Yamaha FX Nytro FX10X 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may become outdated due to future changes in this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

1st Edition, May 2007

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

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)

AOwner’s tool bag

BPouch

COwner’s 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

GOwner’s 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)

kOwner’s 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

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 Owner’s tool bag 1 in the carton box “B”

3 Owner’s 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 “1”M8 L = 20 mm (0.79 in)

7 Screw 3 in the vinyl bag “3”M6 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 “4”d = 5

2

9

4

0

A

6

5

6

7

1

3

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)

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

3

2-3

WINDSHIELD

Parts List

No Parts name Qty Location Remark

1 Nut 6 in the vinyl bag “3”d = 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 “3”M5 L = 18 mm (0.71 in)

3

2

4

1

4

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 “2”M10 L = 47 mm (1.85 in)

5 Self-locking nut 2 in the vinyl bag “2”d = 10

6Collar 2 in the vinyl bag “2”D = 15 L = 36 mm (1.42 in)

(For FX10/FX10MT/FX10MTR/

FX10MTRA)

7 Flange bolt 2 in the vinyl bag “2”M10 L = 54 mm (2.13 in)

8 Self-locking nut 2 in the vinyl bag “2”d = 10

4

5

1

7

8

Valve face

2

3

6

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 “B”L = 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 “2”d = 16 mm (0.63 in)

D = 25 mm (0.98 in)

3 Collar 2 in the vinyl bag “2”L = 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 “2”L = 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 “2”M10 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 “2”M10

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 “B”M8 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 “3”M5 L = 20 mm (0.79 in)

7 Left wind deflector 1 in the carton box “A”

8 Bolt 2 in the vinyl bag “3”M6 L = 15 mm (0.59 in)

9 Right wind deflector stay 1 in the carton box “A”

0 Bolt 2 in the vinyl bag “3”M5 L = 20 mm (0.79 in)

A Right wind deflector 1 in the carton box “A”

B Bolt 2 in the vinyl bag “3”M6 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)

7 Nm (0.7 m • kg, 5.1 ft • lb)

23 Nm (2.3 m • kg, 17 ft • lb)

00

C

6

4

1

2

4

9

5

A

7

B

8

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 “B”M8 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

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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