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Yamaha Vector RS90RX 2008 Supplementary Service Manual

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2008
SUPPLEMENTARY SERVICE MANUAL
RS90RX
RS90GTX
RS90GTAX
RS90LTX
RS90LTGTX
LIT-12618-02-70
8GM-28197-10

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Summary of Contents for Yamaha Vector RS90RX 2008

  • Page 1 2008 SUPPLEMENTARY SERVICE MANUAL RS90RX RS90GTX RS90GTAX RS90LTX RS90LTGTX LIT-12618-02-70 8GM-28197-10...
  • Page 2 NOTE: NOTICE A NOTE provides key information that can make procedures easier or clearer. This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers MANUAL FORMAT and their qualified mechanics. It is not possible All of the procedures in this manual are orga- to put an entire mechanic’s education into one...

  • Page 3: Chassis

    ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols are designed as thumb tabs to indicate the chapter’s number and content. General information Periodic inspections and adjustments Chassis Power train Engine Cooling system Carburetion Electrical Specifications Illustrated symbols are used to iden- tify the specifications which appear.

  • Page 4: Table Of Contents

    CONTENTS GENERAL INFORMATION INFO PERIODIC INSPECTION AND INSP ADJUSTMENT CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB ELECTRICAL ELEC SPECIFICATIONS SPEC...

  • Page 5: Carburetion

    CHAPTER 2. CHAPTER 4. PERIODIC INSPECTION POWER TRAIN AND ADJUSTMENT DRIVE CHAIN HOUSING......37 INTRODUCTION..........1 SLIDE RAIL SUSPENSION ......40 RS90RX/RS90GTX/RS90GTAX ... 40 PERIODIC MAINTENANCE CHART FOR RS90LTX/RS90LTGTX ......44 THE EMISSION CONTROL SYSTEM ...1 CHAPTER 5. GENERAL MAINTENANCE AND LUBRICATION CHART .........2 ENGINE ENGINE............3...

  • Page 6: Insp Adj

    INTRODUCTION/PERIODIC MAINTENANCE INSP CHART FOR THE EMISSION CONTROL SYSTEM PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced.

  • Page 7: General Maintenance And Lubrication Chart

    INSP GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART Initial Every 1 month or Seasonally Item Remarks 800 km or 4,000 km (500 mi) (2,500 mi) (40 hr) (200 hr) Engine oil • Change (warm engine before draining) Every Engine oil filter cartridge •...

  • Page 8: Engine

    INSP ENGINE IDLE SPEED ADJUSTMENT ENGINE ENGINE IDLE SPEED ADJUSTMENT NOTE: NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes.

  • Page 9: Throttle Cable Free Play Adjustment

    THROTTLE CABLE FREE PLAY ADJUSTMENT / INSP ENGINE OIL LEVEL INSPECTION THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: NOTE: • Before adjusting the throttle cable free play, the engine idle speed should be adjusted. • Adjust the throttle cable free play while the cable is in the cable guide.
  • Page 10 INSP ENGINE OIL LEVEL INSPECTION Inspection steps: • Place the snowmobile on a level surface and apply the parking brake. • Start the engine, warm it up for 10 ~ 15 min- utes, and then turn off. • Disconnect the oil level switch coupler CAUTION: Disconnect the oil level switch coupler before removing the oil level gauge.

  • Page 11: Cylinder Head Breather Hose Inspection

    ENGINE OIL LEVEL INSPECTION/CYLINDER HEAD BREATHER INSP HOSE INSPECTION/OIL TANK BREATHER HOSE INSPECTION • Start the engine, warm it up for several min- utes, and then turn it off. • Check the engine oil level again. NOTE: NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.

  • Page 12: Chassis

    INSP LUBRICATION CHASSIS LUBRICATION Front and rear suspension 1. Use a grease gun to inject grease into the nipples (Both sides) 2. Apply grease Recommended lubricant: Esso Beacon 325 Grease or Aeroshell Grease #7A Apply grease Apply grease (Both sides) Apply grease (Both sides) Front Rear (RS90RX/RS90GTX/RS90GTAX)

  • Page 13: Electrical

    INSP HEADLIGHT BEAM ADJUSTMENT ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Place the machine from the wall at a dis- tance indicated by the chart below. 3. Measure the distance from the floor to the center of the headlight and place a mark on the wall equal to distance...

  • Page 14: Fuse Inspection

    INSP FUSE INSPECTION FUSE INSPECTION The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replac- ing a fuse. 1. Inspect: • Continuity Inspection steps: •...
  • Page 15 INSP FUSE INSPECTION 2. Replace: • Blown fuse Replacing steps: • Set the main switch to “OFF”. • Install a new fuse of the correct amperage. • Set the main switch to “ON” and verify if the electrical circuit is operational. •...

  • Page 16: Tuning

    INSP CARBURETOR TUNING TUNING CARBURETOR TUNING The carburetors are set at the factory to run at temperatures of 0°C ~ –20°C (32°F ~ –4°F) at sea level. If the machine is to be operated under conditions other than those specified above, the carburetors must be properly adjusted.
  • Page 17 Use the chart in CHAPTER 9 to select main jets according to variations in elevation and temperature. NOTE: NOTE: These jetting specifications are subject to change. Consult the latest technical information from Yamaha to be sure you have the most up-to- date jetting specifications. Main jet Pilot jet...
  • Page 18 INSP CARBURETOR TUNING Guide for carburetion...
  • Page 19 INSP CARBURETOR TUNING Standard main jet Main jet whose diameter is 10% smaller than standard Main jet whose diameter is 10% larger than standard CAUTION: If the air filter case is removed from the car- buretors, the change in pressure in the intake will create a lean mixture that may cause severe engine damage.

  • Page 20: Clutch

    INSP CLUTCH CLUTCH G Green O Orange P Pink High altitude S Silver Y Yellow Specifications Model: RS90RX/RS90GTX/RS90GTAX ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft)
  • Page 21 INSP CLUTCH G Green P Pink Blue W White Specifications Model: RS90LTX/RS90LTGTX ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft) ←...

  • Page 22: Gear Selection

    INSP GEAR SELECTION GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions. If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions exist, decrease the ratio.
  • Page 23 INSP GEAR SELECTION Chain and sprocket part number Parts name Teeth & links Parts no. Standard 18 teeth 8FA-17682-80 19 teeth 8FA-17682-90 20 teeth 8FA-17682-00 21 teeth 8FA-17682-10 Drive sprocket RS90RX/RS90GTX/RS90GTAX 22 teeth 8FA-17682-20 RS90LTX/RS90LTGTX 23 teeth 8FA-17682-30 24 teeth 8FA-17682-40 37 teeth 8DW-47587-71...
  • Page 24 INSP GEAR SELECTION Secondary sheave spring Spring rate Preload Wire Free Outside No. of Part no. N•mm/rad N/mm (kg / mm) Color gauge length diameter Standard coils (kg•mm/rad) (lb/in) mm (in) mm (in) mm (in) 90508-500B1 6003 (613) 6.2 (0.63), 35.28 Brown 5.0 (0.196) 5.19...
  • Page 25 INSP GEAR SELECTION Primary spring Spring identification color code Spring rate color Preload color Spring rate Wire Outside Free Preload No. of Parts No. N/mm Color gauge diameter length Standard N (kg) coils (kg/mm) mm (in) mm (in) mm (in) 90501-550A2 19.6 (2.00) 196 (20)
  • Page 26 INSP GEAR SELECTION Clutch weight Weight g (oz) Parts no. without bush Shape & ID mark Standard and rivets 8BU-17605-20 45.41 (1.603) 8DJ-17605-00 37.77 (1.333) RS90RX/RS90GTX/ RS90GTAX/ 8ES-17605-00 54.63 (1.928) RS90LTX/ RS90LTGTX 8FA-17605-10 63.81 (2.252) 8FP-17605-00 67.81 (2.392) 8FS-17605-00 65.52 (2.311) 8FN-17605-00 75.28 (2.655)
  • Page 27 INSP GEAR SELECTION Weight rivets Length Weight Parts No. Material Standard Effects mm (in) g (oz) 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) OUT: RS90LTX/RS90LTGTX Increased 3.6 (0.127) Force 90269-06006 Steel 17.2 (0.677) with hole IN: RS90RX/RS90GTX/RS90GTAX/RS90LTX/ 90261-06034 Steel 13.9 (0.547) 3.6 (0.127) RS90LTGTX OUT: RS90RX/RS90GTX/RS90GTAX...
  • Page 28 INSP GEAR SELECTION Rollers I.D. 9 mm (0.354 in) Roller with Outside Bushing Identification bushing part diameter Standard Effects type (P/N) mark (Width) number mm (in) Grooved & Machined VESPEL Increased TP-8549 force 8FG-17624-00 14.5 (0.57) (1.46 mm) 90386-09001 Grooved VESPEL TP-8549 8FG-17624-10...

  • Page 29: Front Suspension

    INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: • Spring preload Adjustment steps: • Loosen the locknut • Turn the spring seat in or out. RS90RX/RS90LTX Standard Spring seat Shorter ← → Longer distance Harder ← → Softer Preload Minimum Maximum Length...
  • Page 30 INSP FRONT SUSPENSION CAUTION: Be sure that the left and right spring pre- loads are the same. WARNING These shock absorber contain highly pres- surized nitrogen gas. Do not tamper with or attempt to open the shock absorber assemblies. Do not subject the shock absorber assem- blies to flames or high heat, which could cause it to explode.

  • Page 31: Rear Suspension

    INSP FRONT SUSPENSION/REAR SUSPENSION Compression damping force adjustment (RS90GTX/RS90GTAX/RS90LTGTX) The compression damping force can be adjusted by turning the adjuster 12 clicks out 7 clicks out 2 clicks out Adjuster position Minimum Standard Maximum → Turns in Turns out *← Compres- sion Soft ←...
  • Page 32 INSP REAR SUSPENSION Adjustment steps: • Remove the stopper band bolts , nuts and washers. • Adjust the length of the stopper band inserting the bolts in different holes. Standard setting: No. 2 holes 1. Tighten the stopper band nuts. Stopper band nut: 4 Nm (0.4 m•kg, 2.9 ft•lb) Choosing other settings:...
  • Page 33 INSP REAR SUSPENSION Rear side • Turn the adjusting ring to the proper posi- tion. Spring adjuster position Softer ← → Harder Preload Standard Rebound damping force adjustment The rebound damping force can be adjusted by turning the rebound damping force remote adjustment dial in direction “HARD”...
  • Page 34 INSP REAR SUSPENSION Control rod 1. Adjust: • Control rod stroke Adjustment steps: • Loosen the locknut • Turn the control rod adjuster in direction to adjust the control rod stroke. Adjusting position Increase Decrease ← → Effect weight Pitching transfer RS90RX/RS90GTX/RS90GTAX: Second mark to the left of MAX...

  • Page 35: Chas

    CHAS COWLINGS CHASSIS COWLINGS 7 Nm (0.7 m•kg, 5.1 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Shroud Side cover (left and right) Side under cover (left and right) Top cover Headlight assembly Headlight stay...

  • Page 36: Steering

    CHAS STEERING STEERING 10 Nm (1.0 m•kg, 7.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job/Part Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Top cover Refer to “COWLINGS”. Steering pad NOTE: NOTE: When setting up, adjust the free play of the throttle cable.
  • Page 37 CHAS STEERING 10 Nm (1.0 m•kg, 7.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job/Part Q’ty Remarks Throttle cable Starter cable clip Starter cable Left handlebar switch Brake lever holder Master cylinder assembly NOTE: NOTE: After installing all parts, refer to “CABLE ROUTING”...
  • Page 38 CHAS STEERING 23 Nm (2.3 m•kg, 17 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) ESSO beacon 325 grease 67 Nm (6.7 m•kg, 49 ft•lb) or Aeroshell grease #7A Order Job name/Part name Q’ty...
  • Page 39 CHAS STEERING 23 Nm (2.3 m•kg, 17 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) ESSO beacon 325 grease 67 Nm (6.7 m•kg, 49 ft•lb) or Aeroshell grease #7A Order Job name/Part name Q’ty...

  • Page 40: Front Suspension

    CHAS FRONT SUSPENSION FRONT SUSPENSION 11 Nm (1.1 m•kg, 8.0 ft•lb) RS90GTAX 34 Nm (3.4 m•kg, 24 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 37 Nm (3.7 m•kg, 27 ft•lb) 40 Nm (4.0 m•kg, 29 ft•lb) 45 Nm (4.5 m•kg, 32 ft•lb) 65 Nm (6.5 m•kg, 47 ft•lb) RS90GTX/RS90GTAX/ RS90LTGTX...
  • Page 41 CHAS FRONT SUSPENSION 11 Nm (1.1 m•kg, 8.0 ft•lb) RS90GTAX 34 Nm (3.4 m•kg, 24 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 37 Nm (3.7 m•kg, 27 ft•lb) 40 Nm (4.0 m•kg, 29 ft•lb) 45 Nm (4.5 m•kg, 32 ft•lb) 65 Nm (6.5 m•kg, 47 ft•lb) RS90GTX/RS90GTAX/ RS90LTGTX...

  • Page 42: Chapter 4. Power Train

    POWR DRIVE CHAIN HOUSING POWER TRAIN DRIVE CHAIN HOUSING 6 Nm (0.6 m•kg, 4.3 ft•lb) 24 Nm (2.4 m•kg, 17 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 90 Nm (9.0 m•kg, 65 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 43 Nm (4.3 m•kg, 31 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb)

  • Page 43: Powr Tr

    POWR DRIVE CHAIN HOUSING 6 Nm (0.6 m•kg, 4.3 ft•lb) 24 Nm (2.4 m•kg, 17 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 90 Nm (9.0 m•kg, 65 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 43 Nm (4.3 m•kg, 31 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb)
  • Page 44 POWR DRIVE CHAIN HOUSING 6 Nm (0.6 m•kg, 4.3 ft•lb) 24 Nm (2.4 m•kg, 17 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 90 Nm (9.0 m•kg, 65 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 43 Nm (4.3 m•kg, 31 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb)

  • Page 45: Slide Rail Suspension

    POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION RS90RX/RS90GTX/RS90GTAX 10 Nm (1.0 m•kg, 7.2 ft•lb) 60 Nm (6.0 m•kg, 43 ft•lb) 84 Nm (8.4 m•kg, 61 ft•lb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below.
  • Page 46 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 m•kg, 2.9 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 49 Nm (4.9 m•kg, 35 ft•lb) 60 Nm (6.0 m•kg, 43 ft•lb) 72 Nm (7.2 m•kg, 52 ft•lb) 74 Nm (7.4 m•kg, 55 ft•lb) ESSO beacon 325 grease or Aeroshell grease #7A...
  • Page 47 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 m•kg, 35 ft•lb) 60 Nm (6.0 m•kg, 43 ft•lb) 72 Nm (7.2 m•kg, 52 ft•lb) 74 Nm (7.4 m•kg, 55 ft•lb) Order Job name/Part name Q’ty Remarks Rear shock absorber Collar Oil seal Bearing Control rod assembly Spacer...
  • Page 48 POWR SLIDE RAIL SUSPENSION 75 Nm (7.5 m•kg, 54 ft•lb) Order Job name/Part name Q’ty Remarks Rear axle shaft Guide wheel Guide wheel Collar Tension adjuster Collar Collar Sliding frame For assembly, reverse the disassembly procedure.

  • Page 49: Rs90Ltx/Rs90Ltgtx

    POWR SLIDE RAIL SUSPENSION RS90LTX/RS90LTGTX 10 Nm (1.0 m•kg, 7.2 ft•lb) 60 Nm (6.0 m•kg, 43 ft•lb) 84 Nm (8.4 m•kg, 61 ft•lb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below.
  • Page 50 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 m•kg, 2.9 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 49 Nm (4.9 m•kg, 35 ft•lb) 60 Nm (6.0 m•kg, 43 ft•lb) 72 Nm (7.2 m•kg, 52 ft•lb) 74 Nm (7.4 m•kg, 55 ft•lb) ESSO beacon 325 grease or Aeroshell grease #7A...
  • Page 51 POWR SLIDE RAIL SUSPENSION 10 Nm (1.0 m•kg, 7.2 ft•lb) 49 Nm (4.9 m•kg, 35 ft•lb) 60 Nm (6.0 m•kg, 43 ft•lb) 72 Nm (7.2 m•kg, 52 ft•lb) 74 Nm (7.4 m•kg, 55 ft•lb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty...
  • Page 52 POWR SLIDE RAIL SUSPENSION 75 Nm (7.5 m•kg, 54 ft•lb) Order Job name/Part name Q’ty Remarks Rear axle shaft Guide wheel Guide wheel Collar Tension adjuster Collar Collar Sliding frame For assembly, reverse the disassembly procedure.
  • Page 53 POWR SLIDE RAIL SUSPENSION Control rod parts number Control rod 1 Length Length Length Standard parts number (in) (in) (in) RS90RX/ 364.5 ~ 365.5 RS90GTX/ (14.350 ~ 14.390) RS90GTAX 8FR-4745A-00 277.3 (10.92) 150.5 (5.93) 359.5 ~ 360.5 RS90LTX/ (14.153 ~ 14.193) RS90LTGTX Control rod 2 Washer plate parts number...

  • Page 54: Eng

    SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) Order Job name/Part name Q’ty Remarks Seat and fuel tank removal Remove the parts in the order listed below. Handlebar Refer to “STEERING”...

  • Page 55: Oil Tank

    OIL TANK OIL TANK 10 Nm (1.0 m•kg, 7.2 ft•lb) 11 Nm (1.1 m•kg, 8.0 ft•lb) Order Job name/Part name Q’ty Remarks Oil tank removal Remove the parts in the order listed below. Right side cover Refer to “COWLINGS” in CHAPTER 3. Engine oil Drain.

  • Page 56: Camshafts

    CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER 10 Nm (1.0 m•kg, 7.2 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 13 Nm (1.3 m•kg, 9.4 ft•lb) Order Job name/Part name Q’ty Remarks Cylinder head cover removal Remove the parts in the order listed below. Coolant Drain.

  • Page 57: Ac Magneto Rotor And Starter Clutch

    AC MAGNETO ROTOR AND STARTER CLUTCH AC MAGNETO ROTOR AND STARTER CLUTCH 6 Nm (0.6 m•kg, 4.3 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 130 Nm (13.0 m•kg, 94 ft•lb) Order Job name/Part name Q’ty Remarks AC magneto rotor and starter...

  • Page 58: Carb

    CARB CARBURETORS AND FUEL PUMP CARBURETION CARBURETORS AND FUEL PUMP 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job name/Part name Q’ty Remarks Carburetor removal Remove the parts in the order listed below. Right side cover Refer to “BRAKE” in CHAPTER 4. Coolant Drain.
  • Page 59 CARB CARBURETORS AND FUEL PUMP 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job name/Part name Q’ty Remarks Carburetor heating inlet hose Disconnect. Carburetor heating outlet hose Disconnect. Vacuum hose Disconnect. Carburetor assembly Carburetor joint Fuel hose Disconnect. Fuel pump Collar For installation, reverse the removal procedure.

  • Page 60: Spec

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Model code number: 8GM1 (RS90RX) 8HC1 (RS90GTX) 8HC3 (RS90GTAX) 8HD1 (RS90LTX) 8HE1 (RS90LTGTX) Dimensions: Overall length 2,755 mm (108.5 in) (RS90RX/RS90GTX/RS90GTAX) 3,000 mm (118.1 in) (RS90LTX/RS90LTGTX) Overall width 1,225 mm (48.2 in) Overall height 1,160 mm (45.7 in) Weight:...
  • Page 61 SPEC GENERAL SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Drive chain housing oil: Type SAE 75W or 80W API GL-4 Gear oil Capacity 0.25 L (0.22 lmp qt, 0.26 US qt) Coolant: Capacity 4.8 L (4.22 Imp qt, 5.07 US qt) (RS90RX/RS90GTX/ RS90GTAX) 5.6 L (4.93 Imp qt, 5.92 US qt) (RS90LTX/RS90LTGTX) Fuel: Type Regular unleaded gasoline (Pump Octane...
  • Page 62 SPEC GENERAL SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Electrical: Ignition system Transistorized coil ignition Generator system AC magneto Bulb wattage × Quantity: 12 V, 60 W/55 W × 2 Headlight 12 V, 5 W/21 W × 2 Tail/Brake light 14 V, 50 mA × 6 Meter light 14 V, 80 mA ×...

  • Page 63: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Cylinder head: Volume (with spark plug) 22.82 ~ 23.62 cm (1.39 ~ 1.44 cu. in) <Warpage limit> 0.10 mm (0.0039 in) * Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating Bore size 79.000 ~ 79.010 mm (3.1102 ~ 3.1106 in) <Taper limit>...
  • Page 64 SPEC MAINTENANCE SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX 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 29.9 ~ 30.1 mm (1.1772 ~ 1.1850 in) Exhaust 25.9 ~ 26.1 mm (1.0197 ~ 1.0276 in) Head Diameter...
  • Page 65 SPEC MAINTENANCE SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Valve spring: Free length Intake 39.73 mm (1.56 in) <Limit> 37.74 mm (1.49 in) Exhaust 39.73 mm (1.56 in) <Limit> 37.74 mm (1.49 in) Installed length (valve closed) Intake 33.0 mm (1.30 in) Exhaust 33.0 mm (1.30 in) Compressed spring force (installed) Intake 136 ~ 158 N (13.9 ~ 16.1 kg, 30.6 ~ 35.5 lb)
  • Page 66 SPEC MAINTENANCE SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX 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) Ring type Taper Dimensions (B × T) 1.00 × 2.90 mm (0.039 × 0.114 in) Oil ring Dimensions (B ×...
  • Page 67 SPEC MAINTENANCE SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Carburetors: Type × Quantity CVK40 × 3 Manufacturer KEIHIN I.D. mark 8GM1 00 Main jet (M.J) #148 Main air jet (M.A.J) Jet needle (J.N) N425-8SJ00 Needle jet (N.J) W9554-26538#6 Pilot jet (P.J) Pilot air jet (P.A.J) #120 Pilot outlet...
  • Page 68 SPEC MAINTENANCE SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Cooling system: Filler cap opening pressure 95.0 ~ 125.0 kPa (0.95 ~ 1.25 kg/cm 13.5 ~ 17.8 psi) Water pump type Single-suction centrifugal pump (Impeller type) Reduction ratio 22/28 (0.786) Thermostat Opening temperature 69.0 ~ 73.0 °C (156.2 ~ 163.4 °F) Valve lift 7.0 mm (0.28 in)/85 °C (185 °F) Coolant type...

  • Page 69: Power Train

    SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Transmission: Type V-belt automatic Range of ratio 3.8 ~ 1.0 : 1 Engagement speed r/min 3,300 ~ 3,700 r/min (RS90RX/RS90GTX /RS90GTAX) 3,400 ~ 3,800 r/min (RS90LTX/RS90LTGTX) Shift r/min 8,250 ~ 8,750 r/min Sheave distance 267.0 ~ 270.0 mm (10.51 ~ 10.63 in) Sheave offset 13.5 ~ 16.5 mm (0.53 ~ 0.65 in)
  • Page 70 SPEC MAINTENANCE SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Rivet: Outer Part number 90261-06034 (RS90RX/RS90GTX/RS90GTAX) 90261-06033 (RS90LTX/RS90LTGTX) Material Steel Size 13.9 mm (0.547 in) (RS90RX/RS90GTX/RS90GTAX) 17.2 mm (0.677 in) (RS90LTX/RS90LTGTX) Quantity Hole quantity Inner Part number 90261-06034 Material Steel Size 13.9 mm (0.547 in) Quantity Hole quantity...
  • Page 71 SPEC MAINTENANCE SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Secondary sheave spring: Part number 90508-60012 Color code PINK Outside diameter 69.5 mm (2.736 in) Wire diameter 6.0 mm (0.236 in) Hole position Sheave side-spring side (twist angle) 3-3 (60°) Spring rate Compression 12.32 N/mm (1.256 kg/mm, 70.34 lb/in) Torsion 11,876 N•mm/rad (1,211 kg•mm/rad, 67,811 lb/in/rad) Number of coils...
  • Page 72 SPEC MAINTENANCE SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Slide rail suspension (Rear suspension): Front travel 256.0 mm (10.08 in) Rear travel 295.0 mm (11.61 in) (RS90RX/RS90GTX/RS90GTAX) 297.0 mm (11.69 in) (RS90LTX/RS90LTGTX) Spring type Coil spring Spring rate 44.1 N/mm (4.5 kg/mm, 251.9 lb/in) (RS90RX/RS90GTX/RS90GTAX) 53.9 N/mm (5.5 kg/mm, 307.8 lb/in) (RS90LTX/RS90LTGTX)

  • Page 73: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Frame: Frame material Aluminum Seat height 765 mm (30.1 in) Luggage box location Rear Steering: Lock-to-lock angle (left) 29.0° (R ski) 34.5° (L ski) (right) 34.5° (R ski) 29.0° (L ski) Ski alignment Toe-out Toe-out size 0 ~ 15 mm (0 ~ 0.59 in) Caster angle...

  • Page 74: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5° at 1,000 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T558/MITSUBISHI 1.19 ~ 1.61 Ω at 20°C (68°F) Primary coil resistance Secondary coil resistance 8.5 ~ 11.5 kΩ at 20°C (68°F) Charging system: Type AC magneto...
  • Page 75 SPEC MAINTENANCE SPECIFICATIONS Model RS90RX/RS90GTX/RS90GTAX/RS90LTX/RS90LTGTX Starter relay: Model/Manufacturer MS5F-421/ JIDECO Amperage rating 180 A 4.18 ~ 4.62 Ω at 20°C (68°F) Coil resistance T.P.S. (throttle position sensor): Manufacturer KEIHIN Resistance 4 ~ 6 kΩ at 20°C (68°F) (Blue – Black) 0 ~ 4 kΩ...

  • Page 76: High Altitude Settings

    SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS Temperature –30 °C –10 °C 10 °C (–22 °F) (–14 °F) (50 °F) Idling speed (r/min) Altitude 0 ~ 200 m #150 #148 #148 1,400 (0 ~ 700 ft) 200 ~ 1,500 m #148 #148 #145 1,400...

  • Page 77: Tightening Torque

    SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m•kg ft•lb Spark plug Cylinder head bolt (M10 × 1.25) See NOTE.*1 Apply the engine oil. Cylinder head bolt Camshaft cap and cylinder head Apply the engine oil. Cylinder head cover Camshaft and camshaft sprocket Timing chain tensioner...
  • Page 78 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m•kg ft•lb Balancer ® Balancer shaft bearing retainer Apply LOCTITE AC magneto rotor 13.0 Apply the engine oil. AC magneto rotor cover bolt (M6 × 1.0) × 11 AC magneto rotor cover bolt (M6 × 1.0) × 1 ®...

  • Page 79: Power Train

    SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Remarks m•kg ft•lb Primary sheave See NOTE. Spider and fixed sheave 20.0 145 Left-hand thread. ® Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) ®...
  • Page 80 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m•kg ft•lb Shock absorber adjuster assembly and frame Stopper band ® Sliding runner and sliding frame Apply LOCTITE ® Shaft and sliding frame Apply LOCTITE Shock absorber and front pivot arm Front pivot arm and control rod Front pivot arm and front pivot arm bracket Front pivot arm bracket and sliding frame...

  • Page 81: Chassis

    SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Remarks m•kg ft•lb Handlebar holder Steering column 1 (front) Steering column 1 (rear upper) Steering column 1 (rear lower) Steering column 2 (upper) Steering column 2 (lower) Steering column 2 and steering shaft ®...

  • Page 82: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (bolt) This chart specifies torque for standard fasten- m•kg ft•lb ers with standard I.S.O. pitch threads. Torque 10 mm 6 mm specifications for special components or assem- 12 mm 8 mm blies are included in the applicable sections of...

This manual is also suitable for:

Vector rs90gtx 2008Vector rs90gtax 2008Vector rs90ltx 2008Vector rs90ltgtx 2008

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