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Yamaha YFM400FWA 2000 5GH3-AE1, Service Manual

The Yamaha YFM400FWA 2000 5GH3-AE1 Service Manual is a comprehensive guide for owners and technicians alike, providing in-depth instructions and diagrams to properly maintain and repair this ATV model. Available for free download from manualshive.com, it ensures you have all the necessary resources at your fingertips.

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10 - 5

TRBL

SHTG

FAULTY CLUTCH PERFORMANCE/OVERHEATING/

OVER COOLING/FAULTY BRAKE

POOR SPEED PERFORMANCE
V-belt

●

Oil or grease on the V-belt

Primary pulley weight

●

Faulty operation

●

Worn primary pulley weight

Primary fixed sheave

●

Worn primary fixed sheave

Primary sliding sheave

●

Worn primary sliding sheave

Secondary fixed sheave

●

Worn secondary fixed sheave

Secondary sliding sheave

●

Worn secondary sliding sheave

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

Engine oil

●

Improper oil level

●

Improper oil viscosity

●

Inferior oil quality

Brake

●

Brake drag

Cooling system

●

Low coolant level

●

Clogged or damaged radiator

●

Damaged or faulty water pump

●

Thermostat stays closed

OVER COOLING

COOLING SYSTEM
Thermostat

●

Thermostat stays open

FAULTY BRAKE

POOR BRAKING EFFECT
Disc brake

●

Worn brake pads

●

Worn disc

●

Air in brake fluid

●

Leaking brake fluid

●

Faulty master 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

Summary of Contents for YFM400FWA 2000 5GH3-AE1

Page 1: ...SERVICEMANUAL YFM400FWA M 5GH3 AE1 2000 ...

Page 2: ...A M 2000 SERVICE MANUAL 1999 by Yamaha Motor Co Ltd First Edition July 1999 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...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 4: ...ntify 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 t...

Page 5: ...t 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 lightweight lithium soap base grease N Apply molybdenum disulfide grease Illustrated symbols O to P in the explode...

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

Page 7: ...GEN INFO 1 ...

Page 8: ...EL 1 1 FEATURES 1 2 LIQUID COOLING ENGINE 1 2 PARK POSITION 1 2 IMPORTANT INFORMATION 1 3 PREPARATION FOR REMOVAL PROCEDURES 1 3 REPLACEMENT PARTS 1 3 GASKETS OIL SEALS AND O RINGS 1 3 LOCK WASHERS PLATES AND COTTER PINS 1 4 BEARINGS AND OIL SEALS 1 4 CIRCLIPS 1 4 CHECKING OF CONNECTIONS 1 5 SPECIAL TOOLS 1 6 ...

Page 9: ...GEN INFO ...

Page 10: ...FORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 11: ...ar preventing the drive select lever and transmission from moving When the drive select lever is at the L H N or R positions the stopper lever end 1 is moved away from the stop per gear 2 by the return spring 3 When the drive select lever is in the P position the lever cam 4 at the side of the shift cam 5 lifts the stopper lever end 6 and the stopper lever end locks the drive axle 7 When the stopp...

Page 12: ...rts and place them in trays in the order of disassembly This will speed up assem bly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EB101010 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 func tion and appearance but inferior i...

Page 13: ...oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liber ally when installing if appropriate 1 Oil seal CAUTION Do not use compressed air to spin the bear ings dry This will damage the bearing sur faces 1 Bearing EB101050 CIRCLIPS 1 Check all circlips carefully before reas sembly Always replace piston pin clips after one use Replace distorted circlips ...

Page 14: ...erminals several times 3 Check Connector leads Looseness Bend up the pin 1 and con nect the terminals 4 Connect Connector terminals NOTE The two terminals click together 5 Check Continuity using a pocket tester NOTE If there is no continuity clean the termi nals When checking the wire harness be sure to perform steps 1 to 3 As a quick remedy use a contact revital izer available at most part stores...

Page 15: ...90890 01083 Weight 90890 01084 Set YU 01083 A Slide hammer bolt M6 weight set These tools are used to remove the rocker arm shaft 90890 01135 YU 01135 A Crankcase separating tool This tool is used to separate the crank case 90890 01225 YM 01225 A Valve guide remover 7 0 mm This tool is needed to remove and install the valve guide 90890 04017 YM 04017 Valve guide installer 7 0 mm This tool is neede...

Page 16: ... 01304 Piston pin puller This tool is used to remove the piston pin 90890 01311 YU 08035 Tappet adjusting tool 3 mm This tool is necessary for adjusting the valve clearance 90890 01312 YM 01312 A Fuel level gauge This gauge is used to measure the fuel level in the float chamber 90890 01325 YU 24460 01 Radiator cap tester This tool is used to check the cooling system 90890 01352 YU 33984 Adapter Th...

Page 17: ...retainer 90890 01426 YU 38411 Oil filter wrench This tool is needed to loosen or tighten the oil filter cartridge 90890 01430 YM 38404 Ring nut wrench This tool is needed to removing and installing the middle driven shaft bear ing retainer 90890 01467 YM 01467 90890 01475 YM 01475 Gear lash measurement tool This tool is used to measure the gear lash 90890 01701 YU 01880 Sheave holder This tool is ...

Page 18: ...ve assemblies Middle driven shaft bearing driver 90890 04058 YM 04058 1 Mechanical seal installer 90890 04078 YM 33221 Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal 90890 04050 YM 04050 Bearing retainer wrench This tool is needed when removing or installing the final drive shaft bearing retainer 90890 04062 YM 04062 Universal joint...

Page 19: ... is used to hold the shift cam 90890 06754 Ignition checker This instrument is necessary for check ing the ignition system components YM 34487 Dynamic spark tester This instrument is necessary for check ing the ignition system components Bond 90890 85505 Sealant ACC 11001 05 01 Yamaha bond No 1215 Sealant Quick Gasket This sealant bond is used on crank case mating surfaces etc Tool No Tool name Ho...

Page 20: ...SPEC 2 ...

Page 21: ...TENANCE SPECIFICATIONS 2 5 ENGINE 2 5 CHASSIS 2 15 ELECTRICAL 2 19 HOW TO USE THE CONVERSION TABLE 2 21 GENERAL TORQUE SPECIFICATIONS 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 COOLANT FLOW DIAGRAMS 2 23 OIL FLOW DIAGRAMS 2 25 CABLE ROUTING 2 28 ...

Page 22: ...SPEC ...

Page 23: ...ent 401 cm3 Bore stroke 84 5 71 5 mm 3 33 2 81 in Compression ratio 10 5 1 Starting system Electric and recoil starter Lubrication system Wet sump Oil type or grade Engine oil API service SE SF SG type or higher Final gear oil SAE 80API GL 4 Hypoid Gear Oil Differential gear oil SAE 80API GL 4 Hypoid Gear Oil Oil capacity Engine oil Periodic oil change 2 3 L 2 0 lmp qt 2 4 US qt With oil filter re...

Page 24: ... Oceania X24ES U DENSO For Oceania Spark plug gap 0 6 0 7 mm 0 02 0 03 in Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Spur gear Secondary reduction ratio 39 24 24 18 33 9 7 944 Transmission type V belt automatic Operation Left hand operation Single speed automatic 2 55 0 75 1 Sub transmission ratio low 45 16 2 813 high 38 23 1 652 R...

Page 25: ... DUNLOP For CDN GB F CH CHENG SHIN For Oceania rear DUNLOP For CDN GB F CH CHENG SHIN For Oceania Type front KT123 For CDN GB F CH C828 For Oceania rear KT127 For CDN GB F CH C828 For Oceania Item Standard GENERAL SPECIFICATIONS ...

Page 26: ... Swingarm monocross Shock absorber 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 C D I Generator system A C magneto Battery type YTX20L BS Battery capacity 12 V 18 AH Headlight type Krypton bulb Bulb wattage quantity Headlight 12 V 30 W 30 W 2 Tail lig...

Page 27: ...1 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 C 8 61 8 73 mm 0 3390 0 3437 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 C 8 61 8 73 mm 0 3390 0 3437 in Camshaft runout limit 0 03 mm 0 0012 in ...

Page 28: ... 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 0314 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 2722 in Guide inside diameter IN 7 000 7 012 mm 0 2756 0 2...

Page 29: ...33 6 mm 1 32 in Compressed pressure installed IN 104 9 120 6 N 10 70 12 30 kg 23 58 27 11 lb EX 104 9 120 6 N 10 70 12 30 kg 23 58 27 11 lb Tilt limit IN 2 5 1 6 mm 2 5 0 06 in EX 2 5 1 6 mm 2 5 0 06 in Direction of winding top view IN Counterclockwise EX Counterclockwise Outer spring Free length IN 43 27 mm 1 70 in 41 27 mm 1 62 in EX 43 27 mm 1 70 in 41 27 mm 1 62 in Set length valve closed IN 3...

Page 30: ...on size D 84 445 84 460 mm 3 3246 3 3252 in Measuring point H 5 mm 0 20 in Piston off set 0 5 mm 0 0200 in Piston pin bore inside diameter 20 004 20 015 mm 0 7876 0 7880 in 20 045 mm 0 7892 in Piston pin outside diameter 19 993 20 000 mm 0 7871 0 7874 in 19 973 mm 0 7863 in Piston rings Top ring Type Barrel Dimensions B T 1 2 3 1 mm 0 0472 0 1220 in End gap installed 0 2 0 4 mm 0 0079 0 0157 in 0 ...

Page 31: ...kshaft Crank width A 62 95 63 00 mm 2 4783 2 4803 in Runout limit C1 0 03 mm 0 0012 in C2 0 03 mm 0 0012 in Big end side clearance D 0 25 0 75 mm 0 0098 0 0295 in 1 0 mm 0 0394 in Big end radial clearance E 0 010 0 025 mm 0 0004 0 0010 in Balancer Balancer drive method Gear Automatic centrifugal clutch Clutch shoe thickness 1 5 mm 0 06 in 1 0 mm 0 04 in Clutch in revolution 1 900 2 300 r min Clutc...

Page 32: ... screw P S 2 1 2 Valve seat size V S 2 0 Starter jet G S 1 70 Starter jet G S 2 0 9 Throttle valve size Th V 90 Float height F H 13 mm 0 51 in Fuel level F L 2 3 mm 0 08 0 12 in Engine idle speed 1 450 1 550 r min Intake vacuum 32 kPa 240 mmHg 9 45 inHg Oil pump Oil pump type Trochoid Tip clearance A or B 0 15 mm 0 006 in 0 2 mm 0 008 in Side clearance 0 04 0 09 mm 0 002 0 004 in Bypass valve sett...

Page 33: ... US qt Water pump Type Single suction centrifugal pump Reduction ratio 38 32 1 188 Thermostat Valve opening temperature 63 5 66 5 C 146 3 151 7 F Valve full open temperature 80 C 176 F Valve lift full open 3 mm 0 12 in 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 08 0 39 mm 0 003 0 015 in Lubrication chart Ite...

Page 34: ...2 12 SPEC Cylinder head tightening sequence Item Standard Limit MAINTENANCE SPECIFICATIONS ...

Page 35: ...rainer cover Plug M35 1 32 3 2 23 Oil drain plug Bolt M14 1 23 2 3 17 Oil pump drive gear Nut M14 1 50 5 0 36 Oil delivery pipe Union bolt M8 2 18 1 8 13 Oil filter bolt Union bolt M20 1 63 6 3 46 E Oil filter cartridge M20 1 17 1 7 12 Carburetor joint Bolt M8 2 20 2 0 14 Muffler and exhaust pipe Bolt M8 2 15 1 5 11 Muffler and pipe Bolt M6 1 8 0 8 5 8 Muffler protector 1 2 Bolt M6 7 14 1 4 10 LT ...

Page 36: ... 1 14 1 4 10 Shift rod Nut M8 2 15 1 5 11 Primary 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 lever Bolt M6 1 14 1 4 10 Shift control cable M12 1 6 0 6 4 3 Select lever unit Bolt M8 3 15 1 5 11 Shift cam ball holding bolt M14 1 18 1 8 13 CDI unit Screw M6 2 7 0 7 5 1 Neutral switch M10 1 20 2 0 14 ...

Page 37: ...nsion Shock absorber travel 130 mm 5 12 in Spring free length 319 mm 12 56 in Spring fitting length 285 5 mm 11 24 in Spring rate K1 31 4 N mm 3 20 kg mm 179 29 lb in Stroke K1 0 130 mm 0 5 12 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 ...

Page 38: ...ngle Disc outside diameter thickness 220 0 3 6 mm 8 66 0 14 in Pad thickness inner 5 6 mm 0 22 in 1 mm 0 04 in Pad thickness outer 5 6 mm 0 22 in 1 mm 0 04 in Master cylinder inside diameter 14 mm 0 55 in Caliper cylinder inside diameter 32 mm 1 26 in Brake fluid type DOT 4 Brake lever and brake pedal Brake lever free play at lever end 0 mm 0 in Brake lever free play left 0 5 2 mm 0 02 0 08 in Bra...

Page 39: ...g stem pitman arm and frame M14 110 11 0 80 LS Steering stem holder and frame M8 23 2 3 17 Use lock washer Steering stem and handlebar holder M8 20 2 0 14 Pitman arm and tie rod end M10 25 2 5 18 Tie rod and locknut M10 15 1 5 11 Steering knuckle and upper front arm M10 25 2 5 18 Steering knuckle and lower front arm M10 48 4 8 35 LS Steering knuckle and tie rod M10 25 2 5 18 Fuel tank and fuel coc...

Page 40: ... 39 3 9 28 LT Differential gear case and bearing housing M8 25 2 5 18 Gear motor M8 13 1 3 9 4 Four wheel drive switch M10 20 2 0 14 Final gear case oil filler bolt M14 23 2 3 16 Final gear case oil drain bolt M14 23 2 3 16 Bearing retainer drive pinion gear M65 100 10 0 72 Final gear case and bearing housing M10 40 4 0 29 Final gear case and bearing housing M8 23 2 3 17 Part to be tightened Threa...

Page 41: ... at 20 C 68 F Secondary winding resistance 6 32 9 48 kΩ at 20 C 68 F Spark plug cap Type Resin type Resistance 10 kΩ Charging system Type A C magneto generator Model manufacturer F4T464 MITSUBISHI Nominal output 14 V 12 A at 3 000 r min Charging coil resistance color 0 70 0 86 Ω at 20 C 68 F White White Rectifier Model manufacturer SH640E 11 SHINDENGEN Capacity 14 A Withstand voltage 200 V Electri...

Page 42: ... 108 db 2 m Coil winding resistance 4 35 4 80 Ω Electric fan Running rpm 3 000 r min Thermostat switch Model manufacturer 4BA DENSO Circuit breaker Type Fuse Amperage for individual circuit Main fuse 30 A 1 Headlight fuse 15 A 1 Signal fuse 10 A 1 Ignition fuse 10 A 1 Auxiliary DC jack fuse 10 A 1 Four wheel drive fuse 3 A 1 Reserve 30 A 1 Reserve 15 A 1 Reserve 10 A 1 Reserve 3 A 1 Item Standard ...

Page 43: ...ts 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 3937 0 03937 mi ft y...

Page 44: ...d bolt E Oil pump shaft rotor housing E Oil filter O ring E Starter idle gear shaft E Transmission gear wheel pinion M Axle main drive M Shift fork guide bar E Shift cam shift shaft shift cam stopper ball E Shift lever select lever shift guide LS Shift cam lever M Stopper lever E Clutch housing E One way bearing M Drive chain sprocket E Driven cam M Front drive shaft collar E Crankcase mating surf...

Page 45: ...2 23 SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 Fan motor ...

Page 46: ...2 24 SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermostat ...

Page 47: ...2 25 SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle ...

Page 48: ...2 26 SPEC OIL FLOW DIAGRAMS 1 Oil filter ...

Page 49: ...2 27 SPEC OIL FLOW DIAGRAMS 1 Oil pump 2 Oil strainer ...

Page 50: ... Throttle cable 6 On command four wheel drive switch lead 7 Front brake switch lead 8 Handlebar switch 9 Starter cable 0 Coolant reservoir breather hose A Sub wire harness 1 to fan motor coupler B Sub wire harness 1 to gear motor and four wheel drive switch C Differential gear case breather hose D Fan motor breather hose E Horn switch ...

Page 51: ...indicator light 7 Parking indicator light 8 Reverse indicator light 9 Coolant reservoir breather hose 0 Fan motor breather hose A Differential gear case breather hose B Indicator light coupler C Main switch coupler D Ignition coil lead E Ignition coil F Circuit braker Å Connect the headlight lead of the circuit breaker to the headlight on the right side ...

Page 52: ...e battery lead 5 Speed sensor 6 Carburetor drain hose 7 Wire harness 8 Sub wire harness 2 9 Ground lead 0 Speed sensor A CDI magneto lead B Final drive gear case breather hose C Rectifier regulator D Sub wire harness 1 E Coolant reservoir breather hose F Coolant reservoir hose G Speedometer cable ...

Page 53: ...the front fender ı Insert the fuel tank into the hole in the handlebar cover Ç Fasten the CDI magneto lead and starter motor lead with a plastic band Î To hole on the rear fender Pass the speedometer cable through the guide on the air duct ...

Page 54: ...2 32 SPEC CABLE ROUTING 1 Cylinder head breather hose 2 Spark plug lead 3 Rear brake cable 4 Select lever control cable 5 Rear brake reservoir hose 6 Rear brake hose ...

Page 55: ...ad 5 Starter relay 6 CDI unit 7 Main fuse 8 Reverse relay 9 Starting circuit cut off relay 0 Fuse box A Negative battery lead B Final drive gear case breather hose C Cylinder head breather hose D Starter cable E Rear brake cable F Wire harness G Rear brake hose Å 65 75 mm 2 6 3 0 in ...

Page 56: ...2 34 SPEC ...

Page 57: ...INSP ADJ 3 ...

Page 58: ...MENT 3 17 SPARK PLUG INSPECTION 3 18 IGNITION TIMING CHECK 3 19 COMPRESSION PRESSURE MEASUREMENT 3 20 ENGINE OIL LEVEL INSPECTION 3 22 ENGINE OIL REPLACEMENT 3 23 AIR FILTER CLEANING 3 26 COOLANT LEVEL INSPECTION 3 28 COOLANT REPLACEMENT 3 29 COOLANT TEMPERATURE INDICATOR LIGHT CHECK 3 33 V BELT INSPECTION 3 33 CHASSIS 3 35 FRONT BRAKE ADJUSTMENT 3 35 REAR BRAKE ADJUSTMENT 3 35 BRAKE FLUID LEVEL I...

Page 59: ...OE IN ADJUSTMENT 3 47 FRONT SHOCK ABSORBER ADJUSTMENT 3 49 REAR SHOCK ABSORBER ADJUSTMENT 3 49 TIRE INSPECTION 3 49 WHEEL INSPECTION 3 52 CABLE INSPECTION AND LUBRICATION 3 52 LEVERS PEDAL ETC LUBRICATION 3 53 ELECTRICAL 3 54 BATTERY INSPECTION 3 54 FUSE INSPECTION 3 59 HEADLIGHT BEAM ADJUSTMENT 3 61 HEADLIGHT BULB REPLACEMENT 3 61 ...

Page 60: ...heck condition Adjust gap and clean Replace if necessary Air filter Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check and adjust idle speed starter operation Adjust if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace warm engine before draining Engine oil filter Replace Engine oil strainer Clean Final gear...

Page 61: ...r caliper cylinder replace the brake fluid Nor mally check the brake fluid level and add fluid as required 2 On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 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 ...

Page 62: ...e Part name Q ty Remarks Seat and side panels removal Remove the parts in the order below 1 Seat 1 2 Fuel tank side panel left 1 3 Fuel tank side panel right 1 4 Engine side panel 1 5 Engine side cover 1 For installation reverse the removal procedure NOTE Pull up the seat lock lever then pull up on the rear of the seat ...

Page 63: ...y Remarks Front carrier front bumper and front fender removal Remove the parts in the order below Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS 1 Front carrier 1 2 Front fender panel 1 3 Engine skid plate front 1 4 Front bumper 1 5 Headlight coupler 2 6 Front grill 1 7 Handlebar cover 1 8 Fuel tank cover 1 ...

Page 64: ... 1 Disconnect 11 Main switch coupler 1 Disconnect 12 Auxiliary DC jack coupler 1 Disconnect 13 Speedometer light coupler 1 Disconnect 14 Speedometer cable 1 Disconnect 15 Coolant reservoir breather hose 1 16 Fan motor breather hose 1 17 Differential gear case breather hose 1 18 Front fender 1 19 Drain hose 1 For installation reverse the removal procedure ...

Page 65: ...ve the parts in the order below Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS Fuel tank Refer to FUEL TANK 1 Rear carrier 1 2 Battery holding bracket 1 3 Battery lead cover 1 4 Battery lead 2 Disconnect 5 Battery 1 6 Starter relay ground lead 1 7 Taillight connector 2 CAUTION First disconnect the negative lead then disconnect the positive lead ...

Page 66: ...L TANK Order Job name Part name Q ty Remarks 8 Final drive gear case breather hose 1 9 Cylinder head breather hose 1 10 Clamp screw 1 Loosen 11 Air filter case 1 12 Plastic band 1 13 Rear fender 1 For installation reverse the removal procedure ...

Page 67: ... Fuel tank cover Refer to FRONT CARRIER FRONT BUMPER AND FRONT FENDER 1 Fuel hose 1 2 Fuel cock 1 3 Fuel tank 1 4 Vacuum chamber breather hose 1 5 Plastic band 4 6 Rubber cover 1 For installation reverse the removal procedure NOTE Before disconnecting the fuel hose turn the fuel cock to OFF NOTE When installing the fuel tank pass the fuel tank breather hose through the hole in the handlebar protec...

Page 68: ...marks Footrest boards removal Remove the parts in the order below Fuel tank side panels Refer to SEAT AND SIDE PANELS 1 Footrest 2 2 Left footrest board 1 3 Right footrest board 1 4 Left footrest bracket 1 5 Right footrest bracket 1 For installation reverse the removal procedure ...

Page 69: ... to the touch Adjust the valve clearance when the pis ton is at the Top Dead Center T D C on the compression stroke 1 Remove Seat Front carrier Front fender Fuel tank Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Remove Tappet cover intake 1 Tappet cover exhaust 2 3 Disconnect Spark plug cap 3 4 Remove Spark plug 5 Remove Recoil starter 1 ...

Page 70: ... the T mark 1 on the rotor with the stationary pointer 2 on the crankcase cover When the T mark is aligned with the stationary pointer the piston is at the Top Dead Center T D C NOTE When the piston is at the Top Dead Center T D C on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the cran...

Page 71: ...tighten the locknut Measure the valve clearance If the clearance is incorrect repeat the above steps until the proper clearance is obtained Valve adjusting tool P N YM 08035 90890 01311 T R Locknut 20 Nm 2 0 m kg 14 ft lb 9 Install All removed parts NOTE Install all removed parts in the reverse order of their disassembly Note the follow ing points 10 Install Recoil starter Spark plug Tappet covers...

Page 72: ...djustment free IDLING SPEED ADJUSTMENT 1 Start the engine and let it warm up for several minutes 2 Remove Seat Fuel tank side panels Refer to SEAT CARRIERS FENDERS AND FUEL TANK 3 Attach Inductive tachometer or engine tachometer to the spark plug lead 4 Check Engine idling speed Out of specification Adjust Inductive tachometer P N YU 8036 A Engine tachometer P N 90890 03113 Engine idling speed 1 4...

Page 73: ...ine tachometer 7 Adjust Throttle lever free play Refer to THROTTLE LEVER FREE PLAY ADJUSTMENT 8 Install Fuel tank side panels Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK Turning in Idling speed becomes higher Turning out Idling speed becomes lower Throttle lever free play 3 5 mm 0 12 0 20 in THROTTLE LEVER FREE PLAY ADJUSTMENT NOTE Engine idling speed should be adjusted properly before adjus...

Page 74: ...1 Loosen the locknut 2 on the carburetor side Turn the adjuster 3 in or out until the cor rect free play is obtained Tighten the locknut 2 Push in the adjuster cover 1 NOTE If the free play cannot be adjusted here adjust it at the throttle lever side of the cable Second step Pull back the adjuster cover 4 Loosen the locknut 5 Turn the adjuster 6 in or out until the cor rect free play is obtained T...

Page 75: ...CARRIERS FENDERS AND FUEL TANK SPEED LIMITER ADJUSTMENT The speed limiter keeps the carburetor throttle from becoming fully opened even when the throttle lever is applied to the maximum position Screwing in the adjuster stops the engine speed from increasing 1 Check Speed limiter length a Out of specification Adjust Speed limiter length 12 mm 0 47 in 2 Adjust Speed limiter length Speed limiter len...

Page 76: ... 12 mm 0 47 in Also always adjust the throttle lever free play to 3 5 mm 0 12 0 20 in Turning in Speed limiter length is decreased Turning out Speed limiter length is increased STARTER LEVER FREE PLAY ADJUSTMENT 1 Check Starter lever free play a Out of specification Adjust Starter lever free play 5 5 14 2 mm 0 22 0 56 in 2 Remove Seat Fuel tank side panel left Refer to SEAT CARRIERS FENDERS AND FU...

Page 77: ...out Free play decreased SPARK PLUG INSPECTION 1 Remove Seat Fuel tank side panel right Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Remove Spark plug 3 Inspect Spark plug type Incorrect Replace Standard spark plug DR8EA NGK For CDN GB F CH D8EA NGK For Oceania X24ES U DENSO For Oceania 4 Inspect Electrode 1 Wear damage Replace Insulator 2 Abnormal color Replace Normal color is a medium to light ...

Page 78: ...NDERS AND FUEL TANK Spark plug gap 0 6 0 7 mm 0 024 0 028 in T R 18 Nm 1 8 m kg 13 ft lb IGNITION TIMING CHECK NOTE Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing 1 Remove Seat Fuel tank side panel right Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Attach Inductive tachometer or engine tachometer Timing light to spark plug lead In...

Page 79: ...iring range 4 indicated on the flywheel Incorrect firing range Check the pulser coil assembly Install the timing plug Install the recoil starter 4 Detach Timing light Inductive tachometer or engine tachome ter 5 Install Seat Fuel tank side panel right Refer to SEAT CARRIERS FENDERS AND FUEL TANK Engine speed 1 450 1 550 r min T R Recoil starter bolt 10 Nm 1 0 m kg 7 2 ft Ib LOCTITE COMPRESSION PRE...

Page 80: ...uge 1 Compression gauge P N YU 33223 90890 03081 Adapter P N YU 33223 3 90890 04082 7 Measure Compression pressure Above the maximum pressure Inspect the cylinder head valve surfaces and piston crown for carbon deposits Below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again Refer to the table below Compression pressure with oil introduced into cylinder Re...

Page 81: ... gauge stabilizes WARNING When cranking the engine ground the spark plug lead to prevent sparking 8 Install Spark plug 9 Remove Fuel tank side panel right Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK T R 18 Nm 1 8 m kg 13 ft lb ENGINE OIL LEVEL INSPECTION 1 Place the machine on a level surface 2 Remove Engine side panel Refer to SEAT CARRIERS FENDERS AND FUEL TANK 3 Inspect Engine oil level O...

Page 82: ...s before inspecting the oil level WARNING Never remove the dipstick just after high speed operation because the heated oil could spurt out Wait until the oil cools down before removing the dipstick 6 Install Engine side panel 0 10 30 50 70 90 110 F YAMALUBE 4 20W40 or SAE 20W40 YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 C ENGINE OIL REPLACEMENT 1 Start the engine and let it warm up...

Page 83: ...cartridge 1 with an oil filter wrench 2 Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil CAUTION Make sure that the O ring 3 is positioned correctly in the groove of the oil filter car tridge Tighten the new oil filter cartridge to spec ification with an oil filter wrench Oil filter wrench P N YU 38411 90890 01426 T R Oil filter cartridge 17 Nm 1 7 m kg 12 ft l...

Page 84: ...il comes out after one minute turn the engine off so that it will not seize Check the engine oil passages the oil fil ter cartridge and the oil pump for damage or leakage Refer to OIL PAN AND OIL PUMP in CHAPTER 4 Start the engine after solving the prob lem s and check the engine oil pressure again Tighten the oil gallery bolt to specifica tion 12 Install Engine side cover Fuel tank side panel lef...

Page 85: ... cover 3 4 Remove Air filter element assembly 1 Air filter element cap Air filter element NOTE When removing the air filter element rotate the air filter element cap 1 4 of a turn and remove the element 2 Air filter element cap 3 Air filter element CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid wear and possible engine dam...

Page 86: ...out the element This could damage the foam material Apply engine oil to the element Squeeze out the excess oil NOTE The element should be wet but not drip ping 7 Install Air filter element Air filter case cover NOTE Insert the lobes 1 on the filter element into the receptacles 2 on the filter case To prevent air leaks make sure that the sealing surface of the element matches the sealing surface of...

Page 87: ...g 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 the coolant Use only distilled water However soft water may be used if distilled water is not available 4 Start the engine warm it up for several minutes and then turn it off 5 Inspect Coolant level NOTE Before inspecting the coo...

Page 88: ...IERS FENDERS AND FUEL TANK Left footrest board Refer to FOOTREST BOARDS 2 Remove Engine skid plate rear 1 3 Remove Plastic band 1 Coolant reservoir bolts 2 Coolant reservoir cap 3 4 Disconnect Coolant reservoir breather hose 4 5 Drain Coolant from the coolant reservoir 6 Connect Coolant reservoir breather hose 7 Install Coolant reservoir bolts Plastic band ...

Page 89: ...d 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 9 Remove Coolant drain bolt cylinder 1 along with the copper washer Coolant drain bolt water pump 2 along with the copper washer 10 Drain Coolant 11 Check Copper washer 1 Coo...

Page 90: ...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 the coolant Use only distilled water However soft water may be used if distilled water is not available If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antif...

Page 91: ...several minutes and then turn it off 18 Inspect Coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Before inspecting the coolant level wait a few minutes until the coolant has settled 19 Install Engine skid plate rear Left footrest board Refer to FOOTREST BOARDS Front fender Front carrier Engine side cover Fuel tank side panel left Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ...

Page 92: ...tor light V BELT INSPECTION 1 Remove Right footrest board Crankcase cover right Refer to PRIMARY AND SECONDARY SHEAVES in CHAPTER 4 2 Inspect V belt 1 Cracks wear scaling chipping Replace Oil grease Check primary sheave and secondary sheave 3 Measure V belt width 2 Out of specification Replace V belt width 29 3 mm 1 15 in Limit 27 3 mm 1 07 in ...

Page 93: ...NOTE Tightening the bolts 1 will push the sec ondary sliding sheave away causing the gap between the secondary fixed and slid ing sheaves to widen Remove the V belt 1 from the primary sheave and secondary sheave Install the V belt NOTE Install the V belt so that its arrow faces the direction shown in the illustration Remove the bolts ...

Page 94: ...in at brake lever end REAR BRAKE ADJUSTMENT WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake 1 Check Rear brake pedal free play a Out of specification Bleed the rear brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM Rear brake pedal free play 5 7 mm 0 2 0 3 in 2 Check Rear brake lever free play b Out of specification Adjust Rear brake le...

Page 95: ...ar 2 until the clearance a is within the specified limits Rear brake pedal height 53 60 mm 2 09 2 36 in Clearance a 0 mm 0 in Remove the rear brake master cylinder cover 3 Loosen the locknut 4 Turn the adjusting bolt 5 until the brake pedal height is within the specified limits Tighten the locknut 4 NOTE When adjusting the brake pedal height make sure the locknut to adjusting bolt clearance b does...

Page 96: ...e adjuster han dlebar 2 until the rear brake lever free play d is within the specified limits Tighten the locknut handlebar 1 Adjust the select lever control cable Refer to SELECT LEVER CONTROL CABLE AND SHIFT ROD ADJUSTMENT Install the rear brake master cylinder cover WARNING After this adjustment is performed lift the front and rear wheels off the ground by placing a block under the engine and s...

Page 97: ...ake CAUTION Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately WARNING Use only the designed quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance Be careful that water doe...

Page 98: ... 4 Install Front wheels Brake pad wear limit a 1 mm 0 04 in REAR BRAKE PAD INSPECTION 1 Remove Rear wheel left 2 Inspect Brake pad Wear indicator groove 1 almost disap peared Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in CHAPTER 8 3 Operate the brake lever or brake pedal 4 Install Rear wheel left Brake pad wear limit a 1 mm 0 04 in BRAKE HOSE INSPECTION 1 Remove Seat Front carr...

Page 99: ...T BRAKE and REAR BRAKE in CHAPTER 7 6 Install Right footrest board Refer to FOOTREST BOARDS Front fender Front carrier Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK AIR BLEEDING HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if The system has been disassembled A brake hose or brake pipe have been loosened or removed The brake fluid has been very low The brake operation has been faulty A...

Page 100: ...he lever or pedal to travel towards its limit h Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal i Repeat steps e to h until all the air bubbles have disappeared from the fluid j Tighten the bleed screw NOTE If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bub...

Page 101: ...ontrol cable and select lever shift rod adjustment steps Control cable Make sure the select lever is in NEUTRAL Adjust the control cable so there is zero free play in the cable When the adjust ment is correct slack in the return spring 1 will be taken up NOTE In some cases it will be necessary to further adjust the cable with the locknuts 2 arrangement that holds the cable to its mount When the br...

Page 102: ...s in NEUTRAL Loosen both locknuts 1 Adjust the shift rod length for smooth and correct shifting Tighten the locknuts 1 FINAL GEAR OIL LEVEL INSPECTION 1 Place the machine on a level place 2 Remove Oil filler bolt 1 3 Inspect Oil level Oil level should be up to the bottom brim 2 of the hole Oil level low Add oil to the proper level CAUTION Take care not allow foreign material to enter the final gea...

Page 103: ...ged replace it with a new one 7 Fill Final gear case CAUTION Take care not to allow foreign material to enter the final gear case 8 Inspect Oil level Refer to FINAL GEAR OIL LEVEL INSPEC TION 9 Install Oil filler bolt Final gear case protector Periodic oil change 0 19 L 0 17 Imp qt 0 20 US qt Total amount 0 22 L 0 19 Imp qt 0 23 US qt Recommended oil SAE80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m ...

Page 104: ... gear oil is filled to the brim of the oil filler hole oil may start leaking from the differen tial gear case breather hose Therefore check the quantity of the oil not its level Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity periodic oil change 0 35 L 0 31 Imp qt 0 37 US qt T R 23 Nm 2 3 m kg 16 ft lb DIFFERENTIAL GEAR OIL REPLACEMENT 1 Place the machine on a level surface 2 Place a ...

Page 105: ... CAUTION Take care not to allow foreign material to enter the differential gear case 7 Install Oil filler bolt Periodic oil change 0 35 L 0 31 Imp qt 0 37 US qt Total amount 0 40 L 0 35 Imp qt 0 42 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 10 Nm 1 0 m kg 7 ft lb T R 23 Nm 2 3 m kg 16 ft lb CONSTANT VELOCITY JOINT DUST BOOT INSPECTION 1 Inspect Dust boots 1 Damage Replace Refer to D...

Page 106: ...ght 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 bearings TOE IN ADJUSTMENT 1 Place the machine on a level surface 2 Measure Toe in Out of specification Adjust Toe in 0 10 mm 0 0 40 in Toe in measurement steps NOTE Before measuring the toe in make sure that the tire pre...

Page 107: ...nt After setting the toe in to specification run the machine slowly for some distance with both hands lightly holding the handlebar and check that the handlebar responds cor rectly If not turn either the right or left tie rod within the toe in specification Adjustment steps Mark both tie rods ends This reference point will be needed during adjustment Loosen the locknuts tie rod end 1 of both tie r...

Page 108: ...andard position 2 Minimum Soft position 1 Maximum Hard position 5 REAR SHOCK ABSORBER ADJUSTMENT 1 Adjust Spring preload Turn the adjuster 1 to increase or decrease the spring preload NOTE The spring preload of the rear shock absorber can be adjusted to suit the rider s preference weight and the riding condi tions TIRE INSPECTION WARNING This model is equipped with low pressure tires It is importa...

Page 109: ...he following are minimums Front 22 kPa 0 22 kg cm2 3 2 psi Rear 22 kPa 0 22 kg cm2 3 2 psi 3 Use no more than Front 250 kPa 2 5 kg cm2 36 psi Rear 250 kPa 2 5 kg cm2 36 psi when seating the tire beads Higher pres sures may cause the tire to burst Inflate the tires slowly and carefully Fast inflation could cause the tire to burst Manufacturer Size Type Front DUNLOP For CDN GB F CH AT25 8 12 KT123 C...

Page 110: ... the second reading WARNING Uneven or improper tire pressure may adversely affect the handling of this machine and may cause loss of control Maintain proper 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 Inspect Tire surfaces Wear damage Replace WARNING It is dangerous to ride with a worn out tire When tire ...

Page 111: ...elf properly on the rim CABLE INSPECTION AND LUBRICATION WARNING A damaged cable sheath may cause corro sion and interfere with the cable move ment An unsafe condition may result so replace a damaged cable as soon as possi ble 1 Inspect Cable sheath Damage Replace 2 Check Cable operation Unsmooth operation Lubricate or replace NOTE Hold the cable end up and apply several drops of lubricant to the ...

Page 112: ...3 53 INSP ADJ LEVERS PEDAL ETC LUBRICATION 1 Lubricate the pivoting parts Recommended lubricant Yamaha chain and cable lube or Engine oil LEVERS PEDAL ETC LUBRICATION ...

Page 113: ...ttery are different from those of general type bat teries The MF battery should be charged as explained in CHARGING METHOD If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the bat tery WARNING Battery electrolyte is dangerous it contains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures Av...

Page 114: ...acket Battery lead cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Disconnect Battery leads CAUTION First disconnect the negative lead 1 then disconnect the positive lead 2 3 Remove Battery 4 Check Battery condition Battery condition checking steps Connect a digital voltmeter to the battery terminals NOTE The charge state of an MF battery can be checked by measuring the open circuit volt age ...

Page 115: ...e negative termi nal Never remove the sealing caps of an MF battery Make sure that the charging clips are in full contact with the terminal and that they are not shorted together A cor roded clip on the charger may cause the battery to generate heat in the contact area A weak clip spring may cause sparks Before removing the clips from the bat tery terminals be sure to turn off the charger s power ...

Page 116: ...3 57 INSP ADJ BATTERY INSPECTION Charging method using a variable voltage charger ...

Page 117: ...3 58 INSP ADJ BATTERY INSPECTION Charging method using a constant voltage charger ...

Page 118: ...t connect the positive lead 1 then connect the negative lead 2 8 Install Battery lead cover Battery holding bracket Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK FUSE INSPECTION CAUTION Always turn off the main switch when checking or replacing a fuse Otherwise a short circuit may occur 1 Remove Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Inspect Fuses Inspection steps Connect the pock...

Page 119: ...er use a fuse with a rating other than that specified Never use other materials in place of a fuse An improper fuse may cause extensive damage to the electrical system a malfunction of the lighting and ignition systems and could possibly cause a fire 4 Install Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK Pocket tester P N YU 03112 90890 03112 Description Current rating Quantity Main 30 A 1 He...

Page 120: ...ed HEADLIGHT BULB REPLACEMENT 1 Remove Front carrier Front fender panel Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Disconnect Headlight lead couplers 1 3 Remove Cover 1 4 Remove Cover 1 Bulb holder 2 Bulb NOTE Turn the bulb holder counterclockwise and remove the defective bulb WARNING Keep flammable products and your hands away from the bulb while it is on since it will be hot Do not touch the...

Page 121: ...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 6 Install Bulb holder Cover 7 Connect Headlight lead couplers 8 Install Front fender panel Front carrier Refer to SEAT CARRIERS FENDERS AND FUEL TANK New ...

Page 122: ...ENG 4 ...

Page 123: ...G REMOVAL 4 17 CAMSHAFT INSPECTION 4 18 ROCKER ARM AND CAMSHAFT INSPECTION 4 18 VALVE AND VALVE SPRING INSPECTION 4 19 VALVE AND VALVE SPRING INSTALLATION 4 24 CAMSHAFT AND ROCKER ARM INSTALLATION 4 25 CYLINDER AND PISTON 4 26 PISTON REMOVAL 4 27 TIMING CHAIN GUIDE INSPECTION 4 27 CYLINDER AND PISTON INSPECTION 4 27 PISTON RING INSPECTION 4 29 PISTON PIN INSPECTION 4 30 PISTON INSTALLATION 4 31 CY...

Page 124: ...ND OIL FILTER 4 56 CRANKCASE 4 58 CRANKCASE BEARING 4 59 OIL PUMP DRIVE GEAR REMOVAL 4 60 CRANKCASE SEPARATION 4 60 TIMING CHAIN AND GUIDE INSPECTION 4 61 OIL STRAINER AND OIL DELIVERY PIPE INSPECTION 4 61 CRANKCASE INSPECTION 4 62 BEARINGS AND OIL SEALS INSPECTION 4 62 CRANKCASE ASSEMBLY 4 62 SHIFT LEVER INSTALLATION 4 63 OIL PUMP DRIVE GEAR INSTALLATION 4 64 CRANKSHAFT AND OIL PUMP 4 65 OIL PUMP...

Page 125: ...E DRIVEN SHAFT 4 76 MIDDLE DRIVE SHAFT REMOVAL 4 78 MIDDLE DRIVEN SHAFT REMOVAL 4 78 INSPECTION 4 80 MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION 4 81 MIDDLE DRIVEN SHAFT INSTALLATION 4 84 MIDDLE DRIVE SHAFT INSTALLATION 4 86 GEAR LASH MEASUREMENT 4 86 ...

Page 126: ...ENG ...

Page 127: ... below Engine oil Refer to ENGINE OIL REPLACEMENT in CHAPTER 3 Front and rear fender footrest boards Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Fuel tank rubber cover Carburetor assembly Refer to CARBURETOR in CHAPTER 6 1 Air duct assembly 1 1 2 Muffler 1 3 Exhaust pipe stay 1 1 4 Exhaust pipe gasket 1 1 5 Air duct assembly 2 1 For installation reverse the removal procedure ...

Page 128: ... ty Remarks Select lever unit and coolant reservoir removal Remove the parts in the order below 1 Shift arm 1 2 Select lever shift rod 1 3 Select lever unit 1 4 Coolant reservoir breather hose 1 5 Coolant reservoir hose 1 6 Coolant reservoir 1 For installation reverse the removal procedure ...

Page 129: ... PUMP in CHAPTER 5 1 Cylinder head breather hose 1 2 Spark plug lead 1 3 Thermo switch lead 1 4 Starter motor lead 1 5 CDI magneto lead coupler 2 6 Speed sensor lead coupler 1 7 Neutral switch lead 1 Sky blue 8 Parking switch lead 1 Blue Red 9 Reverse switch lead 1 Green Blue 10 Engine ground lead 1 11 Speedometer gear unit 1 For installation reverse the removal procedure ...

Page 130: ... AND SWINGARM in CHAPTER 8 1 Engine mounting bolt rear lower nut 1 1 2 Engine mounting bolt rear upper nut 1 1 3 Engine bracket bolt front lower 4 4 Engine mounting bolt font lower 2 5 Engine bracket front lower 2 6 Engine bracket bolt front upper 2 7 Engine mounting bolt front upper nut 1 1 8 Engine bracket front upper 1 CAUTION Install all of the bolts nuts and then tighten them to full torque s...

Page 131: ...4 5 ENG ENGINE REMOVAL Order Job name Part name Q ty Remarks 9 Engine assembly 1 For installation reverse the removal procedure NOTE Remove the engine assembly from the left side of the machine ...

Page 132: ...e mount bolt rear lower nut 8 NOTE Do not fully tighten the bolts and nuts 2 Tighten Engine mount bolt front upper nut 2 Engine bracket bolt front upper 3 Engine mount bolt front lower 5 Engine bracket bolt front lower 6 Engine mount bolt rear upper nut 7 Engine mount bolt rear lower nut 8 T R 42 Nm 4 2 m kg 30 ft lb T R 33 Nm 3 3 m kg 24 ft lb T R 42 Nm 4 2 m kg 30 ft lb T R 33 Nm 3 3 m kg 24 ft ...

Page 133: ...AND FUEL TANK in CHAPTER 3 Front fender air filter case Air duct assembly 1 Refer to ENGINE REMOVAL Exhaust pipe muffler Carburetor assembly Refer to CARBURETOR in CHAPTER 6 Recoil starter timing plug Refer to VALVE CLEARANCE ADJUST MENT in CHAPTER 3 Thermostat Refer to THERMOSTAT in CHAPTER 5 1 Spark plug lead 1 2 Spark plug 1 3 Engine mount bolt upper nut 1 1 4 Engine bracket upper 1 ...

Page 134: ...g 1 1 7 Tappet cover O ring 2 2 8 Thermo switch lead 1 Disconnect 9 Timing chain tensioner cap bolt 1 Refer to CYLINDER HEAD REMOVAL INSTALLATION 10 Timing chain tensioner gasket 1 1 11 Camshaft sprocket 1 12 Cylinder head 1 13 Cylinder head gasket 1 14 Dowel pin 2 15 O ring 1 For installation reverse the removal procedure ...

Page 135: ... at the Top Dead Center T D C NOTE When the piston is at the Top Dead Center T D C on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crank shaft counterclockwise one turn 2 Loosen Camshaft sprocket bolt 1 NOTE Use the rotor holder 2 to hold the starter pulley Rotor holder P N YU 01235...

Page 136: ...in a crisscross pattern loosen each 10 mm bolt 1 4 of a turn After all the bolts are loosened remove them TAPPET COVER INSPECTION 1 Inspect Tappet covers 1 O rings 2 Cracks damage Replace TIMING CHAIN TENSIONER INSPECTION 1 Check One way cam operation tensioner Unsmooth operation Replace CAMSHAFT SPROCKET INSPECTION 1 Inspect Camshaft sprocket Wear damage Replace the camshaft sprocket and timing c...

Page 137: ...liminate 3 Measure Cylinder head warpage Out of specification Resurface Warpage measurement and resurfacement steps Place a straightedge and a feeler gauge across the cylinder head Use a feeler gauge to measure the warpage If the warpage is out of specification resurface the cylinder head Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pa...

Page 138: ...aft to align the camshaft pin 1 with the cylinder head match mark 2 Turn the crankshaft counterclockwise with a wrench Align the T mark 3 on the rotor with the stationary pointer 4 on the crankcase cover When the T mark is aligned with the stationary pointer the piston is at the Top Dead Center T D C CAUTION Do not turn the crankshaft during the cam shaft sprocket installation Place the timing cha...

Page 139: ...head match mark 2 If the marks are aligned tighten the cam shaft sprocket bolt If the marks are not aligned change the meshing position of the camshaft sprocket and timing chain 3 Install Timing chain tensioner Installation steps Remove the tensioner cap bolt 1 washer 2 and spring 3 Release the timing chain tensioner one way cam 4 and push the tensioner rod 5 all the way in Install the tensioner 6...

Page 140: ...Tighten Camshaft sprocket bolt 1 NOTE Use the rotor holder 2 to hold the starter pulley 5 Check Camshaft sprocket punch mark Rotor T mark Out of alignment Adjust Rotor holder P N YU 01235 90890 01235 T R 60 Nm 6 0 m kg 43 ft lb ...

Page 141: ... order below 1 Intake manifold O ring 1 1 2 Thermo switch 1 3 Oil check bolt 1 4 Lock washer bearing retainer 1 1 5 Camshaft 1 Refer to CAMSHAFT AND ROCKER ARM REMOVAL INSTALLATION 6 Rocker arm shaft O ring 2 2 7 Rocker arm 2 8 Locknut valve adjuster 2 2 9 Valve cotter 4 Refer to VALVE AND VALVE SPRING REMOVAL INSTALLATION 10 Valve spring retainer 2 11 Valve spring outer 2 ...

Page 142: ...Order Job name Part name Q ty Remarks 12 Valve spring inner 2 Refer to VALVE AND VALVE SPRING REMOVAL INSTALLATION 13 Valve intake 1 14 Valve exhaust 1 15 Valve stem seal 2 16 Valve spring seat 2 For installation reverse the removal procedure ...

Page 143: ...hammer 3 to remove the rocker arm shafts Slide hammer set P N YU 01083 A Slide hammer bolt M6 P N 90890 01083 Weight P N 90890 01084 VALVE AND VALVE SPRING REMOVAL 1 Check Valve sealing Leakage at the valve seat Inspect the valve face valve seat and valve seat width Refer to VALVE AND VALVE SPRING INSPECTION Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that the val...

Page 144: ...mpressor P N YM 04019 90890 04019 Camshaft lobe limit Intake a 40 52 mm 1 595 in b 32 08 mm 1 263 in Exhaust a 40 52 mm 1 595 in b 32 08 mm 1 263 in ROCKER ARM AND CAMSHAFT INSPECTION 1 Inspect Camshaft bushings Damage wear Replace 2 Inspect Camshaft lobes 1 Valve adjusters 2 Blue discoloration pitting scratches Replace 3 Inspect Rocker arms Rocker arm shafts Damage wear Replace Inspection steps I...

Page 145: ...inside diameter Clearance greater than 0 08 mm 0 003 in Replace the defective part s Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Rocker arm outside diameter 11 981 11 991 mm 0 4717 0 4721 in Rocker arm to shaft standard clearance 0 009 0 037 mm 0 0004 0 0015 in VALVE AND VALVE SPRING INSPECTION 1 Measure Stem to guide clearance Out of specification Replace the valve guide Stem to ...

Page 146: ...re the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance NOTE After replacing the valve guide reface the valve seat Valve guide remover 7 mm P N YM 01225 A 90890 01225 Valve guide installer P N YM 04017 90890 04017 Valve guide reamer 7 mm P N YM 01227 90890 01227 3 Inspect Valve face Pitting wear Grind the face Valve stem end Mushroom shape or diameter larger than t...

Page 147: ...idth a Out of specification Reface the valve seat Measurement steps Apply Mechanic s blueing dye Dykem b to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed If the valve seat is too wide too narro...

Page 148: ...d valve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping compound to the valve face and repeat the above steps NOTE After every lapping operation be sure to clean off all of the compound from the valve face and valve seat Apply Mechanic s blueing dye D...

Page 149: ...length valve spring Inner 39 9 mm 1 57 in Limit 37 9 mm 1 49 in Outer 43 27 mm 1 71 in Limit 41 27 mm 1 62 in Compressed spring force Inner 104 9 120 6 N at 33 6 mm 10 70 12 30 kg 23 58 27 11 lb at 1 32 in Outer 235 4 251 1 N at 36 6 mm 24 00 25 60 kg 52 92 56 45 lb at 1 44 in 12 Measure Spring tilt a Out of specification Replace Spring tilt limit Inner 2 5 1 6 mm 0 06 in Outer 2 5 1 6 mm 0 06 in ...

Page 150: ... retainers NOTE Install the valve springs with the larger pitch a facing upwards b Smaller pitch New 3 Install Valve cotters NOTE Install the valve cotters while compressing the valve spring with the valve spring com pressor 1 Valve spring compressor P N YM 04019 90890 04019 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood CAUTION Hitting the valve t...

Page 151: ...ER ARM INSTALLATION 1 Apply Engine oil onto the rocker arm shafts 2 Install Rocker arms 1 Rocker arm shafts intake and exhaust 2 NOTE Use a slide hammer bolt 3 to install the rocker arm shaft 3 Install Camshaft 1 NOTE Install the camshaft pin hole a facing up ...

Page 152: ...DER HEAD Water pump outlet hose pipe Refer to WATER PUMP in CHAPTER 5 1 Cooling water inlet joint 1 2 Timing chain guide exhaust 1 3 Cylinder O ring 1 1 Refer to CYLINDER INSTALLATION 4 Cylinder gasket 1 5 Dowel pin 2 6 O ring 1 7 Piston pin clip 2 Refer to PISTION REMOVAL INSTAL LATION 8 Piston pin 1 9 Piston 1 10 Piston ring set 1 For installation reverse the removal procedure ...

Page 153: ... use a hammer to drive the piston pin out Piston pin puller P N YU 01304 90890 01304 2 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown TIMING CHAIN GUIDE INSPECTION 1 Inspect Exhaust side timing chain guide Wear damage Replace CYLINDER AND PISTON INSPECTION 1 Inspect Cylinder and piston walls Vertical scratches Rebo...

Page 154: ...lace the cylinder and the pistons and piston rings as a set Cylinder bore C 84 500 84 510 mm 3 3268 3 3272 in Max taper T 0 05 mm 0 0016 in Out of round R 0 01 mm 0 0004 in C maximum of D1 D6 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 2nd step Measure piston skirt diameter P with a micrometer a 5 0 mm 0 20 in from the piston bottom edge If out of spec...

Page 155: ... 1 Measure Ring side clearance Use a feeler gauge Out of specification Replace the piston and rings as a set NOTE Clean carbon from the piston ring grooves and rings before measuring the side clear ance 2 Position Piston ring in cylinder NOTE Insert a ring into the cylinder and push it approximately 40 mm 1 6 in into the cylin der Push the ring with the piston crown so that the ring will be at a r...

Page 156: ...037 in Oil ring 0 2 0 7 mm 0 008 0 028 in PISTON PIN INSPECTION 1 Inspect Piston pin Blue discoloration grooves Replace then inspect the lubrication system 2 Measure Piston pin to piston clearance Measurement steps Measure the piston pin outside diameter a If out of specification replace the piston pin Measure the piston inside diameter b Calculate the piston pin to piston clear ance with the foll...

Page 157: ...ate the piston and piston rings liber ally with engine oil 2 Position Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown a Top ring end b Oil ring end upper c Oil ring end lower d 2nd ring end 3 Install Piston 1 Piston pin 2 Piston pin clips 3 NOTE Apply engine oil onto the piston pin pis ton ring and piston Be sure that the arrow mark a on the pis ton points to the exhaust side o...

Page 158: ...l coating of engine oil CYLINDER INSTALLATION 1 Install Cylinder NOTE Install the cylinder with one hand while compressing the piston rings with the other hand CAUTION Be careful not to damage the timing chain damper during installation Pass the timing chain through the timing chain cavity ...

Page 159: ...gine oil Drain Refer to ENGINE OIL REPLACEMENT in CHAPTER 3 Seat and side panels Refer to SEAT AND SIDE PANELS in CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 1 Recoil starter assembly 1 2 CDI magneto coupler 2 Disconnect 3 Starter pulley 1 Refer to CDI MAGNETO REMOVAL INSTALLATION 4 Crankcase cover left gasket 1 1 5 Dowel pin 2 6 Lead holder 1 ...

Page 160: ...s 7 Pickup coil 1 8 Stator assembly 1 9 CDI rotor 1 Refer to CDI MAGNETO REMOVAL INSTALLATION 10 Starter wheel gear 1 11 Woodruff key 1 12 Bearing washer 1 1 13 Starter idle gear shaft 1 14 Washer bearing 1 1 15 Starter idle gear 1 For installation reverse the removal procedure ...

Page 161: ...l starter disassembly Disassemble the parts in the order below 1 Cap 1 Refer to RECOIL STARTER DISAS SEMBLY ASSEMBLY 2 Starter handle 1 3 Friction plate 1 4 Pawl spring 1 5 Drive pawl 1 6 Spring 1 7 Sheave drum 1 8 Rope 1 9 Coil spring 1 For assembly reverse the disassembly procedure ...

Page 162: ... crisscross pattern loosen each bolt 1 4 of a turn Remove them after all of them are loosened 3 Remove CDI rotor 1 NOTE Use the flywheel puller 2 Flywheel puller P N YM 01404 90890 01404 RECOIL STARTER DISASSEMBLY 1 Remove Cap 1 Starter handle 2 NOTE Before untying the knot 3 above the starter handle make a knot 4 in the rope so that the rope is not pulled into the case CDI MAGNETO INSPECTION 1 In...

Page 163: ...utch and hold the starter clutch When turning the starter wheel gear counter clockwise Å the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it When turning the starter wheel gear clockwise ı the starter wheel gear should turn freely If not the starter clutch is faulty Replace it Bolts starter clutch 30 Nm 3 0 m kg 22 ft lb LOCTITE 2 Inspect Gear tee...

Page 164: ...COIL STARTER INSPECTION 1 Inspect Rope 1 Sheave drum 2 Drive pawl 3 Wear damage Replace Coil spring 4 Pawl spring 5 Spring 6 Fatigue Replace RECOIL STARTER ASSEMBLY 1 Install Sheave drum 1 Rope 2 Pawl spring 3 Drive pawl 4 NOTE Wind the rope 4 1 2 turns clockwise around the sheave drum Then insert the rope into the drum slit a ...

Page 165: ...ction plate 2 Nut NOTE Insert the spring hooks into the pawl side holes 4 Turn the sheave drum 3 turn clockwise to give preload to the spring 5 Install Starter handle 1 Cap 2 NOTE Pass the rope through the case hole and make a knot 3 on the rope so that the rope is not pulled into the case Untie the knot 3 after making a knot 4 above the handle CDI MAGNETO INSTALLATION 1 Apply Sealant Quick Gasket...

Page 166: ...se cover left NOTE When installing the crankcase cover left use a long rod to hold the CDI rotor in position from the outside This will make assembly easier Be careful not to damage the oil seal Tighten the bolts in stages using a criss cross pattern New T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install Starter pulley 1 NOTE Use a rotor holder 2 to hold the starter pul ley NOTE Before installing the starter ...

Page 167: ...ect lever unit Select lever shift rod NOTE Before installing the select lever shift rod make sure that the select lever and shift cam is in the NEUTRAL position 6 Adjust Select lever shift rod Refer to SELECT LEVER CONTROL CABLE AND SHIFT ROD in CHAPTER 3 ...

Page 168: ...the parts in the order below Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Rear fender Right footrest boards 1 Exhaust pipe stay 1 1 2 Exhaust pipe stay 2 1 3 Drive belt cover 1 4 Rubber gasket 1 5 Bearing housing 1 6 Dowel pin 2 7 Primary sheave assembly 1 Refer to PRIMARY AND SECONDARY SHEAVES REMOVAL INSTALLATION 8 V belt 1 ...

Page 169: ...D SECONDARY SHEAVES Order Job name Part name Q ty Remarks 9 Primary fixed sheave 1 Refer to PRIMARY AND SECONDARY SHEAVES REMOVAL INSTALLATION 10 Secondary sheave assembly 1 For installation reverse the removal procedure ...

Page 170: ...isassembly Disassemble the parts in the order below 1 Primary pulley sheave cap 1 Refer to PRIMARY SHEAVE ASSEM BLY 2 Primary pulley slider 4 3 Spacer 4 4 Primary pulley cam 1 5 Primary pulley weight 8 6 Collar 1 7 Oil seal 2 8 Primary sliding sheave 1 9 O ring 1 For assembly reverse the disassembly procedure ...

Page 171: ...sassembly Disassemble the parts in the order below 1 Nut 1 Refer to SECONDARY SHEAVE DIS ASSEMBLY ASSEMBLY 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1 9 Oil seal 1 0 Oil seal 1 For assembly reverse the disassembly procedure ...

Page 172: ...AVE DISASSEMBLY 1 Remove Nut 1 Removing steps Attach the sheave fixed block 2 locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly Place the sheave fixed block in a vise and secure it Tighten the sheave spring compressor nut 5 and compress the spring Loosen the nut 1 with the locknut wrench 3 Remove the nut 1 Remove the sheave spring compressor and locknut wrench Sheave...

Page 173: ...place 3 Inspect Primary sliding sheave Primary fixed sheave Cracks damage Replace SECONDARY SHEAVE INSPECTION 1 Inspect Secondary fixed sheave smooth operation Secondary sliding sheave smooth operation Scratches damage Replace as a set 2 Inspect Torque cam groove 1 Wear damage Replace 3 Inspect Guide pin 2 Wear damage Replace 4 Inspect Secondary sheave spring Damage Replace 5 Measure Secondary she...

Page 174: ...all Apply SSG 2656 2 grease to the inner sur face of the collar Apply SSG 2656 2 grease to the inner sur face of the primary sliding sheave Remove any excess grease 3 Install Spacer Slider 1 Cam 2 Primary sliding sheave cap T R 3 Nm 0 3 m kg 2 2 ft lb SECONDARY SHEAVE ASSEMBLY 1 Apply BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals BEL RAY assembly lube to the b...

Page 175: ...r 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 spec ified 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 90890 01348 Sheave spring...

Page 176: ...e gap between the secondary fixed and slid ing sheaves to widen Install the V belt so that its arrow faces the direction show in the illustration 2 Tighten Nut primary sheave 1 Nut secondary sheave 2 NOTE Use the sheave holder 3 to hold the pri mary sheave First tighten the nut primary sheave 1 then tighten the nut secondary sheave 2 Sheave holder P N YU 01880 90890 01701 T R 100 Nm 10 0 m kg 72 f...

Page 177: ...n the order below Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES 1 Cover 1 2 Clutch housing assembly 1 Refer to CLUTCH REMOVAL INSTAL LATION 3 Gasket dowel pin 1 2 4 One way clutch bearing 1 5 Nut 1 6 Clutch carrier assembly 1 For installation reverse the removal procedure ...

Page 178: ...e Q ty Remarks Clutch housing disassembly Disassemble 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 179: ...e Replace NOTE Replace the one way clutch assembly and clutch housing as a set The one way clutch bearing must be installed with the flange side facing in Clutch operation Install the one way clutch bearing and clutch carrier assembly to the clutch hous ing and hold the clutch carrier assembly When turning the clutch housing clock wise Å the clutch housing should turn freely If not the one way clu...

Page 180: ...LATION 1 Install Collar Clutch carrier assembly Nut 1 NOTE Use a clutch holding tool 2 to hold the clutch carrier assembly 2 Lock the threads with a drift punch Clutch holding tool P N YM 91042 90890 04086 New T R 140 Nm 14 0 m kg 100 ft lb 3 Install One way clutch bearing NOTE The one way clutch bearing should be installed in the clutch carrier assembly with the arrow mark a facing toward the clu...

Page 181: ...pins Gasket Clutch housing assembly NOTE Tighten the bolts in stages using a criss cross pattern After tightening the bolts check that the clutch housing assembly to counterclock wise rotates smoothly New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 182: ...nder head Refer to CYLINDER HEAD Cylinder and piston Refer to CYLINDER AND PISTON Recoil starter and CDI rotor Refer to RECOIL STARTER AND CDI MAGNETO Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES Clutch carrier assembly Refer to CLUTCH 1 Oil pump drive gear straight key 1 1 Refer to OIL PUMP DRIVE GEAR REMOVAL INSTALLATION 2 Oil pump driven gear 1 3 Timing chain guide 1 4 T...

Page 183: ...peed sensor 1 8 Shift cam stopper 1 9 Neutral switch 1 10 Park switch 1 11 Reverse switch 1 12 Oil filler cap 1 13 Bearing cover gasket 1 1 14 Oil delivery pipe 1 15 Drain plug O ring 1 1 16 Compression spring 1 17 Oil strainer 1 For installation reverse the removal procedure ...

Page 184: ...move the parts in the order below 1 Shift lever cover gasket 1 1 Refer to SHIFT LEVER INSTALLA TION 2 Shift lever 1 O ring 1 1 3 Shift lever 2 assembly 1 4 Crankcase left 1 Refer to CRANKCASE SEPARATION ASSEMBLY 5 Dowel pin 2 6 Crankcase right 1 For installation reverse the removal procedure ...

Page 185: ... bearing removal Remove the parts in the order below Crankshaft and oil pump Refer to CRANKSHAFT AND OIL PUMP Transmission Refer to TRANSMISSION Middle drive driven shaft Refer to MIDDLE GEAR 1 Oil seal 2 2 Bearing retainer 2 3 Bearing 10 For installation reverse the removal procedure ...

Page 186: ...ng tool 2 and loosen the oil pump drive gear nut Remove the clutch carrier assembly Clutch holding tool P N YM 91042 90890 04086 CRANKCASE SEPARATION 1 Separate Left crankcase Right crankcase Separation steps Remove the crankcase bolts NOTE Loosen each bolt 1 4 of a turn at a time and after all the bolts are loosened remove them Loosen the bolts in stages using a criss cross pattern Å Left crankca...

Page 187: ...re that the crankcase halves separate evenly Remove the dowel pins TIMING CHAIN AND GUIDE INSPECTION 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Inspect Intake side timing chain guide Wear damage Replace OIL STRAINER AND OIL DELIVERY PIPE INSPECTION 1 Inspect Oil strainer 1 O rings 2 Damage Replace 2 Inspect Oil delivery pipe Cracks damage Replace ...

Page 188: ...e the inner race with a finger Roughness Replace 2 Inspect Oil seals Damage wear Replace CRANKCASE ASSEMBLY 1 Apply Sealant Quick Gasket 1 to the mating surfaces of both case halves 2 Install Dowel pin 2 Sealant Quick Gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 3 Fit the left crankcase onto the right case Tap lightly on the case with a soft hammer CAUTION Before installing and t...

Page 189: ... 0 m kg 7 2 ft lb 5 Apply 4 stroke engine oil to the crank pin bearing and oil delivery hole 6 Check Crankshaft and transmission operation Unsmooth operation Repair SHIFT LEVER INSTALLATION 1 Install Shift lever 2 assembly 1 Shift lever 1 2 NOTE When installing the shift lever 1 align the punch mark a on the shift lever 1 with the punch marks b on the shift lever 2 T R 14 Nm 1 4 m kg 10 ft lb ...

Page 190: ... 2 Tighten Oil pump drive gear nut Tightening steps Temporary install the clutch carrier assembly 1 Hold the clutch carrier assembly with a clutch holding tool 2 and tighten the oil pump drive gear nut Remove the clutch carrier assembly 3 Bend the lock washer tab Clutch holding tool P N YM 91042 90890 04086 T R 50 Nm 5 0 m kg 36 ft lb ...

Page 191: ...and oil pump removal Remove the parts in the order below Crankcase separation Refer to CRANKCASE 1 Washer circlip 1 1 2 Oil pump assembly gasket 1 1 3 Balancer 1 Refer to CRANKSHAFT REMOVAL CRANKSHAFT AND BALANCER INSTALLATION 4 Crankshaft seal 2 5 Crankshaft 1 For installation reverse the removal procedure ...

Page 192: ... Order Job name Part name Q ty Remarks Oil pump disassembly Disassemble the parts in the order below 1 Rotor cover 1 2 Pin 2 3 Shaft 1 4 Pin 1 5 Inner rotor 1 6 Outer rotor 1 7 Oil pump housing 1 For assembly reverse the disassembly procedure ...

Page 193: ...eparating tool 1 Crankcase separating tool P N YU 01135 A 90890 01135 OIL PUMP INSPECTION 1 Inspect Oil pump driven gear Rotor housings Rotor cover Cracks wear damage Replace 2 Measure Tip clearance a between the inner rotor 1 and the outer rotor 2 Side clearance b between the outer rotor 2 and the pump housing 3 Out of specification Replace the oil pump Tip clearance a 0 15 mm 0 006 in Limit 0 2 ...

Page 194: ...t Runout C Out of specification Replace the crank shaft Crankshaft reassembling point The crankshaft 1 and the crank pin 2 oil passages must be properly interconnected with a tolerance of less than 1 mm 0 04 in CAUTION The buffer boss and woodruff key should be replaced when removed from the crank shaft Crank width 62 95 63 00 mm 2 478 2 480 in Big end side clearance 0 25 0 75 mm 0 010 0 030 in Li...

Page 195: ... against the bearing CAUTION Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier Crankshaft installer set 1 P N YU 90050 Buffer boss installer set 2 P N 90890 04088 Adapter 11 3 P N YM 33279 Crank pot spacer 4 P N YM 90070 A 90890 04060 2 Install Crankshaft seal NOTE Install the crankshaft seals in the correct place and in the correct direct...

Page 196: ...ion removal Remove the parts in the order below Crankcase separation Refer to CRANKCASE 1 Driven sprocket 1 2 Drive sprocket 1 3 Chain 1 4 Clutch dog 2 1 5 Shift fork L 1 6 Spring 1 7 Low wheel gear 1 8 Secondary shaft 1 9 Middle driven gear 1 10 Drive axle assembly 1 11 Guide bar 1 ...

Page 197: ...der Job name Part name Q ty Remarks 12 Shift fork R 1 13 Spring 1 14 Shift cam 1 15 Stopper wheel 1 16 Clutch dog 1 1 17 High wheel gear 1 18 Stopper lever 1 19 Spacer O ring 1 1 For installation reverse the removal procedure ...

Page 198: ...ct Guide bar Roll the guide bar on a flat surface Bends Replace WARNING Do not attempt to straighten a bent guide bar 3 Check Shift fork movement on the guide bar Unsmooth operation Replace the shift fork and the guide bar 4 Inspect Spring Cracks damage Replace SHIFT CAM INSPECTION 1 Inspect Shift cam grooves Scratches wear damage Replace ...

Page 199: ...ment Unsmooth Repeat steps 1 and 2 or replace the defective parts 4 Inspect Circlip Bends looseness damage Replace TRANSMISSION INSTALLATION 1 Install Shift cam Washer Spring short Shift fork R 1 Drive axle assembly 2 Guide bar 3 Clutch dog 2 4 Spring long 5 Shift fork L 6 NOTE Install the shift fork with the R mark fac ing towards the right side of the crankcase and the shift fork with the L mark...

Page 200: ...TRANSMISSION 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 201: ... below Crankcase separation Refer to CRANKCASE Transmission Refer to TRANSMISSION 1 Bearing housing assembly 1 2 Nut 1 Refer to MIDDLE DRIVE SHAFT REMOVAL INSTALLATION 3 Middle drive pinion gear 1 4 Shim Refer to MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION 5 Middle drive shaft 1 6 Bearing retainer 2 For installation reverse the removal procedure ...

Page 202: ...er to CRANKCASE 1 Circlip 2 Refer to MIDDLE DRIVEN SHAFT REMOVAL INSTALLATION 2 Bearing 2 3 Universal joint 1 4 Universal joint yoke 1 5 Bearing housing O ring 1 1 6 Shim Refer to MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION 7 Middle drive pinion gear 1 Refer to MIDDLE DRIVEN SHAFT REMOVAL INSTALLATION 8 Bearing retainer 1 9 Damper cam 1 10 Spring 1 11 Gear coupling 1 ...

Page 203: ...4 77 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 204: ...on gear Middle drive pinion gear Shim s MIDDLE DRIVEN SHAFT REMOVAL 1 Remove Universal joint Universal joint removal steps Remove the circlips 1 Place the U joint in a press With a suitable diameter pipe 2 beneath the yoke 3 press the bearing 4 into the pipe as shown NOTE It may be necessary to lightly tap the yoke with a punch Repeat the steps for the opposite bearing Remove the yoke NOTE It may ...

Page 205: ...l result in damage to the shaft thread Install the suitable socket 2 on the shaft end to protect the thread from damage Press the shaft end and remove the bear ing housing 4 Remove Bearing retainer Bearing Removal steps Attach the folded rag 1 Secure the bearing housing edge in the vise Attach the bearing retainer wrench 2 CAUTION The middle driven shaft bearing retainer has left handed threads To...

Page 206: ...d threads To loosen the retainer turn it clockwise Ring nut wrench P N YM 38404 90890 01430 6 Remove Middle drive shaft 1 with bearing INSPECTION 1 Inspect Damper cam surfaces Wear scratches Replace damper and driven pinion gear as a set 2 Inspect Damper spring Damage cracks Replace 3 Inspect Gear teeth drive pinion gear 1 Gear teeth driven pinion gear 2 Pitting galling wear Replace ...

Page 207: ...tion steps Position middle drive and driven gear by using shims 1 and 2 with their respec tive 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 num ber on the bearing housing is either added to or subtracted from 10 5 b drive pinion ge...

Page 208: ...digit and select appropriate shim s In the example above the calculated shim thickness is 0 49 mm The chart instructs you however to round off 9 to 10 Shims are supplied in the following thick ness 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 follow ing formula Middle driven pinion gear s...

Page 209: ...ecimal num ber on the left crankcase specifies a thickness of 95 8 Example 1 If the bearing housing is marked 03 d is 76 03 2 If the driven pinion gear is marked 02 e is 59 02 3 If the driven pinion gear is marked 10 f is 79 40 4 If the crankcase left is marked 95 79 g is 95 79 5 Therefore the shim thickness is 0 63 mm B 76 03 59 02 79 40 95 79 0 05 0 57 6 Round off hundredths digit and select app...

Page 210: ...tach the ring nut wrench 2 CAUTION The middle driven shaft bearing retainer has left handed threads To tighten the retainer turn it counterclockwise 2 Install Bearing retainer 1 Installation steps Secure the bearing housing edge in the vise with a clean 2 Attach the bearing retainer wrench 3 Ring nut wrench P N YM 38404 90890 01430 Bearing retainer wrench P N YM 04128 90890 04128 LT T R 80 Nm 8 0 ...

Page 211: ... the tabs are posi tioned as shown in the illustration T R Bearing retainer 110 Nm 11 0 m kg 80 ft lb 4 Install Universal joint yoke rear side Washer Nut 1 NOTE Use the universal joint holder 2 to hold the yoke Universal joint holder P N YM 04062 90890 04062 LT T R 97 Nm 9 7 m kg 70 ft lb 5 Install Universal joint Universal joint installation steps Install the opposite yoke into the U joint Apply ...

Page 212: ...o the U joint so that the circlip can be installed Install the circlips 2 into the groove of each bearing MIDDLE DRIVE SHAFT INSTALLATION 1 Tighten Nut middle drive pinion gear 1 NOTE Secure the middle drive shaft in the vise with a clean rag 2 Lock the threads with a drift punch New T R 145 Nm 14 5 m kg 105 ft lb GEAR LASH MEASUREMENT 1 Measure Gear lash Measurement steps Temporaly install the le...

Page 213: ... while rotating the middle driven shaft back and forth NOTE Measure the gear lash at 4 positions Rotate the middle driven gear 90 each time If the gear lash is incorrect adjust the gear lash by middle driven pinion gear shims and or middle drive pinion gear shim s Gear lash measurement tool P N YM 01467 90890 01467 ...

Page 214: ...4 88 ENG ...

Page 215: ...COOL 5 ...

Page 216: ...TEM RADIATOR 5 1 RADIATOR INSPECTION 5 3 RADIATOR INSTALLATION 5 4 THERMOSTAT 5 5 THERMOSTAT INSPECTION 5 6 THERMOSTAT INSTALLATION 5 6 WATER PUMP 5 7 WATER PUMP DISASSEMBLY 5 9 WATER PUMP INSPECTION 5 9 WATER PUMP ASSEMBLY 5 10 ...

Page 217: ...COOL ...

Page 218: ...ELS in CHAPTER 3 Front carrier front bumper and front fender Refer to FRONT CARRIER FRONT BUMPER AND FRONT FENDER in CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Coolant Drain Refer to COOLANT REPLACEMENT in CHAPTER 3 1 Radiator fan coupler 1 Disconnect 2 Thermo switch coupler 1 Disconnect 3 Coolant reservoir hose 1 Disconnect 4 Radiator fan breather hose 1 ...

Page 219: ...ADIATOR Order Job name Part name Q ty Remarks 5 Radiator inlet hose 1 Disconnect 6 Radiator outlet hose 1 Disconnect 7 Radiator 1 8 Radiator fan 1 9 Thermo switch 1 For installation reverse the removal procedure ...

Page 220: ...sure Below the specified pressure Replace the radiator cap Measurement steps Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 Apply the specified pressure for ten sec onds and make sure that there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in CHAP TER 9 Radiator cap opening pressure 93 3 122 7 kPa 0 933 1 2...

Page 221: ...RADIATOR RADIATOR INSTALLATION 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to COOLANT REPLACEMENT in CHAPTER 3 2 Check Cooling system Leaks Repair or replace any faulty part ...

Page 222: ...moval Remove the parts in the order below Seat and fuel tank side panel right Refer to SEAT AND SIDE PANELS in CHAPTER 3 Coolant Drain Refer to COOLANT REPLACEMENT in CHAPTER 3 1 Radiator inlet hose 1 2 Thermostat cover 1 3 Thermostat 1 For installation reverse the removal procedure ...

Page 223: ...ontainer Å Fully closed ı Fully open NOTE 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 THERMOSTAT INSTALLATION 1 Install Thermostat 1 Thermostat housing cover NOTE Install the thermostat with its breather hole a toward the projection b 2 Fill Co...

Page 224: ...Seat fuel tank side panel left and engine side cover Refer to SEAT AND SIDE PANELS in CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 O ring 1 4 Water pump inlet hose 1 5 Water pump assembly 1 6 O ring 1 For installation reverse the removal procedure ...

Page 225: ...disassembly Remove the parts in the order below 1 Water pump housing cover 1 2 Gasket 1 3 Circlip 1 4 Impeller 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 1 0 Water pump housing 1 For assembly reverse the disassembly procedure ...

Page 226: ...ide of the water pump housing 2 Water pump housing 3 Remove Oil seal 1 Bearing 2 NOTE Tap out the bearing and oil seal from the outside of the water pump housing 3 Water pump housing WATER PUMP INSPECTION 1 Inspect Water pump housing cover 1 Water pump housing 2 Impeller 3 Rubber damper 4 Rubber damper holder 5 Cracks damage wear Replace 2 Inspect Water pump seal Oil seal Water pump outlet pipe Cr...

Page 227: ...all Water pump seal 1 into the water pump housing 2 CAUTION Never lubricate the water pump seal sur face with oil or grease NOTE Install the water pump seal with the special tools Å Push down Mechanical seal installer 3 P N YM 33221 90890 04078 Middle driven shaft bearing driver 4 P N YM 04058 1 90890 04058 New 3 Install Rubber damper 1 Rubber damper holder 2 NOTE Before installing the rubber damp...

Page 228: ...ure Impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION Make sure that the rubber damper and rub ber damper holder are flush with the impel ler 1 Straightedge 2 Impeller Max impeller shaft tilt 0 15 mm 0 006 in ...

Page 229: ...5 12 COOL ...

Page 230: ...CARB 6 ...

Page 231: ...CARB CHAPTER 6 CARBURETION CARBURETOR 6 1 CARBURETOR INSPECTION 6 4 CARBURETOR ASSEMBLY 6 6 FUEL LEVEL ADJUSTMENT 6 7 ...

Page 232: ...CARB ...

Page 233: ...ls fuel tank rubber cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 1 Drain hose 1 2 Starter cable starter plunger 1 1 3 Air vent hose 1 4 Carburetor assembly 1 5 Throttle valve cover 1 6 Throttle cable end 1 7 Throttle cable 2 For installation reverse the removal procedure NOTE After removing the carburetor assem bly remove the throttle cable ...

Page 234: ...e the parts in the order below 1 Air vent hose 1 2 Throttle stop screw 1 3 Vacuum chamber cover 1 4 Spring 1 5 Jet needle holder 1 6 Spring 1 7 Jet needle set 1 8 Piston valve 1 9 Coasting enricher 1 0 Float chamber 1 A Drain screw 1 B Float 1 Refer to CARBURETOR ASSEMBLY C Needle valve set 1 ...

Page 235: ...Part name Q ty Remarks D Pilot jet 1 E Pilot screw set 1 Refer to CARBURETOR ASSEMBLY F Main jet 1 G Needle jet 1 Refer to CARBURETOR DISASSEM BLY ASSEMBLY H Starter jet 1 I Pilot air jet 1 For assembly reverse the disassembly procedure ...

Page 236: ...in a petroleum based solvent Do not use any caustic carburetor clean ing solution Blow out all of the passages and jets with compressed air 2 Inspect Float 1 Float tang 2 Damage Replace 3 Inspect Valve seat 1 Needle valve 2 O ring 3 Contamination wear damage Replace as a set NOTE Always replace the needle valve and valve seat as a set 4 Inspect Piston valve 1 Scratches wear damage Replace Rubber d...

Page 237: ... Main jet 2 Needle jet 3 Pilot air jet 4 Pilot jet 5 Pilot screw 6 Starter jet 7 Starter plunger 8 Bends wear damage Replace Blockage Blow out the jets with com pressed air 8 Check Free movement piston valve Sticks Replace the piston valve guide and the piston valve Insert the piston valve into the carburetor body and check for free movement 9 Check Free movement throttle valve Sticks Replace ...

Page 238: ...n an upside down position Measure the distance from the front mat ing surface of the float chamber gasket removed to the top of the float NOTE The float arm should be resting on the nee dle valve but not compressing it If the float height is not within the specifi cation inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by bending ...

Page 239: ...ically next to the float chamber line Measure the fuel level a with the gauge If the fuel level is incorrect adjust the fuel level Remove the carburetor Inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float level by bending the float tang 4 slightly Install the carburetor Recheck the fuel level Fuel level 2 0 3 0 mm 0 08 0 12 in Above the flo...

Page 240: ...6 8 CARB ...

Page 241: ...DRIVE 7 ...

Page 242: ...MEASUREMENT AND ADJUSTMENT 7 11 DIFFERENTIAL GEAR OPERATION CHECK 7 13 REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT 7 14 REAR AXLE REMOVAL 7 17 FINAL DRIVE GEAR DISASSEMBLY 7 17 FINAL DRIVE ROLLER BEARING REMOVAL AND REASSEMBLY 7 18 FINAL DRIVE PINION GEAR AND RING GEAR POSITIONING 7 19 REAR AXLE INSPECTION 7 23 DRIVE SHAFT INSPECTION 7 24 FINAL DRIVE GEAR INSPECTION 7 24 FINAL GEAR LASH MEASUREMENT...

Page 243: ...DRIV ...

Page 244: ...ched whine a clunk from a shaft drive component or area 3 A locked up condition of the shaft drive train mechanism no power transmitted from the engine to the front and or rear wheel A Bearing damage B Improper gear lash C Gear tooth damage D Broken drive shaft E Broken gear teeth F Seizure due to lack of lubrication G Small foreign objects lodged between the moving parts Inspection notes 1 Invest...

Page 245: ...e injury to the rider 2 Inspect Drained oil Drained oil shows large amounts of metal particles Check the bearing for seizure NOTE A small amount of metal particles in the oil is normal 3 Inspect Oil leakage Oil leakage inspection steps Clean the entire machine thoroughly then dry it Apply a leak localizing compound or dry powder spray to the shaft drive Road test the machine for the distance neces...

Page 246: ...t Feel for bearing damage NO Constant velocity joint bearings and dif ferential gear bearings are probably not damaged Repeat the test or remove the individual components YES Check the rear brake adjustment NO Adjust per instructions Refer to REAR BRAKE ADJUSTMENT in CHAPTER 3 YES Check the rear axle Feel for bearing damage NO Rear axle bearings and rear drive shaft bearings are probably not damag...

Page 247: ...arts in the order below Engine skid plate front Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Differential gear oil Drain Steering knuckle Refer to STEERING SYSTEM in CHAPTER 8 Front arms lower Refer to FRONT ARMS AND FRONT SHOCK ABSORBER in CHAPTER 8 1 Constant velocity joint 2 2 Gear motor coupler four wheel drive switch lead 1 1 3 Differential gear case breather hose 1 ...

Page 248: ...CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name Part name Q ty Remarks 4 Differential gear 1 5 Drive shaft 1 6 Compression spring 1 7 Coupling gear 1 For installation reverse the removal procedure ...

Page 249: ... velocity joint disassembly Disassemble the parts in the order below 1 Circlip 1 2 Boot band 2 Refer to CONSTANT VELOCITY JOINT ASSEMBLY 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint 1 7 Snap ring 1 8 Ball bearing 1 9 Joint shaft assembly 1 For assembly reverse the disassembly procedure ...

Page 250: ...Disassembly the parts in the order below 1 Gear motor O ring 1 1 2 Four wheel drive switch 1 3 Dust seal 1 4 Circlip 1 5 Coupling gear bearing circlip 1 1 1 6 Stopper bolt shaft 1 1 7 Shift fork sliding gear 1 8 Shift fork 1 9 2WD 4WD shift sleeve 1 0 Differential gear case cover 1 A Shim left B Differential gear assembly 1 ...

Page 251: ...STANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name Part name Q ty Remarks C Shim right 1 D Circlip bearing 1 1 E Drive pinion gear 1 F Differential gear case 1 For assembly reverse the disassembly procedure ...

Page 252: ...ssemble this unit Disassembly will result in the malfunction of the unit CONSTANT VELOCITY JOINT INSPECTION 1 Inspect Double off set joint spline Ball joint spline Shaft spline Wear damage Replace 2 Inspect Dust boots Cracks damage Replace CAUTION Always use a new boot band 3 Inspect Balls and ball races Inner surface of double off set joint Pitting wear damage Replace DIFFERENTIAL GEAR INSPECTION...

Page 253: ...t CONSTANT VELOCITY JOINT ASSEMBLY 1 Apply Molybdenum disulfide grease into the ball joint assembly NOTE Molybdenum disulfide grease is included in the repair kit 2 Install Dust boots 1 Boot bands 2 3 Installation steps Apply molybdenum disulfide grease into the dust boots Install the dust boots Install the dust boot bands NOTE The new boot bands may differ from the original ones The dust boots sh...

Page 254: ...ial gear operation Unsmooth operation Replace the differ ential gear assembly Insert the double off set joint into the dif ferential gear and turn the gear back and forth DIFFERENTIAL GEAR LASH MEASUREMENT AND ADJUSTMENT Differential gear lash measurement 1 Secure the gear case in a vise or another supporting device 2 Remove Drain plug Gasket 3 Install A bolt of the specified size 1 into the drain...

Page 255: ... 015 in Differential gear lash adjustment 1 Remove Shim s left 1 Differential gear assembly 2 Shim s right 3 2 Adjust Gear lash Gear lash adjustment steps Select the suitable shims using the follow ing chart If 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...

Page 256: ...nut right or left 3 Measure the starting torque of the front wheel i e differential gear preload with the torque wrench NOTE Repeat this step several times to obtain an average figure During this test the other front wheel will turn in the opposite direction 4 Out of specification Replace the differ ential gear assembly 5 Within specification Install the new cot ter pin and wheel cap T R Front whe...

Page 257: ...emove the parts in the order below Final gear oil Drain Rear wheel hubs brake disc Refer to FRONT AND REAR WHEELS in CHAPTER 8 1 O ring 1 2 Rear axle dust cover 1 1 Refer to REAR AXLE REMOVAL INSTAL LATION 3 Trailer hitch bracket 1 4 Final drive gear case breather hose 1 Disconnect 5 Final drive gear 1 6 Coupling gear 1 7 Drive shaft 1 8 Circlip 2 For installation reverse the removal procedure ...

Page 258: ...ble the parts in the order below 1 Bolt 2 2 Bolt 6 3 Bearing housing 1 4 Oil seal bearing 1 1 5 Ring gear stopper 1 6 Ring gear stopper shim 1 7 Oil seal bearing 1 1 8 Ring gear shim 1 9 Ring gear 1 0 Thrust washer 1 NOTE Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them ...

Page 259: ...AS SEMBLY ASSEMBLY B Oil seal 1 C Final drive pinion gear 1 D Collar 1 E Bearing 1 F Final drive pinion gear shim 1 G Final drive gear case O ring 1 1 H Bearing oil seal 1 1 Refer to FINAL DRIVE ROLLER BEAR ING REMOVAL AND REASSEMBLY I Bearing 1 Refer to FINAL DRIVE ROLLER BEAR ING REMOVAL AND REASSEMBLY For assembly reverse the disassembly procedure ...

Page 260: ...ight FINAL DRIVE GEAR DISASSEMBLY 1 Remove Bearing retainer final drive pinion gear NOTE Use a bearing retainer wrench 1 CAUTION 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 CAUTION Removal of the final drive pinion gear should only ...

Page 261: ...uter race with an appropriately shaped punch 2 Remove the inner race from the final drive pinion gear NOTE The removal of the final drive pinion gear roller bearing is difficult and seldom neces sary 3 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...

Page 262: ...umeral usually a decimal number on the final drive pinion gear either added to or subtracted from 84 b a numeral usually a decimal number on the final gear case either added to or subtracted from 83 Example 1 If 01 is stamped on the final drive pinion gear a 84 0 01 84 01 2 If 50 is stamped on the final gear case b 83 0 50 83 50 3 Therefore A is 0 51 A 84 01 83 50 0 51 4 Round off the hundredth di...

Page 263: ...nal gear case either added to or subtracted from 45 d a numeral usually a decimal number on the outside of the ring gear bear ing housing and added to 1 e a numeral usually a decimal number on the inside of the ring gear either added to or subtracted from 35 00 f bearing thickness considered con stant Example 1 If 53 is stamped on the final gear case c 45 0 53 45 53 2 If 05 is stamped on the ring ...

Page 264: ...ck nesses Hundredths Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Ring gear shim Thickness mm 0 25 0 30 0 35 0 40 0 45 0 50 Thrust washer selection 1 Measure select Ring gear thrust clearance C Thrust clearance measurement steps Place four pieces of Plastigauge between the originally fitted thrust washer and the ring gear Install the ring gear assembly and tighten the bolts to specification NOTE Do no...

Page 265: ...n Thrust washer selection steps Select a suitable thrust washer using the following chart Repeat the measurement steps until the ring gear thrust clearance is within the specified limits Thrust washer Thickness mm 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 Ring gear stopper shim selection 1 Measure Ring gear stopper clearance D Use a feeler gauge 1 Out of specification Adjust 2 Ring gear 3 Ring gear ...

Page 266: ... 40 0 50 3 Install Shim s Ring gear stopper left hand threads Ring gear NOTE Use LOCTITE on the ring gear stopper T R 9 Nm 0 9 m kg 6 5 ft lb 4 Measure Ring gear stopper clearance Out of specification Repeat adjustment steps Ring gear stopper clearance 0 30 0 60 mm 0 012 0 024 in REAR AXLE INSPECTION 1 Inspect Rear axle runout a Out of specification Replace WARNING Do not attempt to straighten a b...

Page 267: ...aring housing are replaced be sure to adjust the shim of the final drive pinion gear and or ring gear 2 Inspect Gear teeth Pitting galling wear Replace the drive pinion gear and ring gear as a set Oil seals O rings Damage Replace 3 Inspect Bearings Damage Replace NOTE Reusing roller bearings is acceptable but Yamaha recommends installing new ones Do not reuse the oil seal When the final drive pini...

Page 268: ...o 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 27 mm 1 06 in Gear lash measurement tool P N YM 01231 90890 01231 5 Measure Gear lash Gently rotate the gear coupling from engagement to engagement NOTE Measure the gear lash at four positions Rotate the s...

Page 269: ...e than 0 2 mm 0 008 in Reduce the thrust washer thickness by 0 2 mm 0 008 in for every 0 2 mm of ring gear shim increase If reduced by more than 0 2 mm 0 008 in Increase the thrust washer thickness by 0 2 mm 0 008 in for every 0 2 mm that the ring gear shim is decreased Too little gear lash Reduce shim thickness Too large gear lash Increase shim thickness Ring gear shim Thickness mm 0 25 0 30 0 35...

Page 270: ... ft lb CAUTION Always use a new bearing The final drive shaft bearing retainer has left hand threads Turn the retainer coun terclockwise to tighten it 2 Adjust Final gear lash Refer to FINAL GEAR LASH MEASURE MENT AND ADJUSTMENT Bearing retainer wrench P N YM 04050 90890 04050 FINAL DRIVE GEAR INSTALLATION 1 Lubricate Drive shaft Coupling gear O ring Oil seal Bearing 2 Install Drive shaft 1 Coupli...

Page 271: ...alant Quick Gasket to the mating surfaces of the swingarm and the final drive gear case Sealant Quick gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 4 Install Final drive gear Nuts Bolts T R 57 Nm 5 7 m kg 41 ft lb LT T R 63 Nm 6 3 m kg 45 ft lb LT ...

Page 272: ...CHAS 8 ...

Page 273: ...R INSTALLATION 8 19 REAR BRAKE MASTER CYLINDER INSTALLATION 8 20 FRONT BRAKE CALIPER 8 22 REAR BRAKE CALIPER 8 24 FRONT AND REAR BRAKE CALIPER DISASSEMBLY 8 26 FRONT AND REAR BRAKE CALIPER INSPECTION 8 26 FRONT AND REAR BRAKE CALIPER ASSEMBLY 8 27 FRONT BRAKE CALIPER INSTALLATION 8 27 REAR BRAKE CALIPER INSTALLATION 8 29 STEERING SYSTEM 8 30 HANDLEBAR 8 30 REAR BRAKE SWITCH REMOVAL 8 32 HANDLEBAR ...

Page 274: ...R 8 40 FRONT ARMS REMOVAL 8 42 FRONT ARM INSPECTION 8 42 FRONT SHOCK ABSORBER INSPECTION 8 42 FRONT ARMS AND FRONT SHOCK ABSORBER INSTALLATION 8 43 REAR SHOCK ABSORBER AND SWINGARM 8 44 SWINGARM REMOVAL 8 45 REAR SHOCK ABSORBER INSPECTION 8 45 SWINGARM INSPECTION 8 46 RUBBER BOOT INSPECTION 8 46 RUBBER BOOT INSTALLATION 8 46 ...

Page 275: ...l 1 Refer to WHEEL INSTALLATION 2 Wheel cap 1 Refer to WHEEL HUB BRAKE DRUM INSTALLATION 3 Cotter pin 1 4 Axle nut 1 5 Brake caliper assembly 1 6 Wheel hub 1 7 Brake disc 1 For installation reverse the removal procedure WARNING Securely support the machine so there is no danger of it falling over NOTE Do not squeeze the brake lever when the brake caliper is off of the brake disc as the brake pads ...

Page 276: ...on a level surface 1 Rear wheel 2 Refer to WHEEL INSTALLATION 2 Wheel cap 2 Refer to WHEEL HUB BRAKE DRUM INSTALLATION 3 Cotter pin 2 4 Axle nut 2 5 Wheel hub 2 6 Brake caliper mounting bolt 2 7 Brake disc bracket 1 8 Brake disc 1 For installation reverse the removal procedure WARNING Securely support the machine so there is no danger of it falling over ...

Page 277: ...of balance Adjust Wheel runout limit Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in WARNING After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an acci dent resulting in machine damage and pos sible operator injury WHEEL HUB INSPECTION 1 Inspect Wheel hub 1 Cracks damage Replace Splines wheel hub 2 Wear damage Replace ...

Page 278: ...hickness 3 mm 0 12 in WHEEL HUB BRAKE DRUM INSTALLATION 1 Install Cotter pin 1 NOTE Do not loosen the axle nut after torquing it If the axle nut groove is not aligned with the cotter pin hole align the groove with the hole by tightening the axle nut New 2 Adjust Front brake lever free play Refer to FRONT BRAKE ADJUSTMENT in CHAPTER 3 Rear brake lever and pedal free play Refer to REAR BRAKE LEVER A...

Page 279: ...8 5 CHAS FRONT AND REAR WHEELS 2 Tighten Nuts wheel 1 WARNING Tapered wheel nuts 1 are used for both the front and rear wheels Install each nut with its tapered side towards the wheel ...

Page 280: ... ty Remarks Front brake pads removal Remove the parts in the order below Front wheel Refer to FRONT AND REAR WHEELS 1 Brake caliper mounting bolt 2 Refer to FRONT BRAKE PAD REPLACEMENT 2 Brake pad holding bolt 2 3 Brake pad pad shim 2 1 4 Pad spring 1 For installation reverse the removal procedure ...

Page 281: ...ake pads removal Remove the parts in the order below Rear wheel left Refer to FRONT AND REAR WHEELS 1 Brake caliper mounting bolt 2 Refer to REAR BRAKE PAD REPLACEMENT 2 Brake pad holding bolt 2 3 Brake pad insulator pad shim 2 2 2 4 Pad spring 1 For installation reverse the removal procedure ...

Page 282: ...aces or plastic parts as this may cause damage disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly FRONT BRAKE PAD REPLACEMENT NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Measure Brake pad wear limit a Out of specification Replace the ...

Page 283: ... shims 3 and a new brake pad spring Install the retaining bolts and brake cali per NOTE The arrow mark a on the pad shim must point in the direction of the disc rotation T R Brake caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb T R Brake pad holding bolt 18 Nm 1 8 m kg 13 ft lb Brake caliper mounting bolt 30 Nm 3 0 m kg 22 ft lb 3 Inspect Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION in CHA...

Page 284: ...e pad spring as a set Installation steps Connect a suitable hose 1 tightly to the brake caliper bleed screw 2 Put the other end of this hose into an open container Loosen the brake caliper bleed screw and using a finger push the caliper piston into the brake caliper Tighten the brake caliper bleed screw Install new brake pads new insulator new pad shims and a new brake pad spring Install the retai...

Page 285: ...3 Inspect Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 3 4 Check Brake lever or brake pedal operation Soft or spongy feeling Bleed the rear brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 ...

Page 286: ...order below Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake lever 1 5 Union bolt 1 Refer to FRONT BRAKE MASTER CYLINDER INSTALLATION 6 Copper washer 2 7 Brake hose 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 For installation reverse the removal procedure ...

Page 287: ...rt name Q ty Remarks Front brake master cylinder disas sembly Disassemble the parts in the order below 1 Dust boot 1 Refer to FRONT BRAKE MASTER CYLINDER ASSEMBLY 2 Circlip 1 3 Brake master cylinder kit 1 For assembly reverse the disassembly procedure ...

Page 288: ...e the parts in the order below Front fender panel Refer to SEAT CARRIERS FINDERS AND FUEL TANK in CHAPTER 3 Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake master cylinder cover 1 6 Brake fluid reservoir hose 1 7 Hose joint 1 ...

Page 289: ...REAR BRAKES Order Job name Part name Q ty Remarks 8 Union bolt 1 Refer to REAR BRAKE MASTER CYL INDER INSTALLATION 9 Copper washer 2 10 Brake hose 1 11 Brake master cylinder 1 For installation reverse the removal procedure ...

Page 290: ...rt name Q ty Remarks Front brake master cylinder disas sembly Disassemble the parts in the order below 1 Brake master cylinder kit 1 Refer to REAR BRAKE MASTER CYL INDER ASSEMBLY 2 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 291: ...elivery passage brake master cylinder body Blockage Blow out with compressed air Å Front ı Rear Å ı 2 Inspect Brake master cylinder kit Scratches wear damage Replace as a set Å Front ı Rear ı Å 3 Inspect Front brake master cylinder reservoir 1 Front brake master cylinder reservoir dia phragm 2 Cracks damage Replace 4 Inspect Rear brake fluid reservoir 1 Rear brake fluid reservoir diaphragm 2 Crack...

Page 292: ...e fluid DOT 4 EB702060 REAR BRAKE MASTER CYLINDER ASSEMBLY WARNING All internal brake components 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 1 Joint 2 NOTE Turn the adjusting bolt 3 until the clear ance a is within the specified limits when ...

Page 293: ... wire har ness leads etc Correct if necessary WARNING Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING New T R 27 Nm 2 7 m kg 19 ft lb 3 Fill Brake fluid reservoir CAUTION Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING Use only the designated quality brake fluid other brake fluids may de...

Page 294: ...5 Inspect Brake fluid level Brake fluid level is under the LOWER level line Fill up Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 3 REAR BRAKE MASTER CYLINDER INSTALLATION 1 Install Copper washers 1 Brake hose 2 Union bolt 3 CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown WARNING Proper brake hose routing is essen...

Page 295: ... type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake 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 Recommended brake fluid DOT 4 3 Air bleed Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHA...

Page 296: ...rder below Brake fluid Drain Front wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to FRONT BRAKE CALIPER INSTALLA TION 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Cap retaining bolt 1 1 Loosen 5 Brake pad holding bolt 2 Loosen 6 Brake caliper mounting bolt 2 7 Brake caliper assembly 1 For installation reverse the removal procedure ...

Page 297: ...e parts in the order below 1 Brake pad holding bolt 2 2 Brake pad pad shim 2 1 3 Pad spring 1 4 Retaining bolt 1 5 Caliper bracket 1 6 Brake caliper piston 1 Refer to FRONT AND REAR BRAKE CALIPER DISASSEMBLY ASSEM BLY 7 Dust seal 1 8 Caliper piston seal 1 9 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 298: ...e parts in the order below Brake fluid Drain Rear wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to REAR BRAKE CALIPER INSTALLA TION 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad holding bolt 2 Loosen 5 Brake caliper mounting bolt 2 6 Brake caliper assembly 1 For installation reverse the removal procedure ...

Page 299: ... the parts in the order below 1 Brake pad holding bolt 2 2 Brake pad insulator pad shim 2 2 2 3 Pad spring 1 4 Caliper bracket 1 5 Brake caliper piston 1 Refer to FRONT AND REAR BRAKE CALIPER DISASSEMBLY ASSEM BLY 6 Dust seal 1 7 Caliper piston seal 1 8 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 300: ...r Remove the caliper piston seals EB702040 FRONT AND REAR BRAKE CALIPER INSPECTION WARNING All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort Recommended brake component replace ment schedule Brake pads As required Piston seal dust seal Every two years Brake hoses Every two years Brake fluid Replace when brakes ...

Page 301: ...nal brake components should be cleaned and lubricated with new brake fluid only before installation Replace the caliper piston seal whenever a brake caliper is disassembled 1 Install Caliper piston seal 1 Dust seal 2 Recommended brake fluid DOT 4 ı New New 2 Install Brake caliper piston 1 FRONT BRAKE CALIPER INSTALLATION 1 Install Brake caliper assembly Brake caliper mounting bolt 1 Brake hose 2 C...

Page 302: ...fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in va...

Page 303: ...ds may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed B...

Page 304: ...d 4 3 Master cylinder assembly bracket 1 1 Refer to MASTER CYLINDER ASSEMBLY INSTALLATION 4 On command four wheel drive switch 1 5 Throttle lever assembly bracket 1 1 6 Rear brake switch 1 Refer to REAR BRAKE SWITCH REMOVAL 7 Rear brake lever bracket 1 1 Refer to REAR BRAKE LEVER INSTALLATION 8 Handlebar switch 1 9 Horn switch 1 For GB F CH Oceania 10 Handlebar grip 2 ...

Page 305: ...HAS STEERING SYSTEM Order Job name Part name Q ty Remarks 11 Handlebar holder 2 Refer to HANDLEBAR INSTALLA TION 12 Handlebar 1 Refer to HANDLEBAR INSTALLA TION For installation reverse the removal procedure ...

Page 306: ...lebar as this may dangerously weaken the handlebar HANDLEBAR INSTALLATION 1 Install Handlebar Handlebar holders NOTE The upper handlebar holder should be installed with the punched mark 1 forward 2 CAUTION First tighten the bolts 3 on the front side of the handlebar holder and then tighten the bolts 4 on the rear side T R 20 Nm 2 0 m kg 14 ft lb REAR BRAKE LEVER INSTALLATION 1 Install Handlebar sw...

Page 307: ...HAS STEERING SYSTEM MASTER CYLINDER ASSEMBLY INSTALLATION 1 Install Throttle lever assembly Master cylinder assembly NOTE The UP mark on the master cylinder bracket should face up T R 7 Nm 0 7 m kg 5 1 ft lb ...

Page 308: ...below Handlebar Refer to HANDLEBAR Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Front fender 1 Lock washer 1 Refer to CABLE GUIDE INSTALLA TION 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 309: ... STEERING SYSTEM Order Job name Part name Q ty Remarks 11 Oil seal 1 12 Bearing retainer 1 Refer to BEARING RETAINER REMOVAL INSTALLATION 13 Bearing 1 14 Oil seal 1 For installation reverse the removal procedure ...

Page 310: ...ly weaken the stem 2 Inspect Oil seals 1 Steering stem bushings 2 Wear damage Replace BEARING RETAINER INSTALLATION 1 Install Bearing retainer steering stem CABLE GUIDE INSTALLATION 1 Install Cable guide Lock washer 2 Bend the lock washer tab along a flat side of the bolt NOTE Pass the cables and hoses through the cable guide Refer to CABLE ROUTING in CHAPTER 2 Damper rod holder P N YM 01327 90890...

Page 311: ...nt fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Front wheel brake disc Refer to FRONT AND REAR WHEELS 1 Tie rod 1 Refer to TIE ROD INSTALLATION 2 Brake disc guard 1 3 Brake hose holder bolt 1 4 Protector 1 5 Bolt washer nut 1 1 1 6 Nut 1 7 O ring 1 8 Steering knuckle 1 Refer to STEERING KNUCKLE REMOVAL For installation reverse the removal procedure ...

Page 312: ...ace STEERING KNUCKLE INSPECTION 1 Inspect Steering knuckle Damage pitting Replace 2 Inspect Front wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly Replace Oil seals Damage Replace Front wheel bearing replacement steps Clean the outside of the steering knuckle Remove the oil seals 1 Drive out the bearings 2 WARNING Eye protection is recommended when using striking too...

Page 313: ... When installing the oil seals the seal side of the oil seal faces out BALL JOINT INSPECTION 1 Inspect Ball joint Damage pitting Replace the front arm Free play Replace the front arm Turns roughly Replace the front arm TIE ROD INSTALLATION 1 Install Tie rods left and right NOTE The tie rod which must be installed on the out side has grooves 1 T R 25 Nm 2 5 m kg 18 ft lb 2 Adjust Toe in Refer to TO...

Page 314: ...Part name Q ty Remarks Front arms and front shock absorber removal Remove the parts in the order below Engine skid plate front Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Front fender Front wheel brake disc Refer to FRONT AND REAR WHEELS 1 Air duct 1 2 Brake disc guard 1 3 Protector 1 ...

Page 315: ...4 Bolt 1 Refer to FRONT ARMS REMOVAL and FRONT ARMS AND FRONT SHOCK ABSORBER INSTALLATION 5 Nut 1 6 Bolt nut 2 2 7 Front arm lower bushing 1 2 8 Nut bolt 2 2 9 Front shock absorber collar 1 1 10 Bolt nut 2 2 11 Front arm upper bushing 1 2 For installation reverse the removal procedure ...

Page 316: ...nd down If the vertical movement is tight or rough or if there is binding check the bushings 2 Remove Front arms FRONT ARM INSPECTION 1 Inspect Front arms 1 Bends damage Replace 2 Inspect Bushings 2 Wear damage Replace FRONT SHOCK ABSORBER INSPECTION 1 Inspect Shock absorber rod Bends damage Replace the shock absorber assembly Shock absorber assembly Oil leaks Replace the shock absorber assembly S...

Page 317: ...ith lithium soap base grease Be sure to position the bolts 3 so that the bolt head faces outward Temporarily tighten the nuts 4 Install the front shock absorber 5 Install the ball joints Install the new cotter pins Tighten the nuts 4 NOTE Before tightening the nuts 4 adjust the length a to 318 mm 12 5 in T R Nut 6 45 Nm 4 5 m kg 32 ft lb T R Nut 7 25 Nm 2 5 m kg 18 ft lb Nut 8 48 Nm 4 8 m kg 35 ft...

Page 318: ... disc Refer to FRONT AND REAR WHEELS Final drive gear assembly Refer to REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT in CHAPTER 7 1 Clip washer pin 1 1 1 2 Nut bolt 1 1 3 Rear shock absorber 1 4 Collar 2 5 Rear brake hose 1 6 Final drive gear case breather hose 1 7 Metal clamp 1 8 Nut bolt 2 2 Refer to SWINGRAM REMOVAL 9 Swingarm bushing 1 2 10 Spring rubber boot 1 1 For installation reverse the rem...

Page 319: ...t Check the swingarm vertical movement ı by moving it up and down If vertical movement is tight or rough or if there is binding check the bushing and frame pivot 2 Remove Nuts Bolts Swingarm T R Nut swingarm 59 Nm 5 9 m kg 43 ft lb REAR SHOCK ABSORBER INSPECTION 1 Inspect Shock absorber Oil leaks Replace the shock absorber assembly Shock absorber rod Bends damage Replace the shock absorber assembl...

Page 320: ...s damage Replace 2 Inspect Bushings 1 Wear damage Replace RUBBER BOOT INSPECTION 1 Inspect Rubber boot 1 Damage Replace RUBBER BOOT INSTALLATION 1 Apply Adhesive for rubber to the engine 1 2 Install Rubber boot 2 NOTE Be sure to position the rubber boot so that the tang 3 faces towards the left ...

Page 321: ...ELEC 9 ...

Page 322: ... CIRCUIT OPERATION 9 12 TROUBLESHOOTING 9 13 STARTER MOTOR 9 17 STARTER MOTOR INSPECTION 9 18 STARTER MOTOR ASSEMBLY 9 19 CHARGING SYSTEM 9 20 CIRCUIT DIAGRAM 9 20 TROUBLESHOOTING 9 21 LIGHTING SYSTEM 9 23 CIRCUIT DIAGRAM 9 23 TROUBLESHOOTING 9 24 LIGHTING SYSTEM CHECK 9 26 SIGNAL SYSTEM 9 29 CIRCUIT DIAGRAM 9 29 TROUBLESHOOTING 9 30 SIGNAL SYSTEM CHECK 9 32 COOLING SYSTEM 9 40 CIRCUIT DIAGRAM 9 4...

Page 323: ... ELEC ...

Page 324: ... 8 Taillight 9 Main fuse 0 Starter relay A CDI unit B Starting circuit cut off relay C Reverse relay D Fuse box E Rectifier regulator F Neutral switch G Park switch H Speed sensor I Reverse switch J Thermo switch K Gear motor L Four wheel drive switch M Ignition coil N Thermo switch O Fan P Headlight Q Circuit breaker fan R Auxiliary DC jack S Horn switch For GB F CH Oceania T Horn For GB F CH Oce...

Page 325: ... tester P N YU 03112 90890 03112 INSPECTING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indi cates the terminals with continuity The example ...

Page 326: ...EC SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Refer to SWITCH INSPECTION and check for continuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled ...

Page 327: ...hts switch 2 Engine stop switch 3 Starter switch 4 Main switch 5 On command four wheel drive switch 6 Rear brake switch 7 Four wheel drive switch 8 Reverse switch 9 Park switch 0 Neutral switch A Fuse B Horn switch For GB F CH Oceania ...

Page 328: ...O R B W L Y W B G Y B Y G B G Y B Y G B R W W W W W W R B W R W L W G R R R R R B B R B R B P L L L L B B B B B Sb W B B P B B Y G Y G Y G B B B B O O B W W R W L W G Y B G Y G Y L R L R Y B R W L W L W L B R W Br L Br L R Y Br L Br L Br R R Y B W B W L B Br R Br W L B W L W L G L R W R W R W R B R B Br L R W G L G W L R Sb L B R W Br R W L Sb W Br W L B B W R W Br L G Y L Y W B B B B B B G W G L ...

Page 329: ...tank side panels 3 Front carrier 4 Front fender Use the following special tool s for trou bleshooting Dynamic spark tester P N YM 34487 Ignition checker P N 90890 06754 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main ignition Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER...

Page 330: ...hing the starter switch and increase the spark gap until a misfiring occurs Minimum spark gap 6 0 mm 0 24 in MEETS SPECIFICATION The ignition system is not faulty For GB F CH Oceania OUT OF SPECIFICATION OR NO SPARK 4 Ignition spark gap Disconnect the spark plug cap from spark plug Connect the ignition checker 1 as shown 2 Spark plug cap Turn the main switch to ON Check the ignition spark gap a Cr...

Page 331: ...ester lead Spark plug lead Check that the primary coil has the spec ified resistance Primary coil resistance 0 18 0 28 Ω at 20 C 68 F Connect the pocket tester Ω 1k to the ignition coil MEETS SPECIFICATION Check that the spark plug cap has the specified resistance Spark plug cap resistance 10 kΩ at 20 C 68 F OUT OF SPECIFICATION Replace the spark plug cap 5 Spark plug cap resistance Remove the spa...

Page 332: ...stance Pickup coil resistance 459 561 Ω at 20 C 68 F White Red White Green OUT OF SPECIFICATION Replace the pickup coil starter assembly BOTH MEET SPECIFICATION Check that the secondary coil has the specified resistance Secondary coil resistance 6 32 9 48 kΩ at 20 C 68 F OUT OF SPECIFICATION Replace the ignition coil CORRECT 7 Engine stop switch Refer to SWITCH INSPECTION INCORRECT Replace the han...

Page 333: ...assembly C0NTINUITY 10 Charging rotor rotation direction detec tion coil resistance Disconnect the CDI magneto coupler from the wire harness Connect the pocket tester Ω 100 to the charging rotor rotation direction detection coil terminal Tester lead Red terminal 1 Tester lead White Blue terminal 2 CORRECT 11 Wiring connection Check the connections of the entire igni tion system Refer to CIRCUIT DI...

Page 334: ... W W W W W W R B W R W L W G R R R R R B B R B R B P L L L L B B B B B Sb W B B P B B Y G Y G Y G B B B B O O B W W R W L W G Y B G Y G Y L R L R Y B R W L W L W L B R W Br L Br L R Y Br L Br L Br R R Y B W B W L B Br R Br W L B W L W L G L R W R W R W R B R B Br L R W G L G W L R Sb L B R W Br R W L Sb W Br W L B B W R W Br L G Y L Y W B B B B B B G W G L Sb Sb L R L Y R W B W G W Sb WIRE HARNESS...

Page 335: ...ng when the select lever is in gear or in reverse and the rear brake lever is free In this instance the start ing circuit cut off relay is off so that current cannot reach the starter motor 1 Main fuse 2 Battery 3 Starter relay 4 Starter motor 5 Starting circuit cut off relay 6 Start switch 7 Ignition fuse 8 CDI unit 9 Engine stop switch 0 Rear brake switch A Diode B Park switch C Neutral switch Å...

Page 336: ...stem NOTE Remove the following part s before trou bleshooting 1 Seat 2 Fuel tank side panels 3 Fuel tank 4 Air cleaner case 5 Front carrier 6 Front fender panel Use the following special tool s for trou bleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main ignition Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery co...

Page 337: ...parks so be sure that no flammable gas or fluid is in the vicinity DOES NOT TURN Repair or replace the starter motor 4 Starting circuit cut off relay Remove the starting circuit cut off relay from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the starting circuit cut off relay terminals Battery terminal Red White terminal 1 Battery terminal Yellow Black terminal 2 Tester l...

Page 338: ...d Red terminal 3 Tester lead Black terminal 4 Check the starter relay for continuity NO CONTINUITY Replace the starter relay CORRECT 6 Main switch Refer to SWITCH INSPECTION INCORRECT Replace the main switch CORRECT 7 Engine stop switch Refer to SWITCH INSPECTION INCORRECT Replace the handlebar switch right CORRECT 8 Neutral switch Refer to SWITCH INSPECTION INCORRECT Replace the neutral switch CO...

Page 339: ...inals as shown Check the diode for continuity as fol lows Tester positive probe Blue Red 1 Tester negative probe Green Yellow 2 Continu ity Tester positive probe Green Yellow 2 Tester negative probe Blue Red 1 No conti nuity NOTE When you switch the tester s positive and negative probes the readings in the left chart will be reversed INCORRECT Replace the diode EB803028 13 Wiring connection Check ...

Page 340: ...Starter motor lead 1 2 Starter motor O ring 1 1 For installation reverse the removal procedure Starter motor disassembly Disassemble the parts in the order below 1 Bracket 1 1 Refer to STARTER MOTOR ASSEM BLY 2 Washer kit 3 Bracket 2 1 4 Shims 5 Brush seat 1 brush seat 2 1 2 6 Armature coil 1 7 Yoke 1 For assembly reverse the disassembly procedure ...

Page 341: ... hacksaw blade which has been grounded to fit the commutator Outside diameter 28 mm 1 10 in Wear limit 27 mm 1 06 in Mica undercut 0 7 mm 0 03 in 4 Inspect Armature coil insulation continuity Defects Replace the starter motor Armature coil inspection steps Connect the pocket tester for the continu ity check 1 and insulation check 2 Measure the armature resistances If the resistance is incorrect re...

Page 342: ...imit 5 mm 0 20 in 6 Measure Brush spring force Fatigue out of specification Replace as a set Brush spring force 7 65 10 01 Nm 780 1 020 g 27 5 36 0 oz 7 Inspect Oil seal Bushing Bearing O rings Wear damage Replace STARTER MOTOR ASSEMBLY 1 Install Yoke Brackets NOTE Align the match marks a on the yoke with the match marks b on the brackets ...

Page 343: ... Br B Br W Br R B Sb L B BROWN BROWN Y G B Y G B R W W W W W W R B W R W L W G R R R R B B R B R B P L L L L B B Sb W P B Y G Y G Y G B B B B Y B R W L W L W L B R W Br L Br L R Y Br L Br L Br R R Y B W B W L B Br R Br W L B W L R W Br R W L Sb W Br W L B B W R W Br L WIRE HARNESS S C WIRE HARNESS IGNITION COIL LEAD B WIRE HARNESS SUB WIRE HARNESS 2 A BLACK BLACK O B O B Sb L R G L G W Sb L R C C ...

Page 344: ... N YU 8036 A Engine tachometer P N 90890 03113 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace the battery EB804011 ...

Page 345: ...wire harness Connect the pocket tester Ω 1 to the charging coils Tester lead White terminal 1 Tester lead White terminal 2 Tester lead White terminal 1 Tester lead White terminal 3 Measure the stator coil resistance Charging coil resistance 0 70 0 86 Ω at 20 C 68 F OUT OF SPECIFICATION Replace the pickup coil stator assembly EB804015 CORRECT 5 Wiring connections Check the connections of the entire...

Page 346: ...L B BROWN BROWN Br W Sb L B G Y B Y G B G Y B Y G B R W W W W W W R B W R W L W G R R R R B B R B R B P L L L L B B B B B Sb P B B Y G Y G Y G B B B B L W L W L B R Br L Br L R Y Br L Br L Br R R Y B W B W L B Br R Br W L B Sb W Br W L B B W R Br WI WIRE HARNESS IGNITION COIL LEAD WIRE HARNESS SUB WIRE HARNESS 2 BLACK BLACK L R L R C C C C GRAY GRAY 1 2 7 9 4 5 6 c Z 3 X T U Y V W Q b a a 3 Main s...

Page 347: ... trou bleshooting 1 Seat 2 Front carrier 3 Front fender panel Use the following special tool s for trou bleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main headlight Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F ...

Page 348: ... to SWITCH INSPECTION INCORRECT Lights switch is faulty replace the handle bar switch left EB805013 CORRECT 5 Wiring connection Check the connections of the entire light ing system Refer to WIRING DIAGRAM Check the condition of each of the lighting system s circuits Refer to LIGHTING SYSTEM CHECK POOR CONNECTION Properly connect the lighting system ...

Page 349: ...he headlight couplers Tester lead Green terminal 1 or Yellow terminal 2 Tester lead Black terminal 3 Å When the lights switch is on LO ı When the lights switch is on HI Å ı MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12 V of the Green and Yellow leads on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circ...

Page 350: ... Voltage Connect the pocket tester 20 V to the bulb socket coupler Tester lead Blue lead 1 Tester lead Black lead 2 MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12 V of the Blue lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair...

Page 351: ... Voltage Connect the pocket tester 20 V to the bulb socket coupler Tester lead Blue terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12 V of the Blue lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is fault...

Page 352: ... W B B P B B Y G Y G Y G B B B B O O B W W R W L W G Y B G Y G Y L R L R Y B R W L W L W L B R W Br L Br L R Y Br L Br L Br R R Y B W B W L B Br R Br W L B W L W L G L R W R W R W R B R B Br L R W G L G W L R Sb L B R W Br R W L Sb W Br W L B B W R W Br L G Y L Y W B B B B B B G W G L Sb Sb L R L Y R W B W G W Sb WIRE HARNESS SUB WIRE HARNESS 1 WIRE HARNESS IGNITION COIL LEAD WIRE HARNESS SUB WIRE...

Page 353: ... tank 3 Air cleaner case 4 Front carrier 5 Front fender panel Use the following special tool s for trou bleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main ignition signal four wheel drive Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 ...

Page 354: ...N INCORRECT Replace the main switch EB806011 CORRECT 4 Wiring connections Check the connections of the entire sig nal system Refer to CIRCUIT DIAGRAM Check the condition of each of the signal system s circuits Refer to SIGNAL SYSTEM POOR CONNECTION Properly connect the signal system ...

Page 355: ...round MEETS SPECIFICATION Turn the main switch to ON Push the HORN switch Check for voltage 12 V on the Pink lead at the horn terminal OUT OF SPECIFICATION Wiring circuit from main switch to horn terminal is faulty repair HORN IS NOT SOUNDED 3 Horn Disconnect the Black lead at the horn terminal Connect a jumper lead 1 to the horn ter minal and ground the jumper lead Turn the main switch to ON Push...

Page 356: ...he horn at the Black terminal Tester lead Black lead 1 Tester lead Frame ground MEETS SPECIFICATION Turn the main switch to ON Push the HORN switch Check for voltage 12 V on the Black lead at the horn terminal Adjust or replace the horn OUT OF SPECIFICATION Replace the horn ...

Page 357: ...2 Neutral switch Refer to SWITCH INSPECTION NO CONTINUITY Replace the neutral switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead Sky blue terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket co...

Page 358: ...everse relay Remove the reverse relay from the wire harness Connect the pocket tester Ω 1 and battery 12 V to the reverse relay termi nals CONTINUITY Battery terminal Red White terminal 1 Battery terminal Green White terminal 2 Tester lead Green Blue terminal 3 Tester lead Black terminal 4 Check the reverse relay for continuity NO CONTINUITY Replace the reverse relay 4 Voltage Connect the pocket t...

Page 359: ...e bulb and bulb socket for conti nuity NO CONTINUITY Replace the bulb and or bulb socket CONTINUITY 2 Park switch Refer to SWITCH INSPECTION NO CONTINUITY Replace the park switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead Blue Red terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is...

Page 360: ... tester Ω 1 to the thermo switch 1 Immerse the thermo switch in coolant 2 Check the thermo switch for continuity While heating the coolant use a ther mometer 3 to record the temperatures Test step Water temperature Good condition Thermo switch 1 0 103 C 32 217 4 F 2 More than 110 3 C 230 5 4 F 3 110 103 C 230 217 4 F 4 Less than 103 C 217 4 F Tests 1 2 Heat up tests Tests 3 4 Cool down tests Conti...

Page 361: ...ulb socket connector is faulty repair it CORRECT 4 Diode Remove the diode from the coupler Connect the pocket tester Ω 1 to the diode terminals as shown Check the diode for continuity as fol lows Tester positive probe Blue Black 1 Tester negative probe White Blue 2 Continu ity Tester positive probe White Blue 2 Tester negative probe Blue Black 1 No conti nuity NOTE When you switch the tester s pos...

Page 362: ... NO CONTINUITY Replace the bulb and or bulb socket CONTINUITY 2 Four wheel drive switch Refer to SWITCH INSPECTION NO CONTINUITY Replace the four wheel drive switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket lead Tester lead Brown Red terminal 1 Tester lead Frame ground MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECI...

Page 363: ...W Sb L B P O R B W L Y W B G Y B Y G B G Y B Y G B R W W W W W W R B W R W L W G R R R R R B B R B R B P L L L L B B B B B Sb W B B P B B Y G Y G Y G B B B B O O B W W R W L W G Y B G Y G Y L R L R Y B R W L W L W L B R W Br L Br L R Y Br L Br L Br R R Y B W B W L B Br R Br W L B W L W L G L R W R W R W R B R B Br L R W G L G W L R Sb L B R W Br R W L Sb W Br W L B B W R W Br L G Y L Y W B B B B B...

Page 364: ...rrier 3 Front fender Use the following special tool s for trou bleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or r...

Page 365: ...1 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 366: ...es Test step Water temperature Good condition Thermo switch 1 0 92 3 C 32 197 6 5 4 F 2 More than 98 3 C 208 4 5 4 F 3 98 to 92 3 C 208 4 to 197 6 5 4 F 4 Less than 29 3 C 197 6 5 4 F Tests 1 2 Heat up tests Tests 3 4 Cool down tests Continuity No continuity T R Thermo switch 28 Nm 2 8 m kg 20 ft lb Three bond sealock 10 WARNING Handle the thermo switch with special care Never subject it to a stro...

Page 367: ...ING SYSTEM C0NTINUITY EB803028 CORRECT 7 Wiring connection Check the connections of the entire start ing system Refer to CIRCUIT DIAGRAM This circuit is not faulty POOR CONNECTION Properly connect the cooling system ...

Page 368: ...9 45 ELEC 2WD 4WD SELECTING SYSTEM 2WD 4WD SELECTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse T Four wheel drive fuse U On command four wheel drive switch V Gear motor ...

Page 369: ...hooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for trou bleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main four wheel drive Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT...

Page 370: ...terminals 2WD 4WD Battery terminal Brown White terminal 1 Battery terminal Sky blue terminal 2 4WD 2WD Battery terminal Sky blue terminal 2 Battery terminal Blue Black terminal 3 Make sure that the drive gear shift fork sliding gear operates correctly NOTE When installing the differential gear case in the gear motor refer to CON STANT VELOCITY JOINTS AND DIF FERENTIAL GEAR in CHAPTER 7 INCORRECT R...

Page 371: ...9 48 ELEC ...

Page 372: ...TRBL SHTG 10 ...

Page 373: ... SPEED PERFORMANCE 10 2 FAULTY DRIVE TRAIN 10 3 FAULTY GEAR SHIFTING 10 4 HARD SHIFTING 10 4 SHIFT LEVER DOES NOT MOVE 10 4 JUMPS OUT OF GEAR 10 4 FAULTY CLUTCH PERFORMANCE 10 4 ENGINE OPERATES BUT MACHINE WILL NOT MOVE 10 4 CLUTCH SLIPPING 10 4 POOR STARTING PERFORMANCE 10 4 POOR SPEED PERFORMANCE 10 5 OVERHEATING 10 5 OVERHEATING 10 5 OVER COOLING 10 5 COOLING SYSTEM 10 5 FAULTY BRAKE 10 5 POOR ...

Page 374: ...TRBL SHTG UNSTABLE HANDLING 10 6 UNSTABLE HANDLING 10 6 LIGHTING SYSTEM 10 6 HEADLIGHT DARK 10 6 BULB BURNT OUT 10 6 ...

Page 375: ...s broken Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body CDI system Faulty CDI unit Faulty pickup coil Broken woodruff key Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Deformed float Worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Im...

Page 376: ...aft POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Loose pilot jet Clogged pilot jet Clogged pilot air jet Improperly adjusted idle speed Throttle stop screw Improper throttle cable play Flooded carburetor Electrical system Faulty spark plug Faulty CDI unit Faulty pickup coil Faulty ignition coil Valve train Improperly adjusted valve clearanc...

Page 377: ...uses 1 A pronounced hesitation or jerky move ment during acceleration deceleration or sustained speed This must not be con fused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive component or area 3 A locked up condition of the shaft drive mechanism no power transmitted from the engine to the front and or ...

Page 378: ...orn shift cam groove Transmission Worn gear dog FAULTY CLUTCH PERFORMANCE ENGINE OPERATES BUT MACHINE WILL NOT MOVE V belt Bent damaged or worn V belt V belt slips Primary pulley cam and primary pulley slider Damaged or worn primary pulley cam Damaged or worn primary pulley slider Transmission Damaged transmission gears CLUTCH SLIPPING Clutch spring Damaged loose or worn clutch shoe spring Clutch ...

Page 379: ...ange Faulty CDI unit Fuel system Improper carburetor main jet improper setting Improper fuel level Clogged air filter element Compression system Heavy carbon build up Engine oil Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag Cooling system Low coolant level Clogged or damaged radiator Damaged or faulty water pump Thermostat stays closed OVER COOLING COOLING SYSTEM ...

Page 380: ... Tires Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged frame Swingarm Worn bearing or bushing Bent or damaged LIGHTING SYSTEM HEADLIGHT DARK Improper bulb Too many electric accessories Hard charging broken charging coil and or faulty rectifier regulator Incorrect conn...

Page 381: ...B GRAY GRAY 1 2 7 8 9 4 5 C A 0 6 B E D F P I H G O N M J K L c Z d g f e 3 X T U Y V W Q R S b a a A 1 CDI magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Starting circuit cut off relay 9 Ignition fuse 0 Park switch A Diode 1 B Rear brake switch C CDI unit D Ignition coil E Spark plug F Speed sensor G Circuit breaker fan motor H Thermo switch I ...

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