Yamaha RS90LTGTA manual

OWNER’S MANUAL 8JA-28199-11 LIT-12628-02-95 ESU10012 Read this manual carefully before operating this vehicle. RS90GTA RS90LTGTA RST90A RST90GTA DIC183[...]

ESU10041 Read this manua l carefully before opera ting this vehicle. Thi s manual shou ld stay with this ve hicle if it is sol d. U8JA11E0.book Page 1 Monday, June 14, 2010 10:22 AM[...]

Introduction ESU10121 Congratulations on your purchase of a Yamaha snowmob ile. This model is the result of Yamaha’s vast experience in the produc- tion of fine s porting and touring snowmobiles. It represents the high degree of craftsmanship and reliability that have made Yamaha a lead- er in these fields. This manual w ill give you an understan[...]

Important manual information ESU10151 Particularly important information is distin - guished in this manual by the following no ta- tions. This is the safety alert symbol. It is used to alert you to potentia l personal inj ury haz- ards. Obey all safety messages that follow this symbol to avoid pos sible injury or death. W ARNI NG EWS00021 A WARNIN[...]

Contents Location of the importa nt labels ..... 1 Safety informa tion . ............. .............. 6 Description ....... ............. ............ ........ 8 Control functions ................ ............ 11 Main swi tch ................. ............ ..... 11 Starter (choke) leve r (RST90) ...... 11 Throttle lev er ............... ...........[...]

Contents Carburetor s (RST90 ) ... ............ ..... 77 High-al titude settin gs ......... ........... 77 Valve c learance .... ............. ........... 77 Engine o il and oil filt er ca rtridge ... 77 Cooling sy stem ............ ............ ..... 83 V-belt . ............. ............. ............ ..... 88 Drive cha in housi ng ..............[...]

Location of the important labels 1 ESU10216 Read and understand a ll of the labels on your ve hicle. They contai n important information for safe and proper operati on of your vehicle. Ne ver remove any labels from your vehicle. If a label becomes difficult to read or come s off, a replacement label is av ailable from your Yamaha deal- er. 1 4 9 5 [...]

Location of the important labels 2 12 11 10 13 17 17 12 17 15 11 14 10 16 17 11 12 17 14 16 17 15 10 RS90GT / RS90L TGT RST90GT RST90 U8JA11E0.book Page 2 Monday, June 14, 2010 10:22 AM[...]

Location of the important labels 3 ATTENTION 8ET-2815K-10 TUNE-UP SPECIFICATI ONS ENGINE 1.SPARK PLUG 2.SPARK PLUG GAP 3.IDLE SPEED SPEC IFICAT IONS D E LA M ISE AU POINT MOTEUR 1.TYPE DE BOUGIE 2.ECARTEMENT DES ÉLECTRODES 3.RÉGIME DE RALENTI CR8E(NGK) 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 1300 ± 50 r/min CR8E(NGK) 0.7 ~ 0.8 mm 1300 ± 50 r/min 8HF 8H[...]

Location of the important labels 4 DRIVE 1. CHAIN CASE OIL Q ’ TY 2. CHAIN CASE OIL TYPE 3. TRACK TENSION * FOR MORE INFO: SEE SERVICE MANUAL FOR THIS MODEL. * SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE. ENTRA Î NEMENT 1. CAPACIT É D ’ HUILE DU CARTER DE CHA Î NE 2. TYPE D ’ HUILE DU CARTER DE CHA Î NE 3. FL È CHE DE LA CHENILLE * P[...]

Location of the important labels 5 20kg {44lbs} LO AD LIMIT / CHARGE LIMITE 8FM-24897-01 10kg {22lbs} LO AD LIMIT / CHARGE LIMITE 8ET-24897-00 MAX. T O WING FORCE FORCE DE REMORQU A GE MAX. 1176 N (120 kgf), 264 lbf MAX. VER TICAL FORCE FORCE VERTICALE MAX. 147 N (15 kgf), 33 lbf 8GS-2817S-E0 13 RS90LTGT 14 RST90 / RST90GT 15 RST90 / RST90GT 16 RST[...]

Safety information 6 ESU10193 As the vehicle ’ s owner, you are responsible for the safe and proper operation of your snowmobile. When you ride yo ur snowmo- bile, you must know and use the foll owing for your safety. Severe injury or death m ay result if you ignore any of the following . Before you opera te your snowmobile ● Read the Owner ’[...]

Safety information 7 ● Many surfaces such as ice and hardpacked snow require much longer stopping distanc - es. Be alert, plan ahead and begin deceler- ating early. The best braking method on most surfaces is to releas e the throttle and apply the brake gentl y — not suddenly. Avoid carbon monoxide poisoning All engine exhaust c ontains carbon [...]

Descripti on 8 ESU10261 1,2,3 4 5,6,7 8,9 10 11 12 13 14 1,2,3 RS90GT RS90L TGT 4 5,6,7 8,9 10 11 12 13 14 1. Battery 2. Main fuse 3. Air filter 4. Oil fill er cap 5. Fuse box 6. Coolant reservoir 7. Coolant recov ery tank 8. Storage compar tment 9. T ool kit 10. T ail/ brake l ight 11. Slide rail suspension 12. Rear shock absorber damping f orce r[...]

Description 9 1,2,3 4 7 8 9 10,11,12 13 15 16 17 5,6 RST90GT RST90 10,12 1,2,3,4 5,6 20 7 8 9 19 13 15 16 17 14 18 14 1. Battery 2. Main fuse 3. Air filter 4. Oil fill er cap 5. Fuse box 6. Coolant reservoir 7. P assenger grip warmer switch 8. P assenger grip 9. Backrest 10. Storage compar tment 11. Storage pouch (RST90GT) 12. T ool kit 13. T ail/ [...]

Descripti on 10 TIP ● The snowmob ile you have purchased ma y differ sligh tly from thos e shown in the figures of this manual. ● Design and spec ifications are subjected to change without no tice. 1 23 6 7 8 9 10 11 12 124 1 2 14 9 11 5 8 7 10 13 1 RS90GT / RS90L TGT RST90GT RST90 23 7 8 6 11 9 10 12 13 1. Brake le ver 2. P arking brake le ver[...]

Control functions 11 ESU13740 Main switch The main switch controls the ignition and lighting systems. The various positions are described below. Off The ignition circuit is sw itched off. The key can be removed onl y in this position. On The ignition circuit is sw itched on. Start The starting circuit is switched on. The starter motor cranks the en[...]

Control functions 12 ESU13750 Throttle override system (T.O.R.S.) W ARNI NG EWS00041 If the T.O.R.S. is activated, make sure that the cause of the malfunction has been cor- rected and that the engine can be oper ated without a problem before restarting the engine. Continuing to oper ate with a mal- function could cause loss of control or damage. If[...]

Control functions 13 RST90 ESU14100 Multi-function meter un it RS90GT / RS90LTGT / RST90GT The multi-function meter un it is equipped with the following: ● a digital speedometer ● a tachometer ● an odometer ● two tripmeters (which show the di stance traveled since th ey were last set to zero) ● a fuel reserve tripmeter (which shows the di[...]

Control functions 14 Odometer and tripmeter mode s Pushing the “ SELECT ” button switches the display between the odometer mode “ ODO ” and the tripmeter m odes “ TRIP A ” a nd “ TRIP B ” in the follow ing order: ODO → TRIP A → TRIP B → ODO If the fuel level warning indicator and warning light come on (see page 18), the odome [...]

Control functions 15 If the engine oil is changed before the oil change tripmeter appears in the display (i.e., before the periodic oil change interval has been reached), the tripmeter must be rese t af- ter the oil change for the next periodic oil change to be indicated at the correct tim e. In that case, reset the oil change tripmeter as follows.[...]

Control functions 16 ● a tachometer ● an odometer ● a tripmeter (which shows the distance trav- eled since it was la st set to zero) ● warning indicators (which s how engine trouble, coolant tem perature, fuel leve l, and oil level warnings) ● indicator lights (w hich show hig h beam and low coolant temperature con ditions) ● a warning [...]

Control functions 17 RS90GT / RS 90LTGT / RST90GT RST90 ESU13761 Low coolant temperature indi- cator light “” The low coolant temperature indicator light comes on when th e coolant temperature is low and informs the rider that the snowmobile should be warmed up. After the engine is started, warm it up until th e indicator light goes off. The sn[...]

Control functions 18 ESU14040 Fuel meter and gri p/thumb warmer level indica tor RS90GT / RS90LTGT / RST90GT The fuel meter and grip/thumb warmer level indicator have e ight segments w hich show the amount of fuel rem aining in the fuel tank, the grip warmer level, o r the thumb warmer level. Fuel meter The display seg ments of the fuel meter disap[...]

Control functions 19 TIP ● The grip/thumb wa rmer level is dis played for 5 seconds after releasing the grip/thumb warmer adjusting switch, then the dis play switches to the fuel meter. ● When the engine is started, the grip/thumb warmer levels are set to the levels selected when the engine was last stop ped. RST90 The fuel meter and grip/thumb[...]

Control functions 20 TIP ● The grip/thumb wa rmer level is dis played for 5 seconds after releasing the grip/thumb warmer adjusting switch, then the dis play switches to the fuel meter. ● The top segment of the grip/thumb warmer level indicator fla shes once when the grip/thumb warmer adjustment reaches the maximum level. Th e bottom segment of[...]

Control functions 21 RST90 ESU10462 Oil level warning indic ator “” The oil level w arning indicator and the w arn- ing light come on w hen the engine oil level is low. RS90GT / RS 90LTGT / RST90GT RST90 If the oil level wa rning indicator and the warn- ing light come on, place the snowmobile on a level surface and al low it to idle for one min[...]

Control functions 22 RST90 NOT ICE ECS00041 Do not continue to operate the engine if it is overheating. ESU13771 Self-diagnosis device This model i s equipped with a self-diagn osis device for various electrical circuits. If a problem i s detected in any of those cir- cuits, the warning light and the engine trouble warning indicator flash, and an e[...]

Control functions 23 During the first few rides, practice using the stop switch so that you can react quickly in an emergency. ESU10661 Headlight beam sw itch “ LIGHTS ” Push the headlight beam switch to change the headlight to high beam “ HI ” or to low beam “ LO ” . ESU14061 Grip/thumb warm er adjusting switch RS90GT / RS90LTGT / RST9[...]

Control functions 24 To raise the temperature To raise the temperature, press the respec- tive switch to “ HI ” . To lower the temperature To lower the temperature, press the respec- tive switch to “ LO ” . See “ Fuel meter and grip/thumb warmer level indicator ” on page 18 for detai led information. ESU10696 Auxili ary DC ja ck The aux[...]

Control functions 25 ESU13264 Helmet shi eld heater jack (RS9 0GT / R S90LT GT / RST90GT) The helmet shield heater jack is located on the left side of the handlebar. TIP The helmet shield heater jack can only be used if the engine is run ning. To use t he helm et shie ld heate r jack 1. Start the engine. 2. Open the helmet shield heater jack cap, a[...]

Control functions 26 3. Tighten the locknut securely after adjus t- ing the brake leve r position. ESU10581 Parking brake leve r When parking the snowmobile or starting the engine, apply the parking brake by m oving the parking brake lever to the le ft. To release the parking brake, m ove the park- ing brake lever to the right. ESU10593 Shift lever[...]

Control functions 27 RST90 NOT ICE ECS00072 Do not use the shift lever while the snow- mobile is moving, otherwise the drive train could be damaged. ESU14092 Drive guard W ARNI NG EWS00402 ● Coming in contact with the rotating V- belt or clutch parts can caus e severe in- jury or death. Never run the engine with the drive guard removed. ● Make [...]

Control functions 28 The drive guard is designed to protect the V- belt clutch and V-belt in case parts break or come loose. The drive guard is located behind the left side cover (RS90GT / RS90LTGT / RST90GT), or under the shroud (RST90). [See p age 63 (RS90GT / RS90LTGT / RST90GT) or page 67 (RST90) for information on how to access the drive guard[...]

Control functions 29 RS90GT / RS 90LTGT / RST90GT RST90 NOT ICE ECS00180 Make sure that the V-belt is installed se- curely in the holders. ESU13302 Passenger grips (RST90GT) The passenger grips can be installed in three different positions to suit the pass enger ’ s preference. To change the pa ssenger grip posi- tion 1. Remove the passen ger gri[...]

Control functions 30 RST90 RST90GT ESU14050 Passenger foot rests (RST90 / RST90GT) The passenger footrests can be installed in two (RST90) or three (RST90GT) different po- sitions to suit the passenge r ’ s preference. To change the pos ition of a footrest, remove the screws, place the foo trest in the desired position, and then install a nd tigh[...]

Control functions 31 RST90 RST90GT RST90GT To adj ust the backre st po sitio n Pull the backrest adjusting lever upward, and then move the bac krest to the des ired posi- tion. When riding without a passenger, the back- rest can be mov ed to the forward-mos t posi- tion, and its angle can be adjus ted to suit the operator ’ s preference as sho wn[...]

Control functions 32 To clos e th e sto rage compartm ent Fold the storage compartment cover down, and then turn the fastener to the original posi - tion. RST90GT This snowmobil e is equipped with a storage compartment, which includes a storage pouch. Stora ge compartm ent NOT ICE ECS00900 The bottom of the storage compartment may be hot during or [...]

Control functions 33 NOT ICE ECS00781 Before starting the engine, make sure t hat the tool kit is securely fastened and that the storage pouch zipper is completely closed. ESU10823 Storag e areas (RST9 0) This snowmobil e is equipped with a storage compartment, rear storage area, and rear c ar- rier. Stora ge compartm ent The storage compartm ent i[...]

Control functions 34 3. Remove the pass enger seat lock knob, and then remove the passenger seat. 4. Align the holes in the rear carrier with the bolts on the carrier lock bracket, and then place the rear carrier on the c arrier lock bracket. 5. Slide the rear carrier backward until it stops. 6. Pull the carrier lock lever up to lock the rear carri[...]

Control functions 35 3. Align the holes in the backrest bracket with the bolts on the carrier lock bracke t, and then place the ba ckrest on the carrier lock bracket. 4. Align the holes in the rear carrier with the bolts on the carrier lock bracket, and then place the rear carrier on the c arrier lock bracket. 5. Slide both the ba ckrest and th e r[...]

Control functions 36 ESU10605 Fuel W ARNI NG EWS00071 Gasoline and gasoline vapor s are ex- tremely flammable. To avoid fires and ex- plosions and to reduce the risk of injury when refueling, follow these instructions. Make sure there is suffic ient gasoline in the tank. 1. Before refueling, turn off the engi ne and be sure th at nobody is on the s[...]

Control functions 37 Your Yamaha engine has been de signed to use regular unleaded gasolin e with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. NOT ICE ECS00084 ● Oxygenated fuels (gasohol) containing a maximum 10% of ethanol (E10) can be used, although richer jetting may be re- quired to prevent eng[...]

Control functions 38 2. To increase the s pring preload and th ere- by harden the s uspension, turn the ad - justing nut in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting nut in di- rec ti on (b ). RS90GT / RS 90LTGT / RST90GT RST90 TIP The spring preload setting is dete rmined by measuring dista[...]

Control functions 39 To increase the com pression dam ping force, turn the adjusting knob in direction (a). To de - crease the compression d amping force, turn the adjusting knob in direction (b). Rebound damping force The rebound damping force of each shock absorber can be adjusted by turning its re- bound damping force adjusting knob. To increase[...]

Control functions 40 the spring preload and thereby soften the suspension, turn the adjusting nut in di- rec ti on (b ). TIP The spring preload setting is dete rmined by measuring distance A, sh own in the illustra- tion. The longer distance A is, the higher the spring preload; the shorter distanc e A is, the lower the spring preload. 3. Tighten th[...]

Control functions 41 To increase the spring preload and thereby harden the suspens ion, turn the adjusting ring in direction (a). To decrease the spring pre- load and thereby soften the su spension, turn the adjusting ring in direction (b). TIP The spring preload can be further adjusted by changing the position of the spring s eat. Have a Yamaha de[...]

Control functions 42 ESU14010 Adjusting the rebound damping force of the rea r sho ck a bsorb er (R S90G T / RS90LTGT) W ARNI NG EWS00161 Do not turn the remote adjusting dial while the snowmobile is moving as this could cause loss of control, an accident, and in- jury. NOT ICE ECS00291 Be sure to stop the remote adjusting dial at a marked position[...]

Control functions 43 ESU11046 Adjusting the control rods The weight transfer c an be adjusted by turn- ing the adjuster on the control rod (RS90GT / RS90LTGT) or the adjusting nuts on the con- trol rods (RST90 / RST90GT). RS90GT / RS 90LTGT 1. Check the control rod leng th using the scale on the special wrench as shown. TIP In order to obtain a pre[...]

Control functions 44 RST90 / RST90GT W ARNI NG EWS00770 The left and right adjusting nuts must be set to the same position. Uneven settings can cause poor handling and loss of sta- bility. 1. Loosen the lockn ut while hold ing the ad- justing nut. 2. To increase weight transfer, turn the ad- justing nut in di rection (a), and to de- crease weight t[...]

Control functions 45 3. Tighten the lo cknut while holding th e ad- justing nut in place. NOTICE: Always tighten the locknut against the adjust- ing nut, and then tighten t he locknut to the specified torque. [ECS00 860] 1. Lockn ut 2. Control rod adjusting n ut 3. Standard position 4. Adjustable r ange 5. Red paint area Lock nut tig htenin g torqu[...]

Pre-operation checks 46 ESU11071 Inspect your vehicle each tim e you use it to make sure the vehicle is in safe operating c ondition. Always follow the inspection and mai ntenance procedures and schedules described in the Owner ’ s Manual. W ARNI NG EWS00191 Failure to inspect or maintain the vehicle properly increases the possibility of an acci-[...]

Pre-operation checks 47 Drive track • Check the defl ection. • Adjust if nec essar y . • Check f or wear and dam age. • If necessar y , have a Y amaha dealer replace track. 98 Slide runners • Check f or wear and dam age. • If necessar y , have Y amaha dealer replace s lide runners. 98 Steering • Check f or excessive free pla y . 96 Li[...]

Operation 48 ESU13500 Read the Owner ’ s Manual carefully to be- come familiar with al l controls. If there is a control or function you do not understand, ask your Yamaha dealer. W ARNI NG EWS00201 Failure to familiarize yourself with the con- trols can lead to loss of control, which could cause an accident or injury. ESU13212 TIP This model is [...]

Operation 49 4. Warm up the engine until it runs smooth- ly. 5. Be sure the low coolant temperature indi - cator light has gone out before operation. (See page 17 for detailed information about the indicator li ght.) RST90 1. Apply the parking brake. 2. Be sure the engine stop switch is in the run position. The starter motor cannot be operated when[...]

Operation 50 5. Warm up the engine, and then close the starter (choke) leve r when the engine runs smoothly. 6. Be sure the low coolant temperature indi - cator light has gone out before operation. (See page 17 for detailed information about the indicator li ght.) ESU11310 Break- in There is never a more important period in the life of your engine [...]

Operation 51 Pay particular attent ion to the safety informa - tion on page 6. Please read all w arning and notice label s on your snowmobil e. Also, read the Snowmobil - er ’ s Sa fety Handbook that i s supplied with your snowmobile. Learning to ride y our snowmobile Before you ride, always perform the pre-oper- ation checks listed on page 46. T[...]

Operation 52 Improper riding techniques such as abrupt throttle changes, excessiv e braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the snow- mobile to tip. If your snowmobile begins to tip while turning, lean more into th e turn to regain balance. If necessary, gradually let off on the throttle or steer[...]

Operation 53 Trav ersing a slop e W ARNI NG EWS00251 Driving across the face of a slope ( “ si de- hilling ” ) can lead to overturn or loss of control if proper techniques are not used. Follow these instructions to reduce your risk of an accident. Do not try steeper or more difficult inclines until you have de- veloped your skill on gentle slop[...]

Operation 54 ● Sand ● Rocks ● Gras s ● Bare pavement Other surfaces that should be a voided for the sake of drive track and slide runn er life are: ● Glare ice surfaces ● Snow mixed with a lot of dirt and sand All of the above surface s have one thing in common in regard to drive track and slide run- ners: little or no lubricating abili[...]

Operation 55 ESU11394 Driving W ARNI NG EWS00300 Be sure to read the “ SAFETY INFORMA- TION ” section on page 6 and the “ Riding your snowmobile ” section on page 50 carefully before operating the snowmo- bile. TIP Make sure that the engine is w armed up enough before riding. W ARNI NG EWS00310 ● Make sure that the throttle lever is fully[...]

Operation 56 TIP The reverse buzzer beeps w hile the shift lever is in reverse. 2. While squeezing the brake lever, release the parking brak e by moving the parking brake lever to the right, and then release the brake lever. 3. Squeeze the throttle lever slowly to start out. 4. Turn the handlebar in the desired direc - tion. 5. Squeeze the brake le[...]

Operation 57 ● If transporting the snowmobile in an open trailer or truck, put a tight fitting cover on the snowmobile. A cover specificall y designed for your snowmobile is best. This will help keep foreign objects out of the c ooling vents, and also h elp protect the snowmo - bile against damage from debris on the road. ● If transporting the [...]

Periodic mainte nance and adjustment 58 ESU11452 Periodic inspection, adjustment, and lubrication will k eep your snowmobile in the safes t and most efficient condi tion possible. Safety is an obligation of the vehicle owner/operator. The most important points of v ehicle inspec tion, adjustment, and lubrication a re explained on the following page[...]

Periodic maintenance a nd adjustment 59 ESU11461 Periodic m aintena nce char t for the emi ssion co ntrol sy stem Items marked with an asterisk sh ould be performed by a Yamaha d ealer as they re quire special tools, data and technical sk ills. ITEM REMARKS INITIAL EV ER Y PA G E 1 month or 800 km (500 mi) (40 hr) Season ally or 4000 km (2500 mi) ([...]

Periodic mainte nance and adjustment 60 ESU11564 General maintenance and lubrication chart ITEM REMARKS INITIAL EV ER Y PA G E 1 month or 800 km (500 mi) (40 hr) Season ally or 4000 km (2500 mi) (200 hr) Engine oil • Change (warm engine before draining). 77 * Engine o il f ilter car- tridge • Replace. Ev ery 20000 km (12000 mi) 77 * Cooling sys[...]

Periodic maintenance a nd adjustment 61 TIP Brake system: ● After disassembling the master cylinder or caliper c ylinder, always change the b rake fluid. Regularly check the brake fluid le vel and add fluid if neces sary. ● Replace the oil seal s of the master cylinder and caliper cy linder every two years. ● Replace the brake hose every four[...]

Periodic mainte nance and adjustment 62 ESU14111 Tool kit RS90GT / RS90LTGT / RST90 The owner ’ s tool kit is located in the storage compartment. (See page 31 for information on how to access the st orage compartment.) The service information includ ed in this man- ual and the tools provided in the owner ’ s tool kit are intended to assist you [...]

Periodic maintenance a nd adjustment 63 NOT ICE ECS00940 ● Be sure to slide the covers onto the short end of each hexa gon wrench be- fore placing the wrenches in the tool kit. ● Securely tie the strap ar ound the tool kit. ESU14142 Removing and installing the shroud and covers (RS90GT / RS90LTGT / RST90GT) W ARNI NG EWS00091 Be sure shroud and[...]

Periodic mainte nance and adjustment 64 To install a side cover 1. Fit the projection on the rear of the side cover into the hole in the fuel tank c over. 2. Fit the projections on the side cover into the slots as shown. 3. Tighten the fasteners. 4. Install the shroud. Top cover (RS90GT / RS90LTGT) To remove the top cover 1. Remove the shroud and t[...]

Periodic maintenance a nd adjustment 65 5. Lift up the rear of the top cover, discon- nect the main switch coupler, and then remove the cover . To install the top cover 1. Connect the main s witch coupler. 2. Place the top cover in the original posi- tion, making s ure to fit the projections on the cover into the slots in the headlight unit. 3. Tig[...]

Periodic mainte nance and adjustment 66 Top cover (RST90GT) To remove the top cover 1. Remove the shroud and the left side cov - er. (See the above procedures.) 2. Disconnect the auxiliary DC jack coupler. 3. Open the zippers on the left and right sides of the handlebar cover, and then re- move the cover . 4. Pull the windshield stay rubber covers [...]

Periodic maintenance a nd adjustment 67 3. Tighten the quick fastener sc rews. 4. Place the windshield stay rubber c overs in their o riginal posi tion. 5. Install the handlebar cover. 6. Connect the auxilia ry DC jack coupler. 7. Install the left side cover and the s hroud. NOT ICE ECS00372 ● Make sure that all cables, hoses and leads are routed[...]

Periodic mainte nance and adjustment 68 NOT ICE ECS01040 ● Make sure that all cables, leads, and hoses are routed properly before clos- ing the shroud and installing the right side cover. ● When installing the right side cover, be sure to tighten the bolts and screws se - curely. ESU11784 Checking th e spark plugs The spark plugs are important [...]

Periodic maintenance a nd adjustment 69 When installing the s park plug, always clean the gasket surface. Wipe off any grime from the threads and tighten the spark plug to the specified torque. NOT ICE ECS00382 Make sure that the spark plug caps are se- curely installed. Otherwise t he spark plug caps could be damaged due to engine vi- bration. ESU[...]

Periodic mainte nance and adjustment 70 6. To increase the throttle lever f ree play, turn the adjusting bolt in direction (a). To decrease the throttle leve r free play, turn the adjusting bolt in direction (b). 7. Tighten the locknut. 8. Install the headlight un it, making sure to fit the slots on its bottom onto the projec- tions on its sta y. 9[...]

Periodic maintenance a nd adjustment 71 3. Loosen the locknut. 4. To increase the throttle lever f ree play, turn the adjusting bolt in direction (a). To decrease the throttle leve r free play, turn the adjusting bolt in direction (b). 5. Tighten the locknut. 6. Close the shroud. RST90GT 1. Place the snow mobile on a level surface and apply the par[...]

Periodic mainte nance and adjustment 72 9. Fit the weatherstrip on the headlight unit into the recess in the top of the air filter case cover . 10. Install the headlight unit bolts and wind - shield stay bolts, and then tighten them to their specified torques. 11. Install the top cover and the shroud. ESU11863 Checking the throt tle overr ide syste[...]

Periodic maintenance a nd adjustment 73 The T.O.R.S. will be activated and the engine speed wi ll be limited to less than the clutch engagement speed. (See page 122 for the clutch engagement speed.) WARNING! If the engine speed does not decrease to less than the c lutch engagement speed, stop the engine by turning the main switch to the off positio[...]

Periodic mainte nance and adjustment 74 6. Lift up the air filter element frame and check the air filter elemen t. If there is any snow on the air filter element, remove the element, bru sh off the snow, and then in- stall the air filter element. 7. Place the ai r filter eleme nt frame in the original position, and then install the air filter case [...]

Periodic maintenance a nd adjustment 75 3. Remove the air filter case cover by un- hooking the case fastener and the case cover fasteners. 4. Lift up the air filter element frame and check the air filter elemen t. If there is any snow on the air filter element, remove the element, bru sh off the snow, and then in- stall the air filter element. 5. P[...]

Periodic mainte nance and adjustment 76 5. Remove the air filter case cover by un- hooking the fasteners. 6. Lift up the air filter element frame and check the air filter elemen t. If there is any snow on the air filter element, remove the element, bru sh off the snow, and then in- stall the air filter element. 7. Place the air filter element frame[...]

Periodic maintenance a nd adjustment 77 10. Install the headlight unit bolts and wind - shield stay bolts, and then tighten them to their specified torques. 11. Install the top cover and the shroud. ESU11911 Carburetor s (RST90 ) The carburetors are an important part of the engine and its emission control system, which require very sophisticated ad[...]

Periodic mainte nance and adjustment 78 NOT ICE ECS00482 ● Do not run the engine with too much or not enough oil in the oi l tank. Oil could spray out or the engine could be dam- aged. ● Be sure to change the engine oil after the first 800 km (500 mi) of operation, and every 40 00 km (2500 mi) ther eafter or at the start of a new season, other-[...]

Periodic maintenance a nd adjustment 79 TIP The engine oil should be between the “ H ” and “ L ” level marks on the dipstick . RS90GT / RS 90LTGT / RST90GT RST90 6. If the engine oil is below the “ L ” level mark, add sufficient oil of the recom- mended type to raise it to the “ H ” level mark. (See page 122 for the recommend- ed oi[...]

Periodic mainte nance and adjustment 80 RS90GT / RS 90LTGT / RST90GT 5. Remove the bottom panel by removing the bolts. 6. Place an oi l pan un der the oil tank to col- lect the used oil. 7. Disconnect the oi l level gauge coupler. RS90GT / RS 90LTGT / RST90GT RST90 8. Remove the oil filler cap and the cylinder head cap, and then remove the engine o[...]

Periodic maintenance a nd adjustment 81 RST90GT RS90GT / RS 90LTGT / RST90GT RST90 9. Place an oil pan under the engine to col- lect the used oil. 10. Remove the engine oil drain bol t and its gasket to drain the oil from the crank- case . TIP ● A “” mark is stamped on the crankc ase near the engine oil drain bolt for easy iden- tification. ?[...]

Periodic mainte nance and adjustment 82 TIP Make sure that the O-ring is properly seated. 13. Install the new oil filter cartridge with an oil filter wrenc h, and then tighten it to the specified torque. 14. Install the engine oil drain bolts and their new gask et, and then tighte n the bolts to the specified torqu es. 15. Add 2.0 L (2.11 US qt, 1.[...]

Periodic maintenance a nd adjustment 83 18. Install and tighten the oil filler cap. 19. Start the engine, and then let it idle for several minutes while c hecking it for oil leakage. If oil is leaking, immediately turn the engine off and make sure that the en - gine oil drain bolts, the c ylinder head cap, and the oil filler cap are installed c orr[...]

Periodic mainte nance and adjustment 84 When the hissing sound has st opped, press down on the cap while turning coun- terclockwise and remove it. RS90GT / RS 90LTGT RST90 RST90GT RS90GT / RS90LTGT To ch eck t he co olant leve l 1. Place the snow mobile on a level surface and apply the parking brake. 2. Remove the top cover. (See page 63 for remova[...]

Periodic maintenance a nd adjustment 85 4. Install the top cover. Bleeding the c ooling system The cooling sy stem must be bled if the cool - ant reservoir become s empty, if air can be seen in the cooling s ystem, or if there is a cooling system l eak. Consult a Yam aha deal- er. NOT ICE ECS00500 Operating the engine with an improperly bled coolin[...]

Periodic mainte nance and adjustment 86 TIP If you find any leaks, consult a Yamaha deal- er. 7. Check the coolant level in the coolant reservoir. If it is not full, remove the cool- ant reservoir cap, fill the reservoi r with the recommended coolan t, and then install the cap. 8. Install the top cover. RST90 / RS T90GT To ch eck t he co olant leve[...]

Periodic maintenance a nd adjustment 87 2. Remove the shroud, the right side cover, and the top cover (RST90GT), or open the shroud (RST90). [See page 63 (RST90GT) or page 67 (RST90) for the procedures.] 3. Remove the co olant reservoir cap and add coolant until it reaches the “ COLD LEVEL ” mark. RST90 RST90GT RST90 RST90GT 4. Start the engine[...]

Periodic mainte nance and adjustment 88 ESU13912 V-belt W ARNI NG EWS00402 ● Coming in contact with the rotating V- belt or clutch parts can ca use severe in- jury or death. Never run the engine with the drive guard removed. ● Make sure that the drive guard is in- stalled securely before oper ating the snowmobile to protect against severe injur[...]

Periodic maintenance a nd adjustment 89 RS90GT / RS 90LTGT / RST90GT 4. Rotate the secondary sliding sheave clockwise and push it s o that it separates from the secondary fixed sh eave. 5. Pull the V-belt up over the secondary fixed sheave. 6. Remove the V-be lt from the secondary sheave assemb ly and primary s heave assembly. 7. Temporarily instal[...]

Periodic mainte nance and adjustment 90 9. Tighten the V-belt position a djusting bolts. 10. Install the V-belt over the primary s heave assembly. 11. Rotate the sec ondary sliding s heave clockwise a nd push it so that it separates from the secondary fixed she ave. 12. Install the V-belt between the secondary sliding and fixed sheav es. 13. Place [...]

Periodic maintenance a nd adjustment 91 RS90GT / RS 90LTGT / RST90GT 14. Install the drive guard, an d then install the left side cover and the shroud (RS90GT / RS90LTGT / RST90GT), or close the shroud (RST90). ESU13922 Drive chain housing To check the d rive chain ho using oil level 1. Place the snow mobile on a level surface and apply the parking[...]

Periodic mainte nance and adjustment 92 5. Install the dipstic k, making sure to align the notch in the dipstick hand le with the projection on the drive chain hou sing. 6. Install the right side cove r and the shroud (RS90GT / RS90LTGT / R ST90GT), or close the shroud (RST90). To adjust the cha in tension 1. Remove the s hroud and the right side c[...]

Periodic maintenance a nd adjustment 93 Test the brake at a low speed when starting out to mak e sure that it is working properly. If the brake does not provide proper braking performance, inspect the brake for wear or brake fluid leakage. (See the following section for more details.) Checking the brake pads Check the brake pads for wear according [...]

Periodic mainte nance and adjustment 94 3. Install the right side cove r and the shroud (RS90GT / RS90LTGT / R ST90GT), or close the shroud (RST90). To adjust the parking brake As the parking brake pads w ear, adjustment may be necessary to e nsure proper brake performance. 1. Remove the s hroud and the right side cover (RS90GT / RS90LTGT / RST90GT[...]

Periodic maintenance a nd adjustment 95 8. Install the right side cove r and the shroud (RS90GT / RS90LTGT / R ST90GT), or close the shroud (RST90). Checking the brake fluid level W ARNI NG EWS00460 Be careful that water does not e nter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result [...]

Periodic mainte nance and adjustment 96 NOT ICE ECS00560 Avoid scratching the skis w hen loading and unloading the snowmobile, when riding in areas with little or no snow, or on sharp edges such as concrete, curbs, e tc. This will wear or damage the skis. To align the skis 1. Turn the handlebar so the skis face straight ahead. 2. Check the followin[...]

Periodic maintenance a nd adjustment 97 If excessive free play is felt, consult a Yamaha dealer. RST90 To adjust the handlebar height 1. Remove the handle bar cover. 2. Loosen the handlebar bolts. 3. Move the handlebar up or down to adjust the handlebar height to the desired posi- tion. NOTICE: Make sure that the pro- jection on the handlebar is no[...]

Periodic mainte nance and adjustment 98 5. Install the handlebar cover. ESU13702 Drive tr ack and s lide runners Drive t rack W ARNI NG EWS00481 A broken track, track fittings or debris thrown by the drive track could be danger- ous to an operator or bystanders. Observe the following precautions: ● Do not allow anyone to stand behind the snowmobi[...]

Periodic maintenance a nd adjustment 99 Measuring the drive track deflec tion 1. Lay the snowmob ile on its side. 2. Measure the drive track deflection wi th a spring scale. Pull at the center of the drive track with a force of 100 N (10 kgf, 22 lbf). TIP Measure the gap between the slide runner and the edge of the track wind ow on both sides. 3. I[...]

Periodic mainte nance and adjustment 100 4. Loosen the lock nut on the left and the right sides of the snowmobile, then align the drive track b y turning the ad justing bolt on each side. Shifted to right Shifted to left 5. Adjust the drive track defle ction to speci- fication. NOTI CE: The right and left ad- justing bolts should be turned an equal[...]

Periodic maintenance a nd adjustment 101 2. Lift the rear of the snowmobile onto a suit- able stand to raise the driv e track off the ground. 3. Start the engine and rotate the driv e track one or two turns. Stop the engine. 4. Align the drive track by turning the left and right adjusting nuts. Shifted to right Shifted to left 5. Adjust the drive t[...]

Periodic mainte nance and adjustment 102 6. Recheck alig nment and deflection. If nec- essary, repeat steps 3 to 5 until the prop- er adjustment is achiev ed. 7. Lower the snowmobile to the ground. 8. Tighten the rear axle nut. Slide runners Check the slide runners for w ear and dam- age. If the slide runners reach the w ear limit, they should be r[...]

Periodic maintenance a nd adjustment 103 RS90GT RS90LTGT RST90 RST90GT ESU14181 Replacing a headlight bulb RS90GT / RS9 0LTGT 1. Remove the top cover. (See page 63 for removal procedure s.) 2. Remove the screws, and then remove the headlight access pa nel. 1. Grease nipple 1. Grease nipple 1. Grease nipple 1 1 1. Grease nipple 1. Grease nipple 1. G[...]

Periodic mainte nance and adjustment 104 3. Disconnect the he adlight coupler. 4. Remove the bulb ho lder cover. 5. Unhook the bu lb holder, and then remove the burnt-out bulb. 6. Install a new bulb, and th en hook the bulb holder onto the hea dlight unit. NOTICE: Keep oil and your hands away from the glass part of the bulb or its life and illumina[...]

Periodic maintenance a nd adjustment 105 4. Unhook the bu lb holder, and then remove the burnt-out bulb. 5. Install a new bulb, and then hook the bulb holder onto the h eadlight unit. NOTICE: Keep oil and your hands aw ay from the glass part of the bulb or its life and illumination will be affected. If the glass is oil stained, thoroughly cl ean it[...]

Periodic mainte nance and adjustment 106 4. Disconnect the he adlight coupler. 5. Remove the bulb ho lder cover. 6. Unhook the bu lb holder, and then remove the burnt-out bulb. 7. Install a new bulb, and then hook the bulb holder onto the h eadlight unit. NOTICE: Keep oil and your hands aw ay from the glass part of the bulb or its life and illumina[...]

Periodic maintenance a nd adjustment 107 11. Install the headlight unit bolts and wind - shield stay bolts, and then tighten them to their specified torques. 12. Install the top cover and the shroud. ESU14150 Adjusting the headlight beam s RS90GT / RS90LTGT / RST90GT 1. Remove the top cover. (See page 63 for removal procedures.) 2. Use a Phillips s[...]

Periodic mainte nance and adjustment 108 3. Close the shroud. ESU12290 Fittings and fasteners Check the tightness of the fittings and fasten - ers. Tighten in prop er sequence and torque if nec- essary. ESU14020 Battery The battery is located u nder the air filter case. (See page 109.) This model is equipped with a VRLA (Valve Regulated Lead Acid) [...]

Periodic maintenance a nd adjustment 109 ESU14192 Replacing a fuse W ARNI NG EWS00550 Be sure to use the specified fuse. A wr ong fuse could cause electr ical system dam- age or A FIRE HAZARD. NOT ICE ECS00631 Be sure to tur n the main swit ch to the off position and disconnect the negative bat- tery lead to prevent accidental short-cir- cuiting. R[...]

Periodic mainte nance and adjustment 110 5. Loosen the joint clamp bo lts. 6. Slide the oil tank breather hose clamp away from the air filter case, and then dis - connect the oil tank breather hose . 7. Lift up the air filter case, disconnect the ISC (Idle Speed Control) unit inlet hose and cylinder head breather hose from the case, and then remove[...]

Periodic maintenance a nd adjustment 111 10. Replace the blown fuse with one of the proper amperage. RS90GT / RS 90L TGT 1. Negative battery lead 1. Spare fuse 2. Fuel injection system fuse 3. Main fuse 1 1. Fuse box 2. “ IGN ” (ignit ion) fuse 3. “ FA N ” (radiator f an) fuse 4. “ S/H ” (helmet shield heater jack) fuse 5. “ HEAD ” [...]

Periodic mainte nance and adjustment 112 RST90GT 11. Connect the negativ e battery lead by in- stalling the bolt. 12. Install the battery cover, and then hook the battery band onto the holder. 13. Install the air filter case by reversing the removal steps 4 – 7. 14. Install the headlight uni t, making sure to fit the slots on its bottom o nto the[...]

Periodic maintenance a nd adjustment 113 15. Fit the weatherstrip on the headlight unit into the recess in the top of the air filter case cover . 16. Install the headlight unit bolts and wind - shield stay bolts (RST90GT), and then tighten them to their specified torques . 17. Install the top cover, the left and right side covers, and the shroud. T[...]

Periodic mainte nance and adjustment 114 7. Lift up the air filter case, slide the crank- case brea ther hose clamp (air filter case side) down, disconnect the crankcase breather hose from the ai r filter case, and then remove the air filter case. 8. Disconnect the ne gative battery lead. 9. Replace the blown fuse with one of the proper amperage. 1[...]

Periodic maintenance a nd adjustment 115 10. Connect the negative b attery lead. 11. Install the air filter case by reversing the removal steps 3 – 7. NOTICE: Be sure to connect the breather hoses securely when installing the air filter case. [ECS006 41] TIP When installing the air filter case, connect the crankcase breather hose to the air filte[...]

Troubleshooting 116 ESU14162 Engine turns over but does not start 1. Fuel system ● No fuel supplied to combus tion cham- ber • No fuel in tank: Supply fuel. ↓ • Clogged fuel line: Clean fuel line. ↓ • Clogged injector (RS90GT / RS90LTGT / RST90GT): Ask a Yamaha deal er to check. • Clogged carburetor (RST90): Clean carburetor. ● Fuel[...]

Troubleshooting 117 ↓ • Worn or damaged gasket: Replace gasket. ↓ • Worn or damaged piston and cylin - der: Ask a Yamaha deal er to check. Disch arged bat tery If the battery is discharged, the engine can be started using a fully-charged 12-vo lt battery and jumper cables. Two connecting leads have been provided for jump-starting the snowmo[...]

Troubleshooting 118 5. Connect the other end of the red (+) jumper cable to the positive (+) terminal of the booster battery. 6. Connect the bla ck ( – ) jumper cab le to the negative ( – ) terminal of the boos ter bat- tery. 7. Pull the black ( – ) connecti ng lead cover to expose the termina l through the slit in the cover, and then connect[...]

Troubleshooting 119 Engine power is low ● Low coolant temp erature indicato r light is flashing: Warm engine up. ● Faulty spark plugs: Clean or replace spark plugs. ● RST90: Incorrect carburetor jetting for al ti- tude or temperature: Ask a Yamaha dealer to check. ● Improper fuel flow: See “ Engine turns over but does not start – Fuel s[...]

Storage 120 ESU13940 Long-term storage requires s ome preventive procedures to guard against deterioration. Cleaning Thoroughly clean the snowmobile, insi de and out, to remove the c orrosive salts and acids that can accumulate. Use Yam aha Mud, Grease, and Engine C leaner, or an eq uivalent product, to loosen mud, grease, and grime. Wash with mild[...]

Storag e 121 (RS90GT / RS90LTGT / RST90GT) or carbu- retor throats (RS T90) while the engine is run- ning. NOTICE: Do not simply start the engine when in storage, starting the en- gine occasionally during the storage peri- od can cause more harm than good. Moisture and acids form during combus- tion which can actually increase the chance for corros[...]

Specifications 122 ESU1246B Dimensions: Overall length: RS90G T 2805 mm (110 .4 i n) RS90L TGT 30 00 mm (118.1 in) RST 90 3135 mm (123 .4 in) RST90 GT 3185 mm (125 .4 in) Overall width: 1225 mm (48. 2 in) Overall heigh t: RS90G T 1160 mm (45. 7 in ) RS90L TGT 11 60 mm (45.7 in ) RST 90 1330 mm (52.4 in) RST90 GT 1380 mm (54.3 in) Weight: With oil a[...]

Specifications 123 Overa ll r educt ion rati o: RS90 GT 6 .02 – 1. 58 :1 RS90LTG T 6.18 – 1.63 :1 RST90 6. 74 – 1.77 :1 RST90GT 6.44 – 1.70 :1 Sheave dist ance: 267.0 – 27 0.0 mm (10 .51 – 10 .63 in) Sheave offs et: 13.5 – 16.5 mm (0.53 – 0.65 in) Engage ment speed (Sub ject t o chan ge accor ding to e levation setti ngs.): RS90GT 3[...]

Specifications 124 Tail/br ake light : RS90GT LED RS90LTG T LE D RST90GT LED Meter lig hting: RST9 0 14 V, 50 mA × 6 Meter lig hting: RS90GT LED RS90LTG T LE D RST90GT LED High beam indic ator lig ht: RST9 0 14 V, 80 mA × 1 High beam indic ator lig ht: RS90GT LED RS90LTG T LE D RST90GT LED Warn ing ligh t: RS90GT LED RS90LTG T LE D RST90GT LED Wa[...]

Consumer information 125 ESU12481 Identification number records Record the frame serial number, engine serial number (Primary ID), an d key identification number in the s paces provided for assistance when ordering spare parts from a Yamaha dealer. Also, record and keep the ID n umbers in a separate place in case the snowmobile is sto- len. Frame s[...]

Consumer information 126 ESU13461 Vehicle Emission Control Infor- mation labe l RS90GT / RS 90LTGT RST90 RST90GT The Vehicle Emission Control Information la- bel is affixed at the location in the illustration. This label shows specifications related to ex- haust emissions as required by federal law, state law and Environment C anada. 1. V ehicle Em[...]

Consumer information 127 ESU12500 YAMAHA MOTOR CORPORATION, U .S.A. SNOWMOBILE LIMIT- ED WARRANTY Yamaha Motor Corporation, U.S.A . hereby warrants that new Yamaha snowmobiles purchased from an autho- rized Yamaha snowmo bile dealer in the con tinental United States will be free from defects in material and workman- ship for the period of time stat[...]

Consumer information 128 YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WAR- RANTIES OF MERCHANTABILITY AND FIT- NESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIM- ITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPO- RATION, U.S.A. AND EXCLUDED FROM T[...]

Consumer information 129 Q. What responsibility does my dealer have under this warranty? A. Each Yamaha snowmobile dealer is e xpected to: 1. Completely set up every new machine before sale. 2. Explain the operation, maintenance, and warranty requirements to your sat isfaction at the time of sale, and upon your request at any lat er date. 3. In add[...]

Consumer information 130 ESU12510 YAMAHA EXTENDED SERVI CE (Y.E.S.) U8JA11E0.book Page 130 Monday, June 14, 2010 10:22 AM[...]

Index A Air filter, checkin g .................. ........... ........ 73 Auxiliar y DC jack .. ........... ................. ........ 24 B Backrest (RST90 / RST90G T) ............... .. 30 Battery ....... ................. ........... ................. 1 08 Brake and parking b rake . ............ ........... .. 92 Brake lever ......................[...]

Index Shroud and covers, removin g and installi ng (RS90GT / R S90LTGT / RST90GT) ..... 63 Shroud and right sid e cover, opening and clo sing, rem oving and inst alling (RST90) ....... ........... ................. ........... .. 67 Skis and ski runners .................... ........... .. 95 Spark plugs , checking ...................... ........ 68[...]

U8JA11E0.book Page 3 Monday, June 14, 2010 10:22 AM[...]

Y AMAHA MOT OR CO ., L TD . PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2010.06-0.7 × 1 CR ESU12520 DIC183[...]