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2004 Tech Update LIT 12468 00 04 .pdf


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2004
Yamaha Snowmobile Technical Update
©2003 by Yamaha Motor Corporation, U.S.A.
September 2003
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.
03-419

2004 Snowmobile Technical Update

Welcome
The “2004” 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.

2004 SNOWMOBILE TECHNICAL UPDATE
TABLE OF CONTENTS
1. PRODUCT INFORMATION / SPECIFICATIONS
RX-1/ER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Altitude Tuning Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
RX-1 Mountain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Altitude Tuning Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
RX-Warrior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Altitude Tuning Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SXViper S/ER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Altitude Tuning Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
SXViper Mountain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Altitude Tuning Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Venture 600/700 . . . . . . . . . . . . .
Service Data. . . . . . . . . . . . . . . . .
Venture 600 Altitude Tuning Specs
Venture 700 Altitude Tuning Specs

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. . . . . . . 1-25
. . . . . . . 1-25
. . . . . . . 1-27
. . . . . . . 1-30

SXVenom/ ER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Altitude Tuning Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
VK540 III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Altitude Tuning Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
VT500XL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
Altitude Tuning Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
BR250T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
Altitude Tuning Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50
Model Improvement Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
Model Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54
2. TECHNICAL INFORMATION
RX-1 Special Tool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Frequently Used Special Tools for Snowmobiles - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2004 Suspension Components Specifications and Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Front Suspension Linkage Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Control Rod/Spacer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
I

2004 Snowmobile Technical Update
2004 Specifications for Front Shock/Stabilizer Bar/Center Shock/Rear
Shock Control Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Suspension Spring/Optional Spring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Track Drive Sprocket Chart (2004 RX-1, SXV, VT Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
YVXC Clutch Tuning Information - 2004 500/600/700/1000cc Models . . . . . . . . . . . . . . . . . . . . . . 2-27
Gear Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Chain Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
DCS - Detonation Control System (All 2004 700 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
3. TECH TIPS
Track Tension, Track Racheting - All RX-1 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Engine Oil Level Check Procedures - All RX-1 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Electrical Accessories Causing Excessive Current Draw - All RX-1 Models . . . . . . . . . . . . . . . . . . . 3-6
Current Draw if Key and Stop Switch Left ON with Engine OFF - All RX-1 Models. . . . . . . . . . . . . . 3-7
New OptiMate Battery Charger Products - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Digital Gauge Lens Fogging - All Models with a Digital Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Reverse Grinding or Not Staying Engaged All 2003 RX-1 Models with Reverse or Reverse Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Crankcase Breather Hose Blocked by Ice - All 2003 RX-1 Models. . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Broken Carburetor Fuel Inlet “T” Fitting - All RX-1 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Carburetor Coolant Pipe Leaks - All 2003 RX-1 Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Carburetor Vent Hose Routing - All RX-1 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Electrical Problems Due to Wiring Harness Damage - All RX-1 Models . . . . . . . . . . . . . . . . . . . . . 3-16
Stator Pick-up Coil Wire Damaged by Starter Clutch Idler Gear - All 2003 RX-1 Models . . . . . . . . 3-17
RX-1 Starter Clutch Mounting Bolts Loctite Recommendation - All RX-1 Models . . . . . . . . . . . . . . 3-18
RX-1 Mountain Rear Suspension Center Mount Bolt Access - All RX-1 Mountain Models . . . . . . . 3-19
Starter Rope Wear - All 20002~2003 SXViper Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Coolant Leaking from Weephole/Impeller and Shaft Loctite Application All 1997 to Current Three Cylinder Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
New Parts Available Separately - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Optional Suspension Settings - 2003 RX-1 121’’ Track Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Understanding Today’s Fuel with Today’s Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
4. TECH BULLETINS/EXCHANGES REVIEW
S2003-012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
S2003-011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
S2003-010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
S2003-009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
S2003-008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
S2003-007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
S2003-006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
S2003-005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
S2003-004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
S2003-003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
S2003-002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
S2003-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
S2002-008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
S2002-007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
S2002-006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
S2002-005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
S2002-004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
S2002-003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
S2002-002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
II

Product Information / Specifications
S2002-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service per Bulletin Recall List. . . . . . . . . . . . . . . . . . . . .
Service per Bulletin 90 Code List . . . . . . . . . . . . . . . . . . .
1997 ~ 2002 Technical Bulletins/Tech Exchanges Indexes.
1997 ~ 2004 Snowmobile Technical Literature Index . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

5. KIT/ACCESSORY INSTALLATION INSTRUCTIONS
Application Chart for 2004 Snowmobile Accessory Kit Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
RX-1 Reverse Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Reverse Gear Kit Installation Instructions (Except RX-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Electrical Starter Kit Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
2-Up Seat Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Coolant Heater Installation Instructions - RX-1 ER/ Mountain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Traction Bracket Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Skidplate Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Side Panel Accent Cover Set Installation Instructions - RX-1/M/W . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
6. YAMAHA SERVICE TRAINING COURSE 2003 ~ 2004
7. YAMAHA SERVICE, PARTS AND WARRANTY ASSISTANCE
8. REFERENCE MATERIAL
Self-Diagnosis System Warning Light Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
2004 Peak Voltage Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Yamaha track Specification Chart ’97 ~ ’04 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Yamaha Track Application Chart ’97 ~ ’04 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Chain/Sprocket Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Yamaha Drive Belt Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Pop Rivet Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Decal Location Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Snowmobile Model/ID Guide 1968 ~ 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
9. WIRING DIAGRAMS

III

1

1. PRODUCT INFORMATION/
SPECIFICATIONS

1-1

2004 Snowmobile Technical Update
This chapter provides the carburetion, clutching,
and gearing tuning specifications regarding various
elevations and ambient temperatures for all 2004
model snowmobiles. Refer to the charts to adjust
for primary use conditions. The RX10MJ/MSJ and
SXV70MJ 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

Models by Country
USA

CANADA

EUROPE

JAPAN

RX10J-B / L

RX10J-B / L

RX10RJ-R

RX10J-B

RX10SJ

RX10SJ

RX10RSJ

RX10MJ-B

RX10RJ-B / L / R

RX10RJ-B / L / R

RX10MJ-L

RXW10SJ

RX10RSJ

RX10RSJ

RXW10J-B

SXV70J-B

RX10MJ-B / L / R

RX10MJ-L / R

RXW10SJ

SXV70MJ-R

RX10MSJ

RX10MSJ

SXV70ERJ-B

SXV60J

RXW10J-B / L

RXW10J-B / L

SXV70SJ

VK540EJ

RXW10SJ

RXW10SJ

SXV70MJ-R

VT500XLJ

SXV70ERJ-B / L

SXV70ERJ-B / L

VT60J

BR250TJ

SXV70SJ

SXV70SJ

VT70J

SXV70MJ-L / R

SXV70MJ-L / R

VK540EJ

VT70J

VT70J

VT500XLJ

VT60J

VT60J

SXV60ERJ

SXV60ERJ

SXV60J

SXV60J

VK540EJ

VK540EJ
VT500XLJ
BR250TJ

1-2

Product Information / Specifications

RX10J / RJ / SJ / RSJ

RX-1
MODELS:
Prefix:
Starting Serial Number:

Colour:

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:

RX-1 ER
RX10J / RJ / SJ / RSJ
8FA3 / 8ER3,4 / 8EU3,4 / 8EW3,4
RX10J – JYE8FA0044A005543 (Black JYE8EU0094A000603)
RX10RJ – JYE8ER0074A007725 (Black JYE8EW0064A003731)
RX10SJ – JYE8EU0094A000603
RX10RSJ – JYE8EW0064A003731
RX10J – Deep Purplish Blue Metallic C / Yamaha Black
RX10RJ – Deep Purplish Blue Metallic C / Yamaha Black / Heat Red
RX10SJ – Silver 3
RX10RSJ – 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 / 8FA1-01
135
5DHP50-53 (3)
P4M
#115
--- / 17.5
13 ± 2mm (0.43 ~ 0.59 in)
Approx. 2.0 turns
1,350 ± 100
85 / 125 / 120
Dry Sump
5GH-13440-10
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) @ 1,450 rpm
38L / 10.0 gal / Unleaded Regular
250 / SAE # 75-80, API-GL3
4.7 / Aluminum compatible ethylene glycol silicate free /
60:40 (distilled water)
45 / Dot 3 ~ 4

1-3


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