobilewhen starting, inspecting, or adjusting the snowmo-bile. A broken track, track fittings, or de

Page 21 - CONTROL FUNCTIONS

3-33. This snowmobile is not designed for use on surfacesother than snow or ice. Use on dirt, sand, grass,rocks, or bare pavement may cause loss of co

Page 22 - Throttle lever

4-1ESU000124-DESCRIPTIONRS90N/RS90NRRS90MRSG90/RSG90GTRS90R/RS90GTRS90MSE_8gg.book Page 1 Thursday, March 16, 2006 4:23 PM

Page 24 - High beam indicator light

4-21Windshield2Steering handlebar3Seat4Frame5Storage compartment6Rear carrier7Slide rail suspension8Rear suspension damping force remote adjustment di

Page 25 - ESU03824

5-1ESU00013 5-CONTROL FUNCTIONSESU00362Main switchThe main switch controls the following items.1“OFF” The ignition circuit is switched off. The key ca

Page 26 - Oil level warning indicator

5-2ESU00201 Starter lever (choke)Use the starter lever (choke) when starting and warmingup a cold engine.1Starter lever (choke) 2When starting a cold

Page 27 - Self-diagnostic system

5-3ESU04151 Throttle override system (T.O.R.S.)If the carburetor or throttle cable should malfunction dur-ing operation, the T.O.R.S. will operate whe

Page 28 - Brake lever

5-4ESU04160 Speedometer unitThe speedometer unit is equipped with the following:●a digital speedometer (which shows riding speed)●an odometer (which s

Page 29 - Shift lever

5-5ESU03824 Fuel meter and grip/thumb warmer level indica-torThe fuel meter and grip/thumb warmer level indicatorhave eight segments 1 which show the

Page 30 - Auxiliary DC jack

5-6ESU04260 Fuel level warning indicatorThe fuel level warning indicator indicates a malfunction-ing sensor, disconnected coupler, broken lead, or sho

Page 31 - V-belt holders

5-7ESU04180 Coolant temperature warning indicatorIf the engine overheats, the coolant temperature warningindicator 1 and the warning light 2 come on.

Page 32 - Storage compartment

5-8ESU00031 Engine stop switchThe engine stop switch 1 is used to stop the engine inan emergency. Simply push 2 the stop switch to stop theengine. To

Page 33 - Rear carrier

5-9ESU00035Parking brake leverWhen parking the snowmobile or starting the engine,apply the parking brake by moving the brake lever 1 tothe left. To re

Page 34 - PRE-OPERATION CHECKS

ESU002861-MACHINE IDENTIFICATIONIdentification number recordsA. FRAME NUMBER:CZ-01EB. ENGINE NUMBER (PRIMARY ID):CZ-01EC. KEY NUMBER:CZ-01ERecord the

Page 35 - SE, SF, SG

5-10ESU00039Headlight beam switchPush the headlight beam switch to change the headlightbeam to high or low.1Headlight beam switch 2Push 3High beam 4Lo

Page 36 - Engine oil level

5-11ESU00481 Shroud latchesTo open the shroud, unhook the shroud latches, and thenslowly raise the shroud forward until it stops. When clos-ing the sh

Page 37 - ESU00086

5-12ESU04080 Carburetor coolant shut-off leverFor RS90M/RS90MSThe carburetor coolant shut-off lever controls the flow ofcoolant through the carburetor

Page 38

5-13ESU05020 Rear carrierFor RS90MSThe rear carrier is located at the rear of the snowmobile.1Rear carrierWARNING@ Do not use the rear carrier to lift

Page 39 - ESU00091

6-1ESU000726-PRE-OPERATION CHECKSNOTE:@ Pre-operation checks should be made each time thesnowmobile is used. @WARNING@ The engine and muffler will be

Page 40 - Brake fluid leakage

6-2CAUTION:@ ●Oxygenated fuels (gasohol) containing a maxi-mum 5% of ethanol can be used, although richerjetting may be required to prevent engine dam

Page 41 - Drive track

6-3ESU03442 Engine oil levelThe engine oil level should be checked before each use.CAUTION:@ Do not run the engine with too much or not enoughoil in t

Page 42 - Skis and ski runners

6-46. Insert the oil level gauge/dipstick into the oil fillerhole, and then tighten it securely.7. Connect the oil level gauge coupler. ESU00086 Coola

Page 43 - Air filter

6-5ESU00087 Throttle leverCheck the throttle lever operation before starting theengine. The throttle lever must open smoothly and spring back toits ho

Page 44 - Fittings and fasteners

6-6ESU00091 Brake1. Brake lever Test the brake at a low speed when starting out tomake sure that it is working properly. If the brakedoes not provide

Page 45 - OPERATION

ESU00011 2-INTRODUCTIONCongratulations on your purchase of a Yamaha snowmo-bile. This model is the result of Yamaha’s vast experiencein the production

Page 46 - Break-in

6-7ESU00093Brake fluid leakageApply the brake for a few minutes. Check to see if anybrake fluid leaks out from the brake hose joints or themaster cyli

Page 47 - To start out and accelerate

6-8ESU00097Drive trackCheck the drive track for deflection, wear, or damage. Adjust or replace if necessary. (See pages 8-31–8-33 formore details.)WAR

Page 48 - Riding uphill

6-9ESU00982 Slide runnersCheck the slide runners for wear and damage. If the slide runners reach the wear limit, they should bereplaced.1Slide runners

Page 49 - Ice or icy surface

6-10ESU00103 Steering systemCheck the handlebar for excessive free play:1. Push the handlebar up and down and back and forth.2. Turn the handlebar sli

Page 50 - Hard-packed snow

6-11ESU00110Fittings and fastenersCheck the tightness of the fittings and fasteners. Tighten in proper sequence and torque if necessary. ESU00345Tool

Page 51 - Maximizing drive track life

7-1ESU00112 7-OPERATIONESU00366Starting the engineWARNING@ ●Be sure to check the “SAFETY INFORMATION”section carefully before starting the engine. ●Ma

Page 52 - ESU00245

7-2ESU00380Break-inThere is never a more important period in the life of yourengine than the period between 0 and 500 km (300 mi).For this reason, you

Page 53 - ESU03471

7-3ESU01272 Riding your snowmobileGetting to know your snowmobileA snowmobile is a rider active vehicle, andyour riding position and your balance aret

Page 54 - Stopping the engine

7-4Tur n ingFor most snow surfaces, “body English” isthe key to turning.As you approach a curve, slow down andbegin to turn the handlebar in the desir

Page 55 - Transporting

7-5Riding downhillWhen riding downhill, keep speed to a min-imum. It is important to apply just enoughthrottle to keep the clutch engaged whiledescend

Page 56 - PERIODIC MAINTENANCE

WARNING@ PLEASE READ AND UNDERSTAND THIS MANUALCOMPLETELY BEFORE OPERATING THE SNOWMO-BILE. @NOTE:@ ●Yamaha continually seeks advancements in productd

Page 57 - ESU04980

7-6Hard-packed snowIt can be more difficult to negotiate onhard-packed snow as both the skis anddrive track do not have as much traction aswhen the sn

Page 58

7-7ESU00251Maximizing drive track lifeRecommendationsTrack tensionDuring initial break-in, the new drive track will tend tostretch quickly as the trac

Page 59 - Brake system:

7-8ESU00245 StrapFor RS90M/RS90MSThe strap 1 should be used only by experienced opera-tors to assist them when traverse (side-hill) riding.WARNING@ Im

Page 60 - Checking the spark plugs

7-9ESU03471 DrivingWARNING@ Be sure to read the “SAFETY INFORMATION” and“Riding your snowmobile” sections carefully beforeoperating the snowmobile. @N

Page 61

7-10CAUTION:@ Do not shift from “FWD” to “REV” or from “REV” to“FWD” while the snowmobile is moving. Otherwise,the drive system could be damaged. @NOT

Page 62 - Adjusting the carburetors

7-11ESU00367TransportingWhen transporting your snowmobile on a trailer or in atruck, observe the following recommendations to helpprotect it from dama

Page 63 - Adjusting the valve clearance

8-1ESU04960 8-PERIODIC MAINTENANCESafety is an obligation of the owner. Periodic inspection, adjustment, and lubrication willkeep your snowmobile in t

Page 64 - Changing the engine oil

8-2ESU04980 General maintenance and lubrication chartCD-32E∗Fuel lineCheck fuel hose for cracks or damage.Replace if necessary.●∗Idle speedCheck and a

Page 65

8-3Drive guardCheck for cracks, bends or damage.∗Replace if necessary.●5-11, 6-7V-beltCheck for wear and damage.Replace if necessary.●6-7,8-14–8-16Dri

Page 66

8-4NOTE:@ Brake system: ●After disassembling the master cylinder or caliper cylinder, always change the brakefluid. Regularly check the brake fluid le

Page 67 - Cooling system

ESU00003 CONTENTSYAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTY...1-1YAMAHA EXTENDED SERVICE (Y.E.S.

Page 68

8-5ESU03761 Tool kitThe owner’s tool kit has the tools which are sufficient formost periodic maintenance and minor repairs. A torquewrench is also nec

Page 69 - Replacing the V-belt

8-6Spark plugs are produced in several different threadlengths. The thread length or reach is the distance fromthe spark plug gasket seat to the end o

Page 70

8-7ESU03701 Adjusting the engine idling speedCAUTION:@ ●Be sure to have a Yamaha dealer make thisadjustment. ●Make sure that the throttle lever moves

Page 71 - ESU03514

8-8ESU04860 Adjusting the high-altitude settingsOperating at high altitude reduces the performance of agasoline engine about 3% for every 305 m (1,000

Page 72

8-9ESU04202 Changing the engine oilIt is recommended to have a Yamaha dealer change theengine oil.WARNING@ Engine oil is extremely hot immediately aft

Page 73 - Checking the brake pads

8-107. Remove the oil filter cartridge 9 with an oil filterwrench.NOTE:@ An oil filter wrench is available at a Yamaha dealer. @8. Apply a thin coat o

Page 74 - Suspension

8-1113. Add sufficient oil of the recommended type to raise itto the “H” level mark on the oil level gauge/dipstick.(See page 6-3 for the checking pro

Page 75 - ESU01912

8-12ESU03173 Cooling systemBleeding the cooling systemWARNING@ ●Do not remove the coolant reservoir cap whenthe engine is hot. Scalding hot fluid and

Page 76 - ESU05100

8-131“COLD LEVEL” mark 2Coolant reservoir cap2. Start the engine and add coolant until the coolantlevel does not go down, and then stop the engine.3.

Page 77

8-14ESU01661 Replacing the V-beltWARNING@ When installing the new V-belt, make sure it is posi-tioned from 1.5 mm (0.06 in) above the edge of thesecon

Page 78

Riding uphill ...7-4Riding downhill ...7-5Traversing a slope ...

Page 79 - ESU04750

8-153. Pull 3 the V-belt up over the secondary fixed sheave. 4. Remove the V-belt from the secondary sheaveassembly and primary sheave assembly. 5. Pu

Page 80 - ESU04045

8-168. Install the V-belt over the primary sheave assembly. 9. Rotate the secondary sliding sheave clockwise 6and push 7 it so that it separates from

Page 81

8-173. Remove the dipstick and check that the oil is betweenthe maximum and minimum level marks. If the oil isbelow the minimum level mark, add suffic

Page 82 - “MAX HARD”

8-18ESU01741 Checking the brake padsCheck the brake pads for wear. If the brake pads reach the wear limit, ask a Yamahadealer to replace them.1Brake p

Page 83

8-19ESU00180 Checking the brake fluid levelPlace the snowmobile on a level surface. Check that thebrake fluid is above the lower level and replenish w

Page 84 - ESU04092

8-20ESU01912 Adjusting the ski spring preloadThe spring preload can be adjusted by turning the springpreload adjuster 1.For RS90R/RSG90CD-11EFor RS90M

Page 85

8-21WARNING@ This shock absorber contains highly pressurizednitrogen gas. It could explode by improper handling,causing injury or property damage. ●Do

Page 86 - Adjusting the drive track

8-223. Remove the air valve cap 2 from the shock absorber. 4. Install the hose connector 3 of the special pumponto the air valve of the shock absorber

Page 87

8-23CAUTION:@ Do not exceed 1,034 kPa (10.3 kgf/cm2, 150 psi). @7. Install the air valve cap.NOTE:@ If the front suspension bottoms too easily or roll

Page 88 - Adjusting the handlebar

8-24ESU04750 Adjusting the ski damping forcesFor RS90GT/RSG90GTCompression damping forceThe compression damping force of each ski shockabsorber can be

Page 89

1-1ESU05070 1-YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTYCW-07EYamaha Motor Corporation, U.S.A. hereby warrants thatnew Yamaha snowmo

Page 90 - Lubrication

8-25WARNING@ This shock absorber contains highly pressurizednitrogen gas. It could explode by improper handling,causing injury, or property damage. ●D

Page 91 - Adjusting the headlight beam

8-26For RS90N/RS90NR/RS90M/RS90MSCD-23EFor RS90R/RS90GT/RSG90/RSG90GTCD-26ENOTE:@ The rear suspension spring preload can be furtheradjusted by changin

Page 92 - Replacing a fuse

8-27ESU04763 Adjusting the rear suspension damping forcesFor RS90R/RS90GT/RSG90/RSG90GTThe rebound damping force can be adjusted by turningthe rear su

Page 93

8-28For RS90N/RS90NRThe compression damping force can be adjusted by turn-ing the adjuster 1.CD-30ECAUTION:@ ●Do not continue to turn the adjuster ind

Page 94

8-29ESU04092 Adjusting the control rodsThe weight transfer can be adjusted by turning the con-trol rod adjuster or adjusting nut.For RS90R/RS90GT/RSG9

Page 95 - TROUBLESHOOTING

8-30For RS90N/RS90NR/RS90M/RS90MS1. Loosen the locknut 1.2. Turn the control rod adjusting nut 2 in direction a toincrease weight transfer or directio

Page 96

8-31ESU03532 Adjusting the drive trackWARNING@ A broken track, track fittings or debris thrown by thedrive track could be dangerous to an operator orb

Page 97

8-32Adjusting the drive trackWARNING@ ●Be sure to have a Yamaha dealer make thisadjustment. ●Support the snowmobile securely on a suitablestand before

Page 98 - Yamaha dealer to inspect

8-33CAUTION:@ The right and left adjusters should be turned to anequal amount. @6. Recheck alignment and deflection. If necessary,repeat steps 3 to 5

Page 99 - ESU03594

8-342. Loosen the handlebar bolts.3. Move the handlebar up or down to adjust the handle-bar height to the desired position.CAUTION:@ Make sure that th

Page 100

1-2CW-08EYAMAHA MOTOR CORPORATION, U.S.A.MAKES NO OTHER WARRANTY OF ANY KIND,EXPRESSED OR IMPLIED. ALL IMPLIED WAR-RANTIES OF MERCHANTABILITY AND FIT-

Page 101 - SPECIFICATIONS

8-35ESU00371LubricationLubricate the following points.1Throttle cable endWARNING@ Apply a dab of grease onto the cable end only. Donot grease the thro

Page 102 - ESU00231

8-36ESU02082 Replacing a headlight bulb1. Lift up the shroud. 2. Disconnect the headlight coupler. 3. Remove the bulb holder cover. 4. Unhook the bulb

Page 103 - Approx. 15 mm (0.59 in)

8-37ESU00355BatteryThis snowmobile is equipped with a sealed-type (MF)battery, which does not require any maintenance. Thereis no need to check the el

Page 104 - Electric

8-381. Lift up the shroud. 2. Remove the right side cover 1. 3. Unhook the latch 2. 4. Loosen the clamp screws 3. 5. Slide the oil tank breather hose

Page 105

8-39ESpare fuses (20 A, 10 A, 15 A, 3 A) FSpare main fuse Specified fuses: 9Main fuse: 30 A0“HEAD” (Headlight) fuse: 20 AA“SIG” (Signal) fuse: 10 AB“D

Page 106 - WIRING DIAGRAM

9-1ESU04241 9-TROUBLESHOOTINGA. Engine turns over but does not start1. Fuel systemNo fuel supplied to combustion cham-ber ●No fuel in tank ... Supply

Page 107

9-2CAUTION:@ Use the connecting leads to jump-startthe snowmobile only. Do not use theconnecting leads for any other purpose. @1. Apply the parking br

Page 108

9-38. Start the engine.9. Disconnect the black (-) jumper cablefrom the black (-) connecting lead, andthen pull the cover completely over thelead term

Page 109

9-4G. Snowmobile does not move 1. Malfunctioning V-belt clutch ... Ask aYamaha dealer to inspect. 2. Drive track does not move ... Foreignobject is ca

Page 110

10-1ESU03594 10-STORAGELong-term storage requires some preven-tive procedures to guard against deteriora-tion.1. Cleaning Thoroughly clean the snowmob

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