Yamaha RST90K Owner's Manual

OWNER’S MANUALSNOWMOBILERST90K8ET-28199-10LIT-12628-02-39PRINTED ON RECYCLED PAPERPRINTED IN JAPAN2004.06-1.0×1 CR(E)YAMAHA MOTOR CO., LTD.

1-3CW-03EU8ET10.book Page 3 Monday, June 14, 2004 5:42 PM

1-4ESU04280 YAMAHA EXTENDED SERVICE (Y.E.S.)CW-06EU8ET10.book Page 4 Monday, June 14, 2004 5:42 PM

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

2-2NOTE:@ The following suspension adjustment charts are includedwith the Owner’s Manual. @ U8ET10.book Page 2 Monday, June 14, 2004 5:42 PM

3-1ESU029703-SAFETY INFORMATIONWhen you ride your snowmobile, you must know and usethe following for your safety. Severe injury or death mayresult if

3-27. Handle fuel with care; it is HIGHLY FLAMMABLE.●Never add fuel when the engine is running or hot. Allow the engine to cool for several minutes af

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

4-1ESU000124-DESCRIPTION1Windshield2Steering handlebar3Seat4Passenger grip warmer switch5Large solo touring storage area6Rear carrier7Frame8Slide rail

4-2DSide mirrorETail/brake lightsFSnow flapGBrake leverHParking brake leverIGrip warmer adjustment switchJHeadlight beam switchKEngine stop switchLThu

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

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

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

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

5-5ESU03821 Fuel meter and grip/thumb warmer level indica-torThe fuel meter and grip/thumb warmer level indicatorhave eight segments 1 which show the

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

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

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

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

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

5-11ESU04290 Passenger grip warmer switchThe passenger grip warmer switch controls the electri-cally heated passenger grips.1Passenger grip warmer swi

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

5-12ESU00481 Shroud latchesTo open the shroud, unhook the shroud latches, and thenslowly raise the shroud forward until it stops. When clos-ing the sh

5-13ESU00053 V-belt holdersKeep a spare V-belt for emergency use by placing it intothe V-belt holders provided.CAUTION:@ Make sure that the V-belt is

5-14To remove the passenger seat, backrest, and rearcarrier 1. Pull the carrier lock lever 1 away from the carrierlock bracket, and then push it down

5-151. Install the passenger seat, and then install the pas-senger seat lock knob. 2. Align the holes 1 in the backrest bracket with thebolts 2 on the

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

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

6-3ESU03441 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

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

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

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

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

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

6-8ESU00097Drive trackCheck the drive track for deflection, wear, or damage. Adjust or replace if necessary. (See pages 8-29–8-31 formore details.)WAR

6-9ESU01020 Skis and ski runnersCheck the skis and ski runners for wear and damage.Replace if necessary.CAUTION:@ Avoid scratching the skis when loadi

6-10ESU00350Air filterAlways check that no snow is under the air filter element.Remove the air filter case cover and take out the air filterelement. I

6-11ESU00345Tool kit and recommended equipmentIt is good practice to carry the tool kit, spare parts, andother necessary equipment with you while ridi

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

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

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

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

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

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

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

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

7-8ESU04360 DrivingWARNING@ Be sure to read the “SAFETY INFORMATION” and“Riding your snowmobile” sections carefully beforeoperating the snowmobile. @N

7-92. Release the parking brake by moving the parkingbrake lever to the right. 3. Press the throttle lever slowly to move the snowmo-bile. 4. Turn the

7-10ESU00367TransportingWhen transporting your snowmobile on a trailer or in atruck, observe the following recommendations to helpprotect it from dama

8-1ESU00139 8-PERIODIC MAINTENANCEESU00140Periodic maintenance chartRegular maintenance is most important for best performance and safe operation.CD-0

8-2Drive guardCheck for cracks, bends or damage.∗Replace if necessary.●5-10, 6-7V-beltCheck for wear and damage.Replace if necessary.●6-7,8-15–8-17Dri

8-3NOTE:@ Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid.Normally check the brake flu

8-4ESU00376Tool kitThe owner’s tool kit has the tools which are sufficient formost periodic maintenance and minor repair. A torquewrench is also neces

8-5Spark plugs are produced in several different threadlengths. The thread length or reach is the distance fromthe spark plug gasket seat to the end o

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

8-6ESU00370Engine idle speed adjustmentCAUTION:@ ●Be sure to have a Yamaha dealer make thisadjustment. ●Make sure that the throttle lever moves smooth

8-7ESU04190 Carburetor adjustmentCAUTION:@ ●Be sure to have a Yamaha dealer make thisadjustment. ●Make sure that the air filter case is installed dur-

8-8Main jet replacementReplace the main jet according to the setting chart whichis available at a Yamaha dealer.WARNING@ ●Never remove the drain plug

8-9ESU00157 High altitude adjustmentsOperating at high altitude reduces the performance of agasoline engine to about 3% for every 305 m (1,000 ft) ofe

8-10ESU04200 Changing the engine oilIt is recommended to have a Yamaha dealer change theengine oil.WARNING@ Engine oil is extremely hot immediately af

8-117. 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

8-1213. Add sufficient oil of the recommended type to raise itto the “F” level mark on the oil level gauge/dipstick.(See page 6-3 for the checking pro

8-13ESU03171 Cooling systemBleeding the cooling systemWARNING@ ●Do not remove the coolant reservoir cap whenthe engine is hot. Scalding hot fluid and

8-14Coolant replenishment1. Remove the coolant reservoir cap and add coolantuntil it reaches the “COLD LEVEL” mark.1“COLD LEVEL” mark 2Coolant reservo

8-15ESU00166 V-belt replacementWARNING@ When installing the new V-belt, make sure it is posi-tioned from 1.5 mm (0.06 in) above the edge of theseconda

Maximizing drive track life ...7-7Driving ...7-8Stopping the engine...7-9T

8-163. 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. Put

8-178. 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 t

8-183. Remove the dipstick and check that the oil is betweenthe upper and lower levels. If not, add oil to the upperlevel.2Upper level 3Lower levelÈFo

8-19ESU00174 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

8-20ESU00180 Checking the brake fluid levelPlace the snowmobile on a level surface. Check that thebrake fluid is above the lower level and replenish w

8-21ESU03041 Ski spring preload adjustmentThe spring preload can be adjusted by turning the springpreload adjuster 1.CD-10ECAUTION:@ The left and righ

8-22ESU04350 Rear suspension spring preload adjustmentThe rear suspension is equipped with two shock absorb-ers and the spring preload for each shock

8-23ESU04220 Control rod adjustmentThe weight transfer can be adjusted by turning the con-trol rod adjusting nut 1.1. Loosen the locknut 2 while holdi

8-24ESU04341 2-up adjusting block spring force adjustmentThe spring force can be adjusted by changing the posi-tion of the 2-up adjusting blocks.NOTE:

8-25ESU03531Drive track adjustmentWARNING@ A broken track, track fittings or debris thrown by thedrive track could be dangerous to an operator orbysta

1-1ESU000041-YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTYCW-01EU8ET10.book Page 1 Monday, June 14, 2004 5:42 PM

8-26Drive track adjustmentWARNING@ ●Be sure to have a Yamaha dealer make thisadjustment. ●Support the snowmobile securely on a suitablestand before wo

8-27CAUTION:@ The right and left adjusters should be turned to anequal amount. @6. Recheck alignment and deflection. If necessary,repeat steps 3 to 5

8-283. Move the handlebar up or down to adjust the handle-bar height to the desired position.CAUTION:@ Make sure that the projection on the handlebar

8-29ESU00371LubricationLubricate the following points.1Throttle cable endWARNING@ Apply a dab of grease onto the cable end only. Donot grease the thro

8-30ESU00208 Headlight bulb replacement1. Lift up the shroud. 2. Disconnect the headlight connector. 3. Remove the bulb holder cover. 4. Remove the bu

8-31ESU00355BatteryThis snowmobile is equipped with a sealed-type (MF)battery, which does not require any maintenance. Thereis no need to check the el

8-321. 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

8-33ESpare 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

9-1ESU04240 9-TROUBLESHOOTINGA. Engine turns over but does not start1. Fuel systemNo fuel supplied to combustion cham-ber ●No fuel in tank ... Supply

9-22. Open the shroud.3. Remove the red (+) lead from the leadholder and move it away from the black(-) lead.CAUTION:@ Be sure to connect the red (+)

1-2CW-02EU8ET10.book Page 2 Monday, June 14, 2004 5:42 PM

9-3NOTE:@ Make sure that both the red (+) lead andthe black (-) lead are seated securely in thelead holders. @WARNING@ Be sure to pull the lead covers

9-4J. Engine does not upshift or down-shift properly or engages harshly 1. Worn or damaged V-belt ... Replace theV-belt or ask a Yamaha dealer toinspe

10-1ESU03593 10-STORAGELong-term storage requires some preven-tive procedures to guard against deteriora-tion.1. Cleaning Thoroughly clean the snowmob

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

11-1ESU00228 11-SPECIFICATIONSESU00229 Dimensions CS-01EESU00230 EngineCS-02ERST90Overall length 3,135 mm (123.4 in)Overall width 1,225 mm ( 48.2 in)O

11-2ESU00231 ChassisCS-03ERST90Drive track and suspension:Track Molded rubber, fiber glass rod reinforcedWidth 381 mm (15.0 in)Track deflection 30–35

11-3ESU00232 ElectricCS-04ERST90Ignition system TCISpark plug Type · R · CR8E (NGK)Gap 0.7–0.8 mm (0.028–0.031 in)Battery Capacity YTX20L-BS 12 V 18 A

12-1ESU00233 1-WIRING DIAGRAMOFFONHILOOFFONSTARTLOOFFHIRUNSTOPCLOSEOPENG/BChBGDgBL/ WGLgBY(3A) (20A) (10A) (20A)(20A) (15A)(BLACK)PO/RB/WL/ YWChB/YBrB

12-21Pickup coil 2A.C. magneto3Rectifier/regulator4Main switch5Load control relay6Main fuse7Starter relay8Starter motor9Battery0Engine stop switchAThr

OWNER’S MANUALSNOWMOBILERST90K8ET-28199-10LIT-12628-02-39PRINTED ON RECYCLED PAPERPRINTED IN JAPAN2004.06-1.0×1 CR(E)YAMAHA MOTOR CO., LTD.