1

p/n 2259-977
SNOWMOBILE SETUP AND
PRE-DELIVERY INSTRUCTIONS
(Yamaha SRViper)
This publication displays the words Warning, Caution, and Note to emphasize important information. The symbol
! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals
with the possibility of serious injury or death. A CAUTION identifies unsafe practices which may result in
vehicle-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the
vehicle. The symbol NOTE: identifies supplementary information worthy of particular attention.
NOTE: Read these instructions thoroughly before starting. Retain these Setup and Pre-Delivery Instructions on
a permanent basis until further notice (effective - August 2013).
Removing Snowmobile From Crate
1. Remove the top and four sides of the crate. Remove
the skis from the crate sides.
2. Remove the windshield and hardware kit.
3. Remove all mounting hardware securing the snow-
mobile to the crate base; then lift the snowmobile
free of the crate base.
Removing Shipping Bracket
(SR10XS)
Remove the cable tie securing the throttle cable to the
handlebar; then remove the four cap screws securing the
shipping bracket to the handlebar and steering post.
SETUP AND PRE-DELIVERY CHECKLIST
Remove snowmobile from crate
Remove shipping bracket (SR10XS)
Install/adjust handlebar
Install handlebar cable ties
Install front shock absorbers/skis
Service battery
Check throttle lever free-play
Check brake system (fluid/lever travel)
Check tool kit contents
Check engine oil level/fill oil tank
Check cooling system coolant level
Check chain case lubricant level
Check fuel level
EFI system
Engine break-in
Check gas, oil, and coolant hoses for proper routing
Check electrical connections/wire routing
Check altitude calibration
Check/adjust (if necessary) clutch offset
Install drive belt
Install the windshield
Pre-Operation checks (electrical/fluids/brakes)
Check/adjust track tension/alignment
Check steering alignment
Check ski alignment
Check/adjust headlight aim
Check decals/verify hangtags properly displayed
Complete Dealer Comment Card
Clean and polish
Explain Operators Manual to customer
Explain/advise adjustable ski stance/local laws and/
or regulations to the customer (if applicable)
Explain engine/drive belt break-in procedure to cus-
tomer
Explain the Limited Warranty to customer
Complete Owner Registration form with customer
on the date of the sale
Completed by:_____________________________
CAUTION
Care should be taken when removing the snowmobile from
the crate. Damage that is not warrantable may occur.
2
PC015A
NOTE: The shipping bracket screws will be used to
secure the handlebar.
Installing/Adjusting Handlebar
1. On the SR10XS, install and secure the handlebar to
the steering post with the handlebar cap and cap
screws (from the shipping bracket); then with the
handlebar in position, tighten the cap screws evenly
to 2.0 kg-m (15 ft-lb).
2. On the SR10XS, install the throttle cable into the
throttle control assembly; then with the cable prop-
erly seated in the control assembly, install the cable
end into the throttle lever.
3. On the SR10L and SR10R, swing the handlebar up
and tighten the cap screws evenly to 2.0 kg-m (15 ft-
lb); then check steering for maximum right/left turn-
ing capabilities. Install the handlebar pad assembly.
0747-828
Installing Handlebar Cable Ties
NOTE: Cable ties for the following procedures are
located in the Component Package along with the
shock absorbers/Operators Manual/etc.
1. On models with a 165 mm (6.5 in.) riser block han-
dlebar, install the cable ties to secure the handlebar
harness to the riser block.
NOTE: Do not secure the brakeline hose with the
lower cable tie.
NOTE: Make sure when securing the harness or hoses
to the riser that all cable tie locks are directed inward.
SNO-329
2. On models with a 114 mm (4.5 in.) riser block han-
dlebar, install three cable ties to secure the handlebar
harness to the riser block.
NOTE: Also secure the brakeline hose with the
lower cable tie.
0746-219
NOTE: After installing and adjusting the handlebar,
verify that the throttle lever free-play is within specifi-
cation.
Installing Front Shock Absorbers/
Skis
1. Elevate the front of the snowmobile.
2. With the shock sleeves installed in the eyelets of the
shock absorber, place the shock absorber into posi-
tion; then secure the shock absorber with the cap
screws and lock nuts. Tighten lock nuts to 4.4 kg-m
(32 ft-lb).
! WARNING
Do not attempt to operate the snowmobile with the ship-
ping bracket still attached. Severe injury or even death
could result.
Riser Block Style
CAUTION
With the handlebar secured and the cable ties installed,
check maximum right/left turning capabilities to assure the
throttle cables, brakeline hose, and harness wires are routed
so they do not become pinched or stretched.
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0746-120
0747-548
NOTE: On models with adjustable shock spring ten-
sion, the shock spring adjusters have been set at the
factory as an initial setting. Any adjustments made
on the front suspension ski shocks must be made
equally on each side.
NOTE: On models with Fox Shocks, mount the
shocks making sure the air/nitrogen valve is directed
towards the spindle.
746-120A
NOTE: On models with Fox Air Shocks, mount the
shocks making sure the air/nitrogen valve is at the
top and facing outward.
747-548A
3. Slide a washer onto the cap screw; then apply all-
temperature grease to the shaft portion of the cap
screw and spindle axle.
4. Install the spindle axle and spacer into the spindle;
then position the ski damper into the bottom of the
ski making sure the damper is properly positioned
for the desired ski stance.
0746-796
0747-827
5. With the cap screw hole of the ski centered with the
spindle axle, slide the cap screw with washer through
the outside of the ski and spindle assemblies.
NOTE: Local laws and/or regulations as to maxi-
mum width of the ski stance may be applicable.
Always comply with the maximum width laws and/or
regulations when adjusting ski stance.
NOTE: Install the cap screw so the lock nut will be
located to the inside of the ski and the cotter pin slot
in the cap screw will be horizontal with the ski.
4
6. Install the remaining washer and lock nut; then
tighten the lock nut to 4.8 kg-m (35 ft-lb).
NOTE: Assure the cotter pin slot in the cap screw is
still horizontal with the ski (see illustration); then pro-
ceed to step 7.
7. Install the cotter pin from the back side of the ski cap
screw and spread the pin. Repeat for opposite side.
Servicing Battery
The battery requires an initial charge after activation as
well as periodic maintenance-charging during periods of
non-use or storage.
Always activate and maintain the battery in accordance
with the following instructions to ensure maximum ser-
vice life and performance from the battery.
Activating Battery
NOTE: To access and install the battery, the seat
must be removed.
0747-739
NOTE: Refer to all warnings and cautions provided
with the battery.
Each sealed battery comes with an electrolyte container
and proper amount for each specific battery type. DO
NOT add additional electrolyte to any sealed battery.
Sealed battery electrolyte has a higher concentration of
sulfuric acid.
1. Remove the battery from the snowmobile.
2. Carefully remove and save the sealing strip from the
battery electrolyte container. This will be used to seal
the battery later.
3. Remove and discard the foil sealing strip covering
the fill holes from the battery.
4. Place electrolyte container with the foil-sealed top of
the cells facing down into the fill ports of the battery.
5. Hold the container level in the fill ports of the battery.
Push down to break the seals. Air bubbles will appear as
the ports fill. Do not tilt the electrolyte container. Do not
remove the container from the battery until it is empty.
6. Let the battery stand for 60 minutes (1 hr) prior to
charging. This will allow the electrolyte to permeate
into the plates for optimum performance.
7. Fully insert the sealing strip over the fill holes by
hand. DO NOT use a hammer.
8. Charge battery completely before installation.
Charging New Battery
NOTE: Refer to all warnings and cautions provided
with the battery or battery charger.
NOTE: Batteries filled with electrolyte are only at
80% of their capacity.
NOTE: All battery chargers are not the same.
Yamaha recommends the use of a maintenance-free
battery charger.
Batteries can be charged two ways - Standard Charge and
Fast Charge. Standard charging is the only recommended
way to charge a battery. It gives the battery optimal per-
formance and battery life.
1. Place the battery charger in a location so battery acid
will not come in contact with the charger cables. Be
sure the charger is unplugged from the 110-volt elec-
trical outlet.
2. Connect the red terminal lead from the charger to the
positive terminal of the battery; then connect the
black terminal lead of the charger to the negative ter-
minal of the battery.
3. Plug the charger into a 110-volt electrical outlet.
4. Once the battery has reached full charge, unplug the
charger from the 110-volt electrical outlet and dis-
connect the charging leads.
5. Allow the battery to sit for 2 hours before testing.
Yamaha recommends the use of the Yuasa BTY01
Battery Tester.
6. When installing the battery into the snowmobile,
coat the battery terminals with a light coat of grease
to minimize battery terminal corrosion.
NOTE: Make sure the harness wires and cables are
routed properly.
7. Secure the red positive cable to the positive terminal
on the battery using a cap screw, lock washer, and a
flat washer. Tighten securely; then cover with the ter-
minal boot if provided.
8. Secure the main black negative cable and the small
black negative cable to the battery using a cap screw,
lock washer, and a flat washer. Tighten securely;
then cover with the terminal boot if provided.
9. Secure all three cables to the battery hold down
bracket using a cable tie.
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XM167A
Checking/Adjusting Throttle Lever
Free-Play (Tension)
NOTE: Prior to checking/adjusting free-play, assure
that the throttle cable is properly seated in the throttle
control housing.
1. Check the throttle cable free-play gap between the
throttle lever and the control housing.
2. There must be 0.75-1.5 mm (0.030-0.060 in.) throttle
cable free-play.
0741-518
3. If throttle cable free-play is incorrect, locate and
adjust the in-line throttle cable adjuster until free-
play is within specification.
NOTE: The in-line adjuster is located near the han-
dlebar riser.
Brake System
Checking Brake Lever Travel
1. Test the operation of the hydraulic brake system by
compressing the brake lever.
2. The brake lever must feel firm when compressed.
3. To verify lever travel, compress and hold the brake
lever to its maximum resistance.
NOTE: Do not pump the brake lever as it will pro-
duce an inaccurate reading.
4. Measure the distance between the brake lever and the
handlebar. The distance must be greater than 25.4
mm (1 in.).
0745-816
5. If the distance is less than specified, check the brake
fluid level, inspect for leakage, and check the brake
pads.
Checking Brake Fluid
1. With the brake fluid reservoir in a level position and
the cover removed, check the fluid level. The brake
fluid level must be at the high brake fluid mark in the
reservoir.
745-817A
2. If the brake fluid is below the high brake fluid mark,
add Yamaha approved DOT 4 brake fluid from a sealed
container until the fluid is at the recommended level.
Install and secure the reservoir cover. Do not allow
moisture to contaminate the brake system.
Access Panels/Hood
To remove the access panel and hood, use the following
procedure:
! WARNING
Do not operate the snowmobile if the distance between
the compressed brake lever and handlebar is less than
25.4 mm (1 in.). Brake loss may occur. Brake loss can
result in severe personal injury.
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the snowmobile.
! WARNING
Do not overfill the brake fluid reservoir. Overfilling the
reservoir may cause the brake system to hydraulically
lock. Use only Yamaha approved brake fluid.
6
0747-830
1. Remove the hairpin clip from the pin located at the
front of the access panel. Move the panel up and off
the pin; then swing the panel all the way out and
unhinge the panel from the lower console.
2. Remove the two torx-head screws securing the hood
(located on the underside of the hood above the rear
tube of the upper A-arm); then remove the two torx-
head screws from the top-side of the hood securing
the hood to the upper console and the two torx-head
screws securing the front of the hood.
3. Remove the center intake panel and locate the hood
harness connector (located in front of the speedome-
ter) and unplug the connector; then move the hood
slightly forward and remove the hood.
To install the access panel and hood, use the following
procedure:
1. Position the hood onto the snowmobile and connect
the hood harness connector.
2. Secure the hood with the six torx-head screws and
tighten securely.
NOTE: Before installing the hood, make sure the
mounting screw clips are in position.
3. Install the access panel onto the lower console; then
close the access panel and secure with the hairpin
clip and the quarter turn.
Engine Oil Level
NOTE: The snowmobile must be on a level surface
for this procedure.
1. Prior to starting the engine, verify the engine oil
level in the tank is at least halfway up in the sight
glass.
2. Start the engine and let it idle and warm up until the
fan on the radiator turns on.
3. Shut the engine off; then allow the engine to cool.
Inspect the oil reservoir sight glass for proper oil level.
SNO-244A
4. If step 1 was followed and the oil level is not at least
halfway up in the sight glass, add recommended
engine oil until the oil level is at least halfway up in
the sight glass.
NOTE: Care must be taken not to over-fill the oil
tank.
Coolant Level
NOTE: Always check the coolant level with the
snowmobile on a level surface and the engine cold.
Locate the filler neck located above the resonator; then
remove the coolant cap from the filler neck. Verify that
the coolant is at the bottom of the tab in the filler neck.
0747-547
Locate the coolant tank above the drive clutch; then
remove the plug from the coolant tank. Add coolant to
the full level on the tank. Install the plug.
CAUTION
The snowmobile will be shipped with the correct
amount of oil in the reservoir. If the engine and oil are
not at operating temperature the oil will not be visible in
the sight glass. Tip the snowmobile to the right at a 45
angle; then check to see if oil is present in the sight
glass.
CAUTION
Immediately after the engine is started, check that the oil
pressure warning light goes out.
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0747-766
Chain Case Lubricant Level
NOTE: The snowmobile must be on a level surface
for this procedure.
Check chain case lube level using the chain case sight
glass at the right-side footrest. If the lube is at least half-
way up the sight glass, the level is correct.
If the lube level is low, remove the three screws securing
the shift actuator to the chain case, disconnect the actua-
tor wiring harness, and remove the actuator w/extension;
then add Synthetic Chain Lube through the shift actuator
opening. When the lube is halfway up the sight glass,
install the shift actuator w/extension and connect the
actuator wiring harness.
0746-804
0746-115
Gasoline/Fuel
Fill the gas/fuel tank with the appropriate gasoline.
Recommended Gasoline
The recommended gasoline to use is 87 octane regular
unleaded or 95 octane RON (Europe). In many areas,
oxygenates are added to the gasoline. Oxygenated gaso-
lines containing up to 10% ethanol are acceptable gaso-
lines.
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
NOTE: Please advise the customer (when taking deliv-
ery of the snowmobile) that for optimum performance
not to exceed the recommended 87 octane gasoline or
95 octane RON (Europe). Using a higher octane gaso-
line will not increase overall performance.
EFI System
It is essential that the EFI system not be tampered with in
any way. All the components of the EFI system have been
designed to work together for optimum performance.
Engine Break-In
The engine (when new or rebuilt) requires a short break-
in period before the engine is subjected to heavy load
conditions.
This engine does not require any pre-mixed fuel during
the break-in period.
There is never a more important period in the life of the
engine than the first 500 km (300 miles).
Since the engine is brand new, do not put an excessive
load on it for the first 500 km (300 miles). The various
parts in the engine wear and polish themselves to the cor-
rect operating clearances. During this period, prolonged
full throttle operation or any condition that might result
in engine overheating must be avoided.
Operating your snowmobile for the first time: Start the
engine and let it idle for 15 minutes.
0-160 km (0100 miles): Avoid prolonged operation
above 6000 RPM.
160-500 km (100300 miles): Avoid prolonged operation
above 8000 RPM.
500 km (300 miles) and beyond: The snowmobile can
now be operated normally.
NOTE: After 800 km (500 miles) of operation, the
engine oil must be changed and the oil filter replaced.
If any engine trouble should occur during the engine
break-in period, immediately have a Yamaha dealer
check the snowmobile.
CAUTION
Do not use white gas or gasolines containing methanol.
Only Yamaha approved gasoline additives should be used.
CAUTION
Even the slightest modification will cause the ECM to
receive incorrect data which will cause the system to
perform very poorly or may cause engine damage. Any
damage done by an unauthorized modification to the
system will not be covered by the warranty policy.
8
Hoses
Visually inspect the routing of all hoses to verify they are
free of kinks, cuts, or damage. Also, inspect that hoses
are not lying against objects that could chafe, cut, or burn
a hose (engine, exhaust, sharp edges, etc.).
Electrical Connections/Wire Routing
Visually inspect the routing of all electrical wiring to ver-
ify they are free of kinks, cuts, or damage. Also, inspect
that wires are not lying against objects that could chafe,
cut, or burn a wire (engine, exhaust, sharp edges, etc.).
Altitude Calibrations
Calibrate the snowmobile for the altitude/conditions at
which the snowmobile will be operated.
At the time of sale, determine at what altitude/conditions
the customer will be operating; then using the appropriate
specifications sheet, calibrate the snowmobile accord-
ingly.
Checking Offset
1. Remove the left-side access panel; then move the
console up and out of the way.
2. Remove the drive belt.
NOTE: Use a straightedge that is approximately 470
mm (18.5 in.) long, 20 mm (0.79 in.) wide, and 4 mm
(0.16 in.) thick.
3. Place the straightedge along the back side of the
drive clutch; then measure the offset (a) between the
driven clutch and the straightedge. Sheave offset
must be within 13.0-16.0 mm (0.51-0.63 in.). If
adjustment is needed, proceed to step 4.
SNO-324
NOTE: The straightedge must extend beyond the
front edge of the drive clutch.
4. If offset adjustment needs to be made, remove the
driven clutch and add shims (p/n 8JP-RA449-00: 2
mm, 8JP-RA448-00: 1 mm) to increase the offset or
remove shims to decrease the offset.
5. Once the correct offset is reached, install driven
clutch and tighten cap screw to 6.4 kg-m (46 ft-lb).
NOTE: When adjusting the driven clutch, the clutch
free play (clearance) should be adjusted.
6. Using a feeler gauge, measure the clutch free play
(clearance). Free play (a) should be within 1.0 - 2.0
mm (0.04 - 0.08 in.). If adjustment needs to be made,
proceed to step 7.
SNO-325
7. Remove the driven clutch cap screw and washer;
then add shims (p/n 8JP-RA447-00: 2 mm, 8JP-
RA446-00: 1 mm, 8JP-RA433-00: 0.5 mm).
8. Install the driven clutch cap screw and washer.
Tighten to 6.4 kg-m (46 ft-lb).
Installing Drive Belt
NOTE: Before installing the drive belt, use a suitable
cleaning solvent to thoroughly clean the sheaves.
1. Open the left-side access panel.
2. Rotate the driven clutch sliding sheave clockwise (1)
then push towards the engine (2) so it will separate
from the fixed sheave.
3. Install the drive belt (3) between the sheaves.
SNO-326
CAUTION
Drive train component changes may be required when
operating at varying altitudes. Severe damage could
result from operating a snowmobile in conditions for
which it had not been calibrated. Even short periods of
operation (such as a test-ride) could cause damage.
9
SNO-327
4. Install the left-side access panel.
Drive Belt Break-In
Drive belts require a break-in period of approximately 40
km (25 miles). Drive the snowmobile for 40 km (25
miles) at 3/4 throttle or less. By revving the engine up
and down (but not exceeding 100 km/h [60 mph]), the
exposed cord on the side of a new belt will be worn
down. This will allow the drive belt to gain its optimum
flexibility and will extend drive belt life.
Installing Windshield
1. Remove the protective film from the windshield.
2. Install the inserts into the headlight cowl; then place
the windshield over the cowl and secure using the
supplied screws. Do not over-tighten.
0747-846
Preoperation Checks
1. Visually check the entire snowmobile for any loose
fasteners. Tighten as required.
NOTE: Place the hood into position on the snowmobile
and connect the hood harness. Do not secure the hood
at this time.
NOTE: Hood Harness Extension can be used to start
the engine and inspect the engine compartment with-
out the hood installed.
2. Start and run the engine to operating temperature;
then visually inspect beneath the snowmobile for any
signs of fluid leakage. If a leak is noted, determine
the source and repair the snowmobile prior to further
setup. Ensure handwarmers, thumb warmer, and seat
heater heat properly at all available settings.
3. Check all switches (ignition, dimmer, brakelight,
emergency stop, and throttle/ignition monitor) to
make sure all function properly; then visually check
the headlight, taillight, brake light and speedometer/
tachometer for proper illumination and functions.
4. Test the operation of the brakes. The brake lever
must feel firm when the lever is compressed. Inspect
the brake fluid level. Add Yamaha approved DOT 4
brake fluid from a sealed container as necessary.
5. Burnish the brake pads using the following procedure:
A. Elevate the rear of the snowmobile on a
shielded jack stand high enough to allow the
track to rotate.
B. Accelerate to 50-65 km/h (30-40 mph); then
compress the brake lever to decelerate to a stop.
NOTE: Lightly apply the brake lever to come to an
easy stop; do not over-apply brakes.
C. Repeat procedure 10-15 times allowing some
cooling between stops.
6. Shut the engine off; then allow the engine to cool. Visu-
ally check all fluid levels and add fluids as necessary.
7. Secure the hood and install the access panels.
NOTE: Fine-tuning of the snowmobile for each cus-
tomer is not covered in our warranty policy. If any
area of the snowmobile needs servicing during pre-
delivery, refer to the service manual or call a Yamaha
Dealer Technical Support Representative.
Track Tension/Track Alignment
To adjust track tension/track alignment, use the following
procedure.
! WARNING
Never operate the snowmobile without the belt guard/
access panel secured in place.
CAUTION
Never run the engine with the hood harness discon-
nected or damage to the electrical system will result.
CAUTION
While the engine is running, observe the coolant tem-
perature warning icon in the speedometer/tachometer. If
it begins to flash, shut the engine off and allow it to cool
before proceeding.
CAUTION
Track tension has been initially adjusted at the factory
for run-up testing; however, track tension (and track
alignment) must be adjusted at the dealership according
to the following recommendations.
10
1. Elevate the snowmobile on a shielded safety stand
high enough to use a spring scale.
2. At the mid-point of the track (on the bottom side),
hook a spring scale around a track clip; then pull
down on the scale to the recommended pressure (see
chart). Measure the deflection (distance) between the
bottom of the wear strip and the inside surface of the
track clip. Measurement should be 50 mm (2.0 in.).
0746-788A
3. Loosen the rear idler wheel axle cap screws.
0745-811
4. If the deflection (distance between the bottom of the wear
strip and the running surface of the track clip) exceeds
specifications, tighten the adjusting bolts. If the deflec-
tion is less than specified, loosen the adjusting bolts.
5. Start the engine and accelerate slightly. Use only
enough throttle to turn the track several revolutions.
Shut engine off.
NOTE: Allow the track to coast to a stop. Do not
apply the brake because it could produce an inaccu-
rate alignment condition.
6. When the track stops rotating, check the relationship
of the rear idler wheels and the inner track drive lugs.
If the rear idler wheels are centered between the
inner track drive lugs, no adjustment is necessary.
0745-809
7. If the idler wheels are not centered between the inner
track drive lugs, adjust track alignment.
8. On the side of the track which has the inner track
drive lugs closer to the rear idler wheel, rotate the
adjusting bolt clockwise 1-1 1/2 turns.
9. Check track alignment and make necessary adjust-
ments until proper alignment is obtained.
NOTE: Make sure correct track tension is main-
tained after adjusting track alignment.
10. After proper track adjustments are obtained and the
adjusting bolts are snug against the axle housings,
tighten the idler wheel axle cap screws to 4.7 kg-m
(34 ft-lb).
Steering Alignment
NOTE: Prior to adjusting ski alignment, it is important
to align the handlebar to the straight-ahead position
Checking Steering Alignment
1. Center the handlebar to the straight-ahead position.
! WARNING
The tips of the skis must be positioned against a wall or
similar object for safety.
Track Pressure
3277 mm (129 in.) 9.1 kg (20 lb)
3480 mm (137 in.) 11.3 kg (25 lb)
3581 mm (141 in.) 5.4-6.8 kg (12-15 lb)
! WARNING
DO NOT stand behind the snowmobile or near the rotat-
ing track. NEVER run the track at high speed when the
track is suspended.
! WARNING
Make sure the ignition switch is in the OFF position and
the track is not rotating before checking or adjusting the
track alignment.
! WARNING
Always make sure the adjusting bolts are snug against the
axle and the idler wheel cap screws. Failure to do so could
cause the track to become extremely loose and, under
some operating conditions, allow the idler wheels to climb
over the track lugs forcing the track against the tunnel
causing the track to lock. If a track locks during opera-
tions, severe personal injury could result.
CAUTION
You must instruct the customer (when taking delivery of
the snowmobile) to check track tension every fifty miles
for the first 300 miles to maintain track tension specifica-
tions. If the track tension isnt maintained by the cus-
tomer during this period, it will stretch and may derail
causing suspension and track damage. This is not cov-
ered by the warranty policy.
11
2. Visually inspect the handlebar for being centered and
in the straight-ahead position.
Adjusting Steering Alignment
NOTE: On models with a telescoping handlebar to
access the upper steering tie rod, the hood and upper
console must be removed.
To adjust steering alignment, use the following procedure.
1. Secure the handlebar in the centered (straight-ahead)
position.
2. Loosen the spindle tie rod jam nuts.
3. Using a wrench on the spindle tie rod flats, rotate
the tie rod until the handlebar is in the straight-ahead
position.
4. Apply Yamabond Blue Threadlocker to each jam nut
thread area; then securely lock the jam nuts against the
spindle tie rod.
Ski Alignment
NOTE: Prior to checking/adjusting ski alignment,
verify that the handlebar has been centered and is in
the straight-ahead position.
Checking Ski Alignment
NOTE: Track tension and alignment must be prop-
erly adjusted prior to checking or adjusting ski align-
ment. Ski alignment must be performed on a flat,
level surface. Ski toe-out must fall within the range of
1.6-6.4 mm (1/16 - 1/4 in.).
1. Raise the front end of snowmobile just high enough
that the ski shocks are fully extended but the skis are
still resting on the floor.
2. Center the handlebar to the straight-ahead position.
3. With the handlebar in the straight-ahead position,
secure the handlebar to prevent handlebar alignment
from becoming disturbed during the remainder of the
alignment procedure.
NOTE: Track tension and alignment must be prop-
erly adjusted prior to placing the straightedge against
the outside edge of the track.
4. Place a long straightedge against the outside edge of the
track so it lies near the inside edge of the left-side ski.
NOTE: The straightedge should be long enough to
extend from the back of the track to the front of the ski.
5. Measure the distance from the straightedge to the
left-side ski wear bar bolts in two places: approxi-
mately 180-200 mm (7-8 in.) in front of the spindle
and 180-200 mm (7-8 in.) behind the spindle. Record
the measurements taken for the left side.
729-887A
6. Place the straightedge against the outside edge of the
track so it lies near the inside edge of the right-side ski.
7. Measure the distance from the straightedge to the right-ski
wear bar bolts in two places: 180-200 mm (7-8 in.) in
front of the spindle and 180-200 mm (7-8 in.) behind the
spindle. Record the measurements taken for the right side.
8. If ski alignment is not as specified, adjust the align-
ment of the ski(s) not parallel to the straightedge.
Adjusting Ski Alignment
NOTE: The following procedure can be used to
adjust the alignment of either ski.
To adjust ski alignment, use the following procedure.
1. With the handlebar secured in the straight-ahead
position, loosen both spindle tie rod jam nuts on the
same side as the ski to be aligned.
NOTE: To access the spindle tie rod inner jam nuts,
the belly pan and tie rod boots must be removed.
2. Using a wrench on the spindle tie rod flats, rotate
the spindle tie rod until recommended specification
is attained.
3. Apply Yamabond Blue Threadlocker to each jam nut
thread area; then securely lock the jam nuts against the
spindle tie rod.
NOTE: Repeat this procedure on each side (if nec-
essary) until ski toe-out is within specfication.
! WARNING
The measurement from the front and rear wear bar bolts to
the straightedge can be equal (ski parallel to the track), but
the front measurement must never be less (ski toed-in) or
poor handling will be experienced. The front wear bar bolt
measurement to the straightedge must not exceed the
measurement from the rear wear bar bolt to the straight-
edge (ski toed-out) by more than 3.9 mm (5/32 in.).
! WARNING
Neglecting to lock the tie rod by tightening the jam nuts
may cause loss of snowmobile control and possible per-
sonal injury.
12
Verifying
1. With the handlebar in the straight-ahead position, ver-
ify ski alignment by measuring across from the out-
side edge of the left-side wear bar bolts to the outside
edge of the right-side wear bar bolts (without using
the straightedge) in two places: approximately 180-
200 mm (7-8 in.) in front of the spindle and 180-200
mm (7-8 in.) behind the spindle.
2. The measurement from in front of the spindle to the
outer edge of the wear bar bolts (without using the
straightedge) must be greater than the rear measure-
ment by 1.6 mm (1/16 in.) but must not exceed the
rear measurement by 6.4 mm (1/4 in.).
734-408C
Check Headlight Aim
1. Position the snowmobile on a level floor so the head-
light is approximately 8 m (25 ft) from an aiming
surface (wall or similar surface).
NOTE: There should be a load comparable to the
main operator on the snowmobile when adjusting
headlight aim.
2. Measure the distance from the floor to midpoint of
the headlight.
3. Using the measurement obtained in step 2, make a
horizontal mark on the aiming surface.
4. Make a vertical mark which intersects the horizontal
mark on the aiming surface directly in front of the
headlight.
5. Engage the brake lever lock and start the engine.
Move the headlight dimmer switch to the LOW
beam position. DO NOT USE HIGH BEAM.
6. Observe the LOW beam aim. Proper aim is when the
LOW beam is 5 cm (2 in.) below the horizontal mark on
the aiming surface.
0747-834
7. Adjust the headlight using the adjusting screw on the
backside of the headlight using a 4 mm swivel socket
and long extension until correct aim is obtained. Shut
the engine off; then disengage the brake lever lock.
0746-807
! WARNING
The measurement taken in front of the spindle must
never be less than the measurement taken behind the
spindle or poor handling will be experienced. Neglecting
to lock the tie rod by tightening the jam nuts may cause
loss of snowmobile control and possible personal injury.
NOTE: Read these Installation Instructions thoroughly before beginning the installation process. Retain
these Installation Instructions for future reference.
Yamaha Snowmobile
Installation Instructions
Form No. 1653-911
Radiator Cover Kit
1. Remove both side panels and the hood assembly
from the snowmobile.
2. Remove the four screws securing the radiator
shroud. See Fig. 1.
Fig. 1
YM-030A
3. Place three Rubber Pads on the radiator. See Fig.
2.
Fig. 2
YM-031A
4. Install Radiator Cover onto the radiator and secure
using the existing screws. Tighten the screws to
6.8 ft-lb (9.2 N-m). See Fig. 3.
Fig. 3
YM-032
5. Install the hood and both side panels.
Printed in the U.S.A. 0913
white : customer copy / yellow : dealer copy YMC-PDIEN-00-SM
Snowmobile Pre-delivery Inspection Checklist


ASSEMBLY
1. Inspect for shipping damage and missing parts.
2. Assemble per the Yamaha Assembly Manual and specifications.
3. Clean and inspect product to exceed customers expectations.
PRE-DELIVERY INSPECTION
If any item of this schedule is found to be defective, take the necessary action and re-test.
Brakes
1. Inspect brake system for correct operation and performance.
2. Check and adjust parking brake operation (if applicable).
3. Check and adjust hand brake system.
4. Clean brake disc using an oil-free solvent.
Clutch
5. Clean clutch faces.
6. Check and adjust centre to centre alignment and offset.
7. Check and adjust belt height in secondary clutch.
Carburetors
8. Check and adjust float heights.
9. Check carburetor synchronization (if applicable).
10. Check and adjust throttle cable routing operation and free play.
11. Check and adjust Y.P.V.S. settings (if applicable).
Drive System
12. Check and adjust chain case oil level.
13. Check and adjust drive chain.
14. Check correct belt installation and set-up.
Cooling System
15. Check and adjust coolant strength and level.
16. Visually inspect coolant system.
17. Bleed coolant system (if applicable).
Fuel/Oil System
18. Check, fill and bleed injector oil system (if applicable).
18a. Check engine oil level (if applicable).
19. Check and adjust enrichment system operation and cable free play.
20. Check fuel system for leaks and operation.
21. Install correct fuel/oil ratio for break-in period. (2-stroke only)
T.O.R.S. Operation
22. Check for correct T.O.R.S. operation.
Track/Suspension
23. Check and adjust track for correct tension and alignment.
24. Lubricate all grease points.
25. Check/adjust suspension and operation.
Steering and Controls
26. Check recoil starting operation.
27. Check and adjust ski alignment and settings.
28. Check/adjust controls for operation, fit and comfort.
Electrical Systems
29. Check all lights including safety-warning systems.
30. Fill/charge battery (if applicable) as per Yamaha specification.
31. Check and adjust starter system, including safety switches.
32. Check emergency stop switches.
Other Items
33. Examine tool kit for correct contents.
34. Check all fasteners, nuts and bolts.
Test Ride
35. Instrumentation and warning lights/systems
36. Brake operation
37. Check/set idle speed
38. Cold and hot start performance
39. Clutch shifting, forward and reverse engagement R.P.M. operation
40. Engine performance and throttle response
41. Steering and suspension ride quality, comfort and performance
Post-Test
42. Check for coolant, oil and fluid leaks.
43. Inspect all bodywork for paint damage and defects.
Note: Please ensure unit is suitably calibrated and set up for the riding area/region.
Comments:
YEAR ____________ MODEL __________________________ VIN ___________________________________ ENGINE # ___________________
DATE_________________ Place a check mark only when completed. KEY # ______________________
DEALER STAMP










Assembly Date (YYYYMMDD): ____________
I ___________________________ confirm that I have assembled the above
listed product to the full specifications listed and notified to me by Yamaha
Motor Canada Ltd. in regards to assembly and that it is damage free and
ready for the pre-delivery operation and customer set-up.
Pre-Delivery Inspection Date: ____________
I ___________________________ confirm that I have carried out the PDI as
per Yamaha Motor Canada Ltd. requirements and specifications listed in this
document. I have also visually inspected this product. I have adjusted the
required items to meet all specifications.
Test Ride Date: ____________
I ___________________________ have tested the product and confirm that
it meets all requirements for this product. It has been cleaned and prepared
for delivery to the new owner. The owners manual is available and the
license plate (if applicable) is suitably installed.
Technicians signature___________________________________________
Salespersons signature _________________________________________
The Warranty has been fully explained. Yes No
The dealer has explained the benefits of
Yamalube engine oil. Yes No
Yamaha Protection Plus
Yamaha Protection Plus has been explained
and offered to me. Yes No
Yamaha Protection Plus has been purchased. Yes No
The dealer has provided me warranty information
as per Bill 60, Quebec CPA La Loi sur la protection
du consommateur et le domaine de lautomobile. Yes No
I have inspected the product and found that it meets all of my expectations
and that there are no outstanding issues to be discussed with the dealer. The
Owners Manual, Warranty Guide and tool kit have been supplied and
explained to me.
Signed _______________________________________________________
Customer name________________________________________________
Date of delivery ________________________________________________
Customer comments ____________________________________________

_____________________________________________________________