Yamaha RS90NL, Owner'S Manual

Page 1: ...OWNER S MANUAL SNOWMOBILE RS90NL...

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Page 3: ...ary ID and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer 1 The frame number is the seventeen digit number stamped on the frame of the snowmobile See f...

Page 4: ...y questions concerning the operation or maintenance of your snowmobile please consult a Yamaha dealer To maintain the high quality and performance of this snowmobile it is important that you and your...

Page 5: ...ual should be considered a permanent part of this snowmobile and should remain with the snow mobile when resold Particularly important information is distinguished in this manual by the following nota...

Page 6: ...Shift lever 5 9 Headlight beam switch 5 10 Auxiliary DC jack 5 10 Shroud latches 5 11 Drive guard 5 11 V belt holders 5 11 Carburetor coolant shut off lever 5 12 Rear suspension damping force remote a...

Page 7: ...8 7 Adjusting the high altitude settings 8 8 Adjusting the valve clearance 8 8 Changing the engine oil 8 9 Cooling system 8 12 Replacing the V belt 8 14 Checking the drive chain housing oil level and...

Page 8: ...parts replaced due to normal wear or routine maintenance including oil spark plugs clutch drive belts slide runners and track THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate a...

Page 9: ...mages as well as oil spark plugs clutch drive belts and slide runners Q What are some examples of abnormal strain ne glect or abuse A These terms are general and overlap each other in areas Specific e...

Page 10: ...dealer ship Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YA...

Page 11: ...1 4 ESU04280 YAMAHA EXTENDED SERVICE Y E S CW 06E...

Page 12: ...MPORTANT LABELS Please read the following labels carefully before operat ing this snowmobile NOTE Maintain or replace safety and instruction labels as nec essary 1 RS90N RS90M 1 RS90R RS90NR RS90GT RS...

Page 13: ...er battery service or air box removal See Service Manual Des dommages graves risquent de survenir par suite de fuites d huile r sultant d un mauvais branchement des tuyaux de reniflard du carter Apr s...

Page 14: ...2 3 8 RS90M RSG90...

Page 15: ...2 4 NOTE The following suspension adjustment charts are included with the Owner s Manual RS90M RS90R RS90GT RSG90...

Page 16: ...snowmobile is designed to carry the OPERA TOR ONLY Passengers are prohibited Carrying a passenger can cause loss of control 4 Do not operate the snowmobile after drinking alcohol or taking drugs Your...

Page 17: ...inhale a lot of gasoline vapor or get some gasoline into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash your skin with soap and water and change...

Page 18: ...most surfaces is to release the throttle and apply the brake gently not suddenly Maintenance and storage 1 Do not leave the snowmobile on its left side for an extended period of time Fuel may leak ou...

Page 19: ...4 1 ESU00012 4 DESCRIPTION RS90N RS90NR RS90M RSG90 RS90R RS90GT...

Page 20: ...e stop switch J Thumb warmer adjustment switch K Throttle lever L Shift lever RS90R RS90NR RS90GT RSG90 M Shroud latch N Main switch O Auxiliary DC jack RS90GT P Starter lever Q Tachometer R Low coola...

Page 21: ...rcuit is switched off The key can be removed only in this position 2 ON The ignition circuit is switched on 3 START The starting circuit is switched on The starter motor starts CAUTION Release the swi...

Page 22: ...e snowmobile by varying the throttle position Because the throttle is spring loaded the snowmobile will deceler ate and the engine will return to idle when it is released b WARNING Check the throttle...

Page 23: ...engine can be operated without a prob lem before restarting the engine Be sure to use the specified spark plug and spark plug cap Otherwise the T O R S will not work properly CA 19E Idling starting R...

Page 24: ...2 the warning light 3 and all segments of the meter 4 turn on and off once The grip warmer level is initially displayed for 5 seconds then switches to the fuel meter display Odometer and tripmeter mo...

Page 25: ...mer adjustment switch 2 control the electrically heated handlebar grips and throttle lever respectively To raise the temperature press each switch to HI To lower the temperature press each switch to L...

Page 26: ...light go off the engine oil level is sufficient however it is getting low Add engine oil as soon as possible If the oil level warning indicator and the warning light do not go off check the engine oi...

Page 27: ...he warning light 1 and the self diagnosis warning indicator 2 will flash and then an error code e g 16 and 81 3 will flash slowly in the tripmeter odometer display WARNING If the self diagnosis warnin...

Page 28: ...he handlebar grip to stop the snowmobile 1 Brake lever 2 Brake lever end 3 Handlebar end NOTE When the brake lever is operated the brake light will illu minate CAUTION Make sure that the brake lever e...

Page 29: ...the snowmobile with the parking brake applied This may overheat the brake disc and reduce braking ability ESU00341 Shift lever For RS90R RS90NR RS90GT RSG90 The shift lever is used to put the snowmob...

Page 30: ...e auxiliary DC jack cap 1 and then insert the accessory power plug into the jack 2 NOTE After using the auxiliary DC jack be sure to remove the accessory power plug from the jack and close the auxil i...

Page 31: ...our body and clothing away from rotating parts when servicing with the shroud open Do not touch the hot muffler and engine during or immediately after operation ESU00521 Drive guard The drive guard is...

Page 32: ...bile in temperatures above 0 C 32 F move the carburetor coolant shut off lever to the OFF position to stop the flow of coolant since the carburetor does not need to be warmed ESU04130 Rear suspension...

Page 33: ...el in the fuel tank WARNING Fuel is HIGHLY FLAMMABLE and poisonous Check the SAFETY INFORMATION section carefully before refueling See page 3 2 Do not fill the fuel tank above the bottom of the filler...

Page 34: ...t snow or ice does not enter the fuel tank when refueling Do not use alcohol deicers or water absorbing additives with oxygenated fuel The fuel tank should be filled with straight gaso line as specifi...

Page 35: ...ing it off 3 Disconnect the oil level gauge coupler 1 CAUTION Disconnect the oil level gauge coupler before remov ing the oil level gauge dipstick Otherwise the cable can twist and break 4 Remove the...

Page 36: ...cold If the coolant level is below the COLD LEVEL mark add soft water until it reaches the COLD LEVEL mark See pages 8 12 8 13 for more details 1 COLD LEVEL mark WARNING Do not remove the coolant res...

Page 37: ...le could start moving forward unexpectedly which could cause an accident 1 Start the engine NOTE Refer to the Starting the engine section 2 Hold the pivot point of the throttle lever away from the thr...

Page 38: ...ates a failure in the brake system Do not operate the snowmobile if you find any problems in the brake system You could lose braking ability which could lead to an accident Ask a Yamaha dealer to insp...

Page 39: ...tic parts Never spill any brake fluid If any is spilled clean it up immediately ESU00941 V belt Open the shroud and remove the drive guard Check the V belt for wear and damage Replace if neces sary WA...

Page 40: ...243 51 mm 2 0 in high profile pattern drive track For RS90M This snowmobile is originally equipped with a 51 mm 2 0 in high profile pattern drive track specifically for use in deep snow riding conditi...

Page 41: ...i 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 sn...

Page 42: ...ere is no snow under the air filter element frame 1 Unhook the air filter case cover fasteners and the latch 2 Remove the air filter case cover 3 Lift up the air filter element frame and check the air...

Page 43: ...actice 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...

Page 44: ...warm engine starting NOTE The starter lever choke is not required when the engine is warm Put the starter lever choke in the closed posi tion 2 Turn the main switch to the START position After the eng...

Page 45: ...l throttle operation or any condition that might result in engine overheating must be avoided Operating your snowmobile for the first time Start the engine and let it idle for 15 minutes 0 160 km 0 10...

Page 46: ...ed with added safety and a more reliable snowmobile Always wear the proper cloth ing for both warmth and to help protect you from injury if an accident occurs Become familiar with operating your snow...

Page 47: ...thor oughly familiar with the operation of your snowmobile Riding uphill You should practice first on gentle slopes Try more difficult climbs only after you have developed your skill As you approach a...

Page 48: ...ur downhill leg on the seat and the foot of your uphill leg on the running board This position will make it easier for you to shift your body weight as needed Snow and ice are slippery so be prepared...

Page 49: ...s 2 Snow mixed with a lot of dirt and sand All of the above surfaces have one thing in common in regard to drive track and slide runners little or no lubricating ability Drive track and all slide rail...

Page 50: ...rheating avoid sustained high speed usage in areas such as icy trails frozen lakes and rivers that have minimal snow coverage An overheated track will be weakened internally which may cause fail ure o...

Page 51: ...ntain balance during traverse side hill riding Only experi enced operators should traverse slopes steep enough to require strap use Keep the right hand on the right handlebar grip for steering and gri...

Page 52: ...rking brake by moving the parking brake lever to the left For RS90R RS90NR RS90GT RSG90 1 To select the desired operating position pull the shift lever out slide it to FWD or to REV until it stops and...

Page 53: ...r slowly to move the snowmo bile 4 Turn the handlebar in the desired direction 5 Squeeze the brake lever to stop the snowmobile 6 Apply the parking brake by moving the parking brake lever to the left...

Page 54: ...hydrostatic lock When possible the fuel tank should be empty during transportation especially if the trip takes longer than 30 minutes If transporting the snowmobile in an open trailer or truck put a...

Page 55: ...ONTROL THESE SER VICES NOT ONLY ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERI ODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS...

Page 56: ...4 Replace 8 9 8 11 Engine oil filter cartridge Replace Every 20 000 km 12 000 mi 8 9 8 11 Fuel Check fuel level 6 1 6 2 Engine coolant Check coolant level 6 4 Air bleed the cooling system if necessary...

Page 57: ...slight free play Lubricate shaft with specified grease as required Every 1 600 km 1 000 mi Drive chain oil Check oil level 8 16 8 17 Replace Drive chain Check deflection Adjust if necessary Initial at...

Page 58: ...ear for secondary Replace if necessary Lubricate with specified grease Steering column bearing Lubricate with specified grease Ski and front suspension Lubricate with specified grease 8 33 Suspension...

Page 59: ...The condition of the spark plug can indi cate the condition of the engine Check the coloration on the white porcelain insulator around the center electrode The ideal coloration at this point is a medi...

Page 60: ...d damage Always use a spark plug with the speci fied reach Before installing any spark plug measure the electrode gap with a wire thickness gauge and adjust to specifica tion When installing the spark...

Page 61: ...cable 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...

Page 62: ...ailable even with proper carburetion Expect acceleration and top speed to be reduced at higher altitudes To overcome operating with less power at high altitudes your snowmobile may also require differ...

Page 63: ...0 000 km 12 000 mi of operation To change the engine oil with or without oil filter cartridge replacement 1 Place the snowmobile on a level surface and apply the parking brake 2 Remove the bottom pane...

Page 64: ...US qt of the recom mended engine oil to the oil tank and then install and tighten the oil level gauge dipstick and the cylinder head cap 12 Start the engine warm it up for several minutes and then tur...

Page 65: ...min utes while checking it for oil leakage If oil is leaking immediately turn the engine off and make sure the engine oil drain bolts cylinder head cap and oil level gauge dipstick are installed corre...

Page 66: ...ounter clockwise and remove it The cooling system must be bled of air if the coolant reservoir becomes empty if air can be seen in the cooling system or if there is a cooling system leak Consult a Yam...

Page 67: ...d coolant until the coolant level does not go down and then stop the engine 3 Fill the coolant reservoir with coolant until it reaches the COLD LEVEL mark 4 Install the coolant reservoir cap Check for...

Page 68: ...ng bolt Have a Yamaha dealer make this adjustment CAUTION As the V belt wears adjustment may be necessary To ensure proper clutch performance the V belt position should be adjusted by adding a spacer...

Page 69: ...position is incorrect adjust the V belt position by removing or adding a spacer 4 on each adjusting bolt 5 CD 06E 7 Tighten each adjusting bolt Standard V belt position a From 1 5 mm 0 06 in above the...

Page 70: ...the engine with the V belt or drive guard removed ESU03513 Checking the drive chain housing oil level and the drive chain tension Checking the oil level WARNING The engine oil tank brake disc and cool...

Page 71: ...erse transmissions RS90R RS90NR RS90GT RSG90 CAUTION Make sure that no foreign material enters the drive chain housing 4 Install the dipstick making sure to align the notch 4 in the dipstick handle wi...

Page 72: ...king brake pads wear adjustment may be nec essary to ensure proper brake performance WARNING Be sure to have a Yamaha dealer make this adjust ment 1 Loosen the locknut 1 and the adjusting bolt 2 2 Loo...

Page 73: ...clean it up immediately ESU01811 Changing the brake fluid Brake fluid replacement is necessary when the following components are replaced during the periodic mainte nance or if they are damaged or le...

Page 74: ...Minimum 155 5 mm 6 12 in The spring seat length changes approximately 1 5 mm 0 06 in with each full turn of the adjuster Spring seat length Standard Increased Decreased Preload Harder Softer a Length...

Page 75: ...other high heat source which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose of a worn or damaged shock absorber by yourself Take the unit to a Yamaha de...

Page 76: ...oss of stability 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...

Page 77: ...23E For RS90R RS90GT RSG90 CD 26E A Spring seat length Standard Increased Decreased Preload Harder Softer a Length front Maximum 123 5 mm 4 86 in 113 5 mm 4 47 in Minimum 107 5 mm 4 23 in The spring...

Page 78: ...is 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 shock absorber Do not subje...

Page 79: ...re to stop the remote adjustment dial at a marked position around the dial where there is a click WARNING This shock absorber contains highly pressurized nitrogen gas It could explode by improper hand...

Page 80: ...where there is a click 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 ope...

Page 81: ...3 included in the owner s tool kit as shown Make sure that the rim d of the control rod body is within the range e of the scale 4 Tighten the locknut while holding the adjuster in place CAUTION When...

Page 82: ...er s tool kit make sure that they are situated at a right angle to the control rod as shown and that they are tightly fitted to the locknut and the control rod adjusting nut The left and right adjusti...

Page 83: ...damaged slide metal Replace the drive track if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken Otherwise track damage or failure could result in l...

Page 84: ...the drive track one or two turns Stop the engine 4 Check the drive track alignment with the slide runners 2 If the alignment is incorrect align the drive track by turning the left and right adjusters...

Page 85: ...2001 Aligning the skis 1 Turn the handlebar so the skis face straight ahead 2 Check the following for ski alignment a Skis are facing forward b Ski toe out 1 2 is within specification 3 If the alignme...

Page 86: ...position CAUTION Make sure that the projection on the handlebar is not installed into the area a shown 4 Tighten the handlebar bolts and install the handlebar cover CAUTION Make sure that the small ga...

Page 87: ...dab of grease onto the cable end only Do not grease the throttle cable because it could become frozen which could cause loss of control 2 Front suspension 3 Rear suspension WARNING Be sure to have a Y...

Page 88: ...headlight unit 7 Install the bulb holder cover and then connect the headlight coupler CAUTION Keep oil and your hands away from the glass part of the bulb or its life and illumination will be affecte...

Page 89: ...ct with skin eyes or clothing ANTIDOTE EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately EY...

Page 90: ...wn disconnect the crankcase breather hose from the air filter case and then remove the air filter case 8 Disconnect the negative battery lead 9 Replace the blown fuse with one of the proper amperage 1...

Page 91: ...s 20 A 10 A 15 A 3 A F Spare main fuse Specified fuses 9Main fuse 30 A 0 HEAD Headlight fuse 20 A A SIG Signal fuse 10 A B DC TERM Auxiliary DC jack fuse 3 A C C W Carburetor warmer fuse 20 A D IGN Ig...

Page 92: ...sed position The T O R S is an important safety device in the case of a malfunction take the snowmobile to a Yamaha dealer immediately for repair 3 Compression Insufficient Loose cylinder head nuts Ti...

Page 93: ...cable to the black lead Do not reverse the connections 4 Pull the red lead cover to expose the terminal through the slit in the cover and then connect the red jumper cable to the red terminal of the...

Page 94: ...con nections or ask a Yamaha dealer to inspect 3 Discharged battery Charge battery or see B above 4 Seized engine Seizure is caused by poor lubrication inadequate fuel or an air leak Ask a Yamaha dea...

Page 95: ...ean 2 Problem with the driveline See H above J Engine does not upshift or down shift properly or engages harshly 1 Worn or damaged V belt Replace the V belt or ask a Yamaha dealer to inspect 2 Incorre...

Page 96: ...d fuel gasohol is used because the alcohol content in the fuel increases the chance for water to enter the engine Use Yamaha Stor Rite Engine Fogging Oil or an equiva lent fogging oil to protect both...

Page 97: ...i lated place out of direct sunlight Put a fab ric cover over the snowmobile preferably one that is designed for it Do not use a plastic or vinyl cover condensation could be trapped underneath which c...

Page 98: ...RSG90 Overall width 1 225 mm 48 2 in RS90N RS90R RS90NR RS90GT RSG90 1 165 mm 45 9 in RS90M Overall height 1 090 mm 42 9 in RS90N RS90NR 1 215 mm 47 8 in RS90R RSG90 1 250 mm 49 2 in RS90M 1 150 mm 45...

Page 99: ...er Starting system Electric starter RS90N RS90R RS90NR RS90M RS90GT RSG90 Drive track and suspension Track Molded rubber fiber glass rod reinforced Width 381 mm 15 0 in Track deflection 30 35 mm 1 18...

Page 100: ...0NR 38 22 1 73 RS90R RS90GT 40 20 2 00 RS90M 39 22 1 77 RSG90 Fuel tank Tank capacity 39 3 L 8 6 lmp gal 10 4 US gal Oil quantity With oil filter cartridge replacement 3 0 L 2 6 lmp qt 3 2 US qt Witho...

Page 101: ...Type R CR8E NGK Gap 0 7 0 8 mm 0 028 0 031 in Battery Capacity YTX20L BS 12 V 18 A h Maximum charge rate 1 8 Amperes hr for 10 hrs Headlight Bulb Quantity 12 V 60 55 W 2 Tail brake light Bulb Quantit...

Page 102: ...W Y B L BLACK B W DARK GREEN L G R W Br W R Y Br R Br R W Br W Y B G B R B R B R B R B G B Ch Ch D G G D L R L R D B B B Lg B W R L Br Br L R Y R W O BLACK Br O Br Gy BLACK Br Gy Br L W Y B L W BLACK...

Page 103: ...Y Multi function meter Z Meter light High beam indicator light DC TERM Auxiliary DC jack fuse HEAD Headlight fuse _ SIG Signal fuse a C W Carburetor warmer fuse b IGN Ignition fuse c Auxiliary DC jac...

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