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16 rod recall .pdf



Original filename: 16 rod recall.pdf
Title: S2017-001R.indd

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1/11/2017

SNOWMOBILE

S2017-001R

©2017 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.

AL

CERTAIN TURBO-EQUIPPED 2016 SR10 ("SRVIPER") SNOWMOBILES
FACTORY MODIFICATION CAMPAIGN – Connecting Rod Replacement

SI

O
N

Yamaha Motor Corporation, U.S.A. has decided that a defect that
relates to customer satisfaction, durability, and safety exists in certain
2016 SR10 “SRViper” snowmobiles if fitted with a Yamaha point-ofpurchase, dealer-installed aftermarket Mountain Performance, Inc.
(MPI) turbocharger kit. In certain cases, turbo over-boost could cause
engine stresses in excess of design limits. An internal investigation
has determined that the turbo kit should have included connecting
rods designed specifically to handle these increased pressures and
stresses. A failure under this condition could cause a fire or a loss of
control that could result in a crash with injury or death.

O
VI

To correct this defect, Yamaha is initiating a Modification Campaign.
Affected units must have alternate connecting rods installed that are
specifically designed for the increased pressures and stresses.
IMPORTANT: SRViper snowmobiles that do not have the Yamaha MPI turbocharger installed are not
affected by this bulletin.

PR

Yamaha sold approximately 400 MPI Turbo Kits (p/n: SMA-8JP17-00-TB) to dealers but, out of an abundance
of caution, Yamaha is notifying registered owners of all potentially affected 2016 SRViper snowmobiles by
mail. A copy of this letter is included in this bulletin. The owner of an MPI turbo-equipped SRViper should take
this letter along with the affected snowmobile to an authorized Yamaha dealer for modification. Owners of
potentially affected snowmobiles without the MPI turbo can ignore the letter announcing this campaign; their
units are unaffected.
A computer report listing all potentially affected snowmobiles invoiced to your dealership is included with
this bulletin. Use the list to help ensure affected SRViper snowmobiles with the MPI turbo 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 with the MPI turbo as well as all affected customer-owned snowmobiles with the MPI turbo installed brought to you for this service. Any snowmobile in the
affected range that you purchase from Yamaha in the future will also require modification if you have previously
installed the MPI turbo kit. If you purchase a snowmobile from another dealer with the MPI turbo installed,
check to see if the procedures in this bulletin have already been performed before you sell the snowmobile.

PAGE 1 of 19

Snowmobiles that are affected because they have the MPI turbo installed should not be operated until
they are modified. It is a violation of Yamaha policy for your dealership to deliver any affected MPI
turbo-equipped 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-11760-00-16). Affected 2016 SRViper snowmobiles fitted with
Yamaha dealer-installed aftermarket MPI turbocharger should not be operated until modified with alternate
connecting rods. In addition, any MPI turbocharger kits you have in stock should not be sold or installed on
affected models. It is a violation of Yamaha policy for your dealership to deliver any affected snowmobiles to
customers until the procedures in this bulletin are performed.

Parts:

AL

Sold
Units:

If you have installed the MPI turbo kit on an unsold SRViper in the affected range, install the
alternate connecting rods per the instructions provided in this bulletin. No action is necessary on
units in the affected range that do not have the MPI turbocharger.
If the snowmobile is in the affected range and it has the MPI turbo installed, check first to be
sure the modification has not already been performed and then install the alternate connecting
rods per the instructions provided in this bulletin. No action is necessary on units in the affected
range that do not have the MPI turbocharger.

O
N

Unsold
Units:

Yes, order a SRViper Connecting Rod Kit for each affected unit only if it is also fitted with the
MPI turbocharger. Refer to Parts Information section.

PR

O
VI

SI

Warranty: Factory Modification Campaign. See the Warranty Information section of this bulletin. This modification applies to all affected units when fitted with an MPI turbo regardless of ownership or
warranty status.
Notify
Customers: Yes. You must immediately contact any customer whose snowmobile shows as unregistered on
the enclosed report if you installed the MPI turbo on the unit. Yamaha has sent letters to potentially affected customers whose snowmobiles were registered with Yamaha as of 1/10/2017.

2016 Model:

Model

Sales Name

Primary ID Range

SR10RDGB, SR10RDGR

SRViper R-TX DX

8JP30-0000101 ~ 0000336

SR10RSGL, SR10RSGR

SRViper R-TX SE

8JW40-0000101 ~ 0000375

SR10RLGL, SR10RLGW

SRViper R-TX LE

8KN40-0000101 ~ 0000190

SR10LDGB, SR10LDGR

SRViper L-TX DX

8JX30-0000101 ~ 0000745

SR10LSGL, SR10LSGR

SRViper L-TX SE

8JY40-0000102 ~ 0000611

SR10LLGL, SR10LLGW

SRViper L-TX LE

8KP30-0000101 ~ 0000336

SR10SD37GR

SRViper S-TX DX 137

8LJ10-0000101 ~ 0000391

SR10SD46GB

SRViper S-TX DX 146

8LN10-0000111 ~ 0000421

PAGE 2 of 19

2016 Model (Cont'd):
Model

Sales Name

Primary ID Range

SR10XSGL, SR10XSGR

SRViper X-TX SE

8JR60-0000101 ~ 0000558

SR10XLGL, SR10XLGW

SRViper X-TX LE

8LH10-0000107 ~ 0000225

SR10MS41GL, SR10MS41GR

SRViper M-TX 141 SE

8LK10-0000105 ~ 0000272

SR10M53GB, SR10M53GR

SRViper M-TX 153

8KG30-0000102 ~ 0000196

SR10MS53GL, SR10MS53GR

SRViper M-TX 153 SE

8KS30-0000102 ~ 0000208

SR10ML53GL, SR10ML53GW

SRViper M-TX 153 LE

8LL10-0000101 ~ 0000161

SR10M62GB, SR10M62GR

SRViper M-TX 162

8LM10-0000102 ~ 0000179

SR10MS62GL, SR10MS62GR

SRViper M-TX 162 SE

8KT30-0000103 ~ 0000215

SR10ML62GL; SR10ML62GW

SRViper M-TX 162 LE

8KU30-0000101 ~ 0000158

Model

AL

IMPORTANT: The following two 2016 snowmobile models are excluded from this action due to a different
engine specification:
Sales Name
SRVIPER L-TX LE

SR1EML62GL

SRVIPER M-TX 162 LE

O
N

SR1ELLGL

SI

Refer to the 2016 SRViper Service Manual (LIT-12618-03-26), Engine section, for detailed engine removal
and service procedures.

O
VI

Required Tools
To perform this modification, you will require the following tools:
Source/Identification
YS-11142

Description

Console nut wrench

YS-01881-A; YS-1881-1

Primary Clutch Puller

35-1061

Oetiker® clamp installation tool (crimp type)

YU-33270-B

Flywheel puller
Torque wrench

PR

Local source
Local source

Digital angle torque wrench (recommended over angle torque
gauge tool)

YM-08037

Ring compressor

Local source

Engine lift

It is recommended you review and understand the following Yamaha service videos:
https://youtu.be/K6OAGZoI9_A

Timing Chain Tensioner Service (also applies to 2016 SRViper engine)

https://youtu.be/HaB63_N-lxc

Cam Timing and Cam Chain Tensioner (also applies to 2016 SRViper engine)

• Gasoline is flammable,
• Perform the procedure away from any
spark, flames, or other sources of ignition.

PAGE 3 of 19

1. Engine Removal
1-1
1-2

Set parking brake.
Per the Service Manual, remove:
• Side panels,
• Shroud,
• Seat,
• Disconnect battery cables and remove
battery,

On models equipped with a heated seat (stock
or accessory), lift the rear of the seat and disconnect the seat heater harness connector
BEFORE removing the seat.
Upper and lower consoles (tank shroud).

AL



O
N

Console Nut Wrench:
YS-11142

SI

TIP:
Take several photos overhead, LH and RH side;
this will make it much easier when it comes to reassembly for component location, hose routing and
cable tie locations.
Fuel Tank:
• Drain fuel tank;
• Remove 2 long spars securing tank to
tunnel;
• Remove ties securing fuel hose and
wires;
• Reposition tank at 90 degrees (as per
Figure 4 on page 6);

1-4

Remove heat shield and exhaust header
assembly.

PR

O
VI

1-3

PAGE 4 of 19

1-5







Draining Engine Oil:
• Remove RH footrest;
• Drain engine oil from oil tank;
• Remove lower engine access panel;
• Drain oil from engine;
• Dispose used engine oil in a proper
manner (according to local regulations).

1-6 Drain coolant into a proper container for
reuse.
Remove:
• Drive belt,
• Primary clutch,
• Secondary clutch.

TIP:
Note placement of shims on secondary shaft as per
Service Manual procedures.
Remove muffler and turbo assembly, RH
chassis support and disconnect required
connections. (Fig. 2)

O
N

1-8



FIG. 2

AL

1-7




TIP:
Remove the lower oil hose from the fitting next to
the oil cooler to allow access to the lower turbo
mounting bolt.

Remove and retain oil return and turbo drain
fittings. (Fig. 3)

SI

1-9


FIG. 3

PR

O
VI


Note the position of the shims for reassembly
(they must be re-coated with Yamabond 4B or
RTV silicone prior to installation) as these are
required for proper fitting orientation.


PAGE 5 of 19

1-10 Remove:
• Intake manifold assembly,
• Air intake
• Filter assembly.

Fuel tank repositioned

Disconnect and remove:
• Engine ground strap,
• EABC assembly,
• Thermostat housing,
• Air/oil separator,
• Radiator assembly.

1-12 Remove:
• Frame spars,
• Steering column,
• Throttle body assembly.

SI

O
VI

1-13 Disconnect:
• LH side coolant hose,
• Oil pressure switch,
• Oil pressure sensor,
• Crankshaft sensor.

O
N

TIP:
The wiring harness only needs to be repositioned.

PR

1-14
Confirm that the engine is NOT
CONNECTED to any hose or wire from
the chassis.

1-15









In





the following order:
Remove rear engine mount bolts;
Loosen front engine mounts;
Roll engine forward;
With engine in the upright position,
secure engine with a strap to the
front engine loop (this prevents the
engine from falling backwards.)

PAGE 6 of 19

AL

1-11






FIG. 4

1-16

Remove:
• Inspection panel (5 screws).
• Four bolts retaining front engine loop
bracket to the chassis.

With the assistance of an engine lift:
• Attach securely to engine-and-loop
assembly;
• Lift the engine-and-loop assembly
straight up and out of the right side of
the chassis;
• Place engine on suitable wooden blocks
for step 1-18.

1-18

Remove from engine:
• Front engine loop bracket.

2. Engine disassembly

O
N

1-17

AL

TIP:
DO NOT remove front engine loop bracket from
engine until engine assembly is secured on workbench.

TIP:
Refer to the Service Manual for engine disassembly
procedures.
Remove:
• Ignition coils,
• Spark plugs,
• Cylinder head cover.

2-2

Set #3 (RH) cylinder to TDC by aligning the
marks A and B as shown.

O
VI

SI

2-1

PR

TIP:
It is not necessary to remove the starter as instructed in the Service Manual.

PAGE 7 of 19

Remove:
• Magneto cover,
• Starter idler gear,



Flywheel,
Flywheel Puller:
YU-33270-B

PTO output shaft from the opposite end
of the crankshaft.

O
N



AL

2-3

SI

TIP:
It is not necessary to remove the water pump
assembly as instructed in the Service Manual.

O
VI

However, take care not to damage the exposed
hoses and coolant fitting on top of the water pump
housing as you handle the engine during the repair.

PR

When turning the engine upside down in step 2-5,
use wood blocks to raise the engine from the workbench and prevent damage to the water pump fitting
and hoses.

PAGE 8 of 19

2-4. Remove:
• Oil cooler assembly,
• Cam chain tensioner and gasket,



Camshafts





Cylinder head bolts,

O
N


To prevent damage to the cylinder head, camshafts, or camshaft caps, loosen the camshaft
cap screws in stages and in a criss-cross pattern working from the outside in.

AL



SI

TIP:
Remove the eight cap screws (#3-10) and two Allen
head screws (#1 and #2). Remove the head and
account for the gasket and dowel pins.





O
VI


Loosen the cap screws in the proper sequence
as shown. Loosen each cap screw 1/2 of a turn
at a time. After all of the cap screws are fully
loosened, remove them.
Cylinder head,

PR


To avoid movement of the lifters and shims, do
not turn the cylinder head upside down or on its
intake or exhaust side. If the engine is assembled with a valve shim out of place, it will start
and run for a short time until the valve keepers
become dislodged and result in severe engine
damage.
Set the cylinder head on either end to clean gasket surfaces. Refer to motorcycle Tech Exchange
M2006-014 for service tips about proper handling of
cylinder heads.

• Cam chain guides.
TIP:
It is not necessary to remove the engine mounts as
instructed in the Service Manual.

PAGE 9 of 19


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