Complete Yamaha Exciter EX570 and EX570E Snowmobile Service Manual (1987-1991)

Yamaha Exciter EX570 & EX570E Service Manual - 1987-1991

This technical service publication provides specific maintenance protocols and system diagnostics for the Yamaha Exciter liquid-cooled snowmobile series. It includes critical factory data such as the minimum pump stroke requirement of 0.15–0.20 mm (0.006–0.008 in), a hyper-specific tolerance vital for preventing engine seizure during prolonged idling and ensuring long-term piston reliability.

Technical Applicability & Serial Ranges

• Model Code 82M (Exciter Series)
  • Yamaha EX570 (1987-1991) | Starting Serial: 82M-000101
  • Yamaha EX570E (1987-1991) | Starting Serial: 82M-000101
  • Yamaha EX570L (1990)
• Technical Variants
  • Yamaha Exciter High Altitude (Specific jetting/clutching data)
  • Yamaha Exciter II (1991 Model Year updates)

Operational ROI & Service Accuracy

• Precision Calibration: Detailed fuel flow charts and main jet selection matrices based on ambient temperature and elevation ensure peak engine performance and fuel efficiency.
• System Integrity: Step-by-step air bleeding procedures for the Autolube system eliminate trapped air bubbles to prevent catastrophic lubrication failure.
• Reliability Benchmarks: Factory-specified torque sequences and "Use New Only" gasket indicators guarantee structural integrity and leak-free reassembly.

Document Metadata

• Print No.: 82M-28197-20
• Page Count: 578 Pages
• File Format: Searchable PDF

Technical Depth & Factory Benchmarks

• Engine Timing: Static ignition timing set to 1.5 mm (0.06 in) B.T.D.C. at 7,000 r/min.
• Cylinder Parameters: Standard bore size 73.00–73.02 mm with a wear limit of 73.10 mm.
• Cooling Diagnostics: Filler cap opening pressure rated at 80–100 kPa (11–14 psi).
• Secondary Clutch Settings: Standard twist angle of 50° (Position A-2) for optimized shifting performance.

Visual Navigation Aids

• Exploded View Diagrams: Comprehensive system breakdowns for engine overhaul, powertrain, and chassis components.
• Electrical Architecture: Full-color coded circuit diagrams including the Throttle Override System (T.O.R.S.) and ignition circuit.
• Cable Routing Maps: 5-point perspective maps for precise throttle, starter, and oil pump cable positioning.

Table of Contents

• Chapter 1: General Information & Machine Identification
• Chapter 2: Periodic Inspections and Adjustments
• Chapter 3: Engine Overhaul & Inspection
• Chapter 4: Cooling System (Flow & Pump Service)
• Chapter 5: Carburetion (Mikuni B44-36 Tuning)
• Chapter 6: Power Train (Primary/Secondary Sheaves, Drive Chain, Track)
• Chapter 7: Chassis (Steering, Skis, TSS Suspension)
• Chapter 8: Electrical (Ignition, Lighting, Signal Systems)
• Chapter 9: Appendices (Technical Specifications & Torque Charts)

Operational Limits & Specifications

• General Torque: M6 (6 Nm), M8 (15 Nm), M10 (30 Nm).
• Critical Fasteners: Cylinder Head Final (33 Nm), Primary Sheave Bolt (120 Nm then 58 Nm), CDI Magneto Nut (85 Nm).
• Fluid Capacities: Fuel Tank (30.5 L), Oil Tank (3.0 L), Chain Housing (250 cm³), Coolant (4.2 L).
• Service Clearances: Spark Plug Gap (0.7–0.8 mm), Throttle Cable Free Play (1.0–2.0 mm), Brake Pad Wear Limit (1.0 mm).