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2003 Tech Update LIT 12468 00 03 .pdf


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Title: *03-US-TechUp(Chap1~3)
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Snowmobile Technical Update

2003
Yamaha Snowmobile Technical Update
©2002 by Yamaha Motor Corporation, U.S.A.
September 2002
All rights reserved. Any reprinting
or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
Specifications, features and operations are subject to
change without notice.
02-377

2003 Snowmobile Technical Update

Welcome
The “2003” Snowmobile Technical Update
Seminar has been developed to provide Yamaha
dealers with a convenient, one-day overview of the
service needs of newly released models as well as
those units currently in the marketplace. The
seminar is intended to help you achieve, through
product knowledge, an element critical to your
efforts to attain the highest level of customer
satisfaction.
This booklet is an important part of the seminar. It
provides you with a reference source your
dealership can turn to, again and again, for useful
information. You’ll find important specifications,
significant features and benefits, and key
maintenance and repair points for new models, as
well as updated technical information about the
units you service every day.
Thank you for your involvement in Yamaha’s quality
service effort. The importance of quality service to
overall customer satisfaction and your dealership’s
growth and profitability cannot be over emphasized.
We hope you’ll find this booklet to be a useful tool to
that end.

i

2003 SNOWMOBILE TECHNICAL UPDATE
TABLE OF CONTENTS
1. PRODUCT INFORMATION / SPECIFICATIONS
RX-10H/RH/SH/RSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Technical Orientation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
RX-10MH/MSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
RX-10 & RX-10M New Model Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81
SXV70MH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83
New Model Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88
SXV70H/ERH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92
New Model Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97
MM700H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98
New Model Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103
SX600H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
VX600ERH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109
VT600/700H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114
VK540EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122
VT500XLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-127
2. TECHNICAL INFORMATION
RX-1 Special Tool Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Frequently Used Special Tools for Snowmobiles - All Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2003 Suspension Components Specifications and Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Front Suspension Linkage Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Control Rod/Spacer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Specifications for Front Shock/Stabilizer Bar/Center Shock/Rear Shock Control Rod . . . . . . 2-20
Suspension Spring/Optional Spring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2003 RX10H, SH, RH, RSH Optional Suspension Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Track Drive Sprocket Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
RX-1 Self-Diagnosis System Warning Light Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
SXViper Self-Diagnosis System Warning Light Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
SX, VX, VT, MM Self-Diagnosis System Warning Light Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
YVXC Clutch Tuning Information - 2003 600/700/1000cc Models. . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Decal Location Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Peak Voltage Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Yamaha Track Specification Chart - ’97~’03 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Yamaha Track Application Chart - ’97~’03 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Chain/Sprocket Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Yamaha Drive Belt Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
iii

2003 Snowmobile Technical Update
Cylinder Head and Head Gasket Application Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Yamaha Model History Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
1980 to 2003 Snowmobile Model Identification Starting Engine Numbers & Frame Numbers . . . . 2-75
Pop Rivet Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Snowmobile Paint Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
3. TECHNICAL TIPS / TECH BULLETINS / EXCHANGES REVIEW
RX-1 Service Manual Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
SXViper Service Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Coolant Leak/Impeller and Shaft Installation`. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Thermosensor Part Kit Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
ProAction Suspension Shock R+R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
S2002-007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
S2002-006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
S2002-005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
S2002-004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
S2002-003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
S2002-002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
S2002-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
S2001-009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
S2001-007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
S2001-005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
2002 Technical Bulletin Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
2001 Technical Bulletin Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
2000 Technical Bulletin Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
1999 Technical Bulletin Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
1998 Technical Bulletin Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
1997 Technical Bulletin Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Service Per Bulletin 90 Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Service Per Bulletin Recall List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
1997 ~ 2003 Snowmobile Technical Literature Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

iv

2003 Snowmobile Technical Update

4. KIT / INSTALLATION INSTRUCTIONS
RX-1 Reverse Gear Kit Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Reverse Gear Kit (Except RX-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Electric Starter Kit Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
2-Up Seat Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
RX-1 Coolant Heater Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
RX-1 Traction Bracket Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
RX-1 Skid Plate Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
5. SERVICE TRAINING COURSES 2002 ~ 2003
6. YAMAHA SERVICE, PARTS AND WARRANTY ASSISTANCE
7. WIRING DIAGRAMS

v

1

1. Product Information/
Specifications

1-1

2003 Snowmobile Technical Update
This chapter provides the carburetion, clutching, and
gearing tuning specifications regarding various elevations and ambient temperatures for all 2003 model
snowmobiles. Refer to the charts to adjust for primary
use conditions. The RX10MH/MSH, SXV70MH and
MM700H mountain models have gear and clutch
settings preset to 6,500 ft~10,000 ft from the factory.
The carburetion is, however, set to sea level, so be
sure to set carburetion per specific operation level.
If a mountain model is to be operated at lower
elevation levels than the factory settings, be sure
to adjust the appropriate setting according to the
specification provided.

STANDARD ABBREVIATIONS:
General:
STD
= Standard Setting
Eur.
= European Setting
Clutch Rivets:
ST
= Steel
AL
= Aluminum
Carburetion:
MJ
= Main Jet
NJ
= Needle Jet
PJ
= Pilot Jet
JN
= Jet Needle Clip Position
PAJ
= Pilot Air Jet
PS
= Pilot Screw (turns out)
MN
= Main Nozzle

1-2

Product Information / Specifications

RX10H / RH / SH / RSH

RX-1
MODELS:
Prefix:
Starting Serial Number:

Color:

ENGINE:
Number of Cylinders / Type:
Displacement (cc):
Bore and Stroke (mm):
Valve Clearance Intake / Exhaust Cold:
Exhaust Type:
Cooling Type:
Starting:
CARBURETOR:
Carburetor Type / I.D.:
Main Jet:
Jet Needle (Clip Position):
Needle Jet / Series:
Throttle Valve:
Power Jet / Pilot (Slow) Jet:
Float Height:
Idle Mixture Screw Setting:
Idle RPM:
Pilot (Slow) Air Jet / Power Air Jet / Main Air Jet:
LUBRICATION SYSTEM:
Type:
Oil Filter Type:
Oil Change Capacity – Oil Only (L):
Oil Change Capacity – Oil and Filter (L):
Total Oil Capacity (L):
Engine Oil Type:
Oil Pressure (hot):
CAPACITIES:
Fuel Tank Capacity / Fuel Type:
Chaincase Capacity (cc) / Oil Grade:
Coolant Capacity (L) / Type / Ratio:
Brake Fluid Capacity (cc) / Type:

RX10H / RH / SH / RSH
8FA1 / 8ER1 / 8EU1 / 8EW1
RX10H – JYE8FA0053A000687
RX10RH – JYE8ER0083A001091
RX10SH – JYE8EU0073A000145
RX10RSH – JYE8EW0003A000533
RX10H – Dark Gray Met. B, Deep Purplish Blue Met. C
RX10RH – Heat Red, Deep Purplish Blue Met. C
RX10SH – Silver 3
RX10RSH – Silver 3
Parallel 4 / 4-stroke, DOHC, rearward inclined
998
74.0 x 58.0
0.11~0.20mm (0.004~0.008 in) / 0.21~0.25mm (0.008~0.010 in)
Rear mounted – 4 – 2 – 1 – 2
Liquid
Electric Start Only
Mikuni BSR37 x 4 / 8FA-100
135
Ab (3)
P4M
#115
--- / 17.5
13 ± 2mm (0.43 ~ 0.59 in)
Approx. 2.0 turns
1350 ± 100
85 / 125 / 120
Dry Sump
5GH-13440-00
2.8 (3.0 US qt)
3.0 (3.2 US qt)
3.8 (4.0 US qt)
Yamalube 4, API SJ SAE 5W30
0.5 kg/cm2 (7.1 psi) @ 1450 rpm
38L / 10.0 gal / Unleaded Regular (Min. 88 Pump Octane)
250 / SAE # 75-80, API-GL3
4.7 / Aluminum compatible ethylene glycol silicate free /
60:40 (distilled water)
45 / Dot 3

1-3


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