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viper fuel recall .pdf



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X/XX/2014

SNOWMOBILE

XXXXX-XXXX

©2014 YAMAHA MOTOR CORPORATION, U.S.A.

SAFETY
RECALL

This modification has top priority. This bulletin must be performed
immediately to ensure customer safety.
NOTE: Bulletins that announce a recall will have an “R” at the end of the bulletin number.

All 2014 AND CERTAIN 2015 SR10 (“SRViper”) SNOWMOBILES
FACTORY MODIFICATION CAMPAIGN – Fuel Hose Joint

R

AF
T

Yamaha Motor Corporation, U.S.A. has decided
that a defect which relates to motor vehicle safety
exists in 2014 model SR10R (“SRViper”), SR10RS
(“SRViper R-TX SE”), SR10L (“SRViper L-TX”),
SR10LS (“SRViper L-TX SE”), and SR10XS (“SRViper
X-TX”) snowmobiles, and also early production 2015
SR10LS (“SRViper L-TX SE”) snowmobiles. In affected snowmobiles, there is the possibility that clamps
on the fuel hose joint may have been installed slightly
out of position during manufacturing. If clamps are
not correctly positioned, fuel might leak from the joint
while the fuel system is pressurized during snowmobile operation. A fuel leak increases the risk of a fire
that could result in injury or death.

D

To correct this problem, Yamaha is initiating a Factory Modification Campaign. Affected units must have the
fuel hose assembly inspected and those with fuel joint clamps out of position will require the fuel hose assembly to be replaced.
Yamaha is notifying all registered owners of affected snowmobiles by mail. A copy of this letter is included in
this bulletin. The customer should take this letter along with the affected snowmobile to an authorized Yamaha
dealer for modification.
A computer report listing all affected snowmobiles invoiced to your dealership is included with this bulletin.
Use the list to help ensure all snowmobiles are modified. All sold snowmobiles that have been registered with
Yamaha will show the customer’s name and address. Your dealership must notify the owner of any affected
snowmobile that was actually sold but listed as “unsold” in the report.
You must modify all affected snowmobiles in your inventory as well as all customer-owned snowmobiles
brought to you for this service. Any affected snowmobile that you purchase from Yamaha in the future may
also require modification. If you purchase a snowmobile from another dealer or Yamaha, check to see if the
procedures in this bulletin have already been performed before you sell the snowmobile.
Snowmobiles that are affected should not be operated until they are modified. It is a violation of
Yamaha policy for your dealership to deliver any affected snowmobile to customers until the procedures in this bulletin are performed.
When the modification on each snowmobile is performed, follow the Warranty information section of this bulletin to receive reimbursement. Be sure to use the Factory Modification Campaign procedures in Chapter 7 of
the Warranty and Y.E.S. Handbook (LIT-11760-00-08).
PAGE 1 of 10

Unsold
Units:

Check first to be sure the modification has not already been performed (see Identification
Procedure in this bulletin for more information). Inspect the fuel hose assembly and replace it if
the fuel joint clamps are out of position.
Sold
Units:
Check first to be sure the modification has not already been performed (see Identification
Procedure in this bulletin for more information). Inspect the fuel hose assembly and replace it if
the fuel joint clamps are out of position.
Parts:

Yes, order a fuel hose assembly for each affected unit if inspection confirmed that the clamps
are out of position. Refer to Parts Information section below. You will also need a small amount
of blue paint to mark the hose assembly.

Warranty:

Factory Modification Campaign. See the Warranty Information section of this bulletin. This modification applies to all affected units regardless of ownership or warranty status.

AF
T

Notify
Customers: Yes. You must immediately contact any customer whose snowmobile shows as unregistered on
the enclosed report. Yamaha has sent letters to customers whose snowmobiles were registered
with Yamaha as of xx/xx/2014.

R

2014
SR10REB 8JP00-0000101~0000499
SR10XSEL 8JR00-0000103~0000954
SR10XSER 8JR00-0000957~0001718
SR10RSEL 8JW00-0000111~0000870
SR10LEB 8JX00-0000101~0000870
SR10LSER 8JY00-0000101~0000707
SR10LSEL 8JY00-0000708~0001383

D

2015
SR10LSFO 8JY20-0000101~0000300

Inspection
1. Remove the hairpin clips from the pins located
at the front of the access panels, then unscrew
the thumb screw (left side only). Move the panels
up and off the pins; then swing the panels all the
way out and unhinge the panel from the lower
consoles. See Fig. 1.

Fig. 1
LEFT-HAND SIDE SHOWN

THUMB SCREW
(LEFT SIDE ONLY)

PAGE 2 of 10

HARPIN
CLIP

2. Remove all six Torx®-head screws securing the
hood. See Fig. 2.

Fig. 2

TORX HEAD SCREWS

3. Locate the hood harness connector (located
under the center vent between the intake vents;
see Fig. 2) and unplug the connector. Move the
hood slightly forward and remove the hood.

TORX HEAD
SCREWS

4. Remove the Torx®-head screw from the underside of the seat; then lift on the back of the seat
and move it up and rearward to remove it. See
Fig. 3. NOTICE: On the SRViper and SRViper
L-TX models, also lift the rear of the seat and
disconnect the seat heater harness connector before removing the seat.

TORX HEAD
SCREW

Fig. 3

TORX HEAD
SCREW

AF
T

5. Loosen the two quarter-turn fasteners securing the lower console; the Fuel Tank Filler Neck
Nut Wrench (YS-11142) makes this job easier.
Remove the lower console. Remove the two
screws and the gas tank cap nut securing the
upper console, and then remove the upper console.

Fig. 4

D

R

6. Using a measuring caliper, confirm that there
is no more than 48mm between the end of the
throttle body connector and the hose clamp (see
Fig. 4). If OK, go to step 7. If out of specification,
replace the entire fuel hose assembly (go to step
1 of Fuel Hose Removal now).

7. If there is a fuel pump protector (Fig. 6), remove
it. Using a measuring caliper, confirm that there
is no more than 43mm between the end of the
fuel pump connector and the hose clamp (see
Fig. 5). If OK, go to step 8. If out of specification,
replace the entire fuel hose assembly (go to step
1 of Fuel Hose Removal now).

Fig. 5



PAGE 3 of 10

TIP: The 2015 SR10LSFO model has a fuel
pump protector over the connector (see Fig. 6).
Remove this protector before measuring.

Fig. 6

Fig. 7

AF
T

8. Lift the fuel filter from the fuel filter bracket. See
Fig. 7.

Fig. 8

R

9. Using a measuring caliper, confirm that there is
no more than 9mm between the fuel filter and
the clamp at either end (see Fig. 8). If OK, go to
step 10. If out of specification, replace the entire
fuel hose assembly (go to step 1 of Fuel Hose
Removal now).

D

10. If all clamps are installed correctly, use the fuel
hose clamp crimping tool (K&L P/N: 35-1061)
to make sure all four clamps are tight by
crimping the clamps until the two clamp areas
touch (see Fig. 9). Reinstall the fuel filter in the
bracket. On the SR10LSFO model, reinstall
the fuel pump protector and torque the mounting screws to 4.5 Nm (0.45 m-kgf, 3.3 ft-lbf, 40
in-lbf). NOTICE: Use care not to overtighten
the mounting screws or damage to the fuel
tank may result.

PAGE 4 of 10

MEASURE BOTH ENDS (ONLY ONE END SHOWN)

Fig. 9

11. Put a mark of blue paint on each clamp to
indicate the clamp position and tightness have
been verified. Also, put a blue mark on the
fuel hose assembly 6~8 inches from the fuel
filter (fuel pump connector end), so later on a
technician can see that the hose was verified
or replaced without removing the console (see
Fig 10). See Identification Procedure section
for more information.

Fig. 10

FUEL
PUMP
CONNECTOR

THROTTLE
BODY
CONNECTOR

12. Reinstall the consoles, hood access panels,
and seat. Put a punch mark next to the VIN as
decribed in the Identification Procedure section below and submit a Recall Request for
Inspection Only.
Fig. 11

AF
T

Fuel Hose Removal
1. Remove the two cap screws (A) securing
the right side rear spar to the chassis, then
remove the push-mount cable tie (B) and
the two cable ties (C) securing the fuel hose
assembly to the negative battery cable and
the fuel tank. See Fig. 11.

6~8 INCHES FROM FILTER

Fig. 11

Fig. 12

1
Fig. 11

D

R

2. Disconnect the fuel hose assembly connector
hose from the fuel pump outlet: (1) Push the
white connector toward the fuel pump fitting;
(2) push in the black release tab; (3) slowly
pull the white connector away from the fuel
pump fitting. See Fig. 12.
Since the fuel supply hose may be under pressure, remove it slowly to release the pressure.
Place an absorbent towel around the connection to absorb gasoline; then remove the hose
slowly to release the pressure. Always wear
safety glasses when removing the fuel hoses.

3

2

Fig. 13

3. If not already removed, remove the fuel hose
assembly from the fuel filter bracket. See Fig. 13.

PAGE 5 of 10

4. To disconnect the fuel hose assembly from the
throttle body assembly, pull up on the orange
connector (A), then squeeze the gray release
buttons on both sides (B). Slowly pull the hose
away from the throttle body fitting. See Fig. 14
and 15.
Put an absorbent towel under the hose at the
fuel tank end (white connector) when the hose is
disconnected from the throttle body end (orange
connector). Some fuel will pour out of the hose
at the white end. Also put a towel under the
orange connector end before disconnecting it.
Spilled fuel is a fire hazard. Clean up any spilled
fuel immediately.

Fig. 14

Fig. 15

AF
T

5. Remove the fuel hose assembly from the
chassis.

D

R

New Hose Installation
1. Install the new fuel hose assembly to the throttle
body assembly by squeezing the gray release
buttons and then pressing the connector onto
the throttle body until it is fully locked. Press
down on the orange connector to lock. See
Fig.16.

2. Press the fuel filter into the fuel filter bracket;
then route the other end of the fuel hose assembly to the fuel pump. Press the white connector
onto the fuel pump until it locks into place. See
Fig. 17.


TIP: On the SR10LSFO model, reinstall the
fuel pump protector and torque the mounting
screws to 4.5 Nm (0.45 m-kgf, 3.3 ft-lbf, 40 inlbf). NOTICE: Use care not to overtighten the
mounting screws or damage to the fuel tank
may result.

PAGE 6 of 10

Fig. 16

ORANGE
CONNECTOR

Fig. 17

GRAY
RELEASE
BUTTONS

3. Secure the fuel hose assembly to the fuel tank
using one Push-Mount Cable Tie (B) from the
kit; then secure the fuel hose assembly to the
negative battery cable in the existing locations
(C). See Fig. 18.

Fig. 18

4. Install the right-side spar and secure using
the existing cap screws. Tighten to 27 Nm (2.8
m-kgf, 20 ft-lbf).
5. Temporarily install the hood and connect the
hood harness; then start the engine and check
for any fuel leaks.
6. Put a blue mark on the fuel hose assembly
6~8 inches from the fuel filter (fuel pump
connector end), so later on a technician can
see that the hose was verified or replaced
without removing the console (see Fig 19).
See Identification Procedure section for more
information.

Fig. 19

FUEL
PUMP
CONNECTOR

THROTTLE
BODY
CONNECTOR

AF
T

7. Disconnect the hood harness then install the
upper and lower consoles; then install the seat,
hood, and both access panels. Put a punch
mark next to the VIN as described in Inspection
Procedure below and submit a Recall Request
for Hose Replacement.

6~8 INCHES FROM FILTER

D

R

After performing service, make a punch mark in the upper left hand corner of the vehicle identification number (VIN) as shown in the illustration below. Check for this punch mark if you encounter an unfamiliar unit. You can also check unit status on YDS or by contacting your Regional
Technical Advisor.

VIN

PUNCH MARK HERE.

PAGE 7 of 10

Hose Identification
• An original hose assembly has an orange paint mark only on the fuel filter clamp.
• If an original hose assembly has been verified to be correct, there should be a dealer-applied blue paint
mark on each clamp.
• A new hose assembly has a yellow paint mark on each clamp.
• After verification or replacement, a hose assembly should have a dealer-applied blue paint mark on the
protective sheath about 6 or 7 inches from the fuel filter on the fuel delivery side.
ORIGINAL FUEL
ASSEMBLY
ORIGINAL
FUELHOSE
HOSE
ASSEMBLY

NEWFUEL
FUEL HOSE
ASSEMBLY
NEW
HOSE
ASSEMBLY

AF
T

THROTTLE
BODY
CONNECTORS

ORIGINAL
HOSE
ASEMBLY
ORIGINAL FUEL
FUEL HOSE
ASSEMBLY
AFTER
INSPECTION

AFTERIT
IT PASSES
PASSES INSPECTION

DEALER-APPLIED
BLUE
PAINT
DEALER-APPLIED BLUE
PAINT

FWD

R

NEW
FUEL HOSE
HOSE ASSEMBLY
AFTER
NEW
FUEL
ASSEMBLY
AFTER
INSTALLATION ––DEALER
APPLIED
INSTALLATION
DEALER-APPLIED
BLUEPAINT
PAINT
BLUE

D

FWD

NEW FUEL HOSE ASSEMBLY AFTER
NEW
FUEL HOSE
ASSEMBLY
INSTALLATION
– DEALER
APPLIEDAFTER
VERIFICATION
BLUE PAINT OR REPLACEMENT –
DEALER-APPLIED BLUE PAINT

Order a Fuse Hose Assembly for each affected unit.
Part Number
90891-50158-00

PAGE 8 of 10

Description
SR10 Fuel Hose Assembly
Includes:
Fuel Hose Assembly (1)
Push-Mount Cable Tie (1)
Cable Tie (2)

Qty.

Dealer Cost

1

$30.36

The owner of each registered unit will receive a letter announcing this campaign. The customer’s letter
includes the Primary ID and Recall Number.
The modification is authorized for all affected snowmobiles, both sold and unsold, regardless of ownership or
warranty status. You do not need the customer’s letter to perform the modification or to file for reimbursement.
Inspection Only:
Choose Recall Number XXXXXX if inspection showed that the fuel hose assembly did not need replacement. The labor allowance is 0.2 hour.
Inspection and Modification
Choose Recall Number XXXXXX if the fuel hose assembly required replacement. You will be reimbursed the
cost of the SR10 Fuel Hose Assembly plus your normal warranty handling fee and labor. The labor allowance
is 0.3 hour.

AF
T

YDS:
When signed onto YDS, click on the Service Tab, and then “Recall Request-Add.” This function will allow you
to enter multiple Primary IDs for the same recall. Remember, YDS requires a 7-digit serial number, so use a
“0” as the first digit. The system will check your submission instantly to make sure the Primary ID numbers
you’ve entered are valid for the recall. You can check back the next day for your claim numbers to track your
credit.
MAIL:
Complete a recall Reimbursement Request (LIT-11790-00-03) as shown below:

R N 2 3 Y

0 0 0 0 X X X

0 3

1 2

2 0 1 4

0 3

1 2

2 0 1 4

D

R

9 9 0 0 8 5

9 9 0 0 8 6

R N 2 3 Y

0 0 0 0 X X X

If you have any questions about proper procedures for Factory Modification Campaigns, see Chapter 7 in
your Warranty and Y.E.S. Handbook (LIT-11760-00-08).

PAGE 9 of 10


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