Description
This 1985 1986 1987 1988 1989 1990 Yamaha XLV XL540 Snowmobile Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1985-1990 Yamaha XLV XL540 Snowmobiles.
Yamaha XLV XL540 Snowmobile Service Manual Repair Coverage:
1979 Yamaha EXCEL V
1980 Yamaha EC540D
1985 – 1988, 1990 Yamaha XL540
Table of Contents
GENERAL
EXTERNAL VIEW
MACHINE IDENTIFICATION
A Frame serial number
B Engine serial number
MAINTENANCE INTERVALS CHARTS
A Periodic maintenance
B Lubrication intervals
HIGH ELEVATION SETTING
ENGINE
DISASSEMBLY
A Engine removal
B Carburetor
C Starter
D Starter motor
E Cooling fan
F Flywheel magneto
G Primary sheave
H Oil pump
I Engine disassembly
INSPECTION REASSEMBLY AND ADJUSTMENT
A Engine component
B Oil pump
C Primary sheave
D Flywheel magneto
E Cooling fan
F Starter motor
G Starter
H Carburetor
I Engine remounting
CARBURETION
CARBURETOR
A Carburetor tuning
B Overhauling
C Troubleshooting
REED VALVE
FUEL PUMP
POWER TRAIN
DRIVE
A Sheave adjustment
B Primary sheave
C V-belt
D Secondary sheave
E Chain housing
F Front axle
BRAKE
A Disassembly
B Inspection
C Reassembly
D Adjustment
SUSPENSION
A Removal
B Inspection
C Slide rail suspension adjustment
D Installation
DRIVE TRACK
A Removal
B Inspection
C Installation
D Adjustment
CHASSIS
OIL TANK
FUEL TANK
STEERING
A Installation
B Adjustment
C Throttle lever installation
SKIS
A Inspection
B Installation
ELECTRICAL
IGNITION SYSTEM
A Circuit diagram
B Troubleshooting
C Ignition timing
D Spark gap test
E Ignition coil
F Sparkplug
G Pulser and charging coils test
H CDI unit
LIGHTING SYSTEM
A Circuit diagram
B Headlight beam adjustment
C Lighting circuit test
D Voltage regulator
E Oil caution switch
STARTING SYSTEM
A Circuit diagram
B Starter motor
C Starter relay switch
CHARGING SYSTEM
A Circuit diagram
B Charging circuit test
C Rectifier checking
D Battery
APPENDIX
SPECIAL TOOLS
SPECIFICATIONS
A General
B Engine
C Drive and track suspension
D Chassis
E Electrical
F Tightening torque
CIRCUIT DIAGRAM
WIRE AND PIPE ROUTING DIAGRAM
EC 540 D SUPPLEMENT Table of Contents
NEW SERVICE PROCEDURE
MAINTENANCE INTERVALS
SPECIFICATIONS
SPECIAL TOOLS
WIRING DIAGRAM
WIRE AND PIPE ROUTING DIAGRAM
XL540J SUPPLEMENT Table of Contents
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION
INTERVALS CHARTS
THROTTLE OVERRIDE SYSTEM
TORS CANCELLATION
BLOCK DIAGRAM
PRIMARY SHEAVE
REMOVAL
DISASSEMBLY
INSPECTION
REASSEMBLY
INSTALLATION
V-BELT
REMOVAL
INSPECTION
REASSEMBLY
EXPLODED DIAGRAM
CRANKSHAFT
PISTON CYLINDER AND CYLINDER HEAD
PUMP DRIVE GEAR
OIL PUMP
CDI MAGNETO
COOLING FAN
RECOIL STARTER
STARTER MOTOR
CARBURETOR
INTAKE
PRIMARY SHEAVE
SECONDARY SHEAVE
CHAIN HOUSING
BRAKE
SLIDE RAIL
SUSPENSION WHEELS
DRIVE
SKIS
STEERING
OIL TANK
FUEL TANK
ELECTRICAL COMPONENTS
SEAT
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
GENERAL TORQUE SPECIFICATIONS
CONVERSION TABLES
CABLE ROUTING
WIRING DIAGRAM
