1999 yamaha snowmobile racing 1999 information for open class racer 1999 yamaha sx 700 ron ruzewski...

1999 YAMAHA Snowmobile Racing

1999 Information for Open Class Racer1999 YAMAHA SX 700

Ron Ruzewski

Yamaha Motor Corporation

Snowmobile R&D Group Leader

1998

Confidential


Contents:

I. Introduction

II. Parts List (Front & Rear Suspension)

III. Front Suspension Installation Instructions

IV. Rear Suspension Installation Instructions

V. Tuning Information

VI. Engineering Support Information

VII. Blank Setup and Run Sheets


I. Introduction:

The purpose of this guide is to help the user understand the function of the new suspension system (front and rear).

Please remember that this system is comprised of development parts which we would like to keep confidential as much as possible. These parts are not current production, so it is a privilege to have what we feel is a major advantage. YMUS Marketing will have more information regarding how to handle questions and issues regarding public and press.

We would like to maintain good communication of information that could help the function and development of the suspension system. Please keep a good communication with YMUS Racing and R&D Staff.

All suspension components and designs are proprietary of Yamaha Motor Corporation.

Good Luck and lets win some races!!!!


II. Parts List

Enclosed is the list of parts needed to assemble the front and rear suspensions. New parts are prefixed with 0U58. Existing parts have a number that can be ordered directly from YPAD. We will try to update this list and this manual with most current information.

Please let us know your comments and things that we missed that could help improve this book.


PART NO. PART NAMEQ'TY / MACHINE PART NO. PART NAME

Q'TY / MACHINE

0U58-47410-R0 SLIDING FRAME COMP. 1 91314-10030 BOLT,HEX.SOCKET HEAD 6

0U58-47411-R0 FRAME,SLIDING 1 1 0U58-47413-R0 FRAME SLIDING 3 1

0U58-4741A-R0 FRAME,SLIDING 1 0U58-47414-R0 FRAME SLIDING 4 1

0U58-4741B-R0 BRKT. 1 91314-08020 BOLT,HEX.SOCKET HEAD 10

90263-06015 RIVET 2 0U58-47330-R0 PIVOT ARM COMP., 1

0U58-47421-R0 RUNNER,SLIDING 1 1 0U58-47331-R0 ARM PIVOT,1 1

90151-06010 SCREW 1 93700-05010 NIPPLE,GREASE 1

8CM-47422-10 RUNNER,SLIDING 2 1 93315-42523 BRG. 2

90267-48062 RIVET,BLIND 1 0U58-47465-R0 SHAFT,1 1

90201-047R8 WASHER 1 0U58-47469-R0 COLLAR,1 1

0U58-47420-R0 SLIDING FRAME COMP.2 1 0U58-90400-R0 WASHER,PLAIN 2

0U58-47412-R0 FRAME,SLIDING 2 1 0U58-90401-R0 WASHER,PLAIN 1

0U58-4741A-R0 FRAME,SLIDING 1 0U58-90402-R0 WASHER,PLAIN 1

0U58-4741B-00 BRKT. 1 90185-18104 NUT,SELF-ROCKING 1

90263-06015 RIVET 2 0U58-90403-R0 BOLT,FLG. 2

0U58-47421-R0 RUNNER,SLIDING 1 1 0U58-90404-R0 BOLT,FLG. 2

90151-06010 SCREW 1 0U58-90405-R0 BOLT,FLG. 1

8CM-47422-10 RUNNER,SLIDING 2 1 0U58-47349-R0 BRKT.,ARM PIVOT 2

90267-48062 RIVET,BLIND 1 0U58-47415-R0 BRKT.,1 1

90201-047R8 WASHER 1 93315-21454 BRG. 1

0U58-47456-R0 DAMPER,1 2 93109-14021 SEAL,OIL 2

0U58-47457-R0 DAMPER,2 2 90387-1007N COLLAR 2

8CM-47341-00 SPACER 2 95817-10020 BOLT,FLG. 6

0U58-47341-R0 SPACER 2 0U58-47418-R0 BRKT.,4 1

0U58-90415-R0 WASHER 2 90105-10433 BOLT,FLG. 2

8AX-47458-00 REINF.,DAMPER 1 8 90105-08450 BOLT,FLG. 2

90267-48062 RIVET,BLIND 4 0U58-47329-R0 PIVOT ARM COMP.,2 1

97507-05435 BOLT,HEX. 4 0U58-47332-R0 ARM PIVOT.,2 1

95607-05100 NUT,U 4 93700-05010 NIPPLE,GREASE 1

0U58-47487-R0 SHAFT,5 1 93315-42523 BRG. 2

0U58-47488-R0 SHAFT,6 2 0U58-47465-R0 SHAFT,1 1

0U58-90400-R0 WASHER 2 0U58-47478-R0 COLLAR,2 1

Rear Suspension Parts:


PART NO. PART NAMEQ'TY / MACHINE PART NO. PART NAME

Q'TY / MACHINE

0U58-90401-R0 WASHER,PLAIN 1 0U58-47425-R0 BRKT.,REAR 2 1

0U58-90402-R0 WASHER,PLAIN 1 0U58-4745B-R0 ROD,CONT.,2 1

90185-18104 NUT,SELF-ROCKING 2 93315-21454 BRG. 1

0U58-47550-R0 GUIDE WHEEL ASSY. 2 93109-14021 SEAL,OIL 2

0U58-47530-R0 WHEEL GUIDE COMP. 1 90387-1007N COLLAR 4

99009-52500 CIRCLIP 1 8L8-47520-01 RR. AXLE COMP. 1

93306-20582 BRG. 1 8L8-47521-03 AXLE,REAR 1

0U58-47466-R0 SPACER 2 95827-12025 BOLT,FLG. 1

0U58-90414-R0 BOLT,FLG. 2 90201-120A5 WASHER,PLAIN 1

92014-10045 BOLT,BUTTON 2 91609-40018 PIN,SPRING 1

0U58-90405-R0 BOLT,FLG. 1 0U58-90408-R0 COLLAR 2

0U58-47333-R0 ARM,PIVT 3 1 0U58-90407-R0 COLLAR 1

0U58-47417-RO BRKT.,3 1 90387-2012D COLLAR 2

93700-05010 NIPPLE,GREASE 1 90201-205R6 WASHER,PLAIN 4

93315-21454 BRG. 2 0M40-47550-10 GUIDE WHEEL ASSY. 2

93109-14021 SEAL,OIL 4 0U58-47550-RA GUIDE WHEEL ASSY. 2

90387-1007N COLLAR 2 0U58-47530-RA WHEEL GUIDE COMP. 1

82M-47485-02 SHAFT,3 1 99009-47500 CIRCLIP 1

90201-10136 WASHER,PLAIN 2 93306-20469 BRG. 1

90105-10433 BOLT,FLG. 2 95607-14200 NUT,U FLG. 1

0U58-47480-R0 SHOCK ABS.ASSY.,1 1 91401-30025 PIN,SPLIT 1

0U58-47450-R0 CONT.ROD ASSY.,1 2 0U58-90406-R0 BOLT,HEX. 2

0U58-47426-R0 BRKT.,RR. 1 1 95307-10700 NUT,HEX. 2

0U58-4745C-R0 ROD,CONT.,3 1 0U58-47496-R0 STOPPER,2 2

93315-21454 BRG. 1 95817-10055 BOLT,FLG. 2

93109-14021 SEAL,OIL 2 95617-10200 NUT,U FLG 290170-12406 NUT,HEX.(L j� 1 0U58-90416-R0 WASHER 2

0U58-4745A-R0 ROD CONT.,1 1 0U58-90413-R0 BRKT.,1 4

90170-12407 NUT,HEX.(R j� 1 90179-10679 NUT 4

90201-06747 WASHER,PLAIN 4 92014-10030 BOLT,BUTTON HEAD 14

95707-06300 NUT,NYLON 2 92014-10025 BOLT,BUTTON HEAD 2

92014-08020 BOLT,BUTTON HEAD 10 0U58-90409-R0 PLATE,1 2

0U58-47495-RO STOPPER,1 1 0U58-90410-R0 PLATE,2 2

97007-06025 BOLT,HEX. 2 0U58-90411-R0 PLATE,3 1

0U58-90412-R0 PLATE,4 1

Rear Suspension Parts (cont.):


Front Suspension Parts: Part Number Description Qty Per

Machine

90170 - 12054 - 00 Nut, Hex (LH thread) 295307 - 12700 00 Nut, Hex 20U58 - 23823 - R0 Joint, Universal (LH thread) 28CR - 23823 - 01 Joint, Universal (RH Thread) 20U58 - 2384E - R0 Upper Radius Rod 20U58 - 23741 - R0 Upper Radius Rod Insert (RH thread) 20U58 - 2384A - R0 Upper Radius Rod Assembly 20U58 - 23775 - R0 Upper Radius Rod Insert (LH thread) 20MD0 - 90470 - R0 Joint Universal 40MV0 - 90431 - R0 Washer 495307 - 14700 - 00 Nut, Hex 40U58 - 2384B - R0 Lower Radius Rod Assembly 20U58 - 2384F - R0 Lower Radius Rod 20U58 - 23742 - R0 Lower Radius Rod Insert 40U58 - 23881 - R0 Upper Radius Rod Bracket 191317 - 08035 - 00 Bolt Arm Outside 295607 - 08200 - 00 Nut, Hex 20U58 - 23852 - R0 Arm Outside 2 10U58 - 23851 - R0 Arm Outside 1 190170 - 10186 - 00 Nut, Hex 20U58 - 23830 - R0 Toe Link Assembly 20U58 - 90420 - R0 Jam Nut 3/8"-24 UNF 20U58 - 90421 - R0 Joint High Angle 3/8"bore, 3/8-24 287S - 23847 - 00 Joint, Universal 20U58 - 23831 - R0 Toe Link (8CR-23831-00) 291317 - 10014 - 00 Bolt, Cap Head 291317 - 10025 - 00 Bolt, Cap Head 495617 - 12200 - 00 Nut, Hex 895817 - 12050 - 00 Bolt, Flange 20U58 - 23827 - R0 Steering Boss 40U58 - 23882 - R0 Steering Bracket Plate, Bracket 2 10U58 - 23883 - R0 Bracket 3 20U58 - 90422 - R0 Bolt, Flange Reamer 60U58 - 21961 - R0 Patch Chassis 291401 - 25020 - 00 Pin, Split 195307 - 10700 - 00 Nut, Hex 195707 - 10500 - 00 Nut, Hex 1

Shaded numbers are parts that are available individually.


Front Suspension Parts:

(Cont.)

8CR - 23845 - 00 Joint 190170 - 10186 - 00 Nut, Hex 10U58 - 2381A - R0 Arm Inside Assembly 10U58 - 23837 - R0 Tie Rod 2 187S - 23847 - 00 Joint 1

95617 - 10200 - 00 Nut, Hex 395817 - 10040 - 00 Bolt, Flange 20U58 - 2386R - R0 Steering Rack 10U58 - 2381B - R0 Steering Rack Insert 20U58 - 23836 - R0 Steering Rack Post 10U58 - 23850 - R0 Rack Assembly 10U58 - 23873 - R0 Rack Bearing 20U58 - 23820 - R0 Steering Realy 2 Assembly0U58 - 2376J - R0 Shock Bracket Inside 20U58 - 2386E - R0 Sway bar, dia. 10 10U58 - 2386E - R1 Sway bar, dia. 13 10U58 - 2386C - R0 Sway bar bushing dia. 10 40U58 - 2386C - R1 Sway bar bushing dia. 13 48CR - 2386E - 00 Sway bar, dia. 16 18CR - 2385L - 00 Sway bar link, soft 28CR - 2386G - 00 Sway bar bushing dia. 16 48CW - 2386E - 00 Sway bar, dia. 18 Tuning Parts 18CW - 2386G - 00 Sway bar bushing dia. 18 48DF - 2385L - 00 Sway bar link, hard 28DJ - 2386E - 00 Sway bar, dia. 15 18DJ - 2386G - 00 Sway bar bushing dia. 15 4

0U58 - 23826 - R0 Arm Idler 10U58 - 23884 - R0 Radius Rod Bracket Outside 20U58 - 2382F - R0 Leading Arm Assmbly 1 10U58 - 2382E - R0 Leading Arm Assmbly 2 10U58 - 23787 - R0 Spacer 1 40U58 - 23787 - R1 Spacer 2 40U58 - 2376A - R0 Shock Absorber Ohlins 295817 - 10040 - 00 Bolt, Flange 290105 - 100A9 - 00 Bolt, Shock 491317 - 10030 - 00 Bolt, Cap Head 295607 - 10200 - 00 Nut, Hex 295607 - 10200 - 00 Nut, Hex 48CS - 23743 - 00 Stopper 1 2


III. Front Suspension Installation:

1. Remove belly pan, engine, ,exhaust trail arms, steering, and steering boots.

2. When starting with a SX chassis, remove shock brackets from bulkhead. (please retain bolts for later use)

3. Remove existing steering pivot and steering arms.

4. Remove steering rod boot and keep.

5. Cover any openings that you do not want aluminum chips or filing s to get into.


6. Grind off lip on chassis to prepare for new chassis patch.

7. After riveting on new patch, use this as your template to cut new hole in chassis.

8. The installation of the patch will look like this when finished.

Final Part


7. Bolt front bracket to bulkhead and use as drill template for bulkhead.

8. Use same bracket. Flip upside down and mount to lower set of holes. Now you can use this to transfer holes and drill bulkhead for the rest of the installation.


9. Install steering plate sub-assembly without rack.

10. Add front bracket and slide bolts through. Leave bolts loose until rack is installed.

11. Add upper and lower radius rods. The upper radius rod should have the left hand tread rod end to the outside. You then add the original front bracket.

*Note: Upper radius rod needs to have the boss on the rod end facing the rear of the machine on the inner joint, and facing the front of the machine on the outer joint. This prevents binding at full extension.

Boss


13. Slide steering rack into the steering plate assembly.

14. Now you can tighten up the assembly. Please make sure that the rack slides smoothly. Work the rack a few times by hand to mesh the DU bushings to the rack.

15. Insert anti-rotational pin into the bracket.

16. Install Steering pivot and Toe links.

17. Reconnect pivot to steering post.

RH Thread


18. Reinstall bellypan

19. Install shock brackets. Bulkhead uses original bolt and bushing. New Allen bolt is used on side.

20. Install boot by cutting down original and fasten by rivet and large washer.

21. Finish assemble front end with new trail arm and shocks.


Finished Product.


IV. Rear Suspension Installation:

1. Remove current suspension and track.

2. Using paper templates, make a pattern out of AL. or some other stiff material that can be riveted to the chassis.

3. Rivet the pattern to the chassis using the existing holes in chassis.

4. Carefully drill the new holes into the tunnel.

5. Add the filler plate to the inside of the tunnel. (use a rivet to hold in place.

6. Install new suspension and 50 bar track (0U58-47110-R0).

7. Add plate to outside and bolt in suspension.

8. Use outside plate with reinforcement (“L”shaped) only if necessary. You have two options on this bracket.

9. Install shock absorber.

10. Set track tension to 15-20mm at 10Kg.


V. Tuning Information:

The following pages will help you understand what options you have for tuning.


Front Suspension Setup Data:

Upper Radius Rod Length (C to C):

0U58-2384A-R0

Lower Radius Rod Length (C to C):

0U58-2384B-R0

*Note: Upper Radius Rod has LH and RH thread joints allowing for camber adjustment. Please make sure that equal amounts of thread are engaged in the assembly. After adjusting camber, you must readjust the Toe setting.

360.3 mm + .5

Upper Radius Rod (L&R)

*Note: Lower Radius Rod has RH thread only allowing for overall width adjustment. This adjustment should not be changed unless advised by R&D. The suspension is designed for 42.5 C to C. Please make sure that equal amounts of thread are engaged in the assembly.

480 mm + 0

Lower Radius Rod (L&R)


Rear Suspension Setup Data:

Limit Strap Measuring Method:

Rear Control Rods:

518 mm (Std.)

*Note: Adjustment of this control rod is very critical and should be done with care. One turn of the adjuster is equal to a 2mm change in length. Both rods need to be adjusted the same amount. The rods are marked with a “T” and an arrow indicating the direction to shorten the rod. Limits are 516 - 520. (+ 2mm)

Adjuster(RH & LH Thread)

*Note: Measurement should be done with the suspension unloaded (not touching the ground), from the center of the bolt on the torque arm to the center of the bolt on the front of the rail.


Tuning Parts Rear Suspension (Springs):

Rear Susp. Spring Options

0100200300400500600700800900

100011001200

0 25 50 75 100 125 150 175 200

MM Spring Travel

Kg

Sp

rin

g F

orc

e

Std: 3.9-7.2Opt 1: 3.2 6-5Opt 2: 4.5-8

Std.

Opt. 1

Opt 2


Tuning Parts Front Suspension (Springs):

Front Susp. Springs

0

100

200

300

400

500

600

0 25 50 75 100 125 150 175 200

MM Spring Travel

Kg S

prin

g Fo

rce

Std: 1.6-3.0Opt 1: 1.8-3.6Opt 2: 2.8Opt 3: 1.5-2.8

Std.

Opt 2

Opt 1

Opt 3


Tuning Parts Front Suspension: (Roll Bars)

Diam. Rate(kg/mm)18 3.5316 2.2015 1.7012 0.7010 0.34

These rates assume using using roll bar link with solid bush (8DF-2385L-00). Softer settings can be achieved by using rubber mounted link (8CR-2385L-00) making the installed rate of the roll bar softer.

Std. Setting is with no roll bar being utilized. Use is dependent on race track and driver. Please consider the spring and shock settings when using the roll bars.

Not Std. Parts


Metric Values (mm, deg)

Ski Stroke Caster Camber Scrub B.Steer Motion Ratio Vel Ratio0.0 18.0 -3.0 1064.8 0.0 0.00 0.00

24.7 19.4 -2.4 1071.2 3.0 0.72 0.5249.7 20.8 -2.1 1077.8 3.0 0.72 0.5275.2 22.3 -2.0 1084.0 3.0 0.72 0.52100.9 23.7 -2.3 1089.8 2.0 0.72 0.51126.9 25.1 -2.8 1095.0 1.0 0.71 0.51153.1 26.5 -3.7 1099.6 -1.0 0.72 0.51179.5 28.0 -4.8 1103.4 -1.0 0.72 0.51206.1 29.4 -6.2 1106.6 -1.0 0.72 0.51233.1 30.9 -7.9 1108.8 0.0 0.71 0.51260.2 32.4 -10.0 1110.4 3.0 0.71 0.51

Notes:Bump steer is the total of both sides (one side is #/2)Scrub is total center to center distanceBump rubber on shock reduces the total travel by approximately 12 to 15mmNeg. value = toe in

1G Position

(with rider and fluids)

Front Suspension Engineering/Design Data:


VI. Engineering Support Information:

Snowmobile Racing Manager:

Sno-X Team Engineer / Mngr.:

Snowmobile R&D Group Leader:

Gordy Muetz

Chad Johnson

Ron Ruzewski

R&D Fax:

Race Shop Fax:

Race Shop General Phone:

Gordy Muetz Phone:

Chad Johnson Phone:

Ron Ruzewski Phone:

612-754-6939

612-754-6938

612-754-6925

612-754-6934

612-754-6935

612-754-6927


VII. Setup and Run Sheets

These sheets are provided for you convenience. Use of these will make it much easier to communicate with YMUS racing personnel, and keep track of valuable information. If you have access to E-Mail, and would like us to send them to you, please contact us.

1999 yamaha snowmobile racing 1999 information for open class racer 1999 yamaha sx 700 ron ruzewski...

Documents

yamaha snowmobile racing

rear suspension parts

slide steering rack

yamaha sx

slide bolts

new parts

confidential slide

boss slide