Yamaha RS90MK Manuals

Manuals and User Guides for Yamaha RS90MK. We have 3 Yamaha RS90MK manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha RS90MK Service Manual (841 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 19.52 MB

Yamaha RS90MK Service Manual (409 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 21.67 MB

Table of Contents
5
Chapter 1. General Information

9
Machine Identification

9
- Frame Serial Number
  9
- Engine Serial Number
  9
Important Information

10
- Preparation for Removal and Disassembly
  10
- All Replacement Parts
  10
- Gaskets, Oil Seals, and O-Rings
  11
- Lock Washers/Plates and Cotter Pins
  11
- Bearings and Oil Seals
  11
- Circlips
  11
- Loctite
  11
Special Tools

12
- For Tune up
  12
- For Engine Service
  12
- For Power Train Service
  15
- For Carburetion Service
  16
- For Electrical Service
  16
- Chapter 2
  
  18
- Periodic Inspection and Adjustment
  
  18
Introduction

18
Periodic Maintenance Chart

18
Engine

20
- Spark Plugs
  20
- Fuel Line Inspection
  20
- Cooling System
  21
- Valve Clearance Adjustment
  25
- Carburetor Synchronization
  30
- Engine Idle Speed Adjustment
  31
- Throttle Cable Free Play Adjustment
  32
- Throttle Override System (T.o.r.s.) Check
  33
- Compression Pressure Measurement
  34
- Engine Oil Level Inspection
  35
- Engine Oil Replacement
  37
- Crankcase Breather Hose Inspection
  40
- Carburetor Joints Inspection
  40
- Checking the Air Filter Element
  41
- Exhaust System Inspection
  41
Power Train

42
- Sheave Offset Adjustment
  42
- Drive V-Belt
  44
- Engagement Speed Check
  46
- Parking Brake Adjustment
  47
- Brake Fluid Level Inspection
  47
- Brake Pad Inspection
  48
- Brake Hose Inspection
  48
- Air Bleeding (Hydraulic Brake System)
  49
- Drive Chain
  50
- Track Tension Adjustment
  52
- Slide Runner Inspection
  54
- Maximizing Drive Track Life
  54
Chassis

56
- Ski/Ski Runner
  56
- Steering System
  57
- Lubrication
  59
Electrical

61
- Headlight Beam Adjustment
  61
- Battery Inspection
  61
- Fuse Inspection
  69
- Speedometer Unit Inspection
  71
Tuning

72
- Carburetor Tuning
  72
- Clutch
  79
- Gear Selection
  84
- High Altitude Tuning
  90
- Front Suspension
  91
- Rear Suspension
  93
- Chapter 3. Chassis
  
  100
Steering

100
- Rs90/Rs90R/Rsg90/Rst90/Rst90Tf
  100
- Rs90M
  102
- Removal
  106
- Inspection
  106
- Installation
  107
Ski

111
- RS90/RS90R/RSG90 "Usa/Canada
  111
  - RSG90 "Europe"/Rst90 "Europe"/Rst90Tf
    112
  - Rs90M
    113
  - RST90 "Usa/Canada
    114
  - Inspection
    115
  - INSTALLATION (RST90 "Usa/Canada")
    116
Front Suspension

117
- Handling Notes
  119
- Inspection
  119
- Installation
  120
- Chapter 4. Power Train
  
  123
Primary Sheave and Drive V-Belt

123
- Removal
  125
- Disassembly
  125
- Inspection
  126
- Assembly
  128
- Installation
  131
Secondary Sheave

132
- Disassembly
  134
- Inspection
  134
- Assembly
  135
- Installation
  137
Drive Chain Housing

138
- Without Reverse Model
  138
- Removal
  140
- Inspection
  140
- Installation
  142
- With Reverse Model
  143
- Removal
  146
- Inspection
  146
- Installation
  147
Secondary Shaft

149
- Removal
  150
- Inspection
  151
- Installation
  151
- Secondary Shaft and Drive Chain Housing Installation
  154
Brake

156
- Brake Pad Replacement
  157
- Brake Caliper Disassembly
  160
- Brake Caliper Inspection and Repair
  160
- Brake Caliper Assembly
  161
- Brake Caliper Installation
  161
- Inspection
  163
- Brake Master Cylinder Assembly
  163
- Installation
  163
Slide Rail Suspension

164
- Rs90/Rs90R
  164
- Rsg90
  170
- Rs90M
  175
- Rst90
  181
- Rst90Tf
  187
- Removal
  194
- Inspection
  194
- Assembly
  195
- Installation
  197
Front Axle and Track

200
- Inspection
  201
- Installation
  201
- Chapter 5. Engine
  
  203
Seat and Fuel Tank

203
- Rs90/Rs90R/Rsg90/Rs90M
  203
Backrest and Passenger Seat

204
- Rst90/Rst90Tf
  204
Rider Seat and Fuel Tank

205
- Rst90/Rst90Tf
  205
- Removal
  206
- Installation
  206
Oil Tank

207
Engine Assembly

208
- Hose and Leads
  208
- Engine Assembly
  209
- Removal
  211
- Installation
  211
Exhaust Pipe and Muffler

213
- Installation
  214
Camshafts

216
- Cylinder Head Cover
  216
- Camshafts
  217
- Removal
  218
- Inspection
  219
- Installation
  222
Cylinder Head

226
- Removal
  227
- Inspection
  227
- Installation
  228
Valves and Valve Springs

230
- Removal
  231
- Inspection
  232
- Installation
  236
A.C. Magneto Rotor and Starter Clutch

239
- Removal
  240
- Inspection
  241
- Installation
  242
Oil Pan and Oil Pump

244
- Removal
  247
- Inspection
  247
- Installation
  249
Crankcase

251
- Connecting Rods and Pistons
  253
- Crankshaft and Balancer Shaft
  254
- Removal
  256
- Inspection
  258
- Installation
  269
Heat Exchanger

276
- Chapter 6
  
  279
  - Inspection
    279
  - Installation
    280
Thermostat

281
- Inspection
  282
- Installation
  282
Water Pump

284
- Removal
  286
- Disassembly
  286
- Inspection
  287
- Assembly
  287
- Installation
  288
- Chapter 7. Carburetion
  
  289
Carburetors and Fuel Pump

289
- Inspection
  294
- Assembly
  296
- Installation
  297
- Fuel Level Adjustment
  298
- Throttle Position Sensor (T
  299
- Inspection and Adjustment
  299
- Inspection
  300
- Installation
  301
- Chapter 8. Electrical
  
  302
Switch Inspection

302
- Inspecting a Switch Shown in the Manual
  302
Ignition System

303
- Circuit Diagram
  304
- Troubleshooting
  305
- Ignition Spark Gap
  307
- Ignition Coil
  307
- Pickup Coil
  308
- Throttle Override System (T.o.r.s.)
  309
- Engine Stop Switch
  309
- Throttle Switch
  310
- Main Switch
  310
Electrical Starting System

311
- Circuit Diagram
  313
- Starter Motor
  314
Charging System

319
- Circuit Diagram
  320
- Troubleshooting
  320
- Battery
  321
- A.C. Magneto
  321
Lighting System

322
- Circuit Diagram
  323
- Troubleshooting
  324
- Bulb(S)
  326
- Headlight Beam Switch
  326
- Headlight Relay
  326
- Load Control Relay
  327
Signal System

328
- Circuit Diagram
  329
- Troubleshooting
  330
- Brake Light Switch
  336
- Gear Position Switch (Rs90R/Rsg90/Rst90/Rst90Tf)
  336
- DC Back Buzzer (Rs90R/Rsg90/Rst90/Rst90Tf)
  336
- Coolant Temperature Sensor
  337
- Oil Level Switch
  338
- Fuel Sender
  338
- Speed Sensor
  339
Grip Warmer System

340
- Circuit Diagram
  341
- Troubleshooting
  342
- Grip and Thumb Warmer Coil
  344
- Thumb Warmer Adjustment Switch
  344
- Grip Warmer Adjustment Switch
  345
- Passenger Grip Warmer (Rst90/Rst90Tf)
  345
- Passenger Grip Warmer Switch (Rst90/Rst90Tf)
  346
- Passenger Grip Warmer Relay (Rst90/Rst90Tf)
  346
Carburetor Heater System

347
- Circuit Diagram
  348
- Troubleshooting
  349
- Carburetor Heater Relay
  350
- Carburetor Heater
  350
Self-Diagnosis

351
- Self-Diagnosis Code
  352
- Chapter 9. Specifications
  
  354
General Specifications

354
Maintenance Specifications

357
- Engine
  357
- Power Train
  362
- Chassis
  368
- Electrical
  370
- High Altitude Settings
  372
Tightening Torque

373
- Engine
  373
- Power Train
  375
- Chassis
  378
General Torque Specifications

379
Definition of Units

379
Cable Routing

380

Yamaha RS90MK Owner's Manual (102 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 8.31 MB

Table of Contents
6
Yamaha Motor Corporation, U.s.a. Snowmobile Limited Warranty

8
Yamaha Extended Service (Y.e.s.)

11
Location of the Important Labels

12
Safety Information

15
Description

18
Control Functions

20
- Main Switch
  20
- Starter Lever (Choke)
  21
- Throttle Lever
  21
- Engine Overheating Prevention System
  21
- Throttle Override System (T.O.R.S.)
  22
- Speedometer Unit
  23
- High Beam Indicator Light
  23
- Fuel Meter and Grip/Thumb Warmer Level Indicator
  24
- Fuel Level Warning Indicator
  25
- Oil Level Warning Indicator
  25
- Low Coolant Temperature Indicator Light
  25
- Coolant Temperature Warning Indicator
  26
- Engine Stop Switch
  27
- Brake Lever
  27
- Parking Brake Lever
  28
- Shift Lever
  28
- Headlight Beam Switch
  29
- Shroud Latches
  29
- Drive Guard
  29
- V-Belt Holders
  30
- Carburetor Coolant Shut-Off Lever
  30
- Storage Compartment
  30
Pre-Operation Checks

31
- Fuel
  31
- Engine Oil
  32
- Engine Oil Level
  33
- Coolant
  34
- Throttle Lever
  35
- Throttle Override System (T.O.R.S.)
  35
- Brake
  36
- Brake Fluid Leakage
  37
- V-Belt
  37
- Drive Guard
  37
- Drive Track
  38
- 51-MM (2.0-In) High-Profile Pattern Drive Track
  38
- Slide Runners
  39
- Skis and Ski Runners
  39
- Steering System
  40
- Lights
  40
- Air Filter
  40
- Fittings and Fasteners
  41
- Tool Kit and Recommended Equipment
  41
Operation

42
- Starting the Engine
  42
- Break-In
  43
- Riding Your Snowmobile
  44
- Getting to Know Your Snowmobile
  44
- Learning to Ride Your Snowmobile
  44
- To Start out and Accelerate
  44
- Braking
  44
- Turning
  45
- Riding Uphill
  45
- Riding Downhill
  46
- Traversing a Slope
  46
- Ice or Icy Surface
  46
- Hard-Packed Snow
  47
- Operation on Surfaces Other than
  47
- Snow or Ice
  47
- Maximizing Drive Track Life
  48
- Strap
  49
- Driving
  50
- Stopping the Engine
  51
- Transporting
  52
Periodic Maintenance

53
- Periodic Maintenance Chart
  53
- Tool Kit
  56
- Spark Plug Inspection
  56
- Engine Idle Speed Adjustment
  58
- Throttle Cable Adjustment
  58
- Carburetor Adjustment
  59
- High Altitude Adjustments
  61
- Adjusting the Valve Clearance
  61
- Changing the Engine Oil
  62
- Cooling System
  65
- V-Belt Replacement
  67
- Checking the Drive Chain Housing Oil Level and the Drive Chain Tension
  69
- Checking the Brake Pads
  71
- Checking the Parking Brake Pads
  71
- Checking the Brake Fluid Level
  72
- Brake Fluid Replacement
  72
- Suspension
  72
- Drive Track Adjustment
  81
- Ski Alignment
  83
- Handlebar Adjustment
  83
- Lubrication
  86
- Headlight Bulb Replacement
  87
- Headlight Beam Adjustment
  87
- Battery
  88
- Fuse Replacement
  88
Troubleshooting

91
Storage

95
Specifications

97
- Dimensions
  97
- Engine
  97

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Yamaha RS90MK Manuals

Yamaha RS90MK Service Manual (841 pages)

Table of Contents

Yamaha RS90MK Service Manual (409 pages)

Table of Contents

Chapter 1. General Information

Machine Identification

Important Information

Special Tools

Chapter 2

Periodic Inspection and Adjustment

Introduction

Periodic Maintenance Chart

Engine

Power Train

Chassis

Electrical

Tuning

Chapter 3. Chassis

Steering

Ski

Front Suspension

Chapter 4. Power Train

Primary Sheave and Drive V-Belt

Secondary Sheave

Drive Chain Housing

Secondary Shaft

Brake

Slide Rail Suspension

Front Axle and Track

Chapter 5. Engine

Seat and Fuel Tank

Backrest and Passenger Seat

Rider Seat and Fuel Tank

Oil Tank

Engine Assembly

Exhaust Pipe and Muffler

Camshafts

Cylinder Head

Valves and Valve Springs

A.C. Magneto Rotor and Starter Clutch

Oil Pan and Oil Pump

Crankcase

Heat Exchanger

Chapter 6

Thermostat

Water Pump

Chapter 7. Carburetion

Carburetors and Fuel Pump

Chapter 8. Electrical

Switch Inspection

Ignition System

Electrical Starting System

Charging System

Lighting System

Signal System

Grip Warmer System

Carburetor Heater System

Self-Diagnosis

Chapter 9. Specifications

General Specifications

Maintenance Specifications

Tightening Torque

General Torque Specifications

Definition of Units

Cable Routing

Yamaha RS90MK Owner's Manual (102 pages)

Table of Contents

Yamaha Motor Corporation, U.s.a. Snowmobile Limited Warranty

Yamaha Extended Service (Y.e.s.)

Location of the Important Labels

Safety Information

Description

Control Functions

Pre-Operation Checks

Operation

Periodic Maintenance

Troubleshooting

Storage

Specifications