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Yamaha YFM35FAS, Supplementary Service Manual

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Yamaha YFM35FAS Supplementary Service Manual Download Page 54

– 44 –

ENG

CYLINDER AND PISTON

CYLINDER AND PISTON

Order

Job name/Part name

Q’ty

Remarks

Removing the cylinder and piston 

Remove the parts in the order below.

Cylinder head

Refer to “CYLINDER HEAD”.

1

Cylinder/O-ring

1/1

Refer to “INSTALLING THE CYLINDER”
in CHAPTER 4. 
(Manual No.: 5TE2-AE1)

2

Cylinder gasket

1

3

Dowel pin

1

4

Dowel pin/O-ring

1/1

5

Piston pin clip

2

Refer to “REMOVING THE PISTON” 
and “INSTALLING THE PISTON” in 
CHAPTER 4. 
(Manual No.: 5TE2-AE1)

6

Piston pin

1

7

Piston

1

8

Piston ring set

1

For installation, reverse the removal 
procedure.

Summary of Contents for YFM35FAS

Page 1: ...YFM35FAS YFM350FAS 5UH2 AE1 SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ......

Page 3: ...it is necessary to use this Supplementary Service Manual together with the following manual YFM4FAR YFM400FAR SERVICE MANUAL 5TE2 AE1 YFM35FAS YFM350FAS SUPPLEMENTARY SERVICE MANUAL 2003 by Yamaha Motor Co Ltd First edition July 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ...

Page 5: ...tify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 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...

Page 6: ...cant D Special tool E Torque F Wear limit clearance G Engine speed H Ω V A Illustrated symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lithium soap based grease N Apply molybdenum disulfide grease Illustrated symbols O to P in the exploded diagra...

Page 7: ...K 36 SEAT FRONT CARRIER FRONT BUMPER AND FRONT FENDER 36 FUEL TANK 38 ENGINE 39 CHECKING THE OIL TEMPERATURE WARNING LIGHT 39 ENGINE CYLINDER HEAD 40 CAMSHAFT ROCKER ARMS AND VALVES 42 CYLINDER AND PISTON 44 RECOIL STARTER AND A C MAGNETO 45 BALANCER GEARS AND OIL PUMP 47 OIL PUMP 49 REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 50 REMOVING THE BALANCER DRIVE GEAR AND BUFFER BOSS 50 CH...

Page 8: ... 70 INSTALLING THE TRANSMISSION 71 MIDDLE GEAR 72 MIDDLE DRIVE SHAFT 72 MIDDLE DRIVEN SHAFT 73 SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS 75 DRIVE TRAIN FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 79 MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH 81 CHASSIS REAR BRAKE 83 CHECKING THE REAR BRAKE 85 INSTALLING THE REAR BRAKE 86 STEERING SYSTEM 89 STEERING STEM 89 FRONT ARMS AND FR...

Page 9: ...HOOTING FAULTY GEAR SHIFTING 104 HARD SHIFTING 104 SHIFT LEVER DOES NOT MOVE 104 JUMPS OUT OF GEAR 104 OVERHEATING 104 OVERHEATING 104 FAULTY BRAKE 105 POOR BRAKING EFFECT 105 YFM35FAS YFM350FAS WIRING DIAGRAM ...

Page 10: ......

Page 11: ...ed When placing an order refer to the list provided below to avoid any mistakes For US and CDN P N YM YU YS YK ACC Except for US and CDN P N 90890 Tool No Tool name How to use Illustration Pot 90890 01274 Bolt 90890 01275 Crankshaft installer pot Crankshaft installer bolt These tools are used to install the crankshaft 90890 01309 Spacer This tool is used to install the crankshaft Adapter 90890 013...

Page 12: ... stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 348 cm3 Bore stroke 83 0 64 5 mm 3 27 2 54 in Compression ratio 9 2 1 Standard compression pressure at sea level 1 050 kPa 10 5 kg cm2 149 3 psi at 750 r min Starting system Electric and recoil starter Lubrication system Wet sump Oil type or grade Engine oil For CDN For Europe Oceania API service SE SF SG type or highe...

Page 13: ... 57 US gal Fuel reserve amount 3 3 L 0 73 Imp gal 0 87 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Spark plug Type manufacturer DR8EA NGK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio 41 21 24 18 33 9 9 545 Transmission type V belt automatic...

Page 14: ...on Rear brake type Drum brake operation Left hand and right foot operation Suspension Front suspension Double wishbone Rear suspension Swingarm monocross Shock absorbers Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 160 mm 6 30 in Rear wheel travel 180 mm 7 09 in Electrical Ignition system D C C D I Generator system A C magne...

Page 15: ... 0 0016 in Out of round limit 0 01 mm 0 0004 in Camshaft Drive method Chain drive left Cam dimensions Intake A 40 62 40 72 mm 1 5992 1 6031 in 40 52 mm 1 5953 in B 32 18 32 28 mm 1 2669 1 2709 in 32 08 mm 1 2630 in Exhaust A 40 62 40 72 mm 1 5992 1 6031 in 40 52 mm 1 5953 in B 32 18 32 28 mm 1 2669 1 2709 in 32 08 mm 1 2630 in Camshaft runout limit 0 03 mm 0 0012 in A B MAINTENANCE SPECIFICATIONS ...

Page 16: ... 33 9 34 1 mm 1 3346 1 3425 in B face width IN 2 26 mm 0 0890 in EX 2 26 mm 0 0890 in C seat width IN 1 2 1 4 mm 0 0472 0 0551 in 1 6 mm 0 0630 in EX 1 2 1 4 mm 0 0472 0 0551 in 1 6 mm 0 0630 in D margin thickness IN 1 0 1 4 mm 0 0394 0 0551 in EX 0 8 1 2 mm 0 0315 0 0472 in Stem outside diameter IN 6 975 6 990 mm 0 2746 0 2752 in 6 950 mm 0 2736 in EX 6 955 6 970 mm 0 2738 0 2744 in 6 915 mm 0 27...

Page 17: ... EX 39 9 mm 1 57 in 37 9 mm 1 49 in Set length valve closed IN 33 6 mm 1 32 in EX 33 6 mm 1 32 in Compressed pressure installed IN 104 9 120 6 N 10 7 12 3 kg 23 58 27 11 lb EX 104 9 120 6 N 10 7 12 3 kg 23 58 27 11 lb Tilt limit IN 2 5 1 7 mm 2 5 0 07 in EX 2 5 1 7 mm 2 5 0 07 in Direction of winding top view IN Counterclockwise EX Counterclockwise Item Standard Limit MAINTENANCE SPECIFICATIONS ...

Page 18: ... EX 2 5 1 9 mm 2 5 0 07 in Direction of winding top view IN Clockwise EX Clockwise Piston Piston to cylinder clearance 0 040 0 060 mm 0 0016 0 0024 in 0 150 mm 0 0059 in Piston size D 82 920 82 970 mm 3 2646 3 2665 in Measuring point H 5 mm 0 20 in Piston offset 0 5 mm 0 0200 in Offset direction Intake side Piston pin bore inside diameter 19 004 19 015 mm 0 7482 0 7486 in 19 045 mm 0 7498 in Pisto...

Page 19: ... 40 mm 0 008 0 016 in 0 75 mm 0 0295 in Side clearance 0 03 0 07 mm 0 0012 0 0028 in 0 13 mm 0 0051 in Oil ring Dimensions B T 2 8 2 8 mm 0 11 0 11 in End gap installed 0 3 0 9 mm 0 01 0 04 in Crankshaft Crank width A 58 95 59 00 mm 2 321 2 323 in Runout limit C1 0 03 mm 0 0012 in C2 0 03 mm 0 0012 in Big end side clearance B 0 35 0 85 mm 0 0138 0 0335 in 1 0 mm 0 04 in Big end radial clearance E ...

Page 20: ...oil Carburetor I D mark 5UH1 00 Main jet M J 130 Main air jet M A J 70 Jet needle J N 5ETY1 2 Needle jet N J P 2M Pilot air jet P A J 1 80 Pilot air jet P A J 2 1 3 Pilot outlet P O 0 8 Pilot jet P J 17 5 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 Pilot screw P S 1 1 2 turns out Valve seat size V S 2 0 Starter jet G S 1 57 5 Starter jet G S 2 0 9 Throttle valve size Th V 100 Float he...

Page 21: ... pressure hot 20 kPa 0 20 kg cm2 2 9 psi at 1 500 r min Pressure check location Cylinder head Shaft drive Middle gear backlash 0 1 0 3 mm 0 004 0 012 in Final gear backlash 0 1 0 2 mm 0 004 0 008 in Differential gear backlash 0 05 0 25 mm 0 0020 0 0098 in Lubrication chart Item Standard Limit Oil strainer Transmission Oil pump Crank pin clutch Oil filter Cylinder head Oil cooler Relief valve Oil p...

Page 22: ... 12 SPEC Cylinder head tightening sequence Item Standard Limit 5 2 4 1 6 3 MAINTENANCE SPECIFICATIONS ...

Page 23: ... 2 Oil strainer Bolt M5 2 4 0 4 2 9 Oil filter union bolt M20 1 68 6 8 49 Oil filter cartridge M20 1 17 1 7 12 Oil cooler Bolt M6 4 7 0 7 5 1 Oil cooler fan Bolt M6 3 6 0 6 4 3 Oil hose union bolt M14 2 50 5 0 36 Oil hose oil cooler side M16 2 21 2 1 15 Oil hose crankcase side M16 2 35 3 5 25 Oil pump assembly Bolt M6 3 7 0 7 5 1 Oil pump housing Screw M5 1 5 0 5 3 6 Plate oil pump driven gear Bol...

Page 24: ... retainer Nut M55 1 80 8 0 58 LT Left handed threads Primary sliding sheave cap Screw M4 3 3 0 3 2 2 Primary sliding sheave assembly Nut M16 1 100 10 0 72 Secondary sheave assembly Nut M16 1 100 10 0 72 Secondary sheave spring retainer Nut M36 1 90 9 0 65 Shift shaft stopper bolt M14 1 18 1 8 13 Shift lever assembly Bolt M6 1 14 1 4 10 Neutral switch M10 1 17 1 7 12 Reverse switch M10 1 17 1 7 12 ...

Page 25: ...k absorber travel 126 mm 4 96 in Spring free length 317 mm 12 48 in Spring fitting length 283 1 mm 11 15 in Spring rate K1 27 4 N mm 2 74 kg mm 153 43 lb in Stroke K1 0 126 mm 0 4 96 in Optional spring No Swingarm Free play limit end 1 mm 0 04 in side 1 mm 0 04 in Front wheel Type Panel wheel Rim size 12 6 0 AT Rim material Steel Rim runout limit radial 2 mm 0 08 in lateral 2 mm 0 08 in Rear wheel...

Page 26: ...liper cylinder inside diameter 32 mm 1 26 in Brake fluid type DOT 4 Rear drum brake Type Leading trailing Brake drum inside diameter 160 mm 6 30 in 161 mm 6 34 in Lining thickness 4 0 mm 0 16 in 2 mm 0 08 in Brake lever and brake pedal Brake lever free play pivot front 0 mm 0 in rear 3 5 mm 0 12 0 20 in Brake pedal free play 20 30 mm 0 79 1 18 in Throttle lever free play 3 5 mm 0 12 0 20 in Item S...

Page 27: ...sorber and upper front arm M10 45 4 5 32 Steering stem pitman arm and frame M14 190 19 0 140 Steering stem holder and frame M8 23 2 3 17 Use lock washer Steering stem and handlebar holder M8 23 2 3 17 Pitman arm and tie rod end M12 30 3 0 22 Tie rod and locknut M12 40 4 0 29 Steering knuckle and upper front arm M12 30 3 0 22 Steering knuckle and lower front arm M12 30 3 0 22 Steering knuckle and t...

Page 28: ...t M14 23 2 3 17 Final gear oil drain bolt M14 23 2 3 17 Bearing retainer drive pinion gear M65 100 10 0 72 Final gear case and bearing housing M10 40 4 0 29 M8 23 2 3 17 Battery holding bracket M6 7 0 7 5 1 Footrest board and footrest bracket M6 7 0 7 5 1 Trailer hitch bracket M10 32 3 2 23 Front brake pad holding bolt M8 17 1 7 12 Front brake caliper retaining bolt M8 17 1 7 12 Rear brake light s...

Page 29: ... 18 0 28 Ω at 20 C 68 F Secondary winding resistance 6 32 9 48 kΩ at 20 C 68 F Spark plug cap Type Resin Resistance 10 kΩ Charging system Type A C magneto generator Model manufacturer F4T475 MITSUBISHI Nominal output 14 V 18 A at 5 000 r min Charging coil resistance color 0 49 0 62 Ω at 20 C 68 F White White Rectifier regulator Regulator type Semi conductor short circuit No load regulated voltage ...

Page 30: ... A Coil winding resistance 4 18 4 62 Ω at 20 C 68 F Electric fan Running rpm 6 350 r min Thermostat switch Thermo unit Model manufacturer 4GB DENSO Circuit breakers Type Fuse Amperage for individual circuit Main fuse 30 A 1 Headlight fuse 15 A 1 Ignition fuse 15 A 1 Auxiliary DC jack fuse 10 A 1 Four wheel drive fuse 3 A 1 Signaling system fuse 10 A 1 Reserve 30 A 1 Reserve 15 A 1 Reserve 10 A 1 R...

Page 31: ...rotor housing E Oil filter cartridge O ring LS Starter idle gear shaft E Starter idle gear E Starter one way clutch bearing E Clutch housing assembly shaft end LS Clutch housing E One way bearing M Transmission gear wheel pinion M Axle main drive M Chain sprocket transmission E Damper cam middle driven shaft M Gear coupling middle driven shaft E Shift shaft E Shift fork guide bar E Shift shaft sto...

Page 32: ... 22 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Oil pump 4 Oil strainer OIL FLOW DIAGRAMS ...

Page 33: ... 23 SPEC 1 Thermo unit 2 Oil pump 3 Oil filter È To oil cooler É From oil cooler OIL FLOW DIAGRAMS ...

Page 34: ... 24 SPEC 1 Crankshaft 2 Oil filter OIL FLOW DIAGRAMS ...

Page 35: ... 25 SPEC 1 Oil cooler 2 Oil cooler outlet pipe 3 Oil cooler inlet pipe È From engine É To engine A 1 È É A 1 3 2 2 3 OIL FLOW DIAGRAMS ...

Page 36: ... 5 On command four wheel drive switch lead 6 On command four wheel drive switch 7 Throttle cable 8 Handlebar switch lead 9 Horn switch lead for Europe and Oceania 0 Horn switch for Europe and Oceania A Handlebar switch B Main switch lead C Differential gear case breather hose D Gear motor lead CABLE ROUTING ...

Page 37: ...the handlebar switch lead rear brake switch lead and horn switch lead for Europe and Oceania behind the handlebar with a plastic band Ë Fasten the gear motor lead differential gear case breather hose fan motor lead with a plastic band Ì Loop the horn switch lead for Europe and Oceania around the plastic band as shown Í Fasten the on command four wheel drive switch lead rear brake switch lead main ...

Page 38: ...l drive indicator light 4 Differential gear case breather hose 5 Indicator light speedometer light couplers 6 Speedometer cable 7 Wire harness È Fasten the wire harness with a plastic band É Fasten the wire harness and speedometer cable with a plastic band CABLE ROUTING ...

Page 39: ...ope and Oceania A Horn lead for Europe and Oceania È Insert the fuel tank breather hose into the hole of the handlebar cover É Fasten the starter cable with a plastic band Ê Fasten the brake lever cable and speedometer cable with a plastic band Ë Fasten the oil cooler hose and speedometer cable with a plastic band Ì Fasten the gear motor lead differential gear case breather hose and fan motor lead...

Page 40: ... hose 5 Wire harness 6 Starter motor lead 7 Negative battery lead 8 Rear brake lever cable 9 Air filter case check hose 0 Thermo unit lead A Speedometer cable B A C magneto lead C Rectifier regulator D Reverse switch lead E Neutral switch lead F Carburetor drain hose G Float chamber air vent hose CABLE ROUTING ...

Page 41: ...ead with a plastic band Ê Fasten the final drive gear case breather hose rear brake breather hose ground lead and A C magneto lead with a plastic band Ë Fasten the rectifier regulator lead and rear brake breather hose with a plastic band Ì Fasten the thermo unit lead and A C magneto lead with a plastic clamp CABLE ROUTING ...

Page 42: ...rake light switch lead 7 Rear brake pedal cable È Fasten the select lever control cable rear brake light switch lead and spark plug lead with a plastic band É Fasten the select lever control cable and rear brake light switch lead with a plastic band Ê Fasten the oil cooler hose with a plastic band CABLE ROUTING ...

Page 43: ...SPEC 1 Front brake hose 2 Throttle cable 3 Wire harness 4 Final drive gear case breather hose 5 Rear brake breather hose 6 Float chamber air vent hose 7 Starter cable 8 Rear brake lever cable CABLE ROUTING ...

Page 44: ...wet or dusty areas Carburetor Check and adjust idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter...

Page 45: ... the brake fluid level and add fluid as required On the inner parts of the master cylinder and caliper replace the oil seals every two years Replace the brake hoses every four years or if cracked or damaged WARNING Indicates a potential hazard that could result in serious injury or death Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check ...

Page 46: ... 7 Nm 0 7 m kg 5 1 ft Ib 11 Order Job name Part name Q ty Remarks Removing the seat front carrier front bumper and front fender Remove the parts in the order below 1 Seat 1 NOTE Pull up the seat lock lever then pull up on the rear of the seat 2 Front carrier 1 3 Engine skid plate 1 4 Front bumper 1 5 Headlight coupler 2 Disconnect 6 Front fender 1 7 Main switch coupler 1 Disconnect 8 Handlebar cov...

Page 47: ...9 8 6 6 T R 34 Nm 3 4 m kg 24 ft Ib T R 34 Nm 3 4 m kg 24 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 11 Order Job name Part name Q ty Remarks 10 Indicator lights assembly coupler 2 Disconnect 11 Speedometer cable 1 12 Meter assembly 1 For installation reverse the removal procedure ...

Page 48: ...uel tank cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK 1 Fuel hose 1 NOTE Before disconnecting the fuel hose turn the fuel cock to OFF 2 Fuel cock lever 1 3 Fuel tank 1 NOTE When installing the fuel tank pass the fuel tank breather hose through the hole of the handlebar protector 4 Plastic band 4 5 Rubber cover 1 For installation reverse the removal procedure ...

Page 49: ...emperature warning light comes on Check engine oil temperature Oil temperature warning light does not come on Engine oil temperature and electrical circuit are OK Go ahead with riding Push start switch with the transmission in neutral Inspect the electrical circuit Refer to SIGNAL SYSTEM Oil tempera ture is low Allow to cool Oil tempera ture is high Oil temperature warning light comes on momentari...

Page 50: ... FUEL TANK Front fender Air duct assembly 1 air filter case Refer to ENGINE REMOVAL in CHAPTER 4 Manual No 5TE2 AE1 Exhaust pipe muffler Carburetor assembly Refer to CARBURETOR in CHAPTER 6 Manual No 5TE2 AE1 Recoil starter timing plug Refer to ADJUSTING THE VALVE CLEARANCE in CHAPTER 3 Manual No 5TE2 AE1 1 Spark plug lead 1 2 Spark plug 1 3 Engine mounting bolt upper nut 1 1 4 Engine bracket uppe...

Page 51: ... 2 2 8 Timing chain tensioner cap bolt 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLINDER HEAD in CHAPTER 4 Manual No 5TE2 AE1 9 Timing chain tensioner gasket 1 1 10 Camshaft sprocket 1 11 Cylinder head 1 12 Cylinder head gasket 1 13 Dowel pin 2 14 Gasket 1 15 Timing chain guide exhaust 1 For installation reverse the removal procedure ...

Page 52: ...s and valves Remove the parts in the order below 1 Intake manifold O ring 1 1 2 Oil gallery bolt 1 3 Lock washer bearing retainer 1 1 4 Camshaft 1 Refer to REMOVING THE CAMSHAFT AND ROCKER ARMS and INSTALLING THE CAMSHAFT AND ROCKER ARMS in CHAPTER 4 Manual No 5TE2 AE1 5 Rocker arm shaft O ring 2 2 6 Rocker arm 2 7 Locknut valve adjuster 2 2 ...

Page 53: ...ING THE VALVES AND VALVE SPRINGS and INSTALLING THE VALVES AND VALVE SPRINGS in CHAPTER 4 Manual No 5TE2 AE1 9 Valve spring retainer 2 10 Valve spring outer 2 11 Valve spring inner 2 12 Valve intake 1 13 Valve exhaust 1 14 Valve stem seal 2 15 Valve spring seat 2 For installation reverse the removal procedure ...

Page 54: ...d Refer to CYLINDER HEAD 1 Cylinder O ring 1 1 Refer to INSTALLING THE CYLINDER in CHAPTER 4 Manual No 5TE2 AE1 2 Cylinder gasket 1 3 Dowel pin 1 4 Dowel pin O ring 1 1 5 Piston pin clip 2 Refer to REMOVING THE PISTON and INSTALLING THE PISTON in CHAPTER 4 Manual No 5TE2 AE1 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 For installation reverse the removal procedure ...

Page 55: ... in CHAPTER 3 Manual No 5TE2 AE1 Seat and fuel tank cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Manual No 5TE2 AE1 1 Recoil starter assembly 1 2 A C magneto coupler 2 Disconnect 3 Starter pulley 1 Refer to REMOVING THE A C MAGNETO and INSTALLING THE A C MAGNETO in CHAPTER 4 Manual No 5TE2 AE1 4 Oil filler cap 1 5 Crankcase cover gask...

Page 56: ... Pickup coil 1 9 Stator assembly 1 10 Starter idle gear shaft 1 11 Starter idle gear 1 12 Rotor 1 Refer to REMOVING THE A C MAGNETO and INSTALLING THE A C MAGNETO in CHAPTER 4 Manual No 5TE2 AE1 13 Starter wheel gear 1 14 Woodruff key 1 15 Washer 1 For installation reverse the removal procedure ...

Page 57: ... in the order below Starter wheel gear Refer to RECOIL STARTER AND A C MAGNETO 1 Plate 1 2 Nut lock washer 1 1 3 Balancer driven gear 1 Refer to REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR and INSTALLING THE BALANCER DRIVE GEAR AND BAL ANCER DRIVEN GEAR 4 Straight key 1 5 Spacer 1 6 Plate 1 BALANCER GEARS AND OIL PUMP ...

Page 58: ... 48 ENG BALANCER GEARS AND OIL PUMP Order Job name Part name Q ty Remarks 7 Balancer drive gear 1 8 Spring 8 9 Pin 4 10 Oil pump assembly gasket 1 1 For installation reverse the removal procedure ...

Page 59: ...6 ft Ib 2 3 6 5 4 1 Order Job name Part name Q ty Remarks Disassembling the oil pump Remove the parts in the order below 1 Rotor cover 1 2 Pin 1 3 Oil pump driven gear 1 4 Inner rotor 1 5 Outer rotor 1 6 Oil pump housing 1 For assembly reverse the disassembly procedure ...

Page 60: ...G THE BALANCER DRIVE GEAR AND BUFFER BOSS 1 Remove Plate 1 Balancer drive gear 2 Springs 3 Pins 4 CHECKING THE OIL PUMP DRIVEN GEAR 1 Check Oil pump driven gear 1 Cracks wear damage Replace CHECKING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1 Check Balancer drive gear 1 Balancer driven gear 2 Damage wear Replace the balancer drive gear and balancer driven gear as a set Excessive noise durin...

Page 61: ...ation mark F facing away from the balancer drive gear 3 Install Balancer driven gear NOTE Align the punch mark a on the balancer drive gear with the punch mark b on the balancer driven gear 4 Install Lock washer Balancer driven gear nut 1 NOTE Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4 Apply the molybdenum disulfide grease to the thread of a...

Page 62: ... ty Remarks Removing the oil cooler Remove the parts in the order below Seat fuel tank cover front carrier front bumper and front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Manual No 5TE2 AE1 Engine oil Drain Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Manual No 5TE2 AE1 1 Oil cooler fan coupler 1 Disconnect 2 Oil inlet hose O ri...

Page 63: ...5 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib 4 T R 6 Nm 0 6 m kg 4 3 ft Ib 6 T R 7 Nm 0 7 m kg 5 1 ft Ib New Order Job name Part name Q ty Remarks 3 Oil outlet hose O ring 1 1 Disconnect 4 Oil cooler 1 5 Oil cooler fan 1 6 Oil hose protector 1 For installation reverse the removal procedure ...

Page 64: ...Nm 10 0 m kg 72 ft lb 10 9 Order Job name Part name Q ty Remarks Removing the primary and secondary sheaves Remove the parts in the order below Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK Rear fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Manual No 5TE2 AE1 Right footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Manual No 5TE2 AE1 1 Drive belt case cover 1 2 Rub...

Page 65: ...2 ft lb T R 100 Nm 10 0 m kg 72 ft lb 10 9 Order Job name Part name Q ty Remarks 5 Primary sliding sheave assembly 1 Refer to REMOVING THE PRIMARY AND SECONDARY SHEAVES and INSTALLING THE PRIMARY AND SECONDARY SHEAVES in CHAPTER 4 Manual No 5TE2 AE1 6 V belt 1 7 Primary fixed sheave 1 8 Secondary sheave assembly 1 9 Drive belt case 1 10 Rubber gasket 1 For installation reverse the removal procedur...

Page 66: ...imary sliding sheave Remove the parts in the order below 1 Primary sliding sheave cap 1 Refer to ASSEMBLING THE PRIMARY SHEAVE 2 Primary pulley slider 3 3 Spacer 3 4 Primary pulley cam 1 5 Primary pulley weight 6 6 Collar 1 7 Oil seal 2 8 Primary sliding sheave 1 9 O ring 1 For assembly reverse the disassembly procedure ...

Page 67: ...rts in the order below 1 Nut 1 Refer to DISASSEMBLING THE SECONDARY SHEAVE in CHAPTER 4 Manual No 5TE2 AE1 Refer to ASSEMBLING THE SECONDARY SHEAVE 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 3 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1 9 Oil seal 2 For assembly reverse the disassembly procedure ...

Page 68: ...nner surface of the collar Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave 3 Install Spacer Sliders 1 Primary pulley cam 2 Primary sliding sheave cap T R 3 Nm 0 3 m kg 2 2 ft lb ASSEMBLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals 1 2 Install Secondary sliding sheave 1 Secondary fixed sheave 2 NOT...

Page 69: ...ompressor to the secondary sheave assembly Place the sheave fixed block in a vise and secure it Tighten the sheave spring compressor nut 1 and compress the spring Install the nut 2 and tighten it to the specified torque using the locknut wrench Remove the sheave spring compressor locknut wrench and sheave fixed block Sheave fixed block P N YM 04135 90890 04135 Locknut wrench P N YM 01348 90890 013...

Page 70: ... below Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES 1 Clutch housing assembly 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH in CHAPTER 4 Manual No 5TE2 AE1 2 Gasket 1 3 One way clutch bearing 1 4 Nut 1 5 Clutch carrier assembly 1 For installation reverse the removal procedure ...

Page 71: ... Q ty Remarks Disassembling the clutch housing Remove the parts in the order below 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For assembly reverse the disassembly procedure ...

Page 72: ...b LS LS E E LS 11 Order Job name Part name Q ty Remarks Removing the starter motor timing chain and oil filter Remove the parts in the order below Engine assembly Refer to ENGINE REMOVAL in CHAPTER 4 Manual No 5TE2 AE1 Cylinder head Refer to CYLINDER HEAD Cylinder and piston Refer to CYLINDER AND PISTON Recoil starter and rotor Refer to RECOIL STARTER AND A C MAGNETO Balancer gears and oil pump Re...

Page 73: ... 6 7 1 T R 68 Nm 6 8 m kg 49 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS New New New T R 7 Nm 0 7 m kg 5 1 ft Ib LS LS E E LS 11 Order Job name Part name Q ty Remarks 3 Starter motor O ring 1 1 4 Oil filter cartridge 1 5 Plate 1 6 Spring 1 7 Check ball 1 8 Neutral switch 1 9 Reverse switch 1 10 Thermo unit 1 11 Speedometer gear unit 1 For installation reverse the removal proc...

Page 74: ...0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 7 Order Job name Part name Q ty Remarks Separating the crankcase Remove the parts in the order below 1 Shift lever assembly 1 2 Crankcase left 1 Refer to SEPARATING THE CRANKCASE and ASSEMBLING THE CRANKCASE 3 Dowel pin 2 4 Crankcase right 1 5 Spacer 1 6 Crankshaft seal 2 7 Spacer 1 For installation reverse the removal procedure ...

Page 75: ...ankcase bearings Remove the parts in the order below Crankshaft and balancer Refer to CRANKSHAFT Transmission Refer to TRANSMISSION Middle drive driven shaft Refer to MIDDLE GEAR 1 O ring collar 1 1 2 Oil seal 2 3 Bearing retainer 2 4 Bearing 9 For installation reverse the removal procedure ...

Page 76: ...É Right crankcase È É ASSEMBLING THE CRANKCASE 1 Apply Sealant Quick Gasket 1 to the mating surfaces of both case halves 2 Install Dowel pins 2 3 Fit the right crankcase onto the left case Tap lightly on the case with a soft hammer CAUTION Before installing and torquing the crankcase holding bolts be sure to check whether the transmission is functioning properly by manually rotating the shift shaf...

Page 77: ...ightening sequence È Right crankcase É Left crankcase NOTE Tighten the bolts in stages using a crisscross pattern 5 Apply 4 stroke engine oil to the crank pin bearings and oil delivery hole 6 Check Crankshaft and transmission operation Unsmooth operation Repair È É T R 20 Nm 2 0 m kg 14 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 78: ... Part name Q ty Remarks Removing the crankshaft Remove the parts in the order below Crankcase separation Refer to CRANKCASE 1 Oil strainer 1 2 Balancer 1 Refer to REMOVING THE CRANK SHAFT and INSTALLING THE CRANK SHAFT 3 Crankshaft 1 For installation reverse the removal procedure ...

Page 79: ...TE Hold the connecting rod at the Top Dead Center T D C with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bearing CAUTION Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier Crankshaft installer pot 1 P N 90890 01274 Crankshaft installer bolt 2 P N 9...

Page 80: ...nsmission Remove the parts in the order below Crankcase separation Refer to CRANKCASE 1 Driven sprocket 1 2 Chain 1 3 Secondary shaft 1 4 Guide bar 1 5 Shift fork 1 6 Clutch dog 1 7 Drive axle assembly 1 8 Shift shaft stopper 1 9 Shift shaft 1 For installation reverse the removal procedure ...

Page 81: ...hift fork with the L mark facing towards the left side of the crankcase Be sure that the shift fork guide pin is properly seated in the shift shaft groove 2 Check Shift operation Unsmooth operation Repair NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely ...

Page 82: ...on Refer to CRANKCASE 1 Bearing housing assembly 1 2 Middle driven gear 1 3 Nut 1 Refer to REMOVING THE MIDDLE DRIVE SHAFT and INSTALLING THE MIDDLE DRIVE SHAFT in CHAPTER 4 Manual No 5TE2 AE1 4 Middle drive pinion gear 1 5 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS 6 Middle drive shaft 1 7 Bearing retainer 2 For installation reverse the removal procedure ...

Page 83: ...SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT in CHAPTER 4 Manual No 5TE2 AE1 2 Bearing 2 3 Universal joint 1 4 Universal joint yoke 1 5 Bearing housing O ring 1 1 6 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS 7 Middle driven pinion gear 1 Refer to REMOVING THE MIDDLE DRIVEN SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT in CHAPTER 4 Manual No 5TE2 AE1 8 Bearing retainer 1 9 Damper...

Page 84: ... 74 ENG MIDDLE GEAR Order Job name Part name Q ty Remarks 12 Front drive shaft coupling 1 13 Bearing retainer 1 14 Middle driven shaft 1 For installation reverse the removal procedure ...

Page 85: ...h their respective thickness calculated from information marked on crankcase bearing housing and drive gear end 1 Shim thickness A 2 Shim thickness B To find shim thickness A use following formula Where a a numeral usually a decimal number on the bearing housing is either added to or subtracted from 4 5 b 15 0 c drive pinion gear to driven pinion gear center distance considered constant 55 d a num...

Page 86: ...edths digit and select appropriate shim s In the example above the calculated shim thickness is 0 53 mm The chart instructs you however to round off 3 to 5 Shims are supplied in the following thicknesses Hundredths Round value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle drive pinion gear shim Thickness mm 0 10 0 30 0 15 0 40 0 20 0 50 To find shim thickness B use the following formula Middle driven pinion g...

Page 87: ...sually a decimal number on the right crankcase specifies a thickness of 23 87 Example 1 If the bearing housing is marked 02 e is 76 02 2 If the driven pinion gear is marked 02 f is 59 02 3 If the driven pinion gear is marked 02 g is 79 52 4 If the crankcase left is marked 72 01 h is 72 01 5 If the crankcase left is marked 23 87 i is 23 87 6 Therefore the shim thickness is 0 64 mm B 76 02 59 02 79 ...

Page 88: ... 78 ENG MIDDLE GEAR Shims are supplied in the following thickness Middle drive pinion gear shim Thickness mm 0 10 0 40 0 15 0 50 0 20 0 60 0 30 ...

Page 89: ... in the order below Engine skid plate front Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK Brake light switch cover Refer to FRONT BRAKE in CHAPTER 8 Manual No 5TE2 AE1 Differential gear oil Drain Refer to CHANGING THE DIFFERENTIAL GEAR OIL in CHAPTER 3 Manual No 5TE2 AE1 Steering knuckle Refer to STEERING SYSTEM in CHAPTER 8 Manual No 5TE2 AE1 Front arms lower Refer to FRONT ARMS AND F...

Page 90: ...ame Part name Q ty Remarks 2 Gear motor coupler four wheel drive switch connector 1 1 Disconnect 3 Differential gear case breather hose 1 Disconnect 4 Differential gear 1 5 Drive shaft 1 6 Compression spring 1 7 Coupling gear 1 For installation reverse the removal procedure ...

Page 91: ...e 1 into the drain plug hole CAUTION Finger tighten the bolt until it holds the ring gear Otherwise the ring gear will be damaged 4 Attach Gear lash measurement tool 1 Dial gauge 2 a Measuring point is 25 mm 0 98 in 5 Measure Gear lash Gently rotate the gear coupling from engagement to engagement NOTE Measure the gear lash at four positions Rotate the shaft 90 each time Gear lash measurement tool ...

Page 92: ... it is necessary to increase by more than 0 05 mm 0 002 in Reduce right shim thickness by 0 1 mm 0 004 in for every 0 1 mm 0 004 in of left shim increase If it is necessary to reduce by more than 0 1 mm 0 004 in Increase right shim thickness by 0 1 mm 0 004 in for every 0 1 mm of left shim decrease Too little gear lash Reduce shim thickness Too large gear lash Increase shim thickness Ring gear shi...

Page 93: ...r to FRONT AND REAR WHEELS in CHAPTER 8 Manual No 5TE2 AE1 1 Brake drum cover 1 Refer to REMOVING THE REAR BRAKE in CHAPTER 8 Manual No 5TE2 AE1 Refer to INSTALLING THE REAR BRAKE 2 Dust seal 1 3 Brake drum 1 4 Adjusting nut 2 5 Pin 2 6 Spring 2 7 Rear brake lever cable 1 8 Rear brake pedal cable 1 9 Cotter pin 2 10 Plate 1 11 Brake shoe 2 12 Brake shoe spring 2 ...

Page 94: ...ke camshaft lever 1 Refer to REMOVING THE REAR BRAKE in CHAPTER 8 Manual No 5TE2 AE1 Refer to INSTALLING THE REAR BRAKE 14 Brake shoe wear indicator 1 15 Brake camshaft 1 16 O ring 2 17 Dust seal 1 18 Brake shoe plate 1 For installation reverse the removal procedure ...

Page 95: ...ends cracks damage Replace Dust seal 4 Wear damage Replace 3 Check Brake shoes 1 Brake shoe springs 2 Cracks damage Replace as a set NOTE When replacing the brake shoes replace the brake shoe springs at the same time 4 Check Brake shoe lining Glazed areas Repair Sand the glazed areas with coarse sandpaper NOTE After sanding the glazed areas clean the brake shoe with a cloth ...

Page 96: ... mm 0 08 in 6 Measure Brake drum inside diameter a Out of specification Replace Brake drum inside diameter limit maximum 161 mm 6 34 in 7 Check Brake drum inner surface Oil deposits Clean Remove the oil with a rag soaked in lacquer thinner or solvent Scratches Repair Lightly and evenly polish the scratches with an emery cloth INSTALLING THE REAR BRAKE 1 Lubricate Brake camshaft 1 Pivot pins 2 Lith...

Page 97: ...f the wear indicator scale 2 3 Install Brake camshaft lever 1 NOTE When installing the brake camshaft lever align the punch marks 2 on the brake camshaft lever and brake camshaft 4 Apply Sealant 3 onto the mating surfaces of swingarm 5 Install Brake shoe plate 1 Bearing retainer 2 Brake shoes 3 Spring 4 Plate 5 Cotter pins 6 T R Bolt camshaft lever 9 Nm 0 9 m kg 6 5 ft lb Sealant Quick Gasket P N ...

Page 98: ... 9 Install Springs 3 Pins 4 Adjusting nuts 5 Brake drum Brake drum cover 10 Install Rear wheel hub left Rear wheel left Refer to FRONT AND REAR WHEELS in CHAPTER 8 Manual No 5TE2 AE1 11 Adjust Rear brake pedal free play Rear brake lever free play Refer to ADJUSTING THE REAR BRAKE in CHAPTER 3 Manual No 5TE2 AE1 T R Axle nut 150 Nm 15 m kg 110 ft lb Nut rear wheel 55 Nm 5 5 m kg 40 ft lb ...

Page 99: ...ar Refer to HANDLEBAR in CHAPTER 8 Manual No 5TE2 AE1 Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK Front fender 1 Lock washer 1 Refer to INSTALLING THE CABLE GUIDE in CHAPTER 8 Manual No 5TE2 AE1 2 Cable guide 1 3 Steering stem bushing 2 4 Collar 2 5 Oil seal 2 6 Tie rod end nut 2 7 Tie rod 2 Disconnect 8 Steering stem nut 1 9 Pitman arm 1 10 Steering stem 1 ...

Page 100: ... Part name Q ty Remarks 11 Oil seal 1 12 Bearing retainer 1 Refer to REMOVING THE BEARING RETAINER and INSTALLING THE BEARING RETAINER in CHAPTER 8 Manual No 5TE2 AE1 13 Bearing 1 14 Oil seal 1 For installation reverse the removal procedure ...

Page 101: ... Q ty Remarks Removing the front arms and front shock absorbers Remove the parts in the order below Engine skid plate Refer to SEAT CARRIERS FENDERS AND FUEL TANK Front fender Front wheel brake disc Refer to FRONT AND REAR WHEELS in CHAPTER 8 Manual No 5TE2 AE1 1 Air duct 1 2 Brake disc guard 1 3 Protector 1 ...

Page 102: ... FRONT ARMS and INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER in CHAPTER 8 Manual No 5TE2 AE1 5 Nut 1 6 Bolt nut 2 2 7 Front lower arm bushing 1 2 8 Bolt nut 2 2 9 Front shock absorber 1 10 Bolt nut 2 2 11 Front upper arm bushing 1 2 12 Circlip 1 13 Ball joint 1 For installation reverse the removal procedure ...

Page 103: ... the order below 1 Starter motor lead 1 2 Starter motor O ring 1 1 For installation reverse the removal procedure Disassembling the starter motor Remove the parts in the order below 1 Bracket 1 1 Refer to ASSEMBLING THE STARTER MOTOR 2 Washer kit 3 Bracket 2 spacer 1 4 Shims 5 Brush holder set 1 6 Armature coil 1 7 Yoke 1 For assembly reverse the disassembly procedure ...

Page 104: ...SSEMBLING THE STARTER MOTOR 1 Install Brush holder set 1 NOTE Align the projection a on the brush seat with the slot b on the bracket 2 Install Yoke Brackets NOTE Align the match marks a on the yoke with the match marks b on the brackets ...

Page 105: ... L B Sb Br W BROWN BROWN 2WD 4WD Br R R W R B Br G L B Y L B L B G R Y L B Y BLACK BLACK BLACK BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G B G Y B Y G B G Y B Y G R B R W L B B B Y Br BLACK BLACK Br Y Br Y Y Br BLACK BLACK W L B Sb Br W Sb B L L R W R B W Y R W R B Y B Br B Y Br Y L B B R Br L R W Br L Br R ON OFF Br G Y Y B B Y Br B Y Br R R B W W L W Y R W L R B W W L Br ...

Page 106: ...ight H Four wheel drive indicator light I Diode J Four wheel drive fuse L Gear motor O Neutral indicator light P Reverse indicator light R Ignition fuse T Signaling system fuse V Horn switch W Horn Z Engine stop switch Start switch Front brake light switch _ Rear brake light switch a Tail brake light b Rear brake switch È For Europe and Oceania ...

Page 107: ...lace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler wire harness side Tester lead Red Black terminal 1 Tester lead White Blue terminal 2 MEETS SPECIFICATION Turn the start switch to and the main switch to ON Check the voltage 12 V OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair it CORRECT...

Page 108: ... negative probes the readings in the left chart will be reversed INCORRECT Replace the diode GOOD CONDITION 5 Thermo unit Remove the thermo unit from the crankcase Connect the pocket tester Ω 100 to the thermo unit 1 Immerse the thermo unit in engine oil 2 Measure the resistance Thermo unit resistance 150 C 302 F 307 339 Ω 170 C 338 F 209 231 Ω WARNING Handle the thermo unit with special care Neve...

Page 109: ...L B Y BLACK BLACK BLACK BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G B G Y B Y G B G Y B Y G R B R W L B B B Y Br BLACK BLACK Br Y Br Y Y Br BLACK BLACK W L B Sb Br W Sb B L L R W R B W Y R W R B Y B Br B Y Br Y L B B R Br L R W Br L Br R ON OFF Br G Y Y B B Y Br B Y Br R R B W W L W Y R W L R B W W L Br R R B GRAY GRAY B W Dg W L L B L B W L Br L R R Br GRAY GRAY ON OFF Ê Ê...

Page 110: ...special tool s for troubleshooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main ignition Refer to CHECKING THE SWITCHES in CHAPTER 9 Manual No 5TE2 AE1 NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Manual No 5TE2 AE1 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the ba...

Page 111: ... Battery lead Black terminal 2 Check the operation of the fan motor DOES NOT TURN Replace the fan motor MEETS SPECIFICATION 5 Circuit breaker fan motor Remove the circuit breaker from the wire harness Connect the pocket tester Ω 1 to the circuit breaker Circuit breaker resistance Zero Ω at 20 C 68 F OUT OF SPECIFICATION Replace the circuit breaker ...

Page 112: ...y for continuity NO CONTINUITY Replace the fan motor relay W Y R W R B L 2 1 3 4 GOOD CONDITION 7 Thermo unit Remove the thermo unit from the crankcase Connect the pocket tester Ω 100 to the thermo unit 1 Immerse the thermo unit in engine oil 2 Measure the resistance Thermo unit resistance 150 C 302 F 307 339 Ω 170 C 338 F 209 231 Ω WARNING Handle the thermo unit with special care Never subject it...

Page 113: ...OOLING SYSTEM C0NTINUITY EB803028 CORRECT 8 Wiring connections Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM Replace the CDI unit POOR CONNECTION Properly connect the cooling system ...

Page 114: ...rectly assembled transmission Shift guide Broken shift guide OVERHEATING OVERHEATING Ignition system Improper spark plug gap Improper spark plug heat range Faulty CDI unit Fuel system Improper carburetor main jet improper setting Improper fuel level Clogged air filter element Compression system Heavy carbon build up JUMPS OUT OF GEAR Shift shaft Improperly adjusted shift lever position Worn shift ...

Page 115: ...r cylinder kit cup Faulty caliper kit seal Loose union bolt Broken brake hose and pipe Oily or greasy disc brake pads Improper brake fluid level Rear drum brake Worn brake shoe lining Worn brake drum Oily or greasy brake shoe lining Oily or greasy brake drum Improperly adjusted brake lever free play Improper brake cam lever position Fatigued damaged return spring ...

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Page 118: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 119: ...regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 CDI unit 9 Ignition coil 0 Spark plug A Thermo unit B Reverse switch C Neutral switch D Circuit breaker fan motor E Fan motor relay F Fan motor G Oil temperature warning light H Four wheel drive indicator light I Diode J Four wheel drive fuse K On command four wheel drive switch L Gear motor M Auxiliary DC jack fuse N ...

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