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CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ............................ 1-1
FRAME SERIAL NUMBER ........................ 1-1
ENGINE SERIAL NUMBER ....................... 1-1
IMPORTANT INFORMATION .......................... 1-2
PREPARATION FOR REMOVAL AND
DISASSEMBLY .......................................... 1-2
ALL REPLACEMENT PARTS ..................... 1-2
GASKETS, OIL SEALS, AND O-RINGS .... 1-3
LOCK WASHERS/PLATES AND COTTER
PINS ........................................................... 1-3
BEARINGS AND OIL SEALS ..................... 1-3
CIRCLIPS .................................................... 1-3
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LOCTITE
................................................... 1-3
SPECIAL TOOLS .............................................. 1-4
FOR TUNE UP ........................................... 1-4
FOR ENGINE SERVICE .............................. 1-5
FOR POWER TRAIN SERVICE .................. 1-5
FOR CARBURETION SERVICE ................. 1-6
FOR ELECTRICAL SERVICE ...................... 1-6
CHAPTER 2.
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION .............................................. 2-1
PERIODIC MAINTENANCE TABLE ................. 2-1
ENGINE ............................................................ 2-3
SPARK PLUGS .......................................... 2-3
OIL PUMP .................................................. 2-4
FUEL LINE INSPECTION ........................... 2-5
COOLING SYSTEM ................................... 2-6
CARBURETOR SYNCHRONIZATION ..... 2-10
ENGINE IDLE SPEED ADJUSTMENT .... 2-10
THROTTLE CABLE FREEPLAY
ADJUSTMENT ........................................ 2-11
THROTTLE OVERRIDE SYSTEM (T.O.R.S.)
CHECK ...................................................... 2-12
STARTER (CHOKE) CABLE FREEPLAY
ADJUSTMENT ........................................ 2-13
EXHAUST SYSTEM INSPECTION ......... 2-13
HEAT SHIELD CLAMP REPLACEMENT . 2-14
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YAMAHA POWER VALVE SYSTEM
(Y.P.V.S.) ADJUSTMENT ........................ 2-15
YAMAHA POWER VALVE SYSTEM
(Y.P.V.S.) PRE-SEASON CHECKS .......... 2-16
POWER TRAIN ............................................... 2-18
SHEAVE DISTANCE AND OFFSET
ADJUSTMENT ........................................ 2-18
DRIVE V-BELT .......................................... 2-20
ENGAGEMENT SPEED CHECK .............. 2-22
PARKING BRAKE PAD INSPECTION ..... 2-22
PARKING BRAKE ADJUSTMENT .......... 2-22
BRAKE LEVER ADJUSTMENT ............... 2-23
BRAKE FLUID LEVEL INSPECTION ........ 2-24
BRAKE PAD INSPECTION ...................... 2-24
BRAKE HOSE INSPECTION .................... 2-25
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM) ............. 2-25
DRIVE CHAIN ........................................... 2-26
TRACK TENSION ADJUSTMENT .......... 2-29
SLIDE RUNNER INSPECTION ................ 2-30
CHASSIS ........................................................ 2-31
SKI/SKI RUNNER ..................................... 2-31
STEERING SYSTEM ................................ 2-31
LUBRICATION ......................................... 2-33
ELECTRICAL ................................................... 2-34
HEADLIGHT BEAM ADJUSTMENT ....... 2-34
TUNING .......................................................... 2-35
CARBURETOR TUNING .......................... 2-35
CLUTCH ................................................... 2-42
GEAR SELECTION ................................... 2-43
HIGH ALTITUDE TUNING ....................... 2-49
FRONT SUSPENSION ............................. 2-50
REAR SUSPENSION ............................... 2-52
CHAPTER 3.
CHASSIS
STEERING ........................................................ 3-1
INSPECTION .............................................. 3-3
INSTALLATION ......................................... 3-4
SKI .................................................................... 3-6
INSPECTION .............................................. 3-7
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