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Yamaha 2012 Grizzly 300, Service Manual

The Yamaha 2012 Grizzly 300 Service Manual is a comprehensive guide essential for owners and enthusiasts. Easily download this manual for free from manualshive.com, ensuring you have all the necessary instructions and maintenance procedures for your Yamaha Grizzly 300 at your fingertips.

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Summary of Contents for 2012 Grizzly 300

Page 1: ... 25 16 Service Manual Pgs 306 LIT116162516 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories YAMAHA MOTOR CORPORATION U S A PRINTED IN U S A BY CRESTEC USA Go to www yamaha motor com sport parts home aspx For a list of Genuine YAMAHA Parts LIT 11616 25 16 ...

Page 2: ...r Corporation U S A First edition September 2011 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A LIT 11616 25 16 YFM30GB ...

Page 3: ...dures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice IMPORTANT INFORMATION WARNING NOTICE TIP This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury ...

Page 4: ...ts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram is provided for removal and disassembly jobs 2 Numbers are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by...

Page 5: ...ply wheel bearing grease Apply lithium soap based grease Apply molybdenum disulfide grease Symbols to in the exploded diagrams indicate where to apply a locking agent and when to install a new part Apply the locking agent LOCTITE Replace GEN INFO SPEC ADJ ENG COOL CARB DRIV CHAS ELEC TRBL SHTG T R G M E B LS M LT New 1 2 3 4 5 6 7 8 9 10 General information Specifications Periodic and adjustments ...

Page 6: ......

Page 7: ...RAL INFORMATION 1 SPECIFICATIONS SPEC 2 ADJUSTMENTS 3 ENGINE ENG 4 COOLING SYSTEM COOL 5 CARBURETOR CARB 6 DRIVE TRAIN DRIV 7 CHASSIS CHAS 8 ELECTRICAL ELEC 9 TROUBLESHOOTING 10 GEN INFO ADJ TRBL SHTG PERIODIC AND CHECKS CHK ...

Page 8: ... NUMBER 1 1 MODEL LABEL 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 9: ...L SPECIFICATIONS 2 13 TIGHTENING TORQUES 2 15 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 17 HOW TO USE THE CONVERSION TABLE 2 19 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 OIL FLOW DIAGRAMS 2 24 CABLE ROUTING 2 25 COOLANT FLOW DIAGRAMS 2 22 ...

Page 10: ...KING THE ENGINE OIL LEVEL CHANGING THE ENGINE OIL CLEANING THE AIR FILTER ELEMENT CLEANING THE SPARK ARRESTER CHECKING THE COOLANT LEVEL CHANGING THE COOLANT CHECK THE COOLANT TEMPERATURE INDICATOR LIGHT CHASSIS CHECKING THE FRONT BRAKE ADJUSTING THE REAR BRAKE LEVER ADJUSTING THE REAR PEDAL POSITION ADJUSTING THE PARKING BRAKE CHECKING THE BRAKE FLUID LEVEL CHECKING THE FRONT BRAKE PADS CHECKING ...

Page 11: ...EAR SHOCK ABSORBERS ADJUSTING THE REAR SHOCK ABSORBER CHECKING THE TIRES CHECKING THE WHEELS CHECKING AND LUBRICATING THE CABLES LUBRICATING THE LEVERS AND PEDALS ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY CHECKING THE FUSES ADJUSTING THE HEADLIGHT BEAM REPLACING A HEADLIGHT BULB 3 42 3 43 3 44 3 44 3 45 3 46 3 47 3 48 3 50 3 50 3 51 3 52 3 52 3 59 3 60 3 61 ...

Page 12: ...CKING THE CAMSHAFT 13 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 12 INSTALLING THE CAMSHAFT AND ROCKER ARMS 14 4 4 4 4 VALVES AND VALVE SPRINGS 15 REMOVING THE VALVES AND VALVE SPRINGS 16 CHECKING THE VALVES AND VALVE SPRINGS 17 INSTALLING THE VALVES AND VALVE SPRINGS 20 4 4 4 4 CYLINDER AND PISTON 22 REMOVING THE PISTON 23 CHECKING THE CYLINDER AND PISTON 23 CHECKING THE PISTON RINGS 25 CHECK...

Page 13: ...MOVING THE PRIMARY SHEAVE 4 36 OIL PUMP 4 47 CHECKING THE OIL PUMP 4 48 INSTALLING THE OIL PUMP 4 49 CRANKCASE AND CRANKSHAFT 4 50 REMOVING THE CRANKSHAFT ASSEMBLY 4 51 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 4 52 CHECKING THE CRANKSHAFT AND CONNECTING ROD 4 52 ASSEMBLING THE CRANKCASE 4 55 INSTALLING THE CRANKSHAFT ASSEMBLY 4 53 TRANSMISSION 4 56 REMOVING THE TRANSFER CASE ASSY 4 58 CHE...

Page 14: ...WATER PUMP REMOVING THE WATER PUMP CHECKING THE WATER PUMP INSTALLING THE WATER PUMP 5 1 5 2 5 3 5 4 5 5 5 5 5 6 5 9 5 9 5 10 6 4 CHAPTER 7 DRIVE TRAIN REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT REMOVING THE REAR AXLE DISASSEMBLING THE FINAL DRIVE GEAR REMOVING THE FINAL DRIVE ROLLER ASSEMBLING THE FINAL DRIVE ROLLER BEARING 7 1 7 4 7 4 7 5 7 5 INSTALLING THE REAR AXLE INSTALLING THE DRIVE SHAFT C...

Page 15: ...ASTER CYLINDER REAR BRAKE MASTER CYLINDER CHECKING THE MASTER CYLINDERS ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ASSEMBLING THE REAR BRAKE MASTER CYLINDER INSTALLING THE FRONT BRAKE MASTER CYLINDER INSTALLING THE REAR BRAKE MASTER CYLINDER STEERING SYSTEM HANDLEBAR REMOVING THE CLUTCH SWITCH REMOVING THE HANDLEBAR GRIPS CHECKING THE HANDLEBAR INSTALLING THE HANDLEBAR INSTALLING THE HANDLEBAR GRI...

Page 16: ...RODS REMOVING THE TIE RODS REMOVING THE FRONT ARMS CHECKING THE FRONT ARMS CHECKING THE FRONT SHOCK ABSORBERS CHECKING THE BALL JOINTS INSTALLING THE FRONT ARMS REAR SHOCK ABSORBER AND SWINGARM REMOVING THE REAR SHOCK ABSORBER CHECKING THE REAR SHOCK ABSORBER REMOVING THE SWINGARM CHECKING THE SWINGARM CHECKING THE RUBBER BOOT 8 41 8 36 8 37 8 37 8 38 8 39 8 40 8 40 8 40 8 39 8 42 8 42 8 42 8 43 8...

Page 17: ... CIRCUIT DIAGRAM STARTING CIRCUIT OPERATION TROUBLESHOOTING STARTER MOTOR CHARGING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING LIGHTING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE LIGHTING SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE SIGNALING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING 9 1 9 2 9 3 9 4 9 4 9 4 9 6 9 6 9 7 9 11 9 11 9 12 9 13 9 15 9 16 9 16 9 17 9 ...

Page 18: ... 10 3 SHIFT PEDAL DOES NOT MOVE 10 3 JUMPS OUT GEAR 10 3 FAULTY CLUTCH 10 3 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE 10 3 CLUTCH SLIPPING 10 3 POOR STARTING PERFORMANCE 10 3 POOR SPEED PERFORMANCE 10 3 OVERHEATING 10 4 OVERHEATING 10 4 FAULTY BRAKE 10 4 POOR BRAKING EFFECT 10 4 SHOCK ABSORBER MALFUNCTION 10 4 MALFUNCTION 10 4 UNSTABLE HANDLING 10 5 UNSTABLE HANDLING 10 5 LIGHTING SYSTEM 10 5 HEAD...

Page 19: ...LE IDENTIFICATION NUMBER The vehicle identification number is stamped into the front side of the frame MODEL LABEL The model label is affixed to the air filter case cover This information will be needed to order spare parts MACHINE IDENTIFICATION 1 1 1 1 1 1 ...

Page 20: ...orrect installation of all parts 5 Keep all parts away from any source of fire REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All ga...

Page 21: ...ly when installing if appro priate Oil seal Do not spin the bearing with compressed air because this will damage the bearing surfaces Bearing CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip make sure the sharp edged corner is positioned opposite the thrust that the circlip rece...

Page 22: ...ctions Loose connection Connect properly If the pin on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure all connections are tight 5 Check continuity with the pocket tester If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores Pocket tester 90890 03112...

Page 23: ...83 3 Weight Slide hammer bolt M5 weight This tool is used to remove the rocker arm shaft 90890 04152 YU A9642 Crankcase separating tool Crankcase separator This tool is used to separate the crankcase 90890 01235 YU 01235 Rotor holding tool This tool is needed to hold the starter puller when removing installing the starter puller bolt or camshaft sprocket bolts This tool is used to remove the pisto...

Page 24: ...PECIAL TOOLS 1 6 90890 04163 YM 04163 Adapter M14xP1 5 M14 x P1 25 This tool is used to install the drive shaft 90890 01404 YM 01404 Flywheel puller These tools are needed to remove the rotor M14xP1 25 90890 01348 YM 01348 This tool is needed when removing or installing the clutch nut Locknut wrench M14xP1 5 M14xP1 25 90890 01288 Spacer These tools are used to install the crankshaft 90890 04164 YM...

Page 25: ...ary for checking ignition timing Compressor 90890 04019 YM 04019 Valve spring compressor This tool is needed to remove and install the valve assemblies 90890 01243 YM 01253 1 Valve spring compressor attachment Valve spring compressor adapter 26 mm This tool is needed to remove and install the valve assemblies 90890 04086 YM 91042 Universal clutch holder This tool is needed to hold the clutch carri...

Page 26: ...used to check the cooling system This tool is used to check the cooling system 90890 01325 YU 24460 01 Adapter 90890 03079 YM 34483 Thickness gauge Narrow gauge set This tool is used to measure the valve clear ance and spark plug gap SPECIAL TOOLS 1 8 90890 01474 90890 01480 YM 01480 90890 01514 YM 01514 YM 01474 Ball joint remover Ball joint remover attachment set Ball joint remover short shaft s...

Page 27: ...n ratio 8 6 1 Standard compression pressure at sea level 12 0 kg cm2 174 0 psi Electric starter Starting system Lubrication system Wet sump Oil type or grade Engine oil Transfer gear oil SAE 90 API GL 5 Hypoid gear oil Final gear oil SAE 80 API GL 4 Hypoid gear oil Oil capacity Engine oil Periodic oil change 1 20 L 1 27 US qt 1 06 Imp qt Periodic oil change 1 20 L 1 27 US qt 1 06 Imp qt Total amou...

Page 28: ... Wet type element Fuel Type Unleaded gasoline only Fuel tank capacity 10 7 L 2 35 lmp gal 2 83 US gal Fuel reserve amount 3 0 L 0 66 Imp gal 0 79 US gal Carburetor Type quantity CVK 32 1 Manufacturer KTW Spark plug Type manufacturer NGK CR8E Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch type Dry centrifugal automatic Chassis Frame type Steel tube frame Caster angle 8 1 Camber angle 2 Kingpin ang...

Page 29: ...ke type operation type operation Dual disc brake Right hand operation Single disc brake Left hand and right foot operation Suspension Front suspension Double wishbone Independent Rear suspension Swingarm Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 151 mm 5 9 in Rear wheel travel 141 mm 5 6 in Halogen bulb Hea...

Page 30: ... 1 1417 1 1457in 28 900 mm 1 1378 in Exhaust A 34 640 34 840 mm 1 3638 1 3655 in 34 540 mm 1 3598 in B 29 000 29 100 mm 1 1417 1 1457in 28 900 mm 1 1484 in Camshaft runout limit m m 3 0 0 0 0012 in Timing chain Timing chain type c i t a m o t u A 92RH2010 100M d o h t e m t n e m t s u j d a n i a h c g n i m i T Rocker arm rocker arm shaft Rocker arm inside diameter 11 982 12 000 mm 0 4717 0 4724...

Page 31: ... 0 0197 0 0354 in EX 0 80 1 20 mm 0 0315 0 0472 in Stem outside diameter IN 4 975 4 990 mm 0 1959 0 1965 in 4 900 mm 0 193 in EX 4 950 4 975 mm 0 1949 0 1959 in 4 900 mm 0 193 in Guide inside diameter IN 5 000 5 012 mm 0 1969 0 1973 in 5 030 mm 0 198 in EX 5 000 5 012 mm 0 1969 0 1973 in 5 030 mm Stem to guide clearance IN 0 010 0 037 mm 0 0004 0 0015 in 0 080 mm 0 003 in EX 0 025 0 062 mm 0 0010 ...

Page 32: ...limit IN m m 0 6 1 5 2 2 5 0 063 in EX m m 0 6 1 5 2 2 5 0 063 in Direction of winding e s i w k c o l c r e t n u o C N I w e i v p o t e s i w k c o l c r e t n u o C X E Outer spring 36 90 mm 40 40 mm 1 59 in N I h t g n e l e e r F 1 45 in 36 90 mm 40 40 mm 1 59 in 1 45 in X E Installed length n i 6 2 1 m m 0 0 2 3 N I d e s o l c e v l a v n i 6 2 1 m m 0 0 2 3 X E Spring rate K1 IN 15 79 N m...

Page 33: ...6 in 0 10 mm 0 004 in 74 975 74 985 mm 2 9518 2 9522 in D e z i s n o t s i P 0 50 mm 0 0197 in t e s f f o n o t s i P e d i s e k a t n I n o i t c e r i d t e s f f O Piston pin bore inside diameter 17 002 17 008 mm 0 6694 0 6696 in 17 020 mm 0 6700 in Piston pin outside diameter 16 994 17 000 mm 0 6690 0 6693 in 16 960 mm 0 6677 in Piston pin to piston pin bore clearance 0 002 0 014 mm 0 0001 ...

Page 34: ...T e p y T Dimensions B T 1 00 2 80 mm 0 039 0 110 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 65 mm 0 026 in e c n a r a e l c e d i S Oil ring Dimensions B T 2 00 2 50 mm 0 079 0 098 in End gap installed 0 20 0 70 mm 0 008 0 028 in Crankshaft 56 00 56 05 mm 2 205 2 207 in A h t d i w k n a r C 1 C t i m i l t u o n u R m m 3 0 0 0 0012 in 2 C m m 3 0 0 0 0012 in Big end side clearance D 0 ...

Page 35: ...mit m m 6 0 0 0 0024 in Drive axle runout limit m m 6 0 0 0 0024 in Main axle assembly width 102 2 102 4 mm 4 02 4 03 in Shifter r a b e d i u g d n a m u r d t f i h S e p y t r e t f i h S Max shift fork guide bar bending m m 5 0 0 0 002 in Air filter oil grade Foam air filter oil or equivalent oil ENGINE SPECIFICATIONS 2 9 ...

Page 36: ... 3 J P t e j t o l i P 8 4 ø 1 P B 1 s s a p y B 4 2 ø S V e z i s t a e s e v l a V 5 9 1 S G 1 t e j r e t r a t S n i 7 6 0 m m 0 7 1 H F t h g i e h t a o l F Oil filter type h s e m e r i W Oil pump d i o h c o r T e p y t p m u p l i O Inner rotor to outer rotor tip cleara m m 0 2 0 n i 9 5 0 0 0 m m 5 1 0 e c n 0 0078 in Outer rotor to oil pump housing clearance 0 150 0 200 mm 0 0059 0 0078...

Page 37: ...l Steel Rim runout limit radial 2 0 mm 0 08 in lateral 2 0 mm 0 08 in 9 x 8AT Fork spring free length 281 0 mm 11 06 in e t a r g n i r p S K 1 K K 2 1 3 0 kg mm 1 8 kg mm Spring free length 295 0 mm 11 61 in Spring rate 2 85 kg mm Front disc brake Type Disc outside diameter thickness Brake disk maximum deflection 0 15 mm 0 006 in 0 04 in 0 04 in 3 00 mm 0 12 in Pad thickness inner 4 7 mm 0 19 in ...

Page 38: ...thickness Brake disk maximum deflection 0 15 mm 0 006 in 0 08 in 0 04 in 3 00 mm 0 12 in Pad thickness inner 4 8 mm 0 19 in DOT 4 30 23 mm 1 19 in 12 70 mm 0 50 in Single cylinder 220 0 mm 4 0 mm Pad thickness outer 4 8 mm 0 19 in Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type 1 00 mm 1 00 mm Item Standard Limit 0 mm 0 in 4 0 7 0 mm 0 16 0 28 in 47 57 mm 1 85 2 2...

Page 39: ...0 MAA0 0000 SHIHLIN Ignition coil Model manufacturer C0510 MAA0 0000 SHIHLIN Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 19 0 23 at 20 C 68 F Secondary winding resistance 2 79 3 41 k at 20 C 68 F Spark plug cap Type Resin Resistance 5 kΩ Charging system Type A C magneto Model manufacturer 31120 RFS 0000 SHIHLIN Nominal output 14 V 375 W at 5 000 r min Charging coil resistance color...

Page 40: ...mm 0 50 in 7 2 8 5 N Brush overall length 0 32 in Spring force 734 866 gf 25 89 30 56 oz 27 mm 28 mm 1 10 in Commutator diameter 1 06 in 0 75 mm 0 03 in Mica undercut Starter relay C585A MAA0 0000 E YANG Model manufacturer 150 A Model manufacturer Coil winding resistance 3 2 4 8 at 20 C 68 F Circuit breakers Fuse Type Amperage for individual circuit Main fuse 30A 1 Item Standard Limit Ω ELECTRICAL...

Page 41: ...er Bolt M7 1 12 1 2 8 7 Spark plug M10 1 12 1 2 8 9 Therm unit M10 1 11 1 1 8 0 Cylinder head Nut M10 4 38 3 8 27 4 Reed valve comp Bolt M6 2 12 1 2 8 7 Bolt M6 2 12 1 2 8 7 Air pipe Stator assy Bolt M6 3 12 1 2 8 7 clutch Bolt M6 3 12 1 2 8 7 Pulse Bolt M5 2 5 0 5 3 6 Crankcase cover L Bolt M6 9 12 1 2 8 7 C D I magneto rotor Nut M14 1 55 5 5 40 0 Engine oil drain bolt Bolt M30 1 15 1 5 10 8 Bolt...

Page 42: ...rt to be tightened Part name Thread size Q ty Tightening torque Remarks Nm m kg ft lb Bolt M6 2 12 1 2 8 7 Change switch Starter motor Bolt M6 1 12 1 2 8 7 Crankcase L Bolt Bolt M6 7 10 1 0 7 2 Muffler Bolt M8 2 25 2 5 18 1 Exhaust pipe Nut M8 2 25 2 5 18 1 Air clean case M6 4 8 0 8 5 8 Bolt M6 2 12 1 2 8 7 Oil pump Bolt M3 2 1 5 0 2 1 1 Crankcase L and R ...

Page 43: ... M8 Parking brake adjusting bolt and locknut Parking brake case and caliper M8 M10 35 3 5 25 3 M10 35 3 5 25 3 Final gear case and swingarm Final gear case and rear axle housing Front arm and frame Steering stem and handlebar holder Front wheel and wheel hub Steering knuckle and brake caliper Front brake disc and wheel hub 60 6 0 43 4 60 6 0 43 4 60 6 0 43 4 Select lever assembly and frame M8 25 2...

Page 44: ... 6 20 3 5 1 18 1 18 1 5 8 Front fender and frame Rear fender and frame Footrest bracket and frame Front bumper and frame Front carrier and frame Front carrier and front bumper Rear carrier and frame Battery holding bracket Footrest board and footrest bracket Rear brake master cylinder and brake pedal bracket Air duct front and frame Air duct rear and frame Fuel tank and frame Fuel tank and fuel co...

Page 45: ... threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 281 1 094 0 39...

Page 46: ...periphery Valve stems intake and exhaust Valve stem ends intake and exhaust Rocker arm shafts intake and exhaust Camshaft Valve rocker arms Oil pump rotors inner and outer and oil pump housing and shaft Starter wheel gear Push rods Clutch housing primary driven gear Push lever shaft Push rod ball Drive axle Main axle Transmission gears inside and end Shift fork guide bar Shift drum Shift shaft E E...

Page 47: ...o p n o i t a c i r b u L Crankcase mating surfaces Sealant Three Bond No 1215 Yamaha bond No 1215 AC magneto lead grommet AC magneto cover Sealant Three Bond No 1215 Yamaha bond No 1215 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ...

Page 48: ...SPEC COOLANT FLOW DIAGRAMS Fan motor Radiator Thermostat COOLANT FLOW DIAGRAMS 1 2 3 1 2 3 A A A 2 22 ...

Page 49: ...SPEC Fan motor Radiator Thermo switch COOLANT FLOW DIAGRAMS 1 2 3 Thermostat 1 2 3 4 4 2 23 ...

Page 50: ...Valve Rocker Arm Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Press In Lubrication Oil Route Con Rod Oil Route Oil Pump Oil Strainer 1 2 3 4 5 6 7 8 9 10 11 OIL FLOW DIAGRAMS 1 2 3 4 5 6 7 8 9 10 11 2 24 ...

Page 51: ...through the guide of the handlebar protector Fuel tank breather hose Choke cable 1 2 Rear brake cable 3 Handlebar switch lead 4 Front brake hose Front brake switch lead 5 6 Throttle cable 7 Parking brake cable 8 A B C Route the rear brake cable through the guide of the handlebar protector Fasten the handlebar switch lead and choke cable with a plastic band D E 2 3 4 6 7 8 5 1 2 3 4 5 6 7 8 A B C D...

Page 52: ... C V inlet tube Reverse indicator light Front brake switch terminals Main switch coupler 15 16 Coolant reservoir breather hose Reserve rubber tube 17 18 19 20 21 7 Taillight lead coupler 8 Positive battery lead Start relay Starter motor lead Fuse boxes Head relay Indicator light terminals 9 10 11 12 13 14 C V T inlet tube 22 23 2 26 B A B E A 1 1 2 3 4 6 7 8 9 10 11 12 13 15 16 5 A C 18 19 20 17 2...

Page 53: ...t controller lead on the wire harness and the negative battery lead with plastic bands A B C Connect the negative battery lead to the battery so that the lead is routed to the side of the battery Connect the positive battery lead to the battery so that the lead contacts the battery case D E Route the A I C V inlet tube and C V T inlet tube through the hole in the front fender F 2 27 B A B E A 1 1 ...

Page 54: ...ube Fuel overflow hose Thermostat terminal 15 16 17 18 19 20 21 7 Throttle cable Rear brake cable Select lever control cable Rear brake switch coupler Carburetor air vent hose Change switch terminals Starter motor lead Negative battery lead 8 9 10 11 12 13 14 Route the front brake hose through the guides on the upper front arms A Fasten the fan motor lead and the heater control switch lead on the ...

Page 55: ...ater control switch lead on the wire harness with plastic bands Fasten the taillight lead on the wire harness with plastic bands Pass these leads through rear fender Fasten the starter motor lead negative battery lead and wire harness with plastic bands C D Fasten the front brake switch lead and change switch lead with plastic bands E F G H I 1 2 3 4 5 6 7 8 9 10 11 12 16 17 18 19 20 21 A B C D D ...

Page 56: ... hose 8 9 10 A I C V rubber tube Negative battery lead A I C V outlet tube A I C V inlet tube A I C V connecting tube 11 12 13 14 Route the choke cable and parking brake cable through the guides on the frame A Fasten the radiator inlet hose with plastic bands Route the front brake hose through the guides on the upper front arms B 2 30 15 C 8 10 7 8 9 10 11 12 13 14 A C D 15 1 2 3 4 5 6 B E F E A B...

Page 57: ...rake cable with plastic bands Route the rear brake hose through the guide on the swingarm D E F Fasten the rear brake hose and parking brake cable with plastic bands G Route the parking brake cable through the guide on the swingarm H 2 31 8 10 7 8 9 10 11 12 13 14 A C D 15 1 2 3 4 5 6 B E F E A B B 12 13 14 A G H ...

Page 58: ... Heater control switch coupler 5 6 Horn switch terminals 7 Rectifier regulator Ignition coil Rectifier regulator wire harness coupler Rear brake cable 8 9 10 11 Route the Front brake hose through the guides on the frame and upper front arms A Insert the couplers on the bracket of the front fender holder B 2 32 B B 1 2 3 4 5 6 7 8 9 A A 10 11 A ...

Page 59: ...od of time the month main tenance intervals should be followed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills INTRODUCTION PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM TIP 3 1 NO ITEM CHECK OR MAINTENANCE JOB INITIAL Whichever comes first month 1 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 1 ...

Page 60: ... and correct if necessary 8 Wheel hub bearings Check for looseness or damage and replace if necessary 9 V belt Check for wear cracks or other damage and re place if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Stabilizer bushes C...

Page 61: ...that could result in serious injury or death month 1 hours 3 6 6 12 20 80 160 160 320 24 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 25 Front and rear brake switches Check operation and correct if necessary 26 Lights and switches Check operation and correct if necessary...

Page 62: ...ack the seat lock lever than pull up on the rear of the seat 2 1 Right side cover 1 Left side cover 3 1 1 Left footrest board 4 5 Right footrest board 1 6 Handle plastics For installation reverse the removal procedure SEAT SIDE COVERS AND FOOTREST BOARDS SEAT FENDERS AND FUEL TANK TIP 3 4 X6 X6 X6 X6 X4 X4 1 2 4 5 3 T R 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib 6 ...

Page 63: ... panel 3 1 Fuel tank cap 4 1 Fuel tank cover 5 1 Front fender 7 1 Handlebar cover 6 For installation reverse the removal procedure SEAT FENDERS AND FUEL TANK Disconnect the main switch coupler Disconnect the headlight couplers and thermo switch coupler 3 5 X2 X4 X2 X2 X2 X2 X2 X2 X2 1 2 3 4 5 6 7 T R 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib T R 25 Nm 2 5 m kg 18 1 ft Ib T R 9 Nm 0 9 m k...

Page 64: ...t the positive lead 1 Battery 4 1 CDI unit 5 1 Shift gear control unit 6 Disconnect 1 Disconnect Disconnect 1 7 8 1 Rear fender 9 SEAT FENDERS AND FUEL TANK 3 6 NOTICE X2 T R 25 Nm 2 5 m kg 18 1 ft Ib X2 T R 9 Nm 0 9 m kg 6 5 ft Ib 1 2 X2 X3 9 3 3 4 5 6 7 8 11 X4 T R 25 Nm 2 5 m kg 18 1 ft Ib X4 T R 9 Nm 0 9 m kg 6 5 ft Ib 12 10 Relay Start relay Seat side covers and footrest boards REAR FENDER AN...

Page 65: ...Clamp 10 1 Air filter case 11 4 Footrest bar 12 SEAT FENDERS AND FUEL TANK For installation reverse the removal procedure X2 T R 25 Nm 2 5 m kg 18 1 ft Ib X2 T R 9 Nm 0 9 m kg 6 5 ft Ib 1 2 X2 X3 9 3 3 4 5 6 7 8 11 X4 T R 25 Nm 2 5 m kg 18 1 ft Ib X4 T R 9 Nm 0 9 m kg 6 5 ft Ib 12 10 ...

Page 66: ... n e f t n o r f t a e S TANK 3 Fuel hose fuel cock side 1 Before disconnecting the fuel hose turn the fuel cock to OFF 1 Fuel tank 4 When installing the fuel tank pass the fuel tank breather hose through the hole in the handlebar protector 1 Fuel tank cap 1 1 Fuel tank shield 2 For installation reverse the removal procedure SEAT FENDERS AND FUEL TANK TIP TIP 1 2 3 5 4 13 Nm 1 3 m kg 9 4 ft Ib 13 ...

Page 67: ...e Top Dead Center TDC on the compression stroke 1 Remove seat front fender fuel tank Refer to SEAT FENDERS AND FUEL TANK 2 Remove A I C V outlet tube 3 Remove breather tube cylinder head side cover 4 Measure valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 08 0 12 mm 0 0031 0 0047 in Exhaust valve 0 13 0 17 mm 0 0051 0 0067 in ADJUSTING THE VALVE CLEARANCE air pipe c...

Page 68: ...r head When the I mark is aligned with the stationary pointer the piston is at the Top Dead Center TDC on the compression stroke When the piston is at the Top Dead Center TDC on the compression stroke there should be clearance between the valve stem looseness tips and their respective adjusting screws Do not turn the bolt in Counterclockwise direction to prevent from camshaft bolt b Insert a thick...

Page 69: ... minutes 3 Attach digital tachometer ADJUSTING THE VALVE CLEARANCE ADJUSTING THE ENGINE IDLING SPEED d Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica tion T R Locknut 9 Nm 0 9 m kg 6 5 ft lb T R Cylinder head cover bolt 12 Nm 1 2 m kg 8 7 ft lb T R Cylinder head cover bolt 12 Nm 1 2 m kg 8 7 ft lb T R Cylinder head side cover bolt 12 Nm 1 2 m kg 8 7 ft lb t...

Page 70: ... adjusting the throttle lever free play 8 Install seat left side cover and right side cover 1 Measure throttle lever free play Out of specification Adjust Direction Idling speed becomes higher Direction Idling speed becomes lower Throttle lever free play 5 10 mm 0 20 0 39 in Throttle lever free play 5 10 mm 0 20 0 39 in ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE THROTTLE LEVER FREE PLAY 1 a b...

Page 71: ... the adjusting bolt in direction or until the correct free play is obtained i Tighten the locknut j Slide the rubber cover to its original posi tion After adjusting the free play turn the han dlebar to the right and left to make sure that the engine idling speed does not increase Direction Free play is increased Direction Free play is decreased Direction Free play is increased Direction Free play ...

Page 72: ...or a beginning rider For proper throttle lever operation do not turn out the adjusting screw more than 12 mm 0 47 in Also always adjust the throt tle lever free play to 5 10 mm 0 20 0 39 in Speed limiter length Less than 12 mm 0 47 in Direction Speed limiter length is decreased Direction Speed limiter length is increased ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle f...

Page 73: ...e brush 7 Measure spark plug gap Use a wire gauge or thickness gauge Out of specification Regap 8 Install spark plug Before installing a spark plug clean the gasket surface and plug surface 9 Install spark plug cap Standard spark plug NGK CR8E 1 Remove seat left side cover Refer to SEAT AND FENDERS 10 Install seat left side cover and right side cover Refer to SEAT AND FENDERS Spark plug gap 0 7 0 ...

Page 74: ... speed b Remove the timing mark accessing screw c Visually check the stationary pointer to verify it is within the required firing range indicated on the AC magneto rotor Incorrect firing range Check the pickup coil assembly d Install the timing mark accessing screw 3 Detach timing light digital tachometer Digital tachometer 90890 06760 YU 39951 B Timing light 90890 03141 Inductive clamp timing li...

Page 75: ...several min utes and then turn it off 4 Disconnect Spark plug cap 5 Remove Spark plug Before removing the spark plug use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinder 6 Install Compression gauge Extension Compression gauge 90890 03081 Engine compression tester YU 33223 Extension 90890 04082 MEASURING THE COMPRESSION PRESSURE...

Page 76: ...compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table Compression pressure standard 1 200 kPa 720 r min 12 2 kgf cm2 174 psi 720 r min Compression pressure maximum 1 400 kPa 720 r min 14 3 kgf cm2 203 psi 720 r min Compression pressure minimum 1000 kPa 720 r min 10 2 kgf cm2 145 psi 720 r min...

Page 77: ...rk Low oil level Add oil to the proper level Wait a few minutes until the oil settles before checking the oil level Do not screw the dipstick in when check ing the oil level Spark plug 12 0 Nm 1 20 m kgf 8 9 ft lbf MEASURING THE COMPRESSION PRESSURE CHECKING THE ENGINE OIL LEVEL 1 1 2 a b 2 Recommended engine oil type YAMALUBE SAE10W 30 SAE10W 40 SAE20W 40 SAE20W 50 or SAE5W 30 Recommended engine ...

Page 78: ...gine oil drain bolt 5 Remove 6 Drain engine oil completely from the crankcase CHECKING THE ENGINE OIL LEVEL CHANGING THE ENGINE OIL Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase 4 Remove dipstick engine oil cap cover 1 2 7 Check O ring Damage Replace engine oil drain bolt along ...

Page 79: ...ended engine oil 10 Install dipstick 11 Start the engine warm it up for several min utes and then turn it off 12 Check engine for engine oil leaks 13 Check engine oil level Refer to CHECKING THE ENGINE OIL Quantity Periodic oil change 1 20 L 1 27 US qt 1 06 Imp qt 14 Install engine oil cap cover ...

Page 80: ... in this hose clean the air filter element and air fil ter case 1 Remove seat Refer to SEAT FENDERS AND FUEL TANK 2 Remove air filter case cover 3 Remove 4 Remove bolt air filter element assembly air filter element cap air filter element air filter element frame CLEANING THE AIR FILTER ELEMENT 1 1 1 2 1 1 2 1 bolt TIP 1 1 2 2 3 3 4 4 ...

Page 81: ...maha foam air filter oil or other quality foam air filter oil d Squeeze out the excess oil The element should be wet but not dripping CLEANING THE AIR FILTER ELEMENT TIP WARNING NOTICE The engine should never be run without the air filter excessive piston and or cylinder wear may result 5 Check air filter element Damage Replace NOTICE 7 Install air filter element assembly air filter element cap ai...

Page 82: ...lpipe and gasket from the muffler c Tap the tailpipe lightly with a soft face ham mer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler d Insert the tailpipe and gasket into the muffler e Install the bolts and tighten it T R 12 Nm 1 2 m kgf 8 7 ft lbf CLEANING THE SPARK ARRESTER 1 2 2 3...

Page 83: ...he engine warm it up for several minutes and then turn it off Check Coolant level Before checking the coolant level wait a few minutes until the coolant has settled Coolant level The coolant level should be between the minimum level mark and maximum level mark Below the minimum level mark Add the recommended coolant to the proper level a b a b CHANGING THE COOLANT 1 Remove front carrier front pane...

Page 84: ...adia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped turn the radiator cap counterclockwise while pressing down on it and then remove it 1 1 6 Remove coolant drain bolt water pump along with the copper washer 7 Drain Coolant 8 Check copper washer coolant drain bolt Damage Replace 9 Install coola...

Page 85: ...ughly wash them with water and con sult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of th...

Page 86: ...vel has dropped after the engine has cooled add sufficient coolant until it re aches the top of the radiator and then install the radiator cap and then rev the engine five times 18 Inspect coolant level Refer to CHECKING THE COOLANT LEVEL Before inspecting the coolant level wait a few minutes until the coolant has settled a a front panel Refer to FRONT CARRIER FRONT BUMPER AND FRONT FENDER coolant...

Page 87: ... Push start switch with transmission in neutral Coolant temperature indicator light comes on momentarily Coolant temperature and electrical circuit are OK Go ahead with riding Coolant temperature indicator light does not come on Coolant temperature indicator light comes on Ask a Yamaha dealer to inspect the electrical circuit CHECK THE COOLANT TEMPERATURE INDICATOR LIGHT ...

Page 88: ...he end of the brake lever 0 mm 0 in CHECKING THE FRONT BRAKE ADJUSTING THE REAR BRAKE LEVER a ADJUSTING THE REAR BRAKE LEVER Proper lever free play is essential to avoid excessive brake drag 1 Measure rear brake lever free play Out of specification Adjust 2 Remove Front brake lever free play 4 7 mm 0 16 0 28 in a seat right side cover right footboard TIP NOTICE a a Before adjusting the rear brake ...

Page 89: ...ake lever free play is obtained c Tighten the locknuts Second step Direction Free play is increased Direction Free play is decreased Direction Free play is increased Direction Free play is decreased First step a Loosen the locknut b Turn the adjuster in or out until the specified rear brake lever free play is obtained c Tighten the locknuts If the free play cannot be adjusted here adjust it at the...

Page 90: ...ff the ground by placing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again ADJUSTING THE REAR PEDAL POSITION ADJUSTING THE REAR PEDAL POSITION 1 Measure rear brake pedal height Out of specification Rear brake pedal height 47 0 57 0 mm 1 85 2 24 in a a Refer to SEAT SIDE COVERS AND FOOTREST BOARDS 2 Remove s...

Page 91: ...erformed lift the rear wheels off the ground by placing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again ADJUSTING THE PARKING BRAKE 1 Check parking brake cable end length Out of specification Adjust Parking brake cable end length 52 56 mm 2 05 2 20 in Parking brake cable end length 52 56 mm 2 05 2 20 in a...

Page 92: ...ter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately In order to ensure a correct reading of the brake fluid level make sure that the top of the brake master cylinder reservoir or brake fluid reservoir is horiz...

Page 93: ...o FRONT AND REAR BRAKES in chapter 6 2 Operate the brake pedal and the rear brake lever Brake pad wear limit 1 0 mm 0 04 in CHECKING THE FRONT BRAKE PADS 1 Remove front wheels Refer to FRONT AND REAR WHEELS in chapter 6 CHECKING THE FRONT BRAKE PADS CHECKING THE REAR BRAKE PADS a a brake pads Wear indicators almost touch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES...

Page 94: ...ffect starts 1 Check rear brake light operation timing Incorrect Adjust 2 Adjust rear brake light operation timing a Hold the main body of the rear brake light switch so that it does not rotate and turn the adjusting nut in direction or until the rear brake light comes on at the proper time Direction Brake light comes on sooner Direction Brake light comes on later ADJUSTING THE REAR BRAKE LIGHT SW...

Page 95: ...pply the front or rear brake 5 Check brake hoses Apply the brake lever or brake pedal several times Fluid leakage Replace the hoses or pipe Refer to FRONT AND REAR BRAKES in chapter 6 6 Install front fender seat Refer to SEAT FENDERS AND FUEL TANK CHECKING THE BRAKE HOSES 1 Remove seat front fender Refer to SEAT FENDERS AND FUEL TANK CHECKING THE BRAKE HOSES 1 2 1 1 1 2 ...

Page 96: ...vel with the recommended brake fluid b Install the diaphragm brake master cylin der reservoir or brake fluid reservoir c Connect a clear plastic hose tightly to the bleed screw Front Rear d Place the other end of the hose into a con tainer e Slowly apply the brake lever or brake pedal several times f Fully squeeze the brake lever or fully depress the brake pedal and hold it in posi tion g Loosen t...

Page 97: ... select lever bring the machine to a complete stop and return the throttle lever to its closed position Other wise the transmission may be damaged 1 Adjust rear brake pedal position Refer to ADJUSTING THE REAR PEDAL POSITION Refer to SEAT SIDE COVERS AND FOOTREST BOARDS 1 2 3 4 5 6 the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake flu...

Page 98: ...ocknuts arrangement that holds the cable to its mount c When the brake begins to work 20 30 mm 0 8 1 2 in verify that the select lever can be shifted to REVERSE from NEUTRAL and to NEUTRAL from REVERSE d Before the brake begins to work 0 20 mm 0 0 8 in verify that the select lever cannot be shifted to REVERSE from NEUTRAL and to NEUTRAL from REVERSE 1 2 a a e Check that locknuts are tightened cor ...

Page 99: ...THESELECT LEVER CONTROL CABLE AND SHIFT ROD 1 1 Select lever shift rod g Make sure the select lever is in NEUTRAL h Loosen both locknuts i Adjust the shift rod length for smooth and correct shifting j Tighten the locknuts 1 1 ...

Page 100: ... gear oil drain bolt 5 Drain transfer gear oil 6 Install transfer gear oil drain bolt TIP 3 Remove right footboard right side cover seat Check the gasket drain bolt If it is damaged replace it with a new one T R 40 Nm 4 0 m kgf 28 9 ft lbf 7 Fill transfer gear case NOTICE _ Take care not to allow foreign material to enter the transfer gear case 8 Install transfer gear filling bolt Total amount 1 3...

Page 101: ...final drive gear oil 5 Install final drive gear oil drain bolt Check the gasket drain bolt If it is damaged replace it with a new one T R 30 Nm 3 0 m kgf 21 7 ft lbf 7 Fill final drive gear case _ Take care not to allow foreign material to enter the final gear case Install Total amount 0 15 L 0 16 US qt 0 13 Imp qt Recommended oil SAE 80 API GL 4 Hypoid gear oil final drive gear filling bolt T R 1...

Page 102: ...r slightly in the opposite direction Tie rod end s have vertical play Replace the tie rod end s 4 Raise the front end of the machine so that there is no weight on the front wheels 5 Check ball joints and or wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bear ings CHECKING THE REAR AXLE BOOT CHECKING THE STEERING SYSTE...

Page 103: ...alculate the toe in using the formula given below g If the toe in is incorrect adjust it Forward 3 Adjust toe in Be sure that both tie rods are turned the same amount If not the machine will drift right or left even though the handlebar is positioned straight This may lead to mis handling and an accident After setting the toe in to specification run the machine slowly for some distance with both h...

Page 104: ... damper rod Bends damage Replace the front rear shock absorber assembly oil leakage Excessive oil leakage Replace the front rear shock absorber assembly cylinder Damage the front rear shock absorber assembly spring Fatigue the front rear shock absorber assembly Refer to FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES and REAR SHOCK ABSORBER AND SWINGARM in chapter 8 3 Check operation Pump the shock...

Page 105: ...juster to increase or decrease the spring preload The spring preload of the rear shock absorber can be adjusted to suit the rider s preference weight and the riding conditions Standard position 2 Minimum Soft position 1 Maximum Hard position 4 ADJUSTING THE REAR SHOCK ABSORBER 1 TIP 1 ...

Page 106: ... cm 3 6 psi 2 Tire pressure below the minimum speci fication could cause the tire to dislodge from the rim under severe riding condi tions The following are minimums Front 27 0 kPa 0 270 kgf cm 4 0 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi 3 Use no more than Front 250 kPa 2 6 kg cm2 36 psi Rear 250 kPa 2 6 kg cm2 36 psi when seating the tire beads Higher pressures may cause the tire to burst Inflate ...

Page 107: ...oper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires 2 Check tire surfaces Wear damage Replace It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Tire wear limit Front and rear 3 0 mm 0 12 in CHECKING THE TIRES 1 a TIP WARNING Cold tire pressure Fron...

Page 108: ...able sheath may cause corro sion and interfere with the cable movement An unsafe condition may result so replace a damaged cable as soon as possible 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate or replace Hold the cable end up and apply several drops of lubricant to the cable 3 Apply Lithium soap based grease onto end of the cable Recommended lubricant Y...

Page 109: ... AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedal Recommended lubricants Brake lever Silicone grease Clutch lever and brake pedal Lithium soap based grease LUBRICATING THE LEVERS AND PEDALS ...

Page 110: ...s or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention This is a sealed battery Never remove the sealing caps because the balance between cells will ...

Page 111: ...harging time at 20 C 68 F Charging time hours These values vary with the temperature the condition of the battery plates and the electrolyte level Open circuit voltage V CHECKING AND CHARGING THE BATTERY TIP Since VRLA Valve Regulated Lead Acid batteries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge ...

Page 112: ...y charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the ba...

Page 113: ...in the following illustration the open circuit voltage of an VRLA Valve Regulated Lead Acid battery stabilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit voltage ...

Page 114: ...harg ing amperage after 5 min utes replace the battery Set the timer to the charging time determined by the open circuit voltage Refer to CHECKING AND CHARGING THE BATTERY If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery un...

Page 115: ...circuit voltage This type of battery charger cannot charge an VRLA battery A variable voltage charger is recommended Set the charging time to a maxi mum of 20 hours Constant amperage chargers are not suitable for charging VRLA batteries Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12...

Page 116: ...lead and then the negative battery lead 8 Check battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate battery terminals 10 Install battery holding plate seat Refer to SEAT FENDERS AND FUEL TANK Recommended lubricant Dielectric grease CHECKING AND CHARGING THE BATTERY 1 2 NOTICE ...

Page 117: ...cket tester to the fuse and check the continuity Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Pocket tester 90890 03112 An...

Page 118: ...ibly cause a fire 4 Install battery cover seat Refer to SEAT FENDERS AND FUEL TANK ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting bolt in direction or Items Amperage rating Q ty Direction Headlight beam is raised Direction Headlight beam is lowered CHECKING THE FUSES ADJUSTING THE HEADLIGHT BEAM a b 1 WARNING Main fuse 30 0 A Fan fuse 10 0 A Ignition fuse 10 0...

Page 119: ... 1 Remove Front carrier Front fender panel Refer to FRONT CARRIER FRONT BUMPER AND FRONT FENDER 2 Disconnect headlight lead coupler 4 Remove headlight bulb holder cover 3 Remove cover REPLACING A HEADLIGHT BULB 1 1 1 5 Remove connector 1 1 1 ...

Page 120: ...e it is on since it will be hot Do not touch the bulb until it cools down Install bulb Secure the new bulb with the headlight unit Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 1 ...

Page 121: ...side covers and footrest boards Front carrier front bumper and front fender Rear fender and air fillter case Fuel tank 1 Air duct assembly 1 1 1 Air duct assembly 2 2 1 A I C V assembly 3 1 Spark plug lead 4 1 1 Muffler 5 6 Exhaust pipe 1 Gasket 7 For installation reverse the removal procedure ENGINE REMOVAL 1 3 4 5 6 7 25 Nm 2 5 m kg 18 1 ft Ib 25 Nm 2 5 m kg 18 1 ft Ib 6 Nm 0 6 m kg 4 3 ft Ib 25...

Page 122: ...overs and footrest boards Front carrier front bumper and front fender Rear fender and air fillter case Fuel tank 1 Select lever shift rod 1 1 AC magneto coupler 2 1 Throttle cable 3 1 Starter cable 4 1 1 Coolant reservoir hose 5 6 Radiator inlet hose 1 Radiator outlet hose 7 For installation reverse the removal procedure ENGINE REMOVAL Disconnect 1 A I C V valve assembly 8 Disconnect Disconnect Di...

Page 123: ...emove the parts in the order listed 1 1 Engine mounting bolt front 1 1 Engine bracket L R 2 1 Engine mounting bolt rear upper 3 1 Engine mounting bolt rear lower 4 1 Engine assembly 5 For installation reverse the removal procedure ENGINE REMOVAL 60 Nm 6 m kg 43 4 ft Ib 1 2 2 3 4 5 60 Nm 6 m kg 43 4 ft Ib 60 Nm 6 m kg 43 4 ft Ib ...

Page 124: ...y tighten the bolts and nuts 2 Tighten Engine mounting nut rear lower side Engine mounting nut rear upper side Engine mounting nut front side Engine bracket bolts front side 40 Nm 4 0 m Engine mounting nut rear lower side 60 Nm 6 0 m kg 43 4 ft lb Engine mounting nut rear upper side 60 Nm 6 0 m kg 43 4 ft lb Engine mounting nut front side 60 Nm 6 0 m kg 43 4 ft lb Engine bracket bolt M10 60 Nm 6 0...

Page 125: ... unit Breather assembly Bolt stopper plate Breather plate Sprocket Cylinder head Cylinder head gasket Timing chain tensioner 1 2 1 1 1 1 1 1 1 1 1 1 1 14 1 15 gasket 1 16 exhaust pipe gasket 1 EBS00218 CYLINDER HEAD For installation reverse the removal procedure T R 38 Nm 3 8 m kg 27 4 ft Ib T R 11 Nm 1 1 m kg 8 0 ft Ib T R 11 Nm 1 1 m kg 8 0 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8...

Page 126: ...HAFT SPROCKET AND THE TIMING CHAIN TENSIONER 1 Remove pipe reed pipe assy cylinder head cover TIP Working in a crisscross pattern loosen e ach nut 1 4 of a turn head cover gasket spark plug therm unit breather assy bolt stopper plate sprocket holding nut sealing washer cylinder head gasket timing chain tensioner breather plate TIP Fasten a safety wire to the timing chain to prevent it from falling...

Page 127: ...urface the cylin der head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times Maximum cylinder he...

Page 128: ...ton is at the Top Dead Center TDC on the compression stroke When the piston is at the Top Dead Center TDC on the compression stroke there should be clearance between the valve stem tips and their respective adjusting screws TIP 1 2 1 2 TIP Tighten the nuts in two stages and a crisscross pattern 1 Install cylinder head gasket holding nut sealing washer sprocket breather plate bolt stopper plate bre...

Page 129: ... a thickness gauge between the adjuster end and the valve end c Turn the adjuster clockwise or counter clockwise with the tappet adjusting tool until the proper clearance is obtained 1 2 3 4 9 1 2 3 c Measure the valve clearance with a thick ness gauge Out of specification Adjust Thickness gauge 90890 03079 Narrow gauge set YM 34483 1 1 ...

Page 130: ...s in the order listed Cylinder head Refer to CYLINDER HEAD 1 Plate 1 4 4 2 Rocker arm shaft 4 3 Locknut 2 1 Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS For installation reverse the removal pro cedure 4 Valve adjusting screw 5 6 Rocker arm Camshaft arms T R 9 Nm 0 9 m kg 6 5 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 131: ...bolt plate 2 Remove intake rocker arm shaft exhaust rocker arm shaft intake rocker arm exhaust rocker arm TIP Slide hammer bolt M5 P N 90890 04158 YM 04158 Weight P N 90890 01084 1 1 2 2 Remove the rocker are shafts with a hammer bolt and weight 1 3 Remove Camshaft comp 1 YU 01083 3 ...

Page 132: ...arm inside diameter 11 982 12 000 mm 0 4717 0 4724 in Limit 12 080mm 0 4756 in 4 Measure rocker arm shaft outside diameter a Out of specification Replace Rocker arm shaft outside diameter 11 996 11 984 mm 0 4723 0 4718 in Limit 11 936 mm 0 4699 in 5 Calculate rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker a...

Page 133: ...t lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake a a a a a 34 880 mm 1 3732 in Limit 34 860 mm 1 3724 in b b b b b 34 740 mm 1 3677 in Limit 34 725 mm 1 3671 in Exhaust 4 Check camshaft oil passage Obstruction Blow out with compressed air a a a a a 34 880 mm 1 3732 in Limit 34 860 mm 1 3724 in b b b b b 34 740 mm 1 3677 in Limit 34 725 mm 1 ...

Page 134: ... mark is aligned with the stationary pointer the piston is at the Top Dead Center TDC on the compression stroke When the piston is at the Top Dead Center TDC on the compression stroke there should be clearance between the valve stem looseness tips and their respective adjusting screws Do not turn the bolt in Counterclockwise direction to prevent from camshaft bolt TIP TIP 1 1 1 1 2 1 1 2 2 1 Lubri...

Page 135: ...o CYLINDER HEAD 1 Rocker arm and rocker arm shaft 8 4 2 Valve cotter 4 3 Valve spring retainer 4 8 Valve stem seal 2 Valve spring seat 4 7 Valve exhaust 4 Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT Refer to INSTALLING THE VALVES AND VALVE SPRINGS For installation reverse the removal pro cedure 6 Valve intake 4 Valve outer spring 5 Valve inner spring 2 1 1 2 2 4 3 4 3 7 8 7 8 5 6 ...

Page 136: ...t into the intake and exhaust ports b Check that the valve seals properly There should be no leakage at the valve seat 1 2 1 2 2 Remove valve cotters TIP Attach a valve spring compressor and attachment between the valve spring retainer and the cylinder head to remove the valve cotters Valve spring compressor P N YM 04019 90890 04019 Valve spring compressor attach ment P N YM 01253 1 90890 01243 1 ...

Page 137: ...ance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 0039 in a 2 Check valve face Pitting wear Grind the face valve stem end Mushroom shape or diameter larger than the body of the stem Replace 3 Measure margin thickness Out of specification Replace Margin thickness Intake 0 50 0 90 mm 0 0197 0 0354 in Exhaust 0 0 0315 0 0472 in...

Page 138: ...t width Out of specification Reface the valve seat a Apply Mechanic s blueing dye Dykem to the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear pattern d Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed e If the valve seat is too wide too narrow or the ...

Page 139: ... clean off all of the compound TIP _ For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the above steps TIP _ After every lapping operation be sure to clean off all of the compound from the valve face and valve seat f Apply Mechanic s blueing dye Dykem to the valve face g Instal...

Page 140: ...uter spring 73 97 103 40 N 7 54 10 54 kg 16 63 23 243 lb Valve spring free length Compressed spring force 11 Measure spring tilt Out of specification Replace Spring tilt limit Inner 2 5 1 60 mm 2 5 0 063 in EBS00241 INSTALLING THE VALVES AND VALVE SPRINGS 1 Apply molybdenum disulfide oil onto the valve stem and valve stem seal 2 Install valve spring seats valve stem seals valves valve springs valv...

Page 141: ...sor and attachment 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood Hitting the valve tip with excessive force could damage the valve Valve spring compressor P N YM 04019 90890 04019 Valve spring compressor attach ment P N YM 01253 1 90890 01243 1 2 NOTICE VALVES AND VALVE SPRINGS ...

Page 142: ...sted Refer to Cylinder head CYLINDER HEAD Refer to 1 Cylinder INSTALLING THE CYLINDER 1 2 Cylinder gasket 2 3 Dowel pin 2 4 Piston pin clip Refer to REMOVING THE PISTON and INSTALLING THE PISTON 1 5 Piston pin 1 6 Piston 1 7 Piston ring set For installation reverse the removal pro cedure ENG CYLINDER AND PISTON 1 1 2 3 3 7 4 6 E E New New 4 New 5 ...

Page 143: ...mer to drive the piston pin out 2 Remove piston rings TIP Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown Piston pin puller set P N YU 01304 90890 01304 EBS00249 CHECKING THE CYLINDER AND PISTON 1 Check piston wall cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure pist...

Page 144: ...he following formula f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set Cylinder bore C 74 995 75 015 mm 2 9526 2 9533 in Taper limit T 0 05 mm 0 002 in Out of round R 0 01 mm 0 0004 in C maximum of D1 D2 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 Piston size P Standard 74 430 75 480 mm 2 9303 2 9...

Page 145: ... with the piston crown 3 Measure piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring side clearance Top ring 0 015 0 055 mm 0 0006 0 0022 in Limit 0 09 mm 0 0035 in 2nd ring 0 015 0 055 mm 0 0006 0 0022 in Limit 0 09 mm 0 0035 in Piston ring...

Page 146: ...mm 0 6691 0 6693 in Limit 16 960 mm 0 6677 in 3 Measure piston pin bore diameter Out of specification Replace the piston 4 Calculate piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Piston pin bore diameter 17 002 17 008 mm 0 6694 0 6696 in Limit 17 020 mm 0 671 in Piston pin to piston pin bore clearance Piston pin bore diameter Piston pin out...

Page 147: ...ing end gaps as shown top ring end upper oil ring rail end expander end lower oil ring rail end 2nd ring end 20 mm 0 79 in 3 Install piston piston pin piston pin clips TIP Apply engine oil onto the piston pin piston rings and piston Be sure that the IN mark on the piston points to the intake side of the engine Before installing the piston pin clips cover the crankcase with a clean rag to prevent t...

Page 148: ...cylinder TIP Install the cylinder with one hand while com pressing the piston rings with the other hand Be careful not to damage the timing chain damper during installation Pass the timing chain through the timing chain cavity CYLINDER AND PISTON NOTICE ...

Page 149: ...onnect the C D I magneto lead coupler For installation reverse the removal pro cedure Removing the C D I magneto C D I magneto rotor Starter clutch assembly Gasket Stator coil assembly Refer to INSTALLING STATOR COIL ASSEMBLY NOTICE 1 2 3 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib 4 New C D I MAGNETO ...

Page 150: ...TOR 1 Remove nut plate washer bolt 2 Remove C D I magneto rotor with flywheel puller Flywheel puller 90890 01404 YM 01404 1 2 EBS00259 EBS00262 CHECKING THE PICKUP COIL STATOR ASSEMBLY 1 Check pickup coil stator assembly Damage Replace 2 1 1 2 1 2 1 1 2 ...

Page 151: ...crankshaft and the magneto rotor hub When installing the magneto rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 2 Tighten nut bolt C D I MAGNETO 55 Nm 5 5 m kg 40 0 ft lb T R Pickup coil EBS00268 1 Install 2 Install TIP Stator assembly 1 2 3 3 2 1 1 1 1 2 Tighten the bolts to secure the stator assembly cable 1 2 4 31 ...

Page 152: ...g the belt drive Crankcase cover Crankcase cover gasket Bearing cover plate Bearing Remove the parts in the order listed 4 1 3 5 2 6 x9 x4 For installation reverse the removal pro cedure 5 6 1 1 Dust seal plate Gasket T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New ...

Page 153: ...E AND V BELT For installation reverse the removal pro cedure Removing the V belt clutch primary and secondary sheave Primary sheave nut Plate washer Primary fixed sheave Clutch housing Secondary sheave nut Washer Secondary sheave assembly V belt Collar Primaryslidingsheave Cam Weight Slider V BELT CLUTCH PRIMARY AND SECONDARY SHEAVE BELT DRIVE 7 T R 55Nm 5 5m kg 39 8ft lb 1 2 7 8 6 9 10 3 4 5 ...

Page 154: ... Refer to REMOVING THE SECONDARY SHEAVE AND V BELT Disassembling the secondary sheave Nut Clutch carrier assembly Spring seat 1 Compression spring Spring seat 2 Guide pin DISASSEMBLING THE SECONDARY SHEAVE BELT DRIVE T R 95Nm 9 5m kg 68 7ft lb 1 3 4 5 7 8 9 10 10 6 7 6 11 LS LS 1 2 3 4 5 6 2 ...

Page 155: ...1 For assembly reverse the disassembly procedure Guide roller Secondary sliding sheave O ring Oil seal Secondary fixed sheave DISASSEMBLING THE SECONDARY SHEAVE BELT DRIVE 7 8 9 10 11 T R 95Nm 9 5m kg 68 7ft lb 1 3 4 5 7 8 9 10 10 6 7 6 11 LS LS 2 ...

Page 156: ...olding the clutch carrier with the rotor full turn with the socket wrench 39 mm Rotor holding tool 90890 01235 YU 01235 Socket wrench 39 mm 90890 01493 YM 01493 Rotor holding tool 90890 01235 YU 01235 BELT DRIVE 1 2 collar primary sliding sheave a 1 holding tool loosen the clutch carrier nut one 2 2 1 a 1 1 2 3 4 3 4 4 5 5 1 2 3 3 1 2 1 2 1 2 1 2 NOTICE While holding the clutch housing with the ro...

Page 157: ...cratches Glaze using coarse sand paper Damage carrier assembly wear Replace the clutch Clutch shoe thickness Limit 3 000mm 0 0181 in TIP Inspect clutch shoes After removing the clutch weight spring do not use them again Replace the all three as a set 3 Remove secondary sheave assembly V belt TIP Remove the V belt and clutch assembly from the primary sheave side 2 2 3 3 2 1 1 1 a 1 1 2 a a a 1 2 3 ...

Page 158: ... fixed sheave Cracks damage wear Replace the pri mary sliding sheave primary fixed sheave and V belt EAS00321 CHECKINGTHE PRIMARY SHEAVEWEIGHTS The following procedure applies to all of the pri mary sheave weights 1 Check primary sheave weight Cracks damage wear Replace 2 Measure primary sheave weight outside diameter Out of specification Replace Primary sheave weight outside di ameter 19 500 20 0...

Page 159: ...ixed and sliding sheaves as a set 2 Check torque cam groove Damage wear Replace the secondary fixed and sliding sheaves as a set 3 Check guide pin Damage wear Replace the secondary fixed and sliding sheaves as a set BELT DRIVE 2 2 1 1 1 1 1 4 Measure Compression spring free length Out of specification Replace Compression spring free length 102 400 mm 4 0315 in Limit 97 400 mm 3 8346 in 1 2 1 2 1 1...

Page 160: ...imary sheave weights TIP Use thinner to clean up grease dirt on the pri mary sliding sheave cam side 2 Install primary sheave weights collar 2 2 3 5 1 1 3 4 5 1 2 3 4 1 2 1 2 3 5 1 2 1 1 2 3 1 2 a a 5 Measure Clutch housing internal diameter Out of specification Replace Clutch housing internal diameter 144 850 145 150 mm 5 7028 5 7146 in Limit 145 450 mm 5 7264 in ...

Page 161: ...ded lubricant BEL RAY assembly lube 2 Install secondary sliding sheave TIP Install the secondary sliding sheave onto the secondary fixed sheave with the oil seal guide Oil seal guide 90890 01384 YM 33299 3 Install guide pin and guide roller 4 Lubricate guide pin groove o ring New with the recommended lubricant Recommended lubricant BEL RAY assembly lube BELT DRIVE 1 1 1 2 2 2 3 3 2 1 1 2 3 1 2 3 N...

Page 162: ...ng and tighten the clutch carrier nut BELT DRIVE EAS00325 INSTALLING THE BELT DRIVE 1 Install V belt clutch assembly Do not allow grease to contact the V belt secondary sheave assembly TIP Install the V belt onto the primary sheave side 1 1 1 3 3 5 5 4 4 2 2 2 1 2 1 2 3 4 5 1 2 3 4 5 NOTICE Clutch spring holder Clutch spring holder arm 90890 01337 YM 33285 90890 01464 YM 33285 6 ...

Page 163: ...ng secondary sheave nut TIP Tighten the secondary sheave nut with the rotor holding tool 4 Position V belt TIP Position the V belt in the primary sheave when the pulley is at its widest position and in the secondary sheave when the pulley is at its narrowest position and make sure the V belt is tight BELT DRIVE 90 Nm 9 0 m kg 65 1 ft lb T R 55 Nm 5 5 m kg 39 8 ft lb T R 1 1 1 3 3 2 2 2 1 2 3 1 2 3...

Page 164: ...ble the parts in the order listed For installation reverse the removal pro cedure Removing the starter clutch Shaft Idle gear Nut Bolt Washer Rotor assembly Starter clutch assembly Starter wheel gear STARTER CLUTCH B LS T R 55 Nm 5 5 m kg 39 8 ft Ib 1 3 4 5 6 7 8 2 T R 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 165: ...r wheel gear idle gear Burrs chips roughness wear Replace 2 Check starter clutch operation a Install the starter wheel gear onto the idle gear and hold the starter clutch b When turning the starter wheel gear clock wise the starter clutch and the starter wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear coun terclockwise it s...

Page 166: ...rotor with the sheave holder tighten the starter clutch bolts Do not allow the shave holder to touch the pro jection on the AC magneto rotor TIP Sheave holder 90890 01701 Primary clutch holder YS 01880 A Starter clutch bolt 30 Nm 3 0 m kg 22 ft lb LOCTITE T R R 1 2 3 starter clutch bolts 1 2 3 ...

Page 167: ... C D I magneto Circlip Oil pump driven sprocket Screw Oil pump housing Dowel pin Roller Inner rotor Outer motor Oil pump body Dowel pin Remove the parts in the order listed Refer to C D I MAGNETO For assembly reverse the disassembly procedure OIL PUMP EBS00315 E 1 2 3 4 5 6 7 8 9 10 T R 1 5 Nm 0 15 m kg 1 1 ft Ib ...

Page 168: ...lear ance oil pump housing to inner rotor and outer rotor clearance Out of specification Replace the oil pump Inner rotor Outer rotor Oil pump housing Inner rotor to outer rotor tip clear ance Limit 0 200mm 0 0079 in Outer rotor to oil pump housing clearance Limit 0 250 mm 0 0098 in Oil pump housing to inner rotor and outer rotor clearance Limit 0 120 mm 0 0047 in OIL PUMP a a b b c c 1 1 1 2 3 1 ...

Page 169: ...ll oil pump assembly oil pump screws After tightening the bolts make sure the oil pump turns smoothly 3 Check oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s OIL PUMP 1 5 Nm 0 15 m kg 1 1 ft lb 1 2 NOTICE 1 2 T R ...

Page 170: ...g the crankshaft assembly Engine Cylinder head Cylinder piston V belt clutch primary Secondary sheave Starter clutch C D I magneto Oil pump Bearing cover plate Change switch assembly Change switch collar Bolt 1 Bolt 2 Left crankcase Timing chain guide Timing chain Crankshaft assembly T 10Nm 1 0m kg 7 2ft lb Refer to INSTALLING THE CRANK SHAFT 2 5 6 4 10 1 3 8 7 9 11 12 E T 10Nm 1 0m kg 7 2ft lb 10...

Page 171: ...o the crankshaft sprocket CRANKCASE AND CRANKSHAFT 1 1 2 Remove crankshaft TIP Remove the crankshaft with the crankcase separating tool Make sure the crankcase separating tool is centered over the crankshaft To protect the end of the crankshaft place an appropriate sized socket between the crankcase separating tool bolt and the Do not tap on the crankcase NOTICE Crankcase separating tool 90890 041...

Page 172: ...t runout 0 100 mm 0 0039 in 2 Measure big end side clearance Out of specification Replace the big end bearing crankshaft pin or connecting rod Big end side clearance 0 600 mm 0 0236 in CRANKCASE AND CRANKSHAFT EAS00207 CHECKINGTHE TIMING CHAIN AND TIMING CHAIN GUIDES 1 Check timing chain Damage stiffness Replace the timing chain 2 Check timing chain guide Damage wear Replace the timing chain guide...

Page 173: ...t of specification Replace the crank shaft Crankshaft width 4 Check crankshaft sprocket Damage wear Replace the crankshaft bearing Cracks damage wear Replace the crankshaft oil pump drive gear Damage wear Replace the crankshaft 1 2 1 2 3 2 3 56 00 56 05 mm 2 205 2 207 in 1 Install balance shaft 1 1 TIP Replace the balance shaft if there are cracks wear or damages ...

Page 174: ... Adapter M14 90890 04163 Adapter YM 04163 Spacer crankshaft installer 90890 04164 YM 04164 Pot spacer YM 91044 Spacer 90890 01288 Pot spacer YU 90059 Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier NOTICE TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other...

Page 175: ...in 4 Tighten crankcase 10 Nm 1 0 m kg 7 2ft lb T R crankcase gasket 1 1 2 1 2 1 1 2 To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil TIP Put the timing chain in parallel into the crankcase Manually rotate the crankshaft to check whether it is tightly engaged with the timing chain if...

Page 176: ...ansfer case 2 Gasket Bolt Bearing 2 Thrust shim Washer Spring Driven cam Bearing housing Remove the parts in the order listed Drain Refer to BELT DRIVE Refer to V BELT CLUTCH PRIMARY AND SECONDARY SHEAVE TRANSMISSION x4 x2 x4 x4 3 4 5 6 7 8 9 1 2 10 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 28 Nm 2 8 m kg 20 3 ft Ib T R 28 Nm 2 8 m kg 20 3 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib New New 15 14 17 18 16 13 12 11 T...

Page 177: ...eal Shaft Driven pinion Shim Circlip Bearing 1 TRANSMISSION For installation reverse the removal pro cedure x4 x2 x4 x4 3 4 5 6 7 8 9 1 2 10 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 28 Nm 2 8 m kg 20 3 ft Ib T R 28 Nm 2 8 m kg 20 3 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib New New 15 14 17 18 16 13 12 11 T R 40 Nm 4 0 m kg 28 9 ft Ib ...

Page 178: ... 2 3 3 4 5 6 7 8 1 Remove bolt 1 bolt 2 transfer case 1 o ring 3 Remove ENG TRANSMISSION 1 Measure shaft runout with a centering device and dial gauge Out of specification Replace the drive axle Shaft runout limit 0 08 mm 0 0031 in 4 x4 x2 2 4 1 2 3 4 5 6 7 8 9 9 x4 1 2 3 4 5 6 7 8 9 bolt bearing housing gasket oil seal shaft driven pinion shim circlip bearing 1 1 2 3 4 5 6 7 8 9 ...

Page 179: ...s 1 Install INSTALLING THE TRANSFER CASE ASSY 2 Install 2 2 bearing 1 circlip shim d shaft riven pinion oil seal housing cap gasket bearing housing bolt bolt 1 2 3 4 5 6 7 8 3 Install o ring transfer case 1 bolt 2 bolt 1 1 1 3 4 4 x4 x2 3 x4 1 2 3 4 5 6 7 8 9 x4 1 2 3 4 5 6 7 8 9 9 driven cam spring washer thrust shim bearing 2 washer cap bolt gasket transfer case 2 bolt 1 2 3 4 5 6 8 7 9 T R 12 N...

Page 180: ...ula 0 1 shim thickness Washer to bore bottom clearance c number of shims required truncated 3 Install Required quantity of shims ADJUSTING THE BEARING 1 SHIM 1 Measure Driven pinion to bearing clearance pitch point to bore bottom clearance specified as 57 8 mm or 2 276 in bearing height specified as 16 0 mm or 0 630 in pitch point to crown clearance specified as 41 5 mm or 1 634 in a b c a b d e f...

Page 181: ... 61 ENG TRANSMISSION 2 Calculate Number of shims with the following formula 0 1 shim thickness Driven pinion to bearing clearance number of shims required truncated 3 Install Required quantity of shims g ...

Page 182: ...rive Secondary sheave Circlip Thrust washer Drive pinion Cover stay Cover plate Dowel pin Gear case gasket Remove the parts in the order listed Drain Refer to BELT DRIVE Refer to V BELT CLUTCH PRIMARY AND SECONDARY SHEAVE TRANSMISSION 1 2 3 6 4 5 7 For installation reverse the removal pro cedure T R 28 Nm 2 8 m kg 20 2 ft Ib x9 New New ...

Page 183: ...1 1 Shift fork guide bar Spring 1 Shift fork 1 Spring 2 Shift fork 2 Shift cam assembly Shift shaft assembly TRANSMISSION Removing the shift cam and shift shaft Remove the parts in the order listed For installation reverse the removal pro cedure 1 2 3 4 5 6 7 G B ...

Page 184: ...ift cam assembly 2 Check Shift fork follower Shift fork pawl Bends damage scoring wear Replace the shift fork 3 Check Shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace Do not attempt to straighten a bent shift fork guide bar CHECKING THE SHIFT CAM ASSEMBLY 1 Check Shift cam groove Damage scratches wear Replace the shift drum assembly Shift cam segment Damage wear ...

Page 185: ...13 14 15 16 17 18 Pinion shim Circlip 1 Bearing 1 Low wheel gear Middle shaft Bearing 2 Bearing 3 Gear hold washer 1 Low pinion gear Collar 1 Gear hold washer 2 Dog clutch 1 Circlip 2 Thrush washer High pinion gear Reverse wheel gear 1 Collar 2 Gear hold washer 3 1 2 3 4 5 6 30 29 28 27 17 7 8 9 1011 13 12 14 15 16 18 19 20 21 22 23 24 25 26 31 32 33 New New New New G G G G G ...

Page 186: ...2 33 Dog clutch 2 Gear hold washer 4 1st wheel gear Collar 3 Gear hold washer 5 Bearing 4 Bearing 5 Idle axle Reverse wheel gear 2 Bearing 6 Counter axle Bearing 7 Oil seal For installation reverse the removal pro cedure 1 1 1 2 3 4 5 6 30 29 28 27 17 7 8 9 1011 13 12 14 15 16 18 19 20 21 22 23 24 25 26 31 32 33 New New New New G G G G G ...

Page 187: ... centering device and dial gauge Out of specification Replace the drive axle Middle shaft runout limit 0 08 mm 0 0031 in 3 Measure idle axle runout with a centering device and dial gauge Out of specification Replace the drive axle Idle axle runout limit 0 08 mm 0 0031 in TRANSMISSION 4 Measure drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle Driv...

Page 188: ...e transmission axle assemblies 7 Check transmission gear movement Rough movement Replace the defec tive part s ADJUSTING THE DRIVE PINION SHIM 1 Measure Shaft axis to coupling surface clearance a a 2 Calculate Number of shims with the following formula b c 0 1 shim thickness number of shims required truncated a b c TIP Shaft be derived from the transfer case 1 as illus trated axis to coupling surf...

Page 189: ...Install Required quantity of shims SELECTING THE FINAL SHAFT CIRCLIP WASHER 1 Install Circlip TIP Coupling surface to bearing clearance can be derived from the mission case as illustrated 2 Measure Drive pinion to circlip clearance with a thckness gauge pitch point to back clearance specified as 43 4 mm or 1 709 in coupling surface to bearing clearance b c d d e e ...

Page 190: ...N 2 3 0 01 YELLOW 2 4 0 01 BLUE 2 5 0 01 RED SPEC 3 Select Suitable wahser using the following table TIP Each size has its corresponding color Thickness gauge 90890 03079 Narrow gauge set YM 34483 1SC E7529 00 1SC E7529 10 1SC E7529 20 1SC E7529 30 1SC E7529 40 ...

Page 191: ... reverse the removal procedure Coolant Drain 1 Coolant reservoir hose 1 Disconnect 2 Rubber tube 1 Disconnect 3 Radiator outlet hose 1 Disconnect 4 Radiator inlet hose 1 Disconnect 5 Radiator 6 Radiator fan 1 Disconnect radiator fan coupler 7 Thermo switch 1 Disconnect thermo switch coupler 1 COOLING SYSTEM RADIATOR RADIATOR COOL T R 13 Nm 1 3 m kg 9 4 ft Ib 28 Nm 2 8 m kg 20 3 ft Ib T R 1 4 2 3 5...

Page 192: ... the specified pressure Replace the radiator cap a Install the radiator cap tester and radiator cap tester adapter to the radiator cap b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 107 9 137 3 kPa 1 079 1 373 kg cm2 15 35 1...

Page 193: ...OL EBS00128 INSTALLING THE RADIATOR 1 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part ...

Page 194: ...Drain Coolant Refer to CHANGING THE COOLANT in CHAPTER 3 1 Radiator inlet hose 1 1 Thermostat cover 2 1 Thermostat 3 For installation reverse the removal procedure Order Job Part Q ty Remarks 5 4 THERMOSTAT THERMOSTAT COOL 1 2 3 T R 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 195: ...Fully open If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause serious overheating or overcooling 2 Inspect Thermostat housing cover Thermostat housing Cracks damage Replace INSTALLING THE THERMOSTAT 1 Install Thermostat Thermostat housing cover 2 Fill Cooling system with the specified amount of the recommended coolant Refer to COOLANT REPLACEMENT in CHAPTER 3 ...

Page 196: ...ight footboard and engine side cover Refer to SEAT SIDE COVERS AND FOOTREST BOARDS in CHAPTER 3 1 Water pump outlet hose 1 1 1 1 2 3 Water pump inlet hos Gasket e 4 Water pump assembly For installation reverse the removal pro cedure Drain Engine oil Refer to CHANGING THE ENGINE OIL in CHAPTER 3 1 2 3 4 T R 12 Nm 1 2 m kg 8 7 ft Ib x9 New ...

Page 197: ...housing cover 1 Gasket 1 Circlip 1 Water pump impeller 1 Washer 1 Water pump seal 1 Water pump shaft 1 Oil seal 1 Bearing 1 Bearing 1 Water pump housing 1 For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 10 11 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New 1 2 3 4 5 6 7 8 9 10 11 New New ...

Page 198: ... Bearing Tap out the bearing from the outside of the water pump housing Water pump housing 1 4 Remove Oil seal Bearing Tap out the bearing and oil seal from the outside of the water pump housing Water pump housing TIP 1 2 3 2 The impeller is provided with left turn thread TIP 3 Remove Water pump seal Tap out the water pump seal the inside of the water pump housing Water pump housing 1 2 1 2 1 2 2 ...

Page 199: ... housing Cracks damage wear Replace 2 Check Water pump seal Oil seal Cracks damage wear Replace Bearing Rough movement Replace 1 2 3 4 1 2 3 4 INSTALLING THE WATER PUMP 1 Install Bearing into the water pump housing 1 Inner bearing puller 2 1 2 3 3 2 Install Bearing into the water pump housing 1 Inner bearing puller 2 3 3 2 1 ...

Page 200: ...al seal installer P N YM 33221 90890 04078 New 1 2 5 Install Water pump shaft Circlip Washer Install the impeller with a pump impeller Do not scratch the impeller shaft TIP Water pump impeller 4 4 1 1 2 2 3 3 Gasket Water pump housing 5 5 6 6 The impeller is provided with left turn thread TIP 3 TIP TIP 3 2 1 Before installing the oil seal apply tap water or coolant onto its outer surface Water pum...

Page 201: ...ose 1 2 Starter cable starter plunger 1 1 1 3 Carburetor assembly 4 Throttle valve cover 1 1 Throttle cable 5 For installation reverse the removal procedure After removing the carburetor assembly remove the throttle cable TIP Order Job Part Q ty Remarks 6 1 CARBURETOR CARBURETOR 1 2 3 4 5 2 CARB Refer to SEAT FENDERS AND FUEL ...

Page 202: ...chamber cover 1 Spring 1 Jet needle holder 1 Jet needle set 1 Piston valve 1 Coasting enricher 1 Float chamber 1 Drain screw 1 Float 1 Refer to CARBURETOR ASSEMBLY Needle valve 1 1 2 3 4 5 6 7 8 9 11 12 10 Order Job Part Q ty Remarks 6 2 CARBURETOR CARBURETOR 1 2 3 4 5 6 7 9 8 10 11 12 15 14 13 16 17 CARB New ...

Page 203: ...et 1 Needle jet 1 Starter jet 1 For assembly reverse the disassembly procedure 13 15 14 16 17 THE CARBURETOR Order Job Part Q ty Remarks 6 3 1 2 3 4 5 6 7 9 8 10 11 12 15 14 13 16 17 CARB New Refer to DISASSEMBLY THE CAR BURETOR AND ASSEMBLY ...

Page 204: ...ETOR 1 Check carburetor body float chamber Cracks damage Replace fuel passages Obstruction Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air float chamber body Dirt Clean float chamber rubber gasket Cracks damage wear Replace 2 Check float Damage Replace 3 Check needle valve Damag...

Page 205: ... chamber cover piston valve spring Cracks damage Replace jet needle main jet needle jet holder pilot jet starter jet Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air needle jet air adjusting screw Except for CAN 7 7 6 Check diaphragm coasting enricher spring cover o ring Cracks damage wear Replace New New ...

Page 206: ...ends cracks damage Replace 10 Check throttle valve movement Sticks Replace 9 Check piston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness Replace the piston valve 8 Check fuel hoses Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air ...

Page 207: ...RETOR TIP Before assembling the carburetor make sure to turn out the pilot air screw the same number of times as noted before disassembly from the seated position to the set position Before assembling the carburetor wash all of the parts in a petroleum based sol vent Always use a new gasket 1 Install needle jet main jet pilot jet NOTICE starter jet air adjusting screw 1 2 3 4 5 1 2 3 4 5 ...

Page 208: ...djust throttle cable free play Throttle cable free play at the flange of the throttle grip 5 10 mm 0 20 0 39 in Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 INSTALLING THE CARBURETOR 1 Install carburetor Align the projection on the carburetor with the slot in the carburetor joint 2 Install throttle cable throttle cable cover TIP ...

Page 209: ...Repeat steps a to f until the fuel level is within specification a EBS00154 MEASURING AND ADJUSTING THE FUEL LEVEL 1 Measure fuel level Out of specification Adjust a Stand the machine on a level surface b Install the fuel level gauge onto the fuel drain pipe c Loosen the fuel drain screw d Hold the fuel level gauge vertically next to the line on the float chamber e Measure the fuel level Fuel leve...

Page 210: ... and drive shaft removal Remove the parts in the order below Final gear oil Drain Rear wheel hubs brake disc Refer to FRONT AND REAR WHEELS 1 Rear axle 1 Disconnect 2 O ring 1 3 Axle gear under protect 1 4 Final drive gear case 1 5 Drive shaft 1 6 Drive shaft spring 1 For installation reverse the removal procedure Refer to REMOVING THE REAR AXLE in CHAPTER 8 ...

Page 211: ...risscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them TIP Order Job Part Q ty Remarks 7 2 DRIV REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT T R 15 Nm 1 5 m kg 10 8 ft Ib T R 30 Nm 3 0 m kg 21 7 ft Ib T R 25 Nm 2 5 m kg 18 1 ft Ib LS LS LS LS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 X6 8 4 18 T R 35 Nm 3 5 m kg 25 3 ft Ib T R 20 Nm 2 0 m kg 14 5 ft Ib New New ...

Page 212: ... ROLLER BEARING Final drive pinion gear stopper For assembly reverse the disassembly procedure Bearing Order Job Part Q ty Remarks 1 1 10 11 12 13 14 15 16 17 18 DRIV REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT 1 T R 15 Nm 1 5 m kg 10 8 ft Ib T R 30 Nm 3 0 m kg 21 7 ft Ib T R 25 Nm 2 5 m kg 18 1 ft Ib LS LS LS LS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 X...

Page 213: ...final drive pinion gear Use a bearing retainer wrench The final drive shaft bearing retainer has left handed threads To loosen the retainer turn it clockwise 2 Remove Final drive pinion gear assembly With a soft hammer lightly tap on the final drive pinion gear end Removal of the final drive pinion gear should only be performed if gear replace ment is necessary Always use new bearings and races Be...

Page 214: ...nion gear The removal of the final drive pinion gear roller bearing is difficult and seldom neces sary 1 Install Roller bearing final drive pinion gear Installation steps Heat the main housing only to 150 C 302 F Install the roller bearing outer race using the proper adapter Install the inner race onto the drive pinion gear 2 Install Oil seal Roller bearing Use a suitable press tool and a press to...

Page 215: ...E SHAFT 1 Check Drive shaft splines Wear damage Replace CHECKING THE FINAL DRIVE GEAR 1 Check Final gear case Bearing housing ring gear Cracks damage Replace TIP When the final gear case and or the ring gear bearing housing are replaced be sure to adjust the shim of the final drive pinion gear and or ring gear 2 Check Gear teeth Pitting galling wear Replace the drive pinion gear and ring gear as a...

Page 216: ...ays use a new bearing The final drive shaft bearing retainer has left hand threads Turn the retainer coun terclockwise to tighten it Bearing retainer wrench P N YM 04050 90890 04050 3 Check Bearings Damage Replace TIP Reusing roller bearings is acceptable but Yamaha recommends installing new ones Do not reuse the oil seal When the final drive pinion gear and or ring gear are replaced be sure to ad...

Page 217: ... 2 Install Drive shaft to the universal joint Lithium soap base grease 3 Install Final drive gear Bolts T R 35 Nm 3 5 m kg 25 3 ft lb LT 1 1 1 2 3 ADJUSTING THE BACKLASH 1 Install Final drive pinion gear shim 1 Use only shims 2 00 mm 0 08 in thick TIP 2 Install Left ring gear shim Right ring gear shim 2 3 Use only shims 1 50 mm 0 06 in thick TIP ...

Page 218: ...klash TIP 6 Remove Dial indicator 7 Rotate Ring gear 120 in direction 9 Measure Backlash 8 Re install Repeat this procedure three times Average the three measurements Replace the shims using the table given on page 7 10 TIP Dial indicator a 1 a Install the dial indicator onto the tip of the ring gear Slightly rotate it back and forth from engagement to engagement to read the backlash 1 1 1 ...

Page 219: ...7 10 DRIV REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT Ring gear shim L Ring gear shim R 0 15 0 28 mm 1 5 mm 1 5 mm Avg 0 25 mm 1 55 mm 1 45 mm Avg 0 15 mm 1 45 mm 1 55 mm Name Size Avg ...

Page 220: ...ly support the machine so there is no danger of it falling over The following procedure applies to both of the front wheels 2 Rubber cap 1 3 Cotter pin 1 Refer to INSTALLING THE WHEEL HUBS 4 Axle nut 1 1 Front wheel 1 Referto INSTALLINGTHEFRONTWHEELS WARNING x4 5 6 7 LS x4 T R 40 Nm 4 0 m kg 28 9 ft Ib 28 Nm 2 8 m kg 20 3 ft Ib New 2 1 3 4 LT 45 Nm 4 5 m kg 32 5 ft Ib T R T R T R 135 Nm 13 5m kg 9...

Page 221: ...ING THE WHEEL HUB BEARINGS to INSTALLING FRONT BRAKE DISCS Do not squeeze the brake lever when the brake caliper is off of the brake discs as the brake pads will be forced shut FRONT AND REAR WHEELS x4 5 6 7 LS x4 T R 40 Nm 4 0 m kg 28 9 ft Ib 28 Nm 2 8 m kg 20 3 ft Ib New 2 1 3 4 LT 45 Nm 4 5 m kg 32 5 ft Ib T R T R TIP T R 135 Nm 13 5m kg 97 6 ft Ib Refer ...

Page 222: ...lies to both of the rear wheels Refer to INSTALLING THE WHEEL HUBS 2 3 Cotter pin 2 2 Rubber cap 2 4 Axle nut 5 Shaft connecter 2 1 Rear wheel 2 Refer to INSTALLING THE REAR WHEELS WARNING 4 2 T R 135 Nm 13 5m kg 97 6 ft Ib T T R 55 Nm 5 5 m kg 40 0 ft Ib 3 New 3 New 2 4 x4 x4 1 5 1 5 T T R 55 Nm 5 5 m kg 40 0 ft Ib x3 T T R 170 Nm 17 0 m kg 123 0 ft Ib T T R 40 Nm 4 0 m kg 28 9 ft Ib 7 8 New 6 x2...

Page 223: ... is off of the brake discs as the brake pads will be forced shut Refer to INSTALLING THE REAR BRAKE DISC 9 Brake disc brake disc bracket 1 1 TIP 4 2 T R 135 Nm 13 5m kg 97 6 ft Ib T T R 55 Nm 5 5 m kg 40 0 ft Ib 3 New 3 New 2 4 x4 x4 1 5 1 5 T T R 55 Nm 5 5 m kg 40 0 ft Ib x3 T T R 170 Nm 17 0 m kg 123 0 ft Ib T T R 40 Nm 4 0 m kg 28 9 ft Ib 7 8 New 6 x2 9 LT LT T R 28 Nm 2 8 m kg 20 3 ft Ib T R 1...

Page 224: ...replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulting in machine damage and possible operator injury Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in CHECKING THE WHEEL HUBS The following procedure applies to both of the front and rear wheel hubs 1 Check wheel hub Cracks damage Replace 1 1 1 2 3 1 2...

Page 225: ...place a Clean wheel hub exterior b Drive bearing out by pushing spacer aside and tapping around perimeter of bearing inner race Use soft metal drift punch and hammer The spacer floats between bearings Remove both bearings as described 1 1 CHECKING THE BRAKE DISCS 1 Check brake discs Galling damage Replace 2 Measure brake disc deflection Out of specification Replace brake disc thickness Out of spec...

Page 226: ... A B Front Rear 2 1 Install rear brake disc Install the conical spring washer with the con vex side of the washer facing inward as shown conical spring washer 1 2 nut 3 2 Tighten nut Axle nut wrench 46 90890 01498 YM 37134 1 2 1 TIP TIP 8 7 Tighten the nut with axle nut wrench 46 or axle nut wrench 46 mm to specification while holding the rear axle 2 T R 170 Nm 17 0m kg 123 ft Ib Axle nut wrench 4...

Page 227: ... Rear wheel hub T R 135 Nm 13 5 m kg 97 6 ft lb T R 80 Nm 8 0 m kg 57 9 ft lb 1 2 New 1 2 INSTALLING THE FRONT WHEEL HUB BEARINGS 1 Install bearings Face the oil seal side of the bearing inward 1 INSTALLING THE WHEELS 1 Install wheels The arrow mark on the must point in the direction of rotation of the wheel 2 Tighten nuts Tapered wheel nuts are used for both the front and rear wheels Install each...

Page 228: ... in the order listed Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake caliper assembly 1 For installation reverse the removal procedure Refer to INSTALLING THE REAR BRAKE CALIPER 8 9 3 4 T R 30 Nm 3 0 m kg 21 7 ft Ib 1 2 New T R 28 Nm 2 8 m kg 20 3 ft Ib ...

Page 229: ...FRONT AND REAR BRAKES Order Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed 1 Brake pad 2 2 Brake pad spring 1 For installation reverse the removal procedure 8 10 1 2 ...

Page 230: ... BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Refer to REMOVING THE PARKING BRAKE CABLE 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake caliper assembly 1 5 Parking brake cable 1 For installation reverse the removal procedure Refer to INSTALLING THE REAR BRAKE CALIPER 8 11 T R 30 Nm 3 0 m kg 21 7 ft Ib T R 28 Nm 2 8 m kg 20 3 ft Ib 1 2 New 3 4 5 ...

Page 231: ...embly reverse the disassembly procedure Disassembling the rear brake cali per Adjusting bolt 1 Brake pad 2 Brake pad spring 1 Caliper bracket 1 Bleed screw 1 T R 25 Nm 2 5m kg 18 1ft Ib 8 12 1 2 3 4 5 T R 8 Nm 0 8m kg 6 5ft Ib FRONT AND REAR BRAKES CHAS 1 5 4 2 3 1 2 3 4 5 ...

Page 232: ...damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air Replace the caliper piston seal and dust seal whenever the brake caliper is disas sembled 1 1 CHAS FRONT AND REAR BRAKES A A B Front brake caliper Rear brake caliper REMOVING THE PARKING BRAKE CABLE 1 Loosen nut adjusting bolt 2 Disconnect parking brake cable from parking brake lever 3 Disconnect p...

Page 233: ...ALLING THE BRAKE CALIPER 1 Install brake caliper assembly brake caliper mounting bolts brake hose copper washers union bolt Brake caliper mounting bolt 28 Nm 2 8 m kg 20 3 ft lb Union bolt 28 Nm 2 8 m kg 20 3 ft lb 1 2 3 FRONT AND REAR BRAKES A B Front Rear B 2 3 A 2 Check parking brake arm to parking brake bracket distance Out of specification Adjust Parking brake arm to parking brake bracket dis...

Page 234: ...id allow brake fluid to come in contact with the eyes as this may cause eye injury splash brake fluid onto painted surfaces or plastic parts as this may cause damage disconnect any hydraulic connection as this would require the entire brake system to be disassembled drained cleaned properly filled and bled after reassembly Use only the designated quality brake fluid other brake fluids may deterior...

Page 235: ...he brake caliper bleed screw d Install a new brake pad spring and new brake pads 3 Install brake caliper brake caliper mounting bolts 4 Check brake fluid level Refer to CHECKING THE FRONT BRAKE FLUID LEVEL in chapter 3 Brake caliper mounting bolt 28 Nm 2 8 m kg 20 3 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib a REPLACING THE FRONT BRAKE PADS It is not necessary to disassemble the brake caliper and brake hos...

Page 236: ...ghten the brake caliper bleed screw d Install a new brake pad spring and new brake pads 3 Install brake caliper brake caliper mounting bolts 4 Check brake fluid level Refer to CHECKING THE REAR BRAKE FLUID LEVEL in chapter 3 Brake caliper mounting bolt 28 Nm 2 8 m kg 20 3 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib REPLACING THE REAR BRAKE PADS It is not necessary to disassemble the brake caliper and brake ...

Page 237: ...ap 2 Brake fluid reservoir diaphragm 3 Front brake light switch 1 1 1 1 Brake lever 4 1 Union bolt 5 2 Copper washer 6 t c e n n o c s i D 1 1 Brake hose 7 8 Parking brake lever 1 9 Brake master cylinder For installation reverse the removal procedure Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER FRONT AND REAR BRAKES 8 18 1 2 13 Nm 1 3 m kg 9 4 ft Ib T R 3 4 LS New 5 6 7 8 9 28 Nm 2 8 m kg 2...

Page 238: ...Order Job Part Q ty Remarks Disassembling the front brake master cylinder Remove the parts in the order listed 1 Brake master cylinder kit For assembly reverse the disassembly procedure FRONT AND REAR BRAKES 1 1 ...

Page 239: ...the order listed Rihgt foot portector Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 1 2 1 3 1 4 1 5 1 6 1 Rear brake cable Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose ...

Page 240: ... 2 9 Brake hose 1 10 Brake master cylinder 1 11 Control cable 1 12 Rear brake light switch spring 1 1 1 13 Brake master cylinder arm spring 1 2 14 Brake pedal 1 15 Master cylinder holder 1 16 Axle fixed 1 For installation reverse the removal procedure Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER ...

Page 241: ... Q ty Remarks Disassembling the rear brake master cylinder Remove the parts in the order listed 1 Brake master cylinder kit For assembly reverse the disassembly procedure FRONT AND REAR BRAKES T R 17 Nm 1 7 m kg 12 3 ft Ib 1 1 ...

Page 242: ...assage brake master cylinder body Blockage Blow out with compressed air Front Rear 2 Check brake master cylinder kit Scratches wear damage Replace as a set Front Rear 3 Check front brake master cylinder reservoir front brake master cylinder reservoir dia phragm Cracks damage Replace 4 Check rear brake fluid reservoir rear brake fluid reservoir diaphragm Cracks damage Replace FRONT AND REAR BRAKES ...

Page 243: ...ts should be cleaned and lubricated with new brake fluid only before installation Whenever a master cylinder is disassem bled replace the piston seals and dust seals 1 Install brake master cylinder kit nut joint Turn the adjusting bolt until the clearance is within the specified limits when install the joint Recommended brake fluid DOT 4 Recommended brake fluid DOT 4 Clearance 5 2 6 2 mm 0 20 0 24...

Page 244: ...hose as shown Turn the handlebar to the left and to the right to check that the brake hose does not touch other parts throttle cable wire harness leads etc Correct if necessary Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in chapter 2 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection as sh...

Page 245: ...m ful reaction and lead to poor brake perfor mance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 4 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Brake fluid level is under the LOWER level line Add the recommend...

Page 246: ... Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in chapter 2 2 Install brake fluid reservoir hose 3 Fill brake fluid reservoir Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately Union bolt 28 Nm 2 8 m kg 20 3 ft lb Recommended brake fluid DOT 4 FRONT AND REAR BRAKES 1 2 a b a b 8 27 1 2 1 WARNING ...

Page 247: ...performance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 4 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Brake fluid level is under the LOWER level line Add the recommended brake fluid to the proper level Refe...

Page 248: ...BAR GRIPS and INSTALLING THE HAN DLEBAR GRIPS 4 Rear brake cable 2 5 Rear brake lever assembly 1 Refer to INSTALLING THE REAR BRAKE LEVER ASSEMBLY 1 Refer to INSTALLING THE THROTTLE LEVER ASSEMBLY 7 Throttle lever assembly 6 Throttle cable 1 3 Handlebar switch 1 2 Choke cable 1 8 29 13 12 LS LS LS T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 25 Nm 2 5 m...

Page 249: ...ANDLEBAR For installation reverse the removal pro cedure 14 Upper handlebar holder 1 15 Handlebar 1 16 Lower handlebar holder 1 Fasten the choke cable and handlebar switch lead 13 Plastic band 1 Fasten the front brake switch 8 Front brake switch 1 9 Parking brake cable 1 8 30 13 12 LS LS LS T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 25 Nm 2 5 m kg 18 ...

Page 250: ... the grip off the handlebar REMOVING THE REAR BRAKE SWITCH 1 Remove rear brake switch Push the fastener when removing the rear brake switch out of the rear brake lever holder CHECKING THE HANDLEBAR 1 Check handlebar Bends cracks damage Replace Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar TIP TIP WARNING 8 31 ...

Page 251: ...lebar holder and then tighten the bolt on the front side T R 25 Nm 2 5 m kg 18 1 ft lb 4 5 6 5 6 3 4 1 2 3 INSTALLING THE HANDLEBAR GRIPS 1 Install handlebar grips rear brake lever Before applying the adhesive wipe off grease or oil on the handlebar surface with a lac quer thinner Install the handlebar grips so that the L arrow on the left grip and R arrow on the right grip are placed vertically 1...

Page 252: ...ease align the 5 3 4 1 2 Rear brake lever 13 Nm 1 3 m kg 9 4 ft lb Throttle lever assembly 2 Adjust rear brake lever Refer to ADJUSTING THE REAR BRAKE LEVER in chapter 3 8 Nm 0 8 m kg 5 8 ft lb a 1 Install throttle lever assembly Installing the throttle lever assembly make sure the clearance the throttle lever assembly and handlebar grip Install the throttle lever assembly please align the punch m...

Page 253: ...e damper parking brake lever plate Brake master cylinder Align the holder plate on the handlebar with the align position of the parking brake lever 2 Adjust parking brake Refer to ADJUSTING THE PARKING BRAKE in chapter 3 4 5 3 1 2 a b Throttle lever assembly 13 Nm 1 3 m kg 9 4 ft lb TIP 8 34 a b 2 4 3 1 5 ...

Page 254: ...r 3 Handlebar Refer to HANDLEBAR 1 Lock washer 1 Refer to INSTALLING THE LOCK WASHER 2 Bracket 1 3 Steering stem bushing 2 4 Collar 2 6 Steering stem 1 5 Oil seal 2 Refer to INSTALLING THE STEERING STEM For installation reverse the removal pro cedure T R 25 Nm 2 5 m kg 18 1 ft Ib 1 New T R 55 Nm 5 5 m kg 39 8 ft Ib New New New 2 3 4 5 5 3 New LS LS 6 T R 35 Nm 3 5 m kg 25 3 ft Ib 8 35 New New ...

Page 255: ...ach tie rod end nut hold the tie rod ball joint with a 14 mm wrench CHECKING THE STEERING STEM 1 Check steering stem Bends Replace Do not attempt to straighten a bent stem this may dangerously weaken the stem 2 Check steering stem bushings oil seal Wear damage Replace 2 1 8 36 TIP WARNING ...

Page 256: ...2 When tightening each tie rod end nut 2 hold the tie rod ball joint with a 14 mm wrench 3 INSTALLING THE LOCK WASHER 1 Install lock washer 1 bolts 2 Bend the lock washer tab along a flat side of the bolt T R 55 Nm 5 5 m kg 39 8 ft lb T R 35 Nm 3 5 m kg 25 3 ft lb New T R 25 Nm 2 5 m kg 18 1 ft lb TIP ...

Page 257: ...Refer to INSTALLING THE TIE RODS 4 Lower front arm 1 2 Front brake hose 1 1 Brake disc guard 1 5 Upper front arm 1 6 Steering knuckle 1 Refer to REMOVING THE STEERING KNUCKLES For installation reverse the removal procedure STEERING SYSTEM Front brakes 8 38 3 4 5 6 New 1 2 New T R 35 Nm 3 5 m kg 25 3 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib T R 45 Nm 4 5 m kg 32 5 ft Ib New T R 35 Nm 3 5 m kg 25 3 ft Ib...

Page 258: ...ckles 8 39 TIP TIP Attatch the ball joint remover attatchment set short set and new ball joint with rubber boot and retaining ring 7 to the steering knuckle 8 Always use a new ball joint set Do not tap or damage the top of the ball joint Ball joint remover 90890 01474 Ball joint remover attatchment set 90890 01480 Ball joint adapter set YM 01480 Ball joint remover short shaft set 90890 01514 YM 01...

Page 259: ... Adjust toe in Refer to ADJUSTING THE TOE IN in chapter 3 T R 35 Nm 3 5 m kg 25 3 ft lb STEERING SYSTEM 1 1 2 8 40 TIP CHECKING THE TIE RODS The following procedure applies to both of the tie rods 1 Check tie rod free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 2 Check tie rod Bends damage Replace CHECKING THE STEERING KNUCKLES The following procedure ...

Page 260: ...ont arm 1 4 Upper front arm 1 6 Steering knuckle FRONT ARMS AND FRONT SHOCK ABSORBER Front brakes 5 Front shock absorber Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS 1 1 7 Bush 4 For installation reverse the removal procedure ASSEMBLIES 1 Brake disc guard 1 2 3 4 6 1 T R 45 Nm 4 5 m kg 32 5 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib 5 New New New T R 35 Nm 3 5 m kg 25 3 ft Ib T R 35 Nm ...

Page 261: ...ove front arm CHECKING THE FRONT ARMS 1 Check front arms Bends damage Replace 2 Check bushes Wear damage Replace CHECKING THE FRONT SHOCK ABSORBERS The following procedure applies to both of the front shock absorber assemblies 1 Check shock absorber Oil leaks Replace the front shock absorber assembly shock absorber rod Bends damage Replace the front shock absorber assembly spring Fatigue Replace t...

Page 262: ...e pitting Replace the front arm Free play Replace the front arm Turns roughly Replace the front arm EBS00473 INSTALLING THE FRONT ARMS The following procedure applies to both of the front arms 1 Install upper front arm lower front arm Front arm upper lower 35 Nm 3 5 m kg 25 3 ft lb FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 8 43 ...

Page 263: ... brake hose 1 4 Parking brake cable 5 Plug 2 6 Swing ram bolt R swing ram bolt L nut 1 1 1 7 Metal clamp A 1 9 Metal clamp B 1 10 Rubber boot 1 8 Swingarm 1 REAR SHOCK ABSORBER AND SWINGARM 1 8 44 1 2 5 5 6 6 T R 75 Nm 7 5 m kg 54 2 ft Ib T R 75 Nm 7 5 m kg 54 2 ft Ib T R 38 Nm 3 8 m kg 27 5 ft Ib T R 38 Nm 3 8 m kg 27 5 ft Ib 7 8 9 10 3 4 T R 8 Nm 0 8 m kg 5 38 ft Ib 11 12 13 11 New LS LS LS New ...

Page 264: ...r 1 For installation reverse the removal pro cedure CHAS REAR SHOCK ABSORBER AND SWINGARM 1 2 5 5 6 6 T R 75 Nm 7 5 m kg 54 2 ft Ib T R 75 Nm 7 5 m kg 54 2 ft Ib T R 38 Nm 3 8 m kg 27 5 ft Ib T R 38 Nm 3 8 m kg 27 5 ft Ib 7 8 9 10 3 4 T R 8 Nm 0 8 m kg 5 38 ft Ib 11 12 13 11 New LS LS LS New New 8 45 ...

Page 265: ... lower bolt rear shock absorber upper bolt While removing the rear shock absorber lower bolt hold the swingarm so that it does not drop down REMOVING THE SWINGARM 1 Check swingarm free play a Check the tightening torque of the pivot shaft bolt R and nut L A B b Check the swingarm side play by mov ing it from side to side If side play is noticeable check the spacer bearings and frame pivot Swingarm...

Page 266: ...e pivot 2 Remove plug swing arm nut swing ram left bolt swing ram right bolt swingarm CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check bearings oil seals REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM swingarm play swingarm turns roughly Re place 3 Check bearings oil seal Wheel hub play wheel turns roughly Re place 8 47 ...

Page 267: ...THE RUBBER BOOT 1 Check Rubber boot Damage Replace INSTALLING THE RUBBER BOOT 1 Apply Adhesive for rubber to the swingarm 2 Install Rubber boot Be sure to position the rubber boot so that the ellipsoid towards the swingarm 1 2 3 1 1 2 3 1 3 8 48 TIP ...

Page 268: ...Rear brake switch 4 4 Front brake switch 5 5 6 Battery 7 Indicator light 7 8 Diode 9 Starter relay C D I unit Fuse box Shift gear control unit 14 13 Headlight relay Gear position switch 17 18 15 16 20 18 19 16 17 Thermo unit Ignition coil Thermo switch Fan motor 20 19 Headlight Circuit breaker fan 2 6 8 9 13 15 Handlebar switch left ...

Page 269: ...e When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions are shown in the far left column and the switch lead colors are shown in the top row in the switch illustration TIP indicates a continuity of electricit...

Page 270: ...e Improperly connected Properly connect Incorrect continuity reading Replace the switch Main switch Dimmer switch Start switch Engine stop switch 1 3 2 4 6 1 2 3 4 Rear brake light switch Front brake light switch Gear position switch Fuse 5 5 6 7 8 8 R Y L OFF ON W B Y R Y B Br Br R L R R OFF PUSH OFF LO HI Y B Y B Y R Y R W B W B R Y L Y L Br R Br OFF ON R R R R Br R L Br R L G Y W B 7 W B W B G ...

Page 271: ...their respective socket by turning them counterclockwise Bulbs is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bulbs and are used for meter and indi cator lights and can be removed from their respective socket by carefully pulling them out a c d e b 1 Remove bulb c d e WARNING Sincetheheadlightbulbgetsextremelyhot ch...

Page 272: ... tester to 0 and to the Ω 1 range a Connect the positive tester probe to termi nal and the negative tester probe to ter minal and check the continuity b Connect the positive tester probe to termi nal and the negative tester probe to ter minal and check the continuity c If either of the readings indicate no continu ity replace the bulb Pocket tester P N YU 03112 C 90890 03112 ...

Page 273: ... W B W B W B Y R Y B Y B Y B Y B Y B Y R Y R Y R R L R L R L R L DL DL DL DL B L B L B L B L W W R B W B W B W B W B W B W B R R Y Y Y Y Y Y Y 12V 35 35W 12V 35 35W 12V 21W 5W L L Y L L L L L L L W W B B B G G G B B B G W W W Br Br Br R Br G Y G Y G Y G Y G Y G Y G Y G Y G Y DL B B G L L L H N R W R B W B W G Y W R R B W R W R G R G R R B R B B B Br Y Br Y Neutral indicator Reverse indicator Coola...

Page 274: ... following special tool s EBS01032 YES NO The ignition system fails to operate no spark or intermittent spark Dynamic spark tester P N YM 34487 Ignition checker P N 90890 06754 Pocket tester P N YU 03112 C 90890 03112 1 Spark plug Check the condition of the spark plug Check the spark plug type Measure the spark plug gap Refer to CHECKING THE SPARK PLUG in chapter 3 Standard spark plug CR8E NGK Spa...

Page 275: ...the starter switch and gradually increase the spark gap until a misfire occurs Minimum ignition spark gap 6 mm 0 24 in Is there a spark and is the spark gap within specification The ignition system is OK 3 Spark plug cap resistance Remove the spark plug cap from the spark plug lead Connect the pocket tester Ω 1k range to the spark plug cap as shown Measure the spark plug cap resistance Spark plug ...

Page 276: ...he pocket tester Ω 1k to the ignition coil as shown Positive tester probe spark plug lead Negative tester probe green terminal Measure the secondary coil resistance Secondary coil resistance 2 79 3 41kΩ at 20 C 68 F Is the ignition coil OK Replace the ignition coil 5 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch 6 Engi...

Page 277: ...be green terminal Measure the pickup coil resistance Pickup coil resistance 96 144 Ω at 20 C 68 F between white red and white blue Is the pickup coil OK Replace the pickup coil stator assembly 1 1 2 2 Y Y Y G L EBS01047 YES NO 8 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly connected and without defects Replace the C D I unit Pro...

Page 278: ...G Y G Y B G L L L H N R W R B W B W G Y R B W R W R G R G R R B R B B B Br Y Br Y Neutral indicator Reverse indicator Coolant temperature G R Gr Gr G L G L G R Br Y Br Br Br W R B G G 7 6 2 3 1 8 10 12 13 14 15 16 17 18 20 21 22 23 24 35 36 25 27 28 28 30 29 37 31 32 33 34 G Y Y Y Y Y Y Y R Br R B G Br G L G G L L Y R Y R W B W B W R L G W L G W B W R W L B W L B 11 W B W BW G B W B W W G W G 38 W...

Page 279: ...ated only if the engine stop switch is in the RUN position the Main fuse Battery Starter motor Starter relay Start switch Engine stop switch TO MAIN SWITCH FROM MAIN SWITCH The transmission is in neutral the neutral switch is closed You pull in the rear brake lever the rear brake switch is ON R W B Y R Y R A A B B Y B 7 1 2 3 4 5 5 1 2 3 4 6 G Y G Y W B 9 W B 9 8 11 10 Ignition fuse Shift gear con...

Page 280: ...se for continuity Refer to CHECKING THE SWITCHES Is the mainfuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 0 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Starter motor Connect the positive battery terminal and starter motor lead wi...

Page 281: ...h OK Replace the main switch R B 6 Rear brake switch Check the rear brake switch for continuity Refer to CHECKING THE SWITCHES Is the rear brake switch OK Replace the rear brake switch 7 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK Replace the handle bar switch EBS01042 YES NO 8 Engine stop switch Check the engine stop switch for continui...

Page 282: ...oving the starter motor Remove the parts in the order listed Refer to ENGINE REMOVAL in chapter 4 Exhaust pipe 1 1 Starter motor 1 Starter motor lead 2 For installation reverse the removal procedure 1 T R 9 Nm 0 9 m kg 6 5 ft Ib ELECTRIC STARTING SYSTEM ELEC 2 ...

Page 283: ...B G G G B B B G W W W Br Br Br R Br G Y G Y G Y G Y G Y G Y G Y G Y G Y B G L L L H N R W R B W B W G Y R B W R W R G R G R R B R B B B Br Y Br Y Neutral indicator Reverse indicator Coolant temperature G R Gr Gr G L G L G R Br Y Br Br Br W R B G G 7 6 2 3 1 8 10 12 13 14 15 16 17 18 20 21 22 23 24 35 36 25 27 28 28 30 29 37 31 32 33 34 G Y Y Y Y Y Y Y R Br R B G Br G L G G L L Y R Y R W B W B W R ...

Page 284: ...BS01044 YES NO The battery is not being charged Inductive tachometer P N YU 8036 A Engine tachometer P N 90890 03113 Pocket tester P N YU 03112 C 90890 03112 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSE in chap ter 3 Is the main fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open cir...

Page 285: ...sistance Disconnect the C D I magneto coupler from the wire harness Connect the pocket tester Ω 1 to the charging coils Positive tester probe yellow terminal Negative tester probe yellow terminal Measure the charging coil resistance Charging coil resistance 0 20 0 40 Ω at 20 C 68 F between yellow and yellow Replace the rectifier regulator Replace the pickup coil stator assembly Positive tester pro...

Page 286: ...Y G Y G Y G Y G Y G Y G Y B G L L L H N R W R B W B W G Y R B W R W R G R G R R B R B B B Br Y Br Y Neutral indicator Reverse indicator Coolant temperature G R Gr Gr G L G L G R Br Y Br Br Br W R B G G 7 6 2 3 1 8 11 10 12 13 14 15 16 17 18 20 21 22 23 24 35 36 25 27 28 28 30 29 37 31 32 33 34 G Y Y Y Y Y Y Y R Br R B G Br G L G G L L Y R Y R W B W B W R L G W L G W B W R W L B W L B Main switch B...

Page 287: ...tch for continuity Refer to CHECKING THE SWITCHES Is the light switch OK YES NO Replace the handle bar switch EBS01100 YES NO 2 Charging coil resistance Disconnect the C D I magneto coupler from the wire harness Connect the pocket tester Ω 1 to the charging coils Positive tester probe yellow terminal Negative tester probe yellow terminal Measure the charging coil resistance Charging coil resistanc...

Page 288: ...ty Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK Replace the head light bulb socket or both 2 Voltage Connect the pocket tester AC 20 V to the headlight couplers as shown When the light switch is set to LO When the light switch is set to HI Headlight coupler wire harness side Headlight Positive tester probe white or yellow Negative tester probe black Set the mai...

Page 289: ...t bulb socket or both YES NO YES NO 2 Voltage Connect the pocket tester AC 20 V to the tail brake light coupler as shown Tail brake light coupler wire harness side Tail brake light Positive tester probe yellow Negative tester probe black Set the main switch to ON Start the engine Measure the voltage AC 12 V of yellow on the tail brake light coupler wire har ness side Is the voltage within specific...

Page 290: ... W G Y R B W R W R G R G R R B R B B B Br Y Br Y Neutral indicator Reverse indicator Coolant temperature G R Gr Gr G L G L G R Br Y Br Br Br W R B G G 7 6 2 3 1 8 11 10 12 13 14 15 16 17 18 20 21 22 23 24 35 36 25 27 28 28 30 29 37 31 32 33 34 G Y Y Y Y Y Y Y R Br R B G Br G L G G L L Y R Y R W B W B W R L G W L G W B W R W L B W L B W B W BW G B W B W W G W G 38 Ignition fuse 6 Main switch Batter...

Page 291: ...ce the fuse 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch EBS01044 EBS01074 EBS01041 YES NO YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 0 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or rep...

Page 292: ...l indicator light bulb and socket OK 2 The neutral indicator light fails to come on Replace the neutral indicator light bulb socket or both YES NO 3 Voltage Connect the pocket tester AC 20 V to the tail brake light coupler as shown Tail brake light coupler wire harness side Tail brake light Positive tester probe yellow Negative tester probe black Y B G Y 1 1 2 2 Y G G Y YES NO Set the main switch ...

Page 293: ...ster probe green red 1 1 2 2 YES NO This circuit is OK The wiring circuit from the main switch to the indicator light coupler is faulty and must be repaired 2 Gear position switch Check the gear position switch for continuity Refer to CHECKING THE SWITCHES Is the gear position switch OK Replace the gear position switch YES NO G R G R Br Br 3 Voltage Connect the pocket tester AC 20 V to the trevers...

Page 294: ...emperature warning light bulb socket or both YES NO 1 Coolant temperature warning light bulb Check the coolant temperature warning light Refer to CHECKING THE BULBS AND BULB SOCKETS bulb and socket for continuity and socket not come on when the temperature is high more than 117 123 C 242 6 253 4 F Are the coolant temperature warning light bulb and socket OK 5 The coolant temperature warning light ...

Page 295: ... light connector wire harness side as shown Positive tester probe gray Negative tester probe green 1 1 2 2 1 2 G G Gr Gr Set the main switch to ON Measure the voltage 12 V of gray and green at the indicator light coupler Is the voltage within specification 6 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK Replace the start switch YES NO ...

Page 296: ...Br Br Br R Br G Y G Y G Y G Y G Y G Y G Y G Y G Y B G L L L H N R W R B W B W G Y R B W R W R G R G R R B R B B B Br Y Br Y Neutral indicator Reverse indicator Coolant temperature G R Gr Gr G L G L G R Br Y Br Br Br W R B G G 7 6 2 3 1 8 11 10 12 13 14 15 16 17 18 20 21 22 23 24 35 36 25 27 28 28 30 29 37 31 32 33 34 G Y Y Y Y Y Y Y R Br R B G Br G L G G L L Y R Y R W B W B W R L G W L G W B W R W...

Page 297: ...r fails to turn Pocket tester P N YU 03112 C 90890 03112 EBS01043 1 Fuse Check the fuse for continuity Refer to CHECKING THE SWITCHES Are the fuse OK YES NO Replace the fuse EBS01044 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 0 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Rechar...

Page 298: ...aker Circuit breaker resistance Zero Ω at 20 C 68 F Replace the circuit breaker 6 Thermo switch Remove the thermo switch from the radi ator Connect the pocket tester Ω 1 to the thermo switch as shown Immerse the thermo switch in a container Place a thermometer in the coolant Slowly heat the coolant then let it cool down to the specified temperature Check the thermo switch for continuity at the tem...

Page 299: ... to strong shocks If the thermo switch is dropped replace it The thermo switch circuit is open and the radia tor fan is off The thermo switch circuit is closed and the radiator fan is on 7 Wiring Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM Is the cooling system s wiring properly connected and without defects This circuit is OK Properly connect or repair the cooling system s w...

Page 300: ...es Wire between terminals broken Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body C D I system Faulty C D I unit Faulty pickup coil Faulty charging coil Faulty lighting coil Broken woodruff key Switches and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty gear position switch Loose conn...

Page 301: ...e Improperly adjusted valve timing EBS00538 POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Loose or clogged pilot jet Improperly returned choke Intake manifold Loosen carburetor joint Loose or clogged pilot air jet Improperly adjusted idle speed throttle stop screw Improper throttle cable play Flooded carburetor Electrical system Faulty battery Faulty C D I unit Faulty pickup c...

Page 302: ...ng sheave Worn primary fixed sheave Primary sliding sheave Seized primary sliding sheave Secondary fixed sheave Worn secondary sliding sheave Secondary sliding sheave Seized transmission gear Jammed impurities Incorrectly assembled transmission Transmission Broken shift guide Shift guide Improper thrust play Worn shift drum groove Shift drum Worn gear dog Transmission POOR STARTING PERFORMANCE POO...

Page 303: ...r oil quality Cooling system Low coolant level Clogged or damaged radiator Damaged or faulty water pump Faulty fan motor Faulty thermo switch Brake Brake drag 10 4 EBS00550 FAULTY BRAKE POOR BRAKING EFFECT Front drum brake Worn brake pads Worn disc Air in brake fluid Leaking brake fluid Faulty master cylinder kit cup EBS00551 SHOCK ABSORBER MALFUNCTION MALFUNCTION Bent or damaged damper rod Damage...

Page 304: ...accessories Hard charging broken stator coil and or faulty rectifier regulator Incorrect connection Improperly grounded BULB BURNT OUT Improper bulb Faulty battery Faulty rectifier regulator Improperly grounded Faulty main and or light switch Bulb life expired TAIL BRAKE LIGHT BULB BURNT OUT Wrong tail brake light bulb Faulty battery Faulty rectifier regulator Improperly grounded Faulty main and o...

Page 305: ...PRINTED IN U S A ...

Page 306: ...Black White Br Y Brown Yellow R B Red Black R L Red Blue W B White Black W R White Red Y B Yellow Black Y R Yellow Red G Y Green Yellow Main switch C D I magneto Rectifier Regulator Battery Main fuse Ignition fuse Signal fuse Head fuse Battery lead Battery lead Wire lead Starter relay Starter motor C D I unit Ignition coil Start switch Dimmer switch Engine stop switch Shift gear control unit Headl...

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Club Car 1988 DS Owner'S Manual preview
1988 DS
Brand: Club Car Pages: 20

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