Yamaha 1991-1993 Exciter II - 570 Page 239 Service Manual Download

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Summary of Contents for 1991-1993 Exciter II - 570

Page 1: ...ling system Engine j Carburetion Electrical Appendices Illustrated symbols to are usedto identify the specifications which appear Filling fluid D Lubricant Tightening Wear limit clearance Engine speed n V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and location of lubrication point Apply locking agent LOCTITEIl Apply engine oil Apply gear oil Apply molybdenum disul...

Page 2: ...INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE OVERHAUL COOLING SYSTEM CARBURETION ELECTRICAL APPENDICES ENG X COOL CARB iii ELEC APPX http ReadManuals com ...

Page 3: ...OIL SEALS 1 3 CIRCLIPS 1 4 SPECIAL TOOLS 1 4 FOR TUNE UP 1 4 FOR ENGINESERVICE 1 5 FOR POWER TRAIN SERVECE 1 6 FOR ELECTRICAL SERVICE 1 7 CHAPTER 2 PERIODIC INSPECTIONS AND ADJUSTMETS INTRODUCTION 2 1 PERIODIC MAINTENANCE TABLE 2 1 SIDE COWLING 2 3 ENGINE 2 3 SPARK PLUG 2 3 OIL PUMP 2 4 ENGINE OIL LINE INSPECTION 2 6 OIL FILTER INSPECTION 2 6 FUEL LINE INSPECTION 2 6 FUEL FILTER INSPECTION 2 7 COO...

Page 4: ... 23 LUBRICATION 2 24 ELECTRICAL 2 25 HEADLIGHT AND METER LIGHT BULB REPLACEMENT 2 25 HEADLIGHT BEAM ADJUSTMENT 2 27 TAIL BRAKE LIGHT BULB REPLACEMENT 2 27 BATTERY INSPECTION FOR EX570ER 2 28 FUSE INSPECTION FOR EX570ER 2 30 TUNING 2 31 CARBURETOR TUNING 2 31 CLUTCH TUNING 2 40 GEARING SELECTION 2 41 SLIDE RAIL SUSPENSION TUNING 2 43 ENGINE ROOM PLATES 2 44 HIGH ALTITUDE TUNING 2 45 CHAPTER 3 CHASS...

Page 5: ...CTION 4 12 ASSEMBLY 4 13 INSTALLATION 4 14 SHEAVE DISTANCE AND OFFSET ADJUSTMENT 4 15 DRIVE CHAIN HOUSING AND JACKSHAFT 4 18 REMOVAL 4 19 INSPECTION 4 21 INSTALLATION 4 22 BRAKE 4 23 REMOVAL 4 24 DISASSEMBLY 4 24 INSPECTION 4 25 ASSEMBLY AND INSTALLATION 4 26 SLIDE RAIL SUSPENSION 4 29 REMOVAL 4 31 DISASSEMBLY 4 31 INSPECTION 4 33 ASSEMBLY 4 35 INSTALLATION 4 36 FRONT AXLE AND TRACK 4 37 REMOVAL 4...

Page 6: ...SHAFT 5 6 INSPECTION AND REPAIR 5 6 CYLINDER HEAD 5 6 CYLINDER AND PISTON 5 7 PISTON RINGS 5 9 PISTON PIN AND BEARING 5 10 CRANKSHAFT 5 11 CRANKCASE 5 12 OIL PUMP STROKE ADJUSTMEr JT 5 12 ENGINE ASSEMBLY AND ADJUSTMENT 5 15 CRANKCASE AND CRANKSHAFT 5 15 PISTON 5 19 CYLINDER AND CYLINDER HEAD 5 19 CDI MAGNETO 5 20 WATER PUMP 5 22 OIL PUMP 5 22 REMOUNTING ENGINE 5 22 RECOIL STERTER 5 23 REMOVAL 5 24...

Page 7: ... INSTALLATION 7 6 FUEL LEVEL ADJUSTMENT 7 6 FUEL PUMP 7 7 OPERATION CHECK 7 7 CHAPTER 8 ELECTRICAL CIRCUIT DIAGRAM 8 1 ELECTRICAL COMPONENTS 8 3 ELECTRICAL STARTING SYSTEM FOR EX570ER 8 5 CIRCUIT DIAGRAM 8 5 TROUBLESHOOTING 8 7 MAIN SWITCH FOR EX570ER 8 8 RECTIFIER 8 8 STARTER MOTOR 8 9 CHARGING SYSTEM FOR EX570ER 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 BATTERY 8 18 CHARGING COIL 8 19 http ...

Page 8: ...32 LIGHTING COIL 8 32 SIGNAL SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 TROUBLESHOOTING 8 35 BRAKE LIGHT SWITCH 8 37 THERMO SYSTEM 8 37 GRIP WARMER SYSTEM 8 39 CIRCUIT DIAGRAM 8 39 TROUBLE SHOOTING 8 41 GRIP WARMER SWITCH INSPECTION 8 42 GRIP WARMER COIL INSPECTION 8 42 CHAPTER 9 APPENDIX SPECIFICATIONS 9 1 GENERAL SPECIFICATIONS 9 1 MAINTENANCE SPECIFICATIONS 9 3 GENERAL TORQUE SPECIFICATIONS 9 15 DEFINITI...

Page 9: ...AL NUMBER The engine serial number CD is located on the right hand side of the crankcase NOTE _________________________ The first three digits of these numbers are for model identification the remaining digits are the unit production number Starting Serial Number EX570R 88R 0001 01 EX570ER 88S 0001 01 NOTE ________________________ Designs and specifications are subject to change without notice D h...

Page 10: ...eep mated parts together This includes gears cylinders pistons and other parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During disassembly of the machine clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help assure that all parts are reinstalled correctly 5 Keep away from fire 6 Be sure ...

Page 11: ...LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates CD and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been properly tightened BEARINGS AND OIL SEALS 1 Install the bearing s CD and oil seal s with their manufacturer s marks or numbers facing outward In other words the stamped letters must be on the si...

Page 12: ...embly Using the correct special tool will help prevent damage thet can be caused by the use of improper tools or improvised techniques NOTE _________________________ Be sure to use the correct part number when ordering the tool since the part number differs according to the area as shown below The first part number is for Europe and the last part is for the U S A and Canada e g 90890 YU FORTUNE UP...

Page 13: ...r PIN 90890 04086 YM 91042 This tool is used to hold the starter pulley 2 Piston Pin Puller PIN 90890 01304 YU 01304 This tool is used to remove the piston pin 3 Universal Rotor Holder PIN 90890 01235 YU 01235 This tool is used to hold the COl magneto 4 Rotor Puller PIN 90890 01362 YU 33270 This tool is used to remove the magneto rotor u http ReadManuals com ...

Page 14: ... Track Clip Installer PIN YS 91045 This tool is used for installing the track clip FOR ELECTRICAL SERVICE 1 Pocket Tester PIN 90890 03112 YU 03112 This instrument is necessaryforcheckingthe elec trical components 2 Electro Tester PIN 90890 03021 YU 33260 This instrument is invaluable for checking the electrical system D http ReadManuals com ...

Page 15: ... Check oil hose for cracks or damage Replace if necessary Check coolant level Engine Coolant Air bleed the cooling system if necessary Check throttle lever operation Carburetor Whenever operating condition Adjust the jets elevation temperature is changed Water Pump Belt Check wear and damage Replace if necessary Adjust water pump belt if necessary Manual Starter Check operation and rope damage Rep...

Page 16: ...perating elevation is changed Primary Sheave Check wear and damage Replace if necessary Lubricate with specified grease Lubricate with specified grease Secondary Sheave Adjust if necessary Whenever operating elevation is changed Steering Column Bearing Lubricate with specified grease Ski and Front Suspension Lubricate with specified grease Suspention Component Lubric te with specified grease Brake...

Page 17: ... procedure ENGINE SPARK PLUG 1 Remove Spark plug 2 Inspect Electrode CD Wear Damage Replace Insulator color 3 Measure Plug gap Out of specification Regap Use Wire Thickness Gauge Spark Plug Gap 0 7 0 8 mm 0 028 0 032 in Clean the plug with a spark plug cleaner if necessary Standard spark plug BR9ES NGK Before installing a spark plug clean the gasket surface and plug surface http ReadManuals com ...

Page 18: ... of the oil system has been disconnected When the machine has been turned on its side Whenever the oil tank has been run empty During predelivery 1 Remove Drive V belt guard See page 2 16 Carburetors See page 7 2 2 Fill Oil tank CD Oil tank capacity 3 0 L 2 6 Imp qt 3 2 US qt Recommended oil Vamalube 2 cycle oil 3 Place a rag under the oil pump assembly to catch oil 4 Disconnect Oil hoses CD 5 Kee...

Page 19: ...spect Gasket bleed screw CD Wear Damage Replace 13 Install Gasket bleed screw Bleed screw Cable Adjustment NOTE ________________________ Before adjusting the oil pump cable the throttle cable free play should be adjusted 1 Pull back the adjuster cover CD 2 Adjust Oil pump cable Adjusting steps Loosen the locknut CD Hold the throttle lever at full throttle position Turn the adjuster in or out until...

Page 20: ...emove Cover oil tank right CD Oil tank stay 2 Disconnect Oil hoses NOTE ________________________ Plug the oil hoses so thatthe oil will not run out of the oil tank and oil pump 3 Inspect Oil filter CD Contamination Replace Recommended replacement interval Every season 4 Reverse the removal procedure FUEL LINE INSPECTION 1 Inspect Fuel hoses Fuel delivery hoses Crack Damage Replace http ReadManuals...

Page 21: ...Cap Fuel filter 4 Inspect Fuel filter CD Contamination tReplace Recommended replacement interval Every season 5 Reverse the removal procedure COOLING SYSTEM Coolant Replacement NOTE _________________________ The coolant should be changed at least season ally 1 Place the machine on a level surface 2 Remove Side cowling right See page 2 3 Seat http ReadManuals com ...

Page 22: ...When the engine has cooled place thick rag like a towel over the radiator cap slowly rotate the cap counterclockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it 6 Place an open container under the drain bolts CD 7 Remove Drain bolts 8 Drain the coolant NOTE ________________...

Page 23: ...ant splashes on skin or clothes wash immediately with soap and water 11 Remove the reservoir tank CD and drain the coolant 12 Install Reservoir tank 13 Inspect Gaskets drain bolt Damage Replace 14 Install Gaskets Drain bolts Exhaust pipe gaskets Muffler Drain bolt 32 Nm 3 2 mokg 23 ft lb a Bolts exhaust pipe 23 Nm 2 3 mokg 17 ft lb 15 Fill Cooling system Recommended Coolant High quality ethylene g...

Page 24: ... to the coolant filler Apply 100 kPa 1 0 kg cm2 14 psi Measure the pressure with gauge Air Bleeding 1 Bleed air from the cooling system Air bleeding steps Pour the coolant into the filler neck to the specified level CD Loosen the bleed bolt of heat exchanger Keep the coolant running out until air bubbles disappear Tighten the bleed bolt Bleed bolt 6 Nm 0 6 mokg 4 3 ft Ib Add coolant to fill the fi...

Page 25: ...r bystanders Observe the following precautions Do not allow anyone to stand behind the machine when the engine is running Pour the coolant into the reservoir tank until the coolant level reaches FULL level mark 0 2 Inspect Cooling system Coolant leakage Repair Water Pump Belt Deflection Adjustment 1 Remove Muffler 2 Check Drive belt deflection Out of specification Adjust Drive belt deflection 3 Ad...

Page 26: ...ust the drive belt deflec tion 4 Tighten ENGINE IDLE SPEED ADJUSTMENT 1 Adjust Engine idle speed Adjustment steps Remove the rubber caps i from the carbure tor vacuum fittings and connect the vacuum gauge hoses YU 08030 to the fittings Start the engine and let it warm up Turn the throttle stop screws in or out so that the vacuum readings are the same Turn the throttle stop screws in oroutto adjust...

Page 27: ...play the engine idle speed should be adjusted 1 Measure Throttle cable free play Out of specification Adjust Throttle cable free play 1 0 2 0 mm 0 04 0 08 in 2 Adjust Throttle cable free play Adjustment steps Loosen the locknut CD Turn the adjuster in or out until the fied free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the locknut speci NOTE ____...

Page 28: ...uld cause an accident 1 Start the engine 2 Hold the pivot point of the throttle lever away from the throttle switch CD 3 Press the throttle lever gradually The T O R S warning light should flash and the engine should not exceed 2800 to 3000 r p m If the engine exceeds 2800 to 3000 r p m Repair the T O R S See page 8 26 STARTER CHOKE CABLE ADJUSTMENT 1 Pull back the adjuster cover CD 2 Pull the out...

Page 29: ...STEM 1 Inspect Exhaust pipe gasket s CD Damage Replace Exhaust gas leakage Repair 2 Tighten Exhaust pipe bolt 23 Nm 2 3 mokg 17 ftolb POWER TRAIN DRIVE V BELT AWARNING Be sure there is a 2 0 mm 0 08 in gap CD between secondary fixed and sliding sheaves when installing the NEW belt Ifthere is no gap the clutch engagement speed will be reduced The machine may move unexpectedly when the engine is sta...

Page 30: ...Bolt drive V belt guard CD Drive V belt guard NOTE ________________________ Press the holding pin all the way in until it releases from the hook then rotate it 90 and pull it out 2 Remove Drive V belt CD Removal steps Rotate the secondary sliding sheave clock wise and push it so that it separates from the fixed sheave Pull the belt up over the secondary fixed sheave Remove the belt from the second...

Page 31: ...ner or solvent Check the primary and secon dary sheaves 5 Measure Drive V belt length Out of specification Replace Drive V belt length 1 130 1 118 mm 44 5 44 0 in ENGAGEMENT SPEED CHECK 1 Place the machine on a level area of hard packed snow 2 Check Clutch engagement speed Checking steps Start the engine and open the throttle lever gradually Check the engine speed when the machine starts moving fo...

Page 32: ...Free play is decreased Tighten the locknut CD DRIVE CHAIN Oil Level Inspection 1 Place the machine on a level surface 2 Remove Side cowling right See page 2 3 3 Place a rag under the checking hole oil level 4 Remove Checking bolt CD Gasket checking bolt 5 Inspect Oil level drive chain housing Oil flows out Oil level is correct Oil does not flow out Oil level is low Add oil until oil flows out Reco...

Page 33: ...r Chain housing cover CD Always use a new gasket chain housing cover NOTE Tighten the bolts in stages using a crisscross pattern Before installing the chain housing cover the drive chain slack should be adjusted Bolt chain housing cover Small diameter M6 10 Nm 1 0 m kg 7 2 ft lb Large diameter M8 23 Nm 2 3 m kg 17 ft lb 5 Remove Filler cap CD 6 FiH Drive chain housing Be sure no foreign material e...

Page 34: ...g 3 Remove Chain housing cover 4 Check Drive chain slack Out of specification Adjust Drive chain slack 8 15 mm 0 31 0 59 in 5 Adjust Drive chain slack Adjustment steps Loosen the locknut CD Turn the adjuster in orout untiIthe specified free slack is obtained Turning in Free play is decreased T urning out Free play is increased Tighten the locknut CD 6 Proceed to steps 4 through 7 of Oil Re placeme...

Page 35: ...er allow anyone near a rotating track Inspect track condition frequently Replace the track if it is damaged to the depth where fabric reinforcement material is visible Never install studs cleats closer than three inches from the edge of the track 1 Place the machine with the right side facing down 2 Measure Track deflection Pull at the track center window by a force of 10 kg 22 Ib using a spring s...

Page 36: ...ter Turn in Turn out Slide runner Track Track metal Gap Forward c Adjust track deflection to the specified amount Track deflection More than Less than Specified Specified Left adjuster Turn in Turn out Right adjuster Turn in Turn out The adjusters should be turned an equal amount Recheck alignment and deflection If neces sary repeat steps a to c until proper adjust ment is achieved Tighten the rea...

Page 37: ...e play Push the handlebar up and down and back and forth Turn the handlebar slightly to the right and left Excessive free play check to be sure the handlebar tie rod ends and relay rod ends are installed securely in position lffree play still exists check the steering bearing front suspension links and ski mounting area for wear and replace if necessary See page 3 6 Toe Out Adjustment 1 Place the ...

Page 38: ...sen the locknuts tie rod CD Turn the relay rod in or out until the specified toe out is obtained Tighten the locknuts tie rod CD I Locknut tie rod 25 Nm 2 5 m kg 18 ft Ib LOCTITE AJ Left side lliJ Right side LUBRICATION Front and Rear Suspension 1 Inject grease through nipplesCDusing a grease gun AJ Front lID Rear Esse Beacon 325 Grease or Aeroshell Grease 7A http ReadManuals com ...

Page 39: ...rottle cables themselves because they could become frozen which could cause loss of control ELECTRICAL HEADLIGHT AND METER LIGHT BULB REPLACEMENT 1 Remove Handlbar covers rear and front CD Meter cover See page 3 2 2 Remove Meter assembly CD NOTE ________________________ Speedometercableand meterlightcouplerdo not need removing 3 Remove Bulb defective Pull out the bulb holder CD from the meter case...

Page 40: ... new CD NOTE _________________________ Make sure the projections on the bulb are meshed with the slots on the light case Avoid touching the glass part of the bulb Keep it free from oil otherwise the transparency of the glass life of the bulb and iIIuminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 9 Install Bu...

Page 41: ...orizontal line If not adjust the direction L 3 0 m 10 ft 7 6 m 25 ft H 26 mm 1 0 in 66 mm 2 6 in 3 Remove Handlebar covers rear and front Meter cover See page 3 2 4 Adjust Headlight beam direction Adjust the headlight beam by tightening or loosening the adjusters CD TAIL BRAKE LIGHT BULB REPLACEMENT 1 Remove Tail brake light lens CD 2 Remove Bulb defective NOTE ________________________ While pushi...

Page 42: ...nt 1 6 amps 10 hrs Specific gravity 1 280 at 20 C 68 F Replace the battery if Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging Sulfation of one or more cells occurs as indicated by the plates turning white or an accumulation of material exists in the bottom ofthe cell Specific gravity readings after a long slow charge indicate one cell to ...

Page 43: ...beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventive measures Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes etc DO NOT SMOKE when charging or handling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH...

Page 44: ...pect Fuse Defective Replace Blown fuse new lnspect circuit NOTE _________________________ Install new fuses of proper amperage Description Amperage Quantity Main 10A 1 Spare 10A 1 Replacement steps Turn off the ignition and the circuit Install a new fuse of proper amperage Turn on the switches to verify operation of electrical device Iffuse blows again immediately check circuit in question AWARNIN...

Page 45: ...the throttle opening Therefore after the carburetors have been tuned or maintained or after the float chamber is removed for cleaning or jet replacement be sure to idle the engine for about three minutes in order to avoid engine trouble 2 31 Before performing the carburetor tuning make sure that the following items are set to specification Engine Idle speed adjustment Throttle cable free play adju...

Page 46: ...nd tem perature 30 C 20 C 10 C O C 20 C 22 F 4 F 14 F 32 F 6S0F I I I I I 320 IN 3rd 310 STD IN 3rd STD 310 STD IN 3rd STD 300 IN 3rd 280 IN 3rd 260 IN 3rd 250 IN 3rd 2 32 300 IN 3rd 290 IN 3rd 270 IN 3rd AS 7 8 270 IN 3rd AS 7 8 240 IN 2rd AS 7 8 NOTE ________________________ These jetting specifications are subjectto change Consult the latest technical information from Yamaha to be sure you have...

Page 47: ...h speed tuning Low speed tuning CD Throttle stop screw air screw pilot jet pilot outlet bypass fuel level Throttle valve cutaway Jet needle Needle jet Mainjet 1 c CII co Closed 1 8 1 4 CARBURETOR TUNING IrgrIQ I 1 2 3 4 Full open Throttle opening 2 33 http ReadManuals com ...

Page 48: ...le opening 2 34 If the Air Silencer Box is removed from the carburetors the change in pressure in the intake will create a LEAN MIXTURE that could likely result in severe engine damage The Air Silencer Box has no effect on performance characteristics and it must be secured to the carburetor during carb tuning and adjustment and it must always be in place when the engine is operated Examine the Sil...

Page 49: ...gine and allow it to warm up for a few minutes The warm up is complete when the engine responds normally to the throttle opening AWARNING Do not move the throttle enough to reach the following engagement speed The snowmobile could accidentally start to move forward Engine revolutions 3 000 rlmin 3 Adjust the throttle stop screws evenly until the engine speed is at 2 000 2 500 r min 4 Slowly loosen...

Page 50: ...e NOTE ________________________ In this case set the carburetor on the richer side use a larger number pilot jet Standard pilot jet 42 5 7 By repeating steps 1 to 5 above adjust the idle speed Middle Range and High Speed Tuning No adjustment is normally required but adjust ment is sometimes necessary depending on temperatures and or altitude Middle range speed and high speed tuning from 1 4 to ful...

Page 51: ...intake silencer joint clamps and intake manifold clamps Make sure the throttle cable is in place and the throttle operates smoothly Main jet selection chart Check up Remedy Good carburetor is tuned properly Bad Mixture is too rich Replace main jet with one step smaller one Bad Mixture is too lean Replace main jet with one step larger one Bad Due to too lean a mixture Replace the piston and spark p...

Page 52: ...ack out throttle throttle stop screw so the en Engine tends to gine idles at specified speed stall Throttle stop screw Adjust Tightened too much Engine speed is higher Backed out too much Engine does not idle Damaged pilot screw Replace pilot screw Clogged bypass hole Clean Clogged or loose pilot Clean and retighten Remove pilot jet and blow it jet out with compressed air Air leaking into carbure ...

Page 53: ... Lean mixtures Clean carburetor tion and adjust Mainly backfire Dirty carburetor Clean carburetor Dirty or clogged fuel Clean or replace fuel pipe pipe Overflow Clogged air vent Clean Related symptoms Clogged float valve Disassemble and Clean while taking care not to Poor idling clean scratch valve seat Poor performance at low mid range Scratched or unevenly Clean or replace float Replace if seat ...

Page 54: ...oint 200 300 m 650 1 000 ft from the starting position afterthe machine has been started at full throttle from a dead stop fJ Normally when a machine reaches shift speed the vehicle speed increases but the engine speed remains nearly constant Under unfavorable con A ditions wetsnow icysnow hills or rough terrain t however engine speed may decrease after the engine speed has reached shifting speed ...

Page 55: ...24 0 kg 90501 584G2 25 N mm 140 Ib in 53 0Ib 2 75 kg mm 24 0 kg 90501 584G1 27 N mm 154Ib in 53 0Ib 3 00 kg mm 24 0 kg 90501 604GO 53 0Ib 29 N mm 168 Ib in 2 41 CLUTCH TUNING I I Ill High Altitude Tuning High altitude specifications should be applied for operation at an altitude of more than 900 meters 3 000 ft 900 1 500 m 1 350 3 000 m 3 000 5 000 ft 4 500 10 000 ft f f f f f f f f f Aluminum f 9...

Page 56: ... unfavorable snow conditions the drive driven gear ratio should be made larger If there are few rough surfaces or better snow condition the ratio should be made smaller Gear Ratio Chart The following drive and driven gears and chains are available as options The figures in upper lines represent the driven and drive gear ratios while those in lower lines represent the number of chain links NOTE ___...

Page 57: ...88F 17682 70 88F 17682 60 2 43 17 16 88F 47587 20 35 SLIDE RAIL SUSPENSION TUNING The spring preload is a determining factor in machine stability Consider the course condition and the rider s weight when setting spring pre load The suspension should be set as soft as possible without imparing the stability of the machine Stopper Band Setting 1 Adjust Stopper band length NOTE ______________________...

Page 58: ...Less Rear Hole No Riding comfort Stability No 1 Better Less 1 1 No 5 Less Better Tighen the bolt stopper band Nut stopper band I 4 Nm 0 4 m kg 2 9 ft Ib Spring Preload 1 Adjust Spring preload Adjustment steps Turn the spring seat CD in or out Spring length Shorter H Longer Preload Harder H Softer Standard 193 3 mm 7 6 in spring length 261 8 mm 10 3 in IAl Front rn J Rear http ReadManuals com ...

Page 59: ...OK jet Confirm STD settings Carburetor Page 2 31 Spark plug Page 2 3 Adjust main jet size according to the chart Page 2 37 r NotOK Adjust main jet size Not OK J Re test Check to see if gearing is too high or lOW ciK NotjOK Adjust gearing as required Page 2 41 NotlOK Check engagement and shift speed performance I IK Not OK OK I t High altitude tuning OK Adjust primary clutch as re quired Page 2 41 ...

Page 60: ...5 Nm 2 5 m kg 18 ft Ib STEERING ICHASI J I CHASSIS STEERING CD Handlebar Steering column Bearing Bearing holder Lock washer Relay rod ill lie rod 15 Nm 1 5 m kg 11 ft Ib 143 Nm 4 3 m kg 31 ft Ib 1 n z l 125 Nm 2 5 m kg 18ft Ib 1 1 1 A I u s E N EW o NE I 3 1 http ReadManuals com ...

Page 61: ...ng the handlebar cover rear 2 Remove Meter cover CD 3 Disconnect Meter light coupler Headlight coupler Speedometer cable Handlebar switch coupler right Blake light switch coupler Headlight beam switch coupler Grip warmer leads 4 Remove Upper cowling with meter assembly CD 5 Remove Holder throttle cable CD 6 Disconnect Throttle cable Oil pump cable from throttle lever http ReadManuals com ...

Page 62: ...r holders upper Handlebar Handlebar holder lower 9 Remove Side covers left and right CD Center cover NOTE ____________ Remove the holding nuts main switch STARTER lever and fuel cock when removing the center cover 10 Remove Carburetors See page 7 2 Intake silencer Engine assembly See page 5 1 11 Straighten Lock washer tabs upper and lower 12 Remove Cotter pin CD http ReadManuals com ...

Page 63: ... the steering column the relay rod end needs to be held fixed in order to facilitate the lock nut removal 14 Remove Cap CD Cotter pins AI left side ID Right side 11 Remove Relay rod CD Tie rod INSPECTION 1 Inspect Handlebar CD Steering column Bends Cracks Damage 4 Replace AWARNING Do not attempt to straighten a bent column This may dangerously weaken the column http ReadManuals com ...

Page 64: ... weaken the rod 4 Check Tie rod end movement Tie rod end free play exists Replace Tie rod end turns roughly Replace INSTALLATION Reverse the REMOVAL procedure Note the following points 1 lnstall Tie rod CD Relay rod NOTE _______________________ Install the rod end with left hand threads onto the tie rod on the right side The threads on both rod ends must be the same length Lock nut tie rod end 25 ...

Page 65: ...ly install the handlebar Hold the handlebar straight and check to see that the skis are at right angles to the handle bar Loosen the locknuts steering relay rod CD Direct the skis in parallel to the moving direc tion With the skis thus turn the relay rod either way to adjust the handlebars at right angles with respect to the direction of movement Turning the relay The handlebars move rod in direct...

Page 66: ...orward Align the punch marks with the handlebar holder gaps respectively Tighten the bolts to specification so that the front clearance a is smaller than rear clear ance b First tighten the bolts on the front side of the handlbar holder and then tighten the bolts on the rear side 8 Tighten Upper cowling bolt 3 Nm 0 3 m kg 2 2 ft Ib 9 Adjust Brake lever free play See page 2 18 http ReadManuals com ...

Page 67: ...ositions ofthe left and right ski assembly 3 8 SKI CD Collar Ski stopper Ski Ski runner Recommended grease ESSO Beacon 325 grease or Aeroshell grease 7A Fit the stopper with its raised portion positioned in front SKI DISTANCE C 920 mm 36 2 in SKI TOE OUT 0 0 15 mm 0 0 0 6 in http ReadManuals com ...

Page 68: ... Wear Cracks Damage Replace Mounting bolt Collar Wear Damage Replace INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Tighten Ski runner nut 21 Nm 2 1 m kg 15 ft Ib 2 Install Ski stopper NOTE __________________________________ Fit the stopper with its raised portion posi tioned in front Be careful not to reverse the mounting posi tions of the left and right ski assemblies htt...

Page 69: ...ing nut 43 Nm 4 3 m kg 31 ft Ib NOTE ___________________________________ Lubricate the collar and mounting bolt before installing the ski Recommended grease ESSO Beacon 325 hrease or Aeroshell grease 7A Always use a new cotter pin http ReadManuals com ...

Page 70: ...Absorber holder Spring seat upper Dumper Spring Spring seat lower Shock absorber j Suspension arm I Suspension bracket Front arm upper Front arm lower Stabilizer rod Stabilizer slider Recommended grease 43 Nm ESSO Beacon 325 grease or Aeroshell grease 7A 4 3 m kg 31 ft lbl 121 Nm 2 1 m kg 15 ft bll http ReadManuals com ...

Page 71: ...______________________ When removing the hood the nuts mayfall off Be careful not to lose these parts 3 Remove Ski See page 3 9 4 Remove Cotter pin CD Tie rod A Left ID Right 5 Remove Cotter pins CD Front arm upper Front arm lower Washers Bushing Collars 6 Remove Cap suspension CD Protector http ReadManuals com ...

Page 72: ...CD 8 Remove Spacer collar CD Flange plate Spring seat upper Spring Spring seat lower Absorber cover 9 Loosen Nuts CD Set screw 10 Remove Suspension bracket 11 Remove Shock absorber CD 12 Remove Circlip CD Washer Suspension arm 3 13 http ReadManuals com ...

Page 73: ...the circlip INSPECTION 1 Inspect Shock absorber Oil leaks Bend Damage Replace 2 Inspect Suspension brackets CD Suspension arm Front arms Bushings Cracks Wear Damage Replace 3 Inspect Spring Wear Cracks Damage Replace 4 Measure Spring free length Out of specification Replace Spring free length limit 235 0 mm 9 25 in 5 Inspect Oil seals Damage Replace http ReadManuals com ...

Page 74: ...ricate Bushing suspension support CD Bushing suspension arm Oil seal lips Recommended grease ESSO Beacon 325 grease or Aeroshell grease 7A 2 Tighten Suspension bracket nut 21 Nm 2 1 m kg 15 ft Ib Set screw 2 Nm 10 2 m kg 1 4 ft Ib LOCTITE Absorber holder bolt 10 Nm 1 0 m kg 7 2 ft Ib Shock absorber nut 5 Nm 0 5 m kg 3 6 ft Ib Locknut shock absorber 16 Nm 1 6 m kg 11 ft Ib NOTE ____________________...

Page 75: ...ghten Front arm nut 43 Nm 4 3 m kg 31 ft Ib NOTE ____________ Be sure install the front arms so thatthe UPPER mark is positioned to the upper and the LOWER mark is positioned to the lower Always use a new cotter pin http ReadManuals com ...

Page 76: ... HAND THREAD Stopper jJ V belt Sliding sheave Collar Rivet Weight Bushing Slider Bushing 14 Nm 0 4 m kg 2 9 ft Ib I 200 Nm 20 m kg 145 ft Ib I 2 I I I I I L _______ J 1 Tighten the bolt 120 Nm 12 m kg 87 ft Ib 2 Loosen the bolt completely 3 Retighten the bolt 60 Nm 6 0 m kg 43 ft Ib 14 Nm 1 4 m kg 10 ft Ib 4 4 Nm 0 4 m kg 2 9 ft Ib 15 J 1 6 Nm 0 6 m kg 4 3 ft Ib 4 1 http ReadManuals com ...

Page 77: ...Primary sheave assembly CD NOTE _________________________ Use the Primary Sheave Holder 90890 01701 YS 01880 and Primary Sheave Puller YS 01881 1 YS 38517 DISASSEMBLV 1 Remove Bolts primary sheave cap NOTE _______________________ Attach the Sheave Compressor YS 28891 CD to compress the primary sheave spring 2 Remove Sheave compressor NOTE _________________________ Slowly loosen the wing nut CD of ...

Page 78: ...al tools and LOCTITE are necessary for assembling the spider and fixed sheave If these are unavailable avoid disassembling Removal steps Immerse the primary sheave assembly in appoximately 800 1000 C 1760 2120 F water for several minutes Hold the lower piece of the Clutch Spider Separator YS 28890 B CD on a rigid table using a suitable mounting bolts Then install the Clutch Separator Adapter YS 34...

Page 79: ...be sure that the spider fixed sheave and special tool are placed securely Loosen the spider carefully to prevent cracks and or damage to the sheaves and spider Remove the fixed sheave fixed sheave stopper and sliding sheave from the spider J INSPECTION 1 Inspect Spider tapered portion CD Sliding sheave 00 Fixed sheave Primary sheave cap Cracks Damage Replace 2 Measure Bushing to sheave clearance O...

Page 80: ...riate drill Insert the rivet CD from the 10 mark side Press or peen the rivet head sothatthe diame ter of rivet head measures to 8 2 mm 0 32 in or larger NOTE ______________________ Refer to chart on 2 42 for rivet application 6 Measure Bushing inside diameter primary sheave cap Out of specification Replace Bushing inside diameter primary sheave cap new 28 0 mm 1 10 in wear limit 28 2 mm 1 11 in 7...

Page 81: ...11 Measure Weight bushing inside diameter Out of specification Replace as a set Weight bushing inside diameter new 8 0 mm 0 31 in wear limilt 8 2 mm 0 32 in ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points 1 Install Sliding sheave onto spider NOTE ________________________ Be sure the sliding sheave match mark x is aligned with the spider match mark x 2 Install Fixed sheave onto...

Page 82: ...pider Separator YS 28890 8 CD NOTE _______________________ Securely fit the projections of the Clutch Sepa rator Adapter into the fixed sheave holes Tighten the spider to specification using the bar wrench Spider 200 Nm 20 m kg 145 ft Ib Spider has a left hand thread AWARNING Do not operate the primary sheave until the LOCTITE has dried completely Wait 24 hours before operating primary sheave Sinc...

Page 83: ...ve the bolt CD must be installed with their threaded portions pointing in a counter clockwise direc tion as illustation 6 Lubricate Weight roller contact surface with thin coat I rl Molybdenum disulfide grease 7 Install Primary sheave spring CD Primary sheave cap NOTE __________________________________ Be sure the sheave cap match mark x is aligned with the spider match mark X 8 Tighten Primary sh...

Page 84: ...Bolt primary sheave CD Tightening steps Hold the primary sheave usingthe Primary Sheave Holder 90890 01701 YS 01880 and tighten the bolt primary sheave to speci fication Bolt primary sheave initial tightening a 120 Nm 12 m kg 87 ft Ib Loosen the bolt primary sheave completely Retighten the bolt primary sheave to specifi cation Bolt primary sheave 60 Nm 6 0 m kg 43 ft Ib 4 Install Drive V belt NOTE...

Page 85: ...41 SECONDARY SHEAVE CD Circlip Washer Spring seat Secondary spring Ramp shoe Sliding bushing j Sliding sheave Shim Fixed sheave Collor Shim B Standard twist angle 50 4 Standard position position A 60 Nm 6 0 m kg 43 ft Ib 4 10 http ReadManuals com ...

Page 86: ...AUTION when disassembling the secondary sheave as serious injury can occur from the sudden release of spring tension Use the Sheave Compressor VS 28891 to contain the spring tension before removing the retaining clip Do not attempt the procedure unless you have the proper tools and understand the instructions thoroughly 1 Remove Circlip CD Washer NOTE ________________________ Attach the Sheave Com...

Page 87: ...tension 3 Remove Spring seat CD Secondary sheave spring 4 Remove Sliding sheave CD Shim s drive V belt from fixed sheave INSPECTION 1 Inspect Sliding sheave CD Fixed sheave Spring seat Cracks Damage Replace 2 Inspect Bushing sliding sheave CD Sliding sheave V belt contact surface Scratches Wear Damage Replace Sliding bushing Unsymmetrical wear Damage Replace http ReadManuals com ...

Page 88: ...rocedure Note the following points 1 Lubricate Bushing surface thin coat Recommended Grease 2 Install Esso Beacon 325 grease or Aeroshell grease 7A Secondary sheave spring CD NOTE _________________________ Hookthe end ofthe secondary sheave spring onto the spring hole in the sliding sheave Standard spring position Position A 3 Install Spring seat CD NOTE _________________________ Hook the end of t...

Page 89: ... the sliding sheave cam Turn the sliding sheave the specified degrees in the counterclockwise direction Holding the sliding sheave and fixed sheave in this position Standard twist angle 50 Turn in the screw for the sheave compressor so that the spring seat engages with the slid ing sheave Install the washer and circlip in proper posi tion INSTALLATION Reverse the uREMOVALu procedure Note the follo...

Page 90: ...red Loosen the engine mounting nuts CD Adjust the position of the engine so that the sheave distance is within the specification with the crankshaft and juckshaft parallel to each other Tighten the engine mounting nuts CD Mounting nut 40 Nm 4 0 m kg 29 ft Ib 3 Measure Sheave offset Use the Sheave Gauge YS 91047 Out of specification 4 Adjust Sheave offset 14 5 17 5 mm 0 57 0 69 in 4 Adjust Sheave o...

Page 91: ...sheave offset If out of specifica tion repeat the above steps NOTE When adjusting the sheave offset the secon dary sheave free play clearance should be adjusted 5 Measure Secondary sheave free play clearance Use a feeler gauge Out of specification Adjust Secondary sheave free play clearance t olIioI 0 5 1 0 mm 0 02 0 04 in 6 Adjust Secondary sheave free play clearance Adjustment steps Apply the br...

Page 92: ...art Number Thickness 90201 222FO 0 5 mm 0 02 in 90201 225A4 1 0 mm 0 04 in Install the washer and bolt secondary sheave and tighten the bolt Bolt secondary sheave 60 Nm 6 0 m kg 43 ft lb Recheck the secondary sheave free play clearance If out of specification repeat the above steps 4 17 http ReadManuals com ...

Page 93: ...lder Drive sprocket Collar Oilseal ill locknut Adjuster Drive chain tensioner Driven sprocket jJ Drive chain 50 Nm 5 0 m kg 36 ft Ib A USE NEWONE 23 Nm 2 3 m kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 23 Nm 2 3 m kg 17 ft Ib 23 Nm 2 3 m kg 17 ft Ib A USE NEW ONE 48 Nm 4 8 m kg 35 ft Ib 4 18 http ReadManuals com ...

Page 94: ... Cotter pin CD Nut drive sprocket V Bolt driven sprocket Drive sprocket Driven sprocket Drive chain Collar j NOTE _________________________ Apply the brake to lock the jackshaft when removing the nut drive sprocket and bolt driven sprocket Loosen the adjuster fully when removing the drive sprocket driven sprocket and drive chain 5 Remove Bolts brake caliper body CD Stay intake silencer V http Read...

Page 95: ... key Jackshaft 8 Remove Bearing housing CD Inner race holder NOTE _______________________ Loosen the screw inner race holder 9 Loosen Track See page 4 31 10 Remove Speedometer gear assembly See page 4 38 Bearing holder Drive chain housing CD NOTE _______________________ Push the front axle to the left to remove the drive chain housing 11 Remove Adjuster chain tensioner CD Bolt Collar Chain tension...

Page 96: ...acement steps Remove the circlip bearing holder j Remove the bearing s using a general bearing puller Install the new bearing s NOTE ____________ Use a socket that matches the outside diameter of the race of the bearing Do not strike the inner race of balls of the bearing Contact should be made only with the outer race j Install the new circlip bearing holder Always use a new circlip 2 Inspect Dri...

Page 97: ...ing bolt 43 Nm 4 3 m kg 31 ft Ib Brake caliper body bolt 48 Nm 4 8 m kg 35 ft Ib Drive sprocket nut 50 Nm 5 0 m kg 36 ft Ib Driven sprocket bolt 48 Nm 4 8 m kg 35 ft Ib Inner race holder screw 6 Nm 0 6 m kg 4 3 ft Ib NOTE ____________ Install the washer drive sprocket CD as shown in the illustration Tighten the screw inner race holder aftertight ening the drive sprocket nut 3 Adjust Drive chain sl...

Page 98: ...1 4 23 BRAKE DPad Back up plate Caliper body Lever illStationary cover Washer j One way lock 2 Adjusting screw Adjusting ratchet End cover Brake disc Woodruffkey With silicone grease 10 2 Nm 0 2 m kg 1 4 ft Ib http ReadManuals com ...

Page 99: ...___________ Loosen the locknut and turn in the adjuster fully to release the tension in the brake cable then remove the bolt cable holder 3 Remove Bolts bearing housing See page 4 19 Jackshaft with bearing housing Brake disc Woodruff key OISASSEMBLY 1 Remove Back up plate CD End cover Do not disassemble the torsion spring from the end cover and the guide 2 Remove Adjusting ratchet CD Bolts station...

Page 100: ...ide One way lock 1 CracksNVear Damage Replace the end cover unit 3 Inspect One way lock 2 CD Stationary cover Lever Spiral gear lever CracksNVear Damage Replace Replacement steps Remove the one way lock 2 CD using a thin flat head screw driver Remove the washer and stationary cover Replace a damaged part s use a new one Reassemble the removed part s and reverse the above steps Always use a new one...

Page 101: ...ect Adjusting ratchet CD Cracks Wear Damage Replace Spring brake cable Fatigue Damage Replace Brake pad thickness See page 2 18 Brake disk Bend Cracks Damage Replace ASSEMBLY AND INSTALLATION Reverse the REMOVAL and DISASSEMBLY procedures Note the following points 1 Assemble Caliper body Assemblage steps Lubricate the spiral gears CD on the caliper body and lever with silicone grease Align the pro...

Page 102: ...ts lightly with the end of the back up plate then back out the adjusting screw 1 2 to CD turn Fit the end of the adjusting rachet into the adjusting screw and align the cut in the guide j with the projection of the stationary cover then install the guide j which is fitted to the end cover twisting the end cover clockwise approximately 30 degrees and tighten the screws end cover j Screw end cover 2...

Page 103: ..._ _ _ _ _ _ _ _ _ _ _ BR_AK_Er wR141 3 Tighten Cable holder blot 9 Nm 0 9 m kg 6 5 ft Ib 4 Adjust Brake lever free play See page 2 18 4 28 http ReadManuals com ...

Page 104: ...ar axle PENSION Guide h G d 8minw eel ea 1 iii sw e wheel cen 1 rA 9 UV uspenslo ekclip cente 1 n wheel o Collar jJ Suspen e soon whe I oliaeCcente f ont e 7 Suspension whe I Slide metal Suspe e T k nSlon whe I rae assembl rea e Y 4 29 http ReadManuals com ...

Page 105: ...unner Bushing Suspension wheel Pull rod bracket Rear suspensio Front suspension r r R n Rela U ear stopper band tfi y arm Bracket Bracket Rear suspension Front stopper band bracket I v Front pivot arm 20 Nm 2 0 m kg 14ft o lb 42 Nm 4 2 m kg 30 ft Ib 20 Nm 2 0 m o kg 14ft o lb 20 Nm 2 0 m o kg 14ft o lb http ReadManuals com ...

Page 106: ...t CD and adjusters track tension 3 Remove Guide wheel center CD 4 Remove Suspension mounting bolts NOTE ____________ Loosen both right and left bolts front CD at the same time 5 Place the machine with the left side facing down 6 Remove Slide rail suspension CD DISASSEMBLY 1 Remove Stopper bands front CD and rear http ReadManuals com ...

Page 107: ...e Suspension wheel bracket CD Front suspension Front pivot arm Collar Bushing Washer j Flange washer 4 Remove Suspension wheels center CD Rear suspension Pull rods Washer Collar Bushing 5 Remove Rear pivot arm CD Suspension wheel Pivot arm bracket Collar Washer http ReadManuals com ...

Page 108: ...hly Replace Replacement steps Remove the circlip CD Remove the wheel using a general bearing puller Installthewheel bearing new intothewheel NOTE ____________ Use a socket that matches the outside diameter of the race of the bearing Do not strike the inner race of balls of the bearing Contact should be made only with the outer race Install the circlip Install the wheel to the shaft Always use a ne...

Page 109: ...ect Stopper band CD Frayed Damage Replace Pull rod Bends Damage Replace Shock absorber Oil leaks Damage Replace Bushings Wear Cracks Damage Replace Sliding frame Front pivot arm Rear pivot arms j Cracks Damage Replace http ReadManuals com ...

Page 110: ... 0 kg 14 ft 0 Ib Bolt 68 Nm 6 8 m okg 49 ft 0 Ib Bolt 20 Nm 2 0 m 0 kg 14 ft 0 Ib Bolt 56 Nm 5 6 m 0 kg 41 ft 0 Ib Nut 42 Nm 4 2 m 0 kg 30 ft 0 Ib Bolt j 27 Nm 2 7 m 0 kg 20 ft 0 Ib BOlt 8 Nm 0 8 m 0 kg 5 8 ft 0 Ib BOlt 20 Nm 2 0 m 0 kg 14 ft 0 Ib Nut 74 Nm 7 4 m 0 kg 54 ft 0 Ib Bolt 13 Nm 1 3 m 0 kg 9 4 ft 0 Ib Stopper band nut 4 Nm 0 4 mo kg 2 9 ft 0 Ib NOTE ________________________ Install the ...

Page 111: ...m holding bolts Then fit the rear pivot arm bracket mounting bolts NOTE ____________ Do not tighten the bolts at this point Finger tighten the bolts 2 Tighten Suspension mounting bolts Front A 68 Nm 6 8 m kg 49 ft Ib Rear ill 20 Nm 2 0 m kg 14 ft Ib Guide wheel bolt center 27 Nm 2 7 m kg 20 ft Ib 3 Adjust Track tension See page 2 21 Spring preload See page 2 43 http ReadManuals com ...

Page 112: ...LE AND TRACK 1 141 FRONT AXLE AND TRACK CD Guide wheel Sprocket wheel Front axle Bearing Bearing holder 6 Nm 0 6 m kg 4 3 ft Ib 2 YiJ r 6 N m 0 m kg 4 3 ft lb 2 90 Nm 9 0 m kg 65 ft Ib 4 37 http ReadManuals com ...

Page 113: ...ration 2 Place the track in the chassis NOTE ______________________ Be sure it is positioned as shown in the illustra tion AI TURNING DIRECTION 3 Install Front axle CD NOTE ______________ Install the front axle push up the splined end toward the chain housing and install the threaded end into the speedometer gear hous ing side Be sure the lugs correctly engage the track 4 Tighten Screw 6Nm 0 6 mok...

Page 114: ...er Oil pump Primary sheave Starter motor BATTERY LEADS FOR EX570ER 1 Disconnect Battery leads Disconnect the negative lead CD first and then disconnect the positive lead HOSES 1 Drain Coolant See page 2 7 2 Remove Primary sheave See page 4 2 Carburetors See page 7 2 3 Disconnect Oil hoses CD Oil delivery hoses Pulser hose NOTE ________________________ Plug the oil hoses and oil delivery hoses so t...

Page 115: ...cable from the throttle lever See page 3 2 Spark plug leads COl magneto leads and coupler ill Pickup coil leads Bands OIL TANK 1 Remove Bolts oil tank stay 2 Remove Band coolant hose ill STARTER MOTOR FOR EX570ER 1 Remove Starter motor ill 2 Dissconnect Starter motor lead http ReadManuals com ...

Page 116: ...otor bolt and ground lead before removing the engine assembly DISASSEMBLY OIL PUMP 1 Remove Oil pump CD Washer Worm gear shaft Collar Gasket WATER PUMP 1 Remove Coolant hose Water pump cover Impeller Water pump housing Starter pulley Water pump drive belt Impeller shaft assembly See page 6 3 COl MAGNETO 1 Remove Engine bracket CD Crankcase cover Pickuup coil http ReadManuals com ...

Page 117: ...1362 YU 33270 Fully tighten the tool holding bolts but make sure the tool body is parallel with the magneto rotor If necessary one screw may be backed out slightly to level tool body 4 Remove Stator assembly CD Woodruff key CYLINDER HEAD AND CYLINDER 1 Remove Thermostatic valve cover CD Thermostatic valve D ring AWARNING Handle the thermo unit with special care Never subject it to strong shock or ...

Page 118: ...CD Piston pin Piston Small end bearing NOTE _______________________ Before removing the piston pin clip cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase Before removing the piston pin deburrthe clip groove and pin hole area If the piston pin groove is deburred and the piston pin is still dif ficult to remove use Piston Pin Puller 90890 01304 YU 013...

Page 119: ... stuck together tap lightly on the tabs indicated on the crankcase with a soft head hammer The slits shown in the crankcase can be used to remove it Be sure not to give damages the mating surface 2 Remove Dowel pins CD Crankshaft INSPECTION AND REPAIR CYLINDER HEAD 1 Eliminate Carbon deposit from combustion chamber Use rounded scraper CD Do not use a sharp instrument and avoid damaging or scratchi...

Page 120: ...ead Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern NOTE ______________________ Rotate the head several times to avoid re moving too much material from one side CYLINDER AND PISTON 1 Eliminate Carbon deposits Use a rounded scraper CD NOTE _______________________ Do not use a sharp instrument and avoid damag ing or scratching 2 Ins...

Page 121: ...easure Piston to cylinder clearance Measurement steps F irst step Measure the cylinder bore C with a cylin der bore gauge CD NOTE Measure the cylinder bore lie in parallel to and at right angles to the crankshaft Then find the average ofthe measurements Standard Wear limit Cylinder bore 73 00 73 02 mm 73 10 mm uc 2 874 2 875 in 2 878 in Taper T 0 05mm 0 0019in Out of round 0 01 mm R 0 0004 in C Ma...

Page 122: ... clearance Cylinder bore c Piston skirt diameter P If out of specification rebore or replace cylinder and replace piston and piston rings as a set Piston to cylinder clearance 0 070 0 075 mm 0 0028 0 0030 in Limit 0 1 mm 0 004 in PISTON RINGS 1 Measure Side clearance Out of specification Replace piston and or rings Use B feeler gauge CD NOTE _________________________ Eliminate the carbon deposits ...

Page 123: ...pecification Replace rings as a set Use a feeler gauge CD Top 0 20 0 40 mm 0 008 0 016 in End gap l ____ 307 027 2nd 0 20 0 40 mm 307 018 5 10 0 008 0 016 in 20 mm 0 8 in PISTON PIN AND BEARING 1 Inspect Piston Pin Blue discoloration Grooves Replace piston pin and inspect lubrication system Small end bearing Blue discoloration Bearing turns roughly Replace bearing and inspect lubrication system 2 ...

Page 124: ...nce 0 004 0 020 mm 0 00016 0 00079 in CRANKSHAFT 1 Measure Runout Use V blocks and a Dial Gauge 90890 03097 YU 03097 Out of specification Replace or repair Runout limit C 0 03 mm 0 012 in C2 C3 0 04 mm 0 0016 in C 0 05 mm 0 0020 in 80 mm 3 2 in 99 mm 3 9 in 2 Measure Small end free play Use a dial gauge Out of specification Replace the defective parts Small end free play 0 8 1 0 mm 0 031 0 039 in ...

Page 125: ...e Replace Crankshaft oil seals Wear Damage Replace Lubricate the bearing immediately after examining them to prevent rust CRANKCASE 1 Thoroughly wash the case halves in mild sol vent 2 Clean all the gasket mating surfaces and case mating surfaces thoroughly 3 I spect Crankcase Cracks Damage Replace OIL PUMP STROKE ADJUSTMENT 1 Pull back the rubber cover CD of the oil pump cable 2 Remove Oil pump c...

Page 126: ...s perform the adjustment steps 5 Measure Maximum pump stroke Out of specification Adjust Maximum pump stroke 1 62 1 8 mm 0 064 0 071 in Measurement steps Pull the oil pump cable CD out of its sheath as far as it will go The cable must be held in this taut position when measuring the maximum pump stroke NOTE _______________________ It may be helpful to securely wrap duct tape around the cable where...

Page 127: ...troke is decreased Reinstall the adjusting plate spring washer and locknut Locknut adjusting plate 7 Nm 0 7 m kg 5 1 ft Ib Recheck the minimum and maximum pump stroke If out of specification limits perform the above steps again 7 Apply Lithium soap base grease to outside of pump pulley Yamaha Bond No 5 ACC 11001 31 00 to mating surface of oil pump cover 8 Install Oil pump cover 1 Screw oil pump co...

Page 128: ...FT CD Oil seal Bearing Crank 4 Crank pin Washer Connecting rod j Big end bearing Crank 3 First 13 Nm 1 3 m kg 9 4 ft Ib Final 27 Nm 2 7 m kg 19 ft Ib 5 15 Labyrinth seal j Crank 2 Crank 1 Stopper ring Plain washer Woodruff key Upper crankcase Lower crankcase Yamaha bond No 5 http ReadManuals com ...

Page 129: ...e and labyrinth seal into the pin holes of the bearings and upper crankcase by turning the bearings and labyrinth seal At the same time align the bearing punched marks with the crankcase mating surface The oil seal lip must fit into the crankcase groove 3 Apply Yamabond No 5 to mating surfaces of both case halves 4 Install Dowel pins CD 5 Install Lower crankcase CD onto the upper crankcase NOTE __...

Page 130: ...ghten Bolts Crankcase NOTE _________________________ Tighten the bolts in order starting with the smallest number and torque the bolts in two stages Bolt crankcase First 13 Nm 1 3 m kg 9 4 ft Ib Final 27 Nm 2 7 m kg 19 ft Ib Bolt engine bracket 27 Nm 2 7 m kg 19 ft Ib 7 Apply 2 stroke engine oil to crankpin bearing and oil delivery hole http ReadManuals com ...

Page 131: ... ft Ib First 20 Nm 2 0 m kg 14 ft Ib Final 33 Nm 3 3 m kg 24 ft Ib A USE NEW ONE First Piston ring Piston pin Piston pin clip Small end bearing Spark plug j Cylinder head Head gasket Cylinder Cylinder gasket 20 Nm 2 0 m kg 14 ft Ib Final 28 Nm 2 8 m kg 22 ft Ib 0 A USE NEW ONE 5 18 http ReadManuals com ...

Page 132: ...the pin clip and material into the crankcase Position each piston very carefully in its original place Always use a new piston pin clip Do not allow the clip open ends to meet the piston pin slot 2 Check Piston ring position Make sure ring ends are properly fitted around ring locating pins in piston grooves Be sure to check the manufacturer s marks or numbers stamped on the rings are on the top si...

Page 133: ... Nm 2 0 m kg 14 ft Ib a Bolt cylinder head 20 Nm 2 0 m kg 14 ft Ib Second step Retighten the nutsCD and bolts CD Nut cylinder head 33 Nm 3 3 m kg 24 ft Ib a Bolt cylinder head 28 Nm 2 8 m kg 20 ft Ib 4 Tighten Spark plug 28 Nm 2 8 m kg 20 ft Ib Thermostatic valve cover bolt 7 Nm 0 7 m kg 5 1 ft Ib COl MAGNETO 1 Install Woodruff key CD Stator plate Be sure to remove any oil and or grease from the t...

Page 134: ...e tapered portion of the magneto rotor using a dampened cloth with thinner NOTE ________________________ When installing the magneto rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 3 Tighten Magneto rotor nut CD 85 Nm 8 5 m kg 61 ft Ib NOTE ________________________ Use the Universal Rotor Holder 90890 01235 YU 01235 to hold the magneto rotor 4 Install Pickup coi...

Page 135: ...all Engine assembly Nuts engine bracket CD NOTE _________________________ Install the starter motor bolt and ground lead before installing the engine assembly Before tightening the nut engine bracket rear the sheave distance should be adjusted Nut engine bracket front 40 Nm 4 0 0 kg 29 ft 0 Ib 2 Tighten Starter motor bolt 23 Nm 2 3 m 0 kg 17 ft 0 Ib 3 Fill Cooling system See page 2 7 4 Air bleed O...

Page 136: ... m kg 7 2 ft Ib 5 23 RECOIL STARTER 1 ENG 1 1 RECOIL STARTER CD Recoil starter case Starter rope Starter handle Starter spring Sheave drum Drive pawl j Drive plate 10 Nm 1 0 m kg 7 2 ft Ib 7 http ReadManuals com ...

Page 137: ...at it will not be pulled into the recoil starter case DISASSEMBLY 1 Remove Nut CD Spring washer Washer Special washer Drive plate Spring seat Spring j NOTE _____________ There is a spring drive plate j under the drive plate Care should be taken so that it will not be lost 2 Remove Return spring CD Drive pawl NOTE __________________________ Care should be taken so that the return spring CDwill not ...

Page 138: ...move Starter spring CD INSPECTION 1 Inspect Drive plate CD Cracks Bends Damage Replace Spring drive plate Wear Damage Replace Starter rope Wear Breaks Damage Replace Starter spring Cracks Bends Damage Replace Sheave drum Cracks Damage Replace Drive pawl Return spring j Wear Cracks Damage Replace ASSEMBLY AND INSTALLATION 1 Hook the starter spring around the post in the starter case Carefully wind ...

Page 139: ...____________ Be sure the inner hook on the starter spring hooks around the post on the sheave drum 5 Apply Grease lightly to pivot point ofthe drive pawl I d Low temperature grease 6 Install Drive pawl CD Return spring NOTE ____________ Hook the return spring end to the drive pawl CD Then hook other end of the return spring to the post on the sheave drum 7 Install Spring drive plate Spring seat Dr...

Page 140: ...starter rope from out of the cutout portion in the sheave drum and rotate the sheave drum five times counterclockwise to preload the starter spring Then knot the rope end so that it will not be pulled into the recoil starter case 9 Install Recoil starter Starter handle Bolt recoil starter 10 Nm 1 0 m kg 7 2 ft Ib 10 Check the starter for smooth operation If it does not operate smoothly repair it h...

Page 141: ...4 i 6 1 COOLANT FLOW lcoollKI COOLING SYSTEM COOLANT FLOW CD Water pump Coolant filler cap Reservoir tank Heat exchanger Al Top view 1m Side view http ReadManuals com ...

Page 142: ...lKI COOLING LINE CDReservoir tank Coolant filler cap Hosejoint Thermo switch Coolant hose Thermostatic valve ill Heat exchanger Bleed screw Water pump cover j Impeller Waterpump housing Impeller shaft assembly Water pump drive belt http ReadManuals com ...

Page 143: ...D Gasket Impeller NOTE ________________________ Attach the Primary Sheave Holder 90890 01701 YS 01880 to hold the primary sheave The impeller has left hand threads Turn the impeller clockwise to loosen it 6 Remove Water pump housing CD Recoil starter assembly CID 7 Remove Starter pulley CD NOTE ________________________ Attach the Universal Clutch Holder 90890 04086 YM 91042 to hold the starter pul...

Page 144: ...rn the fuel cock to the close position and plug the fuel hoses so fuel dose not run out Spilled fuel can be a fire hazard NOTE _________________________ Remove the screw on the center cover and pull back the fuel tank while lifting up the cover 10 Remove Slide rail suspension See page 4 31 Track See page 4 38 Rivets CD Heat exchangers http ReadManuals com ...

Page 145: ...s accuracy is in doubt always replace it A faulty unit could cause serious overheating or overcooling 2 Inspect Impeller CD Cracks Damage Replace Mechanical seat Water pump drive belt Wear Damage Replace 3 Inspect Bearing Pitting Damage Replace Replacement steps Remove the circlip CD Remove the bearing using a general bearing puller Install the new bearing NOTE ________________________ Use a socke...

Page 146: ...D 90890 01325 YU 22460 01 to the coolant filler cap Apply the specified pressure for 10 seconds and make sure there is no pressure drop INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Tighten Fuel tank nut 10 Nm 1 0 m kg 7 2 ft Ib Water pump housing bolt 23 Nm 2 3 m kg 17 ft Ib Impeller 14 Nm 1 4 m kg 10 ft Ib Thermostatic valve cover bolt 7 Nm 0 7 m kg 5 1 ft Ib 2 Adjust Wa...

Page 147: ...l Starter plunger Airscrew Piston valve Throttle stop screw Valve seat assembly Pilot jet j Float arm Float Float chamber cover QW Jet needle Main jet Main jet ring Main nozzle Carburetor switch 2 Nm 0 2 m kg 1 4 ft Ib o 8 7 1 http ReadManuals com ...

Page 148: ...arter plunger Take care so that the coil spring starter cable adjuster and starter plunger do not fall off or are not lost Also use special care not to scratch the starter plunger surface 3 Disconnect Carburetor switch T O R S leads CD 4 Disconnect Fuel delivery hoses CD Water hoses AWARNING Turn the fuel cock to the close position and plug the fuel delivery hoses so that fuel does not run out Spi...

Page 149: ...e assembly CD Carburetor assembly 7 Drain Fuel 8 Remove Jet needle holder CD Throttle cable end DISASSEMBLV 1 Remove Float chamber cover CD Float pin caps Floats 2 Remove Main jet CD Main jet ring Pilot jet Main nozzle 3 Remove Pin CD Float arm Valve seat assembly Gasket Valve seat plate 7 3 http ReadManuals com ...

Page 150: ...ts with compressed air 2 Inspect Floats CD Damage Replace Main jet Pilot jet Main nozzle Valve seat assembly Airscrew Jet needle j Bends Wear Damage Replace Contamination Clean NOTE _________________________ Use a petroleum based solvent for cleaning Blowout all passages and jets with compressed air 3 Inspect Throttle valve Wear Damage Replace 4 Check Throttle valve movement Stick Replace carburet...

Page 151: ...67 0 75 in Measurement and adjustment steps Hold the carburetor in an upside down posi tion Measure the distance from the carburetor body to the float arm using a gauge NOTE ______________________ Before measurement remove the gasket be tween the carburetor body and float chamber The float arm should be resting on the valve but not compressing the needle valve If the float arm height is not within...

Page 152: ...nect the Pocket Tester 90890 03112 YU 03112 leads to the switch leads Loosen the lead wires CD from the holder by opening the clamp Loosen the locknut and turn the T O R S switch counterclockwise until the switch is in the OFF position circuit open Turn the T O R S switch clockwise until the T O R S switch is in the ON position circuit closed Then turn the T O R S switch clock wise 1 2 turn and ti...

Page 153: ...uide marks on 7 7 the carburetor body Measure the fuel level with gauge If the fuel level is incorrect adjust the fuel level Remove the carburetor Inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by bending the float tang on the float Recheck the fuel level FUEL PUMP OPERATION CHECK 1 Remove Drive V belt guard See page 2 15 Drive ...

Page 154: ... the fuel flow from the fuel delivery hoses If fuel does not flow out check the fuel cock If no defects are observed on the fuel cock replace the fuel pump assembly To replace the fuel pump assembly perform the following steps from 6 to 7 6 Disconnect Pulser hose CD from the crankcase Fuel hose from the fuel tank Fuel delivery hoses to the carburetor AWARNING Plug the fuel hose so thatfuel does no...

Page 155: ...AGRAM IElECI iiill ELECTRICAL CIRCUIT DIAGRAM I t I t I t t I I I L I Ir _ _ s L __ I r I I I I __ I I Sb I I I I I R R SW L Jry IJ fR W G Y L Y S Y Sr W R SlY 8 1 L l Gy l Sr G R I G l l Sb http ReadManuals com ...

Page 156: ...Red 0 Orange Br Brown Sb Gy W BIY B R B W GIV CIRCUIT DIAGRAM IELECIIii I Tachometer WATER TEMP indicator light Thermo switch WATER TEMP indicator light checker Level gauge light T O R S indicator light Starter relay Starter motor Fuse Battery Rectifier Grip warmer switch Resister Grip warmer To AC50W output option To voltage regulator option Sky blue G R Green Red Grey Y B Yellow Black White Y L ...

Page 157: ...ireharness rip warmer switch WATER TEMP WATER TEMP n cator light checker Vol ge regUlato n Icator light Ignition coil j CDI unit ELECTRICAL COMPONENT IELECIIliiii I Battery Starter relay Fuse jJ Resister Main switch 8 3 http ReadManuals com ...

Page 158: ...ndlebar switch assembly right Handlebar switch assembly left High beam switch Brake switch Starter motor CDI magneto j Pick up coil Stator assembly Stator coil ELECTRICAL COMPONENT IELECI iiiii I 8 4 http ReadManuals com ...

Page 159: ...ELECTRICAL STARTING SYSTEM IElECl1lii I ELECTRICAL STARTING SYSTEM FOR EX570ER CIRCUIT DIAGRAM For EX570ER CD Main switch Starter relay Starter motor 8 5 Fuse Battery Rectifier http ReadManuals com ...

Page 160: ...ELECTRICAL STARTING SYSTEM IELECIIEiIi I 8 6 http ReadManuals com ...

Page 161: ...relay connector 2 Connect Starter relay connector terminals CD Jumper lead 3 Check Starter motor operation OK NO NO 8 7 l ICheck the battery and connectors OK l NO Replace and or charge the battey AWARNING A wire forthe jumper lead CDmust have the equivalent capacity as that of the battery lead or more otherwise it may cause the jumper lead to be burned This check is likely to produce sparks so be...

Page 162: ... Main switch coupler CD 2 Connect Pocket tester 90890 03112 YU 03112 to main switch coupler 3 Check Main switch continuity Faulty Replace Switch Color code position B B W OFF 0 0 ON START RECTIFIER 1 Disconnect Rectifier lead 2 Connect Pocket tester to rectifier terminal 3 Check Rectifier Incorrect Replace R W C Br R 0 0 0 Tester connection Good condition CD 0 x 0 Continuity x No continuity http R...

Page 163: ..._T_E_M_IELEC Iii 1 STARTER MOTOR CDStarter motor assembly Clip Pinion stopper Return spring Pinion gear Plain washer illFront cover O ring Washer j Voke jJ Armature coil Brush plate Brush Brush spring O ring Washer Rearcover O ring 8 9 http ReadManuals com ...

Page 164: ...n the pinion stopper CD Hold the clip with a locking pliers and open the clip with a slotted head screw driver NOTE ______________________ Take care not to scratch the armature shaft Clip will come out when locking pliers is released Support the pinion stopper CD so that the loosened pinion stopper CD and return spring will not fall out Remove the pinion gear 3 Remove Front cover CD from armature ...

Page 165: ... 3 Inspect Commutator outer surface Dirty Clean it with 600 grit sandpaper CD Hold the armature in a vise and copper or aluminium plate NOTE _________________________ Lightly grip the armature with a vise 4 Measure Commutator diameter Measure the diameter a of the commuta tor at points where the brush comes in contact Out of specification Replace Commutator wear limit 27 mm 1 06 in http ReadManual...

Page 166: ...between the segments afterthe above steps IAl CORRECT rnJ INCORRECT 6 Measure Armature coil resistance insulation continuity Defect s 4 Replace starter motor Inspecting steps Connect the pocket tester 90890 03112 YU 03112 for continuity check CDand insula tion check Measure the armature coil resistances Armature coil resistance Continuity check CD 0 01S0 S at 20 C S8 F Insulation check More than 1...

Page 167: ... covers apply bearing grease to the bearings of the front and rear covers 2 Make sure the rear cover and front cover are fitted with O rings 3 Before installing the pinion gear apply grease to the worm gear portion ofthe arma ture shaft 4 Install Pinion gear CD Return spring Pinion stopper 5 Open the end of the new clip about 9 10 mm 0 35 0 40 in Always use a new clip 6 lnstall the clip CD to the ...

Page 168: ... brushes 8 Install Securing bolts starter motor NOTE _________________________ Align the match marks CD on the bracket with the match marks on the yoke Installation Reverse the Removal procedure Note the following points 1 Install Starter motor Bolt starter motor 21 Nm 2 1 m kg 15 ft Ib 8 14 http ReadManuals com ...

Page 169: ...CHARGING SYSTEM FOR EX570ER CIRCUIT DIAGRAM For EX570ER CDI magneto Fuse Battery 8 15 CHARGING SYSTEM IELECIIiillI Rectifier http ReadManuals com ...

Page 170: ...CHARGING SYSTEM IElECl1iii I 8 16 http ReadManuals com ...

Page 171: ...00 rpm 2 Measure Charging voltage Charging voltage 13 3 14 3 V 3 000 rpm IDC20V I 1 I 1 Never disconnect battery cables while generator is operating or rectifier and regulator will be damaged LESS THAN 13 3V Check the fuse rectifier and charging coil OK ICorrect connecter 8 17 OUT OF SPECIFICATIONS i Check the battery See page 2 28 Replace and or charge battery FAULTY 1 Replace the fuse rectifier ...

Page 172: ...a long period 1 Remove Battery Battery storage and maintenance tips Recharge the battery periodically Store the battery in a cool dry place Recharge the battery before reinstalling Battery Electrolyte Specific gravity 1 280 at 20 C 68 F Initial charging 1 6 Amp for 10 hours rate new battery Recharging 10hours or until specific rate gravity reaches 1 280 Refill fluid Distilled water to maximum leve...

Page 173: ...ect CDI magneto coupler and lead White 2 Connect Pocket tester 90890 03112 YS 03112 to CDI magneto coupler and lead 3 Measure Charging coil resistance Out of specification Replace Charging coil resistance White Black 0 380 10 at 20 S8 F http ReadManuals com ...

Page 174: ...CHARGING SYSTEM IElECl1iiiii I MEMO _ 11 8 20 http ReadManuals com ...

Page 175: ...AM CD Main switch CDI unit Ignition coil Sparkplug Pickup coil CDI magneto j Voltage regulator Throttle switch IGNITION SYSTEM IElECl1IIiiiii I Carburetor switch ENGINE STOP switch T O R S indicator light 8 21 http ReadManuals com ...

Page 176: ...IGNITION SYSTEMI ElEel iiiii I 8 22 http ReadManuals com ...

Page 177: ...K 1 Remove Spark plugs 2 Check Spark plug Standard spark plug BR9ES NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in OUT OF SPECIFICATION 1 377 000 IRepair or replace the spark plug OK 1 Remove Spark plug cap 2 Connect Pocket tester to spark plug cap 8 23 http ReadManuals com ...

Page 178: ... G8 F Secondary coil resistance 4 9k o 20 at 20 C G8 F OK ICheck the source coil and pickup coil OK Check the ENGINE STOP switch throttle switch carburetor switch and main switch OK Correct connection and or replace COl unit IGNITION SYSTEM IElEClllliiEl1 OUT OF SPECIFICATION l IReplace the spark cap OUT OF SPECIFICATIONS l IReplace the ignition coil FAULTY l Replace the source coil and or pickup ...

Page 179: ... NO CONTINUITY IReplace the bulb FAULTY l Replace the throttl switch and or carbure tor switch THROTTLE OVERRIDE SYSTEM T O R S Ifthe carburetor or throttle cable should malfunc tion during operation the T O R S warning light turns on and off when the throttle lever is re leased The T O R S is designed to interrupt the ignition and keep the engine revolution between 2800 and 3000 r p m if the carb...

Page 180: ...tor switch Right ON OFF ON OFF OFF Engine RUN RUN T O R S Warning light turns on and off CD Carburetor switch T O R S Throttle switch Throttlle cable Throttle stop screw Throttle valve ON 816 008 OFF I Br SOURCE COIL AND PICKUP COIL 8 26 1 Disconnect COl magneto leads Brown Black Red Pickup coil leads White Red White Green 2 Connect Pockup tester 90890 03112 YS 03112 to COl mag neto leads and pick...

Page 181: ...x No continuity 4 Check Throttle switch continuity Faulty Replace Throttle switch Good condition position Throttle lever is 0 operated Throttle lever is not operated x 0 Continuity x No continuity CARBURETOR SWITCH 1 Disconnect Carburetor switch lead 2 Connect Pocket tester 90890 03112 YU 03112 3 Check Carburetor switch continuity Faulty Adjust See page 7 6 or replace Carburetor switch Good condit...

Page 182: ...I MAIN SWITCH FOR EX570R 8 28 1 Disconnect Main switch coupler 2 Connect Pocket tester 90890 03112 YU 03112 3 Check Main switch continuity Faulty Replace Switch position Good condition OFF 0 ON x 0 Continuity x No continuity http ReadManuals com ...

Page 183: ...YS_T_E_M __IELECI Iii I LIGHTING SYSTEM CIRCUIT DIAGRAM COl magneto j Voltage regulator jJ Headlight beam switch HIGH BEAM indicator light Headlight Tail brake light 8 29 Speedomerter light Tachometer light Level gauge light http ReadManuals com ...

Page 184: ...LIGHTING SYSTEM IELECIIliii I 8 30 http ReadManuals com ...

Page 185: ...ARNING Keep flammable products or your hands away from bulb while it is on it will be hot Do not touch bulb until it cools down 3 Headlight Meter and HIGH BEAM indicator light 3 Check Bulbs Terminal CD CD o Continuity Tail brake light Level gauge light Good condition o o OK NO CONTINUITY IReplace the bulb s Check the headlight beam switch and lighting FA U LTV coil OK Correct connection and or rep...

Page 186: ...beam switch continuity Faulty Replace Switch Good Good position condition condition HI x 0 LO 0 x 0 Continuity x No continuity LIGHTING COIL 8 32 1 Disconnect CDI magneto coupler 2 Connect Pocket tester 90890 03112 YS 03112 to CDI magneto coupler 3 Measure Lighting coil resistance Out of specification Replace Lighting coil resistance Yellow Black 0 360 10 at 20 C 68 F http ReadManuals com ...

Page 187: ...X570ER CD Main switch CDI magneto Brake light switch Tail brake light j Voltage regulator j WATER TEMP indicator light 8 33 SIGNAL SYSTEM IElECI iii I Thermo switch WATER TEMP indicator light checker Fuse em Battery http ReadManuals com ...

Page 188: ...SIGNAL SYSTEM IElECI iii I 8 34 http ReadManuals com ...

Page 189: ...tinuity IReplace the bulb OK Check the brake light switch FAULTY OK IReplace the brake light switch I V FOR EX570R FOR EX570ER Check the lighting coil Check the main switch and fuse OK 4 0UT OF SPECIFICATION OK 4 FAULTY IReplace the lighting coil I IReplace the main switch and or fuse I v V Correct connection and or replace the voltage Replace and or charge battery and or correct regulator connect...

Page 190: ...light bulb 2 Connect Pocket tester I Itl 1 I U 190 3 Check Bulb OK Check the lighting coil ICheck the thermo switch OK Correct connection and or replace the voltage regulator NO CONTINUITY i IReplace the bulb FAULTY i IReplace the lighting coil FAULTY 1 IReplace the thermo unit 8 36 http ReadManuals com ...

Page 191: ...hermo switch lead Green Red and remove the thermo switch CD Handle the thermo switch with special care Never subject it to strong or allow it to be dropped Should it be dropped it must be replaced 2 Connect the pocket tester CD 90890 03112 YU 03112 to the thermo switch NOTE ________________________ Set the tester selector touQ x 1 position 3 Immerse the thermo switch in coolant and check the therm...

Page 192: ...lant to a temperature of 120 C 248 5 F or more 4 Ifthe thermo switch operation is incorrect re place it S Install the thermo switch and connect thermo switch lead Thermo switch 35 Nm 3 5 m kg 25 ft Ib Avoid overtightening 8 38 http ReadManuals com ...

Page 193: ...GRIP WARMER SYSTEM CIRCUIT DIAGRAM CDI magneto Grip warmer switch Grip warmer Resister GRIP WARMER SYSTEM IELECIIliiI http ReadManuals com ...

Page 194: ...GRIP WARMER SYSTEM IELEcl iIiiiii I 8 40 http ReadManuals com ...

Page 195: ... tester 90890 03112 YS 03112 to resister leads 3 Check Resister continuity CONTINUITY 1 Disconnect Grip warmer leads 2 Connect Pocket tester 90890 03112 YS 03112 to grip warmer leads 3 Check Grip warmer continuity CONTINUITY NO CONTINUITY l Replace the resister NO CONTINUITY l Replace the grip warmer 8 41 http ReadManuals com ...

Page 196: ...et tester 90890 03112 YS 03112 to grip warmer switch leads 3 Check Grip warmer switch continuity Faulty Replace Switch Color code position Y R V S LO OFF HI GRIP WARMER COIL INSPECTION 1 Disconnect V L Grip warmer coil leads Yellow Black and Black CD 2 Connect Pocket tester 90890 03112 YS 03112 to grip warmer coil leads 3 Measure Grip warmer coil resistance Out of specification Replace Grip warmer...

Page 197: ...TIONS IAPPXI I APPENDICES EX570R EX570ER EX570R 88R EX570ER 88S EX570R 88R 000101 EX570ER 88S 000101 EX570R 88R 000101 EX570ER 88S 000101 2 680 mm 105 5 in 1 065 mm 41 9 in 1 245 mm 49 0 in EX570R 211 8 kg 467Ib EX570ER 218 9 kg 482 6 Ib 4 5 m 14 8 ft 4 4 m 14 4 ft Liquid cooled 2 stroke piston port Piston valve Forward Inclinded Paralled 2 cylinder 569 cm3 34 7 cu in 73 x 68 mm 2 87 x 2 68 in 6 5...

Page 198: ...pension Type Slide rail suspension Track Track Type Internal drive type Track Width 381 mm 15 0 in Length on Ground 760 mm 29 2in Track Deflection 25 30 mm 0 98 1 18 in 10 kg 22 Ib Brake Brake Type Caliper type disc brake Operation Method Handle lever left hand operated Electrical Ignition System Manufacturer CDI MITSUBISHI Generator System Flywheel magneto Bulb Wattage x Quantity Headlight 60W 55...

Page 199: ...IONS IAPPXI I EX570R EX570ER 28 4 29 0 cm3 0 03mm 0 0012 in Lines indicate straight edge measurement 9 3 Aluminum alloy with dispersion coating 73 00 73 02 mm 2 874 2 875 in 0 01 mm 0 0004 in 0 005 mm 0 0002 in 72 93 72 95 mm 2 871 2 872 in 10 mm 0 39 in 0 070 0 075 mm 0 0028 0 0030 in 0 1 mm 0 004in Keystone B 1 2 mm 0 047 in T 2 7 mm 0 106 in Keystone B 1 2 mm 0 047 in T 2 7 mm 0 106 in 0 20 0 4...

Page 200: ...r Ratio Minimum Stroke Maximum Stroke Pump Cable Free Play 2 M J M A J P J J N P O P S C A V S G S F H 9 4 SPECIFICATIONS IAPPXI I EX570R EX570ER 61 95 62 00 mm 2 439 2 440 in O B 1 0 mm 0 031 0 039 in 0 25 0 75 mm 0 01 0 03 in Below 0 03 mm 0 0012 in Below 0 04 mm 0 0016 in BelowO 05 mm 0 0020 in BO mm 3 15 in 99 mm 3 90 in 179 B5 1BO 15 mm 7 0BO 7 093 in Needle bearing Needle bearing VM3B 2pcs M...

Page 201: ...26 US qt High Altitude Settings 30 C 20 C 10 C O C 10 C 20 C Altitude 22 F 4 F 14 F 32 F 50 F 68 F 0 100 m 320 IN 3rd 0 300 tt 310 STD IN 3rd STD 100 600 m 310 STD IN 3rd STD 300 2 000 tt 300 IN 3rd 600 1 200 m 300 IN 3rd 2 000 4 000 tt 290 IN 3rd 1 200 1 800 m 280 IN 3rd 4 000 6 000 tt 270 IN 3rd AS 7 8 1 800 2 400 m 260 IN 3rd 6 000 8 000 tt 270 IN 3rd AS 7 8 2 400 3 000 m 250 IN 3rd 8 000 10 00...

Page 202: ...d nuts Final 28 2 8 20 in two stages Nut Final 20 2 0 14 Final 33 3 3 24 Spark Plug 28 2 8 20 Thermostatic Valve Cover 7 0 7 5 1 Starter Pully 23 2 3 17 Water Pump Housing 23 2 3 17 Impeller 14 1 4 10 Left Hand threads Oil Pump 7 0 7 5 1 Recoil Starter 10 1 0 7 2 _Engine Mounting Nut 40 4 0 29 Carburetor Pilot Jet 1 0 1 0 7 Valve Seat 5 0 5 3 6 Main Jet 2 0 2 1 4 Thermo Switch 28 2 8 20 Coolant Dr...

Page 203: ...mber Material Quantity Secondary Sheave Spring Part Number Color Code Outside Diameter Wire Diameter Twist Angle 9 7 SPECIFICATIONS IAPPXI I EX570R EX570ER V belt Automatic 3 8 0 95 1 Approx 3 800 r min Approx7 300 r min 267 270 mm 10 5 10 6 in 14 5 17 5 mm 0 57 0 69 in 87X 17641 00 1 118 1 128 mm 44 0 44 4 in 35 0 mm 1 38 in 32 0 mm 1 26 in 90501 553G6 White Yellow White 60 mm 2 36 in 5 5 mm 0 22...

Page 204: ... Front Rear Suspension Spring Wire Diameter Front Rear Suspension Setting Position Stopper Band Hole Position Front Rear No 6 0 No 5 o No 4 a No 1 9 8 SPECIFICATIONS IAPPXI I A 2 EX570R EX570ER 8 7 N mm 0 89 kg mm 49 8 Ib in 4 74 85 05 mm 3 35 in 39 Silent 68 8 0 15 0 mm 0 31 0 59 in 18T 88F 17682 80 33T 88F 47587 00 82M 47110 00 381 mm 15 0 in 3 072 mm 120 94 in 64 mm 2 52 in 48 25 30 mm 0 98 11 ...

Page 205: ... Brake Lever Free Play 0 3 1 0 mm 0 012 0 039 in High Altitude Setting 900 1 500 m 1 350 3 000 m 3 000 5 000 ft 4 500 10 000 ft Clutch Engagement RPM Approx 3 800 r min Shift RPM Approx 7 300 r min Primary Sheave Weight Arm Part Number with bushing 88R 17605 00 Weight 43 g 1 45 oz Rivet Part Number 90261 06015 90261 06028 Materical Steel Aluminum Quantity 3 pes Primary Sheave Spring Part Number 90...

Page 206: ...ring Holder Jackshaft 43 4 3 31 Suspension Wheel 75 7 5 54 Apply LOCTITE Guide Wheel 74 7 4 54 Sliding Frame and Slide Runner 3 0 3 2 2 Slide Rail Suspension Mounting Bolt 68 6 8 49 Rear Pivot Arm and Bracket 68 6 8 49 Shock Absorber and Rear Pivot Arm 42 4 2 30 Apply LOCTITE Rear Pivot Arm and Rod 42 4 2 30 Rear Suspension Bracket and Rod 42 4 2 30 Front Pivot Arm and Sliding Frame 56 5 6 41 Shoc...

Page 207: ...vel Spring Type Spring Rate Wire Diameter Shock Absorber Damping Force Extension Compression SPECIFICATIONS IAPPXI I EX570R EX570ER Aluminum and steel 620 mm 24 4 in Rear Side of Seat 48 48 Toe out 0 15 mm 0 0 6 in 1 820 mm 71 6 in 910 5 mm 35 8 in 510 7 mm 20 1 in 24 Steel 986 mm 38 8 in 145 mm 5 71 in 1 6 mm 0 06 in 363 mm 14 3 in T S S 150 mm 5 9 in Coil Spring 14 N mm 1 4 kg mm 78 3 Ib in 7 5 ...

Page 208: ...5 18 Apply LOCTITE Ski Runner 21 2 1 15 Ski 43 4 3 31 Pinch Nut Suspension bracket 21 2 1 15 Set Screw Suspension bracket 2 0 2 1 4 Apply LOCTITE Absorber Holder 10 1 0 7 2 Mounting Nut Shock absorber 5 0 5 3 6 Locknut Shock absorbser 16 1 6 11 Suspension Bracket and Front Arm Lower 43 4 3 31 Suspension Bracket and Front Arm Upper 43 4 3 31 Front Arm Upper and Front Arm Lower 43 4 3 31 Hood 3 0 3 ...

Page 209: ...ance Color Code Lighting Voltage Minimum Maximum Lighting Coil Resistance Color Code Coil Resistance for Grip Warmer Color Code 2 SPECIFICATIONS IAPPXI I EX570R EX570ER 12V 16 3 4 5 6 7 8 Engine Speed x 103 r min F4T304 MITSUBISHI 220 10 at 20 C 68 F White Red White Green 530 10 at 20 C 68 F Brown Black Red MITSUBISHI 88R OOIYAMAHA 9 mm 0 35 in or more at 300 r min 0 2Q 20 at 20 C 68 F 4 9kQ 20 at...

Page 210: ...ER only Specific Gravity 1 280 YB16AL A2 Electric Starter Ststem EXS70ER only Type Bendix type Starter Motor EXS70ER only Model Manufacturer 84N SO NIPPON DENSO Output 0 6kW Armature Coil Resistance 0 013 0 01SQ at 20 C 68 F Brush Overall Length 12 mm 0 48 in Wear Limit 8 S mm 0 33 in Spring Pressure 6S0 9S0 g 22 9 33 S oz Commutator Diameter 28 mm 1 10 in Wear Limit 27 mm 1 06 in Mica Undercut 0 ...

Page 211: ...ds Components should be at room temperature IA L _ A Distance across flats rn J Outside thread diameter DEFINITION OF UNITS Unit Read A Nut 10 mm 12 mm 14mm 17 mm 19 mm 22 mm Definition mm Millimeter 10 3 meter cm Centimeter 10 2 meter kg Kilogram 10 3 gram N Newton 1kg x m sec 2 Nm Newton meter Nxm m kg Meter kilogram mxkg Pa Pascal N m2 N mm Newtons per Millimeter N mm L Liter cm3 Cubic Centimet...

Page 212: ...oltage regulator Speedometer giar unit CDI unit CABLE ROUTING IAPPXI I Ground lead EX570ER T O R S lead jJ Starter relay EX570ER Rectifier EX570ER COl magneto lead Fuel level hose Oil level hose Brake cable Fuse EX570ER Main switch Battery EX570ER Starter lever Starter motor EX570ER AJ FOR EX570ER 00 I I I I I I I I J I I I I I I I I I I I I I I I I I I L ______________J 9 16 http ReadManuals com ...

Page 213: ...CDMeter light lead Band Voltage regulator Speedometer cable Brake cable Throttle cable j Oil pump cable Resister Headlight lead CABLE ROUTING IAPPXI I 9 17 http ReadManuals com ...

Page 214: ...CDFuel pump Fuel hose Pulser hose Oilpump Thermoswitchlead 6 Ground lead j Fuel level hose Oil level hose Fuel cock 5 4 8 CABLE ROUTING IAPPXI I o 3 9 18 http ReadManuals com ...

Page 215: ...CD Oil tank Clamp Oil hose Oil level hose Oil filter Speedometer cable 2 CABLE ROUTING IAPPXI I 0 1 I I I 1 I 0 9 19 http ReadManuals com ...

Page 216: ...CD Fuel cock Fuel hose Oil delivery hose Tail brake light lead 4 CABLE ROUTING IAPPxl I 9 20 http ReadManuals com ...

Page 217: ...cator light aT O R S indicator light Tachometer j Tachometer light Main switch Rectifier Fuse j Battery Starter relay Starter motor Tail brake light Ignition coil CDI unit Pickup coil CDI magneto Grip warmer Spark plug Voltage regulator Brake light switch Headlight beam switch Carburetor switch Throttle switch ENGIEN STOP switch Grip warmer switch Level gauge light WATER TEMP indicator light check...

Page 218: ...light T O R S indicator light Tachometer CD Tachometer light Main switch Tail brake light Ignition coil Spark plug COl unit Pickup coil COl magneto Voltage regulator Brake light switch Headlight beam switch Carburetor switch Throttle switch ENGIEN STOP switch it Grip warmer switch Resister Level gauge light WATER TEMP indicator light checker Thermo switch Grip warmer AC 50W output connectors COLOR...

Page 219: ...Engine overhaul j Carburetion Electrical Specifications Illustrated symbols to are used to identify the specifications which appear Filling fluid Lubricant Tightening Wear limit clearance Engine speed Special tool Q V A Illustrated symbols to in the exploded dia gram indicate grade of lubricant and location of lubrication point Apply locking agent LOCTITE Apply engine oil Apply gear oil Apply moly...

Page 220: ...OE041 INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE OVERHAUL COOLING SYSTEM CARBURETION ELECTRICAL SPECIFICATIONS CHAS ELEC 0 SPEC http ReadManuals com ...

Page 221: ... IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 ALL REPLACEMENT PARTS 1 3 GASKETS OIL SEALS AND O RINGS 1 3 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 4 SPECIAL TOOLS 1 4 FOR TUNE UP 1 4 FOR ENGINE SERVICE 1 5 FOR POWER TRAIN SERVICE 1 5 FOR ELECTRICAL SERVICE 1 6 http ReadManuals com ...

Page 222: ...gine serial number G is located on the right hand side of the crankcase NOTE ________________________ The first three digits of these numbers are for model identification the remaining digits are the unit production number Starting Serial Number EX570T 8AV 000101 EX570ET 8AW 000101 EX570STT 89L 000101 EX570SXT 8AY 000101 NOTE ________________________ Designs and specifications are subject to chang...

Page 223: ...ep mated parts together This includes gears cylinders pistons and other parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During disassembly of the machine clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help assure that all parts are reinstalled correctly 5 Keep away from fire 6 Be sure t...

Page 224: ... WASHERS PLATES AND COTTER PINS 1 All lock washers plates CD and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been prop erly tightened BEARINGS AND OIL SEALS 1 Install the bearing s CD and oil seal s with their manufacturer s marks or numbers facing outwards In other words the stamped letters must be on the side...

Page 225: ...rrect special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques NOTE ________________________ Be sure to use the correct part number when ordering the tool since the part number differs according to the area as shown below The first part number is for Europe and the last part is for the U S A and Canada e g 90890 YU FORTUNE UP 1 Sheave Gauge PIN...

Page 226: ...his tool is used to remove the piston pin 2 Rotor Puller PIN 90890 01362 YU 33270 This tool is used to remove the magneto rotor 3 Cooling System Tester PIN 90890 01325 YS 22460 01 This tester is used for checking cooling system FOR POWER TRAIN SERVICE 1 Primary Sheave Holder PIN 90890 01701 YS 01880 This tool is used to hold the primary sheave http ReadManuals com ...

Page 227: ...embling and assembling the primary sheave 4 Clutch Separator Adapter PIN 90890 01740 YS 34480 This tool is used when disassembling and assembling the primary sheave 5 Track Clip Installer PIN 90890 01721 YS 91 045 A This tool is used for installing the track clip FOR ELECTRICAL SERVICE 1 Pocket Tester PIN 90890 03112 YU 03112 This instrument is necessary for checking the electrical components http...

Page 228: ...1 7 SPECIAL TOOLS II I I 2 Electro Tester PIN 90890 03021 YU 33260 A This instrument is invaluable for checking the electrical system http ReadManuals com ...

Page 229: ...OVERRIDE SYSTEM T O R S l CHECK 2 15 STARTER CHOKEl CABLE ADJUSTMENT 2 16 POWER TRAIN 2 17 DRIVE V BELT 2 17 ENGAGEMENT SPEED CHECK 2 19 BRAKE PAD INSPECTION 2 19 BRAKE ADJUSTMENT 2 19 DRIVE CHAIN 2 20 TRACK TENSION ADJUSTMENT 2 22 SLIDE RUNNER INSPECTION 2 24 CHASSIS 2 25 SKI SKI RUNNER 2 25 STEERING SYSTEM 2 25 HEADLIGHT BEAM ADJUSTMENT 2 26 LUBRICATION 2 27 TUNING 2 28 CARBURETOR TUNING 2 28 CL...

Page 230: ...r cracks or damage Replace if necessary Oil Line Check oil hose for cracks or damage Replace if necessary Check coolant level Engine Coolant Air bleed the cooling system if necessary Check throttle lever operation Carburetor Whenever operating condition Adjust the jets elevation temperature is changed Check wear and damage Replace if necessary Water Pump Belt Adjust water pump belt if necessary Ma...

Page 231: ...e Correct if necessary Check engagement and shift speed Adjust if necessary Whenever operating elevation is changed Primary Sheave Check wear and damage Replace if necessary Lubricate with specified grease Lubricate with specified grease Secondary Sheave Adjust if necessary Whenever operating elevation is changed Steering Column Bearing Lubricate with specified grease Ski and Front Suspension Lubr...

Page 232: ...ication Regap Use wire thickness gauge Spark plug gap 0 7 0 8 mm 0 028 0 032 in Clean the plug with a spark plug cleaner if necessary Standard spark plug BR9ES NGK Before installing a spark plug clean the gasket surface and plug surface 4 Tighten Spark plug Spark plug 28 Nm 2 8 m kg 20 ft Ib NOTE ________________________ Finger tighten G the spark plug before torquing to specification http ReadMan...

Page 233: ... belt guard see pag e 2 17 Carburetor see page 7 2 7 10 2 Fill Oil tank CD Oil tank capacity 2 2 L 1 9 Imp qt 2 3 US qt Recommended oi1 Yamalube 2 cycle oil 3 Place a rag under the oil pump assembly to catch oil 4 Disconnect Oil hose CD 5 Keep the oil running out until air bubbles disappear from the oil hose CD 6 Connect Oil hose CD 7 Disconnect Oil delivery hoses CD 8 Feed the Yamalube 2 cycle oi...

Page 234: ...ble the throttle cable free play should be adjusted Adjustment steps Loosen the locknut CD For EX570 E ST Hold the throttle lever at full throttle position Turn the adjuster in or out until the adjustment mark isaligned with the end of the adjuster For EX570SX Turn the adjuster in or out until the specified free play is obtained Free play For EX570SX 23 25 mm 0 91 0 98 in Turning in Free play is i...

Page 235: ...oil tank and oil pump 3 Inspect Oil filter CD Contamination Replace Recommended replacement interval Every season 4 Reverse the removal procedure 2E041 FUEL LINE INSPECTION 1 Inspect 2E051 Fuel hoses Fuel delivery hoses Crack Da mage Replace FUEL FILTER INSPECTION 1 Remove Seat 2 Disconnect Tail brake light coupler 3 Remove Spring bands CD Cap Fuel filter 4 Inspect Fuel filter CD Contamination Rep...

Page 236: ... steam may be blown out under pressure which could cause serious injury When the engine has cooled place thick rag like atowel overthe radiator cap Slowly rotate the cap counterclockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it 4 Place an open container under the drain b...

Page 237: ...es wash immediately with soap and water 9 Remove the reservoir tank CD and drain the coolant 10 Install Reservoir tank 11 Inspect Gaskets drain bolt Damage Replace 12 Install Gaskets Drain bolts Exhaust pipe gaskets Muffler 13 Fill Drain bolt 32 Nm 3 2 m kg 23 ft Ib Bolts exhaust pipe 23 Nm 2 3 m kg 17 ft Ib Cooling system Recommended Coolant High quality ethylene glycol anti freeze containing cor...

Page 238: ...he pressure with gauge 2E071 Air bleeding 1 Bleed air from the cooling system Air bleeding steps Lift up the tail ofthe machine Connect plastic tubes CD tightly to the bleed screws on the heat exchanger Loosen the bleed screws of Heat ex changer Keep the coolant running out until air bubbles disappear while adding coolant slowlyto the radiator Tighten the bleed screws Bleed screw 6 Nm 0 6 m kg 4 3...

Page 239: ...cessive V belt wear could occur Operate the engine only in a well ventilated area Remove the radiator cap and bleed air on the cooling system again as shown in the steps above No air bubbles OK Add coolant up to the specified level Pour coolant into the reservoir tank until the coolant level reaches FULL level mark 2E081 Water Pump Belt Deflection Adjustment 1 Remove Muffler 2 Check Drive belt def...

Page 240: ... lower Remove shim Tension becomes higher Shim size Part number Thickness 82M 15721 00 0 5 mm 0 02 in 82M 15722 00 1 0 mm 0 04 in Install the starter pulley and drive belt Recheck the drive belt deflection If out of specification readjust the drive belt deflec tion 4 Tighten Starter pulley bolt 23 Nm 2 3 m kg 17 ft Ib Recoil starter bolt 10 Nm 1 0 m kg 7 2 ft Ib http ReadManuals com ...

Page 241: ...e throttle valve height on the No 1 carburetor with adjusting eccen tric nut Move the throttle lever 2 3 times Make sure all the carburetor throttle valves are on the same height Install the carburetor Remove the rubber caps G from the carburetor vacuum fitting and connect the Vacuum Gauge Hose YU 08030 to the fit tings Start the engine and let it warm up If vacuum reading are not same turn the ad...

Page 242: ...screws in or out so that the vacuum readings are the same Turn the throttle stop screws in or out to adjust the engine idle speed Turning in Idle speed becomes higher Turning out Idle speed becomes lower C Engine idle speed 1 400 1 600 r min Adjustment steps EX570SX Start the engine and let it warm up Turn the throttle stop screw CD in or out to adjust the engine idle speed Turning in Idle speed b...

Page 243: ... 14 1 Measure Throttle cable free play Out of specification Adjust Throttle cable free play 1 0 2 0 mm 0 04 0 08 in 2 Adjust Throttle cable free play Adjustment steps Loosen the locknut CD Turn the adjuster in or out until the specified free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the locknut AJ EX570 E ST 1m EX570SX http ReadManuals com ...

Page 244: ...d unexpectedly which could cause an accident 1 Start the engine NOTE _________________________ Refer to STARTING THE ENGINE 2 Hold the pivot point ofthe throttle lever away from the throttle switch D 3 Press CV the throttle lever gradually The T O R S warning light should turn on and off and the engine should run between 2800 and 3000 rpm A WARNING Ifthe engine does not run between 2800 and 3000 r...

Page 245: ...specification t Adjust Free play 0 5 1 5 mm 0 02 0 06 in 3 Adjust Starter cable free play Adjustment steps Loosen the locknut CD Turn the adjuster in or out until the speci fied free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the locknut and push in the adjuster cover Al FOR EX570 E ST ID FOR EX570SX http ReadManuals com ...

Page 246: ... may move II I II 805 029 805 020 2 17 unexpectedly when the engine is started The spacer of the secondary sheave should be adjusted To ensure proper clutch performance the spacers in the secondary clutch must be repositioned as the V belt wears V belt width CD Number of spacers 00 35 mm 1 38 in or more 2 spacers rnJ 34 mm 1 34 in 1 spacer 33 mm 1 30 in No spacer 32 mm 1 25 in or less Replace the ...

Page 247: ...primary sheave 3 Inspect Drive V belt Crack Wear Damage Replace Oil or grease adhered to the V belt Check the primary and secondary sheaves 4 Inspect Primary sheave Secondary sheave Oil or grease adhered to the primary and secondary sheaves Remove the oil or grease using a rag soaked in lacquerthinner or solvent Check the primary and secon dary sheaves 5 Measure Drive V belt length Out of specific...

Page 248: ...specification Adjust the primary sheave see page 2 42 Engagement speed C Approx 3 800 r min EX570 E ST Approx 3 900 r min EX570SX 2E161 BRAKE PAD INSPECTION 1 Apply the brake lever 2 Measure Brake pad thickness Out of specification Replace brake pad as a set see page 4 21 I Wear limit v 9 5 mm 0 37 in BRAKE ADJUSTMENT NOTE _________________________ Adjust brake every 40 hours of operation or whene...

Page 249: ...level 4 Remove Checking bolt Gasket checking bolt 5 Inspect Oil level drive chain housing Oil flows out t Oil level is correct Oil does not flow out Oil level is low Add oil until oil flows out Recommended oil Gear oil API GL 3 SAE 75 or 80 6 Inspect Gasket checking bolt Damage Replace 7 Tighten Checking bolt 10 Nm 1 0 m kg 7 2 ft Ib Oil Replacement Oil replacement step Warm up the engine for seve...

Page 250: ... the reference mark on the guard 2 TUrri the secondary sheave clockwise by hand until it stops Mark J the sheave again next to the reference mark on the guard 3 Measurethe distance betweenthemarkson the sheave Free turning movement distance Maximum Free Turning Movement 9 mm 0 35 in NOTE ________________________ There will always be at least 4 mm 0 16 in of movement due to drive line slack 4 If fr...

Page 251: ...pin Never allow anyone near a rotating track Inspect track condition frequently Replace the track if it is damaged to the depth where fabric reinforcement material is visible Never install studs cleats closer than three inches to the edge of the track 1 Place the machine with the right side facing down 2 Measure Track deflection CD Pull at the track center window exerting a force of 10 kg 22 Ib us...

Page 252: ... Left adjuster Turn out Turn in Right adjuster Turn in Turn out Slide runner Track Track metal Gap Forward c Adjust track deflection to the specified amount Track deflection More than Less than specified specified G Left adjuster Turn in Tur out Turn in Turn out The adjusters should be turned an equal amount Recheck alignment and deflection If neces sary repeat steps a to c until proper adjust men...

Page 253: ...1 gSI ill 820 001 2 24 SLIDE RUNNER INSPECTION 1 Inspect Slide runner ill Cracks DamageNVear Replace 2 Measure Slide runner thickness Out of specification Replace see page 4 29 I Wear limit v 10 mm 0 39 in http ReadManuals com ...

Page 254: ... ski cover to prevent the ski wear and damage 2E221 STEERING SYSTEM Free Play check 1 Check Steering system free play Push the handlebar up and down and back and forth Turn the handlebar slightly to the right and left Excessive free play tcheck to be sure the handlebar tie rod ends and relay rod ends are installed securely in position Iffree play still exists check the steering bearing front suspe...

Page 255: ...D tie rod Turn the relay rod in or out until the speci fied toe out is obtained Tighten the locknuts CD tie rod Locknut tie rod 25 Nm 2 5 m kg 18 tt Ib LOCTITE A Left side rn J Right side 2E241 HEADLIGHT BEAM ADJUSTMENT 1 Place the machine on a level surface 2 Inspect Headlight beam direction L H The high beam should be directed down wards at an angle of 1 20 to the horizontal If not adjust the di...

Page 256: ... I_IESSO Beacon 325 Grease I A WARNING Apply a dab of grease to the cable end only Do not grease the brake throttle cables themselves because they could become frozen which could cause loss of control 2E261 LUBRICATION Front and Rear Suspension 1 lnjectgreasethrough nipplesG using agrease gun t Esso Beacon 325 Grease or Aeroshell Grease 7A 00 Front ffi Rear http ReadManuals com ...

Page 257: ...fuel enters the carburetors During initial fuel flow to the carburetor it is not always possible to supply the optimum fuel oil mixture depending on the throttle opening Therefore after the carburetors have been tuned or maintained or after the float chamber is removed for cleaning or jet replacement be sure to idle the engine for about three minutes in order to avoid engine trouble Before perform...

Page 258: ...t 1 Start the engine and operate the machine under normal condition to make sure the en gine operates smoothly Thenstoptheengine 2 Remove Spark plugs 3 Check Spark plug insulator CD color A medium to lighttan color indicates normal conditions Distinctly different color t Replace main jet 4 The main jet should be adjusted onthe basis of the following Main jet selection chart NOTE __________________...

Page 259: ...n and tem perature 10 C ooe 10 C 20 C 14 F 32 F 50 F 68 F I I 320 IN 3rd 310 STD IN 3rd STD 310 STD IN 3rd STD 300 IN 3rd 300 IN 3rd 290 IN 3rd 280 IN 3rd 270 IN 3rd AS 7 8 260 IN 3rd 250 IN 3rd AS 7 8 250 IN 3rd 2 30 ill IN J AS 240 IN 2nd AS 7 8 Main jet number Jet needle clip position Air screw turns out NOTE _________________________ These jetting specifications are subjectto change Consult th...

Page 260: ... C 4 F 14 F 32 F 50 F 68 F I I I I 160 157 5 155 STD 152 5 IN 2nd 152 5 IN 2nd 150 IN 2nd 150 IN 2nd 147 5 IN 2nd 145 IN 2nd 142 5 IN 2nd PJ 52 5 AS 1 W 2 31 QJ Q IN f AS PJ Main jet number Jet needle clip position Air screw turns out Pilot jet number NOTE ________________________ These jetting specifications are subjectto change Consult the latest technical information from Yamaha to be sure you ...

Page 261: ... I I I I I I I I i IT Carburetor Bore I JlJ 1 Q High speed tuning I I r J L I I 3 4 I f 1r t _____ r___t_ 1 2 _H __ r_ L 1 4 r_ _r E Closed J11 8 t z l1 t 1 I I Low speed tuning 1 J I I L I I I I I I I I I I I _ I I I I ____ 1 E Closed 1 8 1 4 1 2 3 4 ill Full open A Throttle valve opening 2 32 http ReadManuals com ...

Page 262: ...4 gFull open rn JThrottle opening If the Air Silencer Box is removed from the carburetors the change in pressure in the intake will create a LEAN MIXTURE that could likely result in severe engine damage The Air Silencer Box has no effect on performance characteristics and it must be secured to the carburetor during carbtuning and adjustment and it must always be in place when the engine is operate...

Page 263: ... to too lean a mixture the Replace the piston and spark plug brown spots and with a Tune the carburetor again starting with low bluish burnt appearance piston is damaged or seized speed tuning of electrodes Melted electrodes and Check the piston for holes or seizure possibly blistered Check the cooling system gasoline octane rating insulator Due to too lean a mixture the and ignition timing After ...

Page 264: ...ine Clean spark plug Return starter choke level to its seated position Clean Parts otherthan air carburetor Clogged fuel tank air vent clogged fuel filter or clogged fuel passage Carburetor Clogged orfrozen air vent or clogged valve If water collects in float chamber clean Also check for ice Correct Bottom the pilot screw lightly and back it outto specification Adjust idling speed Start the engine...

Page 265: ...tor tion and adjust Mainly backfire Dirty carburetor Clean carburetor Dirty or clogged fuel Clean or replace fuel pipe pipe Overflow Clogged air vent Clean Related troubles Clogged float valve Disassemble and Clean while taking care not to Power idling clean scratch valve seat Poor performance at low mid range Scratched or unevenly Clean or replace float Valve seat is press fitted to and high spee...

Page 266: ...2 5 N mm 126 Ib in 0 Free Length 76 5 mm 3 01 in M Secondary Sheave Spring E Part Number 90508 50571 OJ Color Code P NJ Twist Angle 60 Q Hole Position pJ Sheave Side B QJ Spring Seat 2 Side 0 Free Length 85 05 mm 33 5 in CLUTCH TUNING High Altitude Tuning 900 1 500 m 1 400 2 100 m 3 000 h 5 000 h 4 500 h 7 000 h MA MA r r r r r r r ITl Aluminum r r 90501 604GO r P Y P r 24 kg 52 9 Ib r 3 0 kg mm r...

Page 267: ...ngth 85 4 mm 3 36 in lMlSecondary Sheave Spring EJ Part Number 90508 50571 ITJ Color Code P N Twist Angle 50 Q Hole Position EJ Sheave Side A Spring Seat 2 Side CO Free Length 85 05 mm 3 35 in CLUTCH TUNING High Altitude Tuning 900 1 500 m 1 400 2 100 m 3 000 ft 5 000 ft 4 500 ft 7 000 ft MA MA r r r r r r r IT Aluminum r r 90501 550J8 r W P W r r r 2 25 kg mm r 22 N mm 126Ib in 78 7 mm 3 1 in r r...

Page 268: ...heave 30 kg 66lb Spring K Spring Rate 2 25 kglmm 22 N mm 126Ib in 1J Free Length 78 7 mm 3 1 in M Secondary Sheave Spring EJ Part Number 90508 50571 ITJ Color Code P N Twist Angle 50 Q Hole Position f Sheave Side A QJ Spring Seat 2 Side 1J Free Length 85 0 mm 3 35 in CLUTCH TUNING High Altitude Tuning 900 1 500 m 1 400 2 100 m 3 000 ft 5 000 ft 4 500 ft 7 000 ft MA MA IT Aluminum 90501 602JO P f 3...

Page 269: ...set according to the snow condition If there are many rough surfaces or unfavorable snow conditions the drive driven gear ratio should be made larger If there are few rough surfaces or better snow condition the ratio should be made smaller Gear Ratio Chart The following drive and driven gears and chains are available as options The figures in upper lines represent the driven and drive gear ratios ...

Page 270: ... 0 3 500 ft STD 3 000 5 000 ft 4 500 7 000 ft 6 500 ft HA AJ Secondary gear ratio 17 33 1 94 f 17 35 2 05 16 35 2 19 EJ Part No 89J 17682 70 f f 89J 17682 60 lID Drive gear EJ Teeth 17T 16T f f Driven gear EJ Part No 89J 47587 30 f 89J 47587 50 f EJ Teeth 33T f 35T f QJ Chain EJ Part No 94860 02068 f f f ill No of links 68 f f f For EX570SX 0 1 100 m 900 1 500 m 1 400 2 100 m 2 000 HA 0 3 500 ft S...

Page 271: ...e engine speed when the ma chine passes a point 200 300 m 650 000 ft from the starting position after the machine has been started at full throttle from a dead stop Normally when a machine reaches shift speed the vehicle speed increases but the engine speed remains nearly constant Under unfavorable con ditions wet snow icy snow hills or rough terrain however engine speed may decrease after the shi...

Page 272: ...main jet size according to the chart page 2 34 Test main jet size I NotOK Adjust main jet size performance plug color I 1 OK Re test OK Not OK Not OK OK OK Not OK OK Decide if problem is pilot jet and adjust accordingly Not OK Check engagement speed and shift performance I Not OK Adjust primary clutch as re quired page 2 42 Not OK Adjust secondary clutch as required page 2 42 2 43 High altitude tu...

Page 273: ...low more precise handling and control over certain types of terrain or riding conditions Front suspension 1 Adjust Damping force Adjustment steps Remove the suspension cap CD Turn the adjuster in or out to adjust the spring preload 12 clicks 5 clicks 1 clicks Adjuster in in in Position Standard Turns in Turns out Preload Harder H Softer Be sure the left and right spring preload is same Reinstall t...

Page 274: ...k well under most general riding conditions The suspension can be adjusted to work better in one condition but only at the expense of another Keep this in mind when you adjust the suspension Front A No 6 hole No 1 hole Shortest Longest More weight on skis Less weight on skis Heavy steering Light steering oversteer understeer More maneuverability Better acceleration and Favors hardpack snow speed i...

Page 275: ...2 74 in EX570ST Max Min Length 84 5 mm 76 5 mm 69 5 mm Front 3 33 in 3 01 in 2 74 in EX570SX Max Min Length 85 5 mm 69 5 mm 69 5 mm Front 3 37 in 2 74 in 2 74 in Max Min Length 85mm 77mm 69mm Rear 3 35 in 3 03 in 2 72 in IAl Front If Rear A WARNING Thisshockabsorbercontains highlypressurized nitrogen gas Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock abs...

Page 276: ...PLATES Open the plates to cool down the engine room Close the baffle plate CD when the machine is operated in deep powder snow Remove the louver plates and belly pan plates G when the atmospheric temperature is 5 C 41 5 F or higher http ReadManuals com ...

Page 277: ...ASI I CHAPTER 3 CHASSIS STEERING 3 1 REMOVAL 3 2 INSPECTION 3 4 INSTALLATION 3 5 SKI 3 8 REMOVAL 3 9 INSPECTION 3 9 INSTALLATION 3 9 FRONT SUSPENSION 3 11 REMOVAL 3 12 INSPECTION 3 13 INSTALLATION 3 14 http ReadManuals com ...

Page 278: ... 2 7 m kg 20 ft Ib A USE NEW ONE 43 Nm 4 3 m kg 31 ft Ib 25 Nm 2 5 m kg 18 ft Ib 3 1 3E011 CHASSIS STEERING illHandlebar Steering column Bearing Bearing holder Lock washer Relay rod J Tie rod 15 Nm 1 5 m kg 11 ft Ib 143 Nm 4 3 m kg 31 ft Ib 1 1AluSE NEW ONE I 43 Nm 4 3 m kg 31 ft Ib http ReadManuals com ...

Page 279: ...er when removing the handlebar cover rear 2 Remove MetercoverG 3 Disconnect Meter light coupler Headlight coupler Speedometer cable Handlebar switch coupler right Blake light switch coupler Headlight beam switch coupler Grip warmer leads 4 Remove Upper cowling G with meter assembly 5 Remove Holder G throttle cable 6 Disconnect Throttlecable Oil pump cable from throttle lever http ReadManuals com ...

Page 280: ...ndCD Handlebar holders upper Handlebar Handlebar holder lower 9 Remove Side covers CD left and right Centercover NOTE ________________________ Remove the holding nuts main switch STARTER lever and fuel cock when removing the center cover 10 Remove Carburetors see page 7 2 7 10 Intake silencer Engine assembly see page 5 1 11 Straighten Lock washer tabs upper and lower 12 Remove CotterpinCD http Rea...

Page 281: ...ay rod from the steering column the relay rod end needs to be held fixed in order to facilitate the locknut removal 14 Remove CapG Cotterpins lAl Left side lID Right side 15 Remove Relay rod G Tierod INSPECTION 1 Inspect Handlebar G Steering column Bending Cracks Damage Replace A WARNING Do not attempt to straighten a bent column This may dangerously weaken the column http ReadManuals com ...

Page 282: ...is may dangerously weaken the rod 4 Check Tie rod end movement Tie rod end free play exists Replace Tie rod end turns roughly Replace INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Install Tie rodCD Relayrod NOTE ________________________ Install the rod end with the left hand thread onto the tie rod on the right side The threads on both rod ends must be the same length Lock...

Page 283: ...ment steps Temporarily install the handlebar Hold the handlebar straight and check to see that the skis are at right angles to the handle bar Loosen the locknuts steering relay rod G Direct the skis in parallel to the moving direc tion With the skis thus turn the relay rod either way to adjust the handlebars at right angles with respect to the direction of movement Turning the relay The handlebars...

Page 284: ...uld be installed with the punch mark ill forward Align the punch marks with the handlebar holder gaps respectively Tighten the bolts to specification so that the front clearance a is smaller than the rear clearance bU First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side 6 Adjust Brake cable distance see page 2 19 http ReadManuals com ...

Page 285: ...embly 3 8 SKI CD Collar Ski stopper Ski 0D Ski runner Ski cover Recommended grease ESSO beacon 325 grease or Aeroshell grease 7A r L _ 1 For EX570ST SX Fit the stopper with its raised portion positioned in front 43 Nm 4 3 m kg 31 ft Ib SKI DISTANCE EX570 E ST 920 mm 36 2 in C EX570SX 980 mm 38 6 in SKI TOE OUT 0 0 15 mm 0 0 0 6 in http ReadManuals com ...

Page 286: ...ar 3 Remove Ski stopper CD Ski runner INSPECTION 1 Inspect Ski CD Ski runner Ski cover see page 2 25 Ski stopper Wear Cracks Damage t Replace Mounting bolt Collar Spacer j Wear Damage Replace INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Tighten Ski runner nut 21 Nm 2 1 m 0 kg 15 ft olb http ReadManuals com ...

Page 287: ...n front Be careful not to reverse the mounting positions of the left and right ski assemblies 3 Tighten Mounting nut 43 Nm 4 3 m kg 31 ft Ib NOTE ________________________ Lubricate the collar dust cover and mounting bolt before installing the ski Recommended grease ESSO beacon 325 grease or Aeroshell grease 7A Always use a new cotter pin http ReadManuals com ...

Page 288: ... lower Shock absorber j Suspension arm Stlspension bracket Front arm upper Front arm lower Stabilizer rod Stabilizer slider Recommended grease ESSO beacon 325 grease or Aeroshell grease 7A 43 Nm 4 3 m kg 31 ft Ib 16 Nm 1 6 m kg 11 ft Ib 21 Nm 2 1 m kg 15 ft Ib 110 Nm 1 0 m kg 7 2 ft Ib 1 5 Nm 0 5 m kg 3 6 ft Ib 3 11 http ReadManuals com ...

Page 289: ...rpin i Tie rod AJ Left lID Right 3 Remove Cotterpins i Front arm upper Front arm lower Bushing Collars 4 Loosen Nuts i Setscrew 5 Remove Suspension bracket 6 Remove Absorber holder i Spacercollar Flange plate Spring seat upper Spring Spring seat lower AbsorbercoverCD 3 12 http ReadManuals com ...

Page 290: ...lizerslider NOTE _______________________ Pull left side of the stabilizer bar to inside then remove the circlip INSPECTION 1 Inspect Shockabsorber j Oil leaks Bending Damage Replace 2 Inspect Suspension brackets j Suspensionarm Frontarms Cracks Wear Damage Replace Bushings Collars Wear Scratches Damage Replace http ReadManuals com ...

Page 291: ...n For EX570SX 251 0 mm 9 88 in 6 Inspect Oil seals Damage Replace 7 Inspect Stabilizer slider Unsmooth movement Apply a low tem perature grease into the stabilizer slider Recommended grease ESSO beacon 325 grease or Aeroshell grease 7A INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Lubricate Bushing suspension support CD Bushing suspension arm 0 Oil seallips Recommended gre...

Page 292: ...et so the L mark is on th left side and the R mark is on the right side Install the spring with the small pitch side upward 4 Tighten Absorber holder bolt 10 Nm 1 0 m 0 kg 7 2 ft 0 Ib Shock absorber nut 5 Nm 0 5 m 0 kg 3 6 ft Ib Locknut shock absorber 16 Nm 1 6 m 0 kg 11 ft olb Front arm nut 43 Nm 4 3 m 0 kg 31 ft 0 Ib Tie rod nut 25 Nm 2 5 m 0 kg 18 ft 0 Ib NOTE _________________________ Be sure ...

Page 293: ... INSTALLATION 4 11 SHEAVE DISTANCE AND OFFSET ADJUSTMENT 4 12 DRIVE CHAIN HOUSING AND JACKSHAFT 4 15 REMOVAL 4 16 INSPECTION 4 18 INSTALLATION 4 19 BRAKE 4 20 REMOVAL 4 21 DiSASSEMBLy 4 21 INSPECTION 4 22 ASSEMBLY AND INSTALLATION 4 23 SLIDE RAIL SUSPENSION 4 25 REMOVAL 4 27 DiSASSEMBLy 4 27 INSPECTION 4 29 ASSEMBLY 4 30 FRONT AXLE AND TRACK 4 31 REMOVAL 4 32 INSPECTION 4 32 INSTALLATION 4 33 http...

Page 294: ...sheave cap Bushing Fixed sheave A LEFT HAND THREAD Stopper V belt Sliding sheave Collar Rivet Weight Bushing Slider Bushing 4 Nm 0 4 m kg 2 9 ft Ib 200 Nm 20 m kg 145 ft Ib r I 2 I I I I I L _______ J 4 1 1 Tighten the bolt 120 Nm 12 m kg 87 ft Ib 2 Loosen the bolt completely 3 Retighten the bolt 60 Nm 6 0 m kg 43 ft Ib 7 14 Nm 1 4 m kg 10 ft Ib http ReadManuals com ...

Page 295: ...heave holder and primary sheave puller Primary sheave holder 90890 01701 YS 01880 Primary sheave puller YS 01881 1 YS 38517 DISASSEMBLY 1 Remove Bolts primary sheave cap 2 Remove Primary sheave cap J Primary sheave spring 3 Loosen Set screws J 4 Remove Nut J Weight Bolt Washers Collar Slider Roller Washers Nut Bolt j Collar http ReadManuals com ...

Page 296: ... the Clutch Separator Adapter 90890 01740 YS 34480 onto the separa tor Fit the primary sheave assembly onto the adapter and secure the supporting plates NOTE ______________________ Securely fit the projections of the adapter into the fixed sheave holes Set the bar wrench onto the spider and turn the special tool clockwise to loosen the spi der Spider has a left hand thread To loosen the spider hig...

Page 297: ...D Cracks Damage Replace 4 Measure Primary sheave spring free length Out of specification Replace Primary sheave spring free length 76 5 mm 3 01 in For EX570 E 85 4 mm 3 36 in For EX570ST 78 7 mm 3 1 in For EX570SX 5 Inspect Weight CD Roller Bushing G Slider G Rivet Collar Wear Scratches Damage Replace Slider inside clearance l Min 0 15 mm 0 0059 in Max 0 45 mm 0 0177 in Rivet replacement steps Rem...

Page 298: ...ht New 8 0mm 0 31 in f Wear limit 8 2mm f 0 32 in ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points 1 Install Sliding sheave onto spider NOTE Be sure the sliding sheave match mark x is aligned with the spider match mark x 2 Install Fixed sheave onto spider NOTE Apply LOCTITE CD to the first 4 threads of the spider LOCTITE should be applied only to the area specified Never apply ...

Page 299: ...NG Do not operate the primary sheave until the LOCTITEi l has dried completely Wait 24 hours before operating primary sheave Since the tightening torque is high make sure the spider fixed sheave and specialtool are placed securely Tighten the spider carefully to prevent cracks and or damage to the sheaves and spider 5 Install Weight and roller Installing steps Tighten the bolt CD Bolt 6 Nm 0 6 m k...

Page 300: ...Primary sheave assembly Be sure to remove any oil and or grease from the tapered portion of the crankshaft and spider using a cloth dampened with thinner 2 Apply YAMALUBE 2 cycle oil equivalent grease to threads of primary sheave bolt 3 Tighten Bolt CD primary sheave Tightening steps Hold the primary sheave using the Primary Sheave Holder 90890 01701 YS 01880 and tighten the bolt primarysheave to ...

Page 301: ...y spring Ramp shoe Sliding bushing j Sliding sheave Shim Fixed sheave 4 Collor Shim Sta ard position position SECONDARY SHEAVE Ip RIO 01 r L _ J For EX570 E SX EX570 E B 2 60 EX570ST SX A 2 50 Standard twist angle 9 60 Nm 6 0 m kg 43 ft Ib 4 8 http ReadManuals com ...

Page 302: ...den release of springtension Use the Sheave Compressor 90890 01712 YS 28891 to contain the spring tension before removing the retaining clip Do not attempt the procedure unless you have the proper tools and understand the instructions thoroughly 1 Remove Circlip CD Washer 2 Remove Spring seat CD Secondary sheave spring Sliding sheave Shim s drive V belt from fixed sheave INSPECTION 1 Inspect Slidi...

Page 303: ...ce Free length limit 85 0 mm 3 35 in 5 Measure Ramp shoe thickness Out of specification Replace I Wear limit v AI 1 0 mm 0 04 in ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points Lubricate Bushing surface thin coat Recommended grease ESSO beacon 325 grease or Aeroshell grease 7A 2 lnstall Secondary sheave spring CD NOTE Hookthe end of the secondary sheave spring onto the spring ...

Page 304: ...ckwise direction Holding the sliding sheave and fixed sheave in this position Standard twist angle A 2 t 50 B 2 t 60 Turn in the screw forthe sheave compressor so that the spring seat engages with the sliding sheave Install the washer and circlip in proper posi tion INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Lubricate Splines fixed sheave Recommended grease ESSO beacon ...

Page 305: ...t damp ers and frame for bends cracks and corro sion Repair or replace as required Loosen the engine mounting nuts ill Adjust the position of the engine with the adjuster Loosen the locknuts and turn the adjuster in or out until the specified distance is ob tained the crankshaft and jackshaft being parallel to each other Tighten the locknuts Tighten the engine mounting nuts ill Mounting nut 40 Nm ...

Page 306: ...ased Removing shim Offset is decreased Shim size Part number Thickness 90201 252F1 0 5 mm 0 02 in 90201 25527 1 0 mm 0 04 in 90201 25526 2 0 mm 0 08 in Install the secondary sheave and bolt secon dary sheave Bolt secondary sheave p 60 Nm 6 0 m kg 43 ft Ib Recheck the sheave offset If out of specifica tion repeat the above steps NOTE When adjusting the sheave offset the secondary sheave free play c...

Page 307: ...arance by adding or removing a shim s Adding shim Free play is decreased Removing shim Free play is increased Shim size Part number Thickness 90201 222FO 0 5 mm 0 02 in 90201 225A4 1 0 mm 0 04 in Install the washer and bolt secondary sheave and tighten the bolt Bolt secondary sheave 60 Nm 6 0 m kg 43 ft Ib Recheck the secondary sheave free play clearance If out of specification repeatthe above ste...

Page 308: ...E031 DRIVE CHAIN HOUSING AND JACKSHAFT CD Jackshaft Bearing Bearing holder Drive sprocket Collar Oil seal rJ Locknut Adjuster Drive chain tensioner Driven sprocket Drive chain Bearing 2 23 Nm 2 3 m kg 17 ft Ib 48 Nm 4 8 m kg 35 ft Ib 4 15 A USE NEW ONE http ReadManuals com ...

Page 309: ...tter pin CD Nut drive sprocket Bolt driven sprocket Drive sprocket G Driven sprocket Drive chain Collar CD NOTE ________________________ Apply the brake to lock the jackshaft when re moving the nut drive sprocket and bolt driven sprocket Loosen the adjuster fully when removing the drive sprocket driven sprocket and drive chain 5 Remove Bolts CD brake caliper body Stay intake silencer http ReadManu...

Page 310: ...uff key Jackshaft 8 Remove Bearing housing CD Inner race holder NOTE ________________________ Loosen the screw inner race holder 9 Loosen Track see page 4 27 10 Remove Speedometer gear assembly see page 4 32 Bearing holder Drive chain housing CD NOTE ________________________ Push the front axle to the left to remove the drive chain housing 11 Remove Adjuster CD chain tensioner Bolt Collar Chain te...

Page 311: ...ent steps Remove the circlip J bearing holder Remove the bearing s using a general bearing puller Install the new bearing s NOTE _______________________ Use a socket that matches the outside diameter of the race of the bearing Do not strike the inner race of balls of the bearing Contact should be made only with the outer race Install the new circlip bearing holder Always use a new circlip 2 Inspec...

Page 312: ...43 Nm 4 3 m kg 31 ft Ib Brake caliper body bolt 48 Nm 4 8 m kg 35 ft Ib Drive sprocket nut 50 Nm 5 0 m kg 36 ft Ib Driven sprocket bolt 48 Nm 4 8 m kg 35 ft Ib Inner race holder screw 6 Nm 0 6 m kg 4 3 ft Ib NOTE ___________________________________ Install the washer drive sprocket CD as shown in the illustration Tighten the screw inner race holder after tightening the drive sprocket nut 3 Adjust ...

Page 313: ...e Caliper body Lever Stationary cover Washer j One way lock 2 Adjusting screw Adjusting ratchet End cover Brake disc Woodruff key With silicone grease I I f9N iQ r _ I I 7 I I I I I I I I I I I 1 0 I I 2 Nm 0 2 m kg 1 4 ft Ib 1 I I I 11 http ReadManuals com ...

Page 314: ...____ Loosen the locknut G and turn in the adjuster fully to release the tension in the brake cable then remove the bolt cable holder 3 Remove Bolts bearing housing see page 4 17 Jackshaft with bearing housing Brake disc Woodruff key DISASSEMBLY 1 Remove Back up plate G End cover Do not disassemble the torsion spring from the end cover and the guide 2 Remove Adjusting ratchet G Bolts stationary cov...

Page 315: ... driver Remove the washer and stationary cover Replace a damaged part s use a new one Reassemble the removed part s and reverse the above steps Always use a new one way lock 2 2 Inspect Torsion spring ill Fatigue Damage Replace end cover unit Inspection steps Check the fatigue ofthe torsion spring by the projection mark on the guide located between the base marks on the end cover If projection mar...

Page 316: ...eps Lubricate the spiral gears CD on the caliper body and lever with silicone grease Align the projection mark on the leverwith the IN mark on the caliper body screw the lever counterclockwise to the caliper body Install the stopper pin into the holes on the caliper body and stationary cover then tighten the bolts stationary cover Bolt stationary cover 9 Nm 0 9 m kg 6 5 ft Ib Lubricatethe one way ...

Page 317: ...ection ofthe stationary cover then install the guide which is fitted to the end cover twisting the end cover clockwise approximately 30 degrees and tighten the screws end cover Screw end cover 2 Nm 0 2 m kg 1 4 ft Ib 2 Install Brake pads NOTE ________________________ When installing the brake pad at the caliper body side make sure that projection on the brake pad are meshed with slot on the calipe...

Page 318: ...4E042 A USE NEW ONE 4 25 G d UI e wheel center 10 Suspension wheel center Suspension wheel front Slide metal Track assembly 13Nm 1 3m o kg 9 4ft o lb http ReadManuals com ...

Page 319: ...uspension ill Rear stopper band Bracket Rear suspension bracket Sliding frame Slide runner Suspension wheel bracket Front suspension Relay arm Bracket Front stopper band Front pivot arm 42 Nm 4 2 m kg 30 ft Ib 20 Nm 2 0 m kg 14 ft Ib 4 26 20 Nm 2 0 m kg 14ft Ib 20 Nm 2 0 m kg http ReadManuals com ...

Page 320: ...nut G and adjusters track tension 3 Remove Guide wheel G center 4 Remove Suspension mounting bolts NOTE ________________________ Loosen both right and left bolts front G at the same time 5 Place the machine with the left side facing down 6 Remove Slide rail suspension G OISASSEMBLV 1 Remove Stopper bands front G and rear http ReadManuals com ...

Page 321: ...s 3 Remove Suspension wheel bracket CD Front suspension Front pivot arm Collar Bushing Washer J Flange washer 4 Remove Suspension wheels CD center Rear suspension Pull rods Washer Collar Bushing 5 Remove Rear pivot arm CD Suspension wheel Pivot arm bracket Collar Washer http ReadManuals com ...

Page 322: ...nspect Suspension wheel Guide wheel Cracks Damage t Replace Wheel bearing Wheel turns roughly t Replace 2 Inspect Stopper band ill Frayed Damage t Replace Pull rod Bends Damage t Replace Shock absorber Oil leaks Damage Replace Bushings Wear Cracks Damage t Replace Sliding frame Front pivot arm Rear pivot arms f Cracks Damage t Replace http ReadManuals com ...

Page 323: ... kg 14 ft Ib Nut 20 Nm 2 0 m kg 14 ft Ib Bolt 68 Nm 6 8 m kg 49 ft Ib Bolt 20 Nm 2 0 m kg 14 ft Ib Bolt 56 Nm 5 6 m kg 41 ft Ib Nut 42 Nm 4 2 m kg 30 ft Ib Bolt j 27 Nm 2 7 m kg 20 ft Ib Bolt 8 Nm 0 8 m kg 5 8 ft Ib Bolt 20 Nm 2 0 m kg 14 ft Ib Nut l 74 Nm 7 4 m kg 54 ft Ib Bolt 13 Nm 1 3 m kg 9 4 ft Ib Stopper band nut 4 Nm 0 4 m kg 2 9 ft Ib NOTE ________________________ Install the pull rod so ...

Page 324: ...FRONT AXLE AND TRACK Ip FrRlo 01 4E052 FRONT AXLE AND TRACK G Guide wheel Sprocket wheel Front axle 1 Bearing Bearing holder Collar 90 Nm 9 0 m kg 65 ft Ib 4 31 http ReadManuals com ...

Page 325: ...____________ Apply the parking brake when removing the nut front axle 2 Remove Muffler Driven sprocket see page 4 16 Slide rail suspension see page 4 27 3 Remove Front axle assembly CD Track assembly INSPECTION 1 Inspect Track CD Slide metal Wear Cracks Damage t Replace 2 Inspect Sprocket wheel CD Wear Break Damage t Replace Front axle Bent Scratched excessively Damage t Replace http ReadManuals c...

Page 326: ...e shown in the illustration 2 Place the track in the chassis NOTE ________________________ Be sure it is positioned as shown in the illustra tion A TURNING DIRECTION 3 Install Front axle CD NOTE _________________________ Install the front axle push up the splined end toward the chain housing and install the threaded end into the speedometer gear hous ing side Be sure the lugs correctly engage the ...

Page 327: ... INSPECTION AND REPAIR 5 6 CYLINDER HEAD 5 6 CYLINDER AND PISTON 5 6 PISTON RINGS 5 8 PISTON PIN 5 9 CRANKSHAFT 5 10 CRANKCASE 5 11 OIL PUMP STROKE ADJUSTMENT 5 11 ENGINE ASSEMBLY AND ADJUSTMENT 5 14 CRANKCASE AND CRANKSHAFT 5 14 PISTON 5 18 CYLINDER AND CYLINDER HEAD 5 18 CDI MAGNETO 5 19 WATER PUMP 5 21 OIL PUMP 5 21 REMOUNTING ENGINE 5 21 RECOIL STARTER 5 22 REMOVAL 5 23 DISASSEMBLY 5 23 INSPEC...

Page 328: ... pump Primary sheave Starter motor BATTERY LEADS FOR ELECTRIC MODEL 1 Disconnect Battery leads Disconnect the negative lead CD first and then disconnect the positive lead HOSES 1 Drain Coolant see page 2 7 2 Remove Primary sheave see page 4 2 Carburetors see page 7 2 7 10 3 Disconnect Oil hoses CD Oil delivery hoses Pulser hose NOTE ________________________ Plug the oil hoses and oil delivery hose...

Page 329: ...from the throttle lever see page 3 2 Spark plug leads CDI magneto leads and coupler CD Pickup coil leads Bands OIL TANK 1 Remove Bolts oil tank stay 2 Remove Band CD coolant hose STARTER MOTOR FOR ELECTRIC MODEL 1 Remove Starter motor CD 2 Dissconnect Starter motor lead 5 2 http ReadManuals com ...

Page 330: ...I 5 3 RECOIL STARTER 1 Remove Recoil starter CD ENGINE REMOVAL 1 Remove Nuts CD engine bracket Engine assembly NOTE ________________________ Remove the starter motor bolt and ground lead before removing the engine assembly http ReadManuals com ...

Page 331: ...ket CD Crankcase cover Pickup coil 2 Remove Nut CD magneto rotor Washer NOTE ________________________ Use the Universal Rotor Holder 90890 01235 YU 01235 to hold the magneto rotor 3 Remove Magneto rotor CD NOTE ________________________ Remove the magneto rotor using the Rotor Puller 90890 01362 YU 33270 Fully tighten the tool holding bolts but make sure the tool body is parallel with the magneto r...

Page 332: ...ks on each piston head for reference during reinstallation Do not use a hammer to drive the piston pin out CRANKCASE AND CRANKSHAFT 1 Remove Engine brackets CD Crankcase lower NOTE _________________________ Removethe bolts starting with the highest num bered one Loosen each bolt 1 4 turn and remove them after all bolts are loosened Ifthe case halves are tightly stuck together tap lightly on the ta...

Page 333: ...inerals Rust t Remove 3 Measure Cylinder head warpage Out of specification t Resurface Warpage limit 0 03 mm 0 0012 in Straight edge CD Thickness gauge CYLINDER AND PISTON 1 Eliminate Carbon deposits Use a rounded scraper CD NOTE _________________________ Do not use a sharp instrument and avoid damaging or scratching the surface 2 Eliminate Carbon deposits from piston crown and ring grooves 3 Insp...

Page 334: ...allel to and at right angles to the crankshaft Then find the average of the measurements Standard Wear limit Cylinder bore 73 00 73 02 mm 73 10 mm lIe 2 874 2 875 in 2 878 in Taper liT 0 05mm 0 0019 in Out of round 0 01 mm R 0 0004 in C Maximum 0 T Maximum 01 or 02 Maximum 05 or 06 R Maximum 01 03 or 05 Minimum 02 04 or 06 If out of specification replace cylinder and replace piston and piston ring...

Page 335: ...GS 1 Measure Side clearance Out of specification Replace piston and or rings Use a feeler gauge CD NOTE _______________________ Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance I Side clearance 2 Install Piston ring Top 2nd into the cylinder 0 03 0 05 mm 0 001 0 002 in 0 03 0 05 mm 0 001 0 002 in Push the ring with the piston crown NOTE _____...

Page 336: ... 008 0 016 in 0 2 0 4 mm 0 008 0 016 in Outside diameter piston pin Out of specification Replace Outside diameter piston pin 20 0 20 005 mm 0 787 0 788 in 2 Measure Piston pin to piston clearance Out of specification Replace piston Piston pin to piston clearance Bore size piston pin Outside diameter piston pin Piston pin to piston clearance 0 004 0 020 mm 0 00016 0 00079 in http ReadManuals com ...

Page 337: ...ee play Use a dial gauge Out of specification t Replace the defective parts Small end free play 0 8 1 0 mm 0 031 0 039 in 3 Measure Big end side clearance Use a feeler gauge Out of specification t Replace the defective parts Big end side clearance 0 25 0 75 mm 0 010 0 030 in 4 Inspect Crankshaft bearing ill Pitting Damage t Replace Stopper ring Bend Damage t Replace Crankshaft oil seals Wear Damag...

Page 338: ... the grease from the plunger top 4 Measure Minimum pump stroke Out of specification Adjust Minimum pump stroke 0 15 0 2 mm 0 0059 0 0079 in Measurement steps Turn the pumpworm gear j with yourfinger until the plunger top is at its maximum dis tance from the pump body mating surface of the pump cover Using a Feeler Gauge measure the minimum pump stroke between the adjusting plate and the raised bos...

Page 339: ...the plungertop isatits maximum dis tance from the pump body Using a Feeler Gauge measurethe maximum pump stroke If maximum pump stroke is not within the specified limits perform the adjustment steps 6 Adjust Oil pump stroke Adjustment steps Remove the locknut CD spring washer and adjusting plate Adjust the pump stroke by adding or remov ing a shim s Adding shim Pump stroke is increased Removing sh...

Page 340: ... I 5 13 7 Apply Lithium soap base grease to outside of pump pulley Yamaha Bond No 5 ACC 11001 31 00 to mating surface of oil pump cover 8 Install Oil pump cover ill Screw oil pump cover 3 Nm 0 3 m kg 2 2 ft Ib http ReadManuals com ...

Page 341: ...T CD Oil seal Bearing Crank 4 Crank pin Washer Connecting rod j Big end bearing Crank 3 First Labyrinth seal Crank 2 Crank 1 Stopper ring Plain washer Woodruff key Upper crankcase Lower crankcase Yamaha bond No 5 A 13 Nm 1 3 m kg 9 4 ft Ib Final 27 Nm 2 7 m kg 19 ft Ib 5 14 http ReadManuals com ...

Page 342: ... upper crankcase and labyrinth seal into the pin holes of the bearings and upper crankcase by turning the bearings and labyrinth seal At the same time align the bearing punched marks with the crankcase mating surface The oil seal lip must fit into the crankcase groove 3 Apply Yamabond No 5 to mating surfaces of both case halves 4 Install Dowel pins CD 5 Install Lower crankcase CD onto the upper cr...

Page 343: ...ighten Bolts crankcase NOTE _________________________ Tighten the bolts in order starting with the smallest number and torque the bolts in two stages Bolt crankcase First 13 Nm 1 3 m kg 9 4 ft Ib Final 27 Nm 2 7 m kg 19 ft Ib Bolt engine bracket 27 Nm 2 7 m kg 19 ft Ib 7 Apply 2 stroke engine oil to crankpin bearing and oil delivery hole http ReadManuals com ...

Page 344: ...ft Ib First C 20 Nm 2 0 m kg 14 ft Ib Final 28 Nm 2 8 m kg 22 ft Ib A USE NEW ONE First Piston ring Piston pin Piston pin clip Small end bearing Spark plug j Cylinder head Head gasket Cylinder Cylinder gasket B 20 Nm 2 0 m kg 14 ft Ib Final 33 Nm 3 3 m kg 24 ft Ib A USE NEW ONE 5 17 http ReadManuals com ...

Page 345: ...entally drop the pin clip and material into the crankcase Position each piston very carefully in its original place Always use a new piston pin clip Do not allow the clip open ends to meet the piston pin slot 3 Check Piston ring position Make sure ring ends are properly fitted around ring locating pins in piston grooves Be sure to check the manufacturer s marks or numbers stamped on the rings are ...

Page 346: ...ad 20 Nm 2 0 m kg 14 ft Ib Bolt cylinder head 20 Nm 2 0 m kg 14 ft Ib Second step Retighten the nuts CD and bolts X Nut cylinder head 33 Nm 3 3 m kg 24 ft Ib Bolt cylinder head 28 Nm 2 8 m kg 20 ft Ib 4 Tighten Spark plug 28 Nm 2 8 m kg 20 ft Ib Thermostatic valve cover bolt 7 Nm 0 7 m kg 5 1 ft Ib COl MAGNETO Install Woodruff key CD Stator plate Be sure to remove any oil and or grease from the ta...

Page 347: ...tapered portion of the magneto rotor using a dampened cloth with thinner NOTE _________________________ When installing the magneto rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 3 Tighten Magneto rotor nut CD 85 Nm 8 5 m kg 61 ft Ib NOTE ________________________ Use the Universal Rotor Holder 90890 01235 YU 01235 to hold the magneto rotor 4 Install Pickup coil...

Page 348: ...points 1 Install Engine assembly Nuts G engine bracket NOTE ________________________ Install the starter motor bolt and ground lead before installing the engine assembly Before tightening the nut engine bracket rear the sheave distance should be adjusted Nut engine bracket front 40 Nm 4 0 m 0 kg 29 ft 0 Ib 2 Tighten Starter motor bolt 23 Nm 2 3 m 0 kg 17 ft 0 Ib 3 Fill Cooling system see page 2 7 ...

Page 349: ..._O_IL_S_T_AA_T_E_RIENGI I 10 Nm 1 0 mokg 7 2 ftolb 5 22 RECOIL STARTER ill Recoil starter case Starter rope Starter handle Starter spring Sheave drum Drive pawl j Drive plate 10 Nm 1 0 mokg 7 2 ftolb http ReadManuals com ...

Page 350: ...t will not be pulled into the recoil starter case Disassembly 1 Remove Nut CD Spring washer Washer Special washer Drive plate Spring seat Spring f NOTE _________________________ There is a spring drive plate f under the drive plate Care should be taken so that it will not be lost 2 Remove Return spring CD Drive pawl NOTE _________________________ Care should be taken so that the return spring CD w...

Page 351: ... Starter spring CD Inspection 1 Inspect Drive plate CD Cracks Bends Damage Replace Spring drive plate Wear Damage Replace Starter rope Wear Breaks Damage Replace Starter spring Cracks Bends Damage Replace Sheave drum Cracks Damage Replace Drive pawl Return spring j Wear Cracks Damage Replace Assembly and installation 1 Hook the starter spring around the post in the starter case Carefully wind the ...

Page 352: ...inner hook on the starter spring hooks around the post on the sheave drum 5 Apply Grease lightly to pivot point of the drive pawl 1 1 __ I_L_O_W_ _te_m_p_e_ra_t_u_re_9 _r_e_a_s_e____ II I 6 Install Drive pawl CD Return spring NOTE Hook the return spring end to the drive pawl CD Then hook other end of the return spring to the post on the sheave drum 7 Install Spring drive plate Spring seat Drive pl...

Page 353: ...f starter rope from out of the cutout portion in the sheave drum and rotate the sheave drum five times counterclockwise to preload the starterspring Then knot the rope end so that it will not be pulled into the recoil starter case 9 Install Recoil starter Starter handle Bolt recoil starter 10 Nm 1 0 m kg 7 2 ft Ib 10 Check the starter for smooth operation If it does not operate smoothly repair it ...

Page 354: ...CHAPTER 6 COOLING SYSTEM COOLANT FLOW 6 1 COOLING LINE 6 2 COOLING SySTEM 6 3 REMOVAL 6 3 INSPECTION 6 5 INSTALLATION 6 6 http ReadManuals com ...

Page 355: ...4 6 1 COOlANTFlOW ICOOLI I COOLING SYSTEM COOLANT FLOW CD Water pump Coolant filler cap Reservoir tank Heat exchanger A Top view r ru Side view http ReadManuals com ...

Page 356: ...g 5 1 ft Ib 5 5 6 2 COOLING LINE CD Reservoir tank Coolant filler cap Hose joint G Thermo switch Coolant hose Thermostatic valve CD Heat exchanger Bleed screw Water pump cover Impeller Water pump housing Impeller shaft assembly Water pump drive belt http ReadManuals com ...

Page 357: ...oses CD 5 Remove Water pump cover Gasket Impeller NOTE ________________________ Attach the Primary Sheave Holder 90890 01701 YS 01880 to hold the primary sheave The impeller has left hand threads Turn the impeller clockwise to loosen it 6 Remove Water pump housing CD Recoil starter assembly 7 Remove Starter pulley CD NOTE Attach the Universal Clutch Holder 90890 04086 YM 91042 to hold the starter ...

Page 358: ...urn the fuel cock to the close position and plug the fuel hoses so fuel does not run out Spilled fuel can be a fire hazard NOTE ________________________ Remove the screw on the center cover and pull back the fuel tank while lifting up the cover 10 Remove Slide rail suspension see page 4 27 Track see page 4 32 Rivets CD Heat exchangers http ReadManuals com ...

Page 359: ...ing is preset If its accuracy is in doubt always replace it A faulty unit could cause serious overheating or overcooling 2 Inspect Impeller CD Cracks Damage Replace Mechanical seat Water pump drive belt Wear Damage Replace 3 Inspect Bearing Pitting Damage Replace Replacement steps Remove the circlip CD Remove the bearing using a general bearing puller Install the new bearing NOTE _________________...

Page 360: ... Tester G 90890 01325 YU 22460 0 1 to the coolant filler cap ev Apply the specified pressure for 10 seconds and make sure there is no pressure drop INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Tighten Fuel tank nut 10 Nm 1 0 m 0 kg 7 2 ft olb Water pump housing bolt 23 Nm 2 3 m 0 kg 17 ft 0 Ib Impeller 14 Nm 1 4 m 0 kg 10 ft 0 Ib Thermostatic valve cover bolt 7 Nm 0 7 m 0...

Page 361: ...ISASSEMBLY 7 3 INSPECTION 7 5 ASSEMBLY 7 6 FUEL LEVEL ADJUSTMENT 7 8 CARBURETOR FOR EX570 E ST 7 9 REMOVAL EX570 E ST 7 10 DISASSEMBLY 7 11 INSPECTION 7 12 ASSEMBLY 7 13 INSTALLATION 7 14 FUEL LEVEL ADJUSTMENT 7 14 FUEL PUMP 7 15 OPERATION CHECK 7 15 http ReadManuals com ...

Page 362: ...e Jet needle Starter plunger Valve seat assembly Main nozzle Main jet ring j Main jet Pilot jet Pilot screw Float Drain screw Float chamber Throttle stop screw Carburetor switch 2 Nm 0 2 m kg 1 4 ft Ib 3 5 Nm 0 35 m kg 2 5 ft Ib 7 1 3 5 Nm 0 35 m kg 2 5 ft Ib http ReadManuals com ...

Page 363: ...move Throttle cable 3 Loosen Clamp screw CD carburetor joint 4 Remove Starter cable CD 5 Disconnect Fuel delivery hoses CD A WARNING Plug the fuel delivery hoses so that fuel does not run out Spilled fuel can be a fire hazard 6 Remove Carburetor assembly CD 7 Drain Fuel from float chambers http ReadManuals com ...

Page 364: ...lcA I 1 DISASSEMBLV 1 Remove Connecting plate G 2 Remove Connecting plate G 3 Remove Top covers G 4 Loosen Screw G 5 Remove Carburetor switch G T O R S Turn throttle stop screw clockwise Throttle cable holder 7 3 http ReadManuals com ...

Page 365: ...rottle valve assembly CD Inner throttle lever assembly Washer 7 Remove Starter plunger assembly CD 8 Remove Pilot screw CD Spring Washer O ring 9 Remove Float chamber CD 10 Remove Main jet CD Main jet ring Main nozzle Pilot jet 7 4 http ReadManuals com ...

Page 366: ...Fuel passage Contamination Clean NOTE ________________________ Use a petroleum based solvent for cleaning Blowout all passages and jets with compressed air 2 Inspect Rubber seals CD Bearing 3 Inspect Float CD 4 Inspect Valve seat assembly CD Main nozzle Main jet Pilot jet Pilot screw assembly Starter plunger assembly Jet needle http ReadManuals com ...

Page 367: ...t main air jet 0 7 Nm 0 07 m kg 0 51 ft Ib Screw valve seat 1 Nm 0 1 m kg 0 7 ft Ib Pilot jet 0 7 Nm 0 07 m kg 0 51 ft Ib Main jet 0 8 Nm 0 08 m kg 0 58 ft Ib Starter plunger assembly 2 5 Nm 0 25 m kg 1 8 ft Ib 2 Measure Float height Out of specification Adjust Float height 21 3 23 3 mm 0 84 0 92 in Measurement and adjustment steps Hold the carburetor in an upside down posi tion Measure the distan...

Page 368: ...um soap base grease 4 Install Return springs G NOTE _________________________ Hook the spring hooks to the projections on the connecting lever and carburetor body while twisting the spring clockwise approximately 315 degrees Carburetors No 1 No 4 5 Install Connecting plate G lower Connecting plate upper Screw connecting plates 3 5 Nm 0 35 m kg 2 5 ft Ib NOTE Plate the carburetors on a surface plat...

Page 369: ...YM 01312 A CD to the float chamber nozzle NOTE ____________ Use the adapter outside diameter flJ6 hose when attaching the Fuel Level Gauge Loosen the drain screw and start the engine Place the tube along the seam line of the carburetor body Measure the fuel level with gauge If the fuel level is incorrect adjust the fuel level Remove the carburetor Inspect the valve seat and needle valve If either ...

Page 370: ...assembly Pilot jet j Float arm Float Float chamber cover Jet needle Main jet Main jet ring Main nozzle Carburetor switch 2 Nm 0 2 m kg 1 4 ft Ib Il if I J J i er ul 11 n Nm 10 m kg 2 9 It Ibl c tl J U JfQJ V f 0V 6 I 1 r 19 N m 0 9 m k g 6 5 ft lb I 5 I5Nm 0 5 m kg 3 6 ft Ib I Nm lo m O kg o lt O h rv 2Nm 0 2 m kg 1 4 ft Ib 7 9 http ReadManuals com ...

Page 371: ...r cables ill with starter plunger Take care so that the coil spring starter cable adjuster and starter plunger do not fall off or are not lost Also use special care not to scratch the starter plunger surface 3 Disconnect Carburetor switch T O R S leads ill 4 Disconnect Fuel deiivery hoses ill Water hoses A WARNING Turn the fuel cock to the close position and plug the fuel delivery hoses so that fu...

Page 372: ...bly Q Carburetor assembly 7 Drain Fuel 8 Remove Jet needle holder Q Throttle cable end DISASSEMBLY 1 Remove Float chamber cover Q Float pin caps Floats 2 Remove Main jet Q Main jet ring Pilot jet Main nozzle 3 Remove Pin Q Float arm Valve seat assembly Gasket Valve seat plate 7 11 http ReadManuals com ...

Page 373: ...ges and jets with compressed air 2 Inspect Floats CD Damage Replace Main jet Pilot jet Main nozzle Valve seat assembly Air screw Jet needle j Bends Wear Damage Replace Contamination Clean NOTE ________________________ Use a petroleum based solvent for cleaning Blowout all passages and jets with compressed air 3 Inspect Throttle valve Wear Damage Replace 4 Check Throttle valve movement Stick Replac...

Page 374: ... 67 0 75 in Measurement and adjustment steps Hold the carburetor in an upside down posi tion Measure the distance from the carburetor body to the float arm using a gauge NOTE _______________________ Before measurement remove the gasket be tween the carburetor body and float cham ber The float arm should be resting on the valve but not compressing the needle valve Ifthe float arm height is not with...

Page 375: ...ectors Connect the Pocket Tester 90890 03112 YU 03112 leads to the switch leads Loosen the lead wires ill from the holder by opening the clamp Loosen the locknut and turn the T O R S switch counterclockwise until the switch is in the OFF pOSition circuit open Turn the T O R S switch clockwise until the T O R S switch is in the ON position circuit closed Then turn the T O R S switch clock wise 1 2 ...

Page 376: ...de marks on 7 15 the carburetor body Measure the fuel level with gauge If the fuel level is incorrect adjust the fuel level Remove the carburetor Inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by bending the float tang on the float Recheck the fuel level FUEL PUMP OPERATION CHECK 1 Remove Drive V belt guard see page 2 17 Drive V...

Page 377: ...rom the fuel delivery hoses If fuel does not flow out check the fuel cock If no defects are observed on the fuel cock replace the fuel pump assembly To replace the fuel pump assembly perform the following steps from 6 to 7 6 Disconnect Pulser hose G from the crankcase Fuel hose from the fuel tank Fuel delivery hoses to the carburetor A WARNING Plug the fuel hose sothatfuel does not run out of the ...

Page 378: ...TION COIL 8 20 SOURCE COIL 8 20 SPARK PLUG 8 21 THROTTLE OVERRIDE SYSTEM T O R S 8 21 HANDLEBAR SWITCH RIGHT 8 22 CARBURETOR SWITCH 8 23 MAIN SWITCH 8 23 LIGHTING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 27 BULB S 8 28 HEADLIGHT BEAM SWITCH 8 28 SIGNAL SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 TAIL BRAKE LIGHT BULB 8 33 BRAKE LIGHT SWITCH 8 33 LIGHTING COIL I 8 33 THERMO SYST...

Page 379: ...M IELECI_1 ELECTRICAL CIRCUIT DIAGRAM CD OFF ON START l _ B I I I I I I I _ _ l Ir T r i l I BW I Sb H _ i J B R B J Br B Jrvi IJ Y L Y B L B R W G Br W R B Y R R 8 1 Sb L L L L L G R L bR G R Sb http ReadManuals com ...

Page 380: ...Orange Br Brown Sb Gy W BIY B R BfN GIY Sky blue Grey White CIRCUIT DIAGRAM IELEe1_1 Tachometer light Tachometer ill WATER TEMP indicator light Thermo switch WATER TEMP indicator light checker Level gauge light T O R S indicator light Starter relay Starter motor Fuse Battery l Thumb warmer Grip warmer switch Grip warmer Resistor To AC50W output option To voltage regulator option G R Green Red Y B ...

Page 381: ...c model CD Handlebar switch assembly right Handlebar switch assembly left High beam switch Brake light switch Starter motor COl magneto j Pick up coil Stator assembly Stator coil ELECTRICAL COMPONENT IELEC I_I 8 3 http ReadManuals com ...

Page 382: ...ness Grip warmer switch WATER TEMP indicator light checker WATER TEMP indicator light Voltage regulator Ignition coil ELECTRICAL COMPONENT IELEC1 1 J COl unit Battery Starter relay Fuse Resistor Main switch 8 4 http ReadManuals com ...

Page 383: ..._E_C_TR_I_CA_L_S_T _A_RT_I_N_G_S_YS_T_E_M_IELECliiil ELECTRICAL STARTING SYSTEM FOR ELECTRIC MODEL CIRCUIT DIAGRAM For Electric model ill Main switch Starter relay l Starter motor Fuse Battery I I 8 5 http ReadManuals com ...

Page 384: ...ELECTRICAL STARTING SYSTEM IELEC1 1 8 6 http ReadManuals com ...

Page 385: ...ay connector 2 Connect Starter relay connector terminals CD Jumper lead 3 Check Starter motor operation OK NO NO 8 7 l ICheck the battery and connectors OK lNO Charge and or replace the battey Repair and or replace the starter motor A WARNING A wire for the jumper lead CD must have the equivalent capacity as that of the battery lead or more otherwise it may cause the jumper lead to be burned This ...

Page 386: ...tion 8 8 Replace the main switch fuse and or rectifier MAIN SWITCH FOR ELECTRIC MODEL 1 Disconnect Main switch coupler CD 2 Connect Pocket Tester 90890 03112 YU 03112 to main switch coupler 3 Check Main switch continuity Faulty Replace Switch Color code position B B W R W OFF 0 ON START 0 Br R 0 0 0 http ReadManuals com ...

Page 387: ...ion gear Plain washer J Front cover O ring Washer A ARMATURE COIL RESISTANCE 0 016 n 6 at 20 C 6S F B BRUSH WEAR LIMIT S 5 mm 0 33 in C COMMUTATOR WEAR LIMIT 27 mm 1 06 in D MICA UNDERCUT 0 6 0 2 mm 0 024 O OOS in Yoke Armature coil Brush plate Brush Brush spring O ring Washer Rear cover O ring S 9 http ReadManuals com ...

Page 388: ... limit 27 mm 1 06 in 3 Measure Mica CD insulation depth between commutator segments Outofspecification Scrape micato proper limits Use a hacksaw blade that is ground to fit Mica undercut 0 4 0 8 mm 0 016 0 03 in 4 Measure Armature coil resistance insulation continuity Defect s Replace starter motor Inspecting steps Connect the pocket tester for the continuity check CD and the insulation check Meas...

Page 389: ...ing the front and rear covers apply bearing grease to the bearings of the front and rear covers 2 Make sure the rear cover and front cover are fitted with O rings 3 When installing the rear cover assembly take care not to scratch the brushes 4 Install Securing bolts starter motor NOTE ________________________ Align the match marks ill on the bracket with the match marks on the yoke Installation Re...

Page 390: ...ELECTRICAL STARTING SYSTEM IELECI_I 8 12 http ReadManuals com ...

Page 391: ...CHARGING SYSTEM IELECIiiiI CHARGING SYSTEM FOR ELECTRIC MODEL CIRCUIT DIAGRAM For Electric model CDI magneto Fuse Batlery l I I B I I I I I I I I I I I 8 13 http ReadManuals com ...

Page 392: ...CHARGINGSVSTEM IELECI_1 8 14 http ReadManuals com ...

Page 393: ...pm 2 Measure Charging voltage Charging voltage 13 3 14 3 V 3 OOO rpm IOC2DVI 1 I I Never disconnect battery cables while generator is operating or rectifier and regulator will be damaged OK ICorrect connecter 8 15 OUT OF SPECIFICATION Check the battery see page 8 16 ge battery Replace and or char OUT OF SPECIFICATION l ICheck the fuse and charging coil OK JFAULTY Replace the fuse and or charging c...

Page 394: ...d maintenance tips Recharge the battery periodically Store the battery in a cool dry place Recharge the battery before reinstalling Battery Electrolyte Specific gravity 1 280 at 20 C 68 F Initial charging 1 6 Amp for 10 hours rate new battery Recharging 10hours or until specific rate gravity reaches 1 280 Refill fluid Distilled water to maximum level line Refill period Check once per month or more...

Page 395: ...G Main switch COl unit Ignition coil G Spark plug Pickup coil COl magneto j Voltage regulator Throttle switch r r l I 1 t1 1 1 1 I I I I I I I I I I Carburetor switch l ENGINE STOP switch T O R S indicator light 8 17 IELEel iiiI http ReadManuals com ...

Page 396: ...IGNITION SYSTEM IELECI_I 8 18 http ReadManuals com ...

Page 397: ...OP switch throttle switch carburetor switch tether switch and main switch OK Correct connection and or replace CDI unit 8 19 OUT OF SPECIFICATION 1 IRepair or replace the spark plug OUT OF SPECIFICATION 1 IReplace the spark cap OUT OF SPECIFICATION l IReplace the ignition coil FAULTY 1 IReplace the source coil FAULTY Replace the handlebar switch right car buretorswitch tetherswitch and or main swi...

Page 398: ...t tester to ignition coil and spark plug lead 3 Measure 8E061 Primary coil resistance ill Secondary coil resistance Primary coil resistance 0 20 20 at 20 C 68 F Secondary coil resistance 4 9 kQ 20 at 20 C 68 F SOURCE COIL 1 Disconnect CDI magneto lead and coupler Brown Black 2 Connect Pocket tester to CDI magneto lead and coupler 3 Measure Source coil pulser coil resistance Out of specification Re...

Page 399: ...carburetor fails to return to idle when the lever is released A WARNING IfT O R S warning light flashes make sure that thecause ofthe malfunction has been corrected and that the engine can be operated without a problem before restarting the engine Be sure to use the standard spark plug and spark plug cap which have resistance Otherwise T O R S does not work properly FOR EX570 E ST Idle J J Switch ...

Page 400: ...h Throttlle cable Throttle stop screw ON OFF BEDll Run ON OFF RUN L9 Trouble OFF OFF T O R S warning light turns on and off HANDLEBAR SWITCH RIGHT ENGINE STOP switch and throttle switch 1 Disconnect Handlebar switch right coupler CD 2 Connect Pocket tester 90890 03112 YU 03112 3 Check ENGINE STOP switch continuity FaultY Replace Switch position Good condition RUN pull x OFF push 0 0 Continuity x N...

Page 401: ...cket tester 3 Check Carburetor switch continuity Faulty Replace Carburetor switch Good condition position Throttle lever is operated x Throttle lever is not operated 0 0 Continuity x No continuity 8E101 MAIN SWITCH 1 Disconnect Main switch coupler 2 Connect Pocket tester 3 Check Main switch continuity Faulty Replace Switch position Good condition OFF 0 ON x 0 Continuity x No continuity For Electri...

Page 402: ...IGNITION SYSTEM IELECI_1 8 24 http ReadManuals com ...

Page 403: ...DIAGRAM COl magneto j Voltage regulator Headlight beam switch LIGHTING SYSTEM IELECIIiiiiI uHIGH BEAM indicator light Headlight l Tail brake light 8 25 Speedomerter light Tachometer light Level gauge light http ReadManuals com ...

Page 404: ...LIGHTING SYSTEM IELECIiiiI 8 26 http ReadManuals com ...

Page 405: ...L LIGHT AND OR METER LIGHT DO NOT COME ON ICheck the bulb s Check the headlight beam switch and lighting coil JLOK Correct connection and or replace the rectifier regulator 8 27 NO CONTINUITY 1 IReplace the bulb s FAULTY 1 Replace the headlight beam switch and or lighting coil http ReadManuals com ...

Page 406: ...e it is on it will be hot Do nottouch bulb until it cools down Headlight Meter light 3 Check Bulb s Tail brake light Terminal Good condition Q Q 0 Continuity HEADLIGHT BEAM SWITCH 1 Disconnect 0 0 Headlight beam switch coupler 2 Connect Pocket tester to headlight beam switch coupler 3 Check Headlight beam switch continuity FauIty tReplace Switch Good Good position condition condition HI x 0 LO 0 x...

Page 407: ... COl magneto j Voltage regulator j Rectifire regulator Brake light switch Taillbrake light SIGNAL SYSTEM IELECIIiiI WATER TEMP indicator light l Thermo switch WATER TEMP indicator light checker Fuse Battery 1 l I I I I I I I I I I I I I I 8 29 http ReadManuals com ...

Page 408: ...SIGNAL SYSTEM IELEC1 8 30 http ReadManuals com ...

Page 409: ...e tail brake light bulb ICheck the brake light switch OK Check the lighting coil OK I OUT OF SPECIFICATION IReplace the lighting coil Correct connection and or replace the voltage regulator 8 31 NO CONTINUITY 1 IReplace the bulb FAULTY IReplace the brake light switch http ReadManuals com ...

Page 410: ...nection and or replace the rectifier regulator II 8 32 NO CONTINUITY IReplace the bulb s FAULTY IReplace the lighting coil I FAULTY Replace the thermo switch or oil level gauge NOTE _____________________________________ The warning lights come on for a few seconds afterthe engine starts Ifthe lights do not come on check the warning light circuit and bulb s If the lights still do not come on replac...

Page 411: ...witch continuity Faulty Replace 0 0 Switch position Good condition Brake lever is operated 0 Brake lever is not operated x o Continuity x No continuity LIGHTING COIL I 1 Disconnect COl magneto coupler 2 Connect Pocket tester 90890 03112 VS 03112 to COl magneto coupler 3 Measure Lighting coil resistance Out of specification Replace Lighting coil resistance Yellow Black 0 36Q 10 at 20 C 68 F http Re...

Page 412: ...o the thermo switch NOTE ________________________ Set the tester selector to n x 1 position 3 Immerse the thermo switch in coolant and check the thermo switch for operation Coolant Operation temperature Less than The switch is open 9S C 209 F oon 9S C 209 F The switch is closed On or more Temprature gauge Never heat the coolant to a temperature of 120 C 24S 5 F or more 4 If the thermo switch opera...

Page 413: ...GRIP WARMER SVSTE CIRCUIT DIAGRAM M COl magneto Gr p warmer switch Gnp warmer Resister l I I o I I I I I I I I I I I GRIP WARMER SYSTEM IELECIIiiI 8 35 http ReadManuals com ...

Page 414: ...GRIP WARMER SYSTEM IELECIiii I 8 36 http ReadManuals com ...

Page 415: ...O CONTINUITY OK IReplace the resistor i 1Check the grip and thumb warmer NO CONTINUITY OK IReplace the grip warmer INCORRECT 1_C_h_ec_k_t_h_e_g_ri_p_w_a_r_m_e_r_sw_itc_h_ _____ 1 _ n CORRECT 7 1Replace the grip warmer switch Replace the grip warmer coil and or correct connection 8 37 http ReadManuals com ...

Page 416: ...ARMER COIL 1 Disconnect Grip warmer leads ill Thumb warmer leads 2 Connect Pocket tester to grip warmer coil leads and or thumb warmer coil leads 3 Check 8E311 Grip warmer ill continuity Thumb warmer continuity No continuity Replace GRIP WARMER SWITCH 1 Check Grip warmer switch continuity Faulty Replace Switch Color code position Y R Y B LO 0 OFF HI 0 0 Continuity Y L http ReadManuals com ...

Page 417: ... MAINTENANCE SPRCIFICATIONS 9 3 ENGINE 9 3 POWER TRAIN 9 8 CHASSIS 9 12 ElECTRiICAl 9 14 GENERAL TORQUE SPECIFICATIONS 9 16 DEFINITION OF UNITS 9 16 CABLE ROUTJNG 9 17 EX570 EX570SX WIRING DIAGRAM EX570E WIRING DIAGRAM EX570ST WIRING DIAGRAM http ReadManuals com ...

Page 418: ...ort Induction System Piston valve Cylinder Arrangement Forward Inclined Parallel 2 cylinder Displacement 569 cm3 34 7 cu in Bore x Stroke 73 x 68 mm 2 87 x 2 68 in Compression Ratio 6 5 1 6 9 1 Starting System Manual model Recoil Hand Starter Electric model Electric and Recoil Hand Starter Lubrication System Separate Lubrication YAMAHA AUTOLUBE Engine Oil Type YAMALUBE 2 Tank Capacity 3 0 L 2 6 Im...

Page 419: ...uspension Type Slide rail suspension Track Track Type Internal drive type Track Width 381 mm 15 0 in Length on Ground 907 mm 35 7 in I 1 093 mm 43 0 in I907 mm 35 7 in Track Deflection 25 30 mm 0 98 1 18 in 10 kg 22Ib Brake Brake Type Caliper type disc brake Operation Method Handle lever left hand operated Electrical Ignition System Manufacturer CDI MITSUBISHI Generator System Flywheel magneto Bul...

Page 420: ... Ring 2nd Ring EX570 E T I EX570STT I EX570SXT 28 4 29 0 cm3 127 1 27 7 cm3 0 03mm 0 0012 in Lines indicate straight edge measurement Aluminum alloy with dispersion coating 73 00 73 02 mm 2 874 2 875 in 0 01 mm 0 0004 in 0 005 mm 0 0002 in 72 93 72 95 mm 2 871 2 872 in 10 mm 0 39 in 0 070 0 075 mm 0 0028 0 0030 in 0 1 mm 0 004in Keystone B 1 2 mm 0 047 in T 2 7 mm 0 106 in Keystone B 1 2 mm 0 047 ...

Page 421: ...tity VM38 2pcs TM38 2pcs Manufacturer MIKUNI MIKUNI 1 0 Mark l 88R 00l R 88R 00R L 8AYOOl R AYOOR Main Jet M J 310 155 Main Air Jet M A J 02 5 02 5 Pilot Jet P J 42 5 50 Jet Needle J N 6Fl82 3 9El2 3 Pilot Outlet P O 00 8 00 7 Air Screw A S 5 8 1 1 2 Throttle Valve Th V 3 0 3 0 Valve Seat Size V S 01 5 01 5 Starter Jet G S 01 0 00 9 Float Height F H 17 1 19 1 mm 0 67 0 75 in 21 3 23 3 mm 0 84 0 92...

Page 422: ... Coolant Water 3 2 Coolant Capacity 4 2 L 3 7 Imp qt 4 4 US qt 4 6 L 4 05 Imp qt 4 86 US qt EX570ST Reservoir Tank Capacity 0 25 L 0 22 Imp qt 0 26 US qt High Altitude Settings For EX570 E ST 30 C 20 C 10 C O C 10 C 20 C Altitude 22 F 4 F 14 F 32 F 50 F 6 OF I I I I I 320 IN 3rd 0 100 m 0 300 tt 310 STO IN 3rd STO 310 STO IN 3rd STO 100 600 m 300 2 000 tt 600 1 200 m 2 000 4 000 tt 1 200 1 800 m 4...

Page 423: ...S ISPECI 0 1 I 30 C 22 F I 162 5 157 5 152 5 150 147 5 145 IN 2nd I PJ 52 5 AS 1 1 4 EX570 E T I EX570STT I EX570SXT 20 C 10 C O C 10 C 20 C 4 F 14 F 32 F 50 F 6 OF I _L 4 160 157 5 155 STD 152 5 IN 2nd 152 5 IN 2nd 4 150 IN 2nd 150 IN 2nd 4 147 5 IN 2nd 145 IN 2nd 4 142 5 IN 2nd PJ 52 5 AS 1 1 4 9 6 Main jet number IN Jet needle clip position AS Air screw turns out PJ Pilot jet number http ReadMa...

Page 424: ...olts and nuts Final 28 2 8 20 in two stages Nut First 20 2 0 14 Final 33 3 3 24 Spark Plug 28 2 8 20 Thermostatic Valve Cover 7 0 7 5 1 Starter Pully 23 2 3 17 Water Pump Housing 23 2 3 17 Impeller 14 1 4 10 Left Hand threads Oil Pump 7 0 7 5 1 Recoil Starter 10 1 0 7 2 Engine Mounting Nut 40 4 0 29 Carburetor Pilot Jet 1 0 1 0 7 Valve Seat 5 0 5 3 6 Main Jet 2 0 2 1 4 Thermo Switch 28 2 8 20 Cool...

Page 425: ...Number 90501 553G6 90501 521J6 90501 550J8 Color Code White Yellow White Gold Pink Gold White Pink White Outside Diameter 60 mm 2 36 in Wire Diameter 5 5 mm 0 22 in 5 2 mm 0 20 in 5 5 mm 0 22 in Pre load Set Length 25 0 kg 55 1 Ib 30 0 kg 66 Ib Spring Rate 22 5 N mm 14 7 N mm 22 5 N mm 2 25 kg mm 126Ib in 1 5 kg mm 84 Ib in 2 25 kg mm 126Ib in Number of Coils 4 61 5 09 4 62 Free Length 76 5 mm 3 0...

Page 426: ...pper Band Hole Position Front Rear MAINTENANCE SPECIFICATIONS ISPECI 0 1 EX570 E T EX570STT EX570SXT B A 2 8 7 N mm f f 0 89 kg mm 49 8Ib in 4 74 f f 85 05 mm 3 35 in f f 39 37 39 Silent f f 68 f f 18T 17T f 89J 17682 80 89J 17682 70 8AY 17682 70 33T f f 89J 47587 00 f 89A 47587 30 8AY 47110 00 89L 47110 00 8AY 47110 00 381 mm 15 0 in f f 3 072 mm 120 94 in 3 456 mm 136 06 in 3 072 mm 120 94 inl 6...

Page 427: ... 28 5 kg 0 3 mls Rear 35 kg 0 3 mls 32 kg 0 3 mls 39 kg 0 3 mls Slide Runner Thickness 14 8 mm 0 58 in Wear Limit 10 mm 0 40 in Track Sprocket Wheel Material Polyethylene Number of Teeth 9T Rear Guide Wheel Material Aluminum with rubber Outside Diameter 178 mm 7 01 in Brake Pad Thickness 15 5 mm 0 61 in Pad Wear Limit 9 5 mm 0 37 in Disc Outside Diameter 168 mm 6 61 in Disc Thickness 4 mm 0 16 in ...

Page 428: ... 35 Bearing Holder Jackshaft 43 4 3 31 Suspension Wheel 75 7 5 54 Apply LOCTITE Guide Wheel 74 7 4 54 Sliding Frame and Slide Runner 3 0 3 2 2 Slide Rail Suspension Mounting Bolt 68 6 8 49 Rear Pivot Arm and Bracket 68 6 8 49 Shock Absorber and Rear Pivot Arm 42 4 2 30 Apply LOCTITE Rear Pivot Arm and Rod 42 4 2 30 Rear Suspension Bracket and Rod 42 4 2 30 Front Pivot Arm and Sliding Frame 56 5 6 ...

Page 429: ...Compression MAINTENANCE SPECIFICATIONS ISPECI 0 1 EX570 E T EX570STT EX570SXT Aluminum and steel 620 mm 24 4 in Rear Side of Seat 25 4 R Ski 27 0 L Ski 26 7 R Ski 25 L Ski Toe out 0 15mm 0 0 6in 820 mm 71 6 in 2 010 mm 79 1 in 1 820 mm 71 6 in 910 5 mm 35 8 in 970 5 mm 38 2 in 510 7 mm 20 1 in 24 Steel 986 mm 38 8 in 145 mm 5 71 in 1 6 mm 0 06 in 363 mm 14 3 in T S S 150 mm 5 9 in Coil Spring 1 3 ...

Page 430: ... 5 18 Apply LOCTITE Ski Runner 21 2 1 15 Ski 43 4 3 31 Pinch Nut Suspension bracket 21 2 1 15 Set Screw Suspension bracket 2 0 2 1 4 Apply LOCTITE Absorber Holder 10 1 0 7 2 Mounting Nut Shock absorber 5 0 5 3 6 Locknut Shock absorbser 16 1 6 11 Suspension Bracket and Front Arm Lower 43 4 3 31 Suspension Bracket and Front Arm Upper 43 4 3 31 Front Arm Upper and Front Arm Lower 43 4 3 31 Hood 3 0 3...

Page 431: ...turer MITSUBISHI Ignition Coil Model Manufacturer 88R OOIYAMAHA Minimum Spark Gap 9 mm 0 35 in or more at 300 r min Primary Coil Resistance 0 20 20 at 20 C 68 F Secondary Coil Resistance 4 9kO 20 at 20 C 68 F Spark Plug Cap Type Rubber Type Model Manufacturer 81EfTOKAIDENSO Resistance 5 kO 25 at 20 C 68 F Charging System Type Flywheel Magneto Flywheel Magneto Model Manufacturer F4T304 MITSUBISHI C...

Page 432: ...age AC 13 8 14 8V DC 14 0 1S 0V Battery EXS70ER only Specific Gravity 1 280 YB16AL A2 Electric Starter Ststem EXS70ER only Type Bendix type Starter Motor EXS70ER only Model Manufacturer 84N SO NIPPON DENSO Output 0 6kW Armature Coil Resistance 0 013 0 01So at 20 C 68 F Brush Overall Length 12 mm 0 48 in Wear Limit 8 S mm 0 33 in Spring Pressure 6SO 9S0 g 22 9 33 S oz Commutator Diameter 8 mm 1 10 ...

Page 433: ...Components should be at room temperature IA L A Distance across flats ID Outside thread diameter DEFINITION OF UNITS Unit Read A Nut 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm Definition mm Millimeter 10 3 meter cm Centimeter 10 2 meter kg Kilogram 10 3 gram N Newton 1kg x m sec 2 Nm Newton meter Nxm m kg Meter kilogram mxkg Pa Pascal N m 2 N mm Newtons per Millimeter N mm L Liter cm3 Cubic Centimeter r ...

Page 434: ...ose Oil level gauge hose Oil pump assembly EX570ST r I 1 I I Clamp I 1 1 I 1 I 1 L__ Regulator 1 I I I 1 I 1 1 I I _ _ _ _ _ 1 Speedometer cable Band fA Clamp the wire h arness 011 breather hose fuel breather hose and speedometer cable onto the frame pipe Band EX570E I i l l Regulator I 1 1 I I I I I I I I I I I I Ground lead I I I I I I I Battery L I Reg lator j CDI unit 9 17 ___ I I _ _ _ J A ht...

Page 435: ...reather hose Oil breather hose Wire harness j Clamp 20 30 mm O 8 1 2 in Regulator For EX570ST only 9 18 CABLE ROUTING ISPECI 0 1 CD Meter light lead ellBrake cable Band AlClamp the speedometer fuel breather hose oil breather hose and wire harness onto the frame pipe http ReadManuals com ...

Page 436: ...rake cable Starter chock lever Main switch Fuel breather hose Oil breather hose Oil hose Oil pump assembly 9 19 CABLE ROUTING ISPECI 0 1 A Clamp the wire harness oil breather hose fuel breather hose and speedometer cable onto the frame pipe http ReadManuals com ...

Page 437: ...ter cable Fuel breather hose Wire harness ill Clamp 20 30 mm 10 8 1 2 in Regulator 9 20 CABLE ROUTING ISPECI 0 1 CD Meter light lead Sand IAl Clamp the speedometer fuel breather hose oil breather hose and wire harness onto the frame pipe http ReadManuals com ...

Page 438: ...CABLE ROUTING ISPECI 0 1 Fuel cock o CD Fuel pump Fuel hose Thermo switch lead Pulser hose ailpump 9 21 http ReadManuals com ...

Page 439: ... Oil level hose Oil hose Clamp CABLE ROUTING ISPECI 0 1 CD Oil tank r 0 1 I _ I I 4 I Oil filter 9 22 http ReadManuals com ...

Page 440: ...CABLE ROUTING ISPECI 0 1 Fuel hose CD Fuel cock Oil delivery hose Tail brake light lead 9 23 http ReadManuals com ...

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Yamaha 1991-1993 Exciter II - 570, Service Manual

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Summary of Contents for 1991-1993 Exciter II - 570

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