Yamaha SR10LE, Operator'S Manual

Page 1: ...Read this manual carefully before operating this vehicle OPERATOR S MANUAL SR10RE SR10RSE SR10LE SR10LSE SR10XSE LIT 12628 03 16 8JR F8199 70 ...

Page 2: ...2 Operating Instructions 13 16 Starting and Stopping Engine 13 Braking 14 Emergency Stopping 15 Throttle Ignition Monitor Switch 15 Varying Altitude Operation 16 Lubrication 17 18 Chain Case 17 Rear Suspension 18 Maintenance 19 38 Periodic Maintenance Checklist 19 Fuel System 20 Checking Engine Oil Level 21 Changing Engine Oil Filter 21 Coolant Level 22 Spark Plugs 23 Checking Adjusting Valve Clea...

Page 3: ...tor s Manual and Safety Handbook Failure to follow this warning could result in personal injury to yourself or others Personal Injury To avoid injury to yourself and others NEVER operate the snowmobile without first reading and understanding this manual and the Snowmobile Safety Hand book then follow the instructions and heed the warnings given USE COMMON SENSE DON T DRINK and DRIVE STAY IN CONTRO...

Page 4: ...storage instructions If major repair or service is ever required contact an authorized Yamaha Snowmobile dealer for professional service At the time of publication all information and illustrations were technically cor rect Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions Because Yamaha constantly refines and improves its pr...

Page 5: ... for Yamaha snowmobiles Location of a specific control will vary according to model 0747 829 Gasoline Oil Recommended Gasoline The recommended gasoline to use in these snowmobiles is 87 octane regular unleaded In many areas oxygenates are added to the gasoline Oxygenated gaso lines containing up to 10 ethanol are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a...

Page 6: ...les Drive the snowmobile for 40 km 25 miles at 3 4 throttle or less By revving the engine up and down but not exceeding 100 km h 60 mph the exposed cord on the side of a new belt will be worn down This will allow the drive belt to gain its opti mum flexibility and will extend drive belt life NOTE Before starting the snowmo bile in extremely cold temperatures the drive belt should be removed and wa...

Page 7: ... Coolant Temperature Battery Voltage Intake Air Temperature This bar display shows coolant tempera ture battery voltage intake air tempera ture and on the 6000 exhaust temperature Press the Lower Left Button to change which parameter is being dis played Press and hold the Lower Left Button to see the actual values associated with the mode selected F Fuel Level Display This display shows the approx...

Page 8: ...ivated take the snow mobile to an authorized Yamaha Snow mobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner Refer to the following chart for diagnos tic codes Code Trouble P0031 O2 Heater Control Circuit Low P0032 O2 Heater Control Circuit High P0107 Manifold absolute pressure circuit low P0108 Manifold absolute pressure circuit hi...

Page 9: ...ge and damage Also the coolant level should be checked daily If leakage or damage is detected take the snowmobile to an authorized Yamaha Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snow mobile owner When filling the cooling system use an ethylene glycol based coolant water mix ture which will satisfy the coldest antici pated weather con...

Page 10: ...rned OFF 5 Disconnect all external accessories such as cell phones GPS units and radios on both vehicles 6 Attach one clamp of the positive red cable to the positive termi nal 1 of the dead battery C being careful not to touch any metal with the other clamp then attach the other clamp of the positive red cable to the positive terminal 2 of the good battery B CAUTION Always turn the ignition switch...

Page 11: ...s first This service is at the discretion and expense of the snowmobile owner When operating the snowmobile at high altitudes it may be necessary to change certain component parts of the drive clutch and or the driven clutch See an authorized Yamaha Snowmobile dealer for further information Drive Clutch Driven Clutch Alignment The alignment between the drive clutch and driven clutch is set at the ...

Page 12: ...re installed Drilling stud holes into the drive track will cut the internal fibers weakening the track Avoid spinning the drive track Studs may catch on an object and pull out of the track leaving tears and damage around the already weakened area To minimize possible damage consult your stud man ufacturer for installation and stud pattern recommendations Yamaha does not rec ommend studding a track...

Page 13: ...tor then move the hood slightly forward and remove the hood To install the access panel and hood use the following procedure 1 Position the hood onto the snowmo bile and connect the hood harness connector making sure the harness does not become pinched 2 Secure the hood with torx head screws and tighten securely 3 Install the access panel onto the lower console then close the access panel and secu...

Page 14: ...o lowering and secur ing the seat connect the seat heater harness connector Towing If the snowmobile is to be towed by another snowmobile do not tow using the loops in the skis The tow rope should be attached to the spindles ...

Page 15: ... If the brake fluid is below the high brake fluid mark add Yamaha approved DOT 4 brake fluid until the fluid is at the recommended level Install and secure the reservoir cover Do not allow moisture to con taminate the brake system 4 Test the throttle control lever by completely compressing and releas ing it several times The lever MUST return to the idle position quickly and completely 5 Move the ...

Page 16: ...function properly This cool down period will vary depending upon the ambient air tem perature and the temperature of the brake fluid If loss of brakes has occurred because of high fluid temper atures do not operate the snowmobile until the cool down period has expired and brake lever firmness has returned 2 Be sure to maintain the brake fluid at the proper level and take care not to get any moistu...

Page 17: ...sing and releasing it several times The lever MUST return to the idle position quickly and completely NOTE If the throttle control lever operates properly and the engine does not start compress the throttle lever slightly approximately 1 8 throttle and try starting the engine If the engine now starts and stops when the throttle lever is released take the snowmobile to an autho rized Yamaha Snowmob...

Page 18: ...e Operation Operating a snowmobile at varying alti tudes requires changes in performance components These changes affect drive train components Have a Yamaha dealer perform altitude related service NOTE Just as important as cali brating the snowmobile for higher alti tudes is recalibrating the snowmobile when going to lower altitudes NOTE Drive train changes can be made by the snowmobile owner if ...

Page 19: ...tart the engine and verify proper reverse and forward operation by shift ing in and out of reverse three times NOTE If excessive build up of moisture or discolored oil is detected in the chain case it may be necessary to replace the lube Replacing Lubricant NOTE Replacing the lubricant can be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bi...

Page 20: ...ust reso nator 5 Start the engine and verify proper reverse and forward operation by shifting in and out of reverse three times Rear Suspension This procedure should be done every 40 operating hours NOTE Yamaha recommends that All Temp Grease be used for this procedure 1 Using Handlebar Stand or Steering Post Stand or a suitable substitute lay the snowmobile on its left side 2 Lubricate all grease...

Page 21: ...ekly Check for wear damage and tight connections Exhaust System Weekly 7 Check for damage leakage and obstructions Nuts Bolts Fasteners Weekly Check tightness Shock Absorbers Weekly 10 33 Check for fluid leakage and damage and air pres sure Fox Air Shocks Spark Plugs 4000 km 2500 Mi Seasonal 23 Check center electrode insulator color carbon and gap Valve Clearance 40000 km 25000 Mi 23 Check adjust ...

Page 22: ...nd to the right of the steering support To access the filter the access panels and hood need to be removed 1 Remove the hose clamps and dis card then slowly remove the fuel hoses from the fuel filter Dispose of the excess fuel from the filter prop erly 2 Inspect the fuel hoses thoroughly for any signs of cracking cuts or wear points 3 Place the new hose clamps on the fuel hoses then with the fuel ...

Page 23: ...n start the engine and let it idle and warm up until the fan on the radiator turns on or if the snowmo bile was operated allow the engine to idle for approximately 30 sec onds Shut the engine off 2 Remove the torx head screws and the rear access plate from beneath the snowmobile 3 Place a drain pan beneath the engine oil drain screw then remove the screw and allow the oil to drain completely XM125...

Page 24: ... icon illuminates from step 11 start the engine The warning icon should go out within five seconds If it does proceed to step 13 NOTE If the warning icon does not go out shut the engine off immedi ately and repeat step 11 then place the ignition switch to the ON posi tion and repeat step 12 If the warn ing icon does not go out take the snowmobile to an authorized Yamaha Snowmobile dealer for ser v...

Page 25: ...and follow instructions provided with battery chargers and battery prod ucts NOTE Battery maintenance may be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Yamaha Snow mobile dealer for this service This service is at the discretion and expense of the snowmobile owner CAUTION If the coolant is below the neck and if cool...

Page 26: ...rned to service see step 9 6 If the meter reads less than specified voltage charge the battery using the following guidelines A When using an automatic battery charger always follow the char ger manufacturer s instructions B When using a constant current battery charger use the follow ing Battery Charging Chart WARNING Battery posts terminals and related accessories contain lead and lead compounds...

Page 27: ...asher and a flat washer Tighten securely NOTE Assure the harness wires and cables are routed properly as noted during removing battery procedure XM167A 12 Install the battery bracket solenoid and tighten the two screws and lock nuts to 1 2 kg m 105 in lb then install the seat and secure with the torx head screw Tighten securely NOTE Prior to lowering and secur ing the seat connect the seat heater ...

Page 28: ... reservoir in a level position and the cover removed check the fluid level The brake fluid level must be at the high brake fluid mark in the reservoir 745 817A 2 If the brake fluid is below the high brake fluid mark add Yamaha approved DOT 4 brake fluid until the fluid is at the recommended level Install and secure the reservoir cover Do not allow moisture to con taminate the brake system WARNING ...

Page 29: ... brake use the follow ing procedure NOTE The brake system may be bled by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Yamaha Snow mobile dealer for this service This service is at the discretion and expense of the snowmobile owner 1 Remove the reservoir cover and if necessary fill the reservoir to the high brake fluid mark wi...

Page 30: ...o the caliper for installing new brake pads Replacing the cover will prevent fluid spillage 2 Open the left side access panel 3 Remove the torx head screws secur ing the brake shield to the belt guard mount then remove the cap screws securing the brake shield to the brake caliper 4 Carefully move the shield out of the way then remove the hairpin clip securing the brake pads to the cali per assembl...

Page 31: ...ly as to get the brake disc red hot NOTE This procedure stabilizes the pad material and extends the life of the pads Chain Tension 1 Remove the shroud right side cover and exhaust assembly 2 Loosen the jam nut 3 Turn the chain tension adjustment bolt clockwise until it is finger tight then loosen it 1 4 turn 0747 831 4 While holding the bolt with a wrench tighten the jam nut to 2 5 kg m 18 ft lb 5...

Page 32: ...e snowmobile owner if qual ified to do so If the owner does not feel qualified take the snowmobile to an authorized Yamaha Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner 1 Place the snowmobile on a level sur face and engage the brake lever lock 2 Open the left side access panel and remove the belt guard assembly 3 Rotate the driven clutch s...

Page 33: ...d be 50 mm 2 0 in 746 788A NOTE Measurement is from the bottom of the wear strip at the point of the shock pad on the slide rail NOTE Only tighten track until the track does not ratchet Too tight of a track will cause the rear suspension to not work properly Adjusting Track Tension NOTE To ensure proper track ten sion adjustment perform all adjust ments on both sides of the snowmobile 1 Loosen the...

Page 34: ...n the track stops rotating check the relationship of the rear idler wheels and the inner track drive lugs If the rear idler wheels are centered between the inner track drive lugs no adjustment is necessary 0745 809 5 If the idler wheels are not centered between the inner track drive lugs an adjustment is necessary Adjusting Track Alignment 1 On the side of the track which has the inner track drive...

Page 35: ...ry so the correct amount of threads are exposed between the adjuster nut and the threaded shock body as an initial setting Additional ski pressure can be obtained by tightening the spring tension ski pressure can be decreased by relaxing spring tension NOTE Equal adjustments should be maintained on both sides of the snowmobile Front ski shock spring pre load adjust ment is accomplished by loosenin...

Page 36: ...mately six rotations NOTE As the pump is being attached to the shock the hose will fill with air This will result in a lower gauge pres sure of 0 14 0 35 kg cm2 2 5 psi 3 To decrease air pressure in the shock press the black bleed valve button half way down and hold until desired pressure is attained NOTE Pressing the button fully down and releasing it will allow only a small amount of air to esca...

Page 37: ...ng Position 2 is for the average operator under normal conditions Always rotate the cam from the lighter position to the heavier position 741 450A To rotate an adjusting cam use the spark plug wrench from the tool kit Rotate the wrench until the cam is in the desired position To stiffen the ride rotate the cam so as to raise the spring end Make the appropriate adjustment on the other cam Lights Fo...

Page 38: ...o the headlight is approxi mately 8 m 25 ft from an aiming surface wall or similar surface NOTE There should be an aver age operating load on the snowmo bile when adjusting headlight aim 2 Measure the distance from the floor to midpoint of the headlight 3 Using the measurement obtained in step 2 make a horizontal mark on the aiming surface 4 Make a vertical mark which inter sects the horizontal ma...

Page 39: ...ki then install the lock nuts Tighten to 2 0 kg m 15 ft lb Adjusting Ski Stance NOTE Local laws and or regula tions as to maximum width of the ski stance on these snowmobiles may be applicable Always comply with the maximum width laws and or reg ulations when adjusting ski stance NOTE Ski stance can be increased decreased by 25 mm 1 0 in 1 Place the front of the snowmobile on a support stand 2 Rem...

Page 40: ... ser vice This service is at the discretion and expense of the snowmobile owner Each time a new set of wear strips are installed they should be tempered Tem per the wear strips by driving the snow mobile for approximately a mile on a hard pack trail then immediately drive into deep snow and allow the wear strips to cool Repeat the procedure warming up the wear strips then cooling them down two or ...

Page 41: ...elt is posi tioned from 1 5 mm 0 06 in above the edge of the driven clutch sheaves to 0 5 mm 0 02 in below the edge SNO 337 3 Adjust the position by removing or adding a spacer on each adjusting bolt SNO 338 Spacer Part Numbers 90201 061H1 0 5 mm 0 02 in 90201 06037 1 0 mm 0 04 in 4 Close the access panel DRIVE CLUTCH AND DRIVEN CLUTCH Keeping the drive clutch and driven clutch clean should be the...

Page 42: ...NO 324 NOTE The straightedge must extend beyond the front edge of the drive clutch 4 If offset adjustment needs to be made remove the driven clutch and add shims p n 8JP RA449 00 2 mm 8JP RA448 00 1 mm to increase the offset or remove shims to decrease the offset 5 Once the correct offset is reached install driven clutch and tighten cap screw to 6 4 kg m 46 ft lb NOTE When adjusting the driven clu...

Page 43: ...tch 9 Apply light oil to the upper steering post bushing and shafts of the shock absorbers 10 Lubricate the rear suspension with all temperature grease 11 Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely Make sure all rivets hold ing the components together are tight Replace all loose rivets 12 Clean and polish the hood console and chassis DO N...

Page 44: ...lace if damaged or worn Install the drive belt NOTE If the old belt is worn but in reasonable condition retain it with the snowmobile as a spare in case of emergency 5 Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely 6 If not done during preparation for storage lubricate the rear suspen sion with all temperature grease 7 Check the coolant level...

Page 45: ...43 Snowmobile Safety Rules ...

Page 46: ...ng or non Yamaha authorized rental use 3 Operation on surfaces other than snow or ice 4 Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts 5 Abnormal strain neglect or abuse 6 Lack of proper maintenance 7 Accident or collision damage 8 Modification to original parts SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wea...

Page 47: ...RANTY EXTENSION A special warranty extension is available for all new Yamaha snowmobiles pur chased between May 1 and November 30 All new Yamaha snowmobiles purchased between May 1 and November 30 will have the warranty extended to November 30 of the following year WARRANTY QUESTIONS AND ANSWERS Q What costs are my responsibility during the warranty period A The customer s responsibility includes ...

Page 48: ... repair work Q Whom should I contact if I have further questions about this war ranty A Your Yamaha snowmobile dealer has the information and experi ence necessary to answer almost any questions about this war ranty If the dealer is not able to do so he is expected to contact Yamaha for clarification or assistance CUSTOMER SERVICE If your machine requires warranty ser vice you must take it to any ...

Page 49: ...ease advise Yamaha of your new address by sending a subsequent owner s card listing your snowmobile model name engine serial number dealer number or dealer s name as it is shown on your warranty registration identification your name and new mailing address Mail to FOR U S A CUSTOMERS YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPART MENT P O Box 6555 Cypress California 90630 FOR CANADIAN CU...

Page 50: ...48 YAMAHA EXTENDED SERVICE Y E S FOR U S A CUSTOMERS ...

Page 51: ...on is avail able to every authorized Yamaha dealer nationwide You can purchase years of our Yamaha Protection Plus coverage for a fraction of what a single major repair could cost you With Yamaha Protection Plus Yamaha is ready to step in to make any needed repairs excluding those repairs due to normal wear or aging using genuine parts and factory authorized service for the full dura tion of your ...

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