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Yamaha FX Nytro FX10MTRAX Service Manual

Other manuals for FX Nytro FX10MTRAX: Owner's Manual, Service Manual, Assembly Manual

Summary of FX Nytro FX10MTRAX

  • Page 1

    Service manual fx10x fx10rtx fx10rtrx fx10rtrax fx10mtx fx10mtrx fx10mtrax lit-12618-02-69 8gl-28197-10 printed on recycled paper printed in u.S.A. 2007.07 cr (e) yamaha motor co., ltd. 2008.

  • Page 3

    Notice this manual was written by the yamaha motor company primarily for use by yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on yamaha snowmobil...

  • Page 4

    Illustrated symbols (refer to the illustration) illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 general information 2 periodic inspection and adjustment 3 chassis 4 power train 5 engine 6 cooling system 7 fuel injection system 8 electrical 9 spec...

  • Page 5: Index

    Index general information gen info 1 periodic inspection and adjustment insp adj 2 chassis chas 3 power train powr tr 4 engine eng 5 cooling system cool 6 fuel injection system fi 7 electrical elec 8 specifications spec 9 – +.

  • Page 6

    Chapter 1. General information snowmobile identification ................... 1-1 frame serial number ......................... 1-1 engine serial number........................ 1-1 important information .......................... 1-2 preparation for removal and disassembly...............................

  • Page 7

    Fx10mt/fx10mtr/fx10mtra ............... 3-17 inspection ............................................ 3-18 front suspension ................................... 3-19 fx10/fx10rt/fx10rtr/fx10rtra....... 3-19 fx10mt/fx10mtr/fx10mtra ............... 3-21 handling notes .................................. ...

  • Page 8

    Oil pan and oil pump .............................. 5-44 removal ................................................ 5-47 inspection ............................................ 5-47 installation ........................................ 5-49 crankcase ................................................. 5...

  • Page 9

    Dc back buzzer (fx10/fx10rtr/ fx10rtra/fx10mtr/fx10mtra) ......... 8-38 coolant temperature sensor .... 8-39 oil level switch................................. 8-40 fuel sender......................................... 8-40 speed sensor...................................... 8-41 grip warmer system ......

  • Page 10

    1-1 gen info general information snowmobile identification frame serial number the frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). Engine serial number the engine serial number 1 is located on the right-hand side of the crank- case. Note: desi...

  • Page 11

    1-2 gen info important information important information preparation for removal and disassembly 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. While cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc...

  • Page 12

    1-3 gen info important information gaskets, oil seals, and o-rings 1. All gaskets, seals, and o-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and o-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the...

  • Page 13

    1-4 gen info special tools special tools some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. Note: • be sure to use the correct part number w...

  • Page 14

    1-5 gen info special tools • radiator pressure tester p/n: yu-24460-01 • radiator cap tester p/n: 90890-01325 this tester is used to check the cooling system. • radiator pressure tester adapter p/n: yu-33984 • radiator cap tester adapter p/n: 90890-01352 this adapter is used to check the cooling sys...

  • Page 15

    1-6 gen info special tools • bearing driver 40 mm p/n: ym-04058 • middle driven shaft bearing driver p/n: 90890-04058 • mechanical seal installer p/n: 90890-04145 these tools are used to install the water pump seal. • universal magneto & rotor holder p/n: yu-01235 • rotor holding tool p/n: 90890-012...

  • Page 16

    1-7 gen info special tools • opama pet-4000 spark checker p/n: ym-34487 • ignition checker p/n: 90890-06754 this tool is used to check the ignition system component. • engine mount spacer wrench p/n: ys-01516 90890-01516 used to turn the engine mounting bolt spacer when removing/installing engine. •...

  • Page 17

    1-8 gen info special tools • clutch bushing press p/n: ys-42424 90890-01529 this tool is used for removing and installing the post bushings (primary sheave cap bush, sliding sheave bush and torque cam bush). • track clip installer p/n: ys-91045-c 90890-01721 this tool is used for installing the trac...

  • Page 18

    2-1 insp adj periodic inspection and adjustment introduction this chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable snowmobile operation and a longer service life. In addition...

  • Page 19

    2-2 insp adj general maintenance and lubrication chart general maintenance and lubrication chart 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...

  • Page 20

    2-3 insp adj spark plugs/fuel line inspection engine spark plugs 1. Remove: • left side cover refer to “covers” in chapter 3. 2. Remove: • ignition coils • spark plugs 3. Inspect: • electrodes 1 damage/wear → replace the spark plug. • insulator color 2 abnormal color → replace the spark plug normal ...

  • Page 21

    2-4 insp adj cooling system cooling system coolant replacement note: the coolant should be changed at least every sea- son. 1. Place the snowmobile on a level surface. 2. Remove: • right lower cover refer to “covers” in chapter 3. 3. Remove: • radiator cap 1 warning do not remove the radiator cap wh...

  • Page 22

    2-5 insp adj cooling system 8. Connect: • coolant reservoir hose • thermostat outlet hose 9. Fill: • cooling system caution: • hard water or salt water is harmful to engine parts. If soft water is not available, use boiled or distilled water. • do not use water containing impurities or oil. 10. Blee...

  • Page 23

    2-6 insp adj cooling system air bleeding steps: note: for models other than fx10mt/fx10mtr/ fx10mtra, skip steps 1–3. • remove the cap 1 on the heat exchanger pipe. • while slowly adding coolant to the radiator filler, drain the coolant until no more air bubbles appear. • install the cap 1. • add co...

  • Page 24

    2-7 insp adj valve clearance adjustment valve clearance adjustment note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at the top dead cen- ter (tdc) on the compression stroke. 1. Drain:...

  • Page 25

    2-8 insp adj valve clearance adjustment • measure the valve clearance with a thickness gauge 1. Note: • if the valve clearance is incorrect, record the measured reading. • measure the valve clearance in the following sequence. È front for each cylinder, starting with cylinder #3 at tdc, turn the cra...

  • Page 26

    2-9 insp adj valve clearance adjustment 6. Adjust: • valve clearance adjustment steps: • remove the valve lifter 1 and the valve pad 2 with a valve lapper 3. Note: • cover the timing chain opening with a rag to pre- vent the valve pad from falling into the crankcase. • make a note of the position of...

  • Page 27

    2-10 insp adj valve clearance adjustment example: original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) rounded value = 150 • locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect...

  • Page 28

    2-11 insp adj valve clearance adjustment valve pad selection table intake exhaust measured clearance ↓ installed pad number 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 ...

  • Page 29

    2-12 insp adj valve clearance adjustment/ throttle body synchronization • install the new valve pad 1 and the valve lifter 2. Note: • apply molybdenum disulfide oil to the valve pad and the valve lifter. • the valve lifter must turn smoothly when rotated by hand. • install the valve lifter and the v...

  • Page 30

    2-13 insp adj throttle body synchronization 2. Remove: • vacuum caps 1 1 1 3. Install: • vacuum gauge 1 4. Install: • fuel tank refer to “seat and fuel tank” in chap- ter 5. 5. Start the engine and let it warm up for several minutes, and then let it run at specified engine idling speed. 6. Adjust: •...

  • Page 31

    2-14 insp adj throttle body synchronization throttle cable free play adjustment adjustment steps: • with throttle body #1 as standard, adjust throttle body #1 and #2 using the synchronizing screws 1. Note: after each step, rev the engine two or three times, each time for less than a second, and chec...

  • Page 32

    2-15 insp adj throttle cable free play adjustment 2. Adjust: • throttle cable free play throttle body side adjustment steps: • remove the left side cover. Refer to “covers” in chapter 3. • loosen the locknut 1. • turn the adjusting nut 2 in direction a or b until the specified free play is obtained....

  • Page 33

    2-16 insp adj throttle override system (t.O.R.S.) check throttle override system (t.O.R.S.) check warning when checking the t.O.R.S.: • be sure the parking brake is applied. • be sure the throttle lever moves smoothly. • do not rev the engine to the point that the clutch engages, otherwise, the snow...

  • Page 34

    2-17 insp adj compression pressure measurement compression pressure measurement note: insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → adjust. Refer to “valve clearance adjust- ment”. 2. Start the engine, warm it up for seve...

  • Page 35

    2-18 insp adj compression pressure measurement 6. Measure: • compression pressure above the maximum pressure → inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure → squirt a few drops of oil into the affected cylinder and measure again. Refer t...

  • Page 36

    2-19 insp adj engine oil level inspection engine oil level inspection 1. Inspect: • engine oil level caution: do not run the engine with too much or not enough oil in the oil tank. Oil could flow into the air filter and the engine could be damaged. Inspection steps: • place the snowmobile on a level...

  • Page 37

    2-20 insp adj engine oil level inspection/ engine oil replacement note: before checking the engine oil level, wait a few minutes until the oil has settled. • start the engine, warm it up for several minutes, and then turn it off. • check the engine oil level again. Note: before checking the engine o...

  • Page 38

    2-21 insp adj engine oil replacement 9. Remove: • oil pan engine oil drain bolt 1 note: a “ ” mark a is stamped in the oil pan near the oil pan drain bolt. A 1 10. Remove: • oil tank engine oil drain bolt 1 11. Drain: • engine oil (completely from the oil pan and oil tank) 12. If the oil filter cart...

  • Page 39

    2-22 insp adj engine oil replacement 13. Install: • drain bolts (along with the new gaskets) 14. Fill: • engine oil (with the specified amount of the recom- mended engine oil) add 2.0 l (1.76 imp qt, 2.11 us qt) of the rec- ommended engine oil to the oil tank, and then install and tighten the oil le...

  • Page 40

    2-23 insp adj cylinder head breather hose inspection 1. Inspect: • cylinder head breather hose 1 cracks/damage → replace. Loosen connection → connect properly. Caution: make sure that the cylinder head breather hose is routed correctly. 1 throttle body joints inspection 1. Inspect: • throttle body j...

  • Page 41

    2-24 insp adj checking the air filter element 4. Clean: • air filter element note: remove the snow. 5. Inspect: • air filter element damage/clogs → replace. 6. Install: • air filter element • air filter element frame • air filter case cover note: push down on the air filter element frame until a cli...

  • Page 42

    2-25 insp adj exhaust system inspection exhaust system inspection 1. Remove: • fuel tank refer to “seat and fuel tank” in chap- ter 5. 2. Inspect: • exhaust pipe joints 1 • exhaust pipe 2 • muffler 3 • exhaust pipe bands 4 • muffler band 5 cracks/damage → replace. • exhaust pipe joint gasket 6 • muf...

  • Page 43

    2-26 insp adj sheave offset adjustment power train sheave offset adjustment 1. Remove: • left side cover • drive guard refer to “covers” in chapter 3. 2. Remove: • drive v-belt 3. Measure: • sheave offset a use a straightedge that is approximately 470 mm (18.5 in) long, 20 mm (0.79 in) wide, and 4 m...

  • Page 44

    2-27 insp adj sheave offset adjustment • install the secondary sheave, secondary sheave bolt and washer. • recheck the sheave offset. If out of specifica- tion, repeat the above steps. Note: when adjusting the sheave offset, the secondary sheave free play (clearance) should be adjusted. T r . . Seco...

  • Page 45

    2-28 insp adj drive v-belt drive v-belt warning when installing the new v-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to –0.5 mm (–0.02 in) below the edge a. If the v-belt is not positioned correctly, the clutch engagement speed will be changed....

  • Page 46

    2-29 insp adj drive v-belt 2. Adjust the position of the v-belt by removing or adding a spacer 1 on each adjusting bolt 2. 3. Tighten: • secondary sheave adjusting bolt 2 v-belt position adjustment more than 1.5 mm (0.06 in) above the edge remove a spacer from 1.5 mm (0.06 in) above the edge to –0.5...

  • Page 47

    2-30 insp adj drive v-belt/ engagement speed check 6. Measure: • drive v-belt circumference a out of specification → replace. V-belt circumference: 1,129 ~ 1,137 mm (44.4 ~ 44.8 in) engagement speed check 1. Place the snowmobile on a level surface. 2. Inspect: • clutch engagement speed inspection st...

  • Page 48

    2-31 insp adj parking brake pad inspection/ parking brake adjustment parking brake pad inspection 1. Remove: • right side cover refer to “covers” in chapter 3. 2. Inspect: • parking brake pad wear limit a reached → replace the parking brake assembly. Parking brake pad wear limit: 1.2 mm (0.05 in) a ...

  • Page 49

    2-32 insp adj parking brake adjustment/ brake fluid level inspection 4. Measure: • brake pad clearance ( a + b) out of specification → adjust. 5. Adjust: • brake pad clearance adjustment steps: • loosen the locknut 1. • turn the adjusting bolt 2 in or out until the specified clearance between the pa...

  • Page 50

    2-33 insp adj brake fluid level inspection/ brake pad inspection/brake hose inspection warning • use only the designated brake fluid. Other flu- ids may deteriorate the rubber seals, causing leakage and poor brake performance. • refill with the same type of fluid. Mixing fluids may result in a harmf...

  • Page 51

    2-34 insp adj air bleeding (hydraulic brake system) air bleeding (hydraulic brake system) warning bleed the brake system in the following cases: • the system has been disassembled. • a brake hose is loosened or removed. • the brake fluid has been very low. • brake operation is faulty. If the brake s...

  • Page 52

    2-35 insp adj drive chain drive chain oil level inspection warning the engine and muffler will be very hot after the engine has run. Avoid touching a hot engine and muffler while they are still hot with any part of your body or clothing during inspection or repair. 1. Remove: • right side cover refe...

  • Page 53

    2-36 insp adj drive chain oil replacement oil replacement steps: • remove the right lower cover. Refer to “covers” in chapter 3. • place the drive chain cover under the drain hole. • remove the oil drain bolt (along with the gas- ket) 1 and drain the oil. Caution: be sure to remove any oil from the ...

  • Page 54

    2-37 insp adj track tension adjustment track tension adjustment warning a broken track or track fittings, and debris thrown by the track could be dangerous to an operator or bystanders. Observe the following precautions. • do not allow anyone to stand behind the snowmobile when the engine is running...

  • Page 55

    2-38 insp adj 3. Adjust: • track deflection adjustment steps: a. Place the snowmobile onto a suitable stand to raise the track off of the ground. B. Loosen the rear axle nut 1. C. Start the engine and rotate the track once or twice. Stop the engine. D. Check the track alignment with the slide runner...

  • Page 56

    2-39 insp adj slide runner inspection/ maximizing drive track life slide runner inspection 1. Inspect: • slide runner 1 cracks/damage/wear → replace. 2. Measure: • slide runner wear limit a out of specification → replace. Slide runner wear limit: 10.5 mm (0.41 in) maximizing drive track life recomme...

  • Page 57

    2-40 insp adj maximizing drive track life off-trail riding avoid off-trail riding until there is sufficient snow coverage. It generally takes several feet of snow to provide a good overall base to properly cover debris, such as rocks, logs, etc. If snow coverage is not sufficient, stay on trails to ...

  • Page 58

    2-41 insp adj ski/ski runner/steering system chassis ski/ski runner 1. Inspect: • ski • ski runner damage/wear → replace. • ski runner thickness a • plastic ski thickness b out of specification → replace. Caution: to avoid scratching, wearing and damaging the plastic skis, be careful when loading an...

  • Page 59

    2-42 insp adj steering system toe-out adjustment 1. Place the snowmobile on a level surface. 2. Measure: • ski toe-out ( a – c) • ski stance b point the skis forward. Out of specification → adjust. Ski toe-out: 0 ~ 15 mm (0 ~ 0.59 in) ski stance (center to center): fx10/fx10rt/fx10rtr/fx10rtra 1,050...

  • Page 60

    2-43 insp adj brake lever adjustment/lubrication brake lever adjustment 1. Adjust: • brake lever position a adjustment steps: • while pushing the brake lever forward, loosen the locknut 1. • while pushing the brake lever forward, turn the adjusting bolt 2 in direction b or c until the brake lever is...

  • Page 61

    2-44 insp adj lubrication rear suspension 1. Use a grease gun to inject grease into the nip- ples. 2. Apply grease to the pivoting parts. È fx10/fx10rt/fx10rtr/fx10rtra É fx10mt/fx10mtr/fx10mtra 1 nipple 2 nipple (both sides) recommended lubricant: esso beacon 325 grease or aeroshell grease #7a 2 1 ...

  • Page 62

    2-45 insp adj headlight bulb replacement electrical headlight bulb replacement the following procedure applies to both of the headlight bulbs. 1. Remove: • shroud refer to “covers” in chapter 3. 2. Disconnect: • headlight coupler 1 3. Remove: • headlight bulb cover 2 4. Detach: • headlight bulb hold...

  • Page 63

    2-46 insp adj headlight beam adjustment/battery inspection headlight beam adjustment 1. Place the snowmobile on a level surface. 2. Place the snowmobile in front of a wall at the recommended distance d. Refer to the table below. 3. Measure the distance h from the floor to the center of the headlight...

  • Page 64

    2-47 insp adj battery inspection first aid in case of bodily contact: external • skin – wash with water. • eyes – flush with water for 15 minutes and get immediate medical attention. Internal • drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil. Get...

  • Page 65

    2-48 insp adj battery inspection 4. Remove: • battery 5. Inspect: • battery charge inspection steps: • connect a pocket tester to the battery terminals. Note: • the charge state of a mf battery can be checked by measuring its open-circuit voltage (i.E., the voltage when the positive terminal is disc...

  • Page 66

    2-49 insp adj battery inspection 6. Charge: • battery (refer to the appropriate charging method illustration) warning do not quick charge a battery. Caution: • make sure that the battery vent is free of obstructions. • never remove the mf battery sealing caps. • do not use a high-rate battery charge...

  • Page 67

    2-50 insp adj battery inspection charging method using a variable voltage charger measure the open-circuit voltage prior to charging. Connect a charged and amp meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery. By ...

  • Page 68

    2-51 insp adj battery inspection charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Note: set the charging time at 20 hours (maximum). Connect a charger and amp meter to the battery and start charging. Make sure that the current is higher than the st...

  • Page 69

    2-52 insp adj battery inspection/fuse inspection 7. Install: • battery 8. Install: • battery bracket 9. Connect: • battery leads (to the battery terminals) caution: first, connect the positive battery lead 1, then the negative battery lead 2. 10. Check: • battery terminals dirt → clean with a wire b...

  • Page 70

    2-53 insp adj fuse inspection 3. Replace: • blown fuse replacing steps: • turn the main switch off. • install a new fuse of the correct amperage. • turn the main switch on and verify if the electri- cal circuit is operational. • if the fuse immediately blows again, check the electrical circuit. *1 :...

  • Page 71

    2-54 insp adj clutch tuning clutch high altitude specifications model: fx10/fx10rt/fx10rtr/fx10rtra p pink s silver y yellow È elevation ~ 800 m (~ 2,500 ft) 600 ~ 1,400 m (2,000 ~ 4,500 ft) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) É e...

  • Page 72

    2-55 insp adj clutch specifications model: fx10mt/fx10mtr/fx10mtra br brown g green l blue p pink w white È elevation ~ 800 m (~ 2,500 ft) 600 ~ 1,400 m (2,000 ~ 4,500 ft) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) É engine idle speed 1,...

  • Page 73

    2-56 insp adj clutch/gear selection the clutch may require tuning depending upon where the snowmobile will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the...

  • Page 74

    2-57 insp adj gear selection 1 chain and sprocket part number 2 gear ratio È parts name É teeth & links Ê parts no. Ë standard Ì drive sprocket 18 teeth 8fa-17682-80 19 teeth 8fa-17682-90 20 teeth 8fa-17682-00 fx10mt/ fx10mtr “usa/canada”/ fx10mtra “usa/canada” 21 teeth 8fa-17682-10 fx10/fx10rt/fx10...

  • Page 75

    2-58 insp adj gear selection 3 secondary sheave spring 4 secondary spring twist angle 5 torque cam (secondary spring seat) È part no. É spring rate n · mm/rad (kg · mm/rad) Ê preload n/mm (kg/mm) (lb/in) Ë color Ì wire gauge mm (in) Í no. Of coils Î free length mm (in) Ï outside diameter mm (in) Ð s...

  • Page 76

    2-59 insp adj gear selection 6 primary spring Ë parts no. Ì spring rate n/mm (kg/mm) Í preload n (kg) Î color Ï wire gauge mm (in) Ð outside diameter mm (in) Ñ no. Of coils Ò free length mm (in) Ó standard 90501-550a2 19.6 (2.00) 196 (20) blue-blue-blue 5.5 (0.217) 59.5 (2.34) 4.89 83.4 (3.28) 90501...

  • Page 77

    2-60 insp adj gear selection 7 clutch weight È parts no. É weight g (oz) without bush and rivets Ê shape & id mark Ë standard 8bu-17605-20 45.41 (1.603) 8dj-17605-00 37.77 (1.333) 8es-17605-00 54.63 (1.928) 8fa-17605-10 63.81 (2.252) 8fn-17605-00 75.28 (2.657) 8fp-17605-00 67.81 (2.394) 8fs-17605-00...

  • Page 78

    2-61 insp adj gear selection 8 weight rivets È parts no. É material Ê length mm (in) Ë weight g (oz) Ì standard Í effects 90261-06033 steel 17.2 (0.677) 4.5 (0.159) in: fx10/fx10rt/fx10rtr/ fx10rtra center: fx10/fx10rt/ fx10rtr/fx10rtra/ fx10mtr “europe”/ fx10mtra “europe” out: fx10mtr “europe”/ fx1...

  • Page 79

    2-62 insp adj gear selection 9 rollers i.D. 9 mm (0.354 in) È roller with bush- ing part number É outside diameter mm (in) Ê bushing type (p/n) Ë identification mark (width) Ì standard Í effects 8fg-17624-00 14.5 (0.57) vespel tp-8549 90386-09001 Î grooved & machined (14.6 mm [0.57 in]) Ó increased ...

  • Page 80

    2-63 insp adj front suspension front suspension spring preload 1. Adjust: • spring preload adjustment steps: • loosen the locknut 1. • turn the spring seat 2 in or out. Fx10 fx10mt/fx10mtr/fx10mtra È fx10 É fx10mt/fx10mtr/fx10mtra caution: be sure that the left and right spring preload are the same....

  • Page 81

    2-64 insp adj front suspension rebound damping force adjustment (fx10) the rebound damping force can be adjusted by turning the adjusting knob 1. * with the adjusting knob fully turned lightly in direction a caution: • do not continue to turn the adjusting knob in direction a after it stops. The sho...

  • Page 82

    2-65 insp adj front suspension compression damping force adjustment (fx10) the compression damping force can be adjusted by turning the adjusting knob 1. * with the adjusting knob fully turned lightly in direction a caution: • do not continue to turn the adjusting knob in direction a after it stops....

  • Page 83

    2-66 insp adj front suspension adjustment steps: warning support the snowmobile securely on a suitable stand before adjusting the shock absorbers. Caution: make sure that there is no load on the shock absorbers and that they are fully extended before making any air pressure adjustments. • place the ...

  • Page 84

    2-67 insp adj front suspension/rear suspension caution: do not exceed 1,034 kpa (10.3 kg/cm², 150 psi). • install the air valve cap. Note: if the front suspension bottoms too easily or rolls too much during cornering, increase the air pres- sure by 34 kpa (0.3 kg/cm², 5 psi). If the suspen- sion is ...

  • Page 85

    2-68 insp adj rear suspension adjustment steps: • remove the stopper band bolts 1, nuts and washers. • adjust the length of the stopper bands 2 by inserting the bolts in different holes. • tighten the stopper band nuts. È fx10/fx10rt/fx10rtr/fx10rtra (front side) É fx10/fx10rt/fx10rtr/fx10rtra (rear...

  • Page 86

    2-69 insp adj rear suspension choosing other settings: caution: the standard settings work well under most general riding conditions. The suspension can be adjusted to work better in one condition, but only at the expense of another. Keep this in mind when you adjust the suspension. È fx10/fx10rt/fx...

  • Page 87

    2-70 insp adj rear suspension • turn the adjusting ring 3 to the proper position. Warning this shock absorber contains highly pressur- ized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could ...

  • Page 88

    2-71 insp adj rear suspension damping force adjustment rebound damping force (front side) (fx10rt/fx10rtr/fx10rtra) the damping force can be adjusted by turning the adjusting dial 1. * with the adjusting dial fully turned lightly in direc- tion a caution: • do not continue to turn the adjusting dial...

  • Page 89

    2-72 insp adj rear suspension rebound damping force (rear side) (fx10rt/fx10rtr/fx10rtra) the damping force can be adjusted by turning the adjusting dial 1. * with the adjusting dial fully turned lightly in direc- tion a caution: • do not continue to turn the adjusting dial in direction a after it s...

  • Page 90

    2-73 insp adj rear suspension compression damping force (front side) (fx10rt/fx10rtr/fx10rtra) the compression damping force can be adjusted by turning the adjusting screw 1. * with the adjusting screw fully turned lightly in direction a caution: • do not continue to turn the adjusting screw in dire...

  • Page 91

    2-74 insp adj rear suspension compression damping force (rear side) (fx10/fx10rt/fx10rtr/fx10rtra) the compression damping force can be adjusted by turning the adjusting screw 1. * with the adjusting screw fully turned lightly in direction a caution: • do not continue to turn the adjusting screw in ...

  • Page 92

    2-75 insp adj rear suspension control rod (fx10mt/fx10mtr/fx10mtra) 1. Adjust: • control rod stroke a caution: make sure the adjusting nut ends are set at the same position on each side. Adjustment steps: • loosen the locknut 1. • turn the adjusting nut 2 in or out to adjust the control rod stroke. ...

  • Page 93

    3-1 chas chassis covers order job name/part name q’ty remarks covers removal remove the parts in the order listed below. 1 windshield 1 2 shroud 1 3 side cover (left and right) 2 4 main switch coupler 1 disconnect. 5 auxiliary dc jack coupler 1 disconnect. Fx10mt/fx10mtr/fx10mtra 6 speedometer coupl...

  • Page 94

    3-2 chas covers order job name/part name q’ty remarks 15 drive guard pin 1 16 drive guard 1 17 lower cover (left and right) 2 18 storage pouch 1 19 reflector 2 20 front cover 1 21 front bumper 1 for installation, reverse the removal proce- dure. 16 17 (3) 15 (4) 19 19 18 17 20 21 È É È È È 7 nm (0.7...

  • Page 95

    3-3 chas installation 1. Install: • headlight assembly 1 2 headlight stay installed position a: 16.0 mm (0.63 in) a 1 2 covers.

  • Page 96

    3-4 chas steering steering fx10 order job name/part name q’ty remarks handlebar removal remove the parts in the order listed below. Shroud/side covers/speedometer cover refer to “covers”. 1 handlebar cover 1 2 wind deflector (left and right) 2 3 wind deflector bracket holder 2 4 wind deflector brack...

  • Page 97

    3-5 chas steering order job name/part name q’ty remarks 14 left handlebar switch 1 15 brake master cylinder holder 1 16 master cylinder assembly 1 17 right handlebar switch cover 1 18 throttle cable holder 1 19 throttle cable 1 disconnect. 20 right handlebar switch/throttle lever assembly 1 21 upper...

  • Page 98

    3-6 chas steering fx10rt/fx10rtr/fx10rtra order job name/part name q’ty remarks handlebar removal remove the parts in the order listed below. Shroud/side covers/speedometer cover refer to “covers”. 1 handlebar cover 1 2 wind deflector (left and right) 2 3 wind deflector bracket holder 2 4 wind defle...

  • Page 99

    3-7 chas steering order job name/part name q’ty remarks 14 left handlebar switch 1 15 brake master cylinder holder 1 16 master cylinder assembly 1 17 right handlebar switch cover 1 18 throttle cable holder 1 19 throttle cable 1 disconnect. 20 right handlebar switch/throttle lever assembly 1 21 handl...

  • Page 100

    3-8 chas steering fx10mt/fx10mtr/fx10mtra order job name/part name q’ty remarks handlebar removal remove the parts in the order listed below. Shroud/side covers/speedometer cover refer to “covers”. 1 handlebar cover 1 fx10mtra 2 plastic band 4 3 rubber cover 2 4 grip/thumb warmer adjustment switch c...

  • Page 101

    3-9 chas steering order job name/part name q’ty remarks 15 throttle cable holder 1 16 throttle cable 1 disconnect. 17 right handlebar switch/throttle lever assembly 1 18 upper handlebar holder 2 19 handlebar 1 20 steering joint 1 note: after installing all parts, refer to “cable routing” in chapter ...

  • Page 102

    3-10 chas steering order job name/part name q’ty remarks steering column and tie rod removal remove the parts in the order listed below. Headlight stay/side covers refer to “covers”. Bottom panel refer to “engine oil replacement” in chapter 2. 1 lock washer 2 2 bearing holder 1 3 plate 1 4 bearing 4...

  • Page 103

    3-11 chas steering removal 1. Straighten the lock washer tabs. Inspection 1. Inspect: • handlebar • steering column bends/cracks/damage → replace. Warning do not attempt to straighten a bent column. This may dangerously weaken the column. 2. Inspect: • bearings (steering column) • collars • bearings...

  • Page 104

    3-12 chas steering installation 1. Install: • tie rod 1 • locknuts 2 • joints 3 2. Check: • tie rod angle c caution: after tightening the inside and outside ball joint locknut 2, make sure the tie rod 1 can be rotated freely through the ball joint travel. If not, loosen the locknut 2 and re-position...

  • Page 105

    3-13 chas steering 4. Install: • steering shaft 1 • locknuts 2 • joints 3 caution: always use new cotter pin. 5. Bend the lock washer tab along a flat side of the bolt. È steering shaft part number É set length a Ê shaft length b 8gl-23820-00 232.2 mm (9.14 in) 174.2 mm (6.86 in) t r . . Steering sh...

  • Page 106

    3-14 chas steering • loosen the steering shaft locknuts 5. • adjust the steering shaft 6 by turning so that the pivot arm point right under. • tighten the steering shaft locknuts 5. • adjust each angle of right and left skis by turn- ing the tie rod respectively. • measure the ski toe-out. Refer to ...

  • Page 107

    3-15 chas steering 8. Install: • handlebar 1 • handlebar holders 2 note: • the handlebar holders should be installed with the punch marks a facing forward. • align the punch mark b on the handlebar with the upper surface of the lower handlebar holder. (fx10) • align the punch mark b on the handlebar...

  • Page 108

    3-16 chas ski ski fx10/fx10rt/fx10rtr/fx10rtra order job name/part name q’ty remarks ski removal remove the parts in the order listed below. The following procedure applies to both of the ski. 1 cotter pin 1 2 nut 1 3 bolt 1 4 collar 1 5 collar 1 6 washer 2 7 collar 1 8 ski stopper 1 9 ski 1 for ins...

  • Page 109

    3-17 chas ski fx10mt/fx10mtr/fx10mtra order job name/part name q’ty remarks ski removal remove the parts in the order listed below. The following procedure applies to both of the ski. 1 cotter pin 1 2 nut 1 3 bolt 1 4 collar 1 5 collar 1 6 washer 2 7 collar 1 8 ski stopper 1 9 ski 1 for installation...

  • Page 110

    3-18 chas ski inspection the following procedure applies of all of the skis and related components. 1. Inspect: • ski • ski runner • ski stopper • ski handle wear/cracks/damage → replace. • mounting bolt • collars wear/damage → replace..

  • Page 111

    3-19 chas front suspension front suspension fx10/fx10rt/fx10rtr/fx10rtra order job name/part name q’ty remarks front suspension removal remove the parts in the order listed below. The following procedure applies to both of the front suspension. Lower cover/front bumper refer to “covers”. Ski refer t...

  • Page 112

    3-20 chas front suspension order job name/part name q’ty remarks 13 stabilizer joint 1 14 stabilizer 1 15 lower arm 1 16 collar 2 17 bushing 4 18 lower arm ball joint 1 for installation, reverse the removal proce- dure. Ê Ë Ë É É 11 1 2 3 8 9 7 12 9 13 18 14 17 15 Ê Ê É 6 È Ë 5 Ê Ì Ê 4 17 16 16 10 n...

  • Page 113

    3-21 chas front suspension fx10mt/fx10mtr/fx10mtra order job name/part name q’ty remarks front suspension removal remove the parts in the order listed below. The following procedure applies to both of the front suspension. Lower cover/front bumper refer to “covers”. Ski refer to “ski”. 1 shock absor...

  • Page 114

    3-22 chas front suspension order job name/part name q’ty remarks 12 stabilizer joint 1 13 stabilizer 1 14 lower arm 1 15 collar 2 16 bushing 4 17 lower arm ball joint 1 for installation, reverse the removal proce- dure. Ê Ë Ë É 1 2 7 8 6 8 12 17 13 16 14 Ê Ê É 5 È Ë 4 Ì Ê 3 16 15 15 9 new new lt Ê É...

  • Page 115

    3-23 chas front suspension handling notes warning this shock absorber contains highly com- pressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The man- ufacturer cannot be held responsible for prop- erty damage or personal injury...

  • Page 116

    3-24 chas front suspension installation 1. Install: • stabilizer 1 • bushing 2 • stabilizer holder 3 note: install the stabilizer holder in the direction shown in the illustration. A forward a 1 2 3 2. Install: • shock absorber 1 note: • install the shock absorber with the air valve a facing outward...

  • Page 117

    3-25 chas front suspension ski alignment note: be sure to verify the spring preload setting before adjusting the ski toe-out since this adjustments may affect the ski toe-out setting. Point the skis straight forward and measure the amount of ski toe-out. Ski toe-out: 0 ~ 15 mm (0 ~ 0.59 in) a – b = ...

  • Page 118

    4-1 powr tr power train primary sheave and drive v-belt s order job name/part name q’ty remarks primary sheave and drive v-belt removal remove the parts in the order listed below. Left side cover/drive guard refer to “covers” in chapter 3. 1 v-belt 1 2 primary sheave assembly 1 for installation, rev...

  • Page 119

    4-2 powr tr primary sheave and drive v-belt order job name/part name q’ty remarks primary sheave disassembly remove the parts in the order listed below. 1 primary sheave cap 1 2 primary sheave spring 1 3 collar 3 4 roller 3 5 washer 6 6 collar 3 7 weight 3 8 washer 6 9 fixed sheave 1 0 stopper 2 a s...

  • Page 120

    4-3 powr tr primary sheave and drive v-belt removal 1. Remove: • primary sheave assembly 1 note: use the primary sheave holder 2 and primary sheave puller 3. Sheave holder: 90890-01701 primary clutch holder: ys-01880-a primary sheave puller (18 mm): 90890-01898, ys-01881-a, ys-01881-1 disassembly 1....

  • Page 121

    4-4 powr tr primary sheave and drive v-belt • fit the primary sheave assembly onto the adapter and secure the supporting plates 8. Note: securely fit the projections on the adapter into the fixed sheave holes. • set the bar wrench 9 onto the spider and turn the special tool clockwise to loosen the s...

  • Page 122

    4-5 powr tr primary sheave and drive v-belt 2. Inspect: • primary sheave spring 1 cracks/damage → replace. 3. Measure: • primary sheave spring (standard) free length a out of specification → replace the primary sheave spring. Note: when changing the primary sheave springs, refer to “gear selection” ...

  • Page 123

    4-6 powr tr primary sheave and drive v-belt rivet replacement steps: • remove old rivet with the appropriate drill. • insert the rivet 1 from the id mark 2 side. • press or peen the rivet head so that the diame- ter a of the rivet head measures 8.2 mm (0.32 in) or larger. 6. Measure: • bushing insid...

  • Page 124

    4-7 powr tr primary sheave and drive v-belt 2. Install: • fixed sheave (onto the spider) note: • clean the threads. • apply loctite ® #648 to the fixed sheave as shown. Caution: loctite ® should be applied only to the speci- fied area. Never apply it to the bushings and other areas. A 16 mm (0.63 in...

  • Page 125

    4-8 powr tr primary sheave and drive v-belt • tighten the spider to specification using the bar wrench 3. Caution: the spider has a left-handed thread. Warning • do not operate the primary sheave until the loctite ® has dried completely. Wait 24 hours before operating the primary sheave. • since a h...

  • Page 126

    4-9 powr tr 6. Install: • primary sheave spring 1 • primary sheave cap 2 note: be sure the sheave cap match mark (x) is aligned with the spider match mark (x). T r . . Primary sheave cap bolt: 14 nm (1.4 m · kg, 10 ft · lb) installation 1. Install: • primary sheave assembly caution: be sure to remov...

  • Page 127

    4-10 powr tr primary sheave and drive v-belt • loosen the primary sheave bolt completely. • retighten the primary sheave bolt to specifica- tion. T r . . Primary sheave bolt: 2nd: 60 nm (6.0 m · kg, 43 ft · lb) 4. Adjust: • v-belt position refer to “drive v-belt” in chapter 2. • sheave offset • seco...

  • Page 128

    4-11 powr tr secondary sheave secondary sheave order job name/part name q’ty remarks secondary sheave removal remove the parts in the order listed below. Note: apply the brake to lock the secondary sheave. Left side cover/drive guard refer to “covers” in chapter 3. V-belt refer to “primary sheave an...

  • Page 129

    4-12 powr tr secondary sheave order job name/part name q’ty remarks secondary sheave disassembly remove the parts in the order listed below. 1 spring seat 1 2 secondary sheave spring 1 3 fixed sheave 1 4 stopper 1 5 sliding sheave 1 for assembly, reverse the disassembly pro- cedure..

  • Page 130

    4-13 powr tr secondary sheave disassembly warning • use extreme caution when disassembling the secondary sheave since serious injury can occur due to the sudden release of spring tension. Use the sheave compressor to con- tain the spring tension before removing the spring seat nuts. • do not attempt...

  • Page 131

    4-14 powr tr secondary sheave 5. Measure: • ramp shoe thickness a out of specification → replace the ramp shoe. Wear limit: 1.0 mm (0.04 in) assembly 1. Install: • secondary sheave spring 1 • spring seat 2 note: hook the end of the secondary sheave spring into the spring holes in the fixed sheave. H...

  • Page 132

    4-15 powr tr secondary sheave 2. Measure: • secondary sheave clearance a out of specification → adjust. 3. Calculate: • shim thickness note: for example, if the clearance is 36 mm (1.42 in), install a 0.5 mm (0.02 in) shim on each bolt so the clearance is 35.5 mm (1.40 in). 4. Adjust: • secondary sh...

  • Page 133

    4-16 powr tr secondary sheave installation 1. Lubricate: • splines (fixed sheave) 2. Tighten: • secondary sheave bolt 3. Adjust: • v-belt position refer to “drive v-belt” in chapter 2. • sheave offset • secondary sheave free play (clearance) refer to “sheave offset adjustment” in chapter 2. Recommen...

  • Page 134

    4-17 powr tr drive chain drive chain without reverse model order job name/part name q’ty remarks drive chain removal remove the parts in the order listed below. Right lower cover refer to “covers” in chapter 3. Brake caliper/parking brake refer to “brake”. 1 shim — t = 0.5 2 washer 1 t = 1.0 3 brake...

  • Page 135

    4-18 powr tr drive chain order job name/part name q’ty remarks 13 drive chain 1 14 collar 1 15 drive sprocket 1 16 collar 1 17 driven sprocket 1 18 collar 1 for installation, reverse the removal proce- dure. Ê Ë Í É È Ì new new new new new new new new 1 2 3 7 5 (5) 4 6 8 15 16 lt 17 18 13 11 10 12 9...

  • Page 136

    4-19 powr tr drive chain removal 1. Remove: • driven sprocket 1 note: while holding the front axle assembly with spanner wrench 2, loosen the driven sprocket nut. 2 1 inspection 1. Inspect: • drive chain cover cracks/damage → replace. • oil seals (drive chain cover) wear/damage → replace. • bearings...

  • Page 137

    4-20 powr tr drive chain 3. Measure: • 14 link section a of the drive chain using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b. Out of specification → replace the drive chain. Note: • measure the length between drive chain pin 1 and e as shown. • perform this measurement at ...

  • Page 138

    4-21 powr tr drive chain installation 1. During installation, pay attention to the follow- ing. È make sure that the bearing seals face towards the drive chain as shown. É properly install the rubber seal onto the drive chain cover, making sure that there are no gaps. Be sure to install the collars ...

  • Page 139

    4-22 powr tr drive chain with reverse model order job name/part name q’ty remarks drive chain removal remove the parts in the order listed below. Right lower cover refer to “covers” in chapter 3. Brake caliper/parking brake refer to “brake”. 1 shim — t = 0.5 2 washer 1 t = 1.0 3 brake disc 1 4 colla...

  • Page 140

    4-23 powr tr drive chain order job name/part name q’ty remarks 13 drive chain cover 1 14 rubber seal 1 15 chain tensioner 1 16 washer 1 t = 0.5 17 collar 1 18 counter gear 1 19 spring 1 20 retainer 1 21 spring 1 22 reverse driven gear assembly 1 23 journal 1 24 washer 1 25 forward driven sprocket 1 ...

  • Page 141

    4-24 powr tr order job name/part name q’ty remarks 29 collar 1 30 drive sprocket 1 31 collar 1 32 plate 1 33 shaft 1 for installation, reverse the removal proce- dure. Lt Ê Í Î É È É Ì Ë Ë É É Ë 8 10 11 7 9 new new new new new new new 1 2 3 12 5 4 18 27 33 32 6 20 13 21 22 29 30 31 lt lt 23 24 25 26...

  • Page 142

    4-25 powr tr drive chain removal 1. Remove: • reverse driven gear 1 note: while holding the front axle assembly with spanner wrench 2, loosen the reverse driven gear bolt. 1 2 inspection 1. Inspect: • drive chain cover cracks/damage → replace. • shift fork pitting/wear/damage → replace. • oil seals ...

  • Page 143

    4-26 powr tr drive chain installation 1. During installation, pay attention to the follow- ing. È properly install the rubber seal onto the drive chain cover, making sure that there are no gaps. Be sure to install the collars in their original positions, otherwise the brake disc and sec- ondary shaf...

  • Page 144

    4-27 powr tr drive chain 2. Install: • shift rod 1 3. Adjust: • shift rod length a adjustment steps: • move the shift lever to the “fwd.” position. • loosen the locknuts 2. • turn the shift rod 1 so that shift rod free play is 0 mm (in direction where a can be shortened appropriately) and then turn ...

  • Page 145

    4-28 powr tr secondary shaft secondary shaft order job name/part name q’ty remarks secondary shaft removal remove the parts in the order listed below. Secondary sheave refer to “secondary sheave”. Drive chain refer to “drive chain”. 1 secondary shaft assembly 1 2 bearing housing 1 3 circlip 1 4 circ...

  • Page 146

    4-29 powr tr secondary shaft inspection 1. Inspect: • secondary shaft 1 scratches (excessive)/damage → replace. • splines 2 wear/damage → replace the secondary shaft. • bearing contact surface 3 scratches/wear/damage → replace the sec- ondary shaft. 2 3 1 2 2.

  • Page 147

    4-30 powr tr secondary shaft secondary shaft and drive chain cover installation 1. Install: • secondary shaft • drive chain cover installation steps: • install the secondary shaft. • tighten the bolts 1. • install the drive chain, drive sprocket and driven sprocket. • install the drive chain cover 2...

  • Page 148

    4-31 powr tr secondary shaft 3. Adjust: • brake disc clearance adjustment steps: • remove the circlip 5. • adjust the brake disc clearance by adding or removing shim(s) 6. • install the new circlip. Shim size part number thickness 90201-222f0 0.5 mm (0.02 in) 90201-225a4 1.0 mm (0.04 in).

  • Page 149

    4-32 powr tr brake brake brake pad order job name/part name q’ty remarks brake pad removal remove the parts in the order listed below. Right side cover refer to “covers” in chapter 3. Battery refer to “battery inspection” in chap- ter 2. 1 screw plug 1 2 retaining pin 1 3 brake pad spring 1 4 brake ...

  • Page 150

    4-33 powr tr brake caution: disc brake components rarely require disas- sembly. Do not: • do not disassemble components unless absolutely necessary. • do not use solvents on internal brake compo- nents. • do not use contaminated brake fluid for cleaning. • use only clean brake fluid. • do not allow ...

  • Page 151

    4-34 powr tr brake 2. Install: • brake pads • brake pad spring installation steps: • connect suitable hoses 1 tightly to the caliper bleed screws 2. Put the other end of each hose into an open container. • loosen the caliper bleed screws and push the pistons into the caliper with your finger. • tigh...

  • Page 152

    4-35 powr tr brake brake caliper and parking brake order job name/part name q’ty remarks brake caliper and parking brake removal remove the parts in the order listed below. Right side cover refer to “covers” in chapter 3. Battery refer to “battery inspection” in chap- ter 2. Brake fluid drain. 1 bra...

  • Page 153

    4-36 powr tr brake order job name/part name q’ty remarks brake caliper disassembly remove the parts in the order listed below. 1 screw plug 1 2 retaining pin 1 3 brake pad spring 1 4 brake pad 2 5 brake caliper piston 4 6 brake caliper piston dust seal 4 7 brake caliper piston seal 4 8 bleed screw 2...

  • Page 154

    4-37 powr tr brake brake caliper disassembly note: before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: • brake caliper pistons • brake caliper piston dust seals • brake caliper piston seals removal ste...

  • Page 155

    4-38 powr tr brake 1. Inspect: • brake caliper pistons scratches/rust/wear → replace the caliper assembly. • brake caliper cylinder wear/scratches → replace the caliper assembly. • brake caliper body cracks/damage → replace. • brake fluid delivery passage (caliper body) blow out with compressed air....

  • Page 156

    4-39 powr tr brake brake master cylinder order job name/part name q’ty remarks brake master cylinder removal remove the parts in the order listed below. Brake fluid drain. Left handlebar switch refer to “steering” in chapter 3. 1 left wind deflector 1 2 wind deflector bracket holder 1 3 left wind de...

  • Page 157

    4-40 powr tr brake order job name/part name q’ty remarks brake master cylinder disassembly remove the parts in the order listed below. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm holder 1 3 brake master cylinder reservoir diaphragm 1 4 brake master cylinder ki...

  • Page 158

    4-41 powr tr brake inspection 1. Inspect: • brake master cylinder 1 wear/scratches → replace the master cylin- der assembly. • brake master cylinder body 2 cracks/damage → replace. • brake fluid delivery passage (master cylinder body) blow out with compressed air. 2. Inspect: • brake master cylinder...

  • Page 159

    4-42 powr tr brake installation 1. Install: • brake hose caution: when installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a as shown. T r . . Union bolt (brake hose): 30 nm (3.0 m · kg, 22 ft · lb) a 2. Install: • left wind deflector bracke...

  • Page 160

    4-43 powr tr slide rail suspension slide rail suspension fx10 order job name/part name q’ty remarks slide rail suspension removal remove the parts in the order listed below. Rear axle nut loosen. Tension adjuster loosen. 1 slide rail suspension 1 for installation, reverse the removal proce- dure. É ...

  • Page 161

    4-44 powr tr slide rail suspension order job name/part name q’ty remarks slide rail suspension disassembly remove the parts in the order listed below. 1 collar 2 2 bushing 4 3 stopper band 1 4 front pivot arm 1 5 slide runner 2 6 suspension wheel 2 7 suspension wheel bracket 2 8 suspension wheel 2 9...

  • Page 162

    4-45 powr tr slide rail suspension order job name/part name q’ty remarks d front shock absorber 1 e spacer 2 f collar 1 g collar 1 h shaft 1 i collar 2 j shaft 1 k bushing 2 l washer 2 m shaft 1 n front suspension bracket 1 lt lt lt lt 49 nm (4.9 m • kg, 35 ft • lb) 60 nm (6.0 m • kg, 43 ft • lb) È:...

  • Page 163

    4-46 powr tr slide rail suspension order job name/part name q’ty remarks o collar 2 p rear suspension bracket 2 q rear shock absorber 1 r spacer 4 s collar 2 t wheel bracket 2 u guide wheel 2 v guide plate 2 w bushing 2 x tension spring 2 y collar 2 p p o o Ê r r r r s s \ g g [ \ q [ w x v u t É Ê ...

  • Page 164

    4-47 powr tr slide rail suspension order job name/part name q’ty remarks z shaft 1 [ collar 2 \ pull rod 2 ] stopper band 1 _ shaft 1 a rear pivot arm 1 b circlip 2 c adjuster 2 d rear pivot arm bracket 1 e shaft 1 f collar 2 g stopper 2 p p o o Ê r r r r s s \ g g [ \ q [ w x v u t É Ê ] d b c x Ê ...

  • Page 165

    4-48 powr tr slide rail suspension order job name/part name q’ty remarks h rear axle 1 i guide wheel 2 j guide wheel 1 k collar 2 l tension adjuster 2 m collar 1 n collar 1 o sliding frame 2 for assembly, reverse the disassembly pro- cedure. H i k l m n o o j k i È l 75 nm (7.5 m • kg, 54 ft • lb) È...

  • Page 166

    4-49 powr tr slide rail suspension fx10rt/fx10rtr/fx10rtra order job name/part name q’ty remarks slide rail suspension removal remove the parts in the order listed below. Rear axle nut loosen. Tension adjuster loosen. 1 slide rail suspension 1 for installation, reverse the removal proce- dure. 1 É È...

  • Page 167

    4-50 powr tr slide rail suspension order job name/part name q’ty remarks slide rail suspension disassembly remove the parts in the order listed below. 1 collar 2 2 bushing 4 3 stopper band 1 4 front pivot arm 1 5 slide runner 2 6 suspension wheel 2 7 circlip 1 8 holder 1 9 bracket 1 0 suspension whe...

  • Page 168

    4-51 powr tr slide rail suspension order job name/part name q’ty remarks g spacer 2 h collar 1 i shaft 1 j shaft 1 k collar 2 l bushing 2 m washer 2 n front shock absorber 1 o collar 1 p shaft 1 q front suspension bracket 1 r gas cylinder bracket 1 lt lt lt lt Ê Ê É k k Ê Ê É i r l q p j l È n o h g...

  • Page 169

    4-52 powr tr slide rail suspension order job name/part name q’ty remarks s collar 2 t rear suspension bracket 2 u rear shock absorber 1 v spacer 4 w collar 2 x wheel bracket 2 y guide wheel 2 z guide plate 2 [ bushing 2 \ tension spring 2 ] collar 2 t t s s v v v v w w b k k a b u a [ \ z y x É h f ...

  • Page 170

    4-53 powr tr slide rail suspension order job name/part name q’ty remarks _ shaft 1 a collar 2 b pull rod 2 c stopper band 1 d shaft 1 e rear pivot arm 1 f circlip 2 g adjuster 2 h rear pivot arm bracket 1 i shaft 1 j collar 2 k stopper 2 t t s s v v v v w w b k k a b u a [ \ z y x É h f g \ Ê Ê É Ê ...

  • Page 171

    4-54 powr tr slide rail suspension order job name/part name q’ty remarks l rear axle 1 m guide wheel 2 n guide wheel 1 o collar 2 p tension adjuster 2 q collar 1 r collar 1 s sliding frame 2 for assembly, reverse the disassembly pro- cedure. L m o p q r s s n o m È p 75 nm (7.5 m • kg, 54 ft • lb) È...

  • Page 172

    4-55 powr tr slide rail suspension fx10mt/fx10mtr/fx10mtra order job name/part name q’ty remarks slide rail suspension removal remove the parts in the order listed below. Rear axle nut loosen. Tension adjuster loosen. 1 slide rail suspension 1 for installation, reverse the removal proce- dure. È È 1...

  • Page 173

    4-56 powr tr slide rail suspension order job name/part name q’ty remarks slide rail suspension disassembly remove the parts in the order listed below. 1 stopper band 2 2 shaft 1 3 collar 2 4 collar 1 5 front pivot arm 1 6 bushing 2 7 shaft 1 8 collar 2 9 shaft 1 0 collar 1 a suspension wheel 2 b sha...

  • Page 174

    4-57 powr tr slide rail suspension order job name/part name q’ty remarks d connecting arm 1 e collar 1 f front suspension bracket 1 g front shock absorber 1 h bushing 4 i collar 2 j suspension wheel 2 k circlip 2 l spring end guide 2 note: apply grease to the inner surface of each spring end guide. ...

  • Page 175

    4-58 powr tr slide rail suspension order job name/part name q’ty remarks n pull rod 2 o collar 4 p bushing 4 q rear shock absorber 1 r collar 2 s collar 2 t shaft 1 u bushing 2 v rear suspension bracket 1 w collar 2 x guide wheel 2 y torsion spring 2 z suspension wheel 2 [ wheel bracket 2 \ rear piv...

  • Page 176

    4-59 powr tr slide rail suspension order job name/part name q’ty remarks ] bushing 2 _ rear pivot arm protector 2 a shaft 1 b circlip 2 c adjuster 2 d collar 2 e shaft 1 f collar 1 g control rod stopper 1 h circlip 2 i control rod 2 j locknut 2 k adjusting nut 2 l bushing 4 9 nm (0.9 m • kg, 6.5 ft ...

  • Page 177

    4-60 powr tr slide rail suspension order job name/part name q’ty remarks m rear axle 1 n guide wheel 2 o guide wheel 1 p collar 2 q tension adjuster 2 r collar 1 s collar 1 t sliding frame 2 for assembly, reverse the disassembly pro- cedure. 75 nm (7.5 m • kg, 54 ft • lb) È: m n p q r s t o t p n È ...

  • Page 178

    4-61 powr tr slide rail suspension handling notes warning this shock absorber contains highly com- pressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The man- ufacturer cannot be held responsible for prop- erty damage or persona...

  • Page 179

    4-62 powr tr slide rail suspension • suspension wheel bracket • front suspension bracket • rear suspension bracket • connecting arm • sliding frame cracks/damage → replace. • slide runner wear/damage → replace. Assembly 1. Install: • tension adjusters 1 note: install the tension adjusters so that th...

  • Page 180

    4-63 powr tr slide rail suspension 5. Install: fx10/fx10rt/fx10rtr/fx10rtra • pull rods 1 • collars 2 • washers 3 note: be sure not to pinch the washers when installing the pull rods. After installing the pull rods, make sure that the washers rotate. 1 1 3 2 2 6. Install: • rear shock absorber 1 (fx...

  • Page 181

    4-64 powr tr slide rail suspension 8. Install: • front shock absorber 1 (fx10/fx10rt/fx10rtr/fx10rtra) note: • for fx10: install the front shock absorber with the charging valve a facing downward. • for fx10rt/fx10rtr/fx10rtra: install the gas cylinder with the adjuster b facing upward. Install the ...

  • Page 182

    4-65 powr tr slide rail suspension 10. Install: • stopper band 1 note: • install the stopper band with a toward the front pivot arm and b toward the shaft. • install the stopper band with c toward the rear pivot arm and d toward the rear pivot arm bracket. È fx10/fx10rt/fx10rtr/fx10rtra (front side)...

  • Page 183

    4-66 powr tr slide rail suspension installation 1. Adjust: • track tension refer to “track tension adjustment” in chapter 2. Control rod part numbers (fx10mt/fx10mtr/fx10mtra) Ó standard position Ô metal washer(s) Õ plastic washer(s) È control rod 1 É length a mm (in) Ê length b mm (in) Ë length c m...

  • Page 184

    4-67 powr tr front axle and track front axle and track order job name/part name q’ty remarks front axle and track removal remove the parts in the order listed below. Drive chain refer to “drive chain”. Slide rail suspension refer to “slide rail suspension”. Secondary sheave refer to “secondary sheav...

  • Page 185

    4-68 powr tr front axle and track inspection 1. Inspect: • track 1 • slide metal 2 wear/cracks/damage → replace. 1 2 2. Inspect: • sprocket wheels 1 wear/break/damage → replace. • front axle 2 bends/scratches (excessive)/damage → replace. È fx10/fx10rt/fx10rtr/fx10rtra É fx10mt/fx10mtr/fx10mtra 3. I...

  • Page 186

    4-69 powr tr front axle and track 2. Install: • sprocket wheels • guide wheels note: • when pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel. • position each sprocket wheel on the axle as shown in the illustration. È fx10/fx10rt/fx10rtr/fx10rtra É fx10mt/fx10mt...

  • Page 187

    5-1 eng engine seat and fuel tank order job name/part name q’ty remarks seat and fuel tank removal remove the parts in the order listed below. Side cover refer to “covers” in chapter 3. 1 rear side cover (left and right) 2 2 seat 1 3 rear upper cover 1 4 fuel tank cover (left and right) 2 5 fuel tan...

  • Page 188

    5-2 eng seat and fuel tank order job name/part name q’ty remarks 11 fuel tank assembly 1 12 fuel pump 1 13 fuel sender 1 for installation, reverse the removal proce- dure. New Ê Ê É É Ë Ë Ì È Ì 1 2 3 4 4 (6) 1 6 5 10 11 7 (4) (3) (3) 8 13 9 12 23 nm (2.3 m • kg, 17 ft • lb) Ì: 4 nm (0.4 m • kg, 2.9 ...

  • Page 189

    5-3 eng seat and fuel tank removal 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose connector holder • fuel hose caution: • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel has been re...

  • Page 190

    5-4 eng seat and fuel tank installation 1. Install: • fuel pump gasket • fuel pump • fuel pump bracket note: • do not damage the installation surface of the fuel tank when installing the fuel pump. • always use a new fuel pump gasket. • install the fuel pump in the direction shown in the illustratio...

  • Page 191

    5-5 eng exhaust pipe and muffler exhaust pipe and muffler order job name/part name q’ty remarks exhaust pipe and muffler removal remove the parts in the order listed below. Fuel tank refer to “seat and fuel tank”. 1 tail/brake light coupler 1 disconnect. Fx10/fx10rt/fx10rtr/ fx10rtra 2 tail/brake li...

  • Page 192

    5-6 eng order job name/part name q’ty remarks 11 muffler cover 1 12 exhaust pipe bolt 2 loosen. 13 exhaust pipe band 3 14 exhaust pipe joint 3 15 exhaust pipe joint gasket 1 16 exhaust pipe 1 for installation, reverse the removal proce- dure. 6 nm (0.6 m • kg, 4.3 ft • lb) 7 nm (0.7 m • kg, 5.1 ft •...

  • Page 193

    5-7 eng exhaust pipe and muffler installation 1. Install: • exhaust pipe 1 (temporarily) note: install the exhaust pipe to the brackets on the frame, making sure to position it as far rearward as possible, and then temporarily tighten the exhaust pipe bolts. 2. Install: • exhaust pipe joint gasket •...

  • Page 194

    5-8 eng exhaust pipe and muffler 6. Tighten: • muffler band bolt 7. Tighten: • exhaust pipe bolts t r . . Muffler band bolt: 20 nm (2.0 m · kg, 14 ft · lb) t r . . Exhaust pipe bolt: 23 nm (2.3 m · kg, 17 ft · lb).

  • Page 195

    5-9 eng oil tank order job name/part name q’ty remarks oil tank removal remove the parts in the order listed below. Lower side cover (left and right) refer to “covers” in chapter 3. Engine oil drain. Refer to “engine oil replacement” in chapter 2. 1 oil level switch coupler 1 disconnect. 2 oil tank ...

  • Page 196

    5-10 eng engine assembly engine assembly hoses and leads order job name/part name q’ty remarks hoses and leads removal remove the parts in the order listed below. Coolant drain. Refer to “cooling system” in chapter 2. Engine oil/oil filter cartridge drain. Refer to “engine oil replacement” in chapte...

  • Page 197

    5-11 eng engine assembly order job name/part name q’ty remarks fuel tank refer to “seat and fuel tank”. Exhaust pipe/muffler refer to “exhaust pipe and muffler”. 1 ignition coil coupler 3 disconnect. 2 oil pressure switch coupler 1 disconnect. 3 crankshaft position sensor coupler 1 disconnect. 4 sta...

  • Page 198

    5-12 eng engine assembly engine assembly order job name/part name q’ty remarks engine assembly removal remove the parts in the order listed below. 1 rear frame cross member 1 2 front frame assembly 1 3 engine mounting nut 3 4 washer 2 5 washer 1 6 left front engine mounting bolt/washer 1/1 7 right f...

  • Page 199

    5-13 eng engine assembly removal 1. Remove: • rear engine mounting nut • front engine mounting nuts • washers note: do not remove the engine mounting bolts. 2. Remove: • engine assembly removal steps: • screw in the engine mounting bolt spacers (front and rear) using the engine mount spacer wrench 1...

  • Page 200

    5-14 eng engine assembly installation steps: • install the engine mounting bolt spacers (right front and rear). • install the engine assembly and then, install the rear engine mounting bolt, right front engine mounting bolt and washers. • install the left front engine mounting bolt spacer to engine ...

  • Page 201

    5-15 eng camshafts camshafts cylinder head cover order job name/part name q’ty remarks cylinder head cover removal remove the parts in the order listed below. Fuel tank refer to “seat and fuel tank”. 1 cylinder head breather hose 1 2 ignition coil 3 3 spark plug 3 4 cylinder head cover 1 5 cylinder ...

  • Page 202

    5-16 eng camshafts camshafts order job name/part name q’ty remarks camshafts removal remove the parts in the order listed below. Engine refer to “engine assembly”. 1 timing accessing screw 1 2 crankshaft end cover 1 3 timing chain tensioner 1 4 timing chain tensioner gasket 1 5 exhaust camshaft cap ...

  • Page 203

    5-17 eng camshafts removal 1. Remove: • timing accessing screw • crankshaft end cover 2. Align: • “i” mark a on the ac magneto rotor (with the stationary pointer b on the ac mag- neto cover) note: • turn the crankshaft clockwise. • when piston #3 is at tdc on the compression stroke, align the “i” ma...

  • Page 204

    5-18 eng camshafts 6. Remove: • exhaust camshaft sprocket 1 • intake camshaft sprocket 2 (use the special tool 3) rotor holding tool: 90890-01235 universal magneto & rotor holder: yu-01235 inspection 1. Inspect: • camshaft lobes blue discoloration/pitting/scratches → replace the camshaft. 2. Measure...

  • Page 205

    5-19 eng camshafts 3. Measure: • camshaft runout out of specification → replace. Camshaft runout: 0.030 mm (0.0012 in) 4. Measure: • camshaft-journal-to-camshaft-cap clearance out of specification → measure the camshaft journal diameter. Measurement steps: • install the camshaft into the cylinder he...

  • Page 206

    5-20 eng camshafts 6. Inspect: • camshaft sprocket more than 1/4 tooth a wear → replace the camshaft sprockets, timing chain, and crank- shaft as a set. A 1/4 tooth b correct 1 timing chain roller 2 camshaft sprocket 7. Inspect: • timing chain guide (top side) damage/wear → replace 8. Remove: • timi...

  • Page 207

    5-21 eng camshafts assembly steps: • install the timing chain tensioner spring and tim- ing chain tensioner rod 1. • squeeze the timing chain tensioner clip 2, and then push the timing chain tensioner rod 3 into the timing chain tensioner housing. Note: do not release the timing chain tensioner clip...

  • Page 208

    5-22 eng camshafts installation 1. Install: • intake camshaft sprocket 1 • exhaust camshaft sprocket 2 (with the special tool 3) • camshaft sprocket bolts note: make sure that the holes a in the cylinder #3 cam and marks b on the camshaft sprockets are in the position shown in the illustration. C: c...

  • Page 209

    5-23 eng camshafts 3. Install: • dowel pins • intake camshaft caps • exhaust camshaft caps note: • the “i” mark refers to the intake camshaft caps and the “e” mark refers to the exhaust camshaft caps. • install the camshaft caps with the arrow mark a pointing towards the right side of the engine. • ...

  • Page 210

    5-24 eng camshafts 5. Install: • timing chain tensioner gasket 1 • timing chain tensioner 2 note: • be sure to install the timing chain tensioner gas- ket so that its section with the “l” mark a is pro- truding from the lower left side of the timing chain tensioner. • the arrow mark b on the timing ...

  • Page 211

    5-25 eng camshafts 9. Install: • cylinder head cover gasket • cylinder head cover note: • apply bond tb1541 ® 1 onto the mating surfaces of the cylinder head cover and cylinder head cover gasket. • apply yamaha bond no. 1215 2 onto the mating surfaces of the cylinder head cover gasket. • tighten the...

  • Page 212

    5-26 eng cylinder head cylinder head order job name/part name q’ty remarks cylinder head removal remove the parts in the order listed below. Engine assembly refer to “engine assembly”. Camshafts refer to “camshafts”. 1 oil delivery hose 1 2 cylinder head 1 3 cylinder head gasket 1 4 dowel pin 2 for ...

  • Page 213

    5-27 eng cylinder head removal 1. Remove: • cylinder head bolts note: • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. 5 4 8 10 6 9 7 3 1 2 inspection 1. Eliminate: • combustion chamber carbon depo...

  • Page 214

    5-28 eng cylinder head installation 1. Install: • cylinder head note: pass the timing chain through the timing chain cav- ity. 2. Tighten: • cylinder head bolts (m10) note: the tightening procedure of the cylinder head bolts is angle controlled, therefore tighten the bolts using the following proced...

  • Page 215

    5-29 eng cylinder head • tighten the cylinder head bolts further to reach the specified angle 175 ~185° in the proper tightening sequence as shown. Warning when the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and pe...

  • Page 216

    5-30 eng valves and valve springs valves and valve springs order job name/part name q’ty remarks valves and valve springs removal remove the parts in the order listed below. Cylinder head refer to “cylinder head”. 1 valve lifter 12 2 valve pad 12 3 valve cotter 24 4 upper spring seat 12 5 valve spri...

  • Page 217

    5-31 eng valves and valve springs removal the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lifter 1 • valve pad...

  • Page 218

    5-32 eng valves and valve springs 4. Remove: • upper spring seat 1 • valve spring 2 • valve 3 • valve stem seal 4 • lower spring seat 5 note: identify the position of each part very carefully so that it can be reinstalled in its original place. Inspection 1. Measure: • valve-stem-to-valve-guide clea...

  • Page 219

    5-33 eng valves and valve springs • after installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance. Note: after replacing the valve guide, reface the valve seat. 3. Eliminate: • carbon deposits (from the valve face and va...

  • Page 220

    5-34 eng valves and valve springs 6. Measure: • valve stem runout out of specification → replace the valve. Note: • when installing a new valve, always replace the valve guide. • if the valve is removed or replaced, always replace the valve stem seal. 7. Eliminate: • carbon deposits (from the valve ...

  • Page 221

    5-35 eng valves and valve springs 10. Lap: • valve face • valve seat note: after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: • apply a coarse lapping compound a to the valve face. Caution: do not let the lapping c...

  • Page 222

    5-36 eng valves and valve springs 11. Measure: • valve spring free length a out of specification → replace the valve spring. 12. Measure: • compressed valve spring force a out of specification → replace the valve spring. B installed length valve spring free length (intake and exhaust): 39.57 mm (1.5...

  • Page 223

    5-37 eng valves and valve springs 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) recommended lubricant: molybdenum disulfide oil 3. Install: • lower spring seat 1 • valve stem seal 2 • valve 3 • valve spring 4 • upper spring seat 5 (into the cylinder head) note: • ...

  • Page 224

    5-38 eng valves and valve springs 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Caution: hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • valve pad • valve lifter (with the recommended lubricant) 7. Install: •...

  • Page 225

    5-39 eng ac magneto rotor and starter clutch ac magneto rotor and starter clutch i order job name/part name q’ty remarks ac magneto rotor and starter clutch removal remove the parts in the order listed below. Engine assembly refer to “engine assembly”. 1 ac magneto rotor cover 1 2 ac magneto rotor c...

  • Page 226

    5-40 eng ac magneto rotor and starter clutch removal 1. Remove: • ac magneto rotor bolt 1 • washer note: while holding the ac magneto rotor 2 with the sheave holder 3, loosen the ac magneto rotor bolt. Sheave holder: 90890-01701 primary clutch holder: ys-01880-a 1 2 3 2. Remove: • ac magneto rotor 1...

  • Page 227

    5-41 eng ac magneto rotor and starter clutch 3. Remove: • starter clutch note: while holding the ac magneto rotor with the sheave holder, remove the starter clutch bolts 1. Sheave holder: 90890-01701 primary clutch holder: ys-01880-a 1 inspection 1. Inspect: • stator coil damage → replace the stator...

  • Page 228

    5-42 eng ac magneto rotor and starter clutch 4. Inspect: • starter clutch operation installation steps: • install the starter clutch gear onto the starter clutch and hold the ac magneto rotor. • when turning the starter clutch gear clockwise È, it should turn freely, otherwise the starter clutch is ...

  • Page 229

    5-43 eng ac magneto rotor and starter clutch 4. Tighten: • ac magneto rotor bolt 1 note: • lubricate the ac magneto rotor bolt and washer with engine oil. • while holding the ac magneto rotor 2 with the sheave holder 3, tighten the ac magneto rotor bolt. T r . . Ac magneto rotor bolt: 130 nm (13.0 m...

  • Page 230

    5-44 eng oil pan and oil pump oil pan and oil pump order job name/part name q’ty remarks oil pan and oil pump removal remove the parts in the order listed below. Engine refer to “engine assembly”. 1 oil pressure switch sub-lead 1 2 oil pressure switch 1 3 oil pan 1 4 oil pan gasket 1 5 dowel pin 2 6...

  • Page 231

    5-45 eng oil pan and oil pump order job name/part name q’ty remarks oil pump disassembly remove the parts in the order listed below. 1 oil pan divider 1 2 oil pump housing cover 1 1 3 oil pump housing cover 2 1 4 pin 4 5 oil strainer 2 6 washer 1 7 pin 3 8 oil pump inner rotor 1 1 9 oil pump outer r...

  • Page 232

    5-46 eng oil pan and oil pump order job name/part name q’ty remarks c oil pump shaft 1 d oil seal 2 e check ball seat 1 f check ball 1 g spring 1 h spacer 1 i relief valve cover 1 j spring 1 k relief valve 1 l oil pump housing 1 for assembly, reverse the disassembly pro- cedure. 1 2 3 4 6 7 9 d 8 a ...

  • Page 233

    5-47 eng oil pan and oil pump removal 1. Remove: • oil pan 1 note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 1 2. Remove: • oil pump driven gear 1 note: • while holding the oil pump driven gear with the ro...

  • Page 234

    5-48 eng oil pan and oil pump 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a (between inner rotor 1 and outer rotor 2) • outer-rotor-to-oil-pump-housing clearance b (between outer rotor 2 and pump housing 3) out of specifications → replace oil pump assembly. Inner-rotor-to-outer-rotor-tip ...

  • Page 235

    5-49 eng oil pan and oil pump 6. Inspect: • check ball seat 1 • check ball 2 • spring 3 • spacer 4 damage/wear → replace the defective part(-s). 1 2 3 4 7. Inspect: • oil strainer damage → replace. Obstruction → wash and blow out with com- pressed air. Contaminants → clean with engine oil. Installat...

  • Page 236

    5-50 eng oil pan and oil pump 4. Install: • oil pump driven gear 1 note: • install the oil pump driven gear with the stamped mark “4xv” facing towards the oil pump assem- bly. • while holding the oil pump driven gear with the rotor holding tool 2, tighten the oil pump driven gear bolt. 5. Install: •...

  • Page 237

    5-51 eng crankcase crankcase order job name/part name q’ty remarks crankcase separate remove the parts in the order listed below. Engine assembly refer to “engine assembly”. Cylinder head refer to “cylinder head”. Ac magneto rotor/starter clutch gear refer to “ac magneto rotor and starter clutch”. O...

  • Page 238

    5-52 eng crankcase order job name/part name q’ty remarks 8 primary sheave drive shaft assembly bolt 4 9 lower crankcase 1 10 dowel pin 1 for installation, reverse the removal proce- dure. Ls e e e e lt lt lt 3 6 5 4 1 1 10 9 7 8 (4) É Ë Ë È È È É É Ê Ê É É É Ì 2 25 nm (2.5 m • kg, 18 ft • lb) 24 nm ...

  • Page 239

    5-53 eng crankcase removal 1. Remove: • crankcase bolts note: • place the engine upside down. • loosen the bolts in decreasing numerical order of the embossed numbers on the crankcase. • loosen each bolt 1/4 of a turn at a time. After all of the bolts are fully loosened, remove them. L 2 h f 5 6 7 c...

  • Page 240

    5-54 eng crankcase installation 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) recommended lubricant: engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) note: do not allow any sealant to come into contact with the oil gallery or crankshaft journal beari...

  • Page 241

    5-55 eng crankcase 5. Tighten: • crankcase bolts (m9 × 105 mm) 1~8 note: tighten the bolts in the order of the embossed numbers on the crankcase. • tighten the crankcase bolts. • loosen and retighten the crankcase bolts. • tighten the crankcase bolts further to reach the specified angle 65 ~ 70°. Wa...

  • Page 242

    5-56 eng crankcase 6. Tighten: • crankcase bolts 9 ~n note: tighten the bolts in the order of the embossed numbers on the crankcase. 7. Install: • primary sheave drive shaft assembly bolts t r . . Crankcase bolt 9 ~ b: 24 nm (2.4 m · kg, 17 ft · lb) crankcase bolt c ~ n: 12 nm (1.2 m · kg, 8.7 ft · ...

  • Page 243

    5-57 eng connecting rods and pistons connecting rods and pistons order job name/part name q’ty remarks connecting rods and pistons removal remove the parts in the order listed below. Crankcase separate. Refer to “crankcase”. 1 connecting rod cap 3 2 big end lower bearing 3 3 piston pin clip 6 4 pist...

  • Page 244

    5-58 eng connecting rods and pistons removal 1. Remove: • connecting rod cap 1 • big end bearings note: identify the position of each big end bearing so that it can be reinstalled in its original place. 1 2. Remove: • piston pin clips 1 • piston pin 2 • piston 3 • connecting rod 4 caution: do not us...

  • Page 245

    5-59 eng connecting rods and pistons inspection 1. Inspect: • piston wall • cylinder wall vertical scratches → replace the crankcase, and replace the piston and piston rings as a set. 2. Measure: • piston-to-cylinder clearance measurement steps: 1st step: • measure cylinder bore “c” with the cylinde...

  • Page 246

    5-60 eng connecting rods and pistons 2nd step: • measure piston skirt diameter “p” with the micrometer. A 11.0 mm (0.43 in) from the bottom edge of the piston. • if out of specification, replace the piston and piston rings as a set. 3rd step: • calculate the piston-to-cylinder clearance with the fol...

  • Page 247

    5-61 eng connecting rods and pistons 4. Install: • piston ring (into the cylinder) note: level the piston ring in the cylinder with the piston crown. A 5.0 mm (0.20 in) 5. Measure: • piston ring end gap out of specification → replace the piston rings as a set. Note: the oil ring expander spacer end ...

  • Page 248

    5-62 eng connecting rods and pistons 8. Measure: • piston pin bore inside diameter out of specification → replace the piston. Piston pin bore inside diameter: 19.004 ~ 19.015 mm (0.7482 ~ 0.7486 in) 9. Calculate: • piston pin to piston pin bore clearance out of specification → replace the piston pin...

  • Page 249

    5-63 eng connecting rods and pistons measurement steps: caution: do not interchange the big end bearings and connecting rods. To obtain the correct crank- shaft-pin-to-big-end-bearing clearance and pre- vent engine damage, the big end bearings must be installed in their original positions. • clean t...

  • Page 250

    5-64 eng connecting rods and pistons • tighten the connecting rod nuts. Refer to “installation” in “connecting rods and pistons” on page 5-65. • remove the connecting rod and big end bear- ings. • measure the compressed plastigauge ® width e on the crankshaft pin. If the clearance is out of specific...

  • Page 251

    5-65 eng connecting rods and pistons installation 1. Install: • top ring 1 • 2nd ring 2 • upper oil ring rail 3 • oil ring expander 4 • lower oil ring rail 5 note: be sure to install the piston rings so that the manu- facturer marks a face up. 2. Install: • piston 1 (onto the respective connecting r...

  • Page 252

    5-66 eng connecting rods and pistons 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) 5. Lubricate: • bolt threads • nut seats (with the recommended lubricant) 6. Lubricate: • crankshaft pins • big end bearings • connecting rod inner surface (with the recommended lub...

  • Page 253

    5-67 eng connecting rods and pistons 8. Align: • bolt heads (with the connecting rod caps) 9. Tighten: • connecting rod nuts warning replace the connecting rod bolts and nuts with new ones. Caution: tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new...

  • Page 254

    5-68 eng crankshaft and balancer shaft crankshaft and balancer shaft order job name/part name q’ty remarks crankshaft and balancer shaft removal remove the parts in the order listed below. Crankcase separate. Refer to “crankcase”. Connecting rod caps refer to “connecting rods and pis- tons”. 1 crank...

  • Page 255

    5-69 eng crankshaft and balancer shaft order job name/part name q’ty remarks 12 balancer shaft 1 13 balancer driven gear 1 14 bearing retainer 1 15 bearing 1 16 circlip 1 17 bearing 1 for installation, reverse the removal proce- dure. E new lt e e e e 16 17 2 2 2 3 4 2 2 new 5 6 8 9 10 11 12 15 14 7...

  • Page 256

    5-70 eng crankshaft and balancer shaft remove 1. Remove: • crankshaft journal lower bearings (from the lower crankcase) • crankshaft journal upper bearings (from the upper crankcase) note: identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its orig- inal ...

  • Page 257

    5-71 eng crankshaft and balancer shaft inspection 1. Measure: • crankshaft runout use the v-blocks and a dial gauge. Out of specification → replace the crank- shaft. Dial gauge: 90890-03097 dial indicator gauge: yu-a8428 crankshaft runout: 0.03 mm (0.0012 in) 2. Inspect: • crankshaft journal surface...

  • Page 258

    5-72 eng crankshaft and balancer shaft measurement steps: caution: do not interchange the crankshaft journal bear- ings. To obtain the correct crankshaft-journal- to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original po...

  • Page 259

    5-73 eng crankshaft and balancer shaft • tighten the bolts in the order of the embossed numbers on the crankcase. Refer to “installation” in “crankcase” on page 5-54. • remove the lower crankcase and the crank- shaft journal lower bearings. • measure the compressed plastigauge ® width e on each cran...

  • Page 260

    5-74 eng crankshaft and balancer shaft installation 1. Install: • balancer driven gear 1 • balancer shaft 2 note: • face the punch mark a on the balancer driven gear inward. • align the projection b on the balancer shaft with the slot c in the balancer driven gear. 1 2 c b a 2. Install: • water pump...

  • Page 261

    5-75 eng crankshaft and balancer shaft 4. Tighten: • balancer weight bolts 1 note: place a wood a between the balancer weight 2 and crankcase. 5. Bend the lock washer tab. T r . . Balancer weight bolt: 35 nm (3.5 m · kg, 25 ft · lb) 1 a 2 1 a 2 6. Install: • crankshaft journal upper bearings (into t...

  • Page 262

    5-76 eng crankshaft and balancer shaft 8. Install: • primary sheave drive shaft assembly 1 (to the crankshaft 2) note: align the shallow groove a in the primary drive shaft assembly with the low spline b of the crank- shaft. A b 1 2 9. Install: • crankshaft 1 (with primary sheave drive shaft assembl...

  • Page 263

    6-1 cool cooling system radiator order job name/part name q’ty remarks radiator removal remove the parts in the order listed below. Coolant drain. Refer to “cooling system” in chapter 2. Steering column refer to “steering” in chapter 3. 1 radiator cap 1 2 coolant reservoir hose 1 3 coolant reservoir...

  • Page 264

    6-2 cool radiator order job name/part name q’ty remarks 11 radiator 1 12 radiator fan motor 1 13 dc back buzzer coupler 1 disconnect. Reverse model only 14 dc back buzzer 1 reverse model only 15 radiator stay 2 for installation, reverse the removal proce- dure. 5 3 4 1 2 15 15 (4) (4) (4) (4) (4) 12...

  • Page 265

    6-3 cool radiator inspection 1. Inspect: • radiator inlet hose • radiator outlet hose • coolant reservoir hose cracks/damage → replace. 2. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Note: _ straighten any flattened fins...

  • Page 266

    6-4 cool radiator installation 1. Install: • radiator stay 1 • dc back buzzer 2 (for reverse model) note: • hook the hooked portion a of the brake hose holder onto the radiator stay, and then fasten the holder with the bolt. • be sure to install the dc back buzzer so that a line drawn through the ce...

  • Page 267

    6-5 cool thermostat thermostat order job name/part name q’ty remarks thermostat removal remove the parts in the order listed below. Coolant drain. Refer to “cooling system” in chapter 2. Air filter case refer to “air filter case” in chapter 7. 1 radiator inlet hose 1 disconnect. 2 throttle body heat...

  • Page 268

    6-6 cool thermostat inspection 1. Inspect: • thermostat does not open at 69.0 ~ 73.0 °c (156.2 ~ 163.4 °f) → replace. Inspection steps: • suspend the thermostat 1 in a container 2 filled with water. • slowly heat the water 3. • place a thermometer 4 in the water. • while stirring the water, observe ...

  • Page 269

    6-7 cool water pump water pump order job name/part name q’ty remarks water pump removal remove the parts in the order listed below. Engine assembly refer to “engine assembly” in chapter 5. 1 timing mark accessing screw 1 2 crankshaft end cover 1 3 water pump assembly 1 4 gasket 2 5 dowel pin 2 6 plu...

  • Page 270

    6-8 cool water pump order job name/part name q’ty remarks water pump disassembly remove the parts in the order listed below. 1 water pump housing cover 1 2 gasket 1 3 circlip 2 4 impeller shaft gear 1 5 pin 2 6 impeller shaft assembly 1 7 water pump seal 1 8 bearing 1 9 oil seal 1 0 water pump housi...

  • Page 271

    6-9 cool water pump removal 1. Remove: • timing mark accessing screw • crankshaft end cover 2. Align: • “i” mark a on the ac magneto rotor (with the stationary pointer b on the ac mag- neto cover) note: turn the crankshaft clockwise. 3. Remove: • water pump assembly a b disassembly 1. Remove: • impe...

  • Page 272

    6-10 cool water pump inspection 1. Inspect: • water pump housing cover • water pump housing • impeller shaft cracks/damage/wear → replace. 2. Inspect: • bearing rough movement → replace. Assembly 1. Install: • oil seal 1 (to the water pump housing) note: • before installing the oil seal, apply tap w...

  • Page 273

    6-11 cool water pump 4. Install: • rubber damper holder 1 • rubber damper 2 note: before installing the rubber damper, apply tap water or coolant onto its outer surface. 5. Measure: • impeller shaft tilt out of specification → repeat steps (4) and (5). Caution: make sure the rubber damper and rubber...

  • Page 274

    6-12 cool oil cooler and heat exchanger oil cooler and heat exchanger order job name/part name q’ty remarks oil cooler and heat exchanger removal remove the parts in the order listed below. Coolant drain. Refer to “cooling system” in chapter 2. Engine assembly refer to “engine assembly” in chapter 5...

  • Page 275

    6-13 cool oil cooler and heat exchanger order job name/part name q’ty remarks 11 heat exchanger hose 1 1 12 heat exchanger pipe 1 13 heat exchanger hose 2 1 14 heat exchanger 1 for installation, reverse the removal proce- dure. Fx10mt/fx10mtr/fx10mtra lt new new 8 2 1 7 4 9 5 6 3 10 È (4) 10 nm (1.0...

  • Page 276

    6-14 cool oil cooler and heat exchanger inspection 1. Inspect: • heat exchanger(s) • oil cooler • cylinder head water jacket • oil cooler hose • water pump hoses • heat exchanger hoses • heat exchanger pipe cracks/damage → replace..

  • Page 277

    7-1 fi fuel injection system fuel injection system 1 battery 2 injector #3 3 cylinder-#3 ignition coil 4 spark plug 5 isc (idle speed control) unit 6 cylinder-#2 ignition coil 7 fuel pump 8 intake air pressure sen- sor 1 (cylinders #1, #2, and #3) 9 cylinder-#1 ignition coil 0 speed sensor a intake ...

  • Page 278

    7-2 fi fuel injection system circ uit d iagra m r /w l/ w (black) l/ w r /g r /w l/ w y lg g (black) b br /b l r /wg /y r /g r /l r /wl /r r w br br/l y /r p /l w /g r /g br /l l /b o lg b g /y l /r b g /b r /y br /l r /b gy /r o /g l br /w p g /w l /wr /w gy p /w r /lc h y /l w l /y b /l y /w y /gb...

  • Page 279

    7-3 fi fuel injection system 3 crankshaft position sensor 4 main switch 5 main fuse 6 load control relay 7 battery 0 fuel injection system fuse b engine stop switch c throttle switch d thumb warmer e grip warmer f oil pressure switch g co adjustment coupler h ecu (engine control unit) i cylinder-#1 ...

  • Page 280

    7-4 fi fuel injection system ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operat- ing normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute character...

  • Page 281

    7-5 fi fuel injection system communication error with the meter 37 isc (idle speed control) valve (stuck fully open) engine speed is high when the engine is idling. Able (unable if valve stuck fully closed) able 42 speed sensor no normal signals are received from the speed sensor. Able able 43 fuel ...

  • Page 282

    7-6 fi fuel injection system troubleshooting chart engine operation is not normal or the warning light and self-diagnostic warning indicator on the lcd flash. * the warning light and self-diagnostic warning indicator on the lcd may not flash even if the engine operation is not normal. The warning li...

  • Page 283

    7-7 fi fuel injection system diagnostic mode it is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode...

  • Page 284

    7-8 fi fuel injection system 6. Verify the operation of the sensor or actuator. • sensor operation the data representing the operating condi- tions of the sensor appears on the odometer/ tripmeter/engine speed meter lcd. • actuator operation push the grip warmer side of the grip/thumb warmer adjustm...

  • Page 285

    7-9 fi fuel injection system fault code table fault code no. Symptom probable cause of malfunction diagnostic code no. 12 no normal signals are received from the crankshaft position sensor. • open or short circuit in wire harness. • defective crankshaft position sensor. • malfunction in pickup rotor...

  • Page 286

    7-10 fi fuel injection system 37 engine speed is high when the engine is idling. • open or short circuit in wire harness. • open or short circuit in fuel injection system sub-wire harness. • malfunction in throttle body. • malfunction in throttle cable. • isc valve is stuck fully open due to disconn...

  • Page 287

    7-11 fi fuel injection system diagnostic mode table switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “diag- nostic mode”. Note: • check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor a...

  • Page 288

    7-12 fi fuel injection system 37 injector #2 if the grip warmer side of the grip/thumb warmer adjust- ment switch is pushed, actuates injector #2 and displays the self-diagnosis warning indicator (five times at one- second intervals). After pushing the switch, check that the injector operates five t...

  • Page 289

    7-13 fi fuel injection system troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctionin...

  • Page 290

    7-14 fi fuel injection system fault code no. 13 symptom intake air pressure sensor 1 (cylinders #1, #2, and #3): open or short circuit detected. Diagnostic code no. 03 (intake air pressure sensor 1 (cylinders #1, #2, and #3)) order item/components and probable cause check or maintenance job reinstat...

  • Page 291

    7-15 fi fuel injection system fault code no. 14 symptom intake air pressure sensor 1 (cylinders #1, #2, and #3): hose system mal- function (clogged or detached hose). Diagnostic code no. 03 (intake air pressure sensor 1 (cylinders #1, #2, and #3)) order item/components and probable cause check or ma...

  • Page 292

    7-16 fi fuel injection system fault code no. 16 symptom stuck throttle position sensor detected. Diagnostic code no. 01 (throttle position sensor) order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. Check for loose...

  • Page 293

    7-17 fi fuel injection system fault code no. 25 symptom intake air pressure sensor 2 (cylinder #1): open or short circuit detected. Diagnostic code no. 04 (intake air pressure sensor 2 (cylinder #1)) order item/components and probable cause check or maintenance job reinstatement method 1 connections...

  • Page 294

    7-18 fi fuel injection system fault code no. 26 symptom intake air pressure sensor 2 (cylinder #1): hose system malfunction (clogged or detached hose). Diagnostic code no. 04 (intake air pressure sensor 2 (cylinder #1)) order item/components and probable cause check or maintenance job reinstatement ...

  • Page 295

    7-19 fi fuel injection system fault code no. 33 symptom malfunction detected in the primary lead of the cylinder-#1 ignition coil. Diagnostic code no. 30 (cylinder-#1 ignition coil) order item/components and probable cause check or maintenance job reinstatement method 1 connections cylinder-#1 ignit...

  • Page 296

    7-20 fi fuel injection system fault code no. 35 symptom malfunction detected in the primary lead of the cylinder-#3 ignition coil. Diagnostic code no. 32 (cylinder-#3 ignition coil) order item/components and probable cause check or maintenance job reinstatement method 1 connections cylinder-#3 ignit...

  • Page 297

    7-21 fi fuel injection system fault code no. 42 symptom no normal signals are received from the speed sensor. Diagnostic code no. 07 (speed sensor) order item/components and probable cause check or maintenance job reinstatement method 1 connections speed sensor coupler wire harness ecu coupler check...

  • Page 298

    7-22 fi fuel injection system fault code no. 43 symptom power supply to the fuel injectors and fuel pump is not normal. Diagnostic code no. 09 (fuel system voltage) order item/components and probable cause check or maintenance job reinstatement method 1 connections fuel injection system relay couple...

  • Page 299

    7-23 fi fuel injection system fault code no. 44 symptom error is detected while reading or writing on eeprom (co adjustment value). Diagnostic no. 60 (eeprom improper cylinder indication) order item/components and probable cause check or maintenance job reinstatement method 1 malfunction in ecu. Exe...

  • Page 300

    7-24 fi fuel injection system fault code no. 81 symptom grip warmer: open or short circuit detected. Diagnostic code no. 26 (grip warmer operation) order item/components and probable cause check or maintenance job reinstatement method 1 open or short circuit in wire harness. Repair or replace if the...

  • Page 301

    7-25 fi fuel injection system fault code no. Er-1 symptom no signals are received from the ecu. Er-2 symptom no signals are received from the ecu within the specified signal time. Er-3 symptom data from the ecu cannot be received correctly. Er-4 symptom non-registered data has been received from the...

  • Page 302

    7-26 fi fuel injection system oil pressure switch 1. Disconnect: • oil pressure switch coupler 1 2. Connect: • pocket tester (between the engine ground and oil pressure switch terminal) 1 3. Check: • oil pressure switch continuity no continuity → replace the oil pressure switch. Intake air temperatu...

  • Page 303

    7-27 fi fuel injection system isc (idle speed control) unit note: do not remove the isc (idle speed control) unit completely from the throttle body. 1. Inspect: • isc (idle speed control) unit inspection steps: • disconnect the isc (idle speed control) unit coupler from the isc (idle speed control) ...

  • Page 304

    7-28 fi air filter case air filter case order job name/part name q’ty remarks air filter case removal remove the parts in the order listed below. Steering column refer to “steering” in chapter 3. Radiator cover refer to “radiator” in chapter 6. 1 intake air temperature sensor coupler 1 disconnect. 2...

  • Page 305

    7-29 fi throttle body throttle body order job name/part name q’ty remarks throttle body removal remove the parts in the order listed below. Coolant drain. Refer to “cooling system” in chapter 2. Steering column refer to “steering” in chapter 3. Radiator refer to “radiator” in chapter 6. Air filter c...

  • Page 306

    7-30 fi throttle body injectors order job name/part name q’ty remarks injectors removal remove the parts in the order listed below. 1 throttle position sensor coupler 1 disconnect. 2 intake air pressure sensor 2 (cylinder #1) coupler 1 disconnect. 3 intake air pressure sensor 1 (cylinders #1, #2, an...

  • Page 307

    7-31 fi throttle body order job name/part name q’ty remarks 13 intake air pressure sensor 1 (cylinders #1, #2, and #3) 1 14 fuel rail 1 15 injector 3 for installation, reverse the removal proce- dure. 14 15 15 15 11 10 10 12 13 10 9 10 10 8 6 5 4 1 2 3 7 new new new.

  • Page 308

    7-32 fi throttle body removal 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose caution: • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel has been removed from the fuel tank be carefu...

  • Page 309

    7-33 fi throttle body fuel pressure inspection 1. Inspect: • fuel pressure measurement steps: • remove the fuel hose connector holder, and then disconnect the fuel hose. Refer to “seat and fuel tank” in chap- ter 5. • connect the fuel pressure adapter 1 between the fuel hose 2 and fuel pump 3. • con...

  • Page 310

    7-34 fi throttle body inspection and adjustment 1. Inspect: • throttle position sensor inspect steps: • disconnect the throttle position sensor coupler. • remove the throttle position sensor from the throttle body. • connect the pocket tester ( Ω × 1k) to the throt- tle position sensor. • measure th...

  • Page 311

    7-35 fi throttle body • measure the throttle position sensor voltage. • adjust the throttle position sensor angle so the measured voltage is within the specified range. • after adjusting the throttle position sensor angle, tighten the throttle position sensor screws. Throttle position sensor voltage...

  • Page 312

    7-36 fi.

  • Page 313

    8-1 – + elec electrical switch inspection switch inspection use a pocket tester to check the terminals for conti- nuity. If the continuity is faulty at any point, replace the switch. Note: • set the pocket tester to “0” before starting a test. • when testing the switch for continuity the pocket test...

  • Page 314

    8-2 – + elec ignition system ignition system circ uit d iagra m r /w l/ w (black) l/ w r /g r /w l/ w y lg g (black) b br /b l r /wg /y r /g r /l r /wl /r r w br br/l y /r p /l w /g r /g br /l l /b o lg b g /y l /r b g /b r /y br /l r /b gy /r o /g l br /w p g /w l /wr /w gy p /w r /lc h y /l w l /y...

  • Page 315

    8-3 – + elec ignition system ignition system circuit diagram 3 crankshaft position sensor 4 main switch 5 main fuse 7 battery b engine stop switch c throttle switch h ecu (engine control unit) i cylinder-#1 ignition coil j spark plug k cylinder-#2 ignition coil l cylinder-#3 ignition coil r throttle...

  • Page 316

    8-4 – + elec ignition system troubleshooting check the main fuse and ignition fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the spark plug gap. Refer to “spark plugs” in chapter 2. Check the ignition spark gap. Check the ignition ...

  • Page 317

    8-5 – + elec ignition system is self-diagnosis code 15, 16, or 42 displayed? Has throttle body icing occurred or is foreign material stuck in the throttle body? Is the throttle switch malfunctioning? Is the throttle cable free play out of specification? Was the engine revved with the v-belt removed?...

  • Page 318

    8-6 – + elec ignition system ignition spark gap the following procedure applies to all of the ignition coils. 1. Measure: • ignition spark gap out of specification → replace the ignition coil(s). Measurement steps: • disconnect the ignition coil 1 from the spark plug. • connect the opama pet-4000 sp...

  • Page 319

    8-7 – + elec ignition system crankshaft position sensor 1. Disconnect: • crankshaft position sensor coupler 2. Connect: • pocket tester (to the crankshaft position sensor coupler) 3. Measure: • crankshaft position sensor resistance out of specification → replace. Crankshaft position sensor resis- ta...

  • Page 320

    8-8 – + elec throttle override system (t.O.R.S.) warning • if the t.O.R.S. Is activated, make sure that the cause of the malfunction has been corrected and that the engine can be operated without a problem before restarting the engine. • be sure to use the specified spark plug and ignition coil. Oth...

  • Page 321

    8-9 – + elec note: • when the t.O.R.S. Is activated, the warning light 4 and self-diagnosis warning indicator 5 will flash and the two-digit code “84” 6 will flash in the odometer/tripmeter/engine speed meter lcd. • the t.O.R.S. Monitors the condition of the throt- tle position sensor, speedometer u...

  • Page 322

    8-10 – + elec ignition system main switch 1. Disconnect: • main switch coupler 2. Connect: • pocket tester (to the main switch coupler) 3. Check: • main switch continuity faulty → replace. Continuity switch position color code br r br/w r/w off on start r/w br/w br r.

  • Page 323

    8-11 – + elec electrical starting system electr ical sta r tin g system circ uit d iagra m r /w l/ w (black) l/ w r /g r /w l/ w y lg g (black) b br /b l r /wg /y r /g r /l r /wl /r r w br br/l y /r p /l w /g r /g br /l l /b o lg b g /y l /r b g /b r /y br /l r /b gy /r o /g l br /w p g /w l /wr /w ...

  • Page 324

    8-12 – + elec electrical starting system troubleshooting 1. Connect: • starter relay terminals (battery side and starter motor side) 1 jumper lead 2. Check: • starter motor operation ok starter motor does not operate. No check the battery and connectors. Refer to “battery inspection” in chapter 2. O...

  • Page 325

    8-13 – + elec electrical starting system ok check the main fuse and ignition fuse. Refer to “fuse inspection” in chapter 2. * faulty replace the main fuse and/or ignition fuse. Ok check the engine stop switch and main switch. Refer to “ignition system”. Faulty replace the right handlebar switch and/...

  • Page 326

    8-14 – + elec electrical starting system starter motor order job name/part name q’ty remarks starter motor removal remove the parts in the order listed below. Engine assembly refer to “engine assembly” in chapter 5. 1 starter motor lead 1 2 starter motor assembly 1 for installation, reverse the remo...

  • Page 327

    8-15 – + elec electrical starting system s order job name/part name q’ty remarks 9 brush holder 1 0 bearing 1 a armature assembly 1 b starter motor yoke 1 for assembly, reverse the disassembly pro- cedure..

  • Page 328

    8-16 – + elec electrical starting system inspection 1. Inspect: • commutator (outer surface) dirty → clean with #600 grit sandpaper 1. Hold the armature in a vise 2 and copper or aluminium plate 3. Caution: lightly grip the armature with a vise. 2. Measure: • commutator diameter a measure the diamet...

  • Page 329

    8-17 – + elec electrical starting system 5. Measure: • brush length a out of specification → replace the brushes as a set. 6. Measure: • brush spring pressure fatigue/out of specification → replace the brush spring as a set. 7. Check: • bearings • oil seal damage/wear → replace the starter motor. Br...

  • Page 330

    8-18 – + elec charging system charging system circ uit d iagra m r /w l/ w (black) l/ w r /g r /w l/ w y lg g (black) b br /b l r /wg /y r /g r /l r /wl /r r w br br/l y /r p /l w /g r /g br /l l /b o lg b g /y l /r b g /b r /y br /l r /b gy /r o /g l br /w p g /w l /wr /w gy p /w r /lc h y /l w l /...

  • Page 331

    8-19 – + elec charging system troubleshooting 1. Connect: • pocket tester (to the battery terminals) 2. Measure: • battery voltage ok battery is not charged. Battery voltage: more than 12 v at 20 °c (68 °f) out of specification • check the battery. • replace or charge the battery. Refer to “battery ...

  • Page 332

    8-20 – + elec charging system battery inspection 1. Inspect: • battery condition refer to “battery inspection” in chap- ter 2. Battery storage the battery should be stored if the snowmobile is not going to be used for a long period. 1. Remove: • battery warning when removing the battery, disconnect ...

  • Page 333

    8-21 – + elec charging system.

  • Page 334

    8-22 – + elec lighting system lightin g system circ uit d iagra m r /w l/ w (black) l/ w r /g r /w l/ w y lg g (black) b br /b l r /wg /y r /g r /l r /wl /r r w br br/l y /r p /l w /g r /g br /l l /b o lg b g /y l /r b g /b r /y br /l r /b gy /r o /g l br /w p g /w l /wr /w gy p /w r /lc h y /l w l ...

  • Page 335

    8-23 – + elec lighting system lighting system circuit diagram 1 rectifier/regulator 2 ac magneto 4 main switch 5 main fuse 6 load control relay 7 battery b engine stop switch h ecu (engine control unit) z frame ground _ tail/brake light d multi-function meter g high beam indicator light h headlight ...

  • Page 336

    8-24 – + elec lighting system troubleshooting check the headlight bulb(s). Check the main fuse, ignition fuse, and headlight fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the stator coil. Refer to “charging system”. Check the engi...

  • Page 337

    8-25 – + elec lighting system check the main fuse and ignition fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the engine stop switch and main switch. Refer to “ignition system”. Check the lighting system wiring. Refer to “circuit d...

  • Page 338

    8-26 – + elec lighting system check the main fuse, ignition fuse, and signal fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the stator coil. Refer to “charging system”. Check the engine stop switch and main switch. Refer to “igniti...

  • Page 339

    8-27 – + elec lighting system bulb(s) note: do not check any of the lights that use leds. 1. Remove: • headlight bulb 2. Connect: • pocket tester (to the bulb terminals) warning keep flammable products and your hands away from the bulb while it is on; it will be hot. Do not touch the bulb until it c...

  • Page 340

    8-28 – + elec lighting system headlight relay 1. Remove: • headlight relay (with the black coupler) inspection steps: • connect the pocket tester ( Ω × 1) to the head- light relay terminals as shown. • if headlight relay does not have continuity between the blue/white and green terminals, replace it...

  • Page 341

    8-29 – + elec lighting system.

  • Page 342

    8-30 – + elec signal system signal system circ uit d iagra m r /w l/ w (black) l/ w r /g r /w l/ w y lg g (black) b br /b l r /wg /y r /g r /l r /wl /r r w br br/l y /r p /l w /g r /g br /l l /b o lg b g /y l /r b g /b r /y br /l r /b gy /r o /g l br /w p g /w l /wr /w gy p /w r /lc h y /l w l /y b ...

  • Page 343

    8-31 – + elec signal system signal system circuit diagram 1 rectifier/regulator 2 ac magneto 4 main switch 5 main fuse 6 load control relay 7 battery b engine stop switch h ecu (engine control unit) s speed sensor w coolant temperature sensor z frame ground [ dc back buzzer \ gear position switch ] ...

  • Page 344

    8-32 – + elec signal system troubleshooting check the main fuse, ignition fuse, and signal fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the stator coil. Refer to “charging system”. Check the engine stop switch and main switch. Re...

  • Page 345

    8-33 – + elec signal system check the main fuse and ignition fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the engine stop switch and main switch. Refer to “ignition system”. Check the coolant temperature sensor. Check the signal ...

  • Page 346

    8-34 – + elec signal system check the main fuse and ignition fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the engine stop switch and main switch. Refer to “ignition system”. Check the fuel sender. Check the signal system wiring. ...

  • Page 347

    8-35 – + elec signal system check the main fuse and ignition fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the engine stop switch and main switch. Refer to “ignition system”. Check the oil level switch. Check the signal system wir...

  • Page 348

    8-36 – + elec signal system check the main fuse and ignition fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the engine stop switch and main switch. Refer to “ignition system”. Check the speed sensor. Check the signal system wiring....

  • Page 349

    8-37 – + elec signal system check the main fuse, ignition fuse, and signal fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the stator coil. Refer to “charging system”. Check the engine stop switch and main switch. Refer to “ignition...

  • Page 350

    8-38 – + elec signal system brake light switch 1. Disconnect: • brake light switch coupler 2. Connect: • pocket tester (to the brake light switch coupler) 3. Check: • brake light switch continuity faulty → replace. Switch position continuity brake lever operates yes brake lever does not operate no l...

  • Page 351

    8-39 – + elec signal system coolant temperature sensor 1. Remove the coolant temperature sensor. Caution: handle the coolant temperature sensor with special care. Never subject it to shock or allow it to be dropped. If it is dropped, it must be replaced. 2. Connect: • pocket tester 1 (to the coolant...

  • Page 352

    8-40 – + elec signal system oil level switch 1. Remove: • oil level switch 2. Connect: • pocket tester (to the oil level switch coupler) 3. Check: • oil level switch continuity faulty → replace. : continuity : no continuity switch position good condition bad condition È down position É up position c...

  • Page 353

    8-41 – + elec signal system speed sensor 1. Inspect: • speed sensor inspection steps: • connect the pocket tester (dc 20 v) to the speed sensor coupler (wire harness side) as shown. • elevate the track and slowly rotate it. • measure the voltage (dc 5 v) of white and black/blue. With each full rotat...

  • Page 354

    8-42 – + elec grip warmer system gr ip w armer system circ uit d iagra m r /w l/ w (black) l/ w r /g r /w l/ w y lg g (black) b br /b l r /wg /y r /g r /l r /wl /r r w br br/l y /r p /l w /g r /g br /l l /b o lg b g /y l /r b g /b r /y br /l r /b gy /r o /g l br /w p g /w l /wr /w gy p /w r /lc h y ...

  • Page 355

    8-43 – + elec grip warmer system grip warmer system circuit diagram 4 main switch 5 main fuse 7 battery b engine stop switch d thumb warmer e grip warmer h ecu (engine control unit) y grip/thumb warmer adjust- ment switch z frame ground d multi-function meter n ignition fuse.

  • Page 356

    8-44 – + elec grip warmer system troubleshooting check the main fuse and ignition fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the engine stop switch and main switch. Refer to “ignition system”. Check the grip warmer and thumb wa...

  • Page 357

    8-45 – + elec grip warmer system grip warmer and thumb warmer 1. Disconnect: • grip warmer couplers • thumb warmer coupler 2. Connect: • pocket tester (to the grip warmer couplers and/or thumb warmer coupler) 3. Measure: • grip warmer resistance 1 • thumb warmer resistance 2 out of specification → r...

  • Page 358

    8-46 – + elec cooling system coolin g system circ uit d iagra m r /w l/ w (black) l/ w r /g r /w l/ w y lg g (black) b br /b l r /wg /y r /g r /l r /wl /r r w br br/l y /r p /l w /g r /g br /l l /b o lg b g /y l /r b g /b r /y br /l r /b gy /r o /g l br /w p g /w l /wr /w gy p /w r /lc h y /l w l /y...

  • Page 359

    8-47 – + elec cooling system cooling system circuit diagram 4 main switch 5 main fuse 7 battery b engine stop switch h ecu (engine control unit) w coolant temperature sensor z frame ground k radiator fan motor l radiator fan motor relay n ignition fuse o radiator fan motor fuse.

  • Page 360

    8-48 – + elec cooling system troubleshooting check the main fuse, ignition fuse, and radiator fan motor fuse. Refer to “fuse inspection” in chapter 2. Check the battery. Refer to “battery inspection” in chapter 2. Check the engine stop switch and main switch. Refer to “ignition system”. Check the ra...

  • Page 361

    8-49 – + elec cooling system radiator fan motor 1. Disconnect: • radiator fan motor coupler 2. Connect: • battery (to the radiator fan motor coupler) 3. Inspect: • radiator fan motor does not move → replace the radiator fan motor. Positive battery terminal → blue 1 negative battery terminal → black ...

  • Page 362

    9-1 spec specifications general specifications model fx10/fx10rt/fx10rtr/fx10rtra/fx10mt/fx10mtr/ fx10mtra model code number: 8gl1 (fx10 “usa/canada”) 8gl2 (fx10 “europe”) 8hj1 (fx10rt “usa/canada”) 8hb1 (fx10rtr “usa/canada”) 8hb2 (fx10rtr “europe”) 8hb3 (fx10rtra “usa/canada”) 8hb4 (fx10rtra “euro...

  • Page 363

    9-2 spec general specifications engine: engine type liquid-cooled, 4-stroke, dohc cylinder arrangement backward-inclined parallel 3-cylinder displacement 1,049.0 cm 3 bore × stroke 82.0 × 66.2 mm (3.23 × 2.61 in) compression ratio 11.0 : 1 maximum hose power r/min 8,750 r/min maximum torque r/min 7,...

  • Page 364

    9-3 spec general specifications transmission: primary reduction system v-belt primary reduction ratio 3.80 ~ 1.00 : 1 clutch type automatic centrifugal engagement secondary reduction system chain secondary reduction ratio 1.86 (39/21) (fx10/fx10rt/fx10rtr/fx10rtra) 1.82 (40/22) (fx10mtr “europe”/fx1...

  • Page 365

    9-4 spec general specifications headlight bulb type: halogen bulb bulb wattage × quantity: headlight 12 v, 60/55 w × 2 tail/brake light led meter light led warning light led high beam indicator light led low coolant temperature indicator light led model fx10/fx10rt/fx10rtr/fx10rtra/fx10mt/fx10mtr/ f...

  • Page 366

    9-5 spec maintenance specifications maintenance specifications engine model fx10/fx10rt/fx10rtr/fx10rtra/fx10mt/fx10mtr/ fx10mtra cylinder head: volume (with spark plug) 25.21 ~ 26.01 cm 3 (1.54 ~ 1.59 cu.In) 0.10 mm (0.0039 in) lines indicate straight edge measurement. Cylinder: material aluminum a...

  • Page 367

    9-6 spec maintenance specifications valves, valve seats, valve guides: valve clearance (cold) intake 0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) exhaust 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) valve dimensions valve head diameter a intake 30.90 ~ 31.10 mm (1.2165 ~ 1.2244 in) exhaust 25.90 ~ 26.10 mm (1.0197 ~ ...

  • Page 368

    9-7 spec maintenance specifications valve spring: free length intake 39.57 mm (1.56 in) 37.59 mm (1.48 in) exhaust 39.57 mm (1.56 in) 37.59 mm (1.48 in) installed length (valve closed) intake 34.60 mm (1.36 in) exhaust 34.60 mm (1.36 in) compressed spring force (installed) intake 112.30 ~ 129.30 n (...

  • Page 369

    9-8 spec maintenance specifications piston ring: top ring ring type barrel dimensions (b × t) 1.00 × 2.80 mm (0.039 × 0.110 in) 2nd ring top ring (same or no) no ring type taper dimensions (b × t) 1.00 × 2.90 mm (0.039 × 0.114 in) oil ring dimensions (b × t) 1.50 × 2.50 mm (0.059 × 0.098 in) end gap...

  • Page 370

    9-9 spec maintenance specifications throttle body: type × quantity 41eidw × 2 manufacturer mikuni i.D. Mark 8gl1 00 throttle valve (th.V) 818-41005-100 ( θ = 10°) throttle cable free play 3.0 ~ 4.0 mm (0.12 ~ 0.16 in) engine idle speed 1,450 ~ 1,550 r/min fuel pump: type electrical model/manufacture...

  • Page 371

    9-10 spec maintenance specifications power train model fx10/fx10rt/fx10rtr/fx10rtra/fx10mt/fx10mtr/ fx10mtra transmission: type v-belt automatic range of ratio 3.80 ~ 1.00 : 1 engagement speed r/min 3,550 ~ 3,950 r/min (fx10/fx10rt/fx10rtr/fx10rtra) 3,300 ~ 3,700 r/min (fx10mt/fx10mtr “usa/canada”/ ...

  • Page 372

    9-11 spec maintenance specifications number of coils 4.92 (fx10/fx10rt/fx10rtr/fx10rtra) 5.08 (fx10mt/fx10mtr “usa/canada”/fx10mtra “usa/canada”) 5.64 (fx10mtr “europe”/fx10mtra “europe”) free length 87.4 mm (3.44 in) (fx10/fx10rt/fx10rtr/fx10rtra) 89.8 mm (3.54 in) (fx10mt/fx10mtr “usa/canada”/ fx1...

  • Page 373

    9-12 spec maintenance specifications secondary sheave spring: part number 90508-60012 color code pink outside diameter 69.5 mm (2.74 in) wire diameter 6.0 mm (0.236 in) hole position sheave side-spring seat side (twist angle) 2-6 (80°) (fx10/fx10rt/fx10rtr/fx10rtra) 1-6 (70°) (fx10mt/fx10mtr/fx10mtr...

  • Page 374

    9-13 spec maintenance specifications track: part number 8fa-47110-00 (fx10/fx10rt/fx10rtr/fx10rtra) 8ha-47110-00 (fx10mt/fx10mtr/fx10mtra) width 381.0 mm (15.0 in) length 3,072.4 mm (120.96 in) (fx10/fx10rt/fx10rtr/fx10rtra) 3,886.2 mm (153.00 in) (fx10mt/fx10mtr/fx10mtra) pitch 64.0 mm (2.52 in) (f...

  • Page 375

    9-14 spec maintenance specifications shock absorber: damping force front extension 1,373 n/0.3 m/s (140.0 kg/0.3 m/s, 308.6 lb/0.3 m/s) (fx10 “usa/canada”) 1,359 n/0.3 m/s (138.6 kg/0.3 m/s, 305.5 lb/0.3 m/s) (fx10 “europe”) 1,346 n/0.3 m/s (137.2 kg/0.3 m/s, 302.6 lb/0.3 m/s) (fx10rt/fx10rtr/fx10rt...

  • Page 376

    9-15 spec maintenance specifications slide runner: thickness 18.3 mm (0.72 in) wear limit 10.5 mm (0.41 in) track sprocket wheel: material ultra high molecular weight polyethylene number of teeth 9 t (fx10/fx10rt/fx10rtr/fx10rtra) 7 t (fx10mt/fx10mtr/fx10mtra) rear guide wheel: material high molecul...

  • Page 377

    9-16 spec maintenance specifications chassis model fx10/fx10rt/fx10rtr/fx10rtra/fx10mt/fx10mtr/ fx10mtra frame: frame material aluminum and steel seat height 770.0 mm (30.31 in) luggage box location front steering: lock-to-lock angle (left) 29.6° (r ski) 35.6° (l ski) (right) 35.6° (r ski) 29.6° (l ...

  • Page 378

    9-17 spec maintenance specifications shock absorber: damping force extension 1,371 n/0.3 m/s (139.8 kg/0.3 m/s, 308.2 lb/0.3 m/s) (fx10 “usa/canada”) 1,334 n/0.3 m/s (137.1 kg/0.3 m/s, 302.1 lb/0.3 m/s) (fx10 “europe”) 1,290 n/0.3 m/s (131.5 kg/0.3 m/s, 290.0 lb/0.3 m/s) (fx10rt/fx10rtr/fx10rtra) 1,...

  • Page 379

    9-18 spec maintenance specifications electrical model fx10/fx10rt/fx10rtr/fx10rtra/fx10mt/fx10mtr/ fx10mtra voltage 12 v ignition system: ignition timing (b.T.D.C.) 5.0° at 1,500 r/min advanced type digital type ignition coil: model/manufacturer f6t558/mitsubishi ignition spark gap 6.0 mm (0.24 in) ...

  • Page 380

    9-19 spec maintenance specifications t.P.S. (throttle position sensor): model/manufacturer 8gl/alps resistance 2.64 ~ 6.16 k Ω at 20 °c (68 °f) (blue – black/blue) oil level switch: model/manufacturer 8gl/asti fuel sender: model/manufacturer 8gl/nippon seiki sender resistance (full) 10 ~ 12 Ω at 20 ...

  • Page 381

    9-20 spec tightening torque tightening torque engine parts to be tightened tightening torque remarks nm m · kg ft · lb spark plug 13 1.3 9.4 cylinder head bolt (m10 × 1.25) see note. *1 apply the engine oil. Cylinder head bolt 12 1.2 8.7 cylinder head cover bolt 12 1.2 8.7 camshaft cap bolt 10 1.0 7...

  • Page 382

    9-21 spec tightening torque note: *1: tighten the cylinder head bolts to 25 nm (2.5 m · kg, 18 ft · lb) in the proper tightening sequence, loosen and retighten the cylinder head bolts to 25 nm (2.5 m · kg, 18 ft · lb) in the proper tightening sequence, and then tighten the cylinder head bolts furthe...

  • Page 383

    9-22 spec tightening torque power train parts to be tightened tightening torque remarks nm m · kg ft · lb primary sheave bolt see note. Spider and sliding sheave 200 20.0 145 left-hand thread. Apply loctite ® primary sheave cap and sliding sheave bolt 14 1.4 10 roller and weight nut (primary sheave)...

  • Page 384

    9-23 spec tightening torque slide runner and front pivot arm 10 1.0 7.2 (fx10/fx10rt/fx10rtr/ fx10rtra) apply loctite ® shaft and sliding frame bolt 72 7.2 52 (fx10/fx10rt/fx10rtr/ fx10rtra) apply loctite ® shaft and sliding frame bolt 60 6.0 43 (fx10mt/fx10mtr/fx10mtra) shock absorber and front piv...

  • Page 385

    9-24 spec tightening torque note: tightening steps: 1. Tighten the bolt to a torque at 120 nm (12.0 m · kg, 85 ft · lb). 2. Loosen the bolt completely. 3. Retighten the bolt to a torque of 60 nm (6.0 m · kg, 43 ft · lb). Control rod shaft and sliding frame 72 7.2 52 (fx10mt/fx10mtr/fx10mtra) rear ax...

  • Page 386

    9-25 spec tightening torque chassis parts to be tightened tightening torque remarks nm m · kg ft · lb headlight stay nut 4 0.4 2.9 front cover screw 7 0.7 5.1 lower cover bolt 7 0.7 5.1 front bumper bolt 23 2.3 17 seat bolt 23 2.3 17 rear upper cover screw 7 0.7 5.1 rear side cover bolt 8 0.8 5.8 ta...

  • Page 387

    9-26 spec general torque specifications/ definition of units general torque specifications this chart specifies torque for standard fasteners with standard i.S.O. Pitch threads. Torque specifi- cations for special components or assemblies are included in the applicable sections of this book. To avoi...

  • Page 388

    9-27 spec cable routing g k l n m p o i h j r 8 9 9 g 0 a b c d f e 1 2 3 4 5 6 7 q s t u v w x y z [ \ _ d ] a b c d e f j i h k l 6 m.

  • Page 389

    9-28 spec cable routing cable routing 1 ecu (engine control unit) 2 load control relay 3 headlight relay 4 fuel injection system relay 5 radiator fan motor relay 6 fasten the wire harness and sta- tor coil lead to the front frame with the plastic band. 7 to the left handlebar switch 8 to the ac magn...

  • Page 390

    9-29 spec cable routing g k l n m p o i h j r 8 9 9 g 0 a b c d f e 1 2 3 4 5 6 7 q s t u v w x y z [ \ _ d ] a b c d e f j i h k l 6 m.

  • Page 391

    9-30 spec cable routing r face the ends of each hose clamp toward the fuel tank. S fuel sender coupler t fasten the tail/brake light lead (wire harness side) to the frame rear cross member with the plas- tic band. U tail/brake light coupler v fuel pump lead w fasten the tail/brake light lead with th...

  • Page 392

    9-31 spec cable routing i h n o p j k l m q r s t u v w 9 a 0 b c d e f g 1 2 3 4 5 6 7 8 y z [ \ ] x _ a 2 b c d e f d a b b a.

  • Page 393

    9-32 spec cable routing 1 to the auxiliary dc jack (fx10mt/fx10mtr/ fx10mtra) 2 throttle cable 3 radiator fan motor coupler 4 wire harness 5 fuel injection system sub-wire harness coupler 6 speed sensor coupler 7 to the radiator fan motor 8 fasten the speed sensor lead to the frame rear cross member...

  • Page 394

    9-33 spec cable routing i h n o p j k l m q r s t u v w 9 a 0 b c d e f g 1 2 3 4 5 6 7 8 y z [ \ ] x _ a 2 b c d e f d a b b a.

  • Page 395

    9-34 spec cable routing p rectifier/regulator lead q rectifier/regulator r route the coolant reservoir breather hose above the coolant reservoir check window. S ecu (engine control unit) t fasten the coolant reservoir breather hose to the front frame with the plastic band, making sure not to pinch t...

  • Page 396

    9-35 spec cable routing b c d e f g h i j 9 0 a 2 3 4 5 7 6 1 8 k q m l n o p r s t u x w v y z [ \ ] 1 a _ b c d t f g d 8 h e a-a b-b a b b a.

  • Page 397

    9-36 spec cable routing 1 fasten the wire harness to the frame rear cross member with the plastic band. Face the end of the plastic band downward. 2 positive battery lead 3 coolant reservoir hose 4 to the main switch 5 to the brake master cylinder 6 brake hose 7 to the parking brake lever 8 parking ...

  • Page 398

    9-37 spec cable routing b c d e f g h i j 9 0 a 2 3 4 5 7 6 1 8 k q m l n o p r s t u x w v y z [ \ ] 1 a _ b c d t f g d 8 h e a-a b-b a b b a.

  • Page 399

    9-38 spec r make sure that the catch of the holder is facing downward. (fx10/fx10rtr/fx10rtra/ fx10mtr/fx10mtra) s dc back buzzer (fx10/ fx10rtr/fx10rtra/ fx10mtr/fx10mtra) t fuse box u pass the wire harness and dc back buzzer lead through the guide, making sure that the guide is positioned to the f...

  • Page 400

    9-39 spec cable routing g h i j k l l m a 0 0 0 b c d e h 9 f 1 1 2 3 4 5 6 9 o p l 2 6 1 m l 1 6 2 n m a-a a a 8 7.

  • Page 401

    9-40 spec cable routing 1 corrugated tube (left grip warmer lead, grip/thumb warmer adjust- ment switch lead, brake light switch lead, and headlight beam switch lead) 2 parking brake cable 3 brake master cylinder 4 left handlebar switch 5 left grip warmer lead 6 brake hose 7 route the brake hose beh...

  • Page 402

    9-41 spec cable routing g h i j k l l m a 0 0 0 b c d e h 9 f 1 1 2 3 4 5 6 9 o p l 2 6 1 m l 1 6 2 n m a-a a a 8 7.

  • Page 403

    9-42 spec cable routing n fasten the corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead), cor- rugated tube (engine stop switch lead, throttle switch leads, right grip warmer lead, and thumb warmer lead), and brak...

  • Page 404

    9-43 spec cable routing 9 1 2 3 4 5 6 6 7 7 8.

  • Page 405

    9-44 spec cable routing 1 fasten the tail/brake light lead with the holder, making sure to push the lead against the fuel tank. 2 fasten the tail/brake light lead with the holder. 3 tail/brake light lead 4 after routing the tail/brake light lead, bend the holder around the lead to fasten it. 5 faste...

  • Page 408: Fx10X

    Service manual fx10x fx10rtx fx10rtrx fx10rtrax fx10mtx fx10mtrx fx10mtrax lit-12618-02-69 8gl-28197-10 printed on recycled paper printed in u.S.A. 2007.07 cr (e) yamaha motor co., ltd. 2008.

  • Page 409

    Wiring diagram fx10/fx10rt/fx10rtr/fx10rtra/fx10mt/fx10mtr/ fx10mtra 2008 8gl-0f001-00/8ha-0f001-00 1 rectifier/regulator 2 ac magneto 3 crankshaft posi- tion sensor 4 main switch 5 main fuse 6 load control relay 7 battery 8 starter motor 9 starter relay 0 fuel injection sys- tem fuse a diode b engi...

  • Page 410

    Wiring diagram fx10/fx10rt/fx10rtr/fx10rtra/fx10mt/fx10mtr/fx10mtra 2008 8gl-0f001-00/8ha-0f001-00 r/w l/w (black) l/w r/g r/w l/w y lg g (black) b br/b l r/w g/y r/g r/l r/w l/r r w br br/l y/r p/l w/g r/g br/l l/b o lg b g/y l/r b g/b r/y br/l r/b gy/r o/g l br/w p g/w l/w r/w gy p/w r/l ch y/l w ...

  • Page 411

    Wiring diagram fx10/fx10rt/fx10rtr/fx10rtra/fx10mt/fx10mtr/fx10mtra 2008 8gl-0f001-00/8ha-0f001-00 (black) (black) hi lo (black) (black) off on start run stop off on close open (gray) (gray) (black) (black) (black) (black) (black) (black) (black) (black) (black) (gray) (gray) (gray) (black) (black) ...