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Yamaha VK540EK Owner's Manual - Periodic Maintenance

Summary of VK540EK

  • Page 1

    Owner’s manual snowmobile vk540ek 8ac-28199-1b lit-12628-02-34 printed on recycled paper printed in japan 2004.04-0.3 ×1 cr (e) yamaha motor co., ltd..

  • Page 3: Machine Identification

    Esu02860 machine identification identification number records a. Frame number: cz-01e b. Engine number (primary id): cz-01e c. Key number: cz-01e record the frame number, engine number (primary id), and key number in the spaces provided for assistance when ordering spare parts from a yamaha dealer. ...

  • Page 4: Introduction

    Esu00011 introduction congratulations on your purchase of a yamaha snowmo- bile. This model is the result of yamaha’s vast experience in the production of fine sporting and touring snowmo- biles. It represents the high degree of craftsmanship and reliability that have made yamaha a leader in these f...

  • Page 5: Warning

    Warning @ please read and understand this manual completely before operating the snowmo- bile. @ note: @ ● yamaha continually seeks advancements in product design and quality. Therefore, while this manual con- tains the most current product information available at the time of printing, there may be...

  • Page 6: Contents

    Esu00030 contents yamaha motor corporation, u.S.A. Snowmobile limited warranty .......................................1-1 yamaha extended service (y.E.S.) ...............................................1-4 location of the important labels..............................................2-1 safety infor...

  • Page 7

    Throttle cable adjustment ................8-6 oil pump cable adjustment ..............8-6 carburetor adjustment.....................8-7 high altitude adjustments ................8-9 checking the fan belt deflection ....8-10 v-belt replacement ........................8-11 checking the drive chain hou...

  • Page 8: Bile Limited Warranty

    1-1 esu00040 1- yamaha motor corporation, u.S.A. Snowmo- bile limited warranty cw-01e u8ac1b.Book page 1 thursday, april 8, 2004 12:57 pm.

  • Page 9

    1-2 cw-02e u8ac1b.Book page 2 thursday, april 8, 2004 12:57 pm.

  • Page 10

    1-3 cw-03e u8ac1b.Book page 3 thursday, april 8, 2004 12:57 pm.

  • Page 11

    1-4 esu04280 yamaha extended service (y.E.S.) cw-06e u8ac1b.Book page 4 thursday, april 8, 2004 12:57 pm.

  • Page 12: Location of The Important

    2-1 esu00070 2- location of the important labels please read the following labels carefully before operat- ing this snowmobile. Note: @ maintain or replace safety and instruction labels, as nec- essary. @ 1 2 3 avertissement warning severe injury or death may result if you ignore any of the followin...

  • Page 13: Safety Information

    3-1 esu00101 3- safety information when you ride your snowmobile, you must know and use the following for your safety. Severe injury or death may result if you ignore any of the following. Before operating 1. Read the owner’s manual and all labels before oper- ating this snowmobile. Become familiar ...

  • Page 14

    3-2 7. Handle fuel with care; it is highly flammable. ● never add fuel when the engine is running or hot. Allow the engine to cool for several minutes after running. ● use an approved fuel container. ● fill the fuel tank outdoors with extreme care. Never remove the fuel cap indoors. Never fill the f...

  • Page 15

    3-3 3. This snowmobile is not designed for use on surfaces other than snow or ice. Use on dirt, sand, grass, rocks, or bare pavement may cause loss of control and may damage the snowmobile. 4. Avoid operating on glare ice, or on snow which has a lot of dirt or sand mixed in. Operation under such con...

  • Page 16: Description

    4-1 esu00120 4- description 1 windshield 2 steering handlebar 3 seat 4 drive track 5 slide rail suspension 6 frame 7 telescopic strut suspension 8 skis 9 headlight 0 engine compartment plate a shroud b tail/brake light c snow flap d tow hitch e storage compartment f headlight adjusting knob g engine...

  • Page 17: Control Functions

    5-1 esu00130 5- control functions esu00180 main switch the main switch controls the following items. 1 “off” the ignition circuit is switched off. The key can be removed only in this position. 2 “on” the ignition circuit is switched on. The engine can be started. Note: @ the headlight, meter lights,...

  • Page 18: Warning

    5-2 esu00220 throttle lever once the engine is running cleanly, squeezing a the throt- tle lever 1 will increase the engine speed and cause engagement of the drive system. Regulate the speed of the snowmobile by varying the throttle position. Because the throttle is spring-loaded, the snowmobile wil...

  • Page 19: Caution:

    5-3 esu00310 engine stop switch the engine stop switch 1 is used to stop the engine in an emergency. Simply push 2 the stop switch to stop the engine. To start the engine, pull 3 the stop switch and proceed with starting the engine. (see page 7-1 for more details.) during the first few rides, practi...

  • Page 20: Warning

    5-4 esu00341 parking brake button when parking the snowmobile or starting the engine, apply the parking brake. Squeeze the brake lever 1, push and hold the parking brake button 2 down 3, and then release the brake lever. To release the parking brake, squeeze the brake lever. Warning @ ● always set t...

  • Page 21

    5-5 esu00390 headlight beam switch push the headlight beam switch to change the headlight beam to high or low. 1 headlight beam switch 2 push 3 high beam 4 low beam esu00401 headlight adjusting knob use the headlight adjusting knob to adjust the headlight vertically. Headlight beam moves: 1 up 2 dow...

  • Page 22: Caution:

    5-6 esu00481 shroud latches to open the shroud, unhook the shroud latches, and then slowly raise the shroud forward until it stops. When clos- ing the shroud, slowly lower it to its home position, and then hook the shroud latches. 1 shroud latch 2 shroud caution: @ make sure that all cables and wire...

  • Page 23: Caution:

    5-7 esu00641 engine compartment plates this snowmobile is equipped with an engine compart- ment plate 1 in the shroud that can be opened and engine compartment plates 2 in the belly pan that can be removed to cool down the engine. Caution: @ ● make sure that the engine compartment plate in the shrou...

  • Page 24: Caution:

    5-8 esu00712 tow hitch use the tow hitch within the specified weight limits. 1 tow hitch caution: @ avoid towing for long periods under 10 km/h (6.2 mph) to prevent early wear of the v-belt. @ tow weight limit: 120 kg (265 lb) vertical weight limit: 15 kg (33.1 lb) u8ac1b.Book page 8 thursday, april...

  • Page 25: Pre-Operation Checks

    6-1 esu00720 6- pre-operation checks note: @ pre-operation checks should be made each time the snowmobile is used. @ warning @ the engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing ...

  • Page 26: Caution:

    6-2 caution: @ ● oxygenated fuels (gasohol) containing a maxi- mum 5% of ethanol can be used, although richer jetting may be required to prevent engine dam- age. Consult a yamaha dealer. Gasohol contain- ing methanol is not recommended. ● make sure that snow or ice do not enter the fuel tank when re...

  • Page 27: Warning

    6-3 esu00890 throttle override system (t.O.R.S.) check the t.O.R.S. For proper operation. Warning @ when checking t.O.R.S.: ● make sure that the parking brake is applied. ● make sure that the throttle lever moves smoothly. ● do not run the engine up to clutch engagement r/min. Otherwise, the snowmob...

  • Page 28: Warning

    6-4 esu00921 brake test the brake at a low speed when starting out to make sure that it is working properly. If the brake does not pro- vide proper braking performance, inspect the brake for wear. (see page 8-14 for more details.) warning @ do not operate the snowmobile if you find any prob- lems in...

  • Page 29: Warning

    6-5 esu03990 drive guard check the drive guard mounts for damage. Make sure that the wing bolt is tightened securely and the drive guard is firmly in place. Esu00970 drive track check the drive track for deflection, wear, or damage. Adjust or replace if necessary. (see pages 8-18–8-20 for more detai...

  • Page 30: Caution:

    6-6 esu01020 skis and ski runners check the skis and ski runners for wear and damage. Replace if necessary. Caution: @ avoid scratching the skis when loading and unload- ing the snowmobile, when riding in areas with little or no snow, or on sharp edges such as concrete, curbs, etc. This will wear or...

  • Page 31

    6-7 esu01111 tool kit and recommended equipment it is good practice to carry the tool kit, spare parts, and other necessary equipment with you while riding the snowmobile so that minor repairs can be done if neces- sary. The following should be carried at all times: ● tool kit ● flashlight ● roll of...

  • Page 32: Operation

    7-1 esu01120 7- operation esu01140 starting the engine warning @ ● be sure to check the “safety information” section carefully before starting the engine. ● make sure that the parking brake is applied. @ note: @ make sure that the engine stop switch is in the on posi- tion. @ 1. Fully open the start...

  • Page 33

    7-2 esu01202 emergency engine starting 1. Proceed with item 1. In “starting the engine”. 2. Turn the main switch to the “on” position. 1 “on” 3. Pull slowly on the recoil starter until it is engaged, then pull it briskly. After the engine starts, put the starter lever (choke) in the half-open positi...

  • Page 34: Warning

    7-3 esu02733 riding your snowmobile getting to know your snowmobile a snowmobile is a rider active vehicle, and your riding position and your balance are the two basic factors of maneuvering your snowmobile. Riding your snowmobile requires skills acquired through practice over a period of time. Take...

  • Page 35: Warning

    7-4 ● improper use of the brake can cause the drive track to lose traction, reduce control, and increase the possibility of an accident. @ turning for most snow surfaces, “body english” is the key to turning. As you approach a curve, slow down and begin to turn the handlebar in the desired direction...

  • Page 36: Warning

    7-5 riding downhill when riding downhill, keep speed to a min- imum. It is important to apply just enough throttle to keep the clutch engaged while descending the hill. This will allow you to use engine compression to help slow the snowmobile, and to keep the snowmobile from rolling freely down the ...

  • Page 37: Warning

    7-6 hard-packed snow it can be more difficult to negotiate on hard-packed snow as both the skis and drive track do not have as much traction as when the snowmobile is operated on fresh snow. Avoid rapid acceleration, turning, and braking. Operation on surfaces other than snow or ice operation of you...

  • Page 38

    7-7 esu02510 maximizing drive track life recommendations track tension during initial break-in, the new drive track will tend to stretch quickly as the track settles. Be sure to correct the track tension and alignment frequently. (see pages 8-18–8-20 for adjustment procedures.) a loose track can sli...

  • Page 39: Warning

    7-8 esu03381 driving warning @ be sure to read the “safety information” and “riding your snowmobile” sections carefully before operating the snowmobile. @ note: @ make sure that the engine is warmed up enough before riding. @ 1. Select the desired operating position by moving the drive select lever....

  • Page 40: Warning

    7-9 6. Apply the parking brake — squeeze the brake lever, push and hold the parking brake button down, and then release the brake lever. Esu01360 stopping the engine turn the main switch to the “off” position to stop the engine. 1 “off” warning @ ● push down the engine stop switch to stop the engine...

  • Page 41

    7-10 esu01380 transporting when transporting your snowmobile on a trailer or in a truck, observe the following recommendations to help protect it from damage: ● make sure that the fuel level in the fuel tank is lower than the bottom of the carburetors. Otherwise, the vibration and bumps from the roa...

  • Page 42: Periodic Maintenance

    8-1 esu01390 8- periodic maintenance esu02621 periodic maintenance chart regular maintenance is most important for best performance and safe operation. Cd-01e item remarks pre- operation check (daily) initial 1 month or 800 km (500 mi) (40 hr) every page seasonally or 3,200 km (2,000 mi) (160 hr) sp...

  • Page 43

    8-2 ∗ exhaust system check for leakage. Tighten or replace gasket if necessary. ● ∗ decarbonization more frequently if necessary. ● drive guard check for cracks, bends or damage. ∗ replace if necessary. ● 5-6, 6-5 v-belt check for wear and damage. Replace if necessary. ● 6-4, 8-11–8-12 drive track a...

  • Page 44

    8-3 ∗ primary and second- ary clutches check engagement and shift speed. Adjust if necessary. ● whenever operating elevation is changed. Inspect sheaves for wear/ damage. Inspect weights/rollers and bushings for wear-for primary. Inspect ramp shoes/bushings for wear-for secondary. Replace if necessa...

  • Page 45: Caution:

    8-4 esu01430 tool kit the owner’s tool kit has the tools which are sufficient for most periodic maintenance and minor repair. A torque wrench is also necessary to properly tighten nuts and bolts. 1 tool kit caution: @ before starting the engine, make sure that the tool kit is firmly seated in the ho...

  • Page 46: Caution:

    8-5 spark plugs are produced in several different thread lengths. The thread length or reach is the distance from the spark plug gasket seat to the end of the threaded portion. If the reach is too long, overheating and engine damage may result. If the reach is too short, spark plug fouling and poor ...

  • Page 47: Caution:

    8-6 esu01471 throttle cable adjustment caution: @ be sure to adjust the engine idle speed first. @ 1. Loosen the locknut. 2. Turn the adjuster in or out until the proper throttle lever free play is achieved. 1 locknut 2 adjuster 3. Tighten the locknut. Esu01491 oil pump cable adjustment caution: @ b...

  • Page 48: Caution:

    8-7 esu01523 carburetor adjustment caution: @ ● be sure to have a yamaha dealer make this adjustment. ● make sure that the carburetor silencer is installed before running to prevent engine damage. @ under some operating conditions, the carburetor setting may have to be changed due to air temperature...

  • Page 49: Warning

    8-8 main jet replacement replace the main jet according to the setting chart which is available at a yamaha dealer. Warning @ ● never remove the drain plug or the float chamber while the engine is hot. Fuel will flow out from the float chamber which could ignite and cause injury. ● place a rag under...

  • Page 50: Caution:

    8-9 esu01570 high altitude adjustments operating at high altitude reduces the performance of a gasoline engine to about 3% for every 305 m (1,000 ft) of elevation. This is because there is less air as altitude increases. Less air means less oxygen available for com- bustion. Your snowmobile can be a...

  • Page 51

    8-10 esu01621 checking the fan belt deflection 1. Remove the fan cover. 2. Measure the fan belt deflection by applying 50 n (5 kg, 11 lb) of force at the center of belt. 1 deflection 2 50 n (5 kg, 11 lb) if the deflection exceeds the specification, consult a yamaha dealer. Standard belt deflection: ...

  • Page 52: Warning

    8-11 esu01645 v-belt replacement warning @ ● when replacing the v-belt, make sure that the two spacers 1 are installed between the secondary fixed sheave and the secondary sliding sheave. If the spacers are not positioned correctly, the v- belt clutch engagement speed will be changed and the snowmob...

  • Page 53: Warning

    8-12 note: @ apply the parking brake before replacing the v-belt. @ 1. Remove the drive guard. 2. Rotate the secondary sliding sheave clockwise 1 and push 2 it so that it separates from the secondary fixed sheave. 3. Pull 3 the v-belt up over the secondary fixed sheave. 4. Remove the v-belt from the...

  • Page 54: Caution:

    8-13 esu01674 checking the drive chain housing oil level and the drive chain tension oil level check 1. Check the oil level by removing the oil level check bolt 1 and filler cap 2. The oil level is correct if a small amount of oil flows out of the oil level check hole. 2. If no oil flows out of the ...

  • Page 55: Warning

    8-14 esu01762 checking the brake pads check the brake pads for wear by measuring the thick- ness of each pad. If the brake pads reach the wear limit, have a yamaha dealer replace them. Adjustment this snowmobile has a self-adjusting brake caliper. No adjustment is necessary under normal conditions. ...

  • Page 56: Warning

    8-15 spring preload adjustment the spring preload can be adjusted by turning the adjuster 1. Cd-13e cd-14e warning @ this shock absorber contains highly pressurized nitrogen gas. It could explode by improper handling, causing injury or property damage. ● do not tamper with or attempt to open the sho...

  • Page 57: Caution:

    8-16 extension spring preload adjustment adjust the extension spring preload by turning the adjuster 1. Cd-22e caution: @ be sure the left and right extension spring preloads are the same. Uneven settings can cause loss of sta- bility. @ adjuster turn in turn out preload hard soft snow condition icy...

  • Page 58: Warning

    8-17 esu01973 rear suspension full rate adjustment the total suspension spring rate and damping character- istics can be adjusted by changing the installed position of the shock absorber. Warning @ be sure to have a yamaha dealer make this adjust- ment. @ cd-07e note: @ be sure to make this adjustme...

  • Page 59: Warning

    8-18 esu03530 drive track adjustment warning @ a broken track, track fittings or debris thrown by the drive track could be dangerous to an operator or bystanders. Observe the following precautions: ● do not allow anyone to stand behind the snow- mobile when the engine is running. ● when the rear of ...

  • Page 60: Warning

    8-19 drive track adjustment warning @ ● be sure to have a yamaha dealer make this adjustment. ● support the snowmobile securely on a suitable stand before working underneath the snowmo- bile. ● operate the engine in a well-ventilated area. @ 1. Lift the rear of the snowmobile onto a suitable stand t...

  • Page 61

    8-20 6. Recheck alignment and deflection. If necessary, repeat steps 3 to 5 until the proper adjustment is achieved. 7. Tighten the rear axle nut. Esu02000 ski alignment 1. Turn the handlebar so the skis face straight ahead. 2. Check the following for ski alignment: a. Skis are facing forward. B. Sk...

  • Page 62: Caution:

    8-21 esu02011 handlebar adjustment 1. Remove the handlebar cover 1. 2. Loosen the handlebar bolts. Move the handlebar up or down to adjust the handlebar height to the desired position. 3. Tighten the handlebar bolts and install the handlebar cover. Caution: @ make sure that the small gap a side of t...

  • Page 63: Warning

    8-22 esu02042 lubrication lubricate the following points. 1 brake/throttle cable ends warning @ apply a dab of grease onto the cable ends only. Do not grease the brake and throttle cables themselves because they could become frozen, which could cause loss of control. @ 2 front suspension 3 rear susp...

  • Page 64: Warning

    8-23 esu02112 headlight bulb replacement 1. Lift up the shroud. 2. Disconnect the lead coupler. 3. Remove the socket cover and bulb set spring. 1 socket cover 4. Remove the bulb. Warning @ keep flammable products or your hands away from the hot bulb until it cools down. @ 5. Install the new bulb. Ca...

  • Page 65: Caution:

    8-24 esu02130 battery replenishing the battery fluid 1. Check the fluid level. The level should be between the upper and lower level marks. A “upper level” b “lower level” 2. Add only distilled water if necessary. Caution: @ normal tap water contains minerals which are harm- ful to a battery; theref...

  • Page 66: Warning

    8-25 esu03071 fuse replacement warning @ be sure to use the specified fuse. A wrong fuse will cause electrical system damage and a fire haz- ard. @ caution: @ make sure that the main switch is turned off to pre- vent accidental short circuiting. @ 1. Lift up the shroud. 2. Replace the blown fuse wit...

  • Page 67: Troubleshooting

    9-1 esu02773 9- troubleshooting a. Engine turns over but does not start 1. Fuel system no fuel supplied to combustion cham- ber ● no fuel in tank ... Supply fuel. ● clogged fuel line ... Clean fuel line. ● clogged carburetor ... Clean carbure- tor. Fuel supplied to combustion chamber ● flooded engin...

  • Page 68

    9-2 e. Engine constantly backfires or mis- fires 1. Faulty spark plugs ... Replace the spark plugs. 2. Clogged fuel system ... See a.1. Above. 3. Malfunctioning t.O.R.S. System ... See a.2. Above. F. Snowmobile does not move 1. Malfunctioning v-belt clutch ... Ask a yamaha dealer to inspect. 2. Driv...

  • Page 69: Storage

    10-1 esu02523 10- storage long-term storage requires some preven- tive procedures to guard against deteriora- tion. 1. Cleaning thoroughly clean the snowmobile, inside and out, to remove the corrosive salts and acids that can accumulate. Use yamaha mud, grease, and engine cleaner, or an equivalent p...

  • Page 70: Warning

    10-2 warning @ ● never smoke around the battery while it is being charged. Sparks may ignite the hydrogen gas created by the battery. ● never connect to or disconnect the battery from the snowmobile while it is being charged. Sparks may ignite the hydrogen gas created by the bat- tery. ● make sure t...

  • Page 71: Specifications

    11-1 esu02280 11- specifications esu02290 dimensions cs-01e esu02300 engine cs-02e vk540e overall length 3,125 mm (123.0 in) overall width 1,140 mm ( 44.9 in) overall height 1,350 mm ( 53.1 in) dry weight 289 kg ( 637 lb) ski tread 960 mm ( 37.8 in) vk540e type axial fan cooled 2-stroke, 7-port cyli...

  • Page 72

    11-2 esu02310 chassis cs-03e vk540e drive track and suspension: track molded rubber, fiber glass rod reinforced width 500 mm (19.7 in) track deflection 35–45 mm (1.38–1.77 in)/ 100 n (10 kg, 22 lb) length on ground 1,204 mm (47.4 in) suspension type slide rail suspension drive sprocket triple polyet...

  • Page 73

    11-3 esu02320 electric cs-04e vk540e ignition system cdi spark plug type br9es (ngk) gap 0.7–0.8 mm (0.028–0.031 in) battery capacity yb16al-a2/12 v 16 a·h maximum charge rate 1.6 amperes/hr for 10 hrs headlight bulb × quantity 12 v, 60/55 w × 1 tail/brake light bulb × quantity 12 v, 8/23 w × 1 mete...

  • Page 74: Wiring Dia

    12-1 es u0233 0 1- wiring dia g ram b /w y /b r br w /r w lb w /r w y b r w w r br b /y b r w /r b /y b /w ch w /r y /b rr l /w r /w b r /w off on start r r /w b b /w br r r /w br b /w b on off run off b y /r b w b /wb /y ch b /yb /w b off on y /r y /b y /r y /b on off lo hi off on g y l y g l g /y ...

  • Page 75

    12-2 1 cdi magn eto 2 r e ct if ie r 3 fuse 4 ba tt er y 5 st ar te r re la y 6 st ar te r mo to r 7 ma in s w itch 8 en gin e stop s witch 9 t h rottle s witch 0 carb uretor s w it ch a cdi un it b ign ition coi l c gr ip and thumb w a rm er s w itch d gr ip w a rm er (l eft) e gr ip w a rm er (r i...

  • Page 76: Owner’S Manual

    Owner’s manual snowmobile vk540ek 8ac-28199-1b lit-12628-02-34 printed on recycled paper printed in japan 2004.04-0.3 ×1 cr (e) yamaha motor co., ltd..