Related Manuals for Yamaha VK540V
Summary of Contents for Yamaha VK540V
- Page 1 OWNER’S MANUAL Read this manual carefully before operating this vehicle. VK5NFN LIT-12628-03-83 8KX-28199-75...
- Page 2 ESU10044 Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your...
- Page 3 CZ-01E Record the vehicle identification number, engine number, and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer. 860-004 1 The vehicle identification number is the seventeen- digit number stamped on the frame of the snowmo- bile.
- Page 4 ESU00022 INTRODUCTION Congratulations on your purchase of a Yamaha snowmo- bile. This model is the result of Yamaha’s vast experience in the production of fine sporting and touring snowmo- biles. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
- Page 5 PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE SNOWMO- BILE. ● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual con- tains the most current product information available at the time of printing, there may be minor discrepan- cies between your snowmobile and this manual.
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Page 6: Table Of Contents
ESU00030 C ONTENTS REPORTING SAFETY DEFECTS Rear carrier ........5-8 (FOR CANADA CUSTOMERS) ..1-1 Tow hitch .........5-8 YAMAHA 2020 AND LATER MODEL PRE-OPERATION CHECKS....6-1 SNOWMOBILE LIMITED Fuel ..........6-1 WARRANTY ........1-2 Engine oil.........6-2 Why Yamalube ........6-3 Throttle lever ........6-3 YAMAHA EXTENDED SERVICE Recoil starter ........6-3... - Page 7 Stopping the engine.......7-10 Transporting ........7-10 PERIODIC MAINTENANCE ....8-1 Periodic maintenance chart .....8-1 Tool kit ..........8-4 Checking the spark plug ....8-4 Adjusting the engine idling speed..8-5 Adjusting the throttle lever free play ..........8-6 Adjusting the oil pump cable free play ..........8-6 Adjusting the carburetor ....8-7 Adjusting the high altitude settings ..........8-8...
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Page 8: Reporting Safety Defects (For Canada Customers)
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform Transport Canada in addition to notifying Yamaha Motor Canada Ltd, Canada. If Transport Canada receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. -
Page 9: Yamaha 2020 And Later Model Snowmobile Limited Warranty
• All Yamaha snowmobiles shall be warranted for a term EMISSION CONTROL SYSTEM WARRANTY of one (1) year from the date of purchase, plus a (U.S.A. - Page 10 Q. Will the warranty be void or canceled if I do not operate or maintain my new Yamaha exactly as specified in the Owner’s Manual? A. No. The warranty on a new Yamaha cannot be “voided” or “canceled.” However, if a particular failure is caused by operation or maintenance other than as shown in the Owner’s Manual, that failure...
- Page 11 If the dealer is not able to do so, he is expected to contact Yamaha, for If you should move after having purchased this clarification or assistance.
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Page 12: Yamaha Extended Service (Y.e.s.) For U.s.a. Customers
Keep your Yamaha protected even after your limited This excellent Y.E.S. plan coverage is only available to warranty expires with genuine Yamaha Extended Yamaha owners like you, and only while your Yamaha is Service (Y.E.S.). still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. -
Page 13: Yamaha Protection Plus (Ypp) For Canada Customers
• Under the Yamaha Protection Plus program, Yamaha picks up the entire cost of parts and labour to repair every applicable mechanical defect. • Yamaha’s computerized warranty system is updated... -
Page 14: Location Of The Important Labels
ESU03231* L OCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operat- ing this snowmobile. Maintain or replace safety and instruction labels, as nec- essary. - Page 15 WARNING AVERTISSEMENT 8DM-E0 NOTICE ATTENTION 8ET-2815K-00 8ET-2815K-10 8KX-77763-E0 TUNE-UP SPECIFICATIONS SPECIFICATIONS DE LA MISE AU POINT ENGINE MOTEUR 1.SPARK PLUG 1.TYPE DE BOUGIE BR9ES(NGK) BR9ES(NGK) 2.SPARK PLUG GAP 2.ECARTEMENT DES ÉLECTRODES 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 0,7 ~ 0,8 mm 3.IDLE SPEED 3.RÉGIME DE RALENTI 1300 ±...
- Page 16 WARNING AVERTISSEMENT This snowmobile is designed for Cette motoneige a été conçu one (1) operator and as many pour un (1) conducteur et autant passengers as there are seats de passagers qu'il y a de sièges with a handgrip strap or handgrips munis de sangle ou poignées installed on the snowmobile.
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Page 17: Safety Information
1. Read the Owner’s Manual and all labels before oper- ating this snowmobile. Become familiar with all of the operating controls and their function. Consult a Yamaha dealer about any control or function you do not understand. 2. This snowmobile was not manufactured for use on public streets, roads, or highways. - Page 18 7. Handle fuel with care; it is HIGHLY FLAMMABLE. ● Never add fuel when the engine is running or hot. Allow the engine to cool for several minutes after running. ● Use an approved fuel container. ● Fill the fuel tank outdoors with extreme care. Never remove the fuel cap indoors.
- Page 19 2. Modifications made to the snowmobile not approved by Yamaha, or the removal of original equipment may render your snowmobile unsafe for use that may cause severe personal injury. Modifications may also make the snowmobile illegal to use.
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Page 20: Description
ESU00120 D ESCRIPTION 1 Fuse box 2 Main fuse 3 Windshield 4 Steering handlebar 5 Seat 6 Storage compartment 7 Drive track 8 Slide rail suspension 9 Frame 0 Telescopic strut suspension A Skis B Headlight C Shroud D Engine compartment plate... - Page 21 E Tail/brake light F Tow hitch G Snow flap H Engine stop switch I Throttle lever J Drive select lever K Main switch L Starter handle M Starter lever (choke) N Thumb warmer adjusting switch O Grip warmer adjusting switch P Auxiliary DC jack Q Headlight beam switch R Brake lever...
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Page 22: Control Functions
ESU00130 C ONTROL FUNCTIONS ESU02561* Main switch The main switch controls the following items. 1 “OFF” The ignition circuit is switched off. The key can be removed only in this position. 2 “ON” The ignition circuit is switched on. The engine can be started. The headlights, meter lighting, and taillight come on after the engine starts. -
Page 23: Throttle Lever
ESU00220 Throttle lever Once the engine is running cleanly, squeezing a the throttle lever 1 will increase the engine speed and cause engagement of the drive system. Regulate the speed of the snowmobile by varying the throttle position. Because the throttle is spring-loaded, the snowmobile will deceler- ate, and the engine will return to idle when it is released WARNING Check the throttle, brake, and steering for proper... -
Page 24: Engine Stop Switch
ESU00310 Engine stop switch The engine stop switch 1 is used to stop the engine in an emergency. Simply push 2 the stop switch to stop the engine. To start the engine, pull 3 the stop switch and proceed with starting the engine. (See pages 7-1–7-2 for more details.) During the first few rides, practice using the stop switch so that you can react quickly in an emergency. -
Page 25: Parking Brake Button
ESU00341 Parking brake button When parking the snowmobile or starting the engine, apply the parking brake. Squeeze the brake lever 1, push and hold the parking brake button 2 down 3, and then release the brake lever. To release the parking brake, squeeze the brake lever. WARNING ●... -
Page 26: Headlight Beam Switch
ESU00390 Headlight beam switch Push the headlight beam switch to change the headlight beam to high or low. 1 Headlight beam switch 2 Push 3 High beam 4 Low beam ESU00421 Grip/thumb warmer adjusting switch The grip warmer adjusting switch and the thumb warmer adjusting switch control the electrically heated handlebar grips and throttle lever respectively. -
Page 27: Tripmeter Reset Knob
The auxiliary DC jack can only be used if the engine is running. ESU00461* Tripmeter reset knob Use the tripmeter reset knob to reset the tripmeter. 1 Tripmeter reset knob 2 Turn counterclockwise 833-005 ESU00481 Shroud latches To open the shroud, unhook the shroud latches, and then slowly raise the shroud forward until it stops. -
Page 28: Drive Guard
ESU00521 Drive guard The drive guard is designed to cover the V-belt clutch and V-belt in case parts break or come loose. WARNING ● Make sure that the drive guard is tightened securely before operating the snowmobile. ● Never run the engine with the V-belt or drive guard removed. -
Page 29: Rear Carrier
2. Remove the seat support rod from its holder, and then secure the seat by inserting the end of the rod into the hole in the seat. 1 Seat support rod 2 Hole 846-012 To close the seat: 1. Remove the end of the seat support rod from the seat, and then secure the rod with its holder. -
Page 30: Pre-Operation Checks
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. ESU00741 Fuel Make sure that there is sufficient fuel in the fuel tank. -
Page 31: Engine Oil
NOTICE ● Make sure that snow or ice does not enter the fuel tank when refueling. ● The fuel tank should be filled with the recom- mended gasoline as specified. ● Handle the fuel tank cap carefully. If the fuel sender attached to the fuel tank cap is bent, the fuel meter may not indicate the correct fuel level. -
Page 32: Why Yamalube
ESU15280 Why Yamalube YAMALUBE oil is a Genuine YAMAHA Part born of the engineers’ passion and belief that engine oil is an impor- tant liquid engine component. We form teams of special- ists in the fields of mechanical engineering, chemistry, electronics and track testing, and have them develop the engine together with the oil it will use. -
Page 33: Throttle Override System (T.o.r.s.)
If the engine speed does not decrease to less than the clutch engagement speed, stop the engine by turning the main switch to the off position and con- sult a Yamaha dealer. Operating the snowmobile with a malfunctioning T.O.R.S. could result in loss of con- trol. -
Page 34: Brake
Do not operate the snowmobile if you find any prob- lems in the brake system. You could lose braking ability, which could lead to an accident. Ask a Yamaha dealer to inspect and repair the brake sys- tem. NOTICE Make sure that the brake lever end does not project out over the handlebar end. -
Page 35: Drive Track
WARNING ● Make sure that the drive guard is tightened securely before operating the snowmobile. ● Never run the engine without the V-belt or with the drive guard removed. ESU00970 Drive track Check the drive track for deflection, wear, or damage. Adjust or replace if necessary. -
Page 36: Skis And Ski Runners
Check the handlebar for excessive free play: 1. Push the handlebar up and down and back and forth. 2. Turn the handlebar slightly to the right and left. If excessive free play is noticed, consult a Yamaha dealer. ESU01041 Lights Check the lights. -
Page 37: Fittings And Fasteners
ESU01100 Fittings and fasteners Check the tightness of the fittings and fasteners. Tighten in proper sequence and torque if necessary. ESU01111* Tool kit and recommended equipment It is good practice to carry the tool kit, spare parts, and other necessary equipment with you while riding the snowmobile so that minor repairs can be done if neces- sary. -
Page 38: Operation
ESU01120 O PERATION ESU02817 Starting the engine WARNING ● Be sure to check the “SAFETY INFORMATION” section carefully before starting the engine. ● Make sure that the parking brake is applied. Make sure that the engine stop switch is in the on posi- tion. -
Page 39: Emergency Engine Starting
NOTICE ● Release the switch immediately after the engine starts. ● If the engine fails to start, release the switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. -
Page 40: Break-In
Also avoid lugging the engine, such as laborious opera- tion in wet snow. If any abnormal condition is noticed, such as excessive vibration or noise, consult a Yamaha dealer. To ensure proper engine break-in, use a 50:1 gasoline/oil mixture when filling the fuel tank of a new snowmobile for the first time. -
Page 41: Riding Your Snowmobile
ESU02733 you are totally familiar with the snowmo- Riding your snowmobile bile’s handling and performance charac- teristics. Getting to know your snowmobile The beginning operator should select a large flat area to become familiar with the A snowmobile is a rider active vehicle, and your riding position and your balance snowmobile. -
Page 42: Turning
alert, plan ahead, and begin decel- Remember: erating early. Avoid higher speeds until you are thor- ● Improper use of the brake can oughly familiar with the operation of your cause the drive track to lose trac- snowmobile. tion, reduce control, and increase the possibility of an accident. -
Page 43: Riding Downhill
WARNING WARNING Side hills and steep slopes are not Traversing slopes recom- recommended for a novice snowmo- mended for a novice snowmobiler. biler. Traversing a slope requires you to prop- erly position your weight to maintain Riding downhill proper balance. As you travel across the slope, lean your body to position your weight towards the uphill side. -
Page 44: Hard-Packed Snow
Also traction aids such as studs, cleats, ing rapidly. Steering is minimal and uncontrolled spins are an ever-present etc., may cause further track damage or danger. failure. WARNING Hard-packed snow Drive track damage or failure could It can be more difficult to negotiate on result in loss of braking ability and hard-packed snow as both the skis and snowmobile... -
Page 45: Maximizing Drive Track Life
Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible dam- age, consult your stud manufacturer for installation and stud pattern recommendations. Yamaha does not recommend track studding. -
Page 46: Driving
ESU03382* Driving WARNING Be sure to read the “SAFETY INFORMATION” and “Riding your snowmobile” sections carefully before operating the snowmobile. Make sure that the engine is warmed up enough before riding. 1. Select the desired operating position by moving the drive select lever. -
Page 47: Stopping The Engine
6. Apply the parking brake — squeeze the brake lever, push and hold the parking brake button down, and then release the brake lever. ESU01360 Stopping the engine Turn the main switch to the “OFF” position to stop the engine. 1 “OFF”... - Page 48 ● If transporting the snowmobile in an open trailer or truck in areas where road salt is used, coat metal suspension surfaces lightly with oil or other protec- tant. This will help protect against corrosion. Be sure to clean the snowmobile when you get to your desti- nation to remove any corrosive salts.
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Page 49: Periodic Maintenance
∗ Repair if necessary. Throttle override sys- Check operation. ● 5-2, 6-4 ∗ Repair if necessary. tem (T.O.R.S.) Check operation. ● Throttle lever 5-2, 6-3 ∗ Repair if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer. - Page 50 Lights Replace bulbs if necessary. 8-19–8-20 ∗ It is recommended that these items be serviced by a Yamaha dealer. ∗∗ Apply “Initial 1 month or 400 km (250 mi, 20 hr)”. ∗∗∗ Apply “Initial 500 km (300 mi, 25 hr)”.
- Page 51 ● Shroud latches latches are hooked. Check tightness. ● Fittings and fasteners ∗ Repair if necessary. Tool kit and recom- ● Check for proper placement. mended equipment ∗ It is recommended that these items be serviced by a Yamaha dealer.
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Page 52: Tool Kit
If you do not have a torque wrench available during a service operation requiring one, take your snowmobile to a Yamaha dealer to check the torque settings and adjust them if necessary. ESU01443* Checking the spark plug The spark plug is an important engine component and is easy to inspect. -
Page 53: Adjusting The Engine Idling Speed
20 N·m (2.0 kgf·m, 15 lb·ft) ESU01462* Adjusting the engine idling speed NOTICE ● Be sure to have a Yamaha dealer make this adjustment. ● Make sure that the throttle lever moves smoothly. 1. Start the engine. Refer to the “Starting the engine” section. -
Page 54: Adjusting The Throttle Lever Free Play
2. Turn the throttle stop screw 1 in or out to adjust the engine idle speed. Standard engine idle speed: 1,200–1,400 r/min 804-027 ESU01473 Adjusting the throttle lever free play NOTICE Be sure to adjust the engine idle speed first. 1. -
Page 55: Adjusting The Carburetor
ESU01527 Adjusting the carburetor NOTICE ● It is advisable to have a Yamaha dealer make this adjustment. ● Make sure that the carburetor silencer is installed before starting the engine to prevent engine dam- age. The carburetor settings may have to be changed due to changes in air temperature and elevation, and use of oxygenated fuels such as gasohol. -
Page 56: Adjusting The High Altitude Settings
Common problems are hard starting, bogging, and plug fouling. Follow the Main Jet Setting chart which is available at a Yamaha dealer carefully. Proper carburetion adjustments will correct the air/fuel ratio. -
Page 57: Checking The Fan Belt Deflection
If you plan to operate your snowmobile at an altitude different from the area where you bought it, be sure to consult a Yamaha dealer. They can tell you if there are any changes necessary for the altitude where you plan to ride. -
Page 58: Replacing The V-Belt
● Have a Yamaha dealer replace the V-belt and adjust the gap between the secondary fixed sheave and the secondary sliding sheave. Serious injury can occur from the sudden release of spring tension during sheave disassembly. - Page 59 Apply the parking brake before replacing the V-belt. 1. Remove the drive guard. 2. Rotate the secondary sliding sheave clockwise 1 and push 2 it so that it separates from the secondary 805-002 fixed sheave. 3. Pull 3 the V-belt up over the secondary fixed sheave. 4.
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Page 60: Adjusting The Drive Chain Tension
ESU01762* Checking the brake pads Check the brake pads for wear by measuring the thick- ness of each pad. If the brake pads reach the wear limit, have a Yamaha dealer replace them. Wear limit a: 10.0 mm (0.39 in) Adjustment This snowmobile has a self-adjusting brake caliper. -
Page 61: Suspension
WARNING Be sure to have a Yamaha dealer make these adjust- ments. Adjusting the spring preload of the center shock absorber and the rear torsion springs... -
Page 62: Checking The Extrovert Drive Sprocket
Adjusting the spring preload of the sliding frame extension WARNING Be sure the left and right extension spring preloads are the same. Uneven settings can cause loss of sta- 820-049 bility. The spring preload of the sliding frame extension can be adjusted by turning the adjusting nuts 1. -
Page 63: Adjusting The Drive Track
ESU04025* Adjusting the drive track WARNING A broken track, track fittings or debris thrown by the drive track could be dangerous to an operator or bystanders. Observe the following precautions: ● Do not allow anyone to stand behind the snow- mobile when the engine is running. - Page 64 Adjusting the drive track WARNING ● Be sure to have a Yamaha dealer make this adjustment. ● Support the snowmobile securely on a suitable stand before working underneath the snowmo- bile. ● Operate the engine in a well-ventilated area. 1. Loosen the rear axle nut 1.
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Page 65: Ski Alignment
Ski toe-out (1 – 2) is within specification. Ski toe-out (1 – 2): 0–15.0 mm (0–0.6 in) Move the front tip of each ski fully inward before measur- ing or aligning. 3. If the alignment is not correct, consult a Yamaha dealer. 8-17... -
Page 66: Lubrication
ESU02042 Lubrication Lubricate the following points. Lubricant: Low-temperature grease 1 Brake/throttle cable ends WARNING Apply a dab of grease onto the cable ends only. Do not grease the brake and throttle cables themselves because they could become frozen, which could cause loss of control. -
Page 67: Replacing A Headlight Bulb
ESU02113* Replacing a headlight bulb 1. Open the shroud. 2. Disconnect the headlight coupler. 3. Remove the bulb holder cover. 832-019 1 Headlight coupler 2 Bulb holder cover 4. Unhook the bulb holder, and then remove the burnt-out bulb. 1 Bulb holder WARNING 832-020 Keep flammable products or your hands away from... -
Page 68: Adjusting The Headlight Beams
ESU04002 Adjusting the headlight beams Turn the headlight beam adjusting screw 1 in or out to adjust the headlight beams. 832-022 ESU02130* Battery Replenishing the battery fluid 1. Check the fluid level. The level should be between the upper and lower level marks. a “UPPER LEVEL”... -
Page 69: Replacing A Fuse
2 “HEAD” (headlight) fuse 3 “SIGNAL” (signal system) fuse 4 “CARB. WARMER” (carburetor warmer) fuse 5 “IGNITION” (ignition) fuse 6 Spare fuse 1 2 3 4 5 If the fuse immediately blows again, ask a Yamaha dealer to inspect the snowmobile. 835-006 8-21... - Page 70 Specified fuses: Main fuse: 30.0 A Auxiliary DC jack fuse: 3.0 A Headlight fuse: 20.0 A Signaling system fuse: 7.5 A Carburetor warmer fuse: 15.0 A Ignition fuse: 15.0 A Spare fuse: 30.0 A, 20.0 A, 15.0 A, 7.5 A, 3.0 A 4.
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Page 71: Troubleshooting
● Worn or damaged piston and cylinder ● No fuel in tank ... Supply fuel..Ask a Yamaha dealer to inspect. ● Clogged fuel line ... Clean fuel line. ● Clogged carburetor ... Clean carbure- B. Engine does not turn over with the recoil tor. - Page 72 Engine does not upshift or downshift properly or engages harshly 1. Worn or damaged V-belt ... Replace the V-belt or ask a Yamaha dealer to inspect. 2. Incorrect V-belt clutch settings for alti- tude or conditions ... Ask a Yamaha dealer to inspect.
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Page 73: Storage
In areas where oxygenated fuel (gaso- avoid using cloths or sponges which hol) is used, completely drain the fuel have been in contact with strong or system. Consult a Yamaha dealer if further abrasive cleaning products, solvent information is needed. or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, 4. - Page 74 For peak performance, it is recommended the hydrogen gas created by the bat- that you have your snowmobile checked tery. and tuned by a Yamaha dealer. The dealer ● Make sure that the battery terminals has the experience and training to help you...
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Page 75: Specifications
ESU02280 S PECIFICATIONS ESU02290 Dimensions CS-01E VK540F Overall length 3,070 mm (120.9 in) Overall width 1,140 mm ( 44.9 in) Overall height 1,430 mm ( 56.3 in) Weight with oil and fuel 331 kg ( 730 lbs) Ski tread 960 mm ( 37.8 in) ESU02300 Engine CS-02E... -
Page 76: Chassis
ESU02310 Chassis CS-03E VK540F Drive track and suspension: Track Molded rubber, fiberglass-rod reinforced Width 500 mm (19.7 in) Track deflection 30.0–35.0 mm (1.18–1.38 in)/ 100 N (10 kgf, 22 lbf) Length on ground 1,085 mm (42.7 in) Suspension type (Front) Telescopic strut suspension Suspension type (Rear) Slide rail suspension... -
Page 77: Electric
ESU02320 Electric CS-04E VK540F Ignition system DC CDI Spark plug Type BR9ES (NGK) 0.7–0.8 mm (0.028–0.031 in) Battery Capacity YB16AL-A2/12 V 16.0 Ah Maximum charge rate 1.6 Amperes/hr for 10 hrs Bulb × Quantity 12 V, 60/55 W × 2 Headlight Tail/brake light Bulb ×... - Page 79 Genuine Yamaha Accessories – Yamaha only offers accessories that meet our high standards for quality and performance. Buy with confidence, knowing your Genuine Yamaha Accessories will fit right and perform right – right out of the box. Yamalube – Take care of your Yamaha with legendary Yamalube oils, lubricants, and care products.
- Page 80 Printed in Japan 2021.04-1.1×1 CR...