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LIT 12668 02 91 2010 RS90 Assembly .pdf


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FOREWORD
This Assembly Manual contains the information required for reassembly of the Yamaha Snowmobile
correctly prior to delivery to the customer. Since some external parts of the snowmobile have been
removed at the Yamaha factory for convenience of packing, assembly by the Yamaha dealer is
required. It should be noted that the reassembled snowmobile should be thoroughly cleaned,
inspected, and adjusted prior to delivery to the purchaser.

IMPORTANT
The service specifications presented in this manual may become outdated due to future changes in
this model. Yamaha dealers will be notified of these changes through technical service information
that will be published by Yamaha.
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.

WARNING

A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.

NOTICE

A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.

TIP

A TIP provides key information to make procedures easier or clearer.

NOTE ON TRANSPORTATION
Take care not to put the snowmobile packed in the crate against a hard object or subject it to heavy
shocks during transportation or in the service shop.

RS90GTZ/RS90LTGTZ/RST90GTZ
ASSEMBLY MANUAL
© 2009 by Yamaha Motor
Corporation, U.S.A.
1st Edition, May 2009
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.
P/N LIT-12668-02-91

SYMBOLS USED IN THE ASSEMBLY
MANUAL
In order to simplify descriptions in this assembly manual, the
following symbols are used:
(1): Filling fluid
(2): Lubricant
(3): Special tool
(4): Tightening torque
(5): Wear limit, clearance
(6): ESSO beacon 325 grease or Aeroshell grease #7A
(7): Locking agent (LOCTITE®)
(8): Size of parts
d/D: Diameter of part
L: Length of part
e.g., 5 (0.2) = 5 mm (0.20 in)

PREPARATION
To assemble the snowmobile correctly, supplies (i.e., greases, shop rags, etc.) and working space
are required.
Workshop
The workshop where the snowmobile is assembled, should be clean and large. The floor should be level.
Self-protection
Protect your eyes with suitable safety glasses or goggles when using compressed air, when grinding
or when doing any operation which may cause particles to fly off.
Protect hands and feet by wearing safety gloves or shoes.

SYMBOLS USED ON TRANSPORT PACKAGE COVER

Contents of the transport package are
fragile therefore it must be handles
with care.

Do not step anywhere on this transport package.

Indicates correct upright position of
the transport package.

: IMPORTANT
This unit delivered to carrier in a good condition. For protection against loss due to damage, inspect thoroughly. If damage is noted,
make note on freight bill. Shipper assumes no
further liability to the transportation company.
Your claim should be filed against carrier for
damage of any nature.

Transport package must be kept away
from rain.
Up to 9 of the transport packages can
be piled up. (RS90GTZ/RS90LTGTZ)
Up to 6 of the transport packages can
be piled up. (RST90GTZ)
Only stack this unit with transport
packages of the same size.
Made of high-density polyethylene.

: WARNING
• Only stack this unit with same crate size.
• Assure units are stacked securely (All four
corners fit securely onto bottom unit).
• Maximum handling (transport & movement)
stack – 3 units.

CONTENTS
PARTS LOCATION ............................................................................. 1-1
PARTS LOCATION (RS90GTZ/RS90LTGTZ) ............................... 1-1
PARTS LOCATION (RST90GTZ) .................................................. 1-6
REMOVAL FROM CRATE (RS90GTZ/RS90LTGTZ).................... 1-12
REMOVAL FROM CRATE (RST90GTZ) ....................................... 1-14
SET UP PROCEDURE (RS90GTZ/RS90LTGTZ) .............................. 2-1
WINDSHIELD, FAIRING, HEADLIGHT.......................................... 2-1
FAIRING ASSEMBLY..................................................................... 2-2
FRONT SUSPENSION................................................................... 2-3
SKI ASSEMBLY ............................................................................. 2-4
FRONT BUMPER AND FRONT COVER ....................................... 2-5
STEERING ASSEMBLY................................................................. 2-6
REAR BUMPER (RS90GTZ).......................................................... 2-8
REAR BUMPER (RS90LTGTZ) ..................................................... 2-9
SLIDE RAIL SUSPENSION DAMPER ........................................... 2-10
SET UP PROCEDURE (RST90GTZ) .................................................. 2-11
FAIRING AND HEADLIGHT UNIT ................................................. 2-11
HEADLIGHT ASSEMBLY AND WINDSHIELD BRACKET ............ 2-12
WINDSHIELD, REARVIEW MIRROR AND WIND
DEFLECTORS ............................................................................... 2-13
FRONT SUSPENSION................................................................... 2-15
SKI ASSEMBLY ............................................................................. 2-16
FRONT BUMPER AND FRONT COVER ....................................... 2-17
STEERING ASSEMBLY................................................................. 2-18
REAR BUMPER ............................................................................. 2-20
BACKREST .................................................................................... 2-21
SLIDE RAIL SUSPENSION DUMPER ........................................... 2-22
FOOTREST .................................................................................... 2-23
STORAGE POUCH, OWNER’S TOOL BAG AND OWNER’S
MANUAL......................................................................................... 2-24

ADJUSTMENTS AND PREDELIVERY SERVICE............................... 3-1
SHROUD AND COVERS................................................................ 3-1
SHEAVE OFFSET ADJUSTMENT ................................................. 3-3
DRIVE V-BELT HEIGHT AND INSTALLATION.............................. 3-5
ENGINE OIL LEVEL ....................................................................... 3-6
BREAK-IN ....................................................................................... 3-8
COOLANT LEVEL .......................................................................... 3-9
DRIVE CHAIN HOUSING OIL LEVEL INSPECTION ..................... 3-12
DRIVE CHAIN TENSION ADJUSTMENT....................................... 3-13
THROTTLE CABLE ADJUSTMENT ............................................... 3-14
BATTERY INSTALLATION............................................................. 3-15
TRACK TENSION ADJUSTMENT.................................................. 3-18
HEADLIGHT BEAM ADJUSTMENT ............................................... 3-20
PARKING BRAKE ADJUSTMENT ................................................. 3-21
SKI ADJUSTMENT ......................................................................... 3-22
FRONT SUSPENSION ADJUSTMENT.......................................... 3-24
REAR SUSPENSION ADJUSTMENT ............................................ 3-27
BRAKE FLUID LEVEL .................................................................... 3-33
BRAKE FLUID REPLACEMENT .................................................... 3-34
HYDRAULIC BRAKE AIR BLEEDING............................................ 3-34
BATTERY INSPECTION ................................................................ 3-36
APPENDICES ...................................................................................... 4-1
SERVICE DATA.............................................................................. 4-1
LUBRICATION POINT AND GRADE OF LUBRICANT ...................... 5-1
CABLE ROUTING................................................................................ 6-1

PARTS LOCATION
PARTS LOCATION (RS90GTZ/RS90LTGTZ)
Carton box
(The items , , , , , and
are packaged in the carton box
for shipment.)
Carton box
Carton box
Carton box
Vinyl bag
Windshield
Flap
Vinyl bag
Battery (VRLA (Valve Regulated Lead Acid) battery)
Tool box
(The storage location after snowmobile assembly is shown in the illustration.)
Owner’s manual
(The storage location after snowmobile assembly is shown in the illustration.)
Safety hand book
(The storage location after snowmobile assembly is shown in the illustration.)
Suspension setting card
(The storage location after snowmobile assembly is shown in the illustration.)
Tag (Normalized emission rate)
(The storage location after snowmobile assembly is shown in the illustration.)
(This tag to be removed only after retail sale.)

NOTE:
TIP
This manual contains the most current product
information available at the time of printing,
there may be minor discrepancies between
your snowmobile and this manual.

1–1

Carton box
Headlight unit
Vinyl bag 1 ~ 5 (RS90GTZ)
Vinyl bag 1 ~ 6 (RS90LTGTZ)
Battery fluid (electrolyte)
Bolt
Cable holder

Carton box
Shock absorbers
Handlebar holders
Bolts

Carton box
Ski assemblies

1–2

Carton box
Headlight cover and meter assembly
Fairing
Front bumper
Front cover
Headlight access panels
Steering pad
Handlebar lower cover 2
Rear bumper cover
Rear bumper (RS90GTZ)
Rear bumper (RS90LTGTZ)
Flap stopper (RS90GTZ)

Vinyl bag
Handlebar joint
Handlebar lower cover 1

Windshield
Windshield

1–3


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