1981 SR540E

SECTION INDEX
GENERAL
ENGINE
CARBURETION
POWER TRAIN
CHASSIS
ELECTRICAL
APPENDIX
RACING TIPS
1981 SR540E
CHAPTER 1. GENERAL
1-1. EXTERNAL VIEW .......................................................................................................... 1-2
1-2. MACHINE IDENTIFiCATION ...................................................................................... 1-3
A. Frame serial number ............................................................................................ 1-3
B. Engine serial number ........................................................................................... 1-3
1-3. MAINTENANCE INTERVALS CHARTS .................................................................... 1-4
A. Periodic maintenance .......................................................................................... 1-4
B. Lubrication intervals ............................................................................................ 1-5
1-4. HIGH ALTITUDE TUNING .......................................................................................... 1-5
1981 SR540E
CHAPTER 1. GENERAL
1-1. EXTERNAL VIEW
1-2
1-2. MACHINE IDENTIFICATION
A. Frame serial number
The frame serial number is located on the
righthand side of frame (just below the front
of seat). The first three digits identify the
model. This is followed by a dash. The re-
maining digits identify the production
number of the unit.
Frame starting serial number 8L9-016101
1-3. MAINTENANCE INTERVALS CHARTS
A. Periodic maintenance
1981 SR540E
B. Engine serial number
The engine serial number is located on the
fan case. The prefix indicates engine type
and displacement. The prefix is followed by a
dash and the serial number. Normally both
frame and engine serial numbers are identi-
cal.
Engine starting serial number SA535-016101
(Use this just as guide only. Certain conditions may require more frequent inspection of compo-
nents.)
Every
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
400km 800km 1.600km
necessary
(250mi) (500mi) (1.000mi)
ENGINE:
Tightness of bolts and nuts 0 0
Bends. cracks and wear 0 0
Abnormal noise 0 0
Loose connection and breaks of fuel and pulse pipes 0 0
Loose connection and breaks of oil pipes 0 0
Loose connection and breaks of oil delivery pipe 0 0
Fan belt tension/cracks/damage 0 0
Manual rope starter system 0 0
Carburetor
Operation of starter jet 0 0
Mixing adjuster (pilot screw) 0 0
Idling speed adjustment 0 0
.. ,,_.
Operation and adjustment of oil pump 0 0
Ignition timing 0
Cylinder compressions 0 0
Cylinder head/exhaust pipe decarbonize 0
Spark plug condition. gap and cleaning 0 0
Tightening of the cylinder head 0
1-3
1981 SR540E
Every
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
400km 800km 1.600 km
necessary
(250mi) (500mi) (1.000mi)
DRIVE:
Tightness of bolts and nuts 0 0
Wear on slide runners 0 0
Primary drive system 0 0
V-belt 0 0
Secondary drive system 0 0
Sheave distance 0 0
Sheave offset 0 0
8rake pad wear 0 0
Brake operation and adjustment 0 0
Guide wheel rubber 0 0
Wear of drive track wheel sprocket 0 0
Drive track adjustment 0 0
Breaks in drive track 0 0
Bends in front and rear axles 0 0
Checking of lock washers 0 0
Drive chain adjustment 0 0
Drive chain oil level ' 0 0
CHASSIS:
Tightness of bolts a nd nuts 0 0
Bends and cracks 0 0
Welded riveted. joints 0 0
Ski adjustment 0 0
Ski runner wear 0 0
Breaks in fuel tank 0 0
Cleaning of fuel tank
0
Fuel filter 0
Loose connection and breaks in fuel pipe 0 0
Breaks in oil tank 0 0
Oil filter 0
ELECTRICAL:
Wear. breakage of wire covering 0 0
Breaks in high-tension cord 0 0
Voltage regulator working voltage 0
Operation of engine stop switch 0 0
Operation of tether switch 0 0
Headlight 0 0
Taillight 0 0
Brake light 0 0
Retighten every 10 hours from the first use.
1-4
1981 SR540E
B. Lubrication intervals
Every
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
. Seasonally
Oil/Grease
400km 800km 1.600km
necessary Brand name
(250mi) (500 mil (1.000 mil
ENGINE:
Starter case 0
Oil pump c o n t r ~ 1 box 0 0
Aeroshell grease #7 A or
Esso Beacon 325 grease
Pump drive cover 0 0
Oil in the oil tank 0 YAMAlUBE 2-cycle oil
DRIVE:
Primary sheave weight
0 0
and roller pins
Molybdenum disulfide
Secondary shaft and
0 0
snowmobile grease
Sliding sheave
Front axle housing 0 0
Shaft 1 and shaft 2
0 0
light all-purpose grease
(Slide rail)
Drive chain oil
0 0
Gear oil API "Gl-3"
replacement SAE #75 or #80
BODY:
Steering column lower
0 0 light all-purpose grease
bearing
Steering column upper
0 0 Motor oil
bearing
Steering links 0 0
Ski column 0 0
light all-purpose grease
Ski retaining pin 0 0 light all-purpose grease
Brake cable end stopper
0 0 Esso Beacon 325 grease
and brake lever
Telescopic strut suspension r>
1-5
1981 SR540E
1-4. HIGH ALTITUDE TUNING
To attain the best machine performance to
match high altitude condition. the
snowmobile must be properly set.
The tuning should be done as follows.
J
Test main jet size
(performance & plug colour!
Not OK
(Page 3-3)
I
OK
Confirm STD settings
.Carburetor (Page 321
.Ignition timing (Page 6-31
Spark plug (Page 6-61
1
Adjust main Jet size according to the chart
(Page 3-41
Adjust main jet size
~
I I
L-____ !Te_s_t_lo_w_s_p_e_e_d_s_et_ti_n_g __ , - ~ ~ I - - - - - - - - ~ ~ ______________ - J ~ K
~ I
Not OK
Not OK OK
Try high altitude settings
Not OK
Decide if problem is slow jet
and adjust accordingly
Not OK
OK
OK
Not OK
Check to see if gearing is too high or low
OK Not OK

Adjust gearing as reqUired
(Page 4-131
I
OK
Check engagement speed and
shift performance
Not OK OK
Adjust primary clutch as required
(Page 4-4)
Not OK
OK
I
Not OK
High altitude
tUning O. K.
Adjust secondary clutch as required
(Page 4-91
OK
'-6
1981 SR540E
CHAPTER 2. ENGINE
2-1. DiSASSEMBLy ............................................................................................................. 2-2
A. Engine removal ..................................................................................................... 2-2
B. Starter ..................................................................................................................... 2-2
C. Cooling fan ............................................................................................................ 2-3
D. Flywheel magneto ................................................................................................ 2-3
E. Oil pump ................................................................................................................ 2-4
F. Engine disassembly ............................................................................................. 2-5
2-2. INSPECTION, REASSEMBLY AND ADJUSTMENT .............................................. 2-6
A. Engine component ............................................................................................... 2-6
B. Oil pump .............................................................................................................. 2-12
C. Flywheel magneto ............................................................................................. 2-14
D. Cooling fan .......................................................................................................... 2-15
E. Starter. ................................................................................................................. 2-18
F.. Engine remounting ............................................................................................ 2-19
1981 SR540E
CHAPTER 2. ENGINE
2-1. DISASSEMBLY
A. Engine removal
Remove the engine by removing the follow-
ing parts.
N O T E : - - - - - - - - - - - - - - - - - - - - - - ~
It is not necessary to remove the engine to
remove the following parts:
Cylinder head
Cylinder
Piston
Autolube pump
Manual starter assembly
Cooling fan
Flywheel magneto
Carburetor
Intake reed valve
Snowmobile
V-belt
Primary sheave
(Refer to "4-1- B. Primary-sheave")
Carburetor
(Refer to "3-1-B. Carburetor Overhauling)
Muffler
Fuel pipe
Oil pipe
Pulse pipe
Tachometer cable
Magneto lead wire
Manual starter handle
Shroud stopper
2-2
Engine mounting nuts
Engine
B. Starter
1. Remove starter assembly from the fan
case .
2. Remove the drive plate mounting nut at
its center, and remove the drive plate.
3. There is a drive plate spring and a drive
pawl under the drive plate.
N O T E : - - - - - - - - - - - - - - - - - - - - - - - - ~
Take care so that they are not lost.
1. Drive plate spring
2. Drive pawl
3. Return spring
4. Remove the sheave drum.
CAUTION: -----------.
There is a starter spring (coiled) under
the sheave drum. Care should be taken
so that it will not spring out.
5. To remove the starter rope. undo the
knot on one end of the rope. Then pull it
out from the starter case.
C. Cooling fan
1. Remove the fan case cap.
2. Using the rotor holding tool. remove the
three bolts. and remove the starter pul-
ley.
Tool name Tool No.
Rotor holding tool 90890-01235
2-3
1981 SR540E
1. Rotor holding tool
3. Remove the drive fan pulley and fan
belt.
4. Remove the fan case assembly.
5. Remove the driven fan pulley securing
nut. spring washer. plate washer. fan
pulley. key. and washers (shims).
NOTE:-------------------------
Take care so that the key and washers
(shims) are not lost.
1981 SR540E
6. Remove the cooling fan assembly by
tapping the fan shaft.
D. Flywheel magneto
1. Using the rotor holder tool. remove the
flywheel mounting nut.
Tool name Tool No.
Rotor holding tool 90890-01235
1. Rotor holding tool
2. Using the flywheel puller. remove the
flywheel assembly.
2-4
No. Tool name Tool No.
1 Drive handle 90890-01817
2 Flywheel puller bolt 90890-01803
3 Flywheel puller body 90890-01848
4
Flywheel puller screw
90890-01806
(4)8 X 80 mm)
5
Flywheel puller
90890-01804
attachment
NOTE:-------------------------
When removing the flywheel. the key must
be removed from the crankshaft.
Take care so that it is not lost.
3. Remove Phillips-head screw. and re-
move the coil plate.
E. Oil pump
1. Remove the oil delivery pipes.
2. Remove the bolts and pump drive case.
NOTE:-------------------------
The oil pump can be removed as an a s s e m b ~
Iy together with the pump drive cover. If it is
hard to remove the pump drive case. tap it
with a soft-faced hammer.

The oil pump must not be disassembled,
because the oil pump is a precision
work.
3. Remove oil pump cap and pump wire.
4. Remove oil pump assembly.
F. Engine disassembly
1. Remove the air shroud.
2. Remove the intake manifold and reed
valves.
NOTE:------------------____ ___
For reed valve inspection. refer to 3-2 Reed
valve.
2-5
1981 SR540E
3. Remove the exhaust pipe assembly.
4. Remove the cylinder head holding nuts.
cylinder head and gasket.
NOTE:--------------------------
Loosen spark plugs before removing cylinder
head.
5. Remove the cylinder holding nuts.
cylinder and cylinder base gasket.
6. Remove piston pin clip from piston.
NOTE:------------------------
Before removing the piston pin clip. cover
the crankcase with a clean rag to prevent the
clip from accidentally falling into the
crankcase.
7. Push piston pin. from opposite side. then
pull out. Protect pin with rag.
NOTE:--------------------------
Before moving piston pin. deburr clip groove
and pin hole area.
8. Remove engine brackets.
9. Remove crankcase holding bolts. Each
bolt position is numbered. Start with the
largest number for disassembly. Loosen
each bolt 1/4 turns and proceed to the
next.
1981 SR540E
10. Split crankcase by lightly striking the
upper and lower crankcases.
11. Remove crankshaft by tapping the shaft
with your hands.
2-2. INSPECTION, REASSEMBLY AND
ADJUSTMENT
A. Engine components
1. Crankcase
a. Thoroughly wash the case halves in
mild solvent.
b. Clean gasket matching surfaces and
crankcase matching surfaces thorough-
ly.
c. Visually inspect case halves for any
cracks, road damage, etc.
d. Check oil delivery passages in transfer.
ports for signs of blockage.
2. Bearing and oil seal inspection
a. After cleaning and lubricating bearings,
rotate outer race with a finger. If rough
spots are noticed, replace the bearing.
b. Check oil seal lips for damage and wear.
Replace as required.
3. Bearing and oil seal installation
a. When installing or removisng left crank
oil seal and bearing, remove the pump
drive gear and install the new drive gear.
2-6
CAUTION: ---------.....,
When removing pump drive gear, re-
place it with new one.
b. Install bearing(s) with . their manufac-
turer's marks or numbers facing out-
ward. (In other words, the stamped let-
ters must be on the. exposed to view
side.)
c. Install oil seal(s) with their manufac-
turer's marks or numbers facing out-
ward.
d. When installing bearing(s) or oil seal(s).
apply the specified lUbrication.
Crank bearing Yamalube 2-cycle oil
Crankshaft oil seal
Low temperature grease
(Esso Beacon 325 or
lip
Aeroshell grease #7 Al
4. Crankshaft inspection
a. Check connection rod axial play at small
end. (to determine the amount of wear
of crank pin and bearing at big end).
If small end play exceeds tolerance, dis-
assemble the crankshaft, check con-
necting rod, crank pin and big end bear-
ing.
Replace defective parts. Play after re-
assembly should be within specification.
Road axial play:
Maximum 2.0 mm (0.079 in)
b. Check the connecting rod side clear-
ance at big end.
If axial play exceeds tolerance. disas-
semble the crankshaft and replace any
worn parts. Big end axial play should be
within specification.
Rod side clearance
Minimum Maximum
0.25 iTlm (0.010 in) 0.75 mm (0.030 in)
c. Check crankshaft assembly runout
(misalignmentof crankshaft parts).
Dial gauge readings should be within
specification.
Correct any misalignment by tapping
the flywheel with a brass hammer an-
d/or by using a wedge.
Deflection tolerance
Left side
Center Center
Right side
(left) (right)
0.03 mm 0.04mm 0.04mm 0.05mm
(0.0012 in) (0.0016 in) (0.0016 in) (0.0020 in)
2-7
1981 SR540E
5. Crankshaft installation
a. Install the circlip half on crank bearing
as illustrated. (The primary sheave side.)
LOWER CASE
UPPER CASE
.1. Circlip 2. Sealing surface 3. Knock-pin
b. Install the crankshaft assembly with oil
seal. align the bearing punch marks with
the crankcase lower and upper match-
ing surfaces.
c. Set the pins of bearing and labyrinth
. seal in pin holes of crankcase upper by
moving the bearings and labyrinth seal.
1981 SR540E
FWD
<=
1. Knock pin 3. Upper case
2. Sealing surface 4. Aligning mark

The oil seal lip must fit into the
crankcase groove.
6. Crankcase installation
a. Apply YAMAHA BON D #4 to the mat-
ing surfaces of both case halves.
Apply thoroughly over all matching sur-
faces.
b. Set the crankcase half onto lower case
half. Install the crankcase holding bolts.
Each bolt position is numbered. Tighten
all crankcase holding bolts gradually in
the order of the numbers marked on
crankcase.
Tightening torque
First 1.0 m-kg (7 ft-Ib)
8 mm Bolt
Final 2.0 m-kg (15 ft-Ib)
6 mm Bolt
First 0.5 m-kg (3.5 ft-Ib)
(No.ll )
Final 1.0 m-kg (7 ft-Ib)
2-8
c. After reassembly. apply a liberal coating
of two-stroke oil to the crank pin. bear-
ing and into each crankshaft bearing oil
delivery hole.
d. Check crankshaft for freedom of
movement.
7. Engine bracket installation
Install the engine brackets in the correct
position.
Tightening torque:
2.0 m-kg (14.5 ft-Ib)
8. Piston pin and bearing inspection
a. Check the pin for signs of wear. If any
wear is evident. replace pin and bearing.
b. Check the pin and bearing for signs of
heat discoloration. If excessive (inden-
tation on pin. etc.). replace pin and be-
aring.
c. Check the bearing cage for excessive
wear or damage. Check the rollers for
signs of flat spots. If such w e a ~ is found.
replace pin and bearing. '
~
, , ~ , ,
d. Apply a light film of oil to pin and bear-
ing surfaces. Install them in connecting
rod small end to inspect for wear. Check
for play. There should be no noticeable
vertical play. If play exists. check con-
necting rod small end for wear. Replace
pin. connecting rod and/or bearing. as
required.
e. The piston pin should have no notice-
able free play in the piston. If the piston
pin is loose. replace the pin and/or
piston.
2-9
1981 SR540E
9. Piston inspection
a. Remove piston rings.
b. Remove carbon deposits from piston
crown.
c. Carefully remove carbon deposits from
ring grooves with filed end of ring.
d. Remove score marks and lacquer de-
posits from sides of piston using 600 !"'oJ
800 grit wet sandpaper. Sand in a cris-
scross pattern. Do not sand excessively.
1981 SR540E
e. Wash piston in solvent and wipe dry.
f. Measure the outside diameter of the
piston at the piston skirt.
Measurement should be made at a
point 17 mm (0.67 in) above the bot-
tom edge of the piston. Place the
micrometer at right angles to the piston
pin.
Piston maximum diameter subtracted
from minimum cylinder diameter gives
piston clearance. If beyond tolerance.
hone cylinder to tolerance or bore to
next oversize and fit oversize piston.
1. 17 mm (0.67 in)
Piston clearance:
Minimum ........ 0.055 mm (0.0022 in)
Maximum ....... 0.060 mm (0.0024 in)
Piston oversize:
73.25 mm (2.884 in)
73.50 mm (2.894 in)
73.75 mm (2.904 in)
74.00 mm (2.913 in)
10. Piston ring inspection
b. Measure ring end gap in free position. If
beyond tolerance. replace ring set.
Ring end cap. free
Approx. 8 mm (0.31 in)
c. Push the ring into the bore and check
end gap clearance with a feeler gauge.
If beyond tolerance. replace ring set.
Ring end gap. installed
Minimum ............. 0.30 mm (0.012 in)
Maximum ............ 0.50 mm (0.020 in)
a. Check rings for scoring any severe
scratches and noticed. replace ring set.
11. Piston installation
1. Piston head
<D
/11111/11111(5111111111111
________ ' l ~ ~ ______ ~
'11111111111JJ1177777171JI
@
2. Piston bottom 3. Piston ring
210
a. Install the piston rings as illustrated.
b. During reassembly. coat the piston ring
grooves. piston skirt areas. piston pin.
and bearing with two-stroke engine oil.
c. Install new piston pin clips and make
sure they are full-seated in their grooves.
NOTE:-------------------------
Take care during installation to avoid
damaging the piston skirts against the
crankcase as the cylinder is installed. Be sure
the arrow stamped on the piston crown
points forward.
12. Cylinder inspection
a. Inspect the cylinder walls for scratches.
If vertical scratches are evident. the
cylinder wall should be rebored or the
cylinder should be replaced.
NOTE:--------------------------
Cylinder size mark is stamped upper part of
the intake port.
b. Measure cylinder wall wear as shown. If
wear is excessive. compression pres-
sure will decrease. Rebore the cylinder
wall and replace the piston and piston
rings. Cylinder wear should be
measured at three depths with a
cylinder bore gauge. (See illustration)
2-11
1981 SR540E
2 ......... ......
.....
----------
3
------
Standard Wear limit
Cylinder bore
73.02 mm 73.05 mm
in) (2.876 in)
Cylinder taper
0.05 mm
-
(0.002 in)
Cylinder 0.01 mm
-
out-of-round (0.004 in)
If the cylinder wall is worn more than
wear limit. it should be rebored.
13. Cylinder installatior
a. Install a new cylinder base gasket.
b. Install cylinder with one hand while
compressing piston rings with other
hand.
NOTE:------------------------
Make sure the rings are properly positioned.
1981 SR540E
c. Working in a crisscross pattern, tighten
the cylinder nuts in two steps.
Cylinder holding nut torque:
2.5 m-kg (18 ft-Ib)
14. Cylinder head inspection
a. Remove spark plug.
b. Using a rounded scraper, remove
carbon deposits from combustion
chamber. Take care to avoid damaging
spark plug threads. Do not use a sharp
instrument. Avoid scratching the al-
uminum.
15. Cylinder head installation
Install cylinder head gasket and cylinder
head. Working in a crisscross pattern,
tighten head nuts in two steps.
Head nut torque:
2.5 m-kg (18 ft-Ib)
16. Intake manifold installation
a. Clean the mating surfaces of cylinder,
reed valve and intake manifold.
b. Coat the mating surfaces of cylinder,
reed valve and intake manifold with
Three Bond #50 and install new intake
manifold gaskets.
212
c. Install the reed valve and intake
manifold.
Tightening torque:
1 .0 m-kg (7 ft-Ib)
NOTE:------------------------
For reed valve inspection, see "3-2. REED
VALVE"
17. Exhaust pipe installation
Remove the carbon deposits from ex-
haust pipe. Inspect the exhaust gasket
for damage and replace it as required.
Install the exhaust pipe with gasket.
Tightening torque:
2.3 m-kg (16.5 ft-Ib)
18. Install air shroud.
Tightening torque:
0.6 m-kg (4 ft-Ib)
B. Oil pump
1. Minimum pump stroke checking and ad-
justment.
Normally the checking the adjustment
of the pump stroke are not required, but
if any sign of trouble resulting from an
incorrect minimum pump stroke is
noticed (e.g., excessive engine oil con-
sumption or engine proceed as
follows:
a. Remove the oil pump assembly from
the engine.
b. Turn the oil pump worm wheel until
the pump plunger moves fully out and
away from the pump body to its ou-
termost limit.
c. Measure the gap with the thickness
gauge between the raised boss on the
pump adjust pulley and the adjust plate.
1. Adjust plate
2. Adjust pulley
3. ~ i n i m u m pump stroke
Minimum pump stroke:
0.20,...... 0.25 mm
. (0.0079,...... 0.0098 in)
d. If clearance is not correct, remove the
adjust plate lock nut and the adjust
plate.
e. Remove or add an adjust shim as re-
quired.
2-13
1981 SR540E
1. Adjust shim
f. Reinstall adjust plate and lock nut.
Tighten the lock nut. Re-measure gap.
Repeat procedure as required.
2. Oil pump drive case installation
Coat the pump drive gear with grease.
And install the pump drive case.
Recommended grease:
Low temperature grease
(Esso Beacon 325 or Aeroshell grease
#7A)
Pump case tightening torque:
1 .0 m-kg (7 ft-Ib)
3. Install pump wire, pump case and oil de-
livery pipe.
CAUTION: ---------...,
Before installing pump wire and pump
case, apply grease to the pump pulley
thoroughly.
Recommended grease:
Low temperature grease
(Esso Beacon 325 or Aeroshell
grease #7A)
4. Air bleeding (After remounting engine)
The oil pump and delivery lines must be
bled on the following occasions:
Setting up a new machine out of the
crate.
Whenever the oil tank has run dry.
Whenever any portion of the oil pump
system is disconnected.
1981 SR540E
a. Bleeding the pump case and/or oil pipe.
1) Remove the oil pump bleed screw.
1. Bleed screw
2) Keep the oil runnin,g out until air bub-
bles disappear.
3) When air bubbles are expelled com-
pletely, tighten the bleed screw.
NOTE:-----------------------
Check the bleed screw gasket, and if dam-
aged, replace with a new one.
b. Bleeding the pump distributor and/or
delivery pipe.
1) Start the engine.
2) Pull the pump wire all the way out to
set the pump stroke to a maximum.
1. Pull
2. Pump wire
NOTE:------------------------
It is difficult to bleed the distributor com-
pletely with the pump stroke at a minimum,
and therefore the pump stroke should be set
to a maximum.
214
3) Keep the engine running at about 2,000
r/min for two minutes or so, and both
distributor and delivery pipe can be
completely bled.
5. Cable adjustment (After remounting
engine)
a. Adjust throttle cable free play.
(See 3-1-A. Carburetor tuning)
b. Pull the oil pump cable outer tube
toward the oil pump and adjust the gap
between the adjuster and the outer tube
to specification,
Play: 25 1 mm (0.98 0.04 in)
c. After adjusting, don't forget to tighten
the lock nut.
1. Play
2. Adjuster
3. Lock nut
C. Flywheel magneto
(For inspection, refer to "6-1-G. Pulser and
charge coil test" and "6-2-C. Lighting
circuit test",)
Inspection
Check the flywheel magneto for any loose-
ness, If it is loose, retighten to the following
torque and apply an adhesive,
Tightening torque:
Weight ring and ring gear stay:
1 ,0 m-kg (7,2 ft-Ib)
Flywheel magneto and ring gear stay:
1.5 m-kg (10.8 ft-Ib)
Tightening torque:
1.0 m-kg (7.2 ft-Ib)
Tightening torque:
1.5 m-kg (1 O.S ft-Ib)
@ : LOCKTITE LOCK "n" SEAL (adhesive)
1. Weighr ring 4. Hexagon socket head bolt
2. Ring gear stay 5. Solt
3. Spring washer 6. Spring washer
1. Install woodruff key.
2. Install flywheel base.
Flywheel base tightening torque:
0.65 m-kg (5 ft-Ib)
3. Install flywheel using sheave holder.
Too name Tool No:
Sheave holder 90890-01701
NOTE:--------------------------
Make sure woodruff key is properly seated in
keyway of crankshaft. Carefully install fly-
wheel while taking care so it aligns with
woodruff key.
Flywheel nut torque:
7.3 m-kg (53 ft-Ib)
4. Adjust ignition timing.

Whenever the flywheel magneto is re-
moved, ignition timing must be reset.
(Refer to 6-1-C. Ignition timing)
2-15
D. Cooling fan
1. Inspection
1981 SR540E
a. Check the fan shaft bearings for
damage. If damaged, replace.
b. Check the cooling fan for damage. If
damaged. replace.
c. Check the fan belt for damage and
wear. If worn excessively. replace.
2. Installation
a. Install the cooling fan assembly and fan
driven pulley assembly.
Driven fan pulley securing nut torque:
4.3 m-kg (31.1 ft-Ib)
NOTE:-------------------------
For shim installation. see fan tension ad-
justment of next section.
b. Install the fan case assembly.
Tightening torque:
2.3 m-kg (16.5 ft-Ib)
c. Install the fan drive pulley with fan
bent.
1981 SR540E
d. Install the starter pulley.
e. Install the fan case cap.
Fan Case Assembly
14
2
Tightening torque:
2.3 mkg (16.6 ft-Ib)
Tightening torque:
4.3 m-kg (31 ft-Ib)
11 9
10
7
8
7
5
5
216
12
Tightening torque:
2.3 m-kg (16.5 ft-Ib)
Ref. No. Description a'ty Remarks
Fan case
2 Bearing (B6203) 2
3 Circlip
4 Plate washer
5 Fan
6 Woodruff key
7 Pulley 2 2
8 Claw washer
9
Spring washer
1 UR
1
10
11
12
+ +
Plain washer
Nut
Belt
Pulley 1
Fan case cover
7
Tightening torque:
4.3 m-kg (31 ft-Ib)
11
3. Fan belt tension adjustment
The fan belt tension should be checked
by pushing the belt 8 mm (0.31 in) at its
center.
If the tension is less than the specified
value. adjust the fan belt.
Fan belt tension:
New belt (preset tension)
6.5 f""'oJ 8.5 kg/8 mm
(14.3 f""'oJ 18.7 Ib/0.31 in)
Normal
4f""'oJ 6 kg/8 mm
(8.8 f""'oJ 13.2 Ib/0.31 in)
a. Remove the fan drive pulley and the fan
belt.
b. Remove the fan driven pulley.
c. Remove or add adjusting washers as re-
quired.
Washer q'ty Decrease
--
Increase
Belt tension Increase
--
Decrease
Washer parts No. Thickness
90214-17017 0.5 mm (0.02 in)
90214-17018 1.0 mm (0.04 in)
2-17
1981 SR540E
NOTE:--------------------------
Take care so that adjusting washers are not
lost.
d. First. install the fan driven pulley.
Next. install the fan drive pulley with fan
belt.
Tightening torque
Fan driven puiiey 4.3 m-kg (31.1 ft-Ib)
Fan drive pulley 2.3 m-kg (16.5 ft-Ib)
CAUTION: ----------,
Before tightening fan driven pulley
securing nut, do not install fan belt.
e. Check the fan belt tension
If the tension is not correct. readjust the
belt tension by repeating the procedures
a. from d. above. until tension is correct.
f. After adjusting fan belt tension correctly
tighten the fan driven pulley. securing
nut. spring washer and plain washer.
1. Fan shaft 3. Spring washer
2. Plain washer 4. Nut
1981 SR540E
E. Starter
1. Install the starter spring in the starter
case.
NOTE:------------------------
1. It is necessary to wind the spring to a
small size before installing it in the
starter case.
2. Be careful' not to install the spring in a
wrong way.
3. Hook the loop on the outer end of the
spring onto the spring hook in the star-
. ter case. Then thoroughly grease the
spring.
2. Wind the starter rope around the sheave
drum. and put it into the starter case.
Hook the knot on the rope end onto the
cut in the sheave drum (as illustrated).
and wind the rope around the sheave
drum in the direction of the arrow. leav-
ing about 370 mm (14.6 in).
The other end of the rope is connected
to the starter handle.
370mm
3. Bring the rope end out of the cut in the
sheave drum. and turn the sheave drum
4 turns counterclockwise to give the
starter spring preload. Pull the starter
2-18
handle and release it. making sure that
the starter handle returns to the housing
rope eye.
4. Place the drive pawl. return spring. drive
plate spring. drive plate and tighten the
thrust washer and nut.
NOTE:-------------------------
Grease the pivot of the drive pawl.
Tightening torque:
1.0 m-kg (7 ft-Ib)
5. After the completion of assembly. check
the starter for smooth operation.
Pull out the starter rope about 80 roo.J
130 mm (3 roo.J 5 in). and make sure that
the starter pawl moves out of the drive
plate.
1. Drove plate spring
2. Drive pawl
3. Return spring
F. Engine remounting
Install the engine as follows:
Engine
Engine mounting nuts
Manual starter handle
Magneto lead wire
Tachometer cable
Carburetor
2-19
1981
6. Install the starter assembly on the fan
case.
Tightening torque
0.7 m-kg (5.0 ft-Ib)
NOTE:-------------------------
Refer to .. 4-1-A. Sheave adjustment".
CAUTION: ----------...
Take care not to pinch the wire and
pipes between the engine and frame.
NOTE:--------------------------
For adjusting. see "3-1, Carburetor",
For routing. see CABLE ROUTING
DIAGRAM.

By turning out the throttle lever 2 or 3
turns, make sure it operates correctly.
1981 SR540E
Pulse pipe
Fuel pipe
Oil pipe
Muffler
Primary sheave
V-belt
Snowmobile

2-20
CAUTION: ----------,
The oil pipe, in which the oil filter is in-
stalled, must be correctly connected to
the oil pump.
NOTE:------------------------
After installing oil pipe, the autolube system
must be bled. (Refer to 2-2-8-4. Air bleeding)
NOTE:------------------------
Refer to "4-1-8. Primary sheave".

For inspection, see "4-1-C. V-belt".
1981 SR540E
CHAPTER 3. CARBURETION
3-1. CARBURETOR .............................................................................................................. 3-2
A. Carburetor tuning ................................................................................................. 3-2
B. Overhauling ........................................................................................................... 3-5
C. Troubleshooting ................................................................................................. 3-10
3-2. REED VALVE ............................................................................................................... 3-12
3-3. FUEL PUMP ................................................................................................................ 3-12
3-4. SILENCER JOINT ....................................................................................................... 3-13
CHAPTER 3. CARBURETION
3-1. CARBURETOR
A. Carburetor tuning
1. Standard specification
The carburetor is set at the factory to
run at temperatures of OC to -20C
(32 F to - 4 F) at sea level. If the
machine has to be operated under con-
ditions other than specified above. the
carburetor must be reset as required.
Special care should be taken in carbure-
tor setting so that pistons will not be
holder or seized.
Main jet #150
Power jet #150
Slow jet #92
Pilot screw 2-1/4 turns out
Starter jet #160
15 +2 mm
Float height -3+
0
.
079
in)
(0.59 -0.118
Idling engine speed 1.500 r/min
CAUTION: -----------.
If the air silencer box is removed from
the carburetors, the change in intake
pressure will create a LEAN MIXTURE
that may result in severe engine
damage. The air silence box has no
effect on performance characteristics
and it must be secured to the carburetor
during carb tuning and adjustment. It
must always be in place when the
engine is operated. Examine the
silencer regularly for cleanliness and
freedom from obstruction.
2. Carburetor cable adjustment
a. Throttle cable adjustment
Check throttle cable free playas
specified when throttle closed (idling
throttle).
Free play:
1.0'" 2.0 mm (0.04", 0.08 in)
3-2
If free play is not correct. loosen the
throttle cable securing screw and adjust
throttle cable. After adjusting. be sure to
tighten the screw prO.l?erly.
Throttle cable securing screw
tightening torque:
0.4 m-kg (3.0 ft-Ib)
1. Screw
WARNING: -----------,
Throttle cable must not be lubricated in
any way. It must be routed correctly to
avoid throttle problems that may lead to
an unsafe condition during operation.
b. Starter cable adjustment
Pull the starter cable outer tube upward.
and adjust the free play between the
outer tube end and adjuster to specifi-
cation by turning the adjuster. After the
adjustment. tighten the lock nut and re-
place the rubber cap to keep the lock
nut free from dust and water.
NOTE:------------------------
Starter cable free play must be adjusted after
the cable is correctly rounted. (Refer to wire
routing diagram.)
Lock nut tightening torque:
0.08 m-kg (0.6 ft-Ib)
0.5 - 1.5 mm (0.02 - 0.06 in)
1. Adjuster
2. Lock nut
Free play between outer tube end
and adjuster:
0.5,...., 1.5 mm (0.02,...., 0.06 in)
c. Oil pump cable adjustment
Refer to "2-2-8-5. Pump cable adjust-
ment".
3. Low speed tuning
The carburetor is built so that low speed
tuning can be done by adjusting the
throttle stop screw and pilot screw.

Always install air silencer before mak-
ing tuning adjustment. High perform-
ance tuning cannot be done without the
silencer. Engine damage may result
from attempting to tune without the
silencer installed.
a. Tighten the pilot screw lightly. and back
it out from its lightly seated position.
Standard pilot screw (turns out):
2-1/4 turns out
3-3
1981 SR540E
1. Pilot screw
b. Start the engine by pulling the starter
lever. and fully warm up the engine.
c. Set the throttle stop screw so that the
engine idles at the specified speed.
Idling engine speed: 1.500 r/min
1. Throttle stop screw
NOTE:------------------------
If the engine shows poor performance in ele-
vation or in an extremely cold area or when it
is suddenly accelerated or run at low speeds.
proceed as follows:
1. Turn the pilot screw in and out 1/4 turn
or less each time. and set it in a position
where the engine idles faster.
2. Follow step C" in the preceding para-
graph.
4. Main circuit tuning
No adjustment is normally required. but
adjustment is sometimes necessary de-
pending on tempeatures and/or alti-
tude. (Refer to Main jet setting chart.)
1981 SR540E
[Main jet setting chart]
~
-30C -20C
Altitude
(-22F) (-4F)
~
Seal level
1--(#155)
-
~ 600 m (2000 ft)
I-- #155
-
-
-
~ 1200 m (4000 ft)
t---#150 ..
- ~ 1800 m (6000 ft)
r--- #145
-
- ~ 2400 m (8000 ft)
r---#140 ..
- ~ 3000 m (10000 ft)
-#135
-
a. Run the engine at high speeds, and
make sure the engine operates smooth-
ly.
c. Check both spark plugs and, depending
on the discoloration of each spark plug,
the main jet should be adjusted on the
basis of the following table. (Refer to
spark plug color samples.)
Standard main jet: #150
Spark plug color
No.1 Good (Carburetor is tuned properly.)
Bad (Mixture is too rich.)
No.2 Replace main jet with one-step
smaller one.
Bad (Mixture is too lean.)
No.3 Replace main jet with one-step
larger one.
Bad (Due to too lean a mixture, piston
is holder or seized.)
No.4 Replace the piston and spark plug.
Tune the carburetor again, starting
with low-speed tuning.
Bad (Due to too lean a mixture, the
engine knocks.)
Check the piston for holes or seizure.
No. 5
Check the cooling system, gasoline
octane rating and ignition timing. After
replacing the spark plug, tune the
carburetor again, starting with
low-speed tuning.
-10C OC 10C 20C
(14F) (32F) (50F) (68F)
#150
#150
#145
#140
#135
#130
No. 6
-
---#145-
-
-
#145
-
-
-
#140
-
..
-
#135
-
-
-
#130
-

-
#125 ..
Bad (Due to lean a mixture, the spark
plug melts.)
Check the piston for holes or seizure.
Check the cooling system, gasoline
octane rating and ignition timing. After
replacing the spark plug with colder
type, tune the carburetor again,
starting with low-speed tuning.
1. Main jet
3-4
WARNING: ------------,
Never remove the main jet cover bolt
while the engine is hot. Fuel with flow
out of the float chamber which could
ignite and cause damage to the snow-
mobile and possible injury to the me-
chanic.
Place a rag under the carburetor so fuel
does not speed, Place the main jet
cover bolt in a clean place. Keep away
from fire. After assembling the carbure-
tor, firmly tighten the rubber joint screw.
Make sure the throttle outer tube is in
place and the throttle cable moves
smoothly. Clean the carburetor and
allow it to dry.
B. Overhauling
6
1. Disassembly
1._14
I=--15
~ ' 6
~ - 2 1
18----9
1 9 ~
4-
20
a. Remove the carburetor from the engine.
and discor;mect the control cables as fol-
lows:
1) Loosen the throttle cable holder screw.
2) Remove the pump cable adjuster from
the stay plate. and remove the pump
cable from the lever.
3) Remove the cap from the carburetor.
together with the starter valve. and dis-
connect the starter cable.
1. Throttle cable
2. Pump cable
3. Starter cable
3-5
1. Carburetor ass'y
2. Spring
3. Hose
4. Slow jet
5. Float
6. O-ring
7. Float cha mber body
B. Starter plunger cap cover
9. Cable adjuster
10. Starter plunger .cap
11. Nut
12. Starter plunger spring
13. Starter plunger
14. Valve seat ass'y
15. Clip
16. Float pin
17. Main jet
lB. O-ring
19. Drain bolt
20. Pan head screw with Vl(asher
21. Flathead screw
22. Spring
23. Adjust screw
24. Bolt with washer
25. Stay
26. Bolt
27. Pan head screw
2B. Spring
1981 SR540E
1981 SR540E
CAUTION: ---------..,
When removing the starter cable, take
care so that the rubber cap, coil spring
and starter cable do not fall off or are
not lost. Also use special care not to
scratch the rubber seat surface.
b. Float chamber
1) Remove the four screws. together with
the float cha mber.
2) Remove the main jet cover bolt.
together with the O-ring.
c. Carburetor body
1) Remove the screw. together with the
float. float arm. and fuel valve assembly.
2) Remove the slow jet and main jet.
3) Remove the pilot screw. together with
the coil spring.
4) Remove the throttle stop screw,
together with the coil spring.
5) Remove the stay plate. together with
the bolt.
3-6
NOTE:-----------------------
1. Hook the clip orito the float arm. and
remove the fuel valve while taking care
not to drop it.
2. The fuel valve plays a very important
role. so special care should be taken so
that the rubber part of the needle is not
scratched.
3. Use care to keep the plastic parts free
from shocks. because they could be
damaged easily.
4. Never wash the rubber parts with al-
cohol or lacquer thinner. Use gasoline.
CAUTION:-------------------,
Never attempt to disassemble the fol-
lowing parts.
1) Throttle valve
2) Throttle shaft
Reason:
1) The threaded portion of the screw is
clinched after the throttle valve is in-
stalled to the throttle shaft so that
the screw will not come loose.
2) The bypass hole is precision-
machined so that the correct dist-
ance can be maintained from the
end of the throttle valve. Therefore,
if the throttle valve is once disas-
sembled, it is difficult to reproduce
the original dimensions, and thus
engine performance will be ad-
verselyaffected.
':::.1
"
II
II
II
II
II
II
II
II
II
____ ,...L... ___ _
2. Inspection

1) Before checking, thoroughly clean
all parts in gasoline, and blow the
jets, float chamber and fuel pas-
sages in the carburetor body with
compressed air so the dust and dirt
can be removed.
2) When washing the carburetor body
and float chamber, be sure to use a
soft brush.
3) When decarbonizing the throttle
valve and its adjacent area, take
special care not to scratch the throt-
tle valve and throttle bore.
4) Never use a hard wire or the like
when cleaning jets. It could scratch
or deformed jet holes, thus adverse-
ly affecting fuel consumption.
5) Use care so that all parts are not de-
formed.
II
II
1 Power air jet (Body jet)
2. Power nozzle
3. Pilot screw
4. Main air jet (Body jet)
5. Power jet (Body jet)
6. Main jet
7. Slow jet
8. Starter jet
9. Slow air jet


@
I 11
I II
:: @ CV II

3-7
1981 SR540E
a. Float chamber
1) Check the starter jet and power jet
circuit for clogging with dust. If clogged,
blow them off with compressed air.
NOTE:--------------------------
If the starter jet is clogged, fuel flow will be
hindered and hard starting will result.
1. Starter jet
2. Power jet circuit
2) Blow the float chamber clean of dust
and dirt with compressed air.
b. Carburetor body
1) Clean the fuel valve seat while taking
care not to scratch the seat. and blow it
with compressed air. Check the end of
the valve needle for damage. If damag-
ed, replace the valve needle. If the valve
seat is damaged, the body should be re-
placed.

A scratched seat could result in the
overflow of fuel.
2) Check the power jet for clogging. If
clogged, blow it with compressed air.
3-8
1. Power jet 3. Slow circuit
2. Main circuit 4. Starter emulsion tube
NOTE:-------------------------
If this jet is clogged, engine power loss will
result at high speed operation.
3) Clean the main circuit. slow circuit and
starter emulsion tube, and blow them
off with compressed air.
4) Clean the main air jet. slow air jet.
starter circuit.' and air vent. and blow
them off with compressed air.
1. Main air jet 2. Slow air jet 3. Starter circuit
5) Blow the pilot screw clean of dust and
dirt with compressed air.
6) Check the end of pilot screw for carbon.
Check the tapered portion and threaded
portion for damage.
7) Blow the main jet and slow jet clean of
dust and dirt with compressed air.
3. Reassembly and adjustment
CAUTION: ------------,
1) Wash all parts in clean gasoline be-
fore assembling.
2) Always use new O-rings.
3) Make sure moving parts rotate or
slide smoothly.
4) Apply grease to contact surfaces of
the throttle shaft.
a. Carburetor body
1) Install the throttle stop screw and coil
spring.
Adjustment: See "Low speed tuning."
2) Install the main jet and slow jet.
3) Install the pilot screw and coil spring.
Adjustment: See "Low speed tuning."
NOTE:--------------------------
The pilot screw must not be tightened exces-
sively.
4) Install the stay plate.
5) Install the clip to the needle valve, and
put it into the valve seat. Insert the arm
pin into the float. install the float. and
secure the arm pin with screw.
NOTE:--------------------------
1. Don't forget toinsert the float arm tang
into the clip attached to the needle
valve.
2. After assembling, take care not to allow
dust and dirt to enter.
3-9
1981 SR540E
6) Float level.
(1) Reinstall components, except for
the float chamber.
(2) Incline the carburetor at 20 "" 30
(so that the end of the float valve
does not hang down of float
weight). and measure the distance
from the mating surface of the
float chamber and carburetor to
the top of the float using a gauge.
Float level:
1 5 _+ 3
2
mm (0.59 + 0.079 in)
-0.118
NOTE:--------------------------
The float should be just resting on, but not
depressing the spring loaded inlet needle.
1. Float level
(3) If the float level is not within the
specified range, check the valve
seat and needle valve. And replace
any damaged part.
(4) If any part is in good condition but
float level is not within the speci-
fied range, correct float level by
bending the float arm tang slightly.
1981 SR540E

After installing the carburetor body, be
sure to apply grease to the following
parts as an anti-freeze measure:
Recommended low
temperature grease:
ESSO Beacon 325 or
Aero Shell #7
1) Throttle return spring, throttle shaft
collar.
2) Space between carburetor body and
throttle shaft (at 2 places).
3) Throttle lock washer, E-clip.
4) Wire holder attached to the throttle
valve.
b. Float chamber
1) Screw the main jet cover bolt (with 0-
ring) into the float chamber.
2) Install the O-ring to the float chamber,
and install it to the carburetor body.

Always use a new O-ring for reassembly.
c. Install the air bent pipe in place.
d. Push the carburetor into the rubber
joint. and secure it with the band.
1) Before installing the carburetor on the
engine, connect the control cables in
the reverse order of disconnection. Keep
the starter valve free from dust and dirt
during this operation.
2) Insert the end of throttle wire into the
hole in the throttle lever, adjust the play
of cable, and secure it with screw. (See
"Throttle cable adjustment.")
3-10
NOTE:------------------------
By turning the throttle lever to the full-open
position two or three times, make sure it
operates correctly.
3) Make sure the starter lever is fully pu-
shed in, and install the starter cable and
spring to the starter valve, and install
the valve in the carburetor.
Adjust the starter cable. (See "Starter
cable adjustment.")
NOTE:------------------------
By pulling the starter lever two or three times
after installation of the starter cable, check
the operation of the starter valve.
4) Install the fuel pipe to the carburetor.
Next, install the clip firmly.
C. Troubleshooting
This troubleshooting guide relates only to the
carburetor. Making an adjustment of the
carburetor, check the engine and electrical
system. If no defect is found, consult this
troubleshooting guide.

1) When disassembling the carburetor,
use care so that parts don't fall off or
are not lost. Also don't strike the
carburetor with a hard tool. Dust
should be blown off with com-
pressed air.
2) When installing the throttle cable,
make sure the throttle valve can be
fully opened and closed, and make
an adjustment.
1981 SR540E
Trouble Checkpoint Remedy Adjustment
Hard starting Insufficient fuel Add gasoline
Excessive use of starter Clean spark plug Return starter lever to its home
(Excessively opened choke) position.
Fuel passage is clogged or Clean Parts other than carburetor
frozen Clogged fuel tank air vent. clogged
fuel filter. or clogged fuel passage
Carburetor
Clogged or frozen air vent clogged
valve
.
If water collects in float chamber
clean
(Also check for ice.)
Overflow Correct See "Overflow"
Poor idling Improper idling speed Tighten pilot screw lightly. and check
adjustment throttle opening. If incorrect. back it
(Relative troubles) Pilot screw adjustment Adjust idling speed out specification. Start the engine

Poor performance at low and turn pilot screw in and out
speeds 1/4 turn each time. When the engine

Poor acceleration runs faster. back out throttle stop

Slow response to throttle screw so the engine idles at

Engine tends to stall specified speed.
Throttle stop screw Adjust Tightened to much-Engine speed
is higher.
Backed out too much-Engine does
no idle.
Damaged pilot screw Replace pilot screw
Clogged bypass hole Clean
Clogged or loose slow jet Clean and retighten Remove slow jet. and blow it out
with compressed air.
Air leaking into carburetor joint Retighten band screw
Defective starter valve seat Clean or replace
Overflow Correct See "Overflow."
Poor performance at Clogged or loose slow jet Clean and retighten Remove slow jet. and blow it out
mid-range speeds with compressed air.
(Relative troubles)

Momentary slow response
to throttle

Poor acceleration Lean mixtures Overhaul carburetor See "Overflow."
Poor performance at normal Clogged air vent Clean Remove the air vent pipe.
speeds and clean.
(Relative troubles)
Clogged or loose main jet Clean and retighten Remove main jet. and blow it out

Excess fuel consumption
with compressed air.

Poor acceleration
Overflow Check float and float valve See "Overflow"
and clean
Poor performance at high Starter valve is left open Fully close valve Return starter lever to its home
speeds position
(Relative trouble)
Clogged air vent Remove and clean

Power loss

Poor acceler'ltion
Clogged or loose main jet Clean and retighten Remove main jet. and clean with
compressed air. then install.
Clogged power jet Clean
Clogged fuel pipe Clean or replace
Dirty fuel tank Clean fuel tank
Air leaking into fuel line Check jOint and retighten
Low fuel pump performance Repair pump or replace
Clogged fuel filter Replace
Clogged silencer outlet Check for ice. and remove
3-11
1981 SR540E
Trouble Check point
Abnormal combustion Lean mixtures
(Mainly backfire)
Dirty carburetor
Dirty or clogged fuel pipe
Overflow Clogged air vent
(Relative troubles)
Clogged float valve
Power idleing
Poor performance at low.
mid-range. and high
Scratched or unevenly worn
speeds
float valve or valve seat
Excessive fuel consumption
Hard starting
Broken float
Power loss
Poor acceleration
I ncorrect float level
Worn float tang
Worn arm pin

Deformed float arm
3-2. REED VALVE
1. Remove the reed valve assembly.
(Refer to 2-1-F. Engine disassembly)
2. Inspect rubber carburetor joint for signs
of weathering. cracking or other deterio-
ration.
3. Inspect reed petals for signs of fatigue
and cracks. Reed petals should fit flush
or nearly flush against neoprene seats.
If in doubt as to sealing ability. apply
suction to carburetor side of assembly.
Leakage should be slight.
4. Check valve stopper clearance. If be-
yond tolerance. replace valve stopper.
Valve stopper clearance:
9.7 0.3 mm (0.38 0.012 in)
Remedy Adjustment
Clean carburetor and adjust
Clean carburetor
Clean or replace fuel pipe
Clean
Disassemble and clean Clean while taking care not to
scratch valve seat.
Clean or replace float valve Valve seat is press-fitted to body.
and valve seat So body must be replaced if seat is
damaged.
Replace float
If not within the specified
range. check the following parts
and replace any defective part
Replace float Replace float assembly.
Replace arm pin
Replace float
3-12
5. Check reed valve for beinding. If beyond
tolerance. replace reed valve.
Reed valve beinding limit:
0.6 mm (0.024 in)
6. If disassembly of the reed valve as-
sembly is required. proceed as follows:
a. Remove Phillips screws securing stop-
per plate and reed to reed block. Handle
reed carefully. Avoid scratches and do
not bend. Note from which side of the
reed block the reed and stopper plate
were removed. Re-install on same side.
NOTE:--------------------------
During reassembly. note the cut in the lower
corner of the reed and stopper plate. Use as
aid to direction of reed installation.
b. During reassembly, clean block, reed
and stopper plate throughly. Apply a
holding agent. such as "Lock-Tite" to
threads of Phillips screws. Tighten each
screw gradually to avoid warping.
Torque: 0.08 m-kg (0.6 ft-Ib)
7. During reassembly of the reed valve
assembly and manifold, install new gas-
kets and torque the securing bolts
gradually and in a crisscross pattern to
the proper torque.
Reed valve securing bolt torque:
1.0 m-kg (7 ft-Ib)
3-3. FUEL PUMP
Check to see if fuel moves from tank to
carburetor, and if any fuel leaks from pipe
joints or fuel pump body.
Replace fuel pump assembly as required.
1. Fuel pump
3-13
1981 SR540E
3-4. SILENCER JOINT
1. To protect the silencer joint against de-
formation, a steel band is used.
-CAUTION: -----------
A deformed silencer joint will result in
an imbalance of temperatures of the
right and left spark plugs. Don't forget
installing the band.
1. Silencer joint
2. Band
2. Assembly procedure
a. The band has six holes. Install the band
so that its largest hole fits over the
largest projection on the silencer joint
and other small five holes over the pro-
tuberances one by one.
NOTE:
Pull the projection using pliers so that the
band tightly fits the silencer joint.
b. Cut off the tip of the projection.
1981 SR540E
CHAPTER 4. POWER TRAIN
4-1. DRiVE ............................................................................................................................. 4-2
A. Sheave adjustment .............................................................................................. 4-2
B. Primary sheave ..................................................................................................... 4-3
C. V-belt. ..................................................................................................................... 4-8
D. Secondary sheve .................................................................................................. 4-8
E. Chain housing ................... , .................................. .............................................. 4-12
F. Front axle ............................................................................................................ 4-16
4-2. BRAKE ......................................................................................................................... 4-19
A. Disassembly ....................................................................................................... 4-19
B. Inspection ........................................................................................................... 4-19
C. Reassembly ................................................................................................ ... 4-19
D. Adjustment ........................................................................................................ ,4-19
4-3. SUSPENSiON ............................................................................................................. 4-20
A. Removal ............. : ................................................................................................. 4-20
B. Inspection ................................................................................................. ,4-21
C. Slide rail suspension adjustment ................................................................... 4-22
D. Installation ......................................................................................................... 4-24
4-4. DRIVE TRACK ............................................................................................................ 4-24
A. Removal ............................................................................................................. 4-24
B. Inspection .......................................................................................................... 4-24
C. Installation ........................................................................ , ................................. 4-24
D. Adjustment ........................................................................................................ 4-25
1981 SR540E
CHAPTER 4. POWER TRAIN
4-1. DRIVE
A. Sheave adjustment
Use the sheave gauge to check the following:
Center to center distance between the
primary and secondary sheaves.
Off-set between the inside edge of the
sheaves.
Alignment of sheaves.
r-----1 CD----1
1. Sheave distance 2. Sheave off-set
in)
11 0.5 mm (0.433 0.020 in)
Sheave distance check
1. Sheave gauge
Sheave offset/alignment check
Place the sheave gauge against inner sur-
faces of the primary fixed sheave and the
secondary sliding sheave. If t,/le sheave
gauge contacts the sheaves at four points
as illustrated, the offset is correct.
NOTE:-------------
Be sure to remove the V-belt before adjust-
ing the sheave offset.
4-2
1. Sheave gauge
If any of these is incorrect. proceed as fol-
lows:
1. Loosen the engine mounting nuts.
2. Adjust sheave distance, off-set and
alignment by moving the engine back,
forth or sideways.
Tool name Tool No.
Sheave gauge 90890-01702
Sheave distance:
o +0
270 mm (10.63 -0.11 in)
Sheave off-set:
11 0.5 mm (0.433 0.020 in)
NOTE:--------------
If sheave off-set is not adjusted at above pro-
cedure, remove the secondary sheave as-
sembly, and adjust the sheave off-set by
installing or removing the plate washers from
the secondary shaft.
Parts name Thickness
Plate washer (90201-25526) 2 mm (0.08 in)
Plate washer (90201-25527) 1 mm (0.04 in)
CAUTION: ----------,
Must be installed the washers at least 2
pieces (3 mm or more thickness).
3. Tighten the engine mounting nuts.
Tightening torque:
5.2 m-kg (37.6 ft-Ibl
B. Primary sheave
1. Removal
a. Remove the V-belt.
b. Straighten the lock washer tab. and re-
move the primary sheave mounting bolt.
using the sheave holder.
Tool name Tool No.
Sheave holder
90890-01701
1. Sheave holder
c. Remove the primary sheave assembly.
using the primary fixed sheave puller
and sheave holder.
Tool name Tool No.
Primary fixed sheave puller 90890-01897
Primary fixed sheave attachment 90890-01899
4-3
1981 SR540E
1. Primary fixed sheave puller
2. Disassembly
a. Install the sheave sub-assembly tool to
the primary sheave.
Tool name Tool No.
Sheave sub-assembly tool 90890-01858
1. Sheave sub-assembly tool
b. Loosen the six bolts securing the
primary sheave cap and sliding sheave.
c. Remove the sheave subassembly tool.
The primary sheave cap and sliding
sheave can now be disassembled.
3. Inspection
a. Check the tapered ends of the crank-
shaft and primary fixed sheave for
scratches. If scratched unduly. replace.
If scratches are minor. burnish with
emery cloth.
b. Check the primary sheave cap bushing
and sliding sheave bushing for wear. If
beyond tolerance. replace the bushing.
Bushing clearance, limit
Small bushing Large bushing
Inside 0.25 mm (0.01 in) 0.25 mm (0.01 in)
Outside 0.25 mm (0.01 in) 0.25 mm (0.01 in)
1981 SR540E
~
Setting parts
Parts No.
Color code
Spring
Set load
Spring constant
Parts No.
Counter sunk rivet Set holes
Weight Parts No.
N O T E : - - - - - - - - - - - - - - - - - - - - - - ~
If bushing is installed tightly, remove the bu-
shing using the bushing tool.
Tool name Tool No.
Bushing tool 90890-01883
1. Bushing tool
c. Check the compression spring for
fatigue. If excessively fatigued, replace.
d. Check the spider and roller for smooth
movement and wear.
e. Check both sheaves for warping. If
warped, replace.
4. Adjustment
The primary sheave tuning should be
set according to the altitude.
Sea level (Std.)
High altitude
(Up to 1 500m (5000 ftl)
(About 1500m (5000 ft)
or more)
90501-50500 90501-55487
Red Silver-Silver
25 kg 50 kg
1.4 kg/mm 2.0 kg/mm
90261-06015 90261-0601 5
r---
r9\
~
- Rivet
0 '6
No rivet
0
0
8L9-17632-00 8L8-17632-00
44
NOTE:--------------------------
On the sea level (Up to 1500 m). if engine
power is poor with snow condition. adjust
sheave at the high altitude setting.
a. Compression spring
Clutch engagement rpm must be ad-
justed to specification using on optional
compression spring.
b. By changing the position and quantity
of primary weight rivets. the thrust of
weight can be changed, and thus the
engine rpm at which the clutch is shift-
ed can also be changed. (As a result. the
engine rpm at which the clutch is en-
gaged can be changed.)
CAUTION: ------------.
The rivets for three weights must be in
the corresponding positions.
Rivet Shifting rpm
No rivet is in use rpm
increases.
CD

CD
8L9
1
rpm
decreases.
O--CD
O--
4-5
1981 SR540E
5. Reassembly
a. Adjust the slider button-to-guide clear-
ance using shims as required under the
slider button.
Slider button-to-guide clearance:
0", 0.2 mm (0", 0.008 in)
Thickness
Shim (90201-090A4) 0.3 mm (0.012 in)
Shim (90201-097 A8) 0.2 mm (0.008 in)
1981 SR540E
b. Oil the points shown in the illustration.
Do not apply the grease on the portion
of X mark. For other parts. greasing is
unnecessary.
-x Free from oil
- Greasing point

When the bushing is replaced with new
one, apply molybdenum disulfide grease
to bushing lightly. Except for this, don't
grease.
pin is removed for the
greasing, replace it with new one.
c. Install the component parts to the slid-
ing sheave and the sheave cap.
NOTE:------------------------
1. When installing the spider and primary
sheave cap to the primary sliding
sheave. be sure to align the X marks on
the spider and sheave cap with that on
sliding sheave.
4-6
2. When installing the spacer and collar to
the spider. the spacer and the spider
projections must be fitted to the collar
slit.
Lock washer Spacer
-+--+-+-.
o
c. Install the sheave sub-assembly tool
and tighten the cap.
d. Tighten the six primary sheave cap bolts
and remove the sub-assembly tool.
Tightening torque:
1.1 m-kg (8 ft-Ib)
CAUTION: ------------------.......
Make sure that the primary sheave cap
assembly slides in contact with the
fixed sheave boss.
e. With the spider projection being in the
receiving recess in the collar, (on the
sliding sheave side: see photo)
put a mark on the sheave cap in line
with either notch in the other end of
the same collar.
This mark will later serve as an effective
guide for confirmation of corrrect fitting.
4-7
1981 SR540E
f. Clean the oil off the tapered portion of
crankshaft using a lacquer thinner.
No oil
g. Fit the primary sheave assembly to the
tapered portion of crankshaft.
h. Apply engine oil to the threaded portion
of primary sheave bolt and its contact
surface with spring washer.
i. Tighten the primary sheave mounting
bolt, using the sheave holder. Next, lock
the lock washer.
NOTE:
Check the lock washer, and if damaged, re-
place with a new one.
1981 SR540E
Tightening torque:
First tighten the bolt to a torque of
A, then loosen it.
Retighten bolt to a final torque of B.
A: 12 m-kg (87 ft-Ib)
B: 6.5 m-kg (47 ft-Ib)
C. V-belt
Check the drive V-belt for damage and wear.
If the width is less than specified value, re-
place with a new belt.
[ Wear limit: 26 mm (1.02 in)
1. New: 31.5 mm (1.24 in) 2. Wear limit: 26 mm (1.02 in)
D. Secondary sheave
1. Disassembly
a. Apply the brake and remove the secon-
dary sheave mounting bolt.
b. Remove the secondary sheave as-
sembly and plate washers.
c. Remove the circlip and disassemble the
secondary sheave component parts.
4-8
2. Inspection
a. Check the ramp shoes on secondary
sliding sheave for wear. Replace ramp
shoes as required.
b. Check the sheave bushing for wear. Re-
place the sheaves as required.
c. Check torsion spring for fatigue. If ex-
cessively fatigued, replace.
d. Check both sheaves for warpage. If
warped replace.
3. Secondary sheave spring adjustment
It is advisable to change the secondary
sheave setting to correspond to the
course and snow conditions. This is
done by changing the secondary spring
preload.
The spring seat (see illustration) has 4
spring holes. The spring tension (pre-
load) can be adjusted by selecting a
spring in the seat and twisting the seat
to engage the sheave ramps. In this way
the preload can be adjusted in 30
steps.
1981 SR540E
[Secondary spring setting]
Course Trail and tour Lake surface
Setting factor Position of spring seat Twist Position of spring seat Twist
Ice snow Std. Std. No.2 180
0
Packed snow Std. Std. Std. or No.2 Std. or 180
0
Wet snow Std. or No.4 Std. or 240
0
Std. Std.
Std. secondary spring:
PIN: 90508-45286
Color code: Yellow
Std. secondary spring position: NO.3
Std. secondary spring twist: 210
0
a. Secondary spring position
The spring seat is provided with four
holes. Nos. 1 to 4, so that the secondary
spring position can be changed as re-
quired.
A. Spring seat
b. Secondary spring tension
The secondary spring tension can be
changed by moving the spring position
from the free position in order to reset
the clutch shifting RPM as required. The
four holes are spaced at intervals of 30.
Secondary spring
Spring wind
position
No.1
30,150.270
No.2 60,180
No.3 90,210
No.4 0,120,240
4-9
Winding the spring more (e.g., from 30
to 60) will increase the clutch shifting
rpm and vise versa. Snow conditions
will also require a change of the spring
tension in orde to attain the standard
shifting rpm. The spring tension must be
greater on wet snow than on packed
snow, and less tension is needed on icy
snow.
4. Reassembly
a. Grease the secondary shaft. and sliding
sheave boss and mount the sliding
sheave on the shaft.
Recommended grease:
Molybdenum disulfide snowmobile
grease
Secondary Sheave Assembly
7
/ 11
~ / 12
z? . ~ / 14
~ ~ , / 1 3
~ . "" ~ /
~ '
Molybdenum disulfide snowmobile grease
<J1] (Wear-resistant grease)
FWD
I Clearance: 0.1 ~ 1.0 mm
Tightening torque:
6.4 m-kg (46 ft-Ib)
16
10
3
1 . Secondary fixed sheave compo
2. Secondary sliding sheave
3. Lamp shoe
4. Secondary spring seat
5. Plain washer
6. Circlip
7. Secondary shaft
8. Plain washer
9. Washer based bolt
2
5
6
4-11
14
11
10. Plain washer
11. Eccentric bearing
12. Bearing housing
13."Bolt
14. Spring washer
15. Plain washer
16. Collar
17. Torsion spring
Tightening torque:
2.3 m-kg (16.5 ft-Ib)
Tightening torque:
6.4 m-kg (46 ft-Ib)
1981 SR540E
1981 SR540E
E. Chain housing
1. Disassembly
a. Remove the chain housing cap and
drain the chain housing oil.
b. Apply the brake and remove the cotter
pin and the drive sprocket nut and
driven sprocket bolt.
c. Loosen the chain tensioner and remove
the drive. driven sprockets and chain.
d. Remove the bearing inner race securing
screw. and loosen the inner race by
using eccentric bearing installer.
Tool name Tool No.
Eccentric bearing installer 90890-01851
4-12
1. Eccentric bearing installer
e. Remove 3 bolts.
f. Remove the brake caliper assembly.
(Refer to 4-2. Brake section)
g. After removing the suspension assemb-
Iy, remove the two bolts mounting the
chain housing. (Refer to 4-3. Suspen-
sion)
h. Remove the chain housing assembly.
i. Remove the brake disc and key.
j. Remove the secondary shaft complete.
Trail riding
Snow condition ICY Packed Wet
Drive chain sprocket Std. Std. 16
Driven chain sprocket Std. Std. Std.
Chain Oinks) Std. Std. Std.
c. Sprocket ratio and chain link chart
The following sprockets. drive and
driven. and chains are available as op-
tions. The figures in upper lines repre-
ICY
Std.
Std.
Std.
4-13
1981 SR540E
2. Inspection
a. Drive chain
Except in case of oil starvation. the
chain wears very little. If the chain has
stretched excessively and it is difficult
to keep the proper chain tension. the
chain should be replaced.
b. Drive. driven and chain tension
sprockets.
Check sprocket for obvious wear. Re-
place sprocket as required.
c. Bearing selection
Check the chain case bearings and oil
seals for damage. If damaged. replace.
3. Gearing selection
The reduction ratio of driven sprocket to
drive sprocket must be set according to
the snow condition.
Many rough surfaces or unfavorable
snow conditions; the driven/drive
sprocket ratio should be made larger.
Few rough surfaces or better snow con-
ditions; the ratio should be made smal-
ler.
a. Std. reduction ratios
Drive chain sprocket 17 (PIN 878-17682-70)
Driven chain sprocket 31 (PIN 878-47587-00)
Chain (Links) 66 (PIN 94850-35066)
b. A guide to reduction ratios
Lake course
High altitude
(Up to 1500 m or more)
Packed Wet ICY Packed Wet
Std.
16 or
15 15 15
Std.
Std. Std. 33 33 33
Std. Std. Std. Std. Std.
sent the driven/drive sprocket ratios.
while those in lower lines represent the
number of chain links.
1981 SR540E
sprocket 15 16 17
~
PIN 878 PIN 878 PIN 878
Teeth of 17682-50 17682-60 17682-70
driven sprocket
29 1.933 1.813 1.706
PIN 878-47548-90 64 66 66
31 2.067 1.938 1.824
PIN 878-47587-00 66 66 66
33 2.200 2.063 1.941
PIN 888-47587-10 66 68 68
35 2.333 2.188 2.059
PIN 878-47587-20 68 68 68 or 70
Chain links Part No.
64 94890-03064
66 94850-35066
68 94850-35068
70 94850-35070
4. Reassembly
a. Apply a low temperature grease to the
chain housing oil seal lip. Install the se-
condary shaft complete with brake disc.
NOTE:------------------------
Make sure woodruff key is properly seated in
key way of secondary shaft. Install brake disc
so that it aligned with the woodruff key.
b. Use the two bolts to mount the chain
housing to frame.
Tightening torque:
2.3 m-kg (16.5 ft-Ib)
c. Install the brake caliper assembly.
Brake caliper mounting bolt
tightening torque:
4.8 m-kg (35 ft-Ib)
18 19 20 21 22
PIN 878 PIN 878 PIN 878 PIN 878 PIN 878
17682-80 17682-90 17693-00 17693-10 17693-20
4-14
1.611
156
1.722
68
1.833
68
1.944
70
1.526 1.450 1.381 1.318
66 68 68 68
1.632 1.550 1.476 1.409
68 68 68 70
1.731 1.650 1.571 1.500
68 or 70 70 70 70
1.842 1.750 1.667 1.591
70 70 70 or 72 72
d. Install the drive and driven sprockets
with chain.
Place the collar into the drive sprocket.
Tighten the drive sprocket nut and fit a
new cotter pin. Don't forget to bend the
cotter pin's ends. Tighten the driven
sprocket bolt.
Tightening torque:
Drive sprocket nut:
6.0 m-kg (43.5 ft-Ib)
Driven sprocket bolt:
4.8 m-kg (35 ft-Ib)
e. Tighten the bearing inner race by using
eccentric bearing installer.
1. Eccentric bearing installer
f. Tighten the bearing inner race securing
screw.
Tightening torque:
0.6 m-kg (4.5 ft-Ib)
g. Install the gasket and chain housing cap.
Tightening torque:
1.6 m-kg (11.5 ft-Ib)
h. To add gear oil. the filler cap and oil
level screw should be removed.
1. Oil level screw
4-15
1981 SR540E
Fill until oil begins to run out the screw
hole.
Recommended oil:
Gear oil API "GL-3"
SAE #75 or #80
Quantity: 250 cc (8.5 OZ)
After adding oil. be sure to install and
tighten the level screw and filler cap.
i. Drive chain tension adjustment
Remove the lock nut. Turn in the adjust
bolt clockwise finger-tight. Then tighten
the lock nut with a spanner while keep-
ing the adjust bolt steady with the other
spanner.
Chain free play:
8 '""""' 15 mm (0.32 '""""' 0.59 in)
Lock nut tightening torque:
3.5 m-kg (25 ft-Ib)
1. Chain free play
8 ~ 15 mm (0.3 - 0.6 in)
1. Adjusting bolt 2. Lock nut
1981 SR540E
F. Front axle
1. Removal
a. Remove the slide rail suspension as-
sembly. (See 4-3. Suspension)
b. Remove the speedometer gear housing
and the joint.
c. Remove the nut mounting the front axle.
collar. and bearing. (Lock the front axle
by applying the brake.)
d. Remove the chain housing cap.
(Refer to "Chain housing".) Drain oil and
remove the chain driven sprocket.
e. Loosen set bolt CD using a 3 mm hex.
wrench and slide guide wheel . be-
fore pulling out the front axle.
4-16
':1 {r-
11,.1
"I ~ ,
r + ~
'---'"
1. Set bolt 2. Guide wheel
f. To remove the wheel sprocket from the
axle. loosen the collar and push out
using a press.
2. Inspection
Check wheel sprocket for damage and
wear. Replace wheel sprocket as re-
quired.
3. Installation
a. When installing the wheel sprocket to
the front axle. position the wheel
sprockets on the front axle as shown.
Use a press.
FWD
l!
104 mm (4.09 in)
b. Be sure the sprocket teeth are aligned
as shown. After positioning. tighten the
collar and clamp.
Tightening torque:
0.55 m-kg (4 ft-Ibl
c. Apply a low temperature grease to the
front axle. and install the collar. bearing.
belleville washer and front axle nut.
Tightening torque:
8.5 m-kg (61.5 ft-Ibl
4-17
104 mm (4.09 in)
59mm
: ( 2 . 3 2 i ~
I Tightening torque:
0.55 m-kg
1981 SR540E
Then. slide guide wheel to the left
until it comes in full contact with collar
<D and secure set bolt @ using a 3 mm
hex. wrench.
1. Set bolt
iJ FWD
1. Collar 2. Guide wheel 3. Set bolt
1981 SR540E
d. Install the speedometer gear housing
together with bearing cover and joint.
Tightening torque:
2.3 m-kg (16.5 ft-Ib)
FWD
e. Apply a low temperature grease to the
chain case oil seal. and insert the right-
hand side of front axle into chain case
through drive track.
Tighten the front axle with chain driven
sprocket.
4-18
1. Bearing cover
2. Joint
3. Speedometer gear housing
4. Collar
5. Guide wheel
6. Collar
7. Set bolt
8. Bearing
9. Belleville washer
10. Nut
Tightening torque:
4.8 m-kg (35 ft-Ib)
f. Install the chain housing cap and add oil.
(See "4-1-E-4. Chain housing")
g. Install the slide rail suspension as-
sembly.
(See "4-3-0. Suspension installation")
4-2. BRAKE
A. Disassembly
1. Remove the brake cable from the brake
caliper.
2. Remove the brake caliper assembly.
3. Remove the brake pads.
NOTE:------------------------
For brake disc removing. refer to "4-1-E-1.
Chain housing".
B. Inspection
1. Check the pads for damage and wear. If
the thickness is less than specified
below. replace pads as a set.
Wear limit: 9.5 mm (0.37 in)
1. New: 13.5 mm (0.53 in)
2. Wear limit: 9.5 mm (0.37 in)
2. Check the brake disc for warpage. If
warped. replace.
3. If the brake lever will not return smooth-
ly to the rest position because of a
fatigued return spring. replace the re-
turn spring.
4-19
1981 SR540E
C. Reassembly
1. Apply a low temperature grease to the
back up plate shaft and screw cam.
2. Install the brake caliper with brake pads
to the chain housing.
Tightening torque:
4.8 m-kg (35 ft-Ib)
3. Install brake cable to the caliper and
brake lever.
CAUTION: ----------,
Apply a small amount of antifreeze
grease to the contact areas of the brake
wire with brake lever stopper surface,
but do not apply a grease between the
outer wire and inner wire.
D. Adjustment
1. Loosen the lock nut (j) and turn the ad-
justing bolt to set the "L" distance
to the specification below.
L = 57 mm (2.24 in)
Next. lock the adjusting bolt with the
lock nut.
1981 SR540E
1. Lining pad 4. Back-up plate 7. Lock nut
2. Brake disc 5. Nut B. Adjusting bolt
3. Screw 6. Brake wire

After step 1, be sure to take step 2,
and3.
2. Loosen the nut @ and back out the
screw @.
Insert a 0.15 mm feeler gauge between
the lining pad CD and brake disc , and
by turning the screw @ so that the
clearance between the pad and disc is
0.15 mm.
1. Adjusting bolt
2. Lock nut
4-20
3. After locking the nut @, insert the
feeler gauge again into the clearance
and make sure the clearance is 0.15
mm.
Clearance = 0.15 mm
1t FWD
O.15mm
4-3. REAR SUSPENSION
A. Removal
NOTE:-------------------------
It is advisable to loosen the track adjusting
nut and the rear axle nut.
1. Remove the two front pivot shaft
mounting bolts and four rear pivot shaft
mounting bolts.
2. Remove the slide rail suspension as-
sembly.
B. Inspection
1. Check to see if slide runners are worn
excessively. If the slide runner thickness
is less than specified value. replace slide
runner.
Wear limit: 10 mm (0.4 in)
Slide runner securing screw tightening
torque:
0.45 m-kg (3.3 ft-Ib)
--- - ------ ------
1. Wear limit: 10 mm (0.4 in)
2. New: 15 mm (0.6 in)

-- !
2. Check the suspension wheel for
damage.
If damaged. replace it.
3. "DE CARBON" type shock absorber
(Rear).
4-21
1981 SR540E
WARNING (Rearshock):----___.
This shock absorber contains highly
pressurized nitrogen gas.
Read and understand the following in-
formation before handling the shock ab-
sorber. The manufacturer cannot be
held responsible for property damage or
personal injury that may result from im-
proper handling.
1) Do not tamper with or attempt to
open the cylinder assembly. Injury
may result.
2) Do not subject shock absorber to an
open flame or other high heat. This
may cause the unit to explode due to
excessive gas pressure.
3) Do not deform or damage the
cylinder in any way. Cylinder dam-
age will result in poor damping per-
formance.
4) Gas pressure must be released be-
fore disposing of the shock absorber.
To do so, drill a 2 '" 3 mm (0.08 '"
0.12 in) hole through the cylinder
wall at a point 1 0 '" 15 mm (0.4 '"
0.6 in) above the bottom of the
cylinder.

2 3 mm 0.12 in)
-r
I
1981 SR540E
WARNING: -----------..,
Wear eye protection to prevent eye
damage from escaping gas and/or metal
chips.
a. Check the rod, and if it is bent or dam-
aged, replace the shock absorber.
b. Check for oil leakage. If oil leakage is
evident. replace the shock absorber.
c. By compressing the shock absorber,
check to see there is no gas leakage.
C. Slide rail suspension adjustment
The setting of suspension greatly affects the
stability and steering of the machine. There-
fore, it is necessary to adjust the suspension
setting according to course conditions and
rider's driving technique.
1. Stopper band setting
The height (L) of the front suspension
can be properly adjusted by changing
the length of the stopper band.
Standard setting:
No. 1 hole from the bottom
Tightening torque:
0.38 m-kg (2.75 ft-Ib)
1. Stopper band
Height Handling Track side slip
Lower Easy Increase
Higher Hard Decrease
2. Rear spring
The rear spring is a determining factor
in machine stability.
Consider the ground surface condition
This adjustment will greatly affect the
stability and handling.of the machine as
well as the side slip of the track while
turning a corner.
NO.5
No.4
No.3
No.2
No.l-+-o4f-STD
Performance of Bumping and
Riding comfort
straight running pitching
4-22
Poor More Poor
Good Less Good
and the rider's weight when setting rear
springs. The suspension should be set
as soft as possible, unless it impairs the
stability of the machine.
1. Normal riding (less gap)
Std. weight rider
2. Trail riding ( m o ~ e gap)
Heavy weight rider
Course or rider's
weight
Normal riding (less gap)
Std. weight rider
Rear spring set position
3. Additional wheel installaion
When the machine is driven on icy sur-
faces for a prolonged period of time (for
instance. trail riding). additional wheels
1. Suspension wheel
2. Washer
3. Bolt
Tightening torque:
2.0 m-kg (14.5 ft-Ib)
4-23
Trail riding (more gap)
Heavy weight rider
1981 SR540E
should be installed to protect the slide
runners from fast wear. This is not ad-
visable for a race because the suspen-
sion will be adversely affected.
1981 SR540E
D. Installation
Grease the slide rail suspension as indicated
by arrows in the illustration.
1. Fully loosen the drive track adjusting
screws.
2. Place the slide rail suspension into track
and fit the forward pivot shaft using
washers and bolts.
NOTE:--------------------------
Install bolts finger-tight. Bolts will be
tightened to proper torque when slide rail
installation is complete.
3. Fit the rear pivot shaft to the frame. The
rear pivot shaft is being forced toward
the rear by the shock absorber.
To assist in rear shaft installation. keep
the shaft forward by using an iron bar.
NOTE:-------------------------
When installation of .slide rail is complete.
tighten front and rear bolts to proper torque.
Tightening torque:
Front pivot shaft mounting bolts:
6.4 m-kg (46 ft-Ib)
Rear pivot shaft mounting bolts:
6.4 m-kg (46 ft-Ib)
4. Adjust the track tension by turning the
track adjusting nuts. For adjustment.
refer to "4-4-0. Track adjustment".
424
For easy installation of the slide rail suspen-
sion in the frame. proceed as folloWs .
. --- ---- -----..
4-4. DRIVE TRACK
A. Removal
1. Remove the slide rail suspension as-
sembly and front axle.
(See 4-1- F. Front axle and 4-3. Suspen-
sion section)
B. Inspection
Check drive track and clips for cracks. dam-
aged or wear. Replace drive track or clip as
required.
c. Installation
Install drive track assembly as illustrated.
(See 4-1-F. Front axle and 4-3. Suspension
section)
Turning direction
D. Adjustment
WARNING: ----------,
A brokert track. track fittings. or debris
thrown by the track could be dangerous
to an operator or bystanders. Observe
the following precautions:
1) Do not allow anyone to stand direct-
ly behind the snowmobile when
starting forward.
2) When the engine is running and the
track is engaged with the snow-
mobile placed on its side. do not
allow anyone to stand behind or on
the track side of the snowmobile.
The operator must stay on the seat
(top side of the machine).
3) Never lift the rear of the snowmobile
to allow the track to turn while the
engine is running. Stop the engine
and prop up the rear with a suitable
stand. Never stand behind the ma-
chine when the track is spinning.
4) Never install studs (cleats) closer
than three inches form the edge of
the track.
5) Replace any track tha is damaged
to. the depth where fabric reinforce-
ment material is visible. Inspect
track condition frequently.
The track tension should be so adjusted that
when pulled at its window in the track cen-
ter by a force of 10 kg (22 Ib) using a spring
scale. the deflection should be as specified
below.
Track deflection:
25", 30 mm/1 0 kg
(0.98 '" 1.18 in/22 Ib)
25 -':':30rnm.. .,
(0.98 -1.18in;
. ; . : ~
4-25
1981 SR540E
The adjustment should be made in the fol-
lowing sequence:
1. Turn the track by running the engine.
2. Loosen the rear axle lock nuts. and turn
the track adjusting nuts both right and
left through the track window using a
box wrench to align the track with the
slide rail.
NOTE:-------------------------
Track tension adjustment is possible without
removing the split pin.
1. Rear axle nut
2. Split pin
1. Adjusting nut
3. After the adjustment specified in 2
above. pull the track window at the cen-
ter of the track with a force of 1 0 kg (22
Ib) using a spring scale. The track de-
flection should be as specified.
4. By repeating the procedures in 1. 2 and
3 above. the track should be brought in
alignment with correct tension.
5. After making sure all adjustments are
correct. tighten the rear axle nut .
Tightening torque:
8.0 m-kg (58 ft-Ib)
1981 SR540E
No good
Slide runner
Track
Track metal
,> 1-.. ........ __ .......
Forward
Gap between slide runner
and edge of track window.
.0-
Forward
When shifted to right: Tighten the right track adjusting
bolt. and loosen the left track adjusting bolt.
Good
Slide runner
4-26
Track metal
iJ,
No good
Slide runner
Forward Gap between slide runner
and edge of track window.
When shifted to left: Tighten the left track adjusting,
bolt and loosen the right track adjusting bolt.
1981 SR540E
CHAPTER 5. CHASSIS
5-1. TELESCOPIC STRUT SUSPENSION .......................................................................... 5-2
A. Disassembly ........................................................................................................... 5-2
B. Inspection ............................................................................................................... 5-5
C. Installation .............................................................................................................. 5-7
5-2. FRONT SHOCK ABSORBER ("DE CARBON" TYPE) ........................................... 5-14
A. Telescopic strut suspension setting ................................................................. 5-14
5-3. "DE CARBON" TYPE SHOCK ABSORBER ............................................................ 5-18
5-4. STEERING .................................................................................................................... 5-19
A. Installation ., ......................................................................................................... 5-19
B. Adjustment ................................................................................................... 5-19
5-5. OIL TANK ..................................................................................................................... 5-20
5-6. FUEL TANK .................................................................................................................. 5-20
5-7. SKIS ......................................................................................................... 5-21
A. Inspection ............................................................................................................ 5-21
1981 SR540E
CHAPTER 5. CHASSIS
5-1. TELESCOPIC STRUCT
SUSPENSION
A. Disassembly
1. Removing the ski assembly.
a. Raise the snowmobile side to an
appropriate inclination.
b. Remove the split pin.
c. Remove the bolt with hole.
d. Remove the ski assy.
2. Removing the lower end bracket..
a. Loosen the set bolt.
5-2
1. Set bolt
NOTE: ------------
The set bolt needs only loosening; not re-
moving.
b. Remove the bolt with hole from the
lower front arm.
c. Loosen the lower end bracket tighten-
ing nuts.
NOTE:--------------------__ __
The nuts needs only loosening; not removing.
d. Remove the lower end bracket.
3. Removing the compression spring.
a. Remove the rubber protector.
b. Remove the 3 nuts tightening the ab-
sorber holder top.
5-3
1981 SR540E
c. Remove the 4 bolts tightening the ab-
sorber holder.
Then remove the absorber holder.
d. Remove the top one of the 2 bolts em-
ployed for double tightening.
1981 SR540E
e. Remove the bottom one of employed
for double tightening.
CAUTION: ---------......
When removing the nut, hold the top of
the damper sub-ass'y by spanner.
Never score the rod of the damper sub-
ass'y with the pliers or the like.
5-4
f. Remove the bearing holder and collar.
g. Remove the spring seat and compres-
sion spring.
NOTE:
Suspension setting can be changed by using
a different compression spring.
4. Remove the damper sub-assy.
5. Removing the outside arm
a. Remove the bolt with hole from the
upper front arm.
b. Remove the 4 panhead screws.
c. Put down the plastic hood.
d. Remove the bolt from the linkage of the
outside arm.
e. Remove the circlip.
55
1981 SR540E
f. Remove the O-rings washers. and out-
side ami.
B. Inspection
1. Damper sub-ass'y
a. Check the rod for scores or oil leakage
or bends. Replace as required.
b. Check the rod for an automatic return
when it is pushed in and then released.
Unless it returns. check the gas pres-
sure. and adjust to the standard figure
below.
Standard static pressure:
15 kg/cm
2
(213 psi)
1981 SR540E
c. Check the rotor for a smooth rotation.
NOTE:--------------------__ _
The bearing has no need grease application
because it is a grease-sealed one.
2. Lower end bracket
Check lower end bracket for a crack.
Replace as required.
Check the bush for wear. Replace as re-
quired.
56
3. Front arm
Check the bush for wear. Replace as re-
quired.
4. Outside arm
Check the bush for wear. Replace as re-
quired.
5. Stopper of ski ass'y
Check the rubber stopper for a crack or
lack of flexibility. Replace as required.
C. Installation
Tightening torque:
(1.6 m-kg, 11.6 l---r-l--$ --1
I @9 I
I I
I I
I . I
J I
- I I
1981 SR540E
--- Collar I
..".,.. ..... -'=---1 0' I
I I I
I
Use Lock Tight
Tightening torque:
(2.1 m-kg, 15.2 ft-Ibl
5-7
I I I
I F'l I
Damper t::J I
WT"'Y 'I' !
I I
I I
I I
:
I I
I _ I
L. __________ .J
Lower end Bracket
....... Greasing
point
(ESSO beacon 3251
1981 SR540E
C-1. Damper sub-ass'y (Strut)
Installation
1. Before inserting the damper sub-ass'y
into the hole in the frame complete,
make sure of the quantity of grease in
the frame complete, and add grease as
required.
Specified grease:
ESSO beacon 325

When inserting damper sub-ass'y into
the frame complete, special care is re-
quired not to damage the oil seal and
bushing.
5-8
2. Fit the lower seat bearing and com-
pression spring.
Then fit the upper seat bearing with the
stop bump and the collar.
3. Install the housing bearing and washer.
Then tighten the nut.
Tightening torque:
0.5 m-kg (3.6 ft-Ib)
4. Tighten the nut for double tightening.
Tightening torque:
1.6 m-kg (11.6 ft-Ib)
5. Allow the holder bearing to be
positioned in the direction as illustrated.
1981 SR540E
5-9
1981 SR540E
6. Install the absorber cover with a paper
protector and tighten the 4 bolts. Then
the 3 nuts on top of the absorber cover.
1. Paper protector
Tightening torque:
0.6 m-kg (4.3 ft-Ibl
Put a rubber protector on the absorber
cover.
5-10
C-2. Outside arm, front arm
and ski compo installation
1. Before installing the O-ring, washer and
circlip, apply grease to the boss on the
frame complete. Then install the circlip.
Specified grease:
ESSO beacon 325
2. Tighten the bolt for securing the linkage.
3. Tighten the bolts with hole to the
upper and lower front arms
a. Apply grease to the collar surface and to
the lower front arm interior.
Specified grease:
ESSO beacon 325
b. Be sure to install plastic washers.
c. After tightening the nut, insert the split
pin; then, spread it on the end.
Tightening torque:
4.3 m-kg (31.1 ft-Ibl

Note that the upper and lower front
arms differ in shape. Be careful not to
reverse their positions. These are mar-
ked "UPPER" and "LOWER".
4. Apply grease the bracket interior for
collar. Then insert the lower end bracket
to the damper sub-ass'y and tighten the
bolt with hole to the lower front arm,
and insert the split pin.
CAUTION: ----------,
Lower end brackets differ in type be-
tween the right and left. Locate the
bracket with its slit outside and with its
set bolt hole forward.
1981 SR540E
5-11
If!
.....
I'J
7

.1


12 ?J 0 9
R 0
o
o
o
o

1. Lower end bracket sub-ass'y left 12. Set bolt
2. *Bracket left 13. Bolt with hole (Long)
3. *Bimetal formed bush 14. Washer
4. *Stud bolt (Short) 15. Ski complete
5. *Stud bolt (Long) 16. Collar (Long)
6. Stopper left 17. Nylonnut(10mm)
7. Lower end bracket sub-ass'y right 18. Split pin
8. * Bracket right 19. Bolt with hole (Short)
9. Stopper right 20. Plain washer (White plastic)
10. Nylon nut (8 mm) 21. Collar (Short)
11. Plain washer 22. Cap

------, r ----- I . . '--3-- ,
"" . i 2. I i
l
I
V l I',. I
22" , -""T" '
2t, i T--J 0 1 i
21 16 3:
. 1 ---_---, 4 ____
, ......c.' ............ -....
l
'. i 11 10

10 11

17 /

13
r
12

15
.....
U)
CO
en
::0
U1

m
5. Tighten the nuts.
Tightening torque:
2.1 m-kg (15.2 ft-Ib)
CAUTION:
The cap is intended to protect the rub-
ber valve in the damper sub-ass'y.
Never fail to put it on. Make sure that
the cap and damper sub-ass'y are
securely fitted in the bracket.
Loose fit will cause the bracket to be
damaged.
6. Tighten the set bolt.
CAUTION: ----------
In assembly, the set bolt should be
tightened at the end of assembly. Also
apply a locking agent to the bolt. When
disassembling, do not forget to loosen
it, or the shock absorber can not be pul-
led out.
Specified holding agent: Nejilock super
5-13
Tightening torque:
0.2 m-kg (1.4 ft-Ib)
7. Insert the stopper into the ski ass'y.
1981 SR540E

Note that stoppers differ in shape be-
tween the right and the left. These are
marked "L" and "R".
8. Install the ski ass'y and tighten it by
means of the bolt with hole. Then
secure with the split pin.
Tightening torque:
4.3 m-kg (31.1 ft-Ib)
CAUTION:---------_
Pay attention to the direction in instal-
ling the ski ass'y to the strut ass'y.
Contact of the cap with the damper
ass'y will result resistance to ski toe up-
and-down movement, thus making it
difficult for the ski to follow the snow
surface properly.
1981 SR540E
5-14
5-2. FRONT SHOCK ABSORBER
("DE CARBON" type)
A. Telescopic strut suspension setting
The telescopic strut suspension setting factors
can be selected from the following table ac-
cording to the rider's preference.
1. Compression spring
Std. spring Optional spring
Parts No. 9050175612 9050170584
Spring constant 1.6 0.8 - 1.2
kg/mm (Ib/in) (89.6) (44.8 - 67.2)
Color Red No Color
2. Damper sub assembly
Std. damper sub assembly
Parts. No. 8L92240100
Tension
84 15 kg/0.8 m/s
Dumping
(185 33Ib/2.6 ft/s)
force
46 5 kg/0.8 m/s
Compression
(101 11 Ib/2.6 ft/s)
*The optional parts will be sold next December.
3. Gas pressure adjustment
The gas pressure of front shock absorber
can be adjusted using the special tools.
By increasing the gas pressure, the initial
load is increased. (The suspension be-
comes hard to compress but stretches
easily.)
By decreasing the gas pressure, the initial
load is decreased. (The suspension can
contract easily but is hard to stretch.)
Maximum S.T.D. Minimum
Gas pressure 20 15
13
kg/cm
2
(psi) (284) (213) (185)
(at 20C degree)
CAUTION: ---------.....,
1) Never make gas pressure checking and
adjustment under temperatures below
oDe.
2) Do not use any other gas than nitrogen
gas. The gas pressure should always be
in specified range.
Cl
::::
w
u
a:
o
LL
(!)
Z
Q.
:?!
<{
o
Tension
1981 SR540E
- - - 13 kg/cm2 (185 psi)
-- 15 kg/cm2 (213 psi)
- - - 20 kg/cm2 (284 psi)
, -
' ~ - - - - - - - - - - - - - - - : ~ /
-----== - =--
Compression
a. Special tools
To check the nitrogen gas pressure or
refill with nitrogen gas, the following
tools are required.
Gauge set ............. 90890-01160
CD Hose .............. 90890-01158
@ Joint gauge ......... 90890-01161
@ Joint holder ........ 90890-01162
@ Joint hose end ...... 90890-01163
@ Joint cover ......... 90890-01164
Needle ............ 90890-01167
(j) Check gauge ........ 90890-03063
Joint .............. 90890-01165
5-15
Stroke: 100 mm (3.93 in)
Speed: 288 rpm
b. Checking nitrogen gas pressure
NOTE:-------------
Oil the injection needle before inserting it in
the Gas adjustment valve.
To check the nitrogen gas pressure in the
gas chamber, use the check gauge. To
measure the gas pressure, and insert the
oiled needle into the gas chamber.
1981 SR540E
c. Refilling nitrogen gas
To refill with nitrogen gas, proceed as
follows:
1) Fit the injector needle onto the nitrogen
pressure hose and oil the injector needle
lightly.
2) Close the regulator off completely by
turning the knob in a counterclockwise
direction. Open the nitrogen bottle main
valve.
3) Insert the injector into the rubber valve
in the housing cap.
NOTE:-------------------------
Support the injector needle with your hand
during pressurization.
5-16
4) Adjust the gas pressure to a desired
value. Hold this pressure for one minute.
Maximum static pressure:
20 kg/cm2 (284 psi)

Do not over-pressurize the gas chamber.
Gradually increase the regulator setting
until the required pressure is reached.
5) Close the nitrogen bottle main valve and
remove the injector needle, from the
housing cap. This will allow the nitrogen
pressure in the hose to flow out. Back
off the pressure regulator.
d. Bleeding nitrogen gas
To bleed the nitrogen gas, oil the injector
(needle) and thrust it into the housing
cap. The gas can easily be bled.
NOTE:--------------
1. After nitrogen gas refilling or bleeding,
screw in the joint cover over the check
gauge.
2. When using the check gauge to verify the
nitrogen pressure, approximately 0.351
kg/cm
2
will be lost. Do not use the
regulator pressure gauge to check the
pressure in the unit.
3. Take care not to damage nitrogen gas
needle during insertion. Replace safety
sheave when needle is not in use.
4. As the suspension is used, it will heat up,
thus increasing the nitrogen gas pres-
sure. It is recommended that gas pressure
be adjusted and check at room tempera-
ture so consistant results can be achieved.
Joint ----____.
r---- Input pressure indicator
r----Cylinder pressure indicator
r---Valve (1)
Valve (2) - - - - - H " - - - ~
Nitrogen cylinder
Hose------"<"
Injector (Oil before inserting) ------,
4. Damper unit pressure adjustment in a
snowmobile.
1. Removing the ski assembly
a. Raise the snowmobile side to an
appropriate inclination.
b. Remove the split pin.
c. Remove the bolt with hole.
d. Remove the ski assembly.
5-17
2. Gas pressure adjustment
a. Refilling nitrogeen gas.
1981 SR540E
1981 SR540E
NOTE:------------------------
Gas pressure adjustment is possible on the
damper sub-assembly and lower end bracket
without removing them.
1. Damper sub-assembly 2. Cap 3. Lower end bracket
b. Checking nitrogen gas pressure.
NOTE:-------------------------
After refilling the nitrogen gas. it is not
necessary to check the pressure.
c. Releasing nitrogen gas.
Nitrogen gas refilling. releasing. or
checking should be done on minimum
necessary occasions; otherwise. it may
damage the rubber valve with the con-
sequent pressure leakage.
5-18
5-3. "DE CARTON" TYPE SHOCK
ABSORBER
WAR N ING: -----------,
This shock absorber contains high-
pressure nitrogen gas. To prevent the
danger of explosion. read and unders-.
tand the following information before
handling the shock absorber.
The manufacturer can not be held re-
sponsible for property damage or per-
sonal injury that may result from im-
proper handling.
1. Never tamper or attempt to disas-
semble the cylinder.
2. N ever throw the shock absorber into
an open flame or other high heat.
The shock absorber may explode as
a result of nitrogen gas expansion.
3. Take care not to scratch the contact
surface of the piston rod with the
cylinder; or oil could leak out. Do not
deform or damage the cylinder in
any way. Cylinder damage will result
in poor damping performance.
4. Never attempt to remove tthe plug
at the bottom of the cylinder. It is
very dangerous to remove the plug.
5. When scrapping the shock absorber.
follow the instructions on disposal.
Notes on disposal
Before disposing the shock absorber. be sure
to extract the nitrogen gas.
In the case of rear shock absorber. drill a 2
,...., 3 mm (0.08 ,...., 0.12 in) hole through the
cylinder at a position 10,...., 15 mm (0.4 ,....,
0.6 in) from the bottom of the cylinder.
The front shock absorber is chromed. Re-
move this chrome deposit from the absorber
before drilling a hole in it. The drilling should
be done in the groove as illustrated. At this
time. wear eye protection to prevent eye
damage from escaping gas and/or metal
chips.
1 0 ~ 15 mm (0.4 ~ 0.6 in)
2 ~ 3 mm (0.08 ~ 0.12 in)
Rear shock absorber
.....
~
[JJ
L
Front shock absorber
5-4. STEERING
A. Installation
1. Secure the steering relay rod (with un-
iversal joint attached) to the outside
arm with the flange nut and cotter pin.
Tightening torque:
4.7 m-kg (34 ft-Ib)
2. Install the steering column on the
frame. Before this operation, coat the
steering lower and upper bearing with
grease. Tighten the nuts and bolts, and
bend the lock washer tab.
1981 SR540E
Tightening torque:
2.3 m-kg (16.5 ft-Ib)
3. Connect the steering relay rod to the
steering column using the flange nut.
Install a new cotter pin.
Tightening torque:
4.7 m-kg (34 ft-Ib)
B. Adjustment
1. Ski
Hold the handlebar straight and check
to see that the skis are parallel. If not,
loosen the steering relay rod lock nut.
and by turning the steering relay rod in
or out. adjust the ski toe-out to specifi-
cation (see below).
Ski stance: 880 mm (34.6 in)
Ski toe-out: 0 mm (O in)
Steering relay rod tightening torque:
4.7 m-kg (34 ft-Ib)
1981 SR540E
11
Front
A--I-.
1. Ski spindle center
A - C = 0 mm (0 in) B. Ski width
520
5-5. OIL TANK
1. Check the hose from the tank to the oil
pump for obstructions such as pinching
or other damage.
2. It is advisable that the oil filter be re-
placed with a new one each season.
1. Oil filter
5-6. FUEL TANK
1. Check for missing pipe retaining dips.
2. Check pipes for flattening caused by
tank.
3. Check the breather pipe for correct
routing.
Check clamps for looseness.
The breather pipe should be routed so
that no fuel leakage will result from
severe vibration. shock and/or banking
of the vehicle.
For routing. refer to piping and wiring
diagrams.
4. It is advisable that the fuel filter be re-
placed with a new one each season.
If the filter is faulty (obstructing the
fuel flow or having a breakage in the
element). it should be replaced as an
assembly unit.
1. Fuel filter
2. Steering handlebar adjustment
By loosening the bolt securing the
handlebars, the height of handlebars
can be adjusted to suit the rider's pre-
ference. After adjustment. be sure to
tighten the bolts.
WARNING: ----------,
Tighten the bolts alternately to maintain
a parallel gap as illustrated.
(1.5 mm for front and 3.5 mm for rear)
Tightening torque:
1.5 m-kg (11 ft-Ib)
1. Holder
2. Handlebar
5-21
1981 SR540E
5-7. SKIS
A. Inspection
Check the ski runner. if worn excessively, re-
place.
1981 SR540E
CHAPTER 6. ELECTRICAL
6-1. IGNITION SYSTEM ...................................................................................................... 6-2
A. Circuit diagram ..................................................................................................... 6-2
B. Troubleshooting ................................................................................................... 6-2
C. Ignition timing ...................................................................................................... 6-3
D. Spark gap test ....................................................................................................... 6-4
E. Ignition coil ............................................................................................................ 6-5
F. Spark plug ............................................................................................................. 6-5
G. Pulser and charging coils test ............................................................................ 6-6
H. C.D.I. unit ............................................................................................................... 6-7
6-2. LIGHTING SYSTEM ..................................................................................................... 6-7
A. Circuit diagram ..................................................................................................... 6-7
B. Headlight beam adjustment ............................................................................... 6-7
C. Lighting coil test ................................................................................................... 6-7
D. Voltage regulator. ................................................................................................. 6-9
E. Oil caution switch .............................................................................................. 6-10
1981 SR540E
CHAPTER 6. ELECTRICAL
6-1. IGNITION SYSTEM
A. Circuit diagram


111
1. C.D.I. magneto 4. C.D.I. unit 7. Engine stop switch
2. Pulser coil 5. Main switch 8. Ignition coil
3. Charging coil 6. Tether switch 9. Spark plug
B. Troubleshooting
No spark is produced or weak.
'---_C_h_e_c_k---,o,f_c_o_n_n_e_c_ti_o_n_s---'I ................. Check lead wire connections or short circuits
I
OK Faulty--------tl Correct.
'---_S_p_a .. _" '_"_" _" ._ .. _ ... _. '_"_" '_"_"_" ._,,_,,_. s_e_e_6-,- 1 - D. "Spa rk gap test"
I
No spark Spark-------tl Plug is faulty .
........................... Measure coil resistance.

(See 6-1-G. "Pulser and charging coil test")
OK Fa u Ity --------------.1 Replace .
............................. Measure coil resistance.

OK
.J.
(See 6-1-G. "Pulser and charging coil test")
Faulty----------+I Replace .
62
11
.......................... Ignition coil test (See 6-1-E. "Ignition coil")
OK Faulty , Replace.
,--C_._D_.I_. ...................................... see 6-1-H. "C.D.I. unit"
l
Faulty , Replace
The engine starts but will not pick up speed.
Spark plug 1 .................................... Clean or replace (See 6-1-F. "Spark plug")
I
OK
........................... Make continuity test
'-----.-----' (See 6-1-G. "Pulser and charging coil test")
OK
'--__ -.-_____ --' .................. (See 6-1-C. "Ignition timing)
...................................... (See 6-1-H. "C.D.I. unit")

'--------------+ Faulty ---------., Replace.
C. Ignition timing
1. Remove the fan case cap.
2. Remove the right side spark plug and
screw dial gauge stand into spark plug
hole.
Tool name Tool No.
Dial gauge stand 90890-01195
3. Insert dial gauge with needle into stand.
Tool name
1981 SR540E
Tool No.
Dial gauge 90890-01252
4. Rotate magneto flywheel until piston is
at top-dead-center (T.D.C.)
Dial gauge needle 90890-03098
6-3
Set the zero on dial gauge face to line
up exactly with a dial gauge needle.
Tighten set screw on dial gauge stand
to secure dial gauge assembly. Rotate
flywheel back and forth to be sure that
indicator needle does not go past zero.
\1981 SR540E
5. Starting at T.D.C., rotate flywheel coun-
terclockwise until dial gauge reads ap-
proximately 3-1/2 needle revolutions
before-top-dead-center (B.T.D.C.).
6. Slowly turn flywheel clockwise until dial
gauge reads specified ignition timing.
Ignition timing (B.T.D.C.)
1.5 0.1 mm (0.059 0.004 in)
7. Check the marks on flywheel and base
for alignment.
If not aligned, adjust ignition timing as
follows.
a. Remove the manual starter assembly.
b. Remove the starter pulley and drive fan
pulley. (Refer to "2-1-0 Cooling fan")
c. Loosen the base set screws and turn
the base assembly until mark alignment
is achieved.
d. Tighten base set screw.
Tightening torque:
0.65 m-kg (5 ft-Ib)
6-4
e. Install the drive fan pulley and starter
pulley. (See "2-2-F-2. Cooling fan in-
stallation")
f. Install the starter assembly. (Refer to
"2-2-G. Starter")
8. Remove the dial gauge and stand.Re-
place the spark plug and fan case cap.
Spark plug tightening torque:
2.8 m-kg (20 ft-Ib)
NOTE:-------------------------
The timing light should be used to check if
the marks on the rotor and base are aligned
when both are replaced with new ones. The
marks should align at any specified timing.
D. Spark gap test
The entire ignition system can be checked for
misfire and weak spark using the Electro
Tester. If the ignition system will fire across a
sufficient gap, the engine ignition system can
be considered good. If not, proceed with in-
dividual component test until the problem is
found.
1. Warm up engine thoroughly so that all
electrical components are at operating
temperature.
2. Stop engine and connect tester as
shown.
GEB
+
CD
1. Electro-Tester
2. Plug wire from coil
3. Spark plug
3. Start engine and increase spark gap
until misfire occurs.
Minimum spark gap: 6 mm (0.24 in)
E. Ignition coil
1. Coil spark gap test
a. Remove the ignition coil from frame.
b. Connect Electro Tester as shown.
c. Connect fully charged battery to tester.
d. Turn on spark gap switch and increase
gap until misfire occurs.
Minimum spark gap: 6 mm (0.24 in)
1. Battery
2. 6 mm (0.24 in)
2. Coil winding resistance tests
Use a pocket tester or equivalent ohm-
meter to determine resistance and con-
tinuity of primary and secondary coil
windings.
Manufacturer
Primary coild Secondary coil
resistance resistance
Hitachi 0.15H 10% 3.6kH 20%
(CM62-20) at 20C (68F) at 20C (68 F)
Toyo Denso 0.12H 10% 4.0kU 20%
(YW-51 ) at 20C (68 F) at 20C (68F)
6-5
1981 SR540E
- Primary coil resistance
---- Secondary coil resistance
F. Spark plug
The life of a spark plug and its discoloring
vary according to the habits of the rider. At
each periodic inspection. replace burned or
fouled plug with suitable one. Suitability may
be determined by asking the rider how long
and how fast he rides. Recommend a hot.
standard. or cold plug type accordingly. It is
actually economical to install a new plug
often since it will tend to keep the engine in
good condition and prevent excessive fuel
consu mption.
1. How to "read" spark plug (condition)
(The spark plug color samples are at the
end of this manual)
CD Good
The insulator normally has a tan color.
This check should be made after driving
the machine over a long distance:
otherwise. the correct reading of the
spark plug will be impossible.
Bad (Mixture is too rich or spark plug
temperature is low).
If mixture are too rich. the metal shell
end will be wet as shown in the photo.
acceleration or high-speed performance
will be poor. If the spark plug tempera-
ture is low. the phenomenon specified
in above will not take place. As shown
in the photo. the insulator is dark and
sooty.
@ Bad (Mixture is too lean or spark plug
temperature is high.)
The insulator is roughened (lower
photo) or burned white (upper photo).
and the ground electrode is green due
to oxidation. This state of the spark plug
1981 SR540E
will result in premature ignition or
power loss.
@ Bad (Piston holed or seized)
The metal shell end and insulator show
signs of overheating. If mixture is too
lean. the piston can be holed or the
engine may tend to knock. As a result.
the spark plug will have occasional al-
uminum deposits.
Bad (Knocking)
Generally. the spark plug will not be
greatly affected by the strength of
mixtures; so long as the distance travel-
led is not long. But after long hours of
driving. the insulator takes a greyish
black color due to aluminum deposits. If
so. the engine will fail to deliver full
power. and the piston could be holed or
seized. As a preventive measure. it is
recommended to use a higher octane
gasoline. adjust the ignition timing. en-
rich the mixture or remove the carbon in
the cylinder.
@ Bad (Melting)
If the spark plug overheats. electrodes
will met away or the piston will be
holed.
2. Inspection
Instruct the rider to:
a. Inspect the clean the spark plug every
400 km (250 mi) or 20 hours.
1. Yellow 3. Black
2. Brown 4. Blue
b. Clean the electrodes of carbon and ad-
just the electrode gap.
c. Be sure to use the proper reach plug as
a replacement to avoid overheating.
fouling or piston damage.
Spark plug type: BR9EV (NGK)
Spark plug gap (use wire gap gauge):
0.7 '" 0.8 mm (0.028 '" 0.031 in)
Spark plug torque:
2.8 m-kg (20 ft-Ib)
G. Pulser and charging coil test
Check the resistance between terminals. If
resistance is out of specification. coil is
broken. Check the coil connections. If the
coil connections are good. then the coil is
broken inside and it should be replaced.
Charging coil resistance:
Black to Brown leads:
350n 10% at 20C (68
0
F)
Black to Blue leads:
15.0n 10% at 20C (68
0
F)
Pulser coil resistance:
Black to White/Red leads:
9.0n 10%at20C(68F)
5. White/Red 7. Pocket tester
6. Flywheel magneto 8. Set tester at "RX1" position
6-6
H. C.D.I. unit
In case of ignition failure with all the above
system check-ups proving in good order, re-
place the C.D.I. unit assembly.
6-2. LIGHTING SYSTEM
A. Circuit diagram
1. Flywheel magneto 5. Meter light
2. Lighting source coil 6. Taillight
3. Voltage regulator 7. Brake light
4. Headlight
B. Headlight beam adjustment
1. Inspection
Check the headlight beam direction. The
high beam must be directed downward
at an angle of 1/2
0
to the horizontal line.
6-7
1981 SR540E
~ - - - - - - - - ~ Q - - - - - - - - - - - - ~
Horizontal line
h
Q
3.0m(10ft) 7.6 m (25 tt)
h 26 mm (1.0 in) 66 mm (2.6 in)
2. Adjustment
When necessary, adjust headlight beam
by tightening or loosing the four head-
light mounting screws.
C. Lighting coil test
Check the resistance between yellow lead
and ground. If resistance is out of specifica-
tion, coil is broken. Check the coil connec-
tions. If the coil connections are good, then
the coil is broken inside and it should be re-
placed.
Lighting coil resistance:
Black to Yellow leads:
0.1911 1 0%/20C (68
0
F)
1981 SR540E
1. Yellow 3. Black
2. Brown 4. Blue
D. Voltage regulator
1. Instruments required for inspection
CD Regulator checker.
Two 12V batteries.
@ Sub lead wire.
5. White/Red 7. Pocket tester
6. Flywheel magneto 8. Set tester at .. RX'" position
@
2. Connections
6-8
Connect two 12V batteries in series
using the sublead wires.
Connect the red lead wire (A) (for pow-
er) of the regulator checker to the posi-
tive side of one of the batteries. and
connect the bl'ack lead wire (8) to the
negative side of the other battery.
Connect the red lead wire (C) (for test)
of the regulator to the regulator case.
and connect the black lead wire (0) to
the lead wire of the regulator.
3. Inspection
Checking the battery voltage
First. set the switches. both right and
left. to "12V" "Va LT". If the checker
needle points to 20 volts or more. the
battery voltage is sufficient.
4. Checking the regulator
a. Set the right switch to "REG". If the
lamp lights up. there is continuity in the
regulator checker.
b. Operation test
Slowly slide the switch to the right. If
the needle quickly swings back to O. the
moment that it moves into the black
zone of the scale. the working voltage of
the thyristor in the regulator is in good
condition. and the regulator is also in
good condition.
6-9
1981 SR54Q.E:
Thyristor working voltage:
13.8 0.5 volts at 5.000 r/min
If the regulator is faulty:
The checker needle swings over the
black zone. and it will not return to 0
from 20V or more.
E. Oil caution switch
The oil caution light comes on when there is
little oil in the oil tank. thus warning the rider.
The oil caution circuiut can be checked by
squeezing the brake lever.
1. Flywheel magneto
2. Brake switch
3. Oil caution switch assy
4. Diode
@
,----
I
I
I
I
G/yl
I
L ___ _
G
---..,
___ ..J
BIR
(j)
5. Oil level switch
6. Brake light
7. Oil caution light
1981 SR540E
1. Oil level switch check
a. Connect the pocket tester leads to the
oil caution switch ass'y lead connector
Pocket tester (-) +----+ Green lead
Pocket tester ( + ) +----+ Black/Red
b. Side the switch float. When the float is
Pocket tester connecting point
(+) (-)
Red Black
Lead wire Black/Red Green/Yellow
color
----------.- -------------
Green/Yellow Black/Red
Black/Red Green
------------- --------------
Green Black/Red
0: Continuity
x : Discontinuity
NOTE:-------------------------
When making this testing. the switch float
must be moved down to the bottom end of
the slider. (switch ON position)
moved down to the bottom end of the
slider. the tester should read zero. If not.
the switch must be replaced.
2. Diode check
Check the diode as specified using the
pocket tester.
Replace Replace
Good (element (element
shorted) opened)
0 0 x
------------- ------------.--- ----------------
x 0 x
0 0 x
--------------- ------------ ---- -----.------
x 0 x
6-10
1981 SR540E
CHAPTER 7. APPENDIX
7-1. SPECIAL TOOLS ........................................................................................................... 7-2
7-2. SPECiFiCATIONS ......................................................................................................... 7-3
A. General .................................................................................................................. 7-3
B. Engine .................................................................................................................... 7-3
C. Drive and track suspension ................................................................................ 7-5
D. Chassis ................................................................................................................... 7-5
E. Electrical ................................................................................................................ 7-6
F. Tightening torque ................................................................................................. 7-7
7-3. WIRING DIAGRAM ..................................................................................................... 7-9
7-4. WIRE AND PIPE ROUTING DIAGRAM ................................................................. 7-10
1981 SR540E
CHAPTER 7. APPENDIX
7-1. SPECIAL TOOLS
1. 4-b,
5.. . ...
~ .... ~ .
3.
7
No. Description Tool No.
1 Dial gauge 90890-03097
"
2 Dial gauge stand No.2 90890-01195
3 Dial gauge needle (56 mm) 90890-03098
4-a Flywheel puller attachment 90890-01803
4-b Flywheel puller attachment 90890-01804
4-c Flywheel puller screw 90890-01906
4-d Drive handle 90890-01817
4-e Flywheel puller body 90890-01848
5 Rotor holding tool 90890-01235
6-a Primary fixed sheave puller (M 18) 90890-01898
iTSL-90018-81-01
6-b Primary fixed sheave puller (M20) 90890-01897
IT TSL-90018-59-02
6-c
Primary fixed sheave puller
90890-01899
attachment
14.
7 Sheave sub-assembly tool 90890-01858
8 Bushing tool 90890-01883
9 Sheave gauge 90890-01702
10 Pocket tester 90890-03104
11 Electro tester 90890-03021
12 A.C. Regulator checker 90890-03090
13 Sheave holder 90890-01701 TSL-90018-80-00
14 Eccentric bearing installer 90B90-0 1851
7-2
1981 SR540E
7-2. SPECIFICATIONS
A. General
Model SR540E
Model:
Model (I.B.M. No.) SR540E (8l9)
Frame 1.0. & starting number 8l9-016101
Engine 1.0. & starting number SA535-016101
Dimension:
Overall leng-th 2,610 mm (102.7 in)
Overall width (std) 1,080 mm (42.5 in)
Overall height (w/windshield) 970 mm (38.2 in)
B. Engine
Description:
Engine type Axial fan cooled two-stroke, torque
induction, twin cylinders
Engine model SA535
Displacement 535 cc (32.65 cu.in)
Bme x Stroke 73 x 64 mm (2.874 x 2.52 in)
Effective compression ratio 6.0: 1
Starting system Recoil hand starter
Ignition system C.D.I.
lubrication system "Autolube" oil injection
Cylinder head:
Combustion chamber volume (with spark plug) 27.5 cc (1.68 cu.in)
Compression chamber type Dome + Squish
Head gasket thickness x Q'ty 0.5 mm (0.02 in) x 1 pc.
Cylinder:
Material Cast iron sleeves aluminum
Bore size 73 mm (2.874 in)
Taper limit 0.05 mm (0.0020 in)
Out of round limit 0.01 mm (0.0004 in)
Piston:
Piston skirt clearance (measuring point) 0.055 ~ 0.060 mm (0.0022 ~ 0.0024 in)
(17 mm from piston skirt end)
Piston oversize 1 st 73.25 mm (2.884 in)
2nd 73.50 mm (2.894 in)
3rd 73.75 mm (2.904 in)
4th 74.00 mm (2.913 in)
Piston pin outside diameter x length 4>20 x 56 mm (4)0.787 x 2.20 in)
Piston ring:
Piston ring design (Top) Keystone
Piston ring design (2nd) Keystone
Ring end gap (installed) 0.30 ~ 0.50 mm (0.012 ~ 0.020 in)
Small end bearing:
Type Needle bearing
Big end bearing:
Type Needle bearing
Crankshaft:
Crankshaft assembly width (A) 200 0.25 mm (7.87 0.010 in)
7-3
1981 SR540E
Crankshaft assembly width (F)
+0 ( +0 .)
60 -0.05 mm 2.362 -0.002 In
Crankshaft deflection (D) 0.03 mm (0-1) 0.04 mm (0-2)
0.04 mm (0-3) 0.05 mm (0-4)
Connecting rod big end side clearance (C) 0.25 ~ 0.75 mm (0.010 ~ 0.030 in)
Connecting rod small end deflection (P) 2.0 mm (0.079 in)
-jf-p
Q
I J
l I ~ A ~ "
Crank pin outside diameter x length 1/>24 x 59 mm (1/>0.945 x 2.323 in)
Crank pin type Solid shaft assembly type with serration
Crank bearing type (left) x q'ty #6306 special x 2 pcs.
Crank bearing type (Center) x q'ty #6206 special x 2 pcs.
Crank bearing type (Right) x q'ty #6206 special x 1 pc.
Crank oil seal type (left) x q'ty FWJ-3278 9.5 TS x 1 pc.
Crank oil seal type (Center) x q'ty labyrinth seal x 1 pc.
Crank oil seal type (Right) x q'ty FWJ-3248 10-1 TS x 1 pc.
Cooling fan:
Fan belt tension 4 ~ 6 kg/8 mm (8.8 ~ 13.2 Ib/0.31 in)
Carburetor:
Type & manufacturer/quantity B044-38/KEIHIN/1 pc.
1.0. Mark 81900
Main jet (M.J.) #150
Main air jet (MAJ.) #180
Power jet (Pw.J.)
#150
Power air jet (Pw.A.J.) #170
Slow jet (S.J.) #92
Slow air jet (SAJ.) #100
Pilot screw (P.S.) 2-1/4 turns out
Starter jet (St.J.) #160
Float height
15 +2 mm (0.59 +0.08 in)
-3 -0.12
Idling engine speed 1500 r/min
[Main jet setting chart]
~
-30C -20C -lOoC OC lOoc 20C
Altitude
(-22F) (-4F) (14F) (32F) (50F) (68F)
..
#150
..
Se.llevel
-(#155)
-
_#145 ___
.. #150 ..
- 600 m (2000 tt)
-#155 .-

#145
-
-
#145 ..
- 1200 m (4000 It)
-#150
-
.. #140

-
#140 .
- 1800 m (6000 It)
-#145
-
#135

#135
.
- 2400 m (8000 It)
-#140
-
#130
-
-
#130 .
- 3000 m (10000 tt)
-#135
-
-
#125

7-4
Intake reed valve:
Type
Bending limit
Valve lift
Lubrication:
Autolobe pump-Color code
Autolube pump-Minimum stroke
Autolube pump-Maximum stroke
Autolube pump-Reduction ratio
Autolube pump-Output Min./200 strokes
Autolube pump-Output Max./200 strokes
Autolube pump wire free play
Oil tank capacity
Oil grade
C. Drive and track suspension
Transmission:
Type
Drive ratio
Engagement rpm
Primary spring:
Part No.
Color code
Secondary spring:
Part No.
Color code
Secondary spring pre-load (twist)
Sheave distance
Sheave off-set
V-belt width and outer line length
V-belt wear limit
Track suspension:
Type
Damper type
Spring color code (Front)
Spring color code (Rear)
.Slide runner wear limit
Track width
Track deflection
Length on ground
Wheel sprocket matenal and number of teeth
Stopper band length
Secondary drive:
Type
Reduction ratio
Chain pitch x Number of links
Free play
Chain housing oil quantity
Chain housing oil grade
Brake:
Type
Brake pad thickness
Brake pad wear limit
Brake cable "L" distance
Clearance between lining pad and disc
7-5
V type
0.6 mm (0.024 in)
9.7 mm (0.38 in)
Pink
0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in)
1.65 ~ 1.87 mm (0.0650 ~ 0.0736 in)
1/40
0.95 ~ 1.19 cc (0.0321 ~ 0.0402 oz)
7 .84 ~ 8.89 CG (0.2651 ~ 0.3006 oz)
25 1 mm (0.98 0.04 in) at idle
2.5 Liter (2.6 US.qt)
YAMALUBE 2-cycle
V-belt automatic centrifugal engagement
3.5: 1 ~ 1 : 1
3400 ~ 3800 r/min
90501-50500
Red
210" (No.3 hole)
90508-45286
Yellow
180
0
(No.2 hole)
+0 +0 .
270 -3 mm (10.63 -011 In)
11 0.5 mm (0.433 0.020 in)
31.6 x 1.099 mm (1.24 x 43.3 in)
26 mm (1.02 in)
Slide rail suspension
Oil and gas damper
Red-Green
No painted
10 mm (0.394 in)
381 mm(15in)
25 ~ 30 mm/l 0 kg (0.98 ~ 1.18 in/22 Ib)
942 mm (37.1 in)
Double Polyethylene. 9 teeth
220 mm (8.66 in) (No.1 hole from the bottom)
Chain (#35K-3)
17/31 (1 : 1.824)
9.525 mm (0.375 in) x 66L
+ 5 +0.2 .
10 -2 mm (0.4 -008 In)
250 cc (8.5 oz)
Gear oil API "GL-3" (SAE #75 or 80)
Floating disc type
13.5 mm (0.53 in)
9.5 mm (0.37 in)
57 mm (2.24 in)
0.15 mm ~ 0.3 mm (0.006 ~ 0.012 in)
1981 SR540E
1981 SR540E
D. Chassis
Frame:
Material Aluminum + Steel
Steering system:
Caster (ski column) 25
Camber 0
Ski length x width x thickness 980 x 120 x 2 mm ( ~ 8 . 6 x 4.7 x 0.08 in)
Ski stance 880 mm (34.6 in)
Ski toe-out Omm(Oin)
Steering linkage type Tie-rod
Lock to lock angle (Ski) Right ski, L: 27.9 R: 33.4
Left ski. L: 33.4 R: 27.9
Steering angle Right: 46
Left: 46
Front suspension:
Type (YAMAHA T.S. SUSPENSION) Coil spring
Damper type Oil and gas damper
Fuel tank:
Capacity 26.6 Liter (7.0 US gal.)
Fuel grade Regular gasoline
E. Electrical
Ignition system:
Type-flywheel magneto (C.D.I. Type)
Model/Manufacturer F3T352/MITSUBISHI
Voltage 12V
Pulser coil resistance 9.0n 10% at 20C (68F) (White/Red-Black)
Charging coil resistance 350n 10% at 20C (68 F) (Brown-Black)
Charging coil resistance 15.0U 10% at 20C (68 F) (Blue-Black)
Ignition timing:
B.T.D.C. 1.5 mm (0.059 in)
Ignition coil: HITACHI : TOYO-DENSO
Manufacturer/Model/Quantity CM62-20/1 pc. : YW-51/1 pc.
Spark gap 9 mm (0.4 in)/300 r/min.
:.
11 mm (0.6 in)/3,OOO r/min.'
Primary winding resistance 0.1 5U 1 0% at 0.12U 10% at .
20C (68F)
20C (68F)
Secondary winding resistance 3.6kU 20% at
4.0kU 20% at
20C (68F)
20C (68F)
Diode (Yes or No) No

Spark plug:
Type & quality NGK BR9EV x 2 pcs.
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Spark plug cap:
Type Resign type with noise suppressor
Noise suppressor resistance 5kn 25% at 20C (68F)
C.D.I. unit:
Model/Manufacturer 8H4-20/MITSU BISH I
Lighting system:
Lighting output 12V-l00W
Lighting coil resistance 0.19n 10% at 20C (68 F) (Yellow-Black)
Headlight type Halogen light
Bulb wattage/q'ty 12V-60/55W x 1 pc.
Tail/Brake light wattage 12V-8W/23W
7-6
1981 SR540E
A.C. regulator:
Model/Manufacturer
Voltage
TRIZ-24B HITACH or SB5 16B TOSHIBA
13.B 0.5V
F. Tightening torque
Part to be tightened
[Engine)
Spark plug
Cylinder head
Cylinder
Flywheel magneto
Crankcase upper and lower
Tightening sequence
Thread size
M14Pl.25
MB Pl.25
MB Pl.25
M16Pl.0
MB Pl.25
M6 Pl.0
Tightening torque
2.B m-kg (20 ft-Ib)
2.5 m-kg) lB ft-Ib)
2.5 m-kg (lB ft-Ib)
7.3 m-kg (53 ft-Ib)
First: 1.0 m-kg (7 ft-Ib)
Final: 2.0 m-kg (15 ft-Ib)
First: 0.5 m-kg (3.5 ft-Ib)
Final: 1.0 m-kg (7 ft-Ib)
,-----1/-
;----:------' -
.. "'0. __
1 4+ i9
Ring weight and stay
Flywheel magneto and stay
Fan shaft and pulley 2
Starter pulley
Crankcase and engine bracket
[Drive and track suspension)
Primary sliding sheave and cap
Installation of primary sheve
Installation of secondary sheave
Bearing housing
Brake caliper and housing chain
Installation of drive chain sprocket
Installation of driven chain sprocket
Chain housing and frame
Installation of front axle L. H.
Front axle housing and frame
Wheel sprocket and front axle
Front pivot shaft
Rear pivot shaft
Rear axle
Sliding runner
[Chassis)
Engine mounting bolt
Steering column and gate
Steering gate
Steering relay rod adjusting nut
Steering lower bracket
Installation of steering column 1.2
M6 Pl.0
MB Pl.O
M16Pl.0
MB Pl.25
MB Pl.25
M6 Pl.O
UNF 1/2"
M14Pl.5
MB Pl.25
M10P1.25
M14Pl.5
M10P1.25
MB Pl.25
M22 Pl.0
MB Pl.25
M6 Pl.0
M10P1.25
Ml0 P l.25
M12 Pl.25
M6 Pl.O
M10P1.25
M8 Pl.25
MB Pl.25
Ml0Pl.25
MB Pl.25
MB Pl.25
7-7
I 11
1.0 m-kg (7.2 ft-Ib)
1.5 m-kg (1 O.B ft-Ib)
4.3 m-kg (31.1 ft-Ib)
2.3 m-kg (16.5 ft-Ib)
2.3 m-kg (16.5 ft-Ib)
1.1 m-kg (B ft-Ib)
Initial: 12 m-kg (B7 ft-Ib)
Loosen once and retighten:
6.5 m-kg (47 ft-Ib)
6.4 m-kg (46 ft-Ib)
2.3 m-kg (16.5 ft-Ib)
4.B m-kg (35 ft-Ib)
6.0 m-kg (43.5 ft-Ib)
4.B m-kg (35 ft-Ib)
2.3 m-kg (16.5 ft-Ib)
B.5 m-kg (61.5 ft-Ib)
2.3 m-kg (16.5 ft-Ib)
0.55 m-kg (4 ft-Ib)
6.4 m-kg (46 ft-Ib)
6.4 m-kg (46 ft-Ib)
B.O m-kg (5B ft-Ib)
0.45 m-kg (3.3 ft-Ib)
5.2 m-kg (37.6 ft-Ib)
2.3 m-kg (16.5 ft-Ib)
1.4 m-kg (10 ft-Ib)
4.7 m-kg (34 ft-Ib)
2.3 m-kg (16.5 ft-Ib)
1.45 m-kg (10.5 ft-Ib)
Remarks
Use Neji lock
(Adhesive)
Use Neji lock
(Adhesive)
Use motor oil
Use lock washer
Use lock washer
1981 SR540E
Steering relay ass'y M10Pl.25 4.7 m-kg (34 ft-Ib) Use cotter pin
Front shock absorber and bracket M8 P1.25 2.1 m-kg (15.2 ft-Ib)
Bracket 1. 2 set bolt M6 Pl.0 0.2 m-kg (1.4 ft-Ib)
Front arm Ml0Pl.25 1.6 m-kg (11.6 ft-Ib)
Ski installation Ml0 P1.25 4.3 m-kg (31. ; ft-Ib)
7-8
Headlight (12V 60W/55W)
01
'-I
cO
LIGI VI
G I G . y I ~
r=1-t
0.1 level switch
~
.
__ I
LI B
VI B,
'--+-+'
~ ~
L
Voltaglf
regulator
1.
@ C.D.I. magneto
...&..
BIW
L IBr"l B
C.D.I. unit
Color code
L. ............ Blue
y ............. yellow
o ............ Orange
G ............ Green
Br ........... Brown
Gy .......... Gray
o o
'"--'"
Ignition coil
L.
R ............. Red
B ............ Black
G/y ........ Green/yellow
B/R ........ Black/Red
B/W ...... Black/White
W/R ....... White/Red
...,
I
W
~
Spark plug
~
.....
<0
00
C/)
:I:1
U1
~
m
Main switch lead
Tai! Ilgl'lt lead
Olile-ve! gauge
Details of wire harness routing
Engme stop switch lead
/ MeIer assembly lead
/ Head l\ghtbeam sWitch lead

Tether SWItch
Fuel pipe
Fuel tank breather pipe
Fuel pump
carburetor
Fuel deJlvery plpe
Details of fuel pipe routing
SR540E
RACING TIPS
Testing in Alaska has yielded the following pro-stock racing specifications and adjustments for
the SR540E. Yamaha has found that these recommendations produce the best performance
under specific test conditions. Different local conditions, however, may require different set-
tings. Use these recommendations as a guide, not hard and fast rules. Always tune your
machine to suit the particular conditions of each race.
ENGINE AND CLUTCH
See technical bulletin S80-012 for standard specifications.
CARBURETOR TUNING
The standard 150 main jet is too rich (especially for the left-side cylinder) even at sea level.
Reduce the main jet size to get good plug color at full throttle. As you reduce the main jet, the
right-side cylinder will not change, but the left-side cylinder will become more and more lean
until it matches the temperature of the right-side cylinder.
CLUTCH TUNING
1. Primary Spring
Standard First Option Second Option
90501-50500-00 90501-55456-00 9050 1-55241-00
Red Silver-White Red-Pink
25 x 1.4 kg/mm 30 x 2.0 kg/mm 35 x 1.75 kg/mm
2. Clutch Weights
Select the rivet quantity and location to maintain a 7100 rv 7200 shift rpm.
3. Secondary Settings
Hole #3 (210)
or
Stretch the spring to 8.5 inches free length. Assemble the clutch with 90(hole #3) of twist
preload. This specification improves the backshifting characteristics of the machine.
Restretch the spring when its free length decreases to 7.5 inches or less.
SUSPENSION
1. Install tunnel protectors (888-21978-00-001. Since the SR540E has a longer track, the stand-
ard protectors are too short. Therefore, mount the protectors as far forward as possible to
protect the steel portion of the frame.
2. Countersink the suspension pivot shafts for
fast installation; install the fender washers
under the slide suspension mounting bolts to
protect the frame.
3. Install an additional rear idler wheel on the rear
axle as shown in the illustration. This addi-
tional wheel will reduce the possibility of the
track derailing.
COUNTERSINK THE
SUSPENSION SHAFTS
INSTALL FENDER
WASHERS
SPACERS
4. Install an additional hose clamp onto each track drive sprocket. The clamps should be
mounted against one another. Check the clamps before each race; they should be tight.
SUSPENSION SETTINGS
A. Smooth Course (Lake Racing)
1. Shorten the slide rail limiter straps so the suspension has the indicated amount of travel. You
will have to drill a new hole in each strap.
------ - . ~ - - - - - . - - - - - - - - - .
-==-------- ---_._-------- -.-
---- -- - - ~ - "
2
. ---------
------------- ~ ' - - ~
2. Install a slide suspension limiter strap to the
T. S. S. steering link bolts to limit travel to
95mm (3.7 in). Set the nitrogen pressure to
7.0 kg/cm2 (100 psi).
3. Select a rear shock absorber from the Optional Parts Summary to suit the local conditions.
4. Install the 1980 SR-V front slide-rail shock (BK4-47481-oo) if desired.
5. For W. S. R. F. lake racing, install the front stabilizer kit and select a softer T. S. S. spring from
the Optional Parts Summary.
SR-V Front Stabilizer Kit
SRX440E Front Stabilizer Kit
B. Rough Course (Cross Country)
BL9-WOO51-00-oo
BM6-W0051-oo-oo
1. Use full travel front and rear. Adjust the slide rail limiter straps for the desired steering
characteristics.
2. Use the front stabilizer kit if desired.
3. Select a rear shock absorber frQm the Optional Parts Summary. We recommend the 1980
SS440/SR540 shock (BK4-47480-oo-00).
4. Install the 19BO SR-V front slide shock absorber (BK4-47489-oo-00) if desired.
TRACK STUDS AND CARBIDES
1. Break in the track and adjust it to specification before each race.
2. Stud the track with carbide penetrators where shown in the illustration. Burn the holes in the
track; do not drill them .

D 0 D 0 0 0 0 D 0 D D D D D D 0




,

D 0 D 0 D D D D D D 0 D 0 D D 0

3
3. Install carbides on the Kalamazoo KXC 925 host bar where shown in the illustration.
a. Lake Racing (no snow)
SKI MOUNTING BOLT
3 FLATS
".
'-.., I I I, l.to I' I 'f I s I .. I 7 111 I , I
approx.
45/8"
9 CARBIDES
4 FLATS
I I I
approx.
5 1/3"
b. Cross Country Racing
SKI MOUNTING BOLT
4 FLATS "". 5 FLATS
'-.. , , I , I I I I I I
I 1 .... 1., I'l'l s I" I ~
7 CARBIDES
I- -l f- ----t
approx. approx.
5 3/8" 6 5/8"
CHASSIS
1. Install SRX ski tip protectors (SM6-23747-00-00), radiator hose and cable ties, or other
suitable ski loop padding to satisfy W.S.R.F. recommendations.
2. Disconnect the handlebar kill switch to eliminate potential mishaps.
3. Install the accessory high windshield (ABA-SK496-00-00) for comfort in cold weather racing.
4. Tie the rear snow flap to the frame to satisfy W.S.R.F. rules (see the rule book).
5. Reinforce the rear tunnel where shown in the illustration.
REINFORCE
4
6. Install a motorcycle-type brake lever with a large free-play adjusting screw to facilitate
adjustment during the race. The brake light must function.
7. Drill the hyfax in the pattern shown below. Use a 3/16 inch drill, and drill the holes 4mm
(0.15 in) deep.
o
o 3/16" 0 0 J9 0
3/8" 00 00
O ~ O ~
o
o
5
SNOWMOBILE TOOL LIST
PART NUMBER DESCRIPTION
TLS-9091 0-47-01 * Sheave Align Gauge
TLS-9091 0-47-02 Sheave Align Gauge
TLS-9091 0-47-03 * * Sheave Gauge
TLS-9091 0-48-00 TSS Strut Holder
TLS-90018-59-02 YP Primary Sheave Puller
TLS-90018-81-01 ST Primary Sheave Puller
TLS-90018-80-00 Primary Sheave Holder
908-90018-83-00 Puller, Bushing
TLS-9091 0-45-00 Track Clip Tool
TLU-90901-05-20 Flywheel Puller
TLM-9091 0-60-00 Nitrogen Charging System
TLM-90910-63-00 Carry Bracket For Nitrogen Charging System
TLM-90011-53-01 Injector Needle
TLS-9091 0-60-00 Clutch Subassembly Too!
TLU-9091 0-35-00 Vacuum Press Test Kit
TLU-9091 0-22-00 COl Tester Kit
* Updated Tool Now Available
* *Tool Updates TLS-90910-47-01
6
DEALER COST
$ 10.20
15.95
5.95
5.95
12.45
12.45
19.95
8.13
43.95
30.67
148.00
14.95
6.39
14.28
72.50
67.95
PERFORMANCE SUSPENSION TUNING
REAR MAIN SPRING AND DAMPER ASSEMBLY
These charts are to be used as a guide. All settings must be checked under actual running
conditions.
DAMPER DAMPER
SPRING SPRING SPRING TENSION COMPRESSION FIRST
PART NUMBER PRELOAD RATE RATE RATE USAGE
8K4-47480-00-00 33.1 kg 1.10 T 65 C55 SR540D,SS440D
8K2-47480-00-00 23.8 kg 1.58 T 95 C 85 SRX440D
8L8-47480-00-00 12.0 kg 1.2 - 1.6 T65 C55 SRX440E,
SS444E,SR540E
NOTE: The lowest preload and damper compression rate allows the most weight transfer and
best acceleration.
REAR MAIN SPRING PRELOAD ADJUSTMENT
LOWEST PRELOAD <IIIIC ... -------------... _ ~ HIGHEST PRELOAD
STD. SEnlNG
NOTE: The lowest preload allows the most weight transfer and best acceleration.
The highest preload is most resistant to bottoming.
7
SPRING
PART NUMBER
90508-99479-00
90508-99480-00
90508-95476-00
905O8-954n-OO
90508-85471-00
90508-85472-00
90508-99482-00
90508-99483-00
90508-90409-00
90508-90408-00
90508-80410-00
90508-80411-00
PERFORMANCE SUSPENSION TUNING
REAR SUSPENSION HAIR PIN SPRING
SPRING SPRING SPRING
PRELOAD RATE COLOR
12.8 kg
435.8
Yellow
kg mm/deg.
15.9 kg
358.1
Pink
kg mm/deg.
8.5 kg
232.7
Brown
kg mm/deg;
10;0 kg
437.5
Red-Green
kg mm/deg.
NA
302.9
Orange
kg mm/deg.
NA
191.2
Blue
kg mm/deg.
NA = Information Not Available
8
FIRST
USAGE
SS440D
Retrofit Spring
SR540D
Retrofit Spring
SS440E
Standard
SR540E
SRX440E
Standard
SRX440D
SR540D
SS440D
PERFORMANCE SUSPENSION TUNING
The fewer number of wheels that can be used without Hyfax wear, the greater the accelera-
tion and top speed.
CONDITION #2 CONDITION #3
ACCESSORY WHEEL CONDITION #1 HARD PACKED ICE OR
PLACEMENT SOFT SNOW OR LlnLE SNOW NO SNOW
~ i ~ O
No Hyfax Wear less Hyfax Wear less Hyfax Wear
less More More
Performance Performance Performance
23_
)
~
)
~
)
~
"-
~ m---=:..
"
.0
,
~
,
f
, ,
"-
-
No Hyfax Wear More Hyfax Wear More Hyfax Wear
More less less
Performance Performance Performance
NOTE: Wheels #1 and #3 come in the crate.
9
SPRING
PART NUMBER
90501-75612-00
BlO-00000-10-00
BlO-OOOOO-OO-OO
90501-70584-00
-
C;
~
-
III
()
~
2
z
o
iii
fn
III
~
A.
~
()
PERFORMANCE SUSPENSION TUNING
TSS SPRINGS
200
175
STRUT TRAVEL (MM)
COLOR FEELING RATE
Red Hard 1.6
Blue Medium 1.0 -1.6
White Medium Soft 1.01.4
No Color Soft 0.8 -1.2
TSS PRELOAD
,
ORIGINAL
i
APPLICATION
SRX440E at SR540E
Accessory
Accessory
SR540D
NOTE: TSS preload is set by adjusting the nitrogen pressure In the shock absorber.
TSS NITROGEN PRESSURE
Max. 284lbs.
Std. 2131bs.
Min. 185lbs.
10
PERFORMANCE SUSPENSION TUNING
FRONT STOPPER BAND
#1
C A
# 5 ~ - - - - ~ . - - - - - ~ ~ - - - - ~ - - - - - - ~ - - - - - - - e ~ - - - - ~
CII
#4
z
C
..
I11:III
III
A.
A.
#3
e
In
I11:III
C
III
D ..
#2
B
#1 ~ - - - - ~ . - - - - - - - + - - - - - - - + - - - - - - - -
The Indicated settings provide:
A. Best straight line acceleration and top speed;
B. Most positive steering;
C. Lowest center of gravity;
D. Maximum suspension travel.
* Stopper band standard position.
X Un useable combination; shock will top out.
11
SPRING
PART NUMBER RATE
9050.1-45534-0.0. 1.0.0.
9050.1-50.50.0.-0.0. 1.40.
90501-50.543-0.0. 1.40.
9050.1-50.351-0.0. 1.40.
9050.1-55230.-0.0. 1.50.
9050.1-50.622-0.0. 1.50.
9050.1-50447-0.0. 1.75
9050.1-55343-0.0. 1.75
90.50.1-55241-0.0. 1.75
9050.1-55403-0.0. 1.75
9050.1-55225-0.0. 1.75
90.501-55404-0.0. 1.75
90.50.1-55419-0.0. 1.80.
9050.1-5540.4-0.0. 1.80.
9050.1-55456-0.0. 2.0.0.
PRIMARY SPRINGS
(Listed In Order of Spring Rates)
WIRE OUTSIDE NUMBER
PRELOAD COLOR DIA. DIA. TURNS
25 Blu-Grn 4.5 55 4.68
25 Red 5.0. 55 5.0.7
20. Grn-Grn 5.0. 55 5.57
40. Yel-Grn 5.0. 54 5.30.
65 Red-SII 5.5 54.5 6.50.
30. Yel-Pnk 5.0. 55 4.83
30. Pnk-Wht 5.0. 55 4.40.
30. Red-Blu 5.5 55 5.80.
35 Red-Pnk 5.5 55 5.80.
40. Yel-Wht 5.5 54.5 5.75
45 Red-Grn 5.5 55 5.80.
55 Grn-Pnk 5.5 55 5.80.
42 Brn-Wht 5.5 55 5.50
49 Org-Wht 5.5 55 5.50.
30. SiI-Wht 5.5 55 5.50.
FREE FIRST
LENGTH USEAGE
86.5 EX44o.D
79.4 ET34o.D
75.8 EC54o.
90.1 GPX-G 50.0.0. rpm
N
10.4.8 GPX433F GYT Kit
81.5 SR54o.E
78.6 EX44o.A
78.6 SRX Opt. 40.0.0. rpm
81.5 GPX338/433F Std.
84.4 EX44o.
87.2 Tuning Part
92.9 Tuning Part
84.8 SRX34o. 50.0.0. rpm
88.2 SRX44o. 50.0.0. rpm
77.3 SRX44o.A Std.
-_ .. --
(Continued)
SPRING
PART NUMBER RATE PRELOAD
90501-55487-00 2.00 50
90501-55242-00 2.00 60
90501-55356-00 2.00 64
w 90501-50396-00 2.00 20
90501-55345-00 2.05 20
90501-55397-00 2.22 24.5
90501-55388-00 2.40 40
90501-55485-00 2.50 30
90501-55559-00 3.00 20
(Continued)
PRIMARY SPRINGS
(Listed In Order of Spring Rates)
WIRE OUTSIDE NUMBER
COLOR DIA. DIA. TURNS
Red-Org 5.5 54.5 5.0
Red-Org 5.5 55 5.40
Blu-Sil 5.5 55 5.40
Grn-Wht 5.0 55 4.10
Red-Red 5.5 54.5 5.30
Red-Wht 5.5 55 4.50
Blu-Wht 5.5 54.5 4.90
Brn-Wht 5.5 55 4.50
Blu 5.5 55 4.60
FREE FIRST
LENGTH USEAGE
93.0 SRX440A Modified
91.5 GPX338F GYT Kit
93.5 GPXG GYT Kit
71.5 SRX340 Std.
71.3 GPXG Std.
72.5 SRX440 Std.
78.2 EX340
73.5 SRX440A Improved
68.2 ET250D
SECONDARY SPRING CHART
SPRING
CONSTANT NO. COIL WIRE FREE
PART NUMBER kg/mm TURNS' DIA. DIA. LENGTH COLOR USED ON
90508-45301-00 4.86 8.0 64.5 4.5 120 Silver EX440
90508-45287-00 4.32 9.05 64.5 4.5 120 Blue EX340, A, B
90508-45286-00 4.86 8.05 64.5 4.5 85 Yellow SRX340,SRX440, A, B,C,
0, E, SR540D, E, EX440,
A, B, C, 0, E, SS440D, E,
EXCEL-V, EC540D
90508-40341-00 4.86 5.05 64.5 4.0 85 White SRX440, A
90508-40080-00 3.19 9.9 50.0 4.0 105 None ET250A, B, C, 0, E '<t
ET340B, C, 0, ET340EC
ET30OC, 0, E
SPRING PULL CHART
Hole Number 2 3 4 1 2 3
Degrees 60
0
90
0
120
0
150
0
180
0
210
0
Preload (TWist) 1/2 3/4 1 1-1/4 1-1/2 1-3/4
Silver - Lbs. Pull 8 11 14 16 19 22
Blue - Lbs. Pull 6 9 11 13 16 19
Yellow - Lbs. Pull 7 10 12 15 18
White - Lbs. Pull 6 9 11 14 17
All ET Series 10 Lbs. Pull@160
0
Preload (Twist)
Refer to service data for additional information on proper settings
CONTENTS
I NEW SERVICE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
1. V-BELT CLUTCH ......................................... 1
2. FRONT AXLE ........................................... 15
3. FUEL TANK ............................................ 16
4. BELLY PAN LID ......................................... 17
5. PULSER AND CHARGING COIL TEST ....................... 18
6. LIGHTING COIL TEST .................................... 18
II SPECiFiCATIONS ........................................... 19
I. NEW SERVICE PROCEDURE
1. V-BELT CLUTCH
NOTE: ________________________ _
The following items under "4-1. Drive" in the
SR540E Service Manual will be changed as
described below:
A. Sheave adjustment
B. Primary sheave
C. V-belt
D. Secondary sheave
A. SHEAVE ALIGNMENT
1. Sheave distance 2. Sheave off-set
270 ~ g mm 11 0.5 mm (0.43 0.02 in)
(10.6 ~ g . 1 1 in)
1. Using the sheave gauge, check the sheave
offset. If the gauge does not contact the
primary and secondary sheaves at the
four indicated points, the sheave offset is
incorrect.
-1-
Sheave gauge: YS-91047 (U.S.A.)
90890-01702
2. Check the sheave center-to-center
distance.
3. If the center-to-center distance or offset
is not within the specification, adjust it
in the following manner:
4. Loosen the four engine-mounting bolts.
By moving the engine back and forth,
adjust the sheave distance so that the
center-to-center distance between the
primary sheave mounting bolt and secon-
dary sheave mounting bolt is equal to
the sheave gauge setting spefied above.
5. Adjust the thickness of shims on both
ends of the secondary sheave so that the
distance (offset) between the primary
fixed sheave and secondary sliding
sheave is equal to the sheave gauge.
6. Repeat steps 4 and 5 above until the
sheave distance and sheave offset are
adjusted correctly.
NOTE: ______________________ __
Select proper shims to be used at A and B.
The total clearance at A and B should be 1.0
mm (0.04 in) or less.
90201-225A4 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
90201-222FO
7. Tighten the engine mounting nuts while
taking care not to move the engine.
B. CLUTCH TUNING
The clutch may require tuning depending
upon the area of operation and the desired
handling characteristics. The clutch can be
turned by changing engagement & shifting
rpm.
Clutch engagement rpm is defined as the
engine speed where the machine first begins
to move from a complete stop.
Shifting rpm is the engine speed when the
Engine rpm
t
90201-252F 1
Tightening torque:
52 Nm (5.2 m kg, 37.6 ftlb)
machine passes a point 200 - 300 m (650 -
1000 ft) from the starting position after the
machine has been started at full-throttle from
a dead stop.
Normally, when a machine reaches shift rpm,
the vehicle speed Increases but the engine
speed remains nearly constant. Under un-
favorable conditions, however (wet snow, icy
snow, hills, or rough terrain), engine speed
can decrease after the engine has reached
shifting rpm.
Engine rpm
t
Clutch
shifint rpm
Clutch shifting rpm
Clutch
engagement rpm
Clutch
engagement rpm
- Travelled distance
Starting position 200 - 300 mm (650 -1000 ft)
Good Condition
-2-
Travelled distance
r-------------,r-
-
Starting position 200 - 300 mm (650 -1000 ft)
Bad Condition
1. Clutch setting data
a. Standard specification
S.t.d. SPEC High altitude spec
Engagement r.p.m. 3600 200 +-
Shifting r.p.m. 7000 200 +-
Parts No. 90501-55672 90501-50500
Set weight 36 kg 25 kg
Primary spring .
Spring constant 2.1 kg/mm 1.4 kg/mm
Color GREEN - ORANGE RED
Q'ty 2 p.c.s.
+-
Spider shim
Part No.
90201-327E3 (3.2 t)
+-
90201-32710 (1.6 t)
Primary spring shim Q'ty 0 +-
Mark 8R6 8R9
Weight
.
Part No. 8R6-17633-00 8 R9-17633-00
Q'ty
.
2 p.c.s. 1 pc (No.1 Hole)
Weight rivet
Parts No. 90261-06015 90261 -06016
Parts No. 90508-45508 +-
Twist angle 90 +-
Secondary spring
Spring hole No. No.3
t
+-
Color GREEN +-
NOTE: __________________________________________________________ __
The "Highland spec" applies to operation at an altitude of more than 1 ,500 meters (4,500 feet).
b. How to change clutch engagement rpms and clutch shifting rpms
~
Clutch engagement r.p.m. Clutch shifting r.p.m.
Decreasing Increasing Decreasing Increasing
Primary spring shim
Lessen number Increase number
of shims of shims
- -
Spring
- - Decrease Increase
constant
Primary spring
Preload Decrease Increase - -
Centrifugal force of weight Increase Decrease Increase Decrease
Torsion spring
- - Decrease Increase
constant
Secondary spring
Twist angle - - Smaller wind Greater wind
-3-
2. Primary clutch engagement rpm setting
The factors which change the clutch
engagement rpm are the primary spring
shim, primary spring preload, and centri-
fugal force of the weights as shown in
1-b. Therefore, the clutch engagement
rpm can be adjusted by replacing the
primary spring shim, the primary spring
itself or the primary weight rivets.
Standard clutch engagement rpm:
3400 ~ 3800
Clutch engagement rpm for highland:
3400 ~ 3800
a. Primary weight setting
By changing the position and quantity of
primary weight rivets, the thrust of the
weights is changed, and thus the engine
rpm at which the clutch is shifted is also
changed. (As a result, the engine rpm at
which the clutch is engaged is changed.)
NOTE: ________________________ __
The position of rivets for the three weights
must be the same.
1) Removal of rivets
Drive out in the manner as illustrated.
2) Clinching of rivets
After driving in the rivets, file down the
rivet heads so they are flush with weight
surfaces.
3. Secondary clutch shifting rpm setting
The secondary clutch must be turned to
match snow and weather conditions.
Tuning the clutch keeps the engine
operating in the proper rpm range.
-4-
Standard clutch shifting rpm:
6800 ~ 7200
Clutch shifting rpm for highland:
6800 ~ 7200
a. Secondary spring setting
1) Secondary spring position
The spring seat is provided with four
holes, Nos. 1 to 4, so that the secondary
spring position can be changed as re-
quired.
1. Spring seat
2) Secondary spring tension
The secondary spring tension can be
changed by moving the spring position
from the free position in order to reset
the clutch shifting rpm as required. The
four holes are spaced at intervals of 30 .
Secondary spring
Spring wind
position
No.1 30,150,270
No.2 60,180
No.3 90,210
No.4 0,120,240
Winding the spring more (i.e., from 30
to 60) will increase the clutch shifting
rpm and vise versa. Snow conditions will
also require a change of the spring
tension in order to attain the standard
shifting rpm. The spring tension must be
greater on wet snow than on packed
snow. Less tension is needed on icy
snow.
3) Secondary spring setting
The secondary spring settings are
classified into two types as shown below.
Select a proper setting according to
operating conditions. (For the setting
procedure, refer to "E. Secondary
Sheave.")
Course Trail and tour
Setting factor Position of spring seat
Ice snow No.2
Packed snow Std.
Wet snow Std.
C. V-BELT
1. Removal
a. Turn the secondary sliding sheave clock-
wise and push it towards the chain case.
b. While holding the sliding sheave in this
compressed position, remove the V-belt
from the secondary sheave, then from
the primary.
2. Inspection
a. Visually inspect the V-belt for signs of
damage. Replace the belt if it is
damaged.
b. Measure the width of the V-belt. If the
belt is worn beyond the wear limit,
replace it.
Wear limit: 26 mm (1.02 in)
\
\
\
\
\
\
\
\
\
\
\
I
I
I
I
I
I
I
I
I
1. New: 31.5 mm (1.24 in) 2. Wear limit: 26 mm (1.02 in)
Twist
60
Std.
Std.
-5-
Std. secondary spring:
PIN: 90508-45508
Color code: Green
Std. secondary spring position: No.3
Std. secondary spring twist: 90
Lake surface
Position of spring seat Twist
No.2 60
Std. Std.
Std. Std.
c. Measure the length of the V-belt. It
should be within specification, if not,
replace the belt.
Part No. Length of V -Belt
SF2-17641-00 1,099 mm (42.S in)
Q)
1. V-belt length
0_ PRIMARY SHEAVE
Washer
Tightening torque: 362 tt-Ib)
500 Nm (50 m-kg,

NOTE: X
Oiling Point
No oiling or greasing
is allowed.
Apply Three Bon . d No 1305 to the top four threads.
Steel shim
Weight
Roller pin
Spider
Slider
Tightening torque: e
First tighten the bolt to a torqu
f A then loosen it.
~ e t i ~ h t e n bolt to a final torque of
!.: 120 Nm (12 m-kg, 87 ft-Ib)
B: 58 Nm (5.8 m-kg, 47 tt-Ib)
-6-
Plastic washer
Sliding sheave
CAUTION:
Always use a self-locking bolt.
Self-locking bolts must never
be reused.
Tightening torque: 54 ftolb)
7.5 Nm (0.75 m-kg, .
Sheave cap
Sheave cap bolt
Tightening torque: 11 ft-Ib)
15 Nm (1.5 m-kg,
1. Removal
a. Remove the drive guard, and remove the
V-belt.
b. Hold the fixed sheave with the primary
sheave holder and remove the clutch
bolt. Drive the primary sheave off the
crankshaft with the primary sheave
puller.
Primary sheave holder:
YS-01880 (U.S.A.)
90890-01701
Primary sheave puller:
YS-01882 (U.S.A.)
90890-01890
1. Sheave holder 2. Sheave puller
2. Disassembly
a. Loosen the six sheave cap bolts
b. Remove the three sliders.
c. Loosen the six weight pin securing bolts
and remove the weights.
d. Loosen the six collar pin securing bolts
and remove the collars.
e. Disassembling the spider, sliding sheave,
and bushing (large)
NOTE: ______________________ _
For this operation, the special tools and
. Three Bond No. 1305 (required for spider and
fixed sheave assembly) are necessary.
If these are unavailable, avoid disassembling.
1) Secure the primary sheave assembly to
the tool (1) gripped in a vise, using the
primary sheave bolt.
Yamaha spider wrench:
90890-01711 YS-28890 (U.S.A.)
-7-
Tightening torque:
120 Nm (12 mkg, 87 ftlb)
. ,
1. Yamaha spider wrench YS-28890 90890-01711
NOTE: ______________________ __
Thoroughly clean the tapered portions of the
primary sheave and tool (1).
2) Install the tool (2) onto the spider and
loosen the spider.
Loosening torque:
500 '" 1 ,000 N m
(50'" 1 00 m kg, 360'" 730 ftlb)
WARNING:
To loosen the spider, high torque is required
and therefore, make sure the primary sheave,
vise, and tools are tightely secured also take
care not to crack the spider.
3) Remove the primary sheave bolt, and
using the primary sheave puller, remove
the primary sheave assembly from the
tool (1).
Primary sheave puller:
9 0 8 9 0 ~ 0 1 8 9 8 YS-01882 (U.S.A.)
3. Inspection
a. Inspect the tapered ends of the crank-
shaft and the primary fixed sheave for
scraches. If either is severely scratched,
replace it. If scratches are minor, burnish
the component with emery cloth.
b. Check the primary sheave cap bushing
and the sliding sheave bushing for wear.
If worn beyond tolerance, replace the
bushing.
Use the bushing tool if a bushing is
difficult to remove.
Bushing tool: 90890-01713
1. Bushing tool
-8-
~
Bushing clearance, limit
Small bushing Large bushing
Inside 0.25 mm (0.01 in) 0.25 mm (0.01 in)
Outside 0.25 mm (0.01 in) 0.25 mm (0.01 in)
c. Weights
Check the bushing bore inside diameter
of each weight and its contact surface
with the collar. If worn more than limits,
replace them with new ones.
Bushing bore
Contact surface with collar
Wear
diameter (d)
A B
limit
10.20 mm 0.5mm 1.0mm
(0.40 in) (0.021 in) (0.04 in)
Contact surface with collar
B
d. Roller
Check the inside diameter of the roller
bushing, then check the contact surface
of the roller and the weight. If either sur-
face is worn unevenly or more than ac-
ceptable limits, replace them.
Bushing bore Contact surface
Wear
diameter (d) with weight (D)
limit
10.3 mm (0.41 in) 15.0 mm (0.59 in)
Contact surface
with weight
d
Uneven wear
If the outer surface of the roller is worn
unevenly, the roller is probably seized to the
pin. Be sure to check the roller pin.
e. Weight pins and roller pins
Check both weight and roller pins. If
metal dust collects on pins, remove it
using sandpaper (# 800 - # 1000).
If the chrome-plated surface of the pin
scales off, replace the pin with a new
one.
f. Slider
Install the slider onto the sliding sheave,
and check for wear on its contact surface
with the spider. If worn more than
limits, replace the slider. Also if it is
cracked, it should be replaced.
Wear limit: 30.5 mm (1.20 in)
-9-
1. Wear limit
g. Spider
Check the contact surface of the spider
with the slider. If it is worn more than
limits or cracked, replace it with a new
one.
Wear limit: 28.5 mm (1.12 in)
1. Wear limit
h. Primary spring
Check the primary spring for damage or
fatique, and replace it as required.
4. Assembly
a. Install the large bushing into the sliding
sheave. Using the weight pin, install the
weight, washers, and steel shim in the
sliding sheave.
Weight
Plastic washer
Sliding sheave
NOTE: ____________ _
The weight should be adjusted so that it has
no thrust play. If any Fe-washer is added, it
should be installed in the position indicated
by the arrow mark.
No. of standard steel shim: 1 pc. I
Weight pin tightening torqu.e:
75 Nm (0.75 m kg, 5.4 ftlb)
b. Using the roller pin, install the collar and
washer on the slider.
Roller pin tightening torque:
7.5 Nm (0.75 m kg, 5.4 ftlb)
c. Install the spider, sliding sheave and
fixed sheave
1) Install the sliding sheave, spider shim and
washer onto the fixed sheave.
2) Apply Three Bond No. 1305 to the
threaded portion of the fixed sheave.
Apply to the top four threads
-10-
Apply Three Bond
No. 1305 to:
4 threads
1. Three Bond should be applied only to
the area apecified. Never apply to the
outer surface of the bushing (large) or
other areas.
2. Do not use the clutch until the Three
Bond has completely cured. Wait 24
hours before using the clutch.
3) Align the arrow mark on the spider with
the slot in the sliding sheave edge, and
install the spider onto the fixed sheave.
Slot in sliding sheave,
4) While sliding the slider toward the
spider, install the slider onto the sliding
sheave.
5) According to "e-l) and 2)," install the
tool (2) on the spider and tighten.
Tightening torque:
500 Nm (50 m' kg, 360 ftlb)
1. Yamaha spider wrench YS-28890 90890-01711
WARNING:
Since tightening torque is high, make sure the
primary sheave, vise, and tools are tightely
secured. Also take care not to crack the
spider.
6) Remove the primary sheave according
to "2 Disassembly e-3".
d. Install the primary spring, and align the
arrow mark on the sheave cap with the
slot in the sliding sheave (and also with
the arrow mark on the spider), and
install the sheave cap.
1. Sliding sheave slot
2. Spider arrow mark
3. Sheave cap arrow mark
- 11 -
e. Tighten the sheave cap bolts.
Tightening torque:
15 Nm (1.5 m'kg, 11 ftlb)
5. Installing
Hold the primary fixed sheave with the
primary sheave holder, and torque the sheave
bolt to specification.
Primary sheave holder:
YS-1880 (U.S.A.)
90890-01701
Tightening torque:
Tighten the bolt to A to properly
seat the primary sheave on the crank-
shaft. Loosen the bolt, then torque it
to B, the final torque.
A: 120 Nm (12 m'kg, 87 ftlb)
B: 58 Nm (5.8 m' kg, 42 ftlb)
E. Secondary sheave
Tightening torque: 4 ~ 7 Nm (0.4 ~ 0 . 7 mkg. 2.9 ~ 5 ft'lb)
CAUTION:------------,
Turn the screw securing the collar clockwise when
viewed from the collar side. and lock the secondary
shaft and collar. tighten the secondary sheave.
Check the ramp shoes on secondary sliding sheave
for wear. Replace ramp shoes as required.
Sliding sheave
Fixed sheave
Tightening torque: 50 ~ 70 Nm (5.0 ~ 7.0 mkg. 36.2 ~ 50.6 ft'lb)
Greasing point
... -+
NOTE: X -+
No oiling or greasing is allowed
1. Removal
a. Apply the brake and remove the secon-
dary sheave mounting bolt.
b. Remove the secondary sheave from the
jack shaft.
2. Disassembly
WARNING:
Use extreme CAUTION when disassembling
the secondary sheave. Serious injury can
occur from the sudden release of spring
tension. Use the Yamaha Secondary Sheave
Assemoly Tool to contain the spring tension
before removing the retaining circlip. DO
NOT attempt this procedure unless you have
the proper tools and understand the instruc-
tions thoroughly.
-12-
a. Install the secondary sheave onto the
tools (1) and (2) so that the fixed sheave
faces downward.
Secondary Compressor:
90890-01712 YS-28891 (U.S.A.)
b. Hold the spring seat with the tool (3),
screw in the tool (4), and separate the
spring seat from the plain washer by
pushing the spring seat downward.
c. Remove the circlip, and while screwing
out the tool (4), set the secondary spring
free.
d. Remove the spring seat, secondary
spring, sliding sheave and fixed sheave.
3. Inspection
a. Inspect both sheaves. If either is warped,
replace it.
b. Inspect the ramp shoes on the sliding
sheave; replace as necessary.
c. Check the sheave bushings for wear; re-
place the sheave as required.
d. Check the spring. If it is fatigued or
damaged, replace it.
4. Assembly
a. Install the secondary fixed sheave and
sliding sheave onto the tools (1) and (2).
b. Hook the end of the secondary spring
onto the spring hole in the sliding
sheave.
c. Hook the other end of the secondary
spring onto the hole (indicated by No.)
in the spring seat.
Std. spring position: No.3 hole
-13 -
d. Install the plain washer and circlip.
e. Install the tools (3) and (4), and screw in
the tool (4) to the position at which the
splined portion of the spring seat nearly
aligns with the splined portion of the
fixed sheave.
f. Bring the spring seat splines to align with
the fixed sheave splines by hand.
NOTE: ________________________ __
Make sure that the three cams of the spring
seat are in a position where they can move
into the guide hole in the sliding sheave cam.
g. Screw in the tool (4) so that the spring
seat is splined to the sliding sheave.
h. Screw in the tool (4) to bring down the
spring seat to a position where the spring
seat cam does not contact the sliding
sheave cam when they turn.
seat cam
Clearnace
sheave cam
-14-
i. Turn the sliding sheave the specified
degrees in the c?unterclockwise direc-
tion, and screw in the tool (4) so that
the spring seat engages with the sliding
sheave.
Standard twist angle: 90
1. Sliding sheave
j. Screw in the tool (4), and while pushing
the spring seat, fit the circlip to the fixed
sheave to lock the spring seat.
. Circlip
k. Remove the secondary sheave from the
tool.
2. FRONT AXLE
The A and B items under "4-1-F-3. Installa-
tion" in the SR540E are altered as follows:
L/H
GUIDE WHEEL
99mm
(3.90 in)
104 mm (4.09 in)
A. Installation
1) Press-fit the sprocket wheels (8R6-
W4753-00) onto the front axle ..
50mm
(.1.97 in)
189.5 mm
(7.46 in)
NOTE: ________________________ _
The right and left sprocket wheels shoud be
installed so that the arrow marks on the A
surfaces are aligned.
2) Secure both guide wheels to the front
axle with the collar set bolts.
Tightening torque:
5.5 Nm (0.55 m kg, 4 ftlb)
104 mm (4.09 in)
NOTE: ________________________________________________________ __
The left side guide wheel should be set to the position shown in the figure after installing the front
axle onto the chassis.
-15-
3. FUEL TANK
The "5-6. Fuel tank" in the SR540E is changed as follows:
1. Check all lines. If any are cracked,
crimped or damaged in any way, replace
them.
2. Be sure all lines are secured in place by a
retaining clip.
-16 -
....... __ ._ .. _. pipe
uel filter
3. Be sure that all lines are routed correct-
Iy. The breather pipe must be routed so
that no fuel will leak during operation.
4. Replace the fuel filter each season.
,
4. BELLY PAN LID
Two belly pan lids are attached to the front
part of the belly pan. These lids should be
used in the following manner.
Holed lid
Belly pan
2. When it is not so cold
When it is not so cold in early spring, the
blind lid should be removed and the
Holed lid
-17-
1. Standard type
As shown below, the holed lid is at-
tached to the engine room side, and the
blind lid is attached to the outside of the
belly pan.
Engine room side
Outside
holed lid should be installed as shown
below for better cooling of the engine
and clutch.
Engine room side
Outside
5. PULSER AND CHARGING COl L TEST
The "6-1-G" in the SR540E is changed as
fol!ows.
Check the resistance of each coil as shown in
the illustration. If the resistance is not within
specification, the coil is not working. Check
the connections. If the connections are good,
the coil is damaged internally; it should be
replaced.
Pulser coil -----
Charge coil--
590Q
(Pulser coil!
Pocket tester: YU-03112
Charging coil resistance:
Black to Brown leads:
590 Q 10% at 20C (68F)
Pulser coil resistance:
Black to White/Red leads:
15.1 Q 10% at 20C (68F)

15.1 Q
(Charge coil!
.QXl
r- "'--'----,..,...
I
I
I
L--::==-_*-CDCJ i
:
__ 1 I
_________ J
6. LIGHTING COl L TEST
The "6-2-C" in the SR540E is changed as
follows.
Check the resistance between the yellow lead
and ground. If the resistance is not within
specification, the coil is not working. Check
1. Yellow
2. Brown
3. Black
4. White/Red
5. Flywheel magneto
6. Pocket tester
7. Set tester at "R x 1" position
the connections. If the connections are good,
the coil is broken internally; it should be
replaced.
Lighting coil resistance:
Black & Yellow:
0.19 Q 1 0% at 20C (68F)
===T---
0.,90"0%
Q x 1
o
1. Yellow
2. Brown
3. Black
4. White/Red
5. Flywheel magneto
6. Pocket tester
7. Set tester at "R x 1" position
-18 -
,
SPECIFICATIONS
A. General
* New specification (Compared with 1981 SR540E)
Model SR540F
Model:
Model (I.B.M. No.) *SR540F (8R6)
Frame I.D. & starting number *8R6027101
Engine I.D. & starting number * SA5350271 0 1
Dimension:
Overall length 2,610 mm (102.7 in)
Overall width (std) 1,080 mm (42.5 in)
Overall height (W/windshield) 970 mm (38.2 in)
B. Engine
Description:
Engine type Axial fan cooled two-stroke, torque
induction, twin cylinders
Engine model SA535
Displacement 535 cc (32.65 cu.in)
Bore x Stroke 73 x 64 mm (2.874 x 2.52 in)
Effective compression ratio 6.0: 1
Starting system Recoil hand starter
Ignition system C.D.I.
Lubrication system "Autolube" oil injection
Cylinder head:
Combustion chamber volume (with spark plug) 27.5 cc (1.68 cu.in)
Compression chamber type Dome + Squich
Head gasket thickness x q'ty 0.5 mm (0.02 in) x 1 pc.
Cylinder:
Material Cast iron sleeves aluminum
Bore size 73 mm (2.874 in)
Taper limit 0.05 mm (0.0020 in)
Out of round limit 0.01 mm (0.0004 in)
Piston:
Piston skirt clearance (measuring point) 0.055 - 0.060 mm (0.0022 - 0.0024 in)
[17 mm (0.67 in) from piston skirt end)
Piston oversize 1st 73.25 mm (2.884 in)
2nd 73.50 mm (2.894 in)
3rd 73.75 mm (2.904 in)
4th 74.00 mm (2.913 in)
Piston pin outside diameter x length cf> 20 x 56 mm (cf> 0.787 x 2.20 in)
Piston ring:
Piston ring design
Keystone
Ring end gap (installed)
*0.2 - 0.4 mm (0.008 - 0.Q16 in)
Small end bearing:
Type Needle bearing
Big end bearing:
Type Needle bearing
Crankshaft:
Crankshaft assembly width (A) 200 0.25 mm (7.87 0.010 in)
Crankshaft assembly width (F)
6 +0 (6 +0
o -0.05 mm 2.3 2 _ 0.002
in)
Crankshaft deflection (D)
D1: 0.03 mm (0.0012 in) D2: 0.04 mm (0.0016 in)
D3: 0.04 mm (0.0016 in) D4: 0.05 mm (0.0020 in)
-19 -
Connecting rod big end side clearance (C) 0.25 - 0.75 mm (0.010- 0.030 in)
Connecting rod small end deflection (P) 2.0 mm (0.079 in)
I
-jf- P
Q
I J
L I ~ A ~ ~
Crank pin outside diameter x length et> 24 x 59 mm (et> 0.945 x 2.323 in)
Crank pin type Solid shaft assembly type with serration
Crank bearing type (Left) x q'ty #6306 special x 2 pcs.
Crank bearing type (Center) x q'ty #6206 special x 2 pcs.
Crank bearing type (Right) x q'ty #6206 special x 1 pc.
Crank oil seal type (Left) x q'ty FWJ-3278 9.5 TS x 1 pc.
Crank oil seal type (Center) x q'ty Labyrinth seal x 1 pc.
Crank oil seal type (Right) x q'ty FWJ-3248 10-1 TS x 1 pc.
Cooling fan:
Fan belt tension 4 - 6 kg/8 mm (8.8 - 13.2Ib/0.31 in)
Carburetor:
Type & manufacturer/quantity B D44-38/K E I H I N/1 pc.
I.D. Mark *8R600
Main jet (M.J.)
*#155
Main air jet (M.A.J.) #180
Power jet (Pw.J.) #150
Power air jet (Pw.A.J.) #170
Slow jet (S.J.) #92
Slow air jet (S.A.J.) #100
Pilot screw (P.S.) *2.0 turns out
Starter jet (St.J.) #160
Float height 15+
2
mm (O.59+
0
.
08
in)
-3 -0.12
Idling engine speed 1500 r/min
* Main jet setting chart
1""-
Temperature
_30
o
e -20
o
e -10
o
e
oOe
10
0
e 20
0
e
Altitude
""
' (- 22F)
(_4F) (14F) (32F) (50F) (SSoF)
.. #150 ..
Sea level
r----#155 #145 .. ..
.. #145
- -600 m (2000 ttl
1--#150 #140 ..
-
.. #140 ..
-1200 m (4000 ttl
r----#145 #135 .. ..
..
#135
-
-1800 m (6000 tt)
1----#140 #130 .. ..
.. #130 ..
-2400 m (8000 tt)
-#135 #125
- -
..
#125 ..
- 3000 m (10000 tt)
-#130 #120
-
..
-20-
Intake reed valve:
Type
Bending limit
Stopper height
Lubrication:
Autolube pump - Color code
Autolube pump - Minimum stroke
Autolube pump - Maximum stroke
Autolube pump - Reduction ratio
Autolube pump - Output Min./200 strokes
Autolube pump - Output Max./200 strokes
Autolube pump wire free play
Oil tank capacity
Oil grade
C. Drive and track suspension
Transmission:
Type
Drive ratio
Engagement rpm
Shfiting rpm
Primary spring:
Part No.
Color code
Secondary spring:
Part No.
Color code
Secondary spring preload (twist)
Sheave distance
Sheave offset
V-belt width and outer line length
Vbelt wear limit
Track suspension:
Type
Damper type
Spring color code (Front)
Spring color code (Rear)
Slide runner wear limit
Track width
Track deflection
Length on ground
Wheel sprocket material and number of teeth
Stopper band length (Front)
Stopper band length (Rear)
Secondary drive:
Type
Reduction ratio
Chain pitch x Number of links
Free play
Chain housing oil quantity
Chain housing oil grade
Brake:
Type
Brake pad thickness
Brake pad wear limit
Brake cable "L" distance
Clearance between lining pad and disc
V type
0.6 mm (0.024 in)
* 12 9.2 mm (0.4724 0.0079 in)
*Gray
0.20 - 0.25 mm (0.0079 - 0.0098 in)
1.65 - 1.87 mm (0.0650 - 0.0736 in)
* 1/36
0.95 - 1.19 cc (0.0321 - 0.0402 oz)
7.84 - 8.89 cc (0.2651 - 0.3006 oz)
25 1 mm (0.98 0.04 in) at idle
2.5 Liter (2.6 US. qt)
YAMALUBE 2-cycle
V-belt automatic centrifugal engagement
3.5: 1 - 1 : 1
3400 - 3800 rpm
* 6800 - 7200 rpm
*90501-55672
* Green - Orange
*90508-45508
* Green
*90
0
(No.3 holes)
mm in)
11 0.5 mm (0.433 0.020 in)
31.6 x 1,099 mm (1.24 x 43.3 in)
26 mm (1.02 in)
Slide rail suspension
Oil and gas damper
Red - Green
No painted
10 mm (0.394 in)
381 mm (15 in)
25 - 30 mm/l0 kg (0.98 -1.18 in/22Ib)
942 mm (37.1 in)
Double polyethylene 9 teeth
*243 mm (9.57 in) (No.1 hole from the bottom)
* 168 mm (6.61 in) (No.3 hole from the bottom)
Chain (#35K-3)
17/31 (1 : 1.824)
9.525 mm (0.375 in) x 66L
10
+ 5 (04+ 0.2 . )
_2
mm
. -o.oa
m
250 cc (8.5 oz)
Gear oil API "GL-3" (SAE #75 or 80)
Floating disc type
5 mm (0.20 in)
1.0 mm (0.04 in)
57 mm (2.24 in)
0.15 - 0.3 mm (0.006 - 0.012 in)
- 21-
D. Chassis
Frame:
Material
Steering system:
Caster (ski column)
Chamber
Ski length x width x thickness
Ski stance
Ski toe-out
Steering linkage type
Lock to lock angle (Ski)
Steering angle
Front suspension:
Type (YAMAHA T.S. SUSPENSION)
Damper type
Fuel tank:
Capacity
Fuel grade
E. Electrical
Ignition system:
Type - flywheel magneto (C.D.I. Type)
Model/Manufacturer
Voltage
Charging coil resistance
Pulser coil resistance
Ignition timing:
B.T.D.C.
Ignition coil:
Manufacturer/Model/Quantity
Spark gap
Primary winding resistance
Secondary winding resistance
Diode (Yes or No)
Spark plug:
Type & quality
Spark pi ug gap
Spark plug cap:
Type
Noise suppressor resistance
C.D.I. unit:
Model/Manufactu rer
Lighting system:
Lighting output
Lighting coil resistance
Headlight type
Bulb wattage/q'ty
Tail/Brake light wattage
Aluminum + Steel
25
0
980 x 120 x 2 mm (38.6 x 4.7 x O.OS in)
880 mm (34.6 in)
o mm (0 in)
Tie-rod
Right ski
Left ski
Right: 46
Left: 46
Coil spring
L: 27.9
L: 33.4
Oil and gas damper
R: 33.4
R: 27.9
26.6 L (5.9 Imp gal, 7.0 US gal)
Regular gasoline
F3T352/mitsubishi
12V
*590 Q 10% at 20C (68F) (Brown-Black)
*15.1 Q 10%at20C (68F) (White/Red-Black)
1.5 mm (0.059 in)
HITACHI i TOYO-DENSO
*CM6221/1 pc.
: YW-51/1 pc.
I
9 mm (0.4 in)/300 rpm
I +-
I
11 mm (0.6 in)/3,OOO rpm :+-
0.15 Q 10% at : 0.12 Q 10% at
20C (6SoF)
I
20C (68F) I
*3.6 kQ 10% at : 4.0 kQ 20% at
20C (6SoF)*
I
20C (6SoF) I
I
No
I
+-
I
NGK BR9EV x 2 pcs.
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Resign type with noise suppressor
5 kQ 20% at 20C (6SoF)
* SN4-20/MITSUBISH I
12V-100W
0.19 Q 10% at 20C (68F) (Yellow-Black)
Halogen light
12V-60/55W x 1 pc.
12V-SW!23W
-22 -
A.C. regulator:
Model/Manufacturer
Voltage
F" Tightening torque
Part to be tightened
[Engine]
Spark plug
Cylinder head
Cylinder
Flywheel magneto
Crankcase upper and lower
Tightening sequence
~ - $
7 6
Thread size
M14 Pl.25
M8 Pl.25
M8 Pl.25
M16 Pl.0
M8 Pl.25
M6 Pl.0
3
2
*TRIZ,50 HITACHI or S85 16B TOSHIBA
13.8 0.5V
Tightening torque
28 Nm (2.8 m"kg, 20 ftlb)
25 Nm (2.5 mokg, 18 ft-lb)
25 Nm (2.5 mokg, 18 ft-lb)
73 Nm (7.3 mokg, 53 ftolb)
First: 10 Nm (1.0 mokg, 7 ft-lb)
Final: 20 Nm (2.0 mokg, 15 ft"lb)
First: 5 Nm (0.5 m"kg, 3.5 ftlb)
Final: 10 Nm (1.0 mokg, 7 ftlb)
/
10
Remarks
- -------- -----
-
8-$ -$ 5 1. 4 ~ .9
11
~
,
Ring weight and stay M6 Pl.0 10 Nm (1.0 mokg, 7.2 ft"lb) Use Neji Lock
(Adhesive)
Flywheel magneto and stay M8 Pl.0 15Nm (l.5mokg,10.8ftolb) Use Neji Lock
(Adhesive)
Fan shaft and pulley 2 M16 Pl.0 43 Nm (4.3 mokg, 31.1 ftolb)
Starter pulley M8 Pl.25 23 Nm (2.3 mokg, 16.5 ft"lb)
Crankcase and engine bracket M8 Pl.25 23 Nm (2.3 m"kg, 16.5 ft"lb)
[Drive and track suspension]
Primary sliding sheave and cap M6 Pl.0 15 Nm (1.5 mokg, 10.8 ft-lb)
Installation of primary sheave UNF 1/2" Initial: Use motor oil
120 Nm (12 m"kg, 87 ft"lb)
Loosen once and retighten:
65 Nm (6.5 mokg, 47 ftolb)
Installation of secondary sheave M14 Pl.5 64 Nm (6.4 mokg, 46 ftolb)
Bearing housing M8 Pl.25 23 Nm (2.3 m"kg, 16.5 ftolb)
Brake caliper and houisng chain Ml0 Pl.25 48 Nm (4.8 m"kg, 35 ft"lb)
Installation of drive chain sprocket M20 Pl.0 60 Nm (6.0 mokg, 43.5 ft-lb)
Installation of driven chain sprocket Ml0 Pl.25 48 Nm (4.8 m"kg, 35 ftolb)
Chain housing and frame M8 Pl.25 23 Nm (2.3 mokg, 16.5 ft"lb)
Installation of front axle L.H. M22 Pl.0 85 Nm (8.5 mokg, 61.5 ft"lb)
Front axle housing and frame M8 Pl.25 23 Nm (2.3 mokg, 16.5 ft"lb)
Front pivot shaft Ml0 Pl.25 64 Nm (6.4 m"kg, 46 ft-lb)
Rear pivot shaft Ml0 Pl.25 64 Nm (6.4 m"kg, 46 ftolb)
Rear axle M14 Pl.25 80 Nm (8.0 mokg, 58 ftlb)
Sliding runner M6 Pl.0 2.5 Nm (0.25 mokg, 1.8 ftolb)
[Chassis]
Engine mounting bolt Ml0 Pl.25 52 Nm (5.2 m"kg, 37.6 ftlb)
Steering column and gate M8 Pl.25 23 Nm (2.3 mokg, 16.5 ft"lb) Use lock washer
-23-
Part to be tightened Thread size Tightening torque Remarks
Steering gate M8 Pl.25 14 Nm (1.4 mkg, 10 ftlb)
Steering relay rod adjusting nut Ml0 Pl.25 47 Nm (4.7 mkg, 34 fHb)
Steering lower bracket M8 Pl.25 23 Nm (2.3 mkg, 16.5 ftlb) Use lock washer
Installation of steering column 1,2 M8 Pl.25 14.5Nm (1.45mkg,10.5ftlb)
Steering relay ass'y Ml0 Pl.25 47 Nm (4.7 mkg, 34 fHb) Use cotterpin
Front shock absorber and bracket M8 Pl.25 21 Nm (2.1 mkg, 15.2 ftlb)
Bracket 1, 2 set bolt M6 Pl.0 2 Nm (0.2 mkg, 1.4 ftlb)
Front arm Ml0 Pl.25 16 Nm (1.6 m kg, 11.6 ftlb)
Ski installation Ml0 Pl.25 43 Nm (4.3 mkg, 31.1 ftlb)
-24-
Particularly important information is distinguished in this manual by the
following notations:
NOTE:
WARNING:
A NOTE provides key information to make procedures
easier or clearer.
A CAUTION indicates special procedures that must be
followed to avoid damage to the machine.
A WARNING indicates special procedures that must be
followed to avoid injury to a machine operator or person
inspecting or repairing the machine.
CONTENTS
I. NEW SERVICE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
V-BELTCLUTCH .. ..................................... 3
II. SPECiFiCATION ......................................... 23
MAINTENANCE AND LUBRICATION CHART
PERIODIC MAINTENANCE
Every
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
400km 800km 1,600 km
necessary
(250mi) (500mi) (1,000 mil
ENGINE:
Tightness of bolts and nuts 0
Bends, cracks and wear 0
Abnormal noise 0
Loose connection and breaks of fuel and pulse pipes 0
Loose connection and breaks of oil pipes 0
Loose connection and breaks of oil delivery pipe 0
Manual rope starter system 0
Carburetor:

Operation of starter jet 0

Mixing adjuster (pilot screwl 0

Idling speed adjustment 0
Operation and adjustment of oil pump 0
Ignition timing 0
Engine compression 0
Cyl inder head/exhaust pipe decarbonization 0
Fan belt tension, damage 0
Spark plug condition, gap and cleaning 0
Tightening of the cylinder head**
DRIVE:
Tightness of bolts and nuts 0
Wear on slide runners 0
Primary drive system 0
Vbelt 0
Secondary drive system 0
Sheave distance 0
Sheave offset 0
Brake pad wear 0
Brake operation and adjustment 0
Guide wheel rubber 0
Wear of drive track wheel sprocket 0
Drive track adjustment 0
Breaks in drive track 0
Bends in front and rear axles 0
Checking of lock washers 0
Drive chain 'adjustment 0
Drive chain oil level 0
BODY:
Tightness of bolts and nuts 0
Bends and cracks 0
Welded/riveted, jOints 0
Ski adjustment 0
Breaks in fuel tank 0
Cleaning of fuel tank 0
Fuel filter 0
Loose connection and breaks in fuel pipe 0
Breaks in oil tank 0
Oil filter 0
* * Retighten every 10hours from the first use.
-1-
Every
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
400km 800km 1,600 km
necessary
(250mi) (500mi) (1,000 mil
ELECTRICAL:
Wear, breakage of wire covering 0
Breaks in high-tension cord 0
Voltage regulator working voltage 0
Operation of engine stop switch 0
Operation of tether switch 0
Headlight 0
Taillight 0
Brake light 0
LUBRICATION INTERVALS
Every
Lubrication point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
Oil/Grease
400 km 800km 1,600 km
necessary Brand name
(250mi) (500 mil (1,000 mil
ENGINE:
Starter case 0
Oil pump control box 0
Aeroshell grease #7A or
Esso Beacon 325 grease
Pump drive cover 0
Oil in the oil tank 0 Y AMALUBE 2-cycle oil
DRIVE:
Secondary shaft and
0
Molybdenum disulfide
sl id i ng sh eave snowmobile grease
Front axle housing 0
Shaft 1 and shaft 2
Light all-purpose grease
(Slide rail)
0
Drive chain oil
0
Gear oil API GL-3
replacement SAE #75 or #80
BODY:
Steering column lower
0
Light all-purpose grease
bearing
Steering column upper
0 Motor oil
bearing
Steering links 0
Light all-purpose grease
Brake wire and stopper
0 0
Esso Beacon 325 grease
and brake lever
Telescopic strut
0
suspension
-2-
I. NEW SERVICE PROCEDURE
CARBURETOR
Carburetor tuning
1. Standard specification
The carburetor is set at the factory to
run at temperatures of OC to -20C
(32 F to _4 F) at sea level. If the
machine has to be operated under con-
ditions other than specified above, the
carburetor must be reset as required.
Special care should be taken in carbure-
tor setting so that pistons will not be
holder or seized.
~
-30
0
e _20
0
e
Altitude
(_22F) (-4FI
I
Sea level
#155
- 600 m (2,000 ttl
#150
- 1,200 m (4,000 ttl
#145
- 1,SOO m (6,000 ttl
#140
- 2,400 m (S,OOO ttl
#135
- 3,000 m (10,000 ttl
#130
V-BELT CLUTCH
NOTE: ____________ _
The following items under "4-1. Drive" in the
SR540E Service Manual will be changed as
described below:
A. Sheave adjustment
B. Primary sheave
C. V-belt
D. Secondary sheave
I
...
...
...
...
...
...
...
...
...
...
...
..
-3-
Main jet #150
Power jet #150
Slow jet #92
Pilot screw 2.0 turns out
Starter jet #160
Float height
1 5 ~ ~ mm
(059 +0.079
in)
. -0.118
Idling engine speed 1,500 r/min
-10
0
e
oOe
10
0
e 20
0
e
(14FI (14FI (50FI (6SoFI
I I I I
#150
...
..
#145
#145
....
...
#140
#140
...
...
#135
#135
~
...
#130
#130
...
...
#125
#125
~
...
#120
A. SHEAVE ALIGNMENT
Sheave offset
Place the sheave gauge against inner surfaces
of the primary fixed sheave and the secondary
sliding sheave. If the sheave gauge contacts
the sheaves at four points as illustrated, the
offset is correct.
NOTE: ____________ _
Be sure to remove the V-belt before adjusting
the sheave offset.
Sheave offset:
13 0.5 mm (0.51 0.02 in)
Sheave gauge:
YS-91047 (U.S.A.)
90890-01702
Sheave gauge adapter:
YS-33274
90890-01718
Sheave distance
If both ends of the primary shaft and the
secondary shaft are aligned with the gradua-
tions, this indicates on the sheave gauge that
the sheave distance is correct.
Sheave distance:
mm in)
-4-
Adjustment
If the center-to-center distance or offset is not
within the specification, adjust it in the
following manner:
1. Loosen the four engine mounting bolts.
By moving the engine back and forth,
adjust the sheave distance so that the
center-to-center distance between the
primary sheave mounting bolt and
secondary sheave mounting bolt is equal
to the sheave gauge set specified above.
2. Adjust the thickness of shims on both
ends of the secondary sheave so that the
distance (offset) between the primary
fixed sheave and secondary sliding
sheave is equal to the sheave gauge.
1. Adjusting shim
3. Repeat steps 1 and 2 above until the
sheave distance and sheave offset are ad-
justed correctly.
4. Tighten the engine mounting nuts while
taking care not to move the engine.
Tightening torque:
52 Nm (5.2 m- kg, 37.6 ft-Ib)
NOTE: ___________ _
Select proper shims to be used at A and B.
The total clearance at A and B should be 1.0
mm (0.4 in) or less.
(t = 1.0 mm)
90201-222FO
(t = 0.5 mm)
90201-25526 (t = 2.0 mm)
90201-25527 (t = 1.0 mm)
90201-252F1 (t = 0.5 mm)
B. CLUTCH TUNING
The clutch may require tuning depending
upon the area of operation and the desired
handling characteristics. The clutch can be
changed by changing engagement & shifting
rpm.
Clutch engagement rpm is defined as the
engine speed where the machine first begins
to move from a complete stop.
Shifting rpm is the engine speed when the
machine passes a point 200 - 300 m (650 -
1,000 ft) from the starting position after the
machine has been started at full-throttle from
a dead stop.
Engine rpm
Clutch
shifting rpm
CI utch engage-
ment rpm
t
--
Good condition
Normally, when a machine reaches shift rpm,
the vehicle splines Increases but the engine
speed remains nearly constant. Under un-
favorable conditions, however (wet snow, icy
snow, hills, or rough terrain), engine speed
can decrease after the engine has reached
shifting rpm.
Engine rpm
Clutch
shifting rpm
Clutch en-
gagement rpm
Bad condition
Travelled distance
I-------t--_- Travelled distance
-
Starting position 200 _ 300 m (650 -1,000 ttl Starting position 200 _ 300 m (650 -1,000 ft)
-5-
CLUTCH SETTING DATA
1. Standard specification
Engagement r.p.m.
Shifting r.p.m.
Parts No.
Set weight
Primary spring
Spring constant
Color
O'ty
Spider shim
Part No.
O'ty
V-belt shim
Part No.
Mark
Weight
Part No.
Parts No.
Twist angle
Secondary spring
Spring hole No.
Color
S.t.d. spec High altitude spec
3,700 200 4,200 200
7,000 200 +-
8U7-17643-00 8U7-17643-10
28.6 kg 46.2 kg
1.73 kg/mm 2.4 kg/mm
SILVER/RED SILVER/GREEN
1 p.c. +-
8 U7 -17654-00
+-
1 p.c. (t = 1.4 mm) +-
8U9-17687-00 +-
A-1 A - 1 (Modify)
8U7-17633-00 8U7-17633-10
90508-50571 +-
20 50
A - No.1 A- No.2
PINK +-
NOTE: ________________________________________________________ ___
The "High altitude spec" supplies to operation at an altitude of more than 1,500 meters (4,500 feet).
2. How to change clutch engagement rpms and clutch shifting rpms.
~
Clutch engagement r.p.m. Clutch shifting r.p.m.
Decreasing
Spring constant -
Primary spring
Preload Decrease
Torsion spring
-
Secondary spring
constant
Twist angle -
Primary clutch engagement rpm setting
The factor which change the clutch engage-
ment rpm is the primary spring preload.
Therefore, the clutch engagement rpm can be
adjusted by replacing the primary spring
itself.
Standard clutch engagement rpm:
3,500 - 3,900
-6-
Increasing Decreasing Increasing
- Decrease Increase
Increase - -
- Decrease Increase
- Smaller wind Greater wind
For high altitude:
4,000 - 4,400
Secondary clutch shifting rpm setting
The secondary clutch must be tuned to match
snow and weather conditions. Tuning the
clutch keeps the engine operating in the pro-
per rpm range.
Standard clutch shifting rpm:
6,800 - 7,200
Secondary spring setting
1. Secondary spring position
The spring seat is provided with four
holes, No. 1 to 4, so that the secondary
spring position can be changed as requir-
ed.
2. Secondary spring tension
The secondary spring tension can be
changed by moving the spring position
from the free position in order to reset
the clutch shifting rpm as required. The
four holes are spaced at intervals of 30.
Course Trail and tour
Spring factor
Position of spring seat and
sliding sheave
Icy snow Std.
Packed snow Std.
Wet snow B - No. 1 or C - No.2
~
spring
NO.1 No.2 No.3 No.4
Hole of
sliding sheade
C 10 40 70 100
A 20 50 80 110
B 30 60 90 120
Winding the spring more (i.e., from 10
to 40) will increase the clutch shifting
rpm and vise versa. Snow conditions will
also require a change of the spring ten-
sion in order to attain the standard
shifting rpm. The spring tension must be
greater on wet snow than on packed
snow. Less tension is needed on icy
snow.
3. Secondary spring setting
Twist
Std.
Std.
30 or 40
-7-
Std. secondary spring:
PIN: 90508-50571
Color code: Pink
Std. secondary spring position:
A - No.1
Std. secondary spring twist:
20
The secondary spring settings are classi-
fied into two types as shown below.
Select a proper setting according to
operating conditions. (For the setting
procedure, refer to "d. Secondary
Sheave.")
Lake surface
Position of spring seat and
Twist
sliding sheave
Std. Std.
Std. Std.
Std. or B - No.1 Std. or 30
Co PRIMARY SHEAVE
V-belt shim
173 Nm (17.3 mokg, 125 ftolbl
~ Oiling point
NOTE: X ~ No oiling or greasing
is allowed.
Tightening torque:
Apply Loctite #262
to the top four threads.
First tighten the bolt to a torque of A, then
loosen it. Retighten bolt to a final torque of B.
A: 120 Nm (12 mokg, 87 ftolbl
B: 58 Nm (5.8 mokg, 47 ftolbl
Sheave cap
Sheave cap bolt

Loctite #262
Weight pin
-8-
Removal
1. Remove the drive guard, and remove the
V-belt.
2. Hold the fixed sheave with the primary
sheave holder and remove the clutch
retaining bolt and washer. Drive the
primary sheave off the crankshaft with
the primary sheave puller.
To remove the clutch, a sheave puller and a
sheave holder are required.
1. Sheave puller
2. Sheave holder
Primary sheave holder:
YS-01880 (U.S.A.)
90890-01701
Primary sheave puller:
YS-33272 (U.S.A.)
90890-01719
-9-
Disassembly
1. Loosen the six sheave cap bolts.
2. Remove the sheave cap and spring.
3. Remove the primary sheave by using the
clutch sprider separater.
Yamaha spider wrench:
90890-01711
YS-28890 (U.S.A.)
Center post:
YS-33273 (cp = 14 mm)
1. Center post (YS33273)
WARNING:
To loosen the spider, high torque is required
and therefore, make sure the primary sheave,
vise, and tools are tightely secured also take
care not to crack the spider.
Do not use steal wool or a wire brush to clean
components having a duralon bushing:
damage will result it bushing is contacted with
the steal wool or a wire brush.
Inspection
1. I nspect the tapered ends of the crank
shaft and the primary fixed sheave for
scraches. If either is severely scratched,
replace it. If scratches are minor, burnish
the component with emery cloth.
2. Bushings
Check the primary sheave cap bushing
and the sliding sheave bushing for wear.
If worn beyond tolerance, replace the
bushing, or cap assembly.
-10-
Bush inside
Sheave cap Sliding sheave
diameter
Standard
28.6 mm 41.7 mm
(1.23 in) (1.64 in)
Wear limit
0.25 mm 0.25 mm
(0.01 in) (0.01 in)
3. Weights
Check the bushing bore inside diameter
of each weight and its contact surface
with the collar. If worn more than
limits, replace them with new ones.
Bushing bore
Contact surface with collar
Wear
diameter (d)
A B
limit
6.7mm 0.5mm i.o mm
(0.26 in) (0.021 in) (0.04 in)
Contact surface with collar
4. Roller
Check the inside diameter of the roller
bushing, then check the contact surface
of the roller and the weight. If either sur-
face is worn unevenly or more than ac-
ceptable limits, replace them.
Bushing bore Contact surface
Wear
diameter (d) with weight (0)
limit
9.9 mm (0.39 in) 13.0 mm (0.51 in)
Contact surface with weight
Uneven wear
- ~
~ = = = : : : : : j - - - - t I
---r--d -0-----+-
I========l---t I
__ ----1
If the outer surface of the roller is worn un-
evenly, the roller is probably seized to the
pin. Be sure to check the roller pin.
5. Weight pins and roller pins
Check both weight and roller pins. If
metal dust collects on pins, remove it
using sandpaper (#800 - #1,000). If the
pin is damaged or bent, replace the pin
with a new one.
6. Spider
Check the contact surface of the spider
with the slider. If it is worn more than
limits or cracked, replace it with a new
one.
Maximum clearance: 2.0 mm (0.08 in)
1. Wear limit
7. Primary spring
Check the primary spring for damage or
fatique, and replace it as required.
Assembly
1. Pay attention the following points when
replace the weight arm.
-11 -
a. Make sure the threads of the pivot bolt
are clean and dry, and apply a generous
amount of red loctite #262 to the
threads of each bolt.
b. Immediatly install new lock nuts on
pivot bolts, and tighten them until they
just touch the aluminum casting. Never
reuse lock nuts.
Do not over tighten the pivot-bolt nuts; over-
tightening may cause binding of the weight
arms. Check the operation of the weight arms
after tightening the pivot-bolt nuts.
VVARNING:
To maintain the balance of the clutch, the
pivot bolts all must be installed with their
threaded portions pointing in a clockwise
direction; see illustration 1.
ILLUSTRATION 1
2. Install the spider, sliding sheave and
fixed sheave.
NOTE:
Install the duralon bushing carefully so it is
not damaged.
a. I nstall the sl iding sheave, spider shim,
V-belt shim onto the fixed sheave.
b. Apply Loctite #262 to the threaded
portion of the fixed sheave.
Apply to the top four threads
Fixed sheave
Spider shim
Apply Loctite
#262 to:
J _ ~ t = = r 4 threads
Outer surface of
bushing (large)
1. Loctite should be applied only to the
area specified. Never apply to the outer
surface of the bushing (large) and other
areas.
2. Do not use the clutch until the Loctite
has completely cured. Wait 24 hours
before using the clutch.
c. Tightening the spider with special tool.
Tightening torque:
173 Nm (17.3 m'kg, 125 ftlb)
-12 -
WARNING:
Since tightening torque is high, make sure the
primary sheave, vise, and tools are tightely
secured. Also take care not to crack the
spider.
3. Tighten the sheave cap bolts.
Tightening torque:
14 Nm (1.4 m'kg, 10 ftlb)
NOTE: ______________________ ___
Make sure the cap bolts are clean and dry.
Apply blue Loctite Lock N'Seal to the
threads of the bolts.
Installing
Hold the primary fixed sheave with the
primary sheave holder, and torque the sheave
bolt to specification.
Primary sheave holder:
YS-1880 (U.S.A.)
90890-01701
Tightening torque:
Tighten the bolt to A to properly seat
the primary sheave on the crankshaft.
Loosen the bolt, then torque it to B,
the final torque.
A: 120Nm(12mkg,87ftlb)
B: 70 Nm (7.0 m' kg, 49 ftlb)
D. SECONDARY SHEAVE
Jackshaft
/4-7 Nm (0.4-0.7 mkg,
/
Turn securing the collar clockwise when
viewed from the collar side, and lock the secondary
, shaft and collar, tighten the secondary sheave.


'"
Plaine washer
CircliP __ Spring seat
"00""',,, 'P';o,
Check the ramp shoes on secondary sliding Sliding sheave
sheave for wear. Replace reamp shoes as re1 _
quired. '

Fixed sheave
NOTE: .-'Greasing point
N.B.: ..........
X-,...-No oiling or greasing is allowed
Removal
1. Apply the brake and remove the secon-
dary sheave mounting bolt.
2. Remove the secondary sheave from the
jack shaft.
-13-
Disassembly
WARNING:
Use the Yamaha Secondary Compressor to
contain the spring tension before removing
the retaining circlip. DO NOT attempt this
procedure unless you have the proper tools
and understand the instructions thoroughly.
1. I nstall the secondary sheave onto the
secondary sheave compressor so that the
fixed sheave faces downward.
2. Hold the spring seat with the sheave
compressor, screw in the wing nut.
3. Remove the circlip, and while screwing
out the wing nut set the secondary
spring free.
Secondary Compressor:
YS-28891 (U.S.A.)
90890-01712
1. Secondary sheave compressor
4. Remove the spring seat, secondary
spring, sliding sheave and fixed sheave.
Inspection
1. Inspect both sheaves. If either is warped,
replace it.
2. Inspect the ramp shoes on the sliding
sheave, replace as necessary.
3. Check the sheave bushings for wear; re-
place the sheave as required.
4. Check the spring. If it is fatigued or
damaged, replace it.
-14-
Assembly
1. Grease the secondary shaft, and sliding
sheave boss and mount the sliding sheave
on the shaft.
Recommended grease:
Molybdenum disulfide snowmobile
grease
2. Install the secondary fixed sheave and
sliding sheave onto the secondary sheave
compressor.
3. Hook the end of the secondary spring
onto the spring hole in the sliding
sheave.
4. Hook the other end of the secondary
spring onto the hole (indicated by No.)
in the spring seat.
Std. spring position: A - No.1 hole
5. Install the plain washer and circlip.
6. Screw in the wing nut to the position at
which the splined portion of the spring
seat nearly alignes with the splined por-
tion of the fixed sheave.
7. Bring the spring seat splines to align with
the fixed sheave splines by hand.
NOTE: ____________ _
Make sure that the three cams of the spring
seat are in a position where they can move
into the guide hole in the sliding sheave cam.
8. Screw in the wing nut so that the spring
seat is splined to the sliding sheave.
9. Screw in the wing nut to bring down the
spring seat to a position where the spring
seat cam does not contact the sliding
sheave cam when they turn.
-4----Spring seat cam
Sliding sheave cam
-15 -
10. Turn the sliding sheave the specified
degrees in the counterclockwise direc-
tion, and screw in so that the spring seat
engages with the sliding sheave.
Standard twist angle: 20
11. Screw in the wing nut, and while pushing
the spring seat, fit the circlip to the fixed
sheave to lock the spring seat.
12. Install the secondary sheave assembly
and adjust the sheave off-set.
Lubrication of transmission
To keep the machine in the best operating
condition, the sheaves should be lubricated
with low temperature grease and motor oil
periodically as illustrated.
+-. Oiling point
+- X Free from oil
+- Greasing point
-16-
1. Do not apply grease to the area marked
X.
For other parts, oiling is unnecessary.
2. When installing the primary sheave, clean
the oil off the taPered portion of crank-
shaft using a lacquer thinner.
Eo FRONT SUSPENSION
Installation
2Nm
(0.2 m-kg, 1.4 ftolb)
I Arm outside I
21 Nm
(2.1 mokg, 15.2 ftolb)
NOTE:
..
Greasing
... .
pOint
(ESSO beacon 325)
-17-
'D-a-m-pe-r - -; --1
I
i
I ,I
_J e9
--- .
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I L- __________ .J
43 Nm
(4.3 m-kg, 31.1 ftolb)
F. REAR SUSPENSION
Removal
NOTE: ___________ _
It is advisable to loosen the track adjusting
nut and the rear axle nut.
1. Remove the two front pivot shaft
mounting bolts and four rear pivot shaft
mounting bolts.
2. Remove the slide rail suspension as-
sembly.
1. Front shock 2. Rear shock
Inspection
1. Check to see if slide runners are worn
excessively. If the slide runner thickness
is less than specified value, replace slide
runner.
Wear limit: 10 mm (0.4 in)
Slide runner securing screw tightening
torque:
4.5 Nm (0.45 m' kg, 3.3 ftlb)
-18 -
-----.--- ---
1. Wear limit: 10 mm (0.4 in)
2. New:: 15 mm (0.6 in)
@
I
2. Check the suspension wheel for damage.
If damaged, replace it.
"DE CARBON" type shock absorber
WARNING:
These shock absorbers contain highly pres-
surized nitrogen gas.
Read and understand the following informa-
tion before handling the shock absorber. The
manufacturer cannot be held responsible for
property damage or personal injury that may
result from improper handling.
1. Do not tamper with or attempt to open
the cylinder assembly. Injury may result.
2. Do not subject shock absorber to an
open flame or other high heat. This may
cause the unit to explode due to exces-
sive gas pressure.
3. Do not deform or damage the cylinder in
any way. Cylinder damage will result in
poor damping performance.
4. Gas pressure must be released before
disposing of the shock absorber. To do
so, drill a 2 - 3 mm (0.08 - 0.12 in)
hole through the cylinder wall at a point
10 - 15 mm (0.4 - 0.6 in) above the
bottom of the cylinder.
10 -15 mm (0.4 -0.6 in)
2 -3 mm (0.08-0.12 in) "' 1-
"" ' I
WARNING:
Wear eye protection to prevent eye damage
from escaping gas and/or metal chips.
1. Check the rod, and if it is bent or dam-
aged, replace the shock absorber.
2. Check for oil leakage. If oil leakage is
evident, replace the shock absorber.
3. By compressing the shock absorber,
check to see there is no gas leakage.
Slide rail suspension adjustment
The setting of suspension greatly affects the
stability and steering of the machine. There-
fore, it is necessary to adjust the suspension
setting according to course conditions and
rider's driving technique.
1. Front stopper band setting
The height (L) of the front suspension
can be properly adjusted by changing the
length of the stopper band.
Standard setting:
No.1 hole from the bottom
Tightening torque:
3.8 Nm (0.38 m' kg, 2.75 ftlb)
1. Stopper band
1. Stopper band
No.5
NO.4
No.3
No.2
No.1
(STD)
This adjustment will affect the stability and maneuverability of the machine.
Snow condition
Length of
Track side slip
stopper band
Lower (No.5) Increase
Hard packed
Std. (No.1) Normal
Lower Increase
Soft deep snow
Std. (No.1) Normal
Rear stopper band setting
The height (L) of the rear suspension can be
properly adjusted by changing the length of
the stopper band.
Standard setting: No.1 hole
Tightening torque:
3.8 Nm (0.38 m' kg, 2.75 ftlb)
- 19--
Performance of Bumping and
Riding comfort
straight running pitching
Poor Less Poor
Normal Normal Normal
Good -- Poor
Normal -- Normal
1. Stopper band
No.5
No.4
No.3
No.2
No.1
(STD)
This adjustment will affect the stability and meneuverability of the machine.
i
Handling Track side slip
Lower Hard Decrease
Std. (No.1) Normal Normla
Main arm adjustment
The location of the main arm can be changed
on this model. This helps to control accelera-
tion when the machine pulls out.
- --- --------- -- - ---- - - - - -- --
1. Main arm 2. Lower 3. Upper (Std.)
Handling
Performance of
Sett i ng facto r straight running
Packed, wet
Std. Normal Std. Normal
Ice snow
No.2 Poor No.2 Increase
Std. Normal Std. Normal
Deep snow
No.2 Poor No.2 Decrease
Rear spring
The rear springs are determining factor in
machine stability.
Consider the ground surface condition and
the rider's weight when setting rear springs.
The suspension should be set as soft as possi-
ble, unless it impairs the stability of the
machine.
-20-
Performance of Bumping and
Riding comfort
straight running pitching
Good More Poor
Normal Normal Normal
Front side spring
~
No.2
1. Normal riding (less gap)
Std. weight rider (No.2)
2. Trail riding (more gap)
Heavy weight rider
Rear side spring
~
No.4 No.1
1. Normal riding (less gap) 2. Trail riding (more gap)
Std. weight rider (No.1) Heavy weight rider
Front side rear spring
~
Handling Track side slip
Increase Poor Decrease
Decrease Good Increase
Rear side rear spring
-------------
Handling Track side slip
Increase Good Increase
Decrease Poor Decrease
Installation
Grease the slide rail suspension as indicated
by arrows in the illustration.
For easy installation of the slide rail suspen-
sion in the frame, proceed as follows .
/
... --- ---- - ~ - . - - ~ - - . - . - - . - - ~ - - ~ -
I
/
Hard packed Deep snow
performance of
+-
Riding comfort
straight running
Good Poor Poor
Poor Good Good
Performance of
Riding comfort
Heavy weight
straight riding rider
Poor Poor Good
Good Good Poor
- - - - . - - . - - . - - - - - - - - . - - - - - . ~ - - ----_.-
1. Fully loosen the drive track adjusting
screws.
2. Place the slide rail suspension into track
and fit the forward pivot shaft using
washers and bolts.
-21 -
NOTE: ___________ _
I nstall bolts finger-tight. Bolts will be tighten-
ed to proper torque when slide rail installa-
tion is complete.
3. Fit the rear pivot shaft to the frame. The
rear pivot shaft is being forced toward
the rear by the shock absorber.
NOTE: ________________________ _
When installation of slide rail is complete,
tighten front and rear bolts to proper torque.
Tightening torque:
Front pivot shaft mounting bolt:
64 Nm (6.4 m kg, 46 ftlb)
Rear pivot shaft mounting bolts:
64 Nm (6.4 m kg, 46 ftlb)
4. Adjust the track tension by turning the
track adjusting nuts.
-22-
SPECI FICATIONS
A. General * New specification (Compared with 1982 SR540F)
Model SR540G
Model:
Model (I.B.M. No.) *SR540G (8U7)
Frame 1.0. & Starting number *8R6-039101
Engine 1.0. & Starting number *SA535
Dimension:
Overall length *2,675 mm (105.3 in)
Overall width (Std.) 1,080 mm ( 42.5 in)
Overall height (W/windshield) 970 mm ( 38.2 in)
B. Engine
Model SR540G
Description:
Engine type Axial fan cooled two-stroke, torque
induction, twin cylinders
Engine model SA535
Displacement 535 cc (32.65 cu.in)
Bore x Stroke 73 x 64 mm (2.874 x 2.52 in)
Effective compression ratio 6.0: 1
Starting system Recoil hand starter
Ignition system C.D.1.
Lubrication system "Autolube" oil injection
Cylinder head:
Combustion chamber volume (with spark plug) *25.5 cc (1.68 cu.in)
Compression chamber type Dome + Squich
Head gasket thickness x Q'ty 0.5 mm (0.02 in) x 1 pc.
Cylinder:
Material Cast iron sleeves aluminum
Bore size 73 mm (2.874 in)
Taper limit 0.05 mm (0.0020 in)
Out of round limit 0.01 mm (0.0004 in)
Piston:
Piston skirt clearance (measuring point) 0.055 - 0.060 mm (0.0022 - 0.0024 in)
[17 mm (0.67 in) from piston skirt end]
Piston oversize 1 st 73.25 mm (2.884 in)
2nd 73.50 mm (2.894 in)
3rd 73.75 mm (2.904 in)
4th 74.00 mm (2.913 in)
Piston pin outside diameter x Length cfJ 20 x 56 mm (cfJ 0.787 x 2.20 in)
Piston ring:
Piston ring design Keyston'e
Ring end gap (installed) 0.2 - 0.4 mm (0.008 - 0.016 in)
Small end bearing:
Type Needle bearing
Big end bearing:
Type Needle bearing
Crankshaft:
Crankshaft assembly width (A) 200 0.25 mm (7.87 0.010 in)
Crankshaft assembly width (F)
60 ~ g.osmm (2.362 ~ g.002 in)
Crankshaft deflection (D) 01: 0.03 mm (0.0012 in) 02: 0.04 mm (0.0016 in)
03: 0.04 mm (0.0016 in) 0-4: 0.05 mm (0.0020 in)
-23-
Model SR540G
Connecting rod big end side clearance (C) I 0.25 - 0.75 mm (0.010 - 0.030 in)
Connecting rod small end deflection (P) Df- P 2.0 mm (0.079 in)
0-1 0-2 0-3 0-4
I ~ I ! ! :
I 'J I ~
L ___ A _ ~ - F -
Crank pin outside diameter x Length cf> 24 x 59 mm (cf> 0.945 x 2.323 in)
Crank pin type Solid shaft assembly type with serration
Crank bearing type (left) x Q'ty #6306 special x 2 pcs.
Crank bearing type (Center) x Q'ty #6206 special x 2 pcs.
Crank bearing type (Right) x Q'ty #6206 special x 1 pc.
Crank oil seal type (Left) x Q'ty FWJ-3278 9.5 TS x 1 pc.
Crank oil seal type (Center) x Q'ty Labyrinth seal x 1 pc.
Crank oil seal type (Right) x Q'ty FWJ-3248 10-1 TS x 1 pc.
Cooling fan:
Fan belt tension 4 - 6 kg/8 mm (8.8 - 13.2 Ib/0.31 in)
Carburetor::
Type & Manufacturer/Quantity B044-38/KE I H I N/l pc.
1.0. Mark *8R601
Main jet (M.J.) *#150
Main air jet (M.A.J.) #180
Power jet (Pw.J.) #150
Power air jet (Pw.A.J.) #170
Slow jet (S.J.) #92
Slow air jet (S.A.J.) #100
Pilot screw (P.S.) 2.0 turns out
Starter jet (St.J.) #160
Float height
15 + 2 mm (0.59 + 0.08
- 3 - 0.12
in)
Idling engine speed 1,500 r/min
*Main jet setting chart
~
-30C -20C -10"e oOe 10C 20C
Altitude (-22FI (-4FI (14FI (14FI (50FI (68FI
I I I I I I

#150 ..
Sea level
F#155
.. . #145----
.. #145
...
- 600 m (2,000 ttl
r---#150
.. ..
#140
.. #140 ..
- 1 ,200 m (4,000 ttl
r---#145 .. ..
#135
..
#135
..
- 1,800 m (6,000 ttl
r---#140 .. .. #130

#130
..
- 2,400 m (8,000 ttl
-#135 ..

#125----
..
#125
..
- 3,000 m (10,000 ttl
-#130

..
#120
-24-
Model
Intake reed valve:
Type
Bending limit
Stopper height
lubrication:
Autolube pump - Color code
Autolube pump - Minimum stroke
Autolube pump - Maximum stroke
Autolube pump - Reduction ratio
Autolube pump - Output Min'/200 strokes
Autolube pump - Output Max./200 strokes
Autolube pump wire free play
Oil tank capacity
Oil grade
C. Drive and track suspension
Transmission:
Type
Drive ratio
Engagement rpm
Shifting rpm
Primary spring:
Part No.
Color code
Secondary spring:
Part No.
Color code
Model
Secondary spring preload (twist)
Sheave distance
Sheave off-set
V-belt width and outer line length
V-belt wear limit
Track suspension:
Type
Damper type
Spring color code (Front)
Spring color code (Rear)
Slide runner wear limit
Track width
Track deflection
length on ground
Wheel sprocket material and number of teeth
Stopper band length (Front)
Stopper band length (Rear)
Secondary drive:
Type
Reduction ratio
Chain pitch x Number of links
Free play
Chain housing oil quantity
Chain housing oil grade
SR540G
V type
0.6 mm (0.024 in)
12 0.2 mm (0.4724 0.0079 in)
Gray
0.20 - 0.25 mm (0.0079 - 0.0098 in)
1.65 - 1.87 mm (0.0650 - 0.0736 in)
1/36
0.95 - 1.19 cc (0.0321 - 0.0402 oz)
7.84 - 8.89 cc (0.2651 - 0.3006 oz)
25 1 mm (0.98 0.04 in) at idle
2.5 l (2.6 US qt, 2.2 Imp qt)
Yamalube 2-cycle
SR540G
V-belt automatic centrifugal engagement
3.5: 1 - 1 : 1
*3,500 - 3,900 rpm
*6,800 - 7,200 rpm
*8U7 -17643-00
*Silver - Red
*90508-50571
*Pink
* 200 (No.1)
in)
*13 0.5 mm (0.433 0.020 in)
31.6 x 1,099 mm (1.24 x 43.3 in)
26 mm (1.02 in)
Slide rail suspension
Oil and gas damper
No painted
No painted
10 mm (0.394 in)
381 mm (15 in)
25 - 30 mm/10 kg (0.98 -1.18 in/22Ib)
902 mm (35.5 in)
Double polyethylene 9 teeth
*250 mm ( 9.84 in) (No.1 hole from the bottom)
*267 mm (10.51 in) (No.1 hole from the bottom)
Chain (#35-3)
17/31 (1 : 1.824)
9.525 mm (0.375 in) x 66l
mm
250 cc (8.5 oz)
Gear oil API "Gl-3" (SAE #75 - 80)
-25-
Model SR540G
Brake:
Type Floating disc type
Brake pad thickness 5 mm (0.20 in)
Brake pad wear limit 1.0 mm (0.04 in)
Brake cable "L" distance 57 mm (2.24 in)
Clearance between lining pad and disc 0.15 - 0.3 mm (0.006 - 0.012 in)
D. Chassis
Model SR540G
Frame:
Material Aluminum + Steel
Steering system;
Caster (ski column) 25
Chamber 0
Ski length x Width x Thickness 980 x 120 x 2 mm (38.6 x 4.7 x 0.08 in)
Ski stance 880 mm (34.6 in)
Ski toe-out o mm (0 in)
Steering linkage type Tie-rod
Steering angle Right: 46
Left: 46
Lock to lock angle (Ski) Right ski L: 27.9 R: 33.4
Left ski L: 33.4 R: 27.9
Front suspension:
Type (YAMAHA T.S. SUSPENSION) Coil spring
Damper type Oil and gas damper
Fuel tank:
I
Capacity 26.6 L (5.9 Imp gal, 7.0 US gal)
Fuel grade Regular gasoline
E. Electrical
Model SR540G
Ignition system:
Type - Flywheel magneto (C.D.1. Type)
Model/Manu factu rer F3T352/MITSUBISHI
Voltage 12V
Charging coil resistance 5900 10% at 20C (68F) (Brown - Black)
Pulser coil resistance 15.10 10% at 20C (68F) (White/Red - Black)
Ignition timing:
B.T.D.C. 1.5 mm (0.059 in), 15at 7,000 r/min
Ignition coil: HITACHI ! TOYO-DENSO
Manufacturer/Model/Quantity CM62-21 /1 pc. YW-51/1 pc.
Spark gap 9 mm (0.4 in)/300 rpm +-
11 mm (0.6 in)/3,000 rpm +-
Primary winding resistance 0.150 10% at 0.120 10% at
20C (68F) 20C (68F)
Secondary winding resistance 3.5 kO 10% at 4.0 kO 20% at
20C (68F) 20C (68F)
Diode (Yes or No) No +-
Spark plug:
Type & Quality NGK BR9EV x 2 pcs.
Spark plug gap
0.7 - 0.8 mm (0.028 - 0.031 in)
-26-
Model SR540G
Spark plug cap:
Type Resign type with noise suppressor
Noise suppressor resistance 5 k,Q 20% at 20C (68F)
C.D.1. unit:
Model/Manufacturer 8N4-20/M ITSUBISH I
Lighting system:
Lighting output 12V-100W
Lighting coil resistance 0.19,Q 10% at 20C (68F) (Yellow - Black)
Headlight type Halogen light
Bulb wattage/Q'ty 12V -60/55W x 1 pc.
Tail/Brake light wattage 12V-8W/23W
A.C. regulator:
I
Model/Manufacturer TRIZ-50/HITACHI or S85 16B/TOSHIBA
Voltage 13.8 0.5V
F. Tightening torque
Part to be tightened Thread size
Tightening torque
Remarks
Nm mokg ftolb
Engine:
Spark plug M14 P1.25 28 2.8 20
Cylinder head M8 P1.25 25 2.5 18
Cylinder M8 P1.25 25 2.5 18
Flywheel magneto M16 P1.0 73 7.3 53
Crankcase upper and lower: First M8 P1.25 10 1.0 7
Final M8 P1.25 20 2.0 15
Tightening sequence: First M6 P1.0 5 0.5 3.5
Final M6 P1.0 10 1.0 7
I

$3 4-2
10 7 6
-
. - " ..__... _- - - ------ ---
5
1. $9
11

Ring weight and stay M6 P1.0 10 1.0 7 Use Loctite
(Adhesive)
Flywheel magneto and stay M8 P1.0 15 1.5 10.8 Use Loctite
(Adhesive)
Fan shaft and pulley 2 M16 P1.0 43 4.3 31.1
Starter pulley M8 P1.25 23 2.3 16.5
Crankcase and engine bracket M8 P1.25 23 2.3 16.5
Drive and track suspension:
Primary sliding sheave and cap M6 P1.0 15 1.5 10.8
Installation of primary sheave:
Initial UNF 1/2" 120 12 87 Use oil
Loosen once and retighten UNF 1/2" 65 6.5 47
Installation of secondary sheave M14 P1.5 64 6.4 46
Bearing housing M8 P1:25 23 2.3 16.5
Brake caliper and housing chain M10 P1.25 48 4.8 35
Installation of drive chain sprocket M20 P1.0 60 6.0 43.5
Installation of driven chain sprocket M10 P1.25 48 4.8 35
Chain housing and frame M8 P1.25 23 2.3 16.5
Installation of front axle L.H. M22 P1.0 85 8.5 61.5
-27 -
Part to be tightened Thread size
Tightening torque
Remarks
Nm m'kg ft'lb
Front axle housing and frame MS Pl.25 23 2.3 16.5
Front pivot shaft Ml0 Pl.25 64 6.4 46
Rear pivot shaft Ml0 Pl.25 64 6.4 46
Rear axle M14 Plo25 SO S.O 5S
Sliding runner M6 PLO 2.5 0.25 1.S
Chassis:
Engine mounting bolt Ml0 Pl.25 52 5.2 37.6
Steering column and gate MS Pl.25 23 2.3 16.5 Use lock washer
Steering gate MS Pl.25 14 1.4 10
Steering relay rod adjusting nut Ml0 Pl.25 47 4.7 34
Steering lower bracket MS Pl.25 23 2.3 16.5 Use lock washer
Installation of steering column 1,2 MS Pl.25 14.5 1.45 10.5
Steering relay ass'y Ml0 Pl.25 47 4.7 34 Use cotterpin
Front shock absorber and bracket MS Pl.25 21 2.1 15.2
Bracket 1, 2 set bolt M6 PLO 2 0.2 1.4
Front arm Ml0 Pl.25 16 1.6 11.6
Ski installation Ml0 Pl.25 43 4.3 31.1
-2S -
MAINTENANCE AND LUBRICATION CHART
PERIODIC MAINTENANCE
Every
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
400 km 800 km 1,600 km
necessary
(250mi) (500mi) (1,000 mil
ENGINE:
Tightness of bolts and nuts 0
Bends, cracks and wear 0
Abnormal noise 0
Loose connection and breaks of fuel and pulse pipes 0
Loose connection and breaks of oil pipes 0
Loose connection and breaks of oil delivery pipe 0
Manual rope starter system 0
Carburetor:

Operation of starter jet 0

Mixing adjuster (pilot screw) 0

Idling speed adjustment 0
Operation and adjustment of oil pump 0
Ignition timing 0
Engine compression 0
Cylinder head/exhaust pipe decarbonization 0
Fan belt tension, damage 0
Spark plug condition, gap and cleaning 0
Tightening of the cylinder head**
DRIVE:
Tightness of bolts and nuts 0
Wear on slide runners 0
Primary drive system 0
V-belt 0
Secondary drive system 0
Sheave distance 0
Sheave offset 0
Brake pad wear 0
Brake operation and adjustment 0
Guide wheel rubber 0
Wear of drive track wheel sprocket 0
Drive track adjustment 0
Breaks in drive track 0
Bends in front and rear axles 0
Checking of lock washers 0
Drive chain adjustment 0
Drive chain oil level 0
BODY:
Tightness of bolts and nuts 0
Bends and cracks 0
Welded/riveted, joints 0
Ski adjustment 0
Breaks in fuel tank 0
Cleaning of fuel tank 0
Fuel filter 0
Loose connection and breaks in fuel pipe 0
Breaks in oil tank 0
Oil filter 0
* * Retighten every 1 Ohours from the first use.
-1-
Every
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
400km 800km 1,600 km
necessary
(250mi) (500mi) (1,000 mil
ELECTRICAL:
Wear, breakage of wire covering 0
Breaks in high-tension cord 0
Voltage regulator working voltage 0
Operation of engine stop switch 0
Operation of tether switch 0
Headlight 0
Taillight 0
Brake light 0
LUBRICATION INTERVALS
Every
Lubrication point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
Oil/Grease
400 km 800km 1,600 km
necessary Brand name
(250mi) (500mi) (1,000 mil
ENGINE:
Starter case 0
Oil pump control box 0
Aeroshell grease #7A or
Esso Beacon 325 grease
Pump drive cover 0
Oil in the oil tank 0 Y AMALUBE 2-cycle oil
DRIVE:
Secondary shaft and
0
Molybdenum disulfide
sl id ing sheave snowmobile grease
Front axle housing 0
Shaft 1 and shaft 2
Light all-purpose grease
(Slide rail)
0
Drive chain oil
0
Gear oil API GL-3
replacement
SAE #75 or #80
BODY:
-
Steering column lower
0
Light allpurpose grease
bearing
Steering column upper
0
Motor oil
bearing
Steering links 0
Light all-purpose grease
Brake wire and stopper
0 0
Esso Beacon 325 grease
and brake lever
Telescopic strut
0
suspension
-2-
NEW SERVICE PROCEDURE
SECONDARY SHEAVE
V-belt shim
There are two V-belt shims between the
fixed and sliding sheaves. By removing one
or both of the shims when the V-belt is worn
you can obtain the same reduction ratio
(3.5:1) as a new V-belt.
Fixed sheave
- ---
V-belt
V-belt shim (2 pes.)
Spare V-belt shim
1. V-belt shim (2 pes.) -
1. When the V-belt width is wron to
30.6 mm (1.20 in): Remove one shim.
NOTE: ______________________ __
The removed shim can be reused when the
V-belt has been replaced, so it should be
stored between the sliding sheave and spring
seat.
-3-
- 2 mm (0.0787 in)
Sliding sheave
Spring seat
2. Spare V-belt shim
V-belt width
NEW: 31.6 mm (1.24 in)
2. When the V-belt width is further worn to
29.6 mm (1.17 in): Remove both two
shims.
3. When the V-belt width is further worn to
26.0 mm (1.02 in): Replace the V-belt
with a new one and install the two
shims.
WARNING:
When replacing the V-belt, be sure to install
the two shims and check to see that there is
a 2 mm (0.0787 in) clearance between the
fixed and sliding sheaves. If no shims are
installed, the clutch-in rpm will drop; this
may cause the snowmobile to lurch when the
engine is started.
Clutch alignment
To achieve clutch alignment, both the sheave
distance and sheave offset must be properly
adjusted. When they are properly adjusted,
the clutch can function correctly.
Standard sheave distance:
. 270 ~ g mm (10.63 ~ g . 1 1 in)
Standard sheave offset:
11 0.5 mm (0.433 0.0196 in)
Tool name Tool No.
Sheave gauge YS-91047
1. Sheave distance
2. Sheave offset
1. Removing the V-belt
a. Turn the secondary sliding sheave clock-
wise when facing toward the chain hous-
ing, and push the sliding sheave.
b. When the sliding sheave is pushed, it
separates from the fixed sheave so that
the V-belt can be removed from the fix-
ed sheave side.
-4-
2. Loosen the four engine mounting bolts.
3. Adjust sheave guage to the specified
standard sheave distance. By moving
the engine back and forth, adjust the
sheave distance so that the center-to-
center distance between the primary
sheave mounting bolt and secondary
sheave mounting bolt is equal to the
specified standard sheave distance.
1. Sheave gauge
4. Adjust the thickness of shims on both
ends of the secondary sheave so that the
distance (offset) between the primary
fixed sheave and secondary sliding
sheave is equal to the sheave gauge.
NOTE: ______________________ ___
When the sheave distance and offset are
properly adjusted, the sheaves are in
contact with the sheave gauge at the four
points as illustrated.
The secondary sheave mounting bolt
should be tightened to the following
specification.
Tightening torque:
60 Nm (6.0 m- kg, 43 ft-Ib)
Select proper shims to be used at A and B.
The total clearance at A and B should be
1.0 mm (0.4 in) or less.
It = 1.0 mm)
90201-222FO
(t = 0.5 mm)
90201-25526 It = 2.0 mm)
90201-25527 (t = 1.0 mm)
90201-252F1 It = 0.5 mm)
5. Repeat steps 3 and 4 above until the
sheave distance and sheave offset are ad-
justed correctly.
6. Tighten the engine mounting nuts while
taking care not to move the engine.
Tightening torque:
52 Nm (5.2 m
o
kg, 37 ft-Ib)
7. I nstall the V -belt.
-5-
SUSPENSION
Front stopper band setting
1. Stopper band
CD
1. Stopper band
No.5
No.4
No.3
No.2
No.1 (STD)
No.O
Snow condition
Length of
Track side slip
Performance of Bumping and
Riding comfort
stopper band
Lower (No.5) Increase
Hard packed Std. (No.1) Normal
Higher (No. 0) Decrease
Lower Increase
Soft deep snow Std. (No.1) Normal
Higher (No. 0) Decrease
Shock absorber spring adjustment
Screwing in the spring seats on the front and
rear shock absorbers shortens the spring set
length, thus making the shock absorbers hard.
Screwing them out softens the shock ab-
sorbers. Adjust, as required.
straight running
poor
Normal
Good
Good
Normal
Poor
set length--------...

7-
Spring Shock absorber
Spring seat

Front shock Rear shock
absorber absorber
Std. spring 196 mm 269 mm
set length (7.72 in) (10.6 in)
-6-
pitching
Less Poor
Normal Normal
More Good
- Poor
- Normal
- Good
Lock nut
1. Front shock absorber spring
-----
STIFFER 4 ~ SOFTER
Spring set
Mini. Max.
184 mm .. ~ 200 mm
length
(7.24 in)
(7.87 in)
~
Hard packed Deep snow
Handling Track side slip performance of
~
Riding comfort
straight running
Increase Good Increase Poor Poor Good
Decrease Poor Decrease Good Good Poor
2. Rear shock absorber spring
------
STIFFER .. ~ SOFTER
Spring set
Mini. Max.
269 mm

~ 269mm
length
(10.6 in)
(10.6 in)
s ~
Handling Track side slip
Performance of
Riding comfort
Heavy weight
straight riding rider
Increase Poor Decrease Good Good Poor
Decrease Good Increase Poor Poor Good
-7-
SPECI FICATIONS
A. General
Model SR540H
Model:
Model (I.B.M. No.) SR540H (8V9)
Frame I.D. & Starting number 8V9060101
Engine I.D. & Starting number SA535-060 101
Dimension:
Overall length 2,675 mm (104.3 in)
Overall width (Std.) 1,080 mm ( 42.5 in)
Overall height (W/windshield) 970 mm ( 38.2 in)
B. Engine
Model SR540H
Description:
Engine type Axial fan cooled two-stroke, torque
induction, twin cylinders
Engine model SA535
Displacement 535 cc (32.65 cu.in)
Bore x Stroke 73 x 64 mm (2.874 x 2.52 in)
Effective compression ratio 6.0: 1
Starting system Recoil hand starter
Ignition system C.D.1.
Lubrication system "Autolube" oil injection
Cylinder head:
Combustion chamber volume (with spark plug) 25.5 cc (1.68 cu.in)
Compression chamber type Dome + Squich
Head gasket thickness x Q'ty 0.5 mm (0.02 in) x 1 pc.
Cylinder:
Material Cast iron sleeves aluminum
Bore size 73 mm (2.874 in)
Taper limit 0.05 mm (0.0020 in)
Out of round limit 0.01 mm (0.0004 in)
Piston:
Piston skirt clearance (measuring point) 0.055 ~ 0.060 mm (0.0022 ~ 0.0024 in)
[17 mm (0.67 in) from piston skirt end]
Piston oversize 1 st 73.25 mm (2.884 in)
2nd 73.50 mm- (2.894 in)
Piston pin outside diameter x Length I/J 20 x 56 mm (I/J 0.787 x 2.20 in)
Piston ring:
Piston ring design Keystone
Ring end gap (installed) 0.2 ~ 0.4 mm (0.008 ~ 0.016 in)
Small end bearing:
Type Needle bearing
Big end bearing:
Type Needle bearing
Crankshaft:
Crankshaft assembly width (A) 200 0.25 mm (7.87 0.010 in)
Crankshaft assembly width (F)
60+0 ( +0
_ 0.05
mm
2.362 _ 0.002'")
Crankshaft deflection (D) D-1: 0.03 mm (0.0012 in) D-2: 0.04 mm (0.0016 in)
D-3: 0.04 mm (0.0016 in) D4: 0.05 mm (0.0020 in)
-8-
Model SR540H
Connecting rod big end side clearance (C) I 0.25 - 0.75 mm (0.010 - 0.030 in)
Connecting rod small end deflection (P) QI- P 2.0 mm (0.079 in)
0, 0-2 0-3 0-4
97mm C "93mm
Crank pin outside diameter x Length if> 24 x 59 mm (if> 0.945 x 2.323 in)
Crank pin type Solid shaft assembly type with serration
Crank bearing type (left) x Q'ty #6306 special x 2 pes.
Crank bearing type (Center) x Q'ty #6206 special x 2 pcs.
Crank bearing type (Right) x Q'ty #6206 special x 1 pc.
Crank oil seal type (Left) x Q'ty FWJ-32 789.5 TS x 1 pc.
Crank oil seal type (Center) x Q'ty Labyrinth seal x 1 pc.
Crank oil seal type (Right) x Q'ty FWJ-3248 10-1 TS x 1 pc.
Cooling fan:
Fan belt tension 4 - 6 kg/8 mm (8.8 - 13.2 Ib/0.31 in)
Carburetor:
Type & Manufacturer/Quantity BD44-38/KE I HI N/1 pc.
I.D. Mark 8R601
Main jet (M.J.) #150
Main air jet (M.A.J.) #180
Power jet (Pw.J.) #150
Power air jet (Pw.A.J.) #170
Slow jet (S.J.) #92
Slow air jet (SAJ.) #100
Pilot screw (P.S.) 2.0 turns out
Starter jet (St.J.) #160
Float height 12 - 17 mm (0.47 - 0.67 in)
Idling engine speed 1,500 r/min
Main jet setting chart
~
-30
o
e _20
o
e _1O
o
e oOe
20
0
e 10
0
e
Altitude
(_22F) (--4F) (14F) (32F) (50F) (68F)"
I I I I I I
..
#150 ~
Sea level
f---#155 .. ..
#145
.. #145 ..
- 600 m (2,000 ft)
f---#150 .. .. #140
.. #140 ..
- 1,200 m (4,000 ft)
1---#145
,..
..
#135
..
#135
..
- 1,800 m (6,000 tt)
1---#140
.. .. #130
..
#130
..
- 2,400 m (8,000 ft)
f---#135
,..
..
#125
..
#125
..
- 3,000 m (10,000 ft)
f---#130
,..
..
#120
-9-
Model
Intake reed valve:
Type
Bending limit
Stopper height
Lubrication:
Autolube pump - Color code
Autolube pump - Minimum stroke
Autolube pump - Maximum stroke
Autolube pump - Reduction ratio
Autolube pump - Output Min.l200 strokes
Autolube pump - Output Max.l200 strokes
Autolube pump wire free play
Oil tank capacity
Oil grade
c. Drive and track suspension
Transmission:
Type
Drive ratio
Engagement rpm
Shifting rpm
Primary spring:
Part No.
Color code
Secondary spring:
Part No.
Color code
Model
Secondary spring preload (twist)
Sheave distance
Sheave off-set
V-belt width and outer line length
V-belt wear limit
Track suspension:
Type
Damper type
Spring color code (Front)
Spring color code (Rear)
Slide runner wear limit
Track width
Track deflection
Length on ground
Wheel sprocket material and number of teeth
Stopper band length (Front)
Stopper band length (Rear)
Secondary drive:
Type
Reduction ratio
Chain pitch x Number of links
Free play
Chain housing oil quantity
Chain housing oil grade
SR540H
V type
0.6 mm (0.024 in)
12 0.2 mm (0.4724 0.0079 in)
Green
0.20 - 0.25 mm (0.0079 - 0.0098 in)
1.65 - 1.87 mm (0.0650 - 0.0736 in)
1/36
0.95 -1.19 cc (0.0321 - 0.0402 oz)
7.84 - 8.89 cc (0.2651 - 0.3006 oz)
25 1 mm (0.98 0.04 in) at idle
2.5 L (2.6 US qt, 2.2 Imp qt)
Yamalube 2-cycle
SR540H
V-belt automatic centrifugal engagement
3.5: 1 1 : 1
3,500 - 3,900 rpm
6,800 - 7,200 rpm
8U7-17643-00
Silver - Red
90508-50571
Pink
30 (No.1)
in)
11 0.5 mm (0.433 0.020 in)
31.6 x 1,099 mm (1.24 x 43.3 in)
26 mm (1.02 in)
Slide rail suspension
Oil and gas damper
No painted
No painted
10 mm (0.394 in)
381 mm (15 in)
25 30 mm/10 kg (0.98 1.18 in/22 Ib)
902 mm (35.5 in)
Double polyethylene 9 teeth
250 mm ( 9.84 in) (No.1 hole from the bottom)
267 mm (10.43 in) (No.1 hole from the bottom)
Chain (#35-3)
17/31 (1 : 1.824)
9.525 mm (0.375 in) x 66L
1 0
+ 5 (0 4 + 0.2 . )
_ 2 mm . _ o.oa ln
250 cc (8.5 oz)
Gear oil API "GL-3" (SAE #75 80)
-10 -
Model SR540H
Brake:
Type Floating disc type
Brake pad thickness 5 mm (0.20 in)
Brake pad wear limit 1.0 mm (0.04 in)
Brake cable "L" distance 57 mm (2.24 in)
Clearance between lining pad and disc 0.15 - 0.3 mm (0.006 - 0.012 in)
D. Chassis
Model SR540H
Frame:
Material Aluminum + Steel
Steering system;
Caster (ski column) 25
Chamber 0
Ski length x Width x Thickness 980 x 120 x 2 mm (38.6 x 4.7 x O.OB in)
Ski stance 880 mm (34.6 in)
Ski toe-out o mm (0 in)
Steering linkage type Tie-rod
Steering angle Right: 46
Left: 46
Lock to lock angle (Ski) Right ski L: 27.9 R: 33.4
Left ski L: 33.4 R: 27.9
Front suspension:
Type (YAMAHA T.S. SUSPENSION) Coil spring
Damper type Oil and gas damper
Fuel tank:
Capacity 26.6 L (5.9 Imp gal, 7.0 US gal)
Fuel grade Regular gasoline
E. Electrical
Model SR540H
Ignition system:
Type - Flywheel magneto (C.D.I. Type)
Model/Manufacturer F3T352/MITSUBISHI
Voltage 12V
Charging coil resistance 1,29012 10% at 20C (68F) (Brown - Black)
Pulser coil resistance 1712 10% at 20C (6BoF) (White/Red - Black)
Ignition timing:
B.T.D.C. 1.5 mm (0.059 in), 15at 7,000 r/min
Ignition coil: HITACHI i TOYODENSO
Manufacturer/Model/Quantity CM62-21 /1 pc.
I
I YW-51/1 pc.
Spark gap 9 mm (0.4 in)/300 rpm
I
I+-
11 mm (0.6 in)/3,000 rpm: +-
Primary winding resistance 0.15n 10% at I 0.12n 10% at
20C (68F) : 20C (6BoF)
Secondary winding resistance 3.5 kn 10% at i 4.0 kn 20% at
20C (68F) 120C (6BoF)
I
Diode (Yes or No) No I+-
Spark plug:
Type & Quality NGK BR9EV x 2 pcs.
Spark plug gap
0.7 - O.B mm (0.028 - 0.031 in)
-11 -
Model SR540H
Spark plug cap:
Type Resign type with noise suppressor
Noise suppressor resistance 5 kn 20% at 20C (68F)
C.D.1. unit:
Model/Manufacturer 8N420/M ITSUB ISH I
Lighting system:
Lighting output 12Vl00W
Lighting coil resistance 0.19n 10% at 20C (68F) (Yellow - Black)
Headlight type Halogen light
Bulb wattage/O'ty 12V -60/55W x 1 pc.
Tail/Brake light wattage 12V-8W/23W
Grip heater coil resistance 0.66n 10% at 20C (68F) (Yellow/Black - Black)
A.C. regulator:
Model /M anufactu rer TRIZ-50/HITACHI or S85 16B/TOSHIBA
Voltage 13.8 0.5V
F. Tightening torque
Part to be tightened Thread size
Tightening torque
Remarks
Nm m'kg ft'lb
Engine:
Spark plug M14 Pl.25 28 2.8 20
Cylinder head M8 Pl.25 25 2.5 18
Cylinder M8 Pl.25 25 2.5 18
Flywheel magneto M16 Pl.0 73 7.3 53
Crankcase upper and lower: First M8 Pl.25 10 1.0 7
Final M8 Pl.25 20 2.0 15
Tightening sequence: First M6 Pl.0 5 0.5 3.5
Final
I
M6 Pl.0 10 1.0 7
/
~ ~
~ 3
2
-$-10
7 6
-
8 ~ ~ 5
1.
4'-
~ 9
11
~
Ring weight and stay M6 Pl.0 10 1.0 7 Use Loctite
Flywheel magneto and stay M8 PloD 15 1.5 10.8 Use Loctite
Fan shaft and pulley 2 M16 Pl.0 43 4.3 31.1
Starter pulley M8 Pl.25 23 2.3 16.5
Crankcase and engine bracket M8 Pl.25 23 2.3 16.5
Drive and track suspension:
Primary sliding sheave and cap M6 Pl.0 15 1.5 10.8
Installation of primary sheave:
Initial UNF 1/2" 120 12 87 Use motor oil
Loosen once and retighten UNF 1/2" 65 6.5 47
Installation of secondary sheave M14 Pl.5 60 6.0 43
Bearing housing M8 Pl.25 23 2.3 16.5
Brake caliper and housing chain Ml0 Pl.25 48 4.8 35
Installation of drive chain sprocket M20 P1.0 60 6.0 43.5
Installation of driven chain sprocket Ml0 Pl.25 48 4.8 35
Chain housing and frame M8 Pl.25 23 2.3 16.5
Installation of front axle L.H. M22 Pl.0 85 8.5 61.5
-12 -
Part to be tightened Thread size
Tightening torque
Remarks
Nm mokg ftolb
Front axle housing and frame MB P1.25 23 2.3 16.5
Front pivot shaft M10 P1.25 64 6.4 46
Rear pivot shaft M10 P1.25 64 6.4 46
Rear axle M14 P1.25 BO B.O 5B
Sliding runner M6 P1.0 2.5 0.25 1.B
Chassis:
Engine mounting bolt M10 P1.25 52 5.2 37.6
Steering column and gate MB P1.25 23 2.3 16.5 Use lock washer
Steering gate MB P1.25 14 1.4 10
Steering relay rod adjusting nut M10 P1.25 47 4.7 34
Steering lower bracket MB P1.25 23 2.3 16.5 Use lock washer
Installation of steering column 1,2 MB P1.25 14.5 1.45 10.5
Steering relay ass'y M10 P1.25 47 4.7 34 Use cotterpin
Front shock absorber and bracket MB P1.25 21 2.1 15.2
Bracket 1 , 2 set bolt M6 P1.0 2 0.2 1.4
Front arm M10 P1.25 16 1.6 11.6
Ski installation M10 P1.25 43 4.3 31.1
-13 -

I
Wiring diagram
Tachometer (12V 3.4W)

Speedometer light Oil caution light
(12V 3.41) _ _ _ I (12V 3.4W)
L-,_
Color code
L ...... Blue
Y ...... Yellow
O ...... Orange
G ...... Green
, B ...... Black
, G/Y .... GreenlYeliow
. B/R .... Black/Red
B/W .... Black/White
Br ...... Brown W/R .... White/Red
R ...... Red Y/B .... Yellow/Black
Opt.
(Grip heater)
Headlight (12V SOW/SSW)




B Y/B II q
t I r,m I I f 11-- I! I __ 3
B/W
Main switch
Headlight beam switch

L-
G-
G Y ,
. Y-
=
G/Y
G/Y
G I B/R
1---'
I
I
Oil level switch
C.D.I. magneto
o-D::::J-O
<=J.
-=-
Ignition coil
C.D.I. unit