Yamaha FX Nytro FX10MTRAX Assembly Manual

Category
Engine
Type
Assembly Manual
ASSEMBLY MANUAL
FX10X
FX10RTX
FX10RTRX
FX10RTRAX
FX10MTX
FX10MTRX
FX10MTRAX
LIT-12688-02-69 8GL-28107-10
PRINTED ON RECYCLED PAPER PRINTED IN U.S.A.
2007.06 CR
(E)
YAMAHA MOTOR CO., LTD.
FOREWORD
This Assembly Manual contains the information
required for reassembly of the Yamaha Snowmo-
bile correctly prior to delivery to the customer.
Since some external parts of the snowmobile have
been removed at the Yamaha factory for conve-
nience 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 pur-
chaser.
NOTICE
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may become outdated due to future changes in this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.
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result
in severe injury or death to the snowmobile opera-
tor, a bystander, or a person inspecting or repairing
the snowmobile.
A CAUTION indicates special precautions that
must be taken to avoid damage to the snowmobile.
A NOTE provides key information to make proce-
dures easier or clearer.
UNPACKING
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.
PREPARATION
To assemble the snowmobile correctly, supplies
and working space are required:
Supplies
Oils, greases, shop rags.
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 spectacles or
safety 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
protective shoes if appropriate to the work you are
doing.
Procedure for unpacking
1. To remove the snowmobile and parts packed in
the crate, cut the vinyl bands around the carton
using a cutter or scissors. Next, remove the
plastic cover by lifting it straight up.
2. Remove the bolts from each corner of the rack,
and remove the struts.
3. Remove the snowmobile from the crate bottom.
4. Before starting the assembly, check for dam-
aged or missing parts. The parts are contained
in the carton and the vinyl bags in the package.
Also check the snowmobile for damage,
scratches and other defects.
WARNING
CAUTION:
NOTE:
FX10X, FX10RTX, FX10RTRX, FX10RTRAX,
FX10MTX, FX10MTRX, FX10MTRAX
ASSEMBLY MANUAL
© 2007 by Yamaha Motor Corporation, U.S.A.
1st Edition, May 2007
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-12688-02-69
SYMBOLS USED IN THE ASSEMBLY MANUAL
In order to simplify descriptions in this assembly manual, the follow-
ing 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): Apply locking agent (LOCTITE®)
Size or material of parts
(8): d/D: Diameter of part
l: Length of part
e.g., 5 (0.2) = 5 mm (0.20 in)
T
R
.
.
LT
d
Dd
dD
d
(1) (2)
(3)
(5)
(7)
(8)
(4)
(6)
PREPARATION
To assemble the snowmobile correctly, supplies (i.e., oils, 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 and shoes.
SYMBOLS USED ON TRANSPORT PACKAGE COVER
a: IMPORTANT
This unit delivered to carrier in a good condition. For
protection against loss due to damage, inspect thor-
oughly.
If damage is noted, make note on freight bill.
Shipper assumes no further liability to the transporta-
tion company.
Your claim should be filed against carrier for damage
of any nature.
b: 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
DO NOT STEP ON
a
b
Contents of the transport package are fragile,
therefore it must be handled with care.
Indicates correct upright position of the trans-
port package.
Transport package must be kept away from
rain.
Up to 9 of the transport packages can be piled
up.
Only stack this unit with transport packages of
the same size.
Made of high-density polyethylene.
Do not step anywhere on this transport pack-
age.
CONTENTS
PARTS LOCATION ....................................................................................................................... 1-1
PARTS LOCATION............................................................................................................ 1-1
REMOVAL FROM CRATE................................................................................................. 1-5
SET UP PROCEDURE .................................................................................................................. 2-1
FRONT BUMPER ............................................................................................................. 2-1
WINDSHIELD .................................................................................................................... 2-3
FRONT SUSPENSION ...................................................................................................... 2-4
SKI ASSEMBLY................................................................................................................. 2-5
STEERING ASSEMBLY (For FX10/FX10RT/FX10RTR/FX10RTRA) ............................... 2-7
STEERING ASSEMBLY (For FX10MT/FX10MTR/FX10MTRA)........................................ 2-8
FLAP (For FX10/FX10RT/FX10RTR/FX10RTRA) ........................................................... 2-10
FLAP (For FX10MT/FX10MTR/FX10MTRA) ................................................................... 2-11
ADJUSTMENTS AND PREDELIVERY SERVICE ........................................................................ 3-1
SHROUD AND COVERS................................................................................................... 3-1
SHEAVE OFFSET ADJUSTMENT .................................................................................... 3-1
DRIVE V-BELT HEIGHT AND INSTALLATION................................................................. 3-4
ENGINE OIL....................................................................................................................... 3-5
ENGINE OIL LEVEL .......................................................................................................... 3-5
BREAK-IN .......................................................................................................................... 3-7
COOLANT LEVEL.............................................................................................................. 3-8
DRIVE CHAIN HOUSING OIL LEVEL CHECK................................................................ 3-10
DRIVE CHAIN TENSION ADJUSTMENT........................................................................ 3-11
THROTTLE CABLE ADJUSTMENT ................................................................................ 3-11
BATTERY INSTALLATION.............................................................................................. 3-12
TRACK TENSION ADJUSTMENT................................................................................... 3-14
HEADLIGHT BEAM ADJUSTMENT ................................................................................ 3-16
PARKING BRAKE ADJUSTMENT................................................................................... 3-17
SKI ADJUSTMENT .......................................................................................................... 3-18
FRONT SUSPENSION SPRING PRELOAD ................................................................... 3-19
REBOUND DAMPING FORCE ADJUSTMENT (FX10)................................................... 3-20
COMPRESSION DAMPING FORCE ADJUSTMENT (FX10).......................................... 3-21
REAR SUSPENSION STOPPER BAND LENGTH.......................................................... 3-24
REAR SUSPENSION SPRING PRELOAD...................................................................... 3-26
REAR SUSPENSION DAMPING FORCE ....................................................................... 3-28
CONTROL ROD ADJUSTMENT (FX10MT/FX10MTR/FX10MTRA) ............................... 3-31
BRAKE FLUID LEVEL ..................................................................................................... 3-33
BRAKE FLUID REPLACEMENT...................................................................................... 3-33
HYDRAULIC BRAKE AIR BLEEDING ............................................................................. 3-34
BATTERY INSPECTION.................................................................................................. 3-35
APPENDICES................................................................................................................................ 4-1
SERVICE DATA................................................................................................................. 4-1
LUBRICATION POINT AND GRADE OF LUBRICANT................................................................ 5-1
CABLE ROUTING ......................................................................................................................... 6-1
1-1
PARTS LOCATION
PARTS LOCATION
ACarton box
BCarton box
CCarton box
DVinyl bag
ECarton box
FShroud (For FX10/FX10RT/FX10RTR/
FX10RTRA)
E
F
A
B
C
D
ACarton box
1Windshield (For FX10/FX10MT/FX10MTR/
FX10MTRA)
2Windshield (For FX10RT/FX10RTR/
FX10RTRA)
3Front cover
4Front bumper
5Flap
6Flap stopper (For FX10/FX10RT/FX10RTR/
FX10RTRA)
7Handlebar cover (For FX10/FX10RT/FX10RTR/
FX10RTRA/FX10MTRA)
8Wind deflector stay (For FX10/FX10RT/
FX10RTR/FX10RTRA)
9Wind deflector (For FX10/FX10RT/FX10RTR/
FX10RTRA)
12
34
56
78
9
1-2
BCarton box
1Rear bumper
2Flange bolt M8 L = 20 mm (0.79 in)
3Vinyl bag 1 ~ 4
4Ski stopper (For FX10/FX10RT/FX10RTR/
FX10RTRA)
5Ski stopper (For FX10MT/FX10MTR/
FX10MTRA)
6Handlebar holder (For FX10RT/FX10RTR/
FX10RTRA/FX10MT/FX10MTR/FX10MTRA)
7Flange bolt M8 L = 35 mm (1.38 in) (For
FX10RT/FX10RTR/FX10RTRA)
8Flange bolt M8 L = 185 mm (7.28 in) (For
FX10MT/FX10MTR/FX10MTRA)
9Steering joint (For FX10MT/FX10MTR/
FX10MTRA)
0Collar L = 76.2 mm (3.00 in) (For FX10/
FX10RT/FX10RTR/FX10RTRA)
L = 101.6 mm (4.00 in) (For FX10MT/
FX10MTR/FX10MTRA)
AOwners tool bag
BPouch
COwners manual
DSafety handbook (For USA/Canada)
ETag 1 (For USA)
FBattery fluid (electrolyte)
1
3
5
7
9
A
C
EF
2
4
6
8
0
B
D
1-3
GOwners tool kit
aOpen ended wrench (8-10)
bOpen ended wrench (10-12) 2 pcs
cOpen ended wrench (14-17)
dBox-end wrench (19-22)
eGrip
fScrewdriver bit (+ -)
gSocket wrench (14)
hSpark plug box wrench (16)
iSpecial wrench
jCombination wrench (19-30) (For FX10MT/
FX10MTR/FX10MTRA)
kOwners tool bag
a
G
b
cd
ef
gh
ij
k
CCarton box
1Front shock absorbers (2pcs) (For FX10)
2Front shock absorbers (2pcs) (For FX10MT/
FX10MTR/FX10MTRA)
3Front shock absorbers (2pcs) and shock
absorber pump (For FX10RT/FX10RTR/
FX10RTRA)
1
2
3
1-4
DVinyl bag
1Key
1
ECarton box
1Ski assemblies (For FX10/FX10RT/FX10RTR/
FX10RTRA)
2Ski assemblies (For FX10MT/FX10MTR/
FX10MTRA)
12
FShroud (For FX10/FX10RT/FX10RTR/
FX10RTRA)
1Shroud
1
1-5
REMOVAL FROM CRATE
1. Open the fastener of plastic cover.
(One side fastener)
2. Remove the crate cover 1.
3. Remove the bolts 2 and then remove the top of the crate
3.
4. Remove the bolts 4 and then remove the sides of the
crate.
5. Remove the carton box.
6. Remove the bolts 5 and then remove the brackets 6.
ÈFX10RT/FX10RTR/FX10RTRA
ÉFX10MT/FX10MTR/FX10MTRA
65
È
6
55
É
1-6
7. Remove the bolts 7, collars 8, and nuts 9.
(Left and right side)
NOTE:
The bolts, collars, and nuts installed are not used for installa-
tion.
798
8. Remove the PPband 0.
0
9. Remove the clips A and pins B and then remove the
brackets C.
(Left and right side)
NOTE:
The clips, pins and brackets are not used for installation.
A
C
B
B
A
AB
C
A
2-1
SET UP PROCEDURE
FRONT BUMPER
Parts List
No Parts name Qty Location Remark
1 Shroud 1 on the seat F(For FX10/FX10RT/ FX10RTR/
FX10RTRA)
2 Owners tool bag 1 in the carton box B
3 Owners tool kit 1 in the carton box B
4 Front cover 1 in the carton box A
5 Front bumper 1 in the carton box A
6 Flange bolt 4 in the vinyl bag 1M8 L = 20 mm (0.79 in)
7 Screw 3 in the vinyl bag 3M6 L = 15 mm (0.59 in)
8 Quick fastener 2 in the vinyl bag 3
9 Quick fastener washer 2 in the vinyl bag 3
0 Reflector 2 in the vinyl bag 4
ANut 2 in the vinyl bag 4d = 5
2
9
9
4
0
0
A
A
6
5
6
6
6
7
7
7
1
3
8
8
7 Nm (0.7 m kg, 5.1 ft lb)
23 Nm (2.3 m kg, 17 ft lb)
7 Nm (0.7 m kg, 5.1 ft lb)
23 Nm (2.3 m kg, 17 ft lb)
23 Nm (2.3 m kg, 17 ft lb)
2 Nm (0.2 m kg, 1.4 ft lb)
2-2
Set up point
1. Fit the front cover 1 onto the front bumper 2, and then
install the bumper to the snowmobile using the flange
bolts 3. Then, install the front cover using the screws 4.
2. Install the reflectors 5 using the nuts 6.
6
1
5
3
5
2
33
4
4
4
3
2-3
WINDSHIELD
Parts List
No Parts name Qty Location Remark
1 Nut 6 in the vinyl bag 3d = 5 mm (0.20 in)
2 Windshield 1 in the carton box A(For FX10/FX10MT/FX10MTR/
FX10MTRA)
3 Windshield 1 in the carton box A(For FX10RT/FX10RTR/FX10RTRA)
4 Screw 6 in the vinyl bag 3M5 L = 18 mm (0.71 in)
3
2
4
4
1
4
4
4
4
11
11
1
0.4 Nm (0.04 m kg, 0.29 ft lb) 0.4 Nm (0.04 m kg, 0.29 ft lb)
0.4 Nm (0.04 m kg, 0.29 ft lb)
2-4
FRONT SUSPENSION
Parts List
No Parts name Qty Location Remark
1 Front shock absorber 2 in the carton box c(For FX10)
2 Front shock absorber 2 in the carton box c(For FX10MT/FX10MTR/FX10MTRA)
3 Front shock absorber 2 in the carton box c(For FX10RT/FX10RTR/FX10RTRA)
4 Flange bolt 2 in the vinyl bag 2M10 L = 47 mm (1.85 in)
5 Self-locking nut 2 in the vinyl bag 2d = 10
6Collar 2 in the vinyl bag 2D = 15 L = 36 mm (1.42 in)
(For FX10/FX10MT/FX10MTR/
FX10MTRA)
7 Flange bolt 2 in the vinyl bag 2M10 L = 54 mm (2.13 in)
8 Self-locking nut 2 in the vinyl bag 2d = 10
4
5
1
7
8
Valve face
Valve face
2
3
6
45 Nm (4.5 m kg, 33 ft lb)
45 Nm (4.5 m kg, 33 ft lb)
2-5
SKI ASSEMBLY
Parts List
No Parts name Qty Location Remark
1 Collar 2 in the carton box BL = 76.2 mm (3.00 in) (For FX10/FX10RT/
FX10RTR/FX10RTRA)
L = 101.6 mm (4.00 in) (For FX10MT/
FX10MTR/FX10MTRA)
2 Washer 4 in the vinyl bag 2d = 16 mm (0.63 in)
D = 25 mm (0.98 in)
3 Collar 2 in the vinyl bag 2L = 13.8 mm (0.54 in) (For FX10/FX10RT/
FX10RTR/FX10RTRA)
L = 30.7 mm (1.21 in) (For FX10MT/
FX10MTR/FX10MTRA)
4 Collar 2 in the vinyl bag 2L = 18.0 mm (0.71 in) (For FX10/FX10RT/
FX10RTR/FX10RTRA)
L = 26.5 mm (1.04 in) (For FX10MT/
FX10MTR/FX10MTRA)
42
2
1
5
3
A0
9
6
8
7
LS
È
2-6
Parts List
No Parts name Qty Location Remark
5 Ski stopper 2 in the carton box B(For FX10/FX10RT/FX10RTR/
FX10RTRA)
6 Ski assembly 2 in the carton box E(For FX10/FX10RT/FX10RTR/
FX10RTRA)
7 Ski stopper 2 in the carton box B(For FX10MT/FX10MTR/FX10MTRA)
8 Ski assembly 2 in the carton box E(For FX10MT/FX10MTR/FX10MTRA)
9 Flange bolt 2 in the vinyl bag 2M10 L = 130 mm (5.12 in) (For FX10/
FX10RT/FX10RTR/FX10RTRA)
M10 L = 153 mm (6.02 in) (For FX10MT/
FX10MTR/FX10MTRA)
0 Self-locking nut 2 in the vinyl bag 2M10
A Cotter pin 2 in the vinyl bag 2
42
2
1
5
3
A0
9
6
8
7
LS
È
2-7
STEERING ASSEMBLY (For FX10/FX10RT/FX10RTR/FX10RTRA)
Parts List
No Parts name Qty Location Remark
1 Handlebar assembly 1 on the snowmobile
2 Handlebar holder 2 in the carton box B(For FX10RT/FX10RTR/FX10RTRA)
3 Flange bolt 4 in the carton box BM8 L = 35 mm (1.38 in) (For FX10RT/
FX10RTR/FX10RTRA)
4 Wind deflector stay holder 2 in the vinyl bag 3
5 Left wind deflector stay 1 in the carton box A
6 Bolt 2 in the vinyl bag 3M5 L = 20 mm (0.79 in)
7 Left wind deflector 1 in the carton box A
8 Bolt 2 in the vinyl bag 3M6 L = 15 mm (0.59 in)
9 Right wind deflector stay 1 in the carton box A
0 Bolt 2 in the vinyl bag 3M5 L = 20 mm (0.79 in)
A Right wind deflector 1 in the carton box A
B Bolt 2 in the vinyl bag 3M6 L = 15 mm (0.59 in)
C Handlebar cover 1 in the carton box A
4 Nm (0.4 m kg, 2.9 ft lb)
4 Nm (0.4 m kg, 2.9 ft lb)
7 Nm (0.7 m kg, 5.1 ft lb)
7 Nm (0.7 m kg, 5.1 ft lb)
23 Nm (2.3 m kg, 17 ft lb)
00
C
6
6
4
1
2
2
4
9
5
A
7
B
B
8
8
3
3
2-8
STEERING ASSEMBLY (For FX10MT/FX10MTR/FX10MTRA)
Parts List
No Parts name Qty Location Remark
1 Steering joint 1 in the carton box B
2 Handlebar assembly 1 on the snowmobile
3 Steering joint holder 2 in the carton box B
4 Flange bolt 4 in the carton box BM8 L = 185 mm (7.28 in)
5 Handlebar cover 1 in the carton box A(For FX10MTRA)
23 Nm (2.3 m kg, 17 ft lb)
2
1
3
5
3
4
4
2-9
Set up point
Handlebar (For FX10)
1. Loosen the bolts 1.
2. Raise the handlebar 2 as shown in the illustration and
align the punch mark a on the handlebar with the upper
surface of the lower handlebar holder.
3. Tighten the bolts.
CAUTION:
First tighten the bolt on the front side, and then tighten
the bolt on the rear side.
For FX10RT/FX10RTR/FX10RTRA/FX10MT/FX10MTR/
FX10MTRA
1. Install the handlebar 1.
CAUTION:
First tighten the bolt on the front side, and then tighten
the bolt on the rear side.
NOTE:
The handlebar holders 2 should be installed with the
punch mark a facing forward.
Align the punch mark b on the handlebar with the upper
surface of the steering joint.
2
1
a
b
1
2
a
Wind deflector (For FX10/FX10RT/FX10RTR/
FX10RTRA)
1. Install the wind deflector stay holder 1 with the taller end
facing forward.
1
FWD
2. Align the punch mark a on the handlebar with the top of
the wind deflector stay 1.
1
a
Handlebar cover (For FX10/FX10RT/FX10RTR/
FX10RTRA/FX10MTRA)
1. Install the handlebar cover 1, making sure not to pinch
the cables, leads, etc.
NOTE:
Adjust the throttle cable after installing the handlebar cover.
Refer to THROTTLE CABLE ADJUSTMENT.
1
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Yamaha FX Nytro FX10MTRAX Assembly Manual

Category
Engine
Type
Assembly Manual

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