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2004 2005 2006 Yamaha RS Vector Nytro Rage Factory Manuals

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(ID 131962503)
2004, 2005, 2006 Yamaha RS Vector Nytro Rage Snowmobiles Factory Service Manual

568 Pages

Covers models -

RS90, RS90R, RSG90, RS90M, RST90, RST90TF
RS90N, RS90NR, RS90RS, RS90MS, RS90GT

RS90K, RS90RK, RSG90K,
RS90MK, RST90K, RST90TFK
RS90NL, RS90NRL,
RS90RSL, RS90GTL, RS90MSL

May also cover model years later than listed.


Chapters Include -

GENERAL INFORMATION
PERIODIC INSPECTION AND ADJUSTMENT
CHASSIS
POWER TRAIN
ENGINE
COOLING SYSTEM
CARBURETION
ELECTRICAL
SPECIFICATIONS

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
LOCTITE® .................................................. 1-3
SPECIAL TOOLS ............................................. 1-4
FOR TUNE UP............................................ 1-4
FOR ENGINE SERVICE............................. 1-4
FOR POWER TRAIN SERVICE ................. 1-7
FOR CARBURETION SERVICE ................ 1-8
FOR ELECTRICAL SERVICE .................... 1-8

CHAPTER 2.
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION............................................... 2-1
PERIODIC MAINTENANCE CHART................ 2-1
ENGINE ............................................................ 2-3
SPARK PLUGS........................................... 2-3
FUEL LINE INSPECTION........................... 2-3
COOLING SYSTEM.................................... 2-4
VALVE CLEARANCE ADJUSTMENT ........ 2-7
CARBURETOR SYNCHRONIZATION..... 2-13
ENGINE IDLE SPEED ADJUSTMENT..... 2-14
THROTTLE CABLE FREE PLAY
ADJUSTMENT.......................................... 2-15
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK.................................... 2-16
COMPRESSION PRESSURE
MEASUREMENT...................................... 2-17
ENGINE OIL LEVEL INSPECTION .......... 2-18
ENGINE OIL REPLACEMENT ................. 2-20
CRANKCASE BREATHER HOSE
INSPECTION............................................ 2-23
CARBURETOR JOINTS INSPECTION.... 2-23
CHECKING THE AIR FILTER
ELEMENT................................................. 2-23
EXHAUST SYSTEM INSPECTION .......... 2-24
POWER TRAIN............................................... 2-25
SHEAVE OFFSET ADJUSTMENT ........... 2-25
DRIVE V-BELT.......................................... 2-27
ENGAGEMENT SPEED CHECK.............. 2-29
PARKING BRAKE ADJUSTMENT............ 2-30
BRAKE FLUID LEVEL INSPECTION ....... 2-30
BRAKE PAD INSPECTION....................... 2-31
BRAKE HOSE INSPECTION.................... 2-31
AIR BLEEDING (HYDRAULIC BRAKE
SYSTEM) .................................................. 2-32
DRIVE CHAIN........................................... 2-33
TRACK TENSION ADJUSTMENT............ 2-35
SLIDE RUNNER INSPECTION ................ 2-37
MAXIMIZING DRIVE TRACK LIFE........... 2-37
CHASSIS ........................................................ 2-39
SKI/SKI RUNNER ..................................... 2-39
STEERING SYSTEM................................ 2-40
LUBRICATION.......................................... 2-41
ELECTRICAL ................................................. 2-44
HEADLIGHT BEAM ADJUSTMENT ......... 2-44
BATTERY INSPECTION........................... 2-44
FUSE INSPECTION.................................. 2-52
SPEEDOMETER UNIT INSPECTION ...... 2-54
TUNING .......................................................... 2-55
CARBURETOR TUNING.......................... 2-55
CLUTCH.................................................... 2-62
GEAR SELECTION................................... 2-67
HIGH ALTITUDE TUNING........................ 2-73
FRONT SUSPENSION ............................. 2-74
REAR SUSPENSION................................ 2-75

CHAPTER 3.
CHASSIS
STEERING........................................................ 3-1
RS90/RS90R/RSG90/RST90/RST90TF..... 3-1
RS90M........................................................ 3-3
REMOVAL................................................... 3-7
INSPECTION .............................................. 3-7
INSTALLATION........................................... 3-8
SKI .................................................................. 3-12
RS90/RS90R/RSG90 USA/Canada ....... 3-12
RSG90 Europe/RST90 Europe/
RST90TF................................................... 3-13
RS90M...................................................... 3-14
RST90 USA/Canada............................... 3-15
INSPECTION ............................................ 3-16
INSTALLATION
(RST90 USA/Canada) ............................ 3-1
FRONT SUSPENSION ................................... 3-18
HANDLING NOTES.................................. 3-20
INSPECTION............................................ 3-20
INSTALLATION ........................................ 3-21

CHAPTER 4.
POWER TRAIN
PRIMARY SHEAVE AND DRIVE V-BELT....... 4-1
REMOVAL .................................................. 4-3
DISASSEMBLY........................................... 4-3
INSPECTION.............................................. 4-4
ASSEMBLY................................................. 4-6
INSTALLATION .......................................... 4-9
SECONDARY SHEAVE ................................. 4-10
DISASSEMBLY......................................... 4-12
INSPECTION............................................ 4-12
ASSEMBLY............................................... 4-13
INSTALLATION ........................................ 4-15
DRIVE CHAIN HOUSING............................... 4-16
WITHOUT REVERSE MODEL ................. 4-16
REMOVAL ................................................ 4-18
INSPECTION............................................ 4-18
INSTALLATION ........................................ 4-20
WITH REVERSE MODEL......................... 4-21
REMOVAL ................................................ 4-24
INSPECTION............................................ 4-24
INSTALLATION ........................................ 4-25
SECONDARY SHAFT .................................... 4-27
REMOVAL ................................................ 4-28
INSPECTION............................................ 4-29
INSTALLATION ........................................ 4-29
SECONDARY SHAFT AND DRIVE CHAIN
HOUSING INSTALLATION....................... 4-32
BRAKE ........................................................... 4-34
BRAKE PAD REPLACEMENT ................. 4-35
BRAKE CALIPER DISASSEMBLY........... 4-38
BRAKE CALIPER INSPECTION
AND REPAIR ............................................ 4-38
BRAKE CALIPER ASSEMBLY................. 4-39
BRAKE CALIPER INSTALLATION........... 4-39
INSPECTION............................................ 4-41
BRAKE MASTER CYLINDER
ASSEMBLY............................................... 4-41
INSTALLATION ........................................ 4-41
SLIDE RAIL SUSPENSION............................ 4-42
RS90/RS90R............................................. 4-42
RSG90 ...................................................... 4-48
RS90M...................................................... 4-53
RST90....................................................... 4-59
RST90TF................................................... 4-65
REMOVAL................................................. 4-72
INSPECTION ............................................ 4-72
ASSEMBLY............................................... 4-73
INSTALLATION......................................... 4-75
FRONT AXLE AND TRACK........................... 4-78
INSPECTION ............................................ 4-79
INSTALLATION......................................... 4-79

CHAPTER 5.
ENGINE
SEAT AND FUEL TANK................................... 5-1
RS90/RS90R/RSG90/RS90M..................... 5-1
BACKREST AND PASSENGER SEAT ........... 5-2
RST90/RST90TF ........................................ 5-2
RIDER SEAT AND FUEL TANK ...................... 5-3
RST90/RST90TF ........................................ 5-3
REMOVAL................................................... 5-4
INSTALLATION........................................... 5-4
OIL TANK ......................................................... 5-5
ENGINE ASSEMBLY ....................................... 5-6
HOSE AND LEADS..................................... 5-6
ENGINE ASSEMBLY.................................. 5-8
REMOVAL................................................... 5-9
INSTALLATION........................................... 5-9
EXHAUST PIPE AND MUFFLER................... 5-11
INSTALLATION......................................... 5-12
CAMSHAFTS.................................................. 5-14
CYLINDER HEAD COVER ....................... 5-14
CAMSHAFTS............................................ 5-15
REMOVAL................................................. 5-16
INSPECTION ............................................ 5-17
INSTALLATION......................................... 5-20
CYLINDER HEAD........................................... 5-24
REMOVAL................................................. 5-25
INSPECTION ............................................ 5-25
INSTALLATION......................................... 5-26
VALVES AND VALVE SPRINGS................... 5-28
REMOVAL................................................. 5-29
INSPECTION ............................................ 5-30
INSTALLATION......................................... 5-34
A.C. MAGNETO ROTOR
AND STARTER CLUTCH............................... 5-37
REMOVAL ................................................ 5-38
INSPECTION............................................ 5-39
INSTALLATION ........................................ 5-40
OIL PAN AND OIL PUMP .............................. 5-42
REMOVAL ................................................ 5-45
INSPECTION............................................ 5-45
INSTALLATION ........................................ 5-47
CRANKCASE ................................................. 5-49
CRANKCASE............................................ 5-49
CONNECTING RODS AND PISTONS..... 5-51
CRANKSHAFT
AND BALANCER SHAFT ......................... 5-52
REMOVAL ................................................ 5-54
INSPECTION............................................ 5-56
INSTALLATION ........................................ 5-67

CHAPTER 6.
COOLING SYSTEM
HEAT EXCHANGER ........................................ 6-1
INSPECTION.............................................. 6-4
INSTALLATION .......................................... 6-5
THERMOSTAT ................................................. 6-6
INSPECTION.............................................. 6-7
INSTALLATION .......................................... 6-7
WATER PUMP.................................................. 6-9
REMOVAL ................................................ 6-11
DISASSEMBLY......................................... 6-11
INSPECTION............................................ 6-12
ASSEMBLY............................................... 6-12
INSTALLATION ........................................ 6-13

CHAPTER 7.
CARBURETION
CARBURETORS AND FUEL PUMP................ 7-1
INSPECTION.............................................. 7-6
ASSEMBLY................................................. 7-8
INSTALLATION .......................................... 7-9
FUEL LEVEL ADJUSTMENT ................... 7-10
THROTTLE POSITION SENSOR (T.P.S.)
INSPECTION AND ADJUSTMENT .......... 7-11
INSPECTION............................................ 7-12
INSTALLATION ........................................ 7-13

CHAPTER 8.
ELECTRICAL
SWITCH INSPECTION ..................................... 8-1
SWITCH INSPECTION............................... 8-1
INSPECTING A SWITCH SHOWN
IN THE MANUAL ........................................ 8-1
IGNITION SYSTEM .......................................... 8-2
CIRCUIT DIAGRAM.................................... 8-2
TROUBLESHOOTING................................ 8-4
IGNITION SPARK GAP .............................. 8-6
IGNITION COIL........................................... 8-6
PICKUP COIL ............................................. 8-7
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.).................................................... 8-8
ENGINE STOP SWITCH ............................ 8-8
THROTTLE SWITCH.................................. 8-9
MAIN SWITCH............................................ 8-9
ELECTRICAL STARTING SYSTEM .............. 8-10
CIRCUIT DIAGRAM.................................. 8-10
TROUBLESHOOTING.............................. 8-11
STARTER MOTOR................................... 8-13
CHARGING SYSTEM..................................... 8-18
CIRCUIT DIAGRAM.................................. 8-18
TROUBLESHOOTING.............................. 8-19
BATTERY.................................................. 8-20
A.C. MAGNETO........................................ 8-20
LIGHTING SYSTEM ....................................... 8-22
CIRCUIT DIAGRAM.................................. 8-22
TROUBLESHOOTING.............................. 8-24
BULB(S) .................................................... 8-26
HEADLIGHT BEAM SWITCH ................... 8-26
HEADLIGHT RELAY................................. 8-26
LOAD CONTROL RELAY......................... 8-27
SIGNAL SYSTEM........................................... 8-28
CIRCUIT DIAGRAM.................................. 8-28
TROUBLESHOOTING.............................. 8-30
BRAKE LIGHT SWITCH ........................... 8-36
GEAR POSITION SWITCH
(RS90R/RSG90/RST90/RST90TF)........... 8-36
DC BACK BUZZER
(RS90R/RSG90/RST90/RST90TF)........... 8-36
COOLANT TEMPERATURE SENSOR .... 8-37
OIL LEVEL SWITCH................................. 8-38
FUEL SENDER......................................... 8-38
SPEED SENSOR...................................... 8-39
GRIP WARMER SYSTEM.............................. 8-40
CIRCUIT DIAGRAM.................................. 8-40
TROUBLESHOOTING.............................. 8-42
GRIP AND THUMB WARMER COIL ........ 8-44
THUMB WARMER ADJUSTMENT
SWITCH.................................................... 8-44
GRIP WARMER ADJUSTMENT
SWITCH.................................................... 8-45
PASSENGER GRIP WARMER
(RST90/RST90TF).................................... 8-45
PASSENGER GRIP WARMER SWITCH
(RST90/RST90TF).................................... 8-46
PASSENGER GRIP WARMER RELAY
(RST90/RST90TF).................................... 8-46
CARBURETOR HEATER SYSTEM............... 8-48
CIRCUIT DIAGRAM.................................. 8-48
TROUBLESHOOTING.............................. 8-50
CARBURETOR HEATER RELAY ............ 8-51
CARBURETOR HEATER ......................... 8-51
SELF-DIAGNOSIS.......................................... 8-52
SELF-DIAGNOSIS CODE ........................ 8-53
CHAPTER 9.
SPECIFICATIONS
GENERAL SPECIFICATIONS ......................... 9-1
MAINTENANCE SPECIFICATIONS ................ 9-4
ENGINE ...................................................... 9-4
POWER TRAIN........................................... 9-9
CHASSIS .................................................. 9-15
ELECTRICAL............................................ 9-17
HIGH ALTITUDE SETTINGS.................... 9-19
TIGHTENING TORQUE.................................. 9-20
ENGINE .................................................... 9-20
POWER TRAIN......................................... 9-22
CHASSIS .................................................. 9-25
GENERAL TORQUE SPECIFICATIONS....... 9-26
DEFINITION OF UNITS.................................. 9-26
CABLE ROUTING .......................................... 9-28

Supplementary Manual for 2006 Models -

GENERAL INFORMATION
SPECIAL TOOLS .................................................1
FOR POWER TRAIN......................................1
PERIODIC INSPECTION AND
ADJUSTMENT
INTRODUCTION...................................................2
PERIODIC MAINTENANCE CHART FOR THE
EMISSION CONTROL SYSTEM..........................2
GENERAL MAINTENANCE AND
LUBRICATION CHART........................................3
CHASSIS ..............................................................5
BRAKE LEVER ADJUSTMENT
(RS90N/RS90NR/RS90RS/RS90GT).............5
LUBRICATION................................................5
TUNING ................................................................8
CARBURETOR TUNING................................8
CLUTCH .......................................................14
GEAR SELECTION ......................................18
FRONT SUSPENSION.................................24
REAR SUSPENSION ...................................26
CHASSIS
STEERING..........................................................34
RS90N/RS90NR/RS90RS/RS90MS.............34
RS90GT........................................................36
INSTALLATION ............................................38
SKI ......................................................................42
RS90N/RS90NR/RS90RS/RS90GT .............42
RS90MS........................................................43
FRONT SUSPENSION .......................................44
POWER TRAIN
PRIMARY SHEAVE AND DRIVE V-BELT.........46
DRIVE CHAIN HOUSING...................................47
WITHOUT REVERSE MODEL .....................47
INSTALLATION ............................................49
WITH REVERSE MODEL.............................50
REMOVAL ....................................................53
INSTALLATION ............................................54
SECONDARY SHAFT ....................................... 56
INSTALLATION............................................ 56
SECONDARY SHAFT AND DRIVE CHAIN
HOUSING INSTALLATION.......................... 58
BRAKE .............................................................. 60
BRAKE CALIPER DISASSEMBLY .............. 63
BRAKE CALIPER INSTALLATION.............. 63
RS90N/RS90NR/RS90RS/RS90MS............ 64
RS90GT ....................................................... 65
SLIDE RAIL SUSPENSION............................... 66
RS90N/RS90NR/RS90RS ........................... 66
RS90GT ....................................................... 72
RS90MS....................................................... 76
ASSEMBLY.................................................. 82
INSTALLATION............................................ 83
FRONT AXLE AND TRACK.............................. 86
INSTALLATION............................................ 87
ENGINE
SEAT AND FUEL TANK.................................... 88
RS90N/RS90NR/RS90RS/RS90GT ............ 88
RS90MS....................................................... 89
EXHAUST PIPE AND MUFFLER...................... 90
RS90MS....................................................... 90
CARBURETION
CARBURETORS AND FUEL PUMP................. 92
SPECIFICATIONS
GENERAL SPECIFICATIONS........................... 94
MAINTENANCE SPECIFICATIONS.................. 97
ENGINE ....................................................... 97
POWER TRAIN.......................................... 102
CHASSIS ................................................... 106
ELECTRICAL............................................. 108
HIGH ALTITUDE SETTINGS..................... 110
TIGHTENING TORQUE................................... 111
ENGINE ..................................................... 111
POWER TRAIN.......................................... 113
CHASSIS ................................................... 116
GENERAL TORQUE SPECIFICATIONS ........ 117
DEFINITION OF UNITS ................................... 117
CABLE ROUTING ........................................... 119

File size - 20.9MB
File Type - pdf file that can be read by Adobe Acrobat Reader
File Delivery - Zip


There are 3 ways to approach car maintenance/repair.

1. Call your Dealer/Service Center/Workshop. Pay $60 to get your vehicle towed or transported to their shop. Wait a few days for an appointment. Get your car back about a week later, and be a few hundred dollars out of pocket.

Result = $1000 dollars out of pocket, fixed car, empty wallet.

2. Try and fix the problem on your own. Create a shopping list and go and buy a few dollars worth of parts. Start the repair/service. Realize you don't have the rights parts or knowledge to fix it. Go and buy more parts to replace the ones you broke trying to fix the original problem. Keep trying/buying until eventually you are having a breakdown yourself.

Result = $300 dollars spent, hours wasted, car still not fixed.

3. Download the original OEM Factory Service Manual for your vehicle from A1 Manuals. Read and study it to determine the problem/resolution. Create a shopping list and buy a few dollars worth of parts that you actually need. Start the repair...and fix it first time.

Result = $50 spent, repair is done, get on with your life and enjoy the ride.



THIS MANUAL COVERS:
Repair and maintenance procedures from the people that actually manufactured your vehicle. You cannot get more detailed or accurate information than you will find in the OEM Factory Service Manual. This is the manual that the dealerships use to fix/repair/service your vehicle. Diagrams/photos/troubleshooting procedures/maintenance schedules etc are all included to help you fix your problem fast.

GET THE INFORMATION YOU WANT NOW:
With this pdf manual, you can find the information you require much faster than a conventional paper repair book. Fully indexed and searchable pdf manuals are portable and practicle. Read it in your smartphone as well as your pc/mac/tablet. You can print out just the information you need to complete your job, then dispose of the printouts later when you are done.

INSTANT DELIVERY:
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