1. 1999 YAMAHA Snowmobile Racing 1999 Information for Open Class Racer 1999 YAMAHA SX 700 Ron Ruzewski Yamaha Motor Corporation Snowmobile R&D Group Leader 1998 Confidential

2. 1999 YAMAHA Snowmobile Racing 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

3. 1999 YAMAHA Snowmobile Racing 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!!!!

4. 1999 YAMAHA Snowmobile Racing 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.

5. 1999 YAMAHA Snowmobile Racing Rear Suspension Parts:

6. 1999 YAMAHA Snowmobile Racing Rear Suspension Parts (cont.):

7. 1999 YAMAHA Snowmobile Racing Front Suspension Parts: Shaded numbers are parts that are available individually.

8. 1999 YAMAHA Snowmobile Racing Front Suspension Parts: (Cont.)

9. 1999 YAMAHA Snowmobile Racing 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.

10. 1999 YAMAHA Snowmobile Racing 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

11. 1999 YAMAHA Snowmobile Racing 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.

12. 1999 YAMAHA Snowmobile Racing 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. 1999 YAMAHA Snowmobile Racing 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

14. 1999 YAMAHA Snowmobile Racing 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.

15. 1999 YAMAHA Snowmobile Racing Finished Product.

16. 1999 YAMAHA Snowmobile Racing 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.

17. 1999 YAMAHA Snowmobile Racing V. Tuning Information: The following pages will help you understand what options you have for tuning.

18. 1999 YAMAHA Snowmobile Racing 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)

19. 1999 YAMAHA Snowmobile Racing 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.

20. 1999 YAMAHA Snowmobile Racing Tuning Parts Rear Suspension (Springs): Std: 3.9-7.2 Opt 1: 3.2 6-5 Opt 2: 4.5-8 Std. Opt. 1 Opt 2

21. 1999 YAMAHA Snowmobile Racing Tuning Parts Front Suspension (Springs): Std: 1.6-3.0 Opt 1: 1.8-3.6 Opt 2: 2.8 Opt 3: 1.5-2.8 Std. Opt 2 Opt 1 Opt 3

22. 1999 YAMAHA Snowmobile Racing Tuning Parts Front Suspension: (Roll Bars) 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

23. 1999 YAMAHA Snowmobile Racing 1G Position (with rider and fluids) Front Suspension Engineering/Design Data:

24. 1999 YAMAHA Snowmobile Racing 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

25. 1999 YAMAHA Snowmobile Racing 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.

26. 1999 YAMAHA Snowmobile Racing