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1979-1990 Yamaha Excel-V C EC540 D XL540 JP Snowmobile Workshop Service Repair Manual 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990

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$16.99
This workshop service repair manual covers the Yamaha Excel-V C, EC540 D, and XL540 JP snowmobiles, with production years ranging from 1979 to 1990. These models represent Yamaha's commitment to...
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Type: Snowmobile
Vendor:
Yamaha
Sku: 136305
Tags: 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 C D EC540 Excel Models Excel-V JP Powersports Snowmobile Snowmobiles XL540 Yamaha
1979-1990 Yamaha Excel-V C EC540 D XL540 JP Snowmobile Workshop Service Repair Manual 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990
This workshop service repair manual covers the Yamaha Excel-V C, EC540 D, and XL540 JP snowmobiles, with production years ranging from 1979 to 1990. These models represent Yamaha's commitment to engineering quality and reliability in the powersports industry, offering robust performance for recreational snowmobiling. The Excel-V line was known for its touring capabilities, while the 540cc engines provided a balance of power and efficiency, making these snowmobiles durable and capable machines for their time. This comprehensive manual is designed to assist DIY enthusiasts, independent repair shops, and owners in maintaining and repairing their Yamaha snowmobiles. It provides detailed coverage of all major systems, including engine overhaul, fuel and electrical systems, and powertrain components. The manual includes routine maintenance procedures, detailed repair instructions, troubleshooting guides with diagnostic flowcharts, and technical specifications, all supported by high-quality diagrams and illustrations. Its practical approach aims to save on professional labor costs by empowering users with the knowledge to service their vehicles effectively.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Excel-V C, EC540 D, XL540 JP
Product Type:
Snowmobile Workshop Service Repair Manual Download
Codes
Engine Codes Covered:
EC540 D, XL540 JP
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, independent repair shops, and owners seeking in-depth knowledge of their Yamaha snowmobiles.
Competitive Analysis
Value Proposition:
Offers a comprehensive and practical resource for servicing and repairing specific Yamaha snowmobile models from 1979-1990, saving on professional labor costs.
Key Features
Usability:
Instant download format with printable pages for convenient workshop use.
Completeness Claim:
Described as the 'most practical' and containing 'high quality diagrams and instructions'.
📋 Manual Details
Coverage Areas
Covered Models Years:
1979-1990 Yamaha Excel-V C, 1980 Yamaha EC540 D, 1985-1990 Yamaha XL540 JP
Page Count
Estimated Page Count:
Comprehensive (specific count not provided, but described as "most practical" and covering extensive areas)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
Compatibility:
All Versions of Windows & Mac
Requirements
Software Requirement:
Adobe PDF Reader
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, top-end, bottom-end, lubrication, cooling (if applicable), ignition system, starting system.
Fuel System:
Carburetion (cleaning, adjustment, rebuilding, jetting), fuel delivery system.
Powertrain:
Drive system (clutch, chaincase, driveshaft, driven shaft), track system, suspension (front and rear), skis, steering.
Chassis:
Frame, body panels, running boards, seat assembly, handlebars, controls.
Electrical System:
Lighting, ignition wiring, battery, charging system (stator, rectifier/regulator), gauges, switches, kill switches.
Supplementary Coverage:
EC 540 D Specific Supplement.
Procedures Included
Maintenance Procedures:
Routine maintenance, lubrication points, inspection checklists, cleaning procedures, track tension adjustment, clutch service.
Repair Procedures:
Engine rebuild (piston replacement, ring replacement, bearing replacement), carburetor rebuilding, clutch adjustment and replacement, track and suspension repairs, electrical component testing and replacement.
Troubleshooting:
Diagnostic flowcharts, common problems and solutions for engine, electrical, and mechanical systems.
Technical Adjustments:
Carburetor jetting and tuning, ignition timing (if adjustable), throttle cable adjustment, brake lever adjustment.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics for engine performance, electrical faults, and drivetrain issues, including specific component testing methods.
Rebuild Instructions:
Detailed step-by-step instructions for complete engine rebuilds and component overhauls.
Diagrams Illustrations:
High-quality diagrams and illustrations for component identification, assembly, and disassembly.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable due to PDF format, enhancing usability.
Print Quality
Printability:
All pages are printable.
Binding Type
Binding Type:
Digital Download (No physical binding)
Paper Type
Paper Type:
N/A (Digital)
Delivery Method
Delivery:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Type Excel V C:
Likely a 2-stroke, air-cooled single or twin cylinder (specifics for 'C' variant depend on exact sub-model within Excel-V line).
Engine Type Ec540 D:
535cc, 2-stroke, reed valve, air-cooled, twin-cylinder (typical configuration for Yamaha's 540cc class of that era).
Engine Type Xl540Jp:
Likely a 535cc or similar displacement 2-stroke, air-cooled, twin-cylinder engine, common in Yamaha's higher-performance models of the late 80s/early 90s.
Performance
Horsepower Range:
Expected to be in the 40-55 HP range for these displacements, depending on specific tuning and model.
Torque Characteristics:
Designed for strong low-to-mid-range torque for snowmobile propulsion, details specific to each model.
Fuel System
Carburetor Type:
Typically Mikuni VM or similar constant-velocity carburetors, often dual carburetors for twin-cylinder engines.
Fuel Mixture:
Pre-mix fuel and oil for 2-stroke engines, or oil injection system depending on model year and specification.
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition) with points or electronic ignition control.
🔧 Transmission
Standard
Drive System:
CVT (Continuously Variable Transmission) utilizing a primary drive clutch (often Yamaha's YC or similar) and a secondary driven clutch.
Optional
Gear Reduction:
Chaincase with integrated gear reduction for drive axle.
Features
Clutch Service:
Detailed procedures for primary and secondary clutch inspection, cleaning, weight and spring adjustment, and roller/button replacement.
Chaincase Maintenance:
Guidance on chaincase oil level checks, oil type, and chain tension adjustment.
📐 Dimensions
Exterior
Track Width:
Varies by model, typically 15" or 16" wide for this era.
Track Length:
Varies by model, commonly between 121" and 136" for this era.
Weights
Dry Weight:
Approximately 450-550 lbs (204-250 kg) depending on specific model and features.
🛡️ Safety Features
Ratings
Safety Standards:
Manufactured to meet industry safety standards of the time; manual will detail pre-ride checks and safe operation.
Active Features
Braking System:
Hydraulic disc brake on driveshaft or track drive, or mechanical drum brake. Manual covers inspection and service.
Passive Features
Kill Switch:
Standard handlebar-mounted kill switch for emergency engine shutdown.
💡 Technology Features
Infotainment
Gauge Cluster:
Basic gauge cluster typically includes speedometer, tachometer, engine temperature indicator, and warning lights.
Driver Assistance
Throttle Control:
Standard thumb throttle with adjustable tension.
Connectivity
No Digital Features:
These models predate modern digital connectivity and advanced driver-assistance systems.
🔧 Maintenance
Service Intervals
Spark Plug Replacement:
Typically every 2,000-3,000 miles or annually, depending on usage and spark plug type (manual will specify).
Chaincase Oil Change:
Recommended annually or every 2,500 miles, depending on operating conditions (manual will specify grade and capacity).
Clutch Service:
Inspect primary and secondary clutches annually or every 2,000 miles for wear and proper function. Clutch weights and spring replacement based on performance needs or wear.
Fluid Specifications
Chaincase Oil:
Yamalube or equivalent SAE 80 or SAE 75W-90 gear oil (manual will specify exact type and quantity).
2 Stroke Oil:
Yamalube 2R or equivalent high-quality 2-stroke snowmobile oil for pre-mix or oil injection system.
Known Issues
Carburetor Fouling:
Common with older 2-stroke engines due to fuel and oil residue, requiring regular cleaning and adjustment.
Clutch Belt Wear:
Drive belts can wear and stretch over time, affecting performance and requiring periodic inspection and replacement.
Suspension Bushings:
Wear on suspension bushings and bearings can lead to poor handling and ride comfort, requiring replacement.
Recoil Starter:
Recoil starter mechanisms can fail or become weak over time, requiring service or replacement.
📚 Vehicle History
Brand Heritage
Yamaha Powersports:
Yamaha has a long-standing reputation for reliability and performance in snowmobiles, stemming from their early entry into the market.
Model Evolution
Excel V Line:
The Excel-V line was known for its comfort and touring capabilities, evolving through various engine and chassis updates.
540Cc Engines:
Yamaha's 540cc 2-stroke twin engines were workhorses, providing a balance of power and efficiency for various snowmobile applications.
Production
Manufacturing Era:
These models represent Yamaha's significant presence in the snowmobile market during the late 1970s and 1980s.
🏆 Awards & Recognition
Recognitions
Historical Reviews:
Models from this era often received positive reviews for their reliability and performance in their respective classes at the time of release.
Ratings
Durability Reputation:
Yamaha snowmobiles from this period are generally regarded as durable and capable machines when properly maintained.
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