2004 2005 2006 Yamaha Rs Vector Nytro Rage Factory Manuals (PS025446)

2004 2005 2006 Yamaha Rs Vector Nytro Rage Factory Manuals (PS025446)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• 2004, 2005, 2006 Yamaha RS Vector Nytro Rage Snowmobiles Factory Service Manual

  568 Pages

  Covers models –

  RS90, RS90R, RSG90, RS90M, RST90, RST90TF
  
  RS90N, RS90NR, RS90RS, RS90MS, RS90GT

  RS90K, RS90RK, RSG90K,
  
  RS90MK, RST90K, RST90TFK
  
  RS90NL, RS90NRL,
  
  RS90RSL, RS90GTL, RS90MSL

  May also cover model years later than listed.

  Chapters Include –

  GENERAL INFORMATION
  
  PERIODIC INSPECTION AND ADJUSTMENT
  
  CHASSIS
  
  POWER TRAIN
  
  ENGINE
  
  COOLING SYSTEM
  
  CARBURETION
  
  ELECTRICAL
  
  SPECIFICATIONS

  CHAPTER 1.
  
  GENERAL INFORMATION
  
  MACHINE IDENTIFICATION………………………. 1-1
  
  FRAME SERIAL NUMBER……………………. 1-1
  
  ENGINE SERIAL NUMBER…………………… 1-1
  
  IMPORTANT INFORMATION …………………….. 1-2
  
  PREPARATION FOR REMOVAL AND
  
  DISASSEMBLY……………………………………. 1-2
  
  ALL REPLACEMENT PARTS………………… 1-2
  
  GASKETS, OIL SEALS, AND O-RINGS….. 1-3
  
  LOCK WASHERS/PLATES
  
  AND COTTER PINS …………………………….. 1-3
  
  BEARINGS AND OIL SEALS ………………… 1-3
  
  CIRCLIPS …………………………………………… 1-3
  
  LOCTITE® ………………………………………….. 1-3
  
  SPECIAL TOOLS ……………………………………… 1-4
  
  FOR TUNE UP…………………………………….. 1-4
  
  FOR ENGINE SERVICE……………………….. 1-4
  
  FOR POWER TRAIN SERVICE …………….. 1-7
  
  FOR CARBURETION SERVICE ……………. 1-8
  
  FOR ELECTRICAL SERVICE ……………….. 1-8

  CHAPTER 2.
  
  PERIODIC INSPECTION AND
  
  ADJUSTMENT
  
  INTRODUCTION……………………………………….. 2-1
  
  PERIODIC MAINTENANCE CHART……………. 2-1
  
  ENGINE …………………………………………………… 2-3
  
  SPARK PLUGS……………………………………. 2-3
  
  FUEL LINE INSPECTION……………………… 2-3
  
  COOLING SYSTEM……………………………… 2-4
  
  VALVE CLEARANCE ADJUSTMENT …….. 2-7
  
  CARBURETOR SYNCHRONIZATION….. 2-13
  
  ENGINE IDLE SPEED ADJUSTMENT….. 2-14
  
  THROTTLE CABLE FREE PLAY
  
  ADJUSTMENT…………………………………… 2-15
  
  THROTTLE OVERRIDE SYSTEM
  
  (T.O.R.S.) CHECK……………………………… 2-16
  
  COMPRESSION PRESSURE
  
  MEASUREMENT……………………………….. 2-17
  
  ENGINE OIL LEVEL INSPECTION ………. 2-18
  
  ENGINE OIL REPLACEMENT …………….. 2-20
  
  CRANKCASE BREATHER HOSE
  
  INSPECTION…………………………………….. 2-23
  
  CARBURETOR JOINTS INSPECTION…. 2-23
  
  CHECKING THE AIR FILTER
  
  ELEMENT…………………………………………. 2-23
  
  EXHAUST SYSTEM INSPECTION ………. 2-24
  
  POWER TRAIN……………………………………….. 2-25
  
  SHEAVE OFFSET ADJUSTMENT ……….. 2-25
  
  DRIVE V-BELT…………………………………… 2-27
  
  ENGAGEMENT SPEED CHECK………….. 2-29
  
  PARKING BRAKE ADJUSTMENT………… 2-30
  
  BRAKE FLUID LEVEL INSPECTION ……. 2-30
  
  BRAKE PAD INSPECTION………………….. 2-31
  
  BRAKE HOSE INSPECTION……………….. 2-31
  
  AIR BLEEDING (HYDRAULIC BRAKE
  
  SYSTEM) ………………………………………….. 2-32
  
  DRIVE CHAIN……………………………………. 2-33
  
  TRACK TENSION ADJUSTMENT………… 2-35
  
  SLIDE RUNNER INSPECTION ……………. 2-37
  
  MAXIMIZING DRIVE TRACK LIFE……….. 2-37
  
  CHASSIS ……………………………………………….. 2-39
  
  SKI/SKI RUNNER ………………………………. 2-39
  
  STEERING SYSTEM………………………….. 2-40
  
  LUBRICATION…………………………………… 2-41
  
  ELECTRICAL …………………………………………. 2-44
  
  HEADLIGHT BEAM ADJUSTMENT ……… 2-44
  
  BATTERY INSPECTION……………………… 2-44
  
  FUSE INSPECTION……………………………. 2-52
  
  SPEEDOMETER UNIT INSPECTION …… 2-54
  
  TUNING …………………………………………………. 2-55
  
  CARBURETOR TUNING…………………….. 2-55
  
  CLUTCH……………………………………………. 2-62
  
  GEAR SELECTION…………………………….. 2-67
  
  HIGH ALTITUDE TUNING…………………… 2-73
  
  FRONT SUSPENSION ……………………….. 2-74
  
  REAR SUSPENSION………………………….. 2-75

  CHAPTER 3.
  
  CHASSIS
  
  STEERING……………………………………………….. 3-1
  
  RS90/RS90R/RSG90/RST90/RST90TF….. 3-1
  
  RS90M……………………………………………….. 3-3
  
  REMOVAL…………………………………………… 3-7
  
  INSPECTION ………………………………………. 3-7
  
  INSTALLATION……………………………………. 3-8
  
  SKI ………………………………………………………… 3-12
  
  RS90/RS90R/RSG90 USA/Canada ……. 3-12
  
  RSG90 Europe/RST90 Europe/
  
  RST90TF…………………………………………… 3-13
  
  RS90M……………………………………………… 3-14
  
  RST90 USA/Canada…………………………. 3-15
  
  INSPECTION …………………………………….. 3-16
  
  INSTALLATION
  
  (RST90 USA/Canada) ………………………. 3-1
  
  FRONT SUSPENSION …………………………….. 3-18
  
  HANDLING NOTES……………………………. 3-20
  
  INSPECTION…………………………………….. 3-20
  
  INSTALLATION …………………………………. 3-21

  CHAPTER 4.
  
  POWER TRAIN
  
  PRIMARY SHEAVE AND DRIVE V-BELT……. 4-1
  
  REMOVAL ………………………………………….. 4-3
  
  DISASSEMBLY……………………………………. 4-3
  
  INSPECTION………………………………………. 4-4
  
  ASSEMBLY…………………………………………. 4-6
  
  INSTALLATION …………………………………… 4-9
  
  SECONDARY SHEAVE …………………………… 4-10
  
  DISASSEMBLY………………………………….. 4-12
  
  INSPECTION…………………………………….. 4-12
  
  ASSEMBLY……………………………………….. 4-13
  
  INSTALLATION …………………………………. 4-15
  
  DRIVE CHAIN HOUSING…………………………. 4-16
  
  WITHOUT REVERSE MODEL …………….. 4-16
  
  REMOVAL ………………………………………… 4-18
  
  INSPECTION…………………………………….. 4-18
  
  INSTALLATION …………………………………. 4-20
  
  WITH REVERSE MODEL……………………. 4-21
  
  REMOVAL ………………………………………… 4-24
  
  INSPECTION…………………………………….. 4-24
  
  INSTALLATION …………………………………. 4-25
  
  SECONDARY SHAFT ……………………………… 4-27
  
  REMOVAL ………………………………………… 4-28
  
  INSPECTION…………………………………….. 4-29
  
  INSTALLATION …………………………………. 4-29
  
  SECONDARY SHAFT AND DRIVE CHAIN
  
  HOUSING INSTALLATION………………….. 4-32
  
  BRAKE ………………………………………………….. 4-34
  
  BRAKE PAD REPLACEMENT …………….. 4-35
  
  BRAKE CALIPER DISASSEMBLY……….. 4-38
  
  BRAKE CALIPER INSPECTION
  
  AND REPAIR …………………………………….. 4-38
  
  BRAKE CALIPER ASSEMBLY…………….. 4-39
  
  BRAKE CALIPER INSTALLATION……….. 4-39
  
  INSPECTION…………………………………….. 4-41
  
  BRAKE MASTER CYLINDER
  
  ASSEMBLY……………………………………….. 4-41
  
  INSTALLATION …………………………………. 4-41
  
  SLIDE RAIL SUSPENSION………………………. 4-42
  
  RS90/RS90R……………………………………… 4-42
  
  RSG90 ……………………………………………… 4-48
  
  RS90M……………………………………………… 4-53
  
  RST90………………………………………………. 4-59
  
  RST90TF…………………………………………… 4-65
  
  REMOVAL…………………………………………. 4-72
  
  INSPECTION …………………………………….. 4-72
  
  ASSEMBLY……………………………………….. 4-73
  
  INSTALLATION………………………………….. 4-75
  
  FRONT AXLE AND TRACK……………………… 4-78
  
  INSPECTION …………………………………….. 4-79
  
  INSTALLATION………………………………….. 4-79

  CHAPTER 5.
  
  ENGINE
  
  SEAT AND FUEL TANK…………………………….. 5-1
  
  RS90/RS90R/RSG90/RS90M………………… 5-1
  
  BACKREST AND PASSENGER SEAT ……….. 5-2
  
  RST90/RST90TF …………………………………. 5-2
  
  RIDER SEAT AND FUEL TANK …………………. 5-3
  
  RST90/RST90TF …………………………………. 5-3
  
  REMOVAL…………………………………………… 5-4
  
  INSTALLATION……………………………………. 5-4
  
  OIL TANK ………………………………………………… 5-5
  
  ENGINE ASSEMBLY ………………………………… 5-6
  
  HOSE AND LEADS………………………………. 5-6
  
  ENGINE ASSEMBLY……………………………. 5-8
  
  REMOVAL…………………………………………… 5-9
  
  INSTALLATION……………………………………. 5-9
  
  EXHAUST PIPE AND MUFFLER………………. 5-11
  
  INSTALLATION………………………………….. 5-12
  
  CAMSHAFTS………………………………………….. 5-14
  
  CYLINDER HEAD COVER ………………….. 5-14
  
  CAMSHAFTS…………………………………….. 5-15
  
  REMOVAL…………………………………………. 5-16
  
  INSPECTION …………………………………….. 5-17
  
  INSTALLATION………………………………….. 5-20
  
  CYLINDER HEAD……………………………………. 5-24
  
  REMOVAL…………………………………………. 5-25
  
  INSPECTION …………………………………….. 5-25
  
  INSTALLATION………………………………….. 5-26
  
  VALVES AND VALVE SPRINGS………………. 5-28
  
  REMOVAL…………………………………………. 5-29
  
  INSPECTION …………………………………….. 5-30
  
  INSTALLATION………………………………….. 5-34
  
  A.C. MAGNETO ROTOR
  
  AND STARTER CLUTCH…………………………. 5-37
  
  REMOVAL ………………………………………… 5-38
  
  INSPECTION…………………………………….. 5-39
  
  INSTALLATION …………………………………. 5-40
  
  OIL PAN AND OIL PUMP ………………………… 5-42
  
  REMOVAL ………………………………………… 5-45
  
  INSPECTION…………………………………….. 5-45
  
  INSTALLATION …………………………………. 5-47
  
  CRANKCASE …………………………………………. 5-49
  
  CRANKCASE…………………………………….. 5-49
  
  CONNECTING RODS AND PISTONS….. 5-51
  
  CRANKSHAFT
  
  AND BALANCER SHAFT ……………………. 5-52
  
  REMOVAL ………………………………………… 5-54
  
  INSPECTION…………………………………….. 5-56
  
  INSTALLATION …………………………………. 5-67

  CHAPTER 6.
  
  COOLING SYSTEM
  
  HEAT EXCHANGER …………………………………. 6-1
  
  INSPECTION………………………………………. 6-4
  
  INSTALLATION …………………………………… 6-5
  
  THERMOSTAT …………………………………………. 6-6
  
  INSPECTION………………………………………. 6-7
  
  INSTALLATION …………………………………… 6-7
  
  WATER PUMP………………………………………….. 6-9
  
  REMOVAL ………………………………………… 6-11
  
  DISASSEMBLY………………………………….. 6-11
  
  INSPECTION…………………………………….. 6-12
  
  ASSEMBLY……………………………………….. 6-12
  
  INSTALLATION …………………………………. 6-13

  CHAPTER 7.
  
  CARBURETION
  
  CARBURETORS AND FUEL PUMP……………. 7-1
  
  INSPECTION………………………………………. 7-6
  
  ASSEMBLY…………………………………………. 7-8
  
  INSTALLATION …………………………………… 7-9
  
  FUEL LEVEL ADJUSTMENT ………………. 7-10
  
  THROTTLE POSITION SENSOR (T.P.S.)
  
  INSPECTION AND ADJUSTMENT ………. 7-11
  
  INSPECTION…………………………………….. 7-12
  
  INSTALLATION …………………………………. 7-13

  CHAPTER 8.
  
  ELECTRICAL
  
  SWITCH INSPECTION ………………………………. 8-1
  
  SWITCH INSPECTION…………………………. 8-1
  
  INSPECTING A SWITCH SHOWN
  
  IN THE MANUAL …………………………………. 8-1
  
  IGNITION SYSTEM …………………………………… 8-2
  
  CIRCUIT DIAGRAM……………………………… 8-2
  
  TROUBLESHOOTING………………………….. 8-4
  
  IGNITION SPARK GAP ………………………… 8-6
  
  IGNITION COIL……………………………………. 8-6
  
  PICKUP COIL ……………………………………… 8-7
  
  THROTTLE OVERRIDE SYSTEM
  
  (T.O.R.S.)……………………………………………. 8-8
  
  ENGINE STOP SWITCH ………………………. 8-8
  
  THROTTLE SWITCH……………………………. 8-9
  
  MAIN SWITCH…………………………………….. 8-9
  
  ELECTRICAL STARTING SYSTEM ………….. 8-10
  
  CIRCUIT DIAGRAM……………………………. 8-10
  
  TROUBLESHOOTING………………………… 8-11
  
  STARTER MOTOR…………………………….. 8-13
  
  CHARGING SYSTEM………………………………. 8-18
  
  CIRCUIT DIAGRAM……………………………. 8-18
  
  TROUBLESHOOTING………………………… 8-19
  
  BATTERY………………………………………….. 8-20
  
  A.C. MAGNETO…………………………………. 8-20
  
  LIGHTING SYSTEM ………………………………… 8-22
  
  CIRCUIT DIAGRAM……………………………. 8-22
  
  TROUBLESHOOTING………………………… 8-24
  
  BULB(S) ……………………………………………. 8-26
  
  HEADLIGHT BEAM SWITCH ………………. 8-26
  
  HEADLIGHT RELAY…………………………… 8-26
  
  LOAD CONTROL RELAY……………………. 8-27
  
  SIGNAL SYSTEM……………………………………. 8-28
  
  CIRCUIT DIAGRAM……………………………. 8-28
  
  TROUBLESHOOTING………………………… 8-30
  
  BRAKE LIGHT SWITCH ……………………… 8-36
  
  GEAR POSITION SWITCH
  
  (RS90R/RSG90/RST90/RST90TF)……….. 8-36
  
  DC BACK BUZZER
  
  (RS90R/RSG90/RST90/RST90TF)……….. 8-36
  
  COOLANT TEMPERATURE SENSOR …. 8-37
  
  OIL LEVEL SWITCH…………………………… 8-38
  
  FUEL SENDER………………………………….. 8-38
  
  SPEED SENSOR……………………………….. 8-39
  
  GRIP WARMER SYSTEM………………………… 8-40
  
  CIRCUIT DIAGRAM……………………………. 8-40
  
  TROUBLESHOOTING………………………… 8-42
  
  GRIP AND THUMB WARMER COIL …….. 8-44
  
  THUMB WARMER ADJUSTMENT
  
  SWITCH……………………………………………. 8-44
  
  GRIP WARMER ADJUSTMENT
  
  SWITCH……………………………………………. 8-45
  
  PASSENGER GRIP WARMER
  
  (RST90/RST90TF)……………………………… 8-45
  
  PASSENGER GRIP WARMER SWITCH
  
  (RST90/RST90TF)……………………………… 8-46
  
  PASSENGER GRIP WARMER RELAY
  
  (RST90/RST90TF)……………………………… 8-46
  
  CARBURETOR HEATER SYSTEM…………… 8-48
  
  CIRCUIT DIAGRAM……………………………. 8-48
  
  TROUBLESHOOTING………………………… 8-50
  
  CARBURETOR HEATER RELAY ………… 8-51
  
  CARBURETOR HEATER ……………………. 8-51
  
  SELF-DIAGNOSIS…………………………………… 8-52
  
  SELF-DIAGNOSIS CODE …………………… 8-53
  
  CHAPTER 9.
  
  SPECIFICATIONS
  
  GENERAL SPECIFICATIONS ……………………. 9-1
  
  MAINTENANCE SPECIFICATIONS ……………. 9-4
  
  ENGINE ……………………………………………… 9-4
  
  POWER TRAIN……………………………………. 9-9
  
  CHASSIS ………………………………………….. 9-15
  
  ELECTRICAL…………………………………….. 9-17
  
  HIGH ALTITUDE SETTINGS……………….. 9-19
  
  TIGHTENING TORQUE……………………………. 9-20
  
  ENGINE ……………………………………………. 9-20
  
  POWER TRAIN………………………………….. 9-22
  
  CHASSIS ………………………………………….. 9-25
  
  GENERAL TORQUE SPECIFICATIONS……. 9-26
  
  DEFINITION OF UNITS……………………………. 9-26
  
  CABLE ROUTING …………………………………… 9-28

  Supplementary Manual for 2006 Models –

  GENERAL INFORMATION
  
  SPECIAL TOOLS ………………………………………….1
  
  FOR POWER TRAIN………………………………..1
  
  PERIODIC INSPECTION AND
  
  ADJUSTMENT
  
  INTRODUCTION……………………………………………2
  
  PERIODIC MAINTENANCE CHART FOR THE
  
  EMISSION CONTROL SYSTEM……………………..2
  
  GENERAL MAINTENANCE AND
  
  LUBRICATION CHART………………………………….3
  
  CHASSIS ……………………………………………………..5
  
  BRAKE LEVER ADJUSTMENT
  
  (RS90N/RS90NR/RS90RS/RS90GT)………….5
  
  LUBRICATION…………………………………………5
  
  TUNING ……………………………………………………….8
  
  CARBURETOR TUNING…………………………..8
  
  CLUTCH ……………………………………………….14
  
  GEAR SELECTION ………………………………..18
  
  FRONT SUSPENSION……………………………24
  
  REAR SUSPENSION ……………………………..26
  
  CHASSIS
  
  STEERING………………………………………………….34
  
  RS90N/RS90NR/RS90RS/RS90MS………….34
  
  RS90GT………………………………………………..36
  
  INSTALLATION ……………………………………..38
  
  SKI …………………………………………………………….42
  
  RS90N/RS90NR/RS90RS/RS90GT ………….42
  
  RS90MS………………………………………………..43
  
  FRONT SUSPENSION …………………………………44
  
  POWER TRAIN
  
  PRIMARY SHEAVE AND DRIVE V-BELT………46
  
  DRIVE CHAIN HOUSING……………………………..47
  
  WITHOUT REVERSE MODEL …………………47
  
  INSTALLATION ……………………………………..49
  
  WITH REVERSE MODEL………………………..50
  
  REMOVAL …………………………………………….53
  
  INSTALLATION ……………………………………..54
  
  SECONDARY SHAFT ………………………………… 56
  
  INSTALLATION…………………………………….. 56
  
  SECONDARY SHAFT AND DRIVE CHAIN
  
  HOUSING INSTALLATION…………………….. 58
  
  BRAKE …………………………………………………….. 60
  
  BRAKE CALIPER DISASSEMBLY ………….. 63
  
  BRAKE CALIPER INSTALLATION………….. 63
  
  RS90N/RS90NR/RS90RS/RS90MS………… 64
  
  RS90GT ………………………………………………. 65
  
  SLIDE RAIL SUSPENSION…………………………. 66
  
  RS90N/RS90NR/RS90RS ……………………… 66
  
  RS90GT ………………………………………………. 72
  
  RS90MS………………………………………………. 76
  
  ASSEMBLY………………………………………….. 82
  
  INSTALLATION…………………………………….. 83
  
  FRONT AXLE AND TRACK………………………… 86
  
  INSTALLATION…………………………………….. 87
  
  ENGINE
  
  SEAT AND FUEL TANK……………………………… 88
  
  RS90N/RS90NR/RS90RS/RS90GT ………… 88
  
  RS90MS………………………………………………. 89
  
  EXHAUST PIPE AND MUFFLER…………………. 90
  
  RS90MS………………………………………………. 90
  
  CARBURETION
  
  CARBURETORS AND FUEL PUMP…………….. 92
  
  SPECIFICATIONS
  
  GENERAL SPECIFICATIONS……………………… 94
  
  MAINTENANCE SPECIFICATIONS……………… 97
  
  ENGINE ………………………………………………. 97
  
  POWER TRAIN…………………………………… 102
  
  CHASSIS …………………………………………… 106
  
  ELECTRICAL……………………………………… 108
  
  HIGH ALTITUDE SETTINGS………………… 110
  
  TIGHTENING TORQUE…………………………….. 111
  
  ENGINE …………………………………………….. 111
  
  POWER TRAIN…………………………………… 113
  
  CHASSIS …………………………………………… 116
  
  GENERAL TORQUE SPECIFICATIONS …….. 117
  
  DEFINITION OF UNITS …………………………….. 117
  
  CABLE ROUTING ……………………………………. 119

  File size – 20.9MB
  
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  File Delivery – Zip

  There are 3 ways to approach car maintenance/repair.

  1. Call your Dealer/Service Center/Workshop. Pay $60 to get your vehicle towed or transported to their shop. Wait a few days for an appointment. Get your car back about a week later, and be a few hundred dollars out of pocket.

  Result = $1000 dollars out of pocket, fixed car, empty wallet.

  2. Try and fix the problem on your own. Create a shopping list and go and buy a few dollars worth of parts. Start the repair/service. Realize you don’t have the rights parts or knowledge to fix it. Go and buy more parts to replace the ones you broke trying to fix the original problem. Keep trying/buying until eventually you are having a breakdown yourself.

  Result = $300 dollars spent, hours wasted, car still not fixed.

  3. Download the original OEM Factory Service Manual for your vehicle from A1 Manuals. Read and study it to determine the problem/resolution. Create a shopping list and buy a few dollars worth of parts that you actually need. Start the repair…and fix it first time.

  Result = $50 spent, repair is done, get on with your life and enjoy the ride.

  THIS MANUAL COVERS:
  
  Repair and maintenance procedures from the people that actually manufactured your vehicle. You cannot get more detailed or accurate information than you will find in the OEM Factory Service Manual. This is the manual that the dealerships use to fix/repair/service your vehicle. Diagrams/photos/troubleshooting procedures/maintenance schedules etc are all included to help you fix your problem fast.

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