Yamaha YFM45FAR Service Manual Download Page 308

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CHAS

FRONT AND REAR BRAKES

EB702060

ASSEMBLING THE FRONT BRAKE
MASTER CYLINDER

WARNING

●

All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

●

Whenever a master cylinder is
disassembled, replace the piston seals
and dust seals.

Recommended brake fluid:

DOT 4

EB702060

ASSEMBLING THE REAR BRAKE MASTER
CYLINDER

WARNING

●

All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

●

Whenever a master cylinder is
disassembled, replace the piston seals
and dust seals.

1.Install:

●

Brake master cylinder kit

●

Nut

●

Joint

NOTE:

Turn the adjusting bolt

until the clearance

is within the specified limits when install the
joint

2.Tighten:

●

Nut

Recommended brake fluid:

DOT 4

Clearance

4 ~ 6 mm (0.16 ~ 0.24 in)

Summary of Contents for YFM45FAR

Page 1: ...YFM45FAR YFM450FAR 5ND2 AE1 SERVICE MANUAL ...

Page 2: ......

Page 3: ...FM450FAR SERVICE MANUAL 2002 by Yamaha Motor Co Ltd First edition March 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

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

Page 5: ...tify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to...

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

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

Page 8: ......

Page 9: ...GEN INFO 1 ...

Page 10: ...RES 1 2 LIQUID COOLING ENGINE 1 2 PARK POSITION 1 2 FRONT DIFFERENTIAL 1 3 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL PROCEDURES 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS AND OIL SEALS 1 9 CIRCLIPS 1 9 CHECKING OF CONNECTIONS 1 10 SPECIAL TOOLS 1 11 ...

Page 11: ...GEN INFO ...

Page 12: ...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 13: ...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 stopper 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 stoppe...

Page 14: ...RES FRONT DIFFERENTIAL 1 Adapter 2 Drive clutch 3 Differential side gear left 4 Differential pinion gear 5 Ring gear 6 Differential side gear right 7 Drive pinion gear 8 Gear motor È To front wheel É From the middle gear ...

Page 15: ...ront drive shaft drive pinion gear 7 ring gear 5 differential pinion gear 4 In the 2WD mode the left differential side gear 3 and the drive clutch 2 are not engaged therefore the left side gear runs idle and does not transmit power to the left front constant velocity joint ...

Page 16: ...utch 2 adapter 1 left front constant velocity joint Meanwhile power from the differential pinion gear 4 is transmitted to the right front constant velocity joint via the right differential side gear 6 The ring gear 5 and the drive clutch 2 are not engaged at this time Therefore the rotational difference that occurs between the right and left wheels while the handlebar is being turned is absorbed b...

Page 17: ... Meanwhile because the ring gear 5 and the drive clutch 2 are engaged the ring gear 5 the drive clutch 2 and the right differential side gear 6 become locked coaxially Thus power is transmitted as follows differential pinion gear 4 right differential pinion gear 6 right front constant velocity joint When the ATV is in the 4WD Diff Lock mode the right and left wheels rotate constantly at the same s...

Page 18: ... lock indicator light in the speedometer unit will flash to alert the driver that the control is on standby When the ATV is stopped the control transfers to the condition described in 2 2 When the ATV is stopped The gear motor operates to connect the drive clutch to the differential case thus resulting in the differential lock condition When this occurs the differential gear lock indicator light i...

Page 19: ...parts and place them in trays in the order of disassembly This will speed up assembly 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 recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in...

Page 20: ...g oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liberally when installing if appropriate 1 Oil seal CAUTION Do not use compressed air to spin the bearings dry This will damage the bearing surfaces 1 Bearing EB101050 CIRCLIPS 1 Check all circlips carefully before reassembly Always replace piston pin clips after one use Replace distorted circlips Wh...

Page 21: ...terminals several times 3 Check Connector leads Looseness Bend up the pin 1 and connect 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 terminals When checking the wire harness be sure to perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores C...

Page 22: ... 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 crankcase 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 needed to install the va...

Page 23: ...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 This tool is used to check the cooling system 90890 01348 Locknut wrench This tool is needed when removing or installing the second...

Page 24: ...lter cartridge 90890 01430 YM 38404 Ring nut wrench This tool is needed to removing and installing the middle driven shaft bearing retainer 90890 01467 YM 01467 90890 01475 YM 01475 Gear lash measurement tool This tool is used to measure the gear lash 90890 01474 YM 01474 Ball joint remover installer set This tool is used to remove and install the ball joint YM 01477 Ball joint remover installer a...

Page 25: ...tool is necessary for checking ignition timing 90890 04019 YM 04019 Valve spring compressor This tool is needed to remove and install the valve 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 Bearin...

Page 26: ...earing retainer 90890 04129 YM 04129 Pinion gear fix clamp This tool is used to hold the shift cam 90890 06754 Ignition checker This instrument is necessary for checking the ignition system components YM 34487 Dynamic spark tester This instrument is necessary for checking the ignition system components Bond 90890 85505 Sealant ACC 11001 05 01 Yamaha bond No 1215 Sealant Quick Gasket This sealant b...

Page 27: ......

Page 28: ...SPEC 2 ...

Page 29: ...TENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 14 ELECTRICAL 2 18 HOW TO USE THE CONVERSION TABLE 2 20 GENERAL TORQUE SPECIFICATIONS 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 COOLANT FLOW DIAGRAMS 2 22 OIL FLOW DIAGRAMS 2 24 CABLE ROUTING 2 27 ...

Page 30: ...SPEC ...

Page 31: ... full fuel tank 267 kg 589 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 421 cm3 Bore stroke 84 5 75 0 mm 3 33 2 95 in Compression ratio 10 1 Standard compression pressure at sea level 1 270 kPa 12 7 kg cm2 181 psi at 700 r min Starting system Electric and recoil starter Lubrication system Wet sump Oil type or grade Engine oil ...

Page 32: ...Fuel reserve amount 4 5 L 0 99 Imp gal 1 19 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Spark plug Type manufacturer DR8EA NGK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Spur gear Secondary reduction ratio 39 24 24 18 33 9 7 944 Transmission type V belt automatic Operation Le...

Page 33: ...oot operation Suspension Front suspension Double wishbone Rear suspension 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 D C C D I Generator system A C magneto Battery type YTX20L BS Battery capacity 12 V 18 Ah Headligh...

Page 34: ... 0 0016 in Out of round limit 0 01 mm 0 0004 in Camshaft Drive method Chain drive Left Cam dimensions Intake A 40 62 40 72 mm 1 5992 1 6031 in 40 52 mm 1 5953 in B 32 18 32 28 mm 1 2669 1 2709 in 32 08 mm 1 2630 in Exhaust A 40 62 40 72 mm 1 5992 1 6031 in 40 52 mm 1 5953 in B 32 18 32 28 mm 1 2669 1 2709 in 32 08 mm 1 2630 in Camshaft runout limit 0 03 mm 0 0012 in A B MAINTENANCE SPECIFICATIONS ...

Page 35: ...1 3346 1 3425 in B face width IN 2 26 mm 0 0890 in EX 2 26 mm 0 0890 in C seat width IN 1 2 1 4 mm 0 0472 0 0551 in 1 6 mm 0 0630 in EX 1 2 1 4 mm 0 0472 0 0551 in 1 6 mm 0 0630 in D margin thickness IN 1 0 1 4 mm 0 0394 0 0551 in EX 0 8 1 2 mm 0 0315 0 0472 in Stem outside diameter IN 6 975 6 990 mm 0 2746 0 2752 in 6 950 mm 0 2736 in EX 6 955 6 970 mm 0 2738 0 2744 in 6 915 mm 0 2722 in Guide in...

Page 36: ... 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 36 6 mm 1 44 in EX 36 6 mm 1 44 in Compressed pressure installe...

Page 37: ...ston off set 0 5 mm 0 0200 in Offset direction Intake side 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 19 991 20 000 mm 0 7870 0 7874 in 19 971 mm 0 7863 in Piston rings Top ring Type Barrel Dimensions B T 1 0 3 1 mm 0 03937 0 1220 in End gap installed 0 20 0 40 mm 0 0079 0 0157 in 0 65 mm 0 0256 in Side clearance installed 0 03...

Page 38: ...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 B 0 25 0 75 mm 0 0098 0 0295 in 1 00 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 1 960 2 240 r min Clut...

Page 39: ...B P 3 0 8 Pilot screw turns out 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 4 0 5 0 mm 0 16 0 20 in Engine idle speed 1 450 1 550 r min Intake vacuum 32 kPa 240 mmHg 9 45 inHg Oil pump Oil filter type Foam Oil pump type Trochoid Tip clearance A or B 0 15 mm 0 006 in 0 20 mm 0 008 in Side clearanc...

Page 40: ...entrifugal 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 05 0 25 mm 0 0020 0 0098 in Lubrication chart Item Standard Limit Oil Strainer Timing ...

Page 41: ...2 11 SPEC Cylinder head tightening sequence Item Standard Limit MAINTENANCE SPECIFICATIONS ...

Page 42: ...Oil strainer cover Plug M35 1 32 3 2 23 Oil drain bolt 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 45 E Oil filter cartridge M20 1 17 1 7 12 Intake manifold Bolt M8 2 20 2 0 14 Muffler and exhaust pipe Bolt M8 2 15 1 5 11 Exhaust pipe Nut M8 2 20 2 0 14 Muffler Bolt M10 2 25 2 5 18 Exhaust pipe sta...

Page 43: ...tator assembly Screw M6 3 7 0 7 5 1 LT Pickup coil Bolt M5 2 7 0 7 5 1 LT Ignition coil Bolt M6 2 7 0 7 5 1 Thermo switch cylinder head PT1 8 1 8 0 8 5 8 LT Speed sensor Bolt M6 1 10 1 0 7 2 LT Thermo switch radiator M18 1 28 2 8 20 Tappet covers Bolt M6 4 10 1 0 7 2 Coolant drain bolt water pump Bolt M6 1 10 1 0 7 2 Coolant inlet joint Bolt M6 2 10 1 0 7 2 Bearing housing Bolt M6 1 10 1 0 7 2 Pri...

Page 44: ...hock absorber travel 126 mm 4 96 in Spring free length 317 mm 12 48 in Spring fitting length 283 mm 11 14 in Spring rate K1 30 4 N mm 3 10 kg mm 173 60 lb in Stroke K1 0 126 mm 0 4 96 in Optional spring No Swingarm Free play limit end 1 mm 0 04 in side 1 mm 0 04 in Front wheel Type Panel wheel Rim size 12 6 0 AT Rim material Steel Rim runout limit radial 2 mm 0 08 in lateral 2 mm 0 08 in Rear whee...

Page 45: ...ke Type Single Disc outside diameter thickness 220 0 3 5 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 03 mm 1 26 in Brake fluid type DOT 4 Brake lever and brake pedal Brake lever free play pivot front 0 mm 0 in rear 0 5 2 mm 0 02 0 08 in Brake pedal p...

Page 46: ... 4 5 32 Steering stem pitman arm and frame M14 130 13 0 94 LS Steering stem holder and frame M8 23 2 3 17 Use lock washer Steering stem and handlebar holder M8 23 2 3 17 Pitman arm and tie rod end M12 30 3 0 22 Tie rod and locknut M12 40 4 0 29 Steering knuckle and upper front arm M12 30 3 0 22 Steering knuckle and lower front arm M12 30 3 0 22 LS Steering knuckle and tie rod M12 30 3 0 22 Fuel ta...

Page 47: ...ar 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 Battery holding bracket M6 7 0 7 5 1 Footrest board and footrest bracket M6 7 0 7 5 1 Yoke drive pinion gear M12 62 6 2 45 Trailer hitch bracket M10 32 3 2 23 Front brake pad holding bolt M10 18 1 8 13 Rear brake pad holding bolt M10 18 1 8 13 Rear brake master cylinder bracket M8 ...

Page 48: ...e 0 18 0 28 Ω at 20 C 68 F Secondary winding resistance 6 32 9 48 kΩ at 20 C 68 F Spark plug cap Type Resin type Resistance 10 kΩ Charging system Type A C magneto generator Model manufacturer F4T464 MITSUBISHI Nominal output 14 V 14 A at 3 000 r min Charging coil resistance color 0 41 0 61 Ω at 20 C 68 F White White Rectifier regulator Regulator type Semi conductor short circuit No load regulated ...

Page 49: ...OMRON Coil winding resistance 94 5 115 5 Ω at 20 C 68 F Four wheel drive relay 3 Model manufacturer 29U MATSUSHITA Coil winding resistance 72 88 Ω at 20 C 68 F Electric fan Running rpm 3 500 r min Thermostat switch Thermostat switch 1 Model manufacturer 5KM DENSO Thermostat switch 2 Model manufacturer 5ND NIPPON THERMOSTAT Circuit breaker Type Fuse Amperage for individual circuit Main fuse 30 A 1 ...

Page 50: ... 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 yd ...

Page 51: ...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 52: ...2 22 SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 Fan motor È To coolant reservoir COOLANT FLOW DIAGRAMS ...

Page 53: ...2 23 SPEC 1 Radiator 2 Thermostat È To coolant reservoir COOLANT FLOW DIAGRAMS ...

Page 54: ...2 24 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle OIL FLOW DIAGRAMS ...

Page 55: ...2 25 SPEC 1 Oil filter OIL FLOW DIAGRAMS ...

Page 56: ...2 26 SPEC 1 Oil pump 2 Oil strainer OIL FLOW DIAGRAMS ...

Page 57: ...r wheel drive switch and differential gear lock switch 6 Throttle cable 7 Handlebar switch 8 Handlebar switch lead 9 Main switch lead 0 Fan motor breather hose A Differential gear case breather hose B Sub wire harness to gear motor C On command four wheel drive switch and differential gear lock switch lead CABLE ROUTING ...

Page 58: ...switch lead behind the handlebar with a plastic band É Fasten the starter cable handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band Ê Fasten the handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band CABLE ROUTING ...

Page 59: ...ire harness 2 Headlight lead 3 Auxiliary DC jack lead 4 Four wheel drive relay 3 5 Fan motor breather hose 6 Differential gear case breather hose 7 Coolant reservoir breather hose 8 Meter assembly coupler CABLE ROUTING ...

Page 60: ...rvoir hose 8 Sub wire harness 9 Differential gear case breather hose 0 Thermo switch 2 È Insert the fuel tank breather hose into the hole of the handlebar cover É Fasten the sub wire harness differential gear case breather hose coolant reservoir hose coolant reservoir breather hose thermo switch lead 2 and fan motor breather hose with a plastic band CABLE ROUTING ...

Page 61: ...ad 5 Negative battery lead 6 Air filter case check hose 7 Water pump breather hose 8 Radiator outlet hose 9 Starter cable 0 Float chamber air vent hose A Cylinder head breather hose B Fuel hose C Low range switch D High range switch E Neutral switch lead F Reverse switch lead G Rectifier regulator CABLE ROUTING ...

Page 62: ...igh range switch lead neutral switch lead reverse switch lead speed sensor lead and A C magneto lead with a plastic band Ê Fasten the wire harness starter motor lead with a plastic band Ë Fasten the low range switch lead high range switch lead neutral switch lead reverse switch lead speed sensor lead A C magneto lead rectifier regulator lead and negative battery lead with a plastic band CABLE ROUT...

Page 63: ... plug lead 4 Main switch 5 Wire harness 6 Rear brake light switch lead 7 Rear brake fluid reservoir hose 8 Select lever control cable 9 Rear brake cable 0 Rear brake hose È Fasten the radiator inlet hose and spark plug lead with a plastic band CABLE ROUTING ...

Page 64: ...2 34 SPEC 1 Front brake hose 2 Float chamber air vent hose 3 Throttle cable 4 Wire harness 5 Final drive gear case breather hose 6 Starter cable 7 Rear brake cable CABLE ROUTING ...

Page 65: ...2 35 SPEC 1 Battery 2 Positive battery lead 3 Tail brake light lead 4 CDI unit 5 Negative battery lead CABLE ROUTING ...

Page 66: ...2 36 SPEC 1 Final drive gear case breather hose 2 Rear brake hose 3 Air filter case check hose CABLE ROUTING ...

Page 67: ...CHK ADJ 3 ...

Page 68: ...3 10 ADJUSTING THE VALVE CLEARANCE 3 10 ADJUSTING THE IDLING SPEED 3 13 ADJUSTING THE THROTTLE LEVER FREE PLAY 3 14 ADJUSTING THE SPEED LIMITER 3 16 ADJUSTING THE STARTER CABLE 3 17 CHECKING THE SPARK PLUG 3 19 CHECKING THE IGNITION TIMING 3 20 MEASURING THE COMPRESSION PRESSURE 3 21 CHECKING THE ENGINE OIL LEVEL 3 23 CHANGING THE ENGINE OIL 3 24 CLEANING THE AIR FILTER 3 26 CHECKING THE COOLANT L...

Page 69: ... 44 CHANGING THE FINAL GEAR OIL 3 45 CHECKING THE DIFFERENTIAL GEAR OIL 3 46 CHANGING THE DIFFERENTIAL GEAR OIL 3 46 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT 3 47 CHECKING THE STEERING SYSTEM 3 48 ADJUSTING THE TOE IN 3 48 ADJUSTING THE FRONT SHOCK ABSORBER 3 50 ADJUSTING THE REAR SHOCK ABSORBER 3 50 CHECKING THE TIRE 3 50 CHECKING THE WHEEL 3 53 CHECKING AND LUBRICATING THE CABLE 3 53 LUBRI...

Page 70: ...e coolant every 24 months Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element 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 Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if...

Page 71: ...e the brake hoses every four years or if cracked or damaged WARNING Indicates a potential hazard that could result in serious injury or death Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Drive shaft universal joint Lubricate Engine mount Check for cracks or damage Front axle boots Check operation ...

Page 72: ...art name Q ty Remarks Removing the seat and side panels Remove the parts in the order below 1 Seat 1 NOTE Pull up the seat lock lever then pull up on the rear of the seat 2 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 ...

Page 73: ...r front bumper and front fender 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 1 4 Front bumper cover 1 5 Front bumper 1 6 Headlight coupler 2 Disconnect 7 Front grill 1 8 Main switch coupler 1 Disconnect 9 Handlebar cover 1 10 Fuel tank cover 1 ...

Page 74: ... assembly coupler 3 Disconnect 12 Four wheel drive relay 3 coupler 1 Disconnect 13 Auxiliary DC jack connector 2 Disconnect 14 Coolant reservoir breather hose 1 15 Fan motor breather hose 1 16 Differential gear case breather hose 1 17 Front fender 1 For installation reverse the removal procedure ...

Page 75: ... 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 CAUTION First disconnect the negative lead then disconnect the positive lead 5 Battery 6 Starter relay ground lead 1 Disconnect 7 Tail brake light connector 3 Disconnect ...

Page 76: ...3 7 CHK ADJ SEAT CARRIERS FENDERS AND FUEL TANK Order Job name Part name Q ty Remarks 8 CDI unit 1 9 Wire harness 1 10 Rear fender 1 For installation reverse the removal procedure ...

Page 77: ...NELS Fuel tank cover Refer to FRONT CARRIER FRONT BUMPER AND FRONT FENDER 1 Fuel hose 1 NOTE Before disconnecting the fuel hose turn the fuel cock to OFF 2 Fuel cock lever 1 3 Fuel tank 1 NOTE When installing the fuel tank pass the fuel tank breather hose through the hole of the handlebar protector 4 Float chamber air vent hose 1 5 Plastic band 4 6 Rubber cover 1 For installation reverse the remov...

Page 78: ...e Part name Q ty Remarks Removing the footrest boards Remove the parts in the order below Fuel tank side panels Refer to SEAT AND SIDE PANELS 1 Left footrest board 1 2 Right footrest board 1 3 Footrest bracket 4 For installation reverse the removal procedure ...

Page 79: ...touch Adjust the valve clearance when the piston 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 6 Remove Timing plug 1 ...

Page 80: ... 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 crankshaft counterclockwise one turn Measure the valve clearance using a feeler gauge 3 Valve clearance cold I...

Page 81: ... tighten the locknut Measure the valve clearance If the clearance is incorrect repeat the above steps until the proper clearance is obtained Tappet 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 following points 10 Install Recoil starter Spark plug Tappet cover...

Page 82: ...LING SPEED 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 1 450 1 550 r min ...

Page 83: ...ne tachometer 7 Adjust Throttle lever free play Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY 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 ADJUSTING THE THROTTLE LEVER FREE PLAY NOTE Engine idling speed should be adjusted properly before ...

Page 84: ...ND FUEL TANK 3 Adjust Throttle lever free play Adjustment steps First step Pull back the adjuster cover 1 Loosen the locknut 2 on the carburetor side Turn the adjuster 3 in or out until the correct 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 Turning in Free play is increased...

Page 85: ...ft to make sure that the engine idling speed does not increase Turning in Free play is increased Turning out Free play is decreased 4 Install Fuel tank side panel right Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully opened even when the throttle lever is applied to the maximum position Screwing in th...

Page 86: ...iter should be screwed in completely Screw it out little by little as their riding technique improves Never remove the speed limiter for a beginning rider For proper throttle lever operation do not turn out the adjuster more than 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 incr...

Page 87: ...lly closed position É Fully open position Pull back the boot 4 Loosen the locknut 5 Turn the adjuster 6 in or out until the correct free play is obtained Tighten the locknut 5 Push in the boot 4 Connect the starter cable to the carburetor WARNING After adjusting the cable turn the handlebar to right and left and make sure that the engine idling speed does not increase Starter plunger stroke distan...

Page 88: ...e Insulator 2 Abnormal color Replace Normal color is a medium to light tan color 5 Clean the spark plug with a spark plug cleaner or wire brush 6 Measure Plug gap a Use a wire gauge or feeler gauge Out of specification Regap 7 Tighten Spark plug NOTE Before installing a spark plug clean the gasket surface and plug surface 8 Install Fuel tank side panel right Seat Refer to SEAT CARRIERS FENDERS AND...

Page 89: ...Check Ignition timing Checking steps Warm up the engine and keep it at the specified speed Remove the recoil starter 1 Remove the timing plug 2 Visually check the stationary pointer 3 to verify it is within the required firing range 4 indicated on the flywheel Incorrect firing range Check the pulser coil assembly Install the timing plug Install the recoil starter Inductive tachometer P N YU 8036 A...

Page 90: ... performance 1 Check Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Start the engine and let it warm up for several minutes 3 Stop the engine 4 Remove Seat Fuel tank side panel right Refer to SEAT CARRIERS FENDERS AND FUEL TANK 5 Remove Spark plug 6 Attach Adapter Compression gauge 1 Compression gauge P N YU 33223 90890 03081 Adapter P N YU 33223 3 90890 04082...

Page 91: ... open until the compression reading on the gauge stabilizes WARNING When cranking the engine ground the spark plug lead to prevent sparking Compression pressure with oil introduced into cylinder Reading Diagnosis Higher than without oil Worn or damaged pistons Same as without oil Defective ring s valves cylinder head gasket or piston is possible Compression pressure at sea level Standard 1 270 kPa...

Page 92: ...e oil level Recommended oil Follow the left chart NOTE Recommended oil classification API Service SE SF type or equivalent e g SF SE CC SF SE SD etc CAUTION Do not allow foreign material to enter the crankcase 4 Start the engine and let it warm up for several minutes 5 Stop the engine and check the oil level again NOTE Wait a few minutes until the oil settles before checking the oil level WARNING ...

Page 93: ...ver Refer to SEAT CARRIERS FENDERS AND FUEL TANK 4 Remove Engine oil filler plug dipstick 1 5 Remove Engine oil drain bolt 1 Drain the engine oil Oil strainer cover 2 Compression spring 3 Oil strainer 4 6 Clean Oil strainer 7 If the oil filter cartridge is also to be replaced perform the following procedure Replacement steps Remove the oil filter cartridge 1 with an oil filter wrench 2 Oil filter ...

Page 94: ... strainer Compression spring Oil strainer cover 1 Engine oil drain bolt 2 9 Fill Crankcase Refer to CHECKING THE ENGINE OIL LEVEL 10 Install Engine oil filler plug 11 Warm up the engine for a few minutes then stop the engine 12 Check Engine for engine oil leaks Oil level Refer to CHECKING THE ENGINE OIL LEVEL Oil quantity Periodic oil change 2 3 L 2 0 Imp qt 2 4 US qt With oil filter replacement 2...

Page 95: ...il filter cartridge and the oil pump for damage or leakage Refer to CRANKCASE in CHAPTER 4 Start the engine after solving the problem s and check the engine oil pressure again Tighten the oil gallery bolt to specification 14 Install Engine side cover Fuel tank side panel left Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK Oil gallery bolt 7 Nm 0 7 m kg 5 1 ft lb CLEANING THE AIR FILTER NOTE The...

Page 96: ...r 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 damage Additionally operation without the filter element will affect carburetor tuning with subsequent poor performance and possible engine overheating 4 Check Air filter element Damaged Replace ...

Page 97: ...xplosion Squeeze the excess solvent out of the element and let it dry CAUTION Do not twist or wring 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 dripping 6 Install Air filter element Air filter case cover NOTE To prevent air leaks make sure that the sealing surface of the element matches the se...

Page 98: ...ing 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 Check Coolant level NOTE Before checking the coola...

Page 99: ...oolant reservoir breather hose 6 Install Coolant reservoir bolts Plastic band 7 Remove Radiator cap 1 WARNING A hot radiator is under pressure Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause serious injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and...

Page 100: ...ed coolant Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING If coolant splashes in your eyes thoroughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention Recommended antifreeze H...

Page 101: ... water Do not mix different types of antifreeze 13 Install Radiator cap 14 Fill Coolant reservoir with the recommended coolant to the maximum level mark a 15 Install Coolant reservoir cap 16 Start the engine warm it up for several minutes and then turn it off 17 Check Coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Before checking the coolant level wait a few minutes until the coolant has s...

Page 102: ...Crankcase cover right Refer to PRIMARY AND SECONDARY SHEAVES in CHAPTER 4 2 Check 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 30 7 mm 1 21 in Limit 27 6 mm 10 9 in ...

Page 103: ... sliding 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 CLEANING THE SPARK ARRESTER 1 Clean Spark arrester Cleaning steps WARNING Select a well ventilated area free of combustible materials Always let the exhaust system cool before performin...

Page 104: ...ler Tap the tailpipe lightly with a soft face hammer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler Insert the tailpipe 2 into the muffler and align the bolt holes Insert the bolt 1 and tighten it ...

Page 105: ...specification Adjust Rear brake lever free play 0 5 2 mm 0 02 0 08 in 2 Check Rear brake pedal height a Out of specification Adjust 1 Brake pedal 2 Footrest Rear brake pedal height 70 80 mm 2 76 3 15 in 3 Adjust Rear brake lever free play Rear brake pedal height Adjustment steps Loosen the locknut handlebar 1 and fully screw in the brake lever cable adjuster handlebar 2 Remove the rear brake maste...

Page 106: ...Hold the adjusting nut 7 and tighten the locknut 6 Turn the brake lever cable adjuster handlebar 2 until the rear brake lever free play c is within the specified limits Tighten the locknut handlebar 1 Adjust the select lever control cable Refer to ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD Install the rear brake master cylinder cover WARNING After this adjustment is performed lift the ...

Page 107: ...lastic parts Always clean up spilled fluid immediately WARNING Use only the designed quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will ...

Page 108: ...t Refer to FRONT AND REAR BRAKES in CHAPTER 8 3 Operate the brake lever 4 Install Front wheels Brake pad wear limit a 1 mm 0 04 in CHECKING THE REAR BRAKE PAD 1 Remove Rear wheel left 2 Check Brake pad Wear indicator groove 1 almost disappeared 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 we...

Page 109: ...heck Front brake hoses 1 Rear brake hoses 2 Cracks wear damage Replace Fluid leakage Replace the hose Refer to FRONT AND REAR BRAKES in CHAPTER 8 NOTE Hold the machine in an upright position and apply the front or rear brake 3 Check Brake hose clamp Loosen Tighten 4 Install Right footrest board Refer to FOOTREST BOARDS Front fender Front carrier Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ...

Page 110: ...e clear plastic hose 1 tightly to the caliper bleed screw 2 È Front É Rear d Place the other end of the hose into a container e Slowly apply the brake lever or pedal several times f Pull the lever in or push down on the pedal and hold it g Loosen the bleed screw and allow the lever or pedal to travel towards its limit h Tighten the bleed screw when the lever or pedal limit has been reached then re...

Page 111: ...elect lever bring the machine to a complete stop and return the throttle lever to its closed position Otherwise the transmission may be damaged 1 Adjust Rear brake pedal free play Refer to ADJUSTING THE REAR BRAKE 2 Adjust Select lever control cable 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 ...

Page 112: ...UTRAL from REVERSE Check that locknuts 2 are tightened correctly If the operation of the select lever is incorrect adjust the select lever control cable 3 with the adjuster 4 Select lever shift rod Make sure the select lever is in NEUTRAL Loosen both locknuts 1 Adjust the shift rod length for smooth and correct shifting Tighten the locknuts 1 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear bra...

Page 113: ...t comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later CHECKING THE FINAL GEAR OIL LEVEL 1 Place the machine on a level place 2 Remove Oil filler bolt 1 3 Check Oil level Oil level should be up to the brim of the hole Oil level low Add oil to the proper level CAUTION Take care not allow foreign material to enter the final gear case Recommended ...

Page 114: ...et drain plug If it is damaged 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 Check Oil level Refer to CHECKING THE FINAL GEAR OIL LEVEL 9 Install Oil filler bolt Final gear case protector Periodic oil change 0 23 L 0 20 Imp qt 0 24 US qt Total amount 0 25 L 0 22 Imp qt 0 26 US qt Recommended oil SAE 80 API GL 4 Hypoi...

Page 115: ...hole Oil level low Add oil to proper level CAUTION Take care not allow foreign material to enter the gear case 4 Install Oil filler bolt Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity periodic oil change 0 23 L 0 20 Imp qt 0 24 US qt T R 23 Nm 2 3 m kg 17 ft lb CHANGING THE DIFFERENTIAL GEAR OIL 1 Place the machine on a level surface 2 Place a receptacle under the differential gear c...

Page 116: ...start leaking from the differential gear case breather hose Therefore check the quantity of the oil not its level CAUTION Take care not to allow foreign material to enter the differential gear case 7 Install Oil filler bolt Periodic oil change 0 23 L 0 20 Imp qt 0 24 US qt Total amount 0 28 L 0 25 Imp qt 0 30 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb CHECKIN...

Page 117: ...nd s 4 Raise the front end of the machine so that there is no weight on the front wheels 5 Check Ball joints and or wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bearings ADJUSTING THE TOE IN 1 Place the machine on a level surface 2 Measure Toe in Out of specification Adjust Measurement steps NOTE Before measuring th...

Page 118: ...cation run the machine slowly for some distance with both hands lightly holding the handlebar and check that the handlebar responds correctly If not turn either the right or left tie rod within the toe in specification t 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 rods The same number of turns should b...

Page 119: ...ing preload Standard position 2 Minimum Soft position 1 Maximum Hard position 5 ADJUSTING THE REAR SHOCK ABSORBER 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 conditions Standard position 2 Minimum Soft position 1 Maximum Hard position 5 ...

Page 120: ...2 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 pressures may cause the tire to burst Inflate the tires slowly and carefully Fast inflation could cause the tire to burst MAXIMUM LOADING LIMIT 1 Vehicle load limit total weight of cargo rider and accessories and tongue weight 210 kg ...

Page 121: ...s 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 Check Tire surfaces Wear damage Replace WARNING It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Cold tire pressure Front Rear Standard 25 kPa...

Page 122: ...tself properly on the rim CHECKING AND LUBRICATING THE CABLE WARNING A damaged cable sheath may cause corrosion and interfere with the cable movement An unsafe condition may result so replace a damaged cable as soon as possible 1 Check Cable sheath Damage Replace 2 Check Cable operation Unsmooth operation Lubricate or replace NOTE Hold the cable end up and apply several drops of lubricant to the c...

Page 123: ...3 54 CHK ADJ LUBRICATING THE LEVERS PEDAL ETC LUBRICATING THE LEVERS PEDAL ETC 1 Lubricate the pivoting parts Recommended lubricant Yamaha chain and cable lube or Engine oil ...

Page 124: ...attery are different from those of general type batteries 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 battery WARNING Battery electrolyte is dangerous it contains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures Avo...

Page 125: ... Battery holding bracket 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 ope...

Page 126: ...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 corroded 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 battery terminals be sure to turn off the charger s power switch The open circuit voltage variatio...

Page 127: ...amperage exceeded NO YES If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring i...

Page 128: ...5 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage NOTE Set the char...

Page 129: ...rst 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 CHECKING THE FUSE 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 Check Fuses Checking steps Connect the pock...

Page 130: ...NING Never 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 Pocket tester P N YU 03112 90890 03112 Description Current rating Quantity Main 30 A 1 Headlight 15 A 1 Ignition 10 A 1 Terminal Auxiliary DC...

Page 131: ...m vertically Turn the adjuster 1 in or out Turning in Headlight beam raised Turning out Headlight beam lowered CHANGING THE HEADLIGHT BULB 1 Remove Cover 1 2 Remove Bulb holder 1 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 bulb until it cools down...

Page 132: ...AUTION Avoid touching the glass part of the bulb Keep it free from oil otherwise the transparency 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 lacquer thinner 4 Install Bulb holder Cover New ...

Page 133: ......

Page 134: ...ENG 4 ...

Page 135: ...8 CHECKING THE CAMSHAFT 4 19 CHECKING THE ROCKER ARM AND CAMSHAFT 4 19 CHECKING THE VALVE AND VALVE SPRING 4 21 INSTALLING THE VALVE AND VALVE SPRING 4 25 INSTALLING THE CAMSHAFT AND ROCKER ARM 4 26 CYLINDER AND PISTON 4 27 REMOVING THE PISTON 4 28 CHECKING THE TIMING CHAIN GUIDE 4 28 CHECKING THE CYLINDER AND PISTON 4 28 CHECKING THE PISTON RING 4 30 CHECKING THE PISTON PIN 4 31 INSTALLING THE PI...

Page 136: ...REMOVING THE OIL PUMP DRIVE GEAR 4 60 SEPARATING THE CRANKCASE 4 60 CHECKING THE TIMING CHAIN AND GUIDE 4 61 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 4 61 CHECKING THE CRANKCASE 4 62 CHECKING THE BEARINGS 4 62 ASSEMBLING THE CRANKCASE 4 62 INSTALLING THE SHIFT LEVER 4 63 INSTALLING THE OIL PUMP DRIVE GEAR 4 64 CRANKSHAFT AND OIL PUMP 4 65 OIL PUMP 4 66 REMOVING THE CRANKSHAFT 4 67 CHECKING ...

Page 137: ...MOVING THE MIDDLE DRIVE SHAFT 4 79 REMOVING THE MIDDLE DRIVEN SHAFT 4 79 CHECKING THE PINION GEAR 4 81 SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM 4 82 INSTALLING THE MIDDLE DRIVEN SHAFT 4 85 INSTALLING THE MIDDLE DRIVE SHAFT 4 87 MEASURING THE MIDDLE GEAR BACKLASH 4 87 ...

Page 138: ...ENG ...

Page 139: ... Engine oil Drain Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Front and rear fender footrest boards Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Fuel tank rubber cover Coolant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 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...

Page 140: ...REMOVAL Order Job name Part name Q ty Remarks 6 Final drive gear case breather hose 1 7 Cylinder head breather hose 1 8 Vacuum chamber breather hose 1 9 Air filter case 1 For installation reverse the removal procedure ...

Page 141: ...y Remarks Removing the select lever unit and coolant reservoir 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 142: ...PUMP in CHAPTER 5 1 Cylinder head breather hose 1 2 Spark plug lead 1 3 Thermo switch 1 lead 1 4 Starter motor lead 1 5 A C magneto lead coupler 2 6 Speed sensor lead coupler 1 7 Reverse switch lead 1 Green White 8 Neutral switch lead 1 Sky blue 9 High range switch 1 Blue White 10 Low range switch 1 White Red 11 Engine ground lead 1 For installation reverse the removal procedure ...

Page 143: ...ER 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...

Page 144: ...4 6 ENG ENGINE REMOVAL Order Job name Part name Q ty Remarks 9 Engine assembly 1 NOTE Remove the engine assembly from the left side of the machine For installation reverse the removal procedure ...

Page 145: ...ne 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 146: ... 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 ADJUSTING THE VALVE CLEARANCE 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 147: ...1 1 7 Tappet cover O ring 2 2 8 Thermo switch 1 lead 1 Disconnect 9 Timing chain tensioner cap bolt 1 Refer to REMOVING INSTALLING THE CYLINDER HEAD 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 148: ...t 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 crankshaft counterclockwise one turn 2 Loosen Camshaft sprocket bolt 1 NOTE Use the rotor holding tool 2 to hold the starter pulley Rotor holding tool P N...

Page 149: ...n a crisscross pattern loosen each 10 mm bolt 1 4 of a turn After all the bolts are loosened remove them CHECKING THE TAPPET COVER 1 Check Tappet covers 1 O rings 2 Cracks damage Replace CHECKING THE TIMING CHAIN TENSIONER 1 Check One way cam operation tensioner Unsmooth operation Replace CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket Wear damage Replace the camshaft sprocket and timing ...

Page 150: ...ust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface Measurement and resurfacing 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 pattern...

Page 151: ...haft 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 camshaft sprocket installation Place the timing cha...

Page 152: ... match mark 2 If the marks are aligned tighten the camshaft 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 with...

Page 153: ...ten Camshaft sprocket bolt 1 NOTE Use the rotor holding tool 2 to hold the starter pulley 5 Check Camshaft sprocket I mark Rotor T mark Out of alignment Adjust Rotor holding tool P N YU 01235 90890 01235 T R 60 Nm 6 0 m kg 43 ft lb ...

Page 154: ... 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 REMOVING INSTALLING THE CAMSHAFT AND ROCKER ARM 6 Rocker arm shaft O ring 2 2 7 Rocker arm 2 8 Locknut valve adjuster 2 2 9 Valve cotter 4 Refer to REMOVING INSTALLING THE VALVE AND VALVE SPRING 10 Valve spring retainer 2 11 Valve spring outer 2 ...

Page 155: ...rder Job name Part name Q ty Remarks 12 Valve spring inner 2 Refer to REMOVING INSTALLING THE VALVE AND VALVE SPRING 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 156: ...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 REMOVING THE VALVE AND VALVE SPRING 1 Check Valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE AND VALVE SPRING Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that th...

Page 157: ...am lobes Pitting scratches blue discoloration Replace 2 Measure Cam lobes length a and b Out of specification Replace Valve spring compressor 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 CHECKING THE ROCKER ARM AND CAMSHAFT 1 Check Camshaft lobe contact surface 1 Valve adjusters 2 Blue discoloration pitt...

Page 158: ...eck lubrication Measure the inside diameter a of the rocker arm holes Out of specification Replace Measure the outside diameter b of the rocker arm shafts Out of specification Replace Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Clearance greater than 0 08 mm 0 003 in Replace the defective part s Rocker arm inside diameter 12 000 ...

Page 159: ...lacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head to 100 C 212 F in an oven Remove the valve guide using a valve guide remover 1 Install the new valve guide using a valve guide remover 1 and valve guide installer 2 After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance NOTE ...

Page 160: ...re Runout valve stem Out of specification Replace NOTE When installing a new valve always replace the guide If the valve is removed or replaced always replace the oil seal 6 Eliminate Carbon deposits from the valve face and valve seat 7 Check Valve seats Pitting wear Reface the valve seat 8 Measure Valve seat width a Out of specification Reface the valve seat Runout limit 0 01 mm 0 0004 in Valve s...

Page 161: ...e seat must be refaced 9 Lap Valve face Valve seat NOTE After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapped Lapping steps Apply a coarse lapping compound to the valve face CAUTION Do not let the compound enter the gap between the valve stem and the guide Apply molybdenum disulfide oil to the valve stem Install the valve into the cylin...

Page 162: ...e seat to make a clear pattern Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat 10 Measure Valve spring free length a Out of specification Replace 11 Measure Compressed spring force a Out of specification Replace b Installed length Free length valve spring Inner 39 9 mm 1 57 in Limit 37 9 mm 1 49 in Outer 43 27 mm 1 70 in Limit 41 2...

Page 163: ...ve stem seals Valves Valve springs inner and outer Valve spring 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 compressor 1 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood CAUTION Hittin...

Page 164: ...SHAFT AND ROCKER ARM 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 165: ...YLINDER HEAD Water pump outlet hose pipe Refer to WATER PUMP in CHAPTER 5 1 Coolant inlet joint 1 2 Timing chain guide exhaust 1 3 Cylinder O ring 1 1 Refer to INSTALLING THE CYLINDER 4 Cylinder gasket 1 5 Dowel pin 2 6 O ring 1 7 Piston pin clip 2 Refer to REMOVING INSTALLING THE PISTON 8 Piston pin 1 9 Piston 1 10 Piston ring set 1 For installation reverse the removal procedure ...

Page 166: ...not 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 CHECKING THE TIMING CHAIN GUIDE 1 Check Exhaust side timing chain guide Wear damage Replace CHECKING THE CYLINDER AND PISTON 1 Check Cylinder and piston walls Vertical scratches R...

Page 167: ...eplace the cylinder and the piston 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 spe...

Page 168: ... 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 clearance 2 Position Piston ring in cylinder NOTE Insert a ring into the cylinder and push it approximately 40 mm 1 6 in into the cylinder Push the ring with the piston crown so that the ring will be at a rig...

Page 169: ...HE PISTON PIN 1 Check Piston pin Blue discoloration grooves Replace then check 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 clearance with the following formula Outside diameter piston pin 19 991 20 000...

Page 170: ...bricate the piston and piston rings liberally 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 piston ring and piston Be sure that the arrow mark a on the piston points to the exhaust side ...

Page 171: ... coating of engine oil INSTALLING THE CYLINDER 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 172: ...gine oil Drain Refer to CHANGING THE ENGINE OIL 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 A C magneto coupler 2 Disconnect 3 Starter pulley 1 Refer to REMOVING INSTALLING THE A C MAGNETO 4 Crankcase cover left gasket 1 1 5 Dowel pin 2 6 Lead holder 1 ...

Page 173: ...emarks 7 Pickup coil 1 8 Stator assembly 1 9 Rotor 1 Refer to REMOVING INSTALLING THE A C MAGNETO 10 Starter wheel gear 1 11 Woodruff key 1 12 Washer 1 13 Starter idle gear shaft 1 14 Washer bearing 1 1 15 Starter idle gear 1 For installation reverse the removal procedure ...

Page 174: ...ling the recoil starter Remove the parts in the order below 1 Cap 1 Refer to DISASSEMBLING ASSEMBLING THE RECOIL STARTER 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 175: ... 4 of a turn Remove them after all of them are loosened Rotor holding tool P N YU 01235 90890 01235 3 Remove Rotor 1 NOTE Use the flywheel puller 2 Flywheel puller P N YM 01404 90890 01404 DISASSEMBLING THE RECOIL STARTER 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 CHECKING THE CDI MA...

Page 176: ...ch and hold the starter clutch When turning the starter wheel gear counterclockwise È 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 É the starter wheel gear should turn freely If not the starter clutch is faulty Replace it T R Bolts starter clutch 30 Nm 3 0 m kg 22 ft lb LOCTITE 2 Check Gear teet...

Page 177: ...ING THE RECOIL STARTER 1 Check Rope 1 Sheave drum 2 Drive pawl 3 Wear damage Replace Coil spring 4 Pawl spring 5 Spring 6 Fatigue Replace ASSEMBLING THE RECOIL STARTER 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 178: ...tion 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 INSTALLING THE A C MAGNETO 1 Apply Sealant Quick Gaske...

Page 179: ...er left NOTE When installing the crankcase cover left use a long rod to hold the 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 crisscross pattern New T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install Starter pulley 1 NOTE Use a rotor holding tool 2 to hold the starter pulley NOTE Before installing the starter pulley...

Page 180: ...e Remove the parts in the order below Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Rear fender Right footrest board 1 Exhaust pipe bracket 1 2 Drive belt cover 1 3 Rubber gasket 1 4 Bearing housing 1 5 Dowel pin 2 6 Primary sliding sheave assembly 1 Refer to REMOVING INSTALLING THE PRIMARY AND SECONDARY SHEAVES 7 V belt 1 ...

Page 181: ... SECONDARY SHEAVES Order Job name Part name Q ty Remarks 8 Primary fixed sheave 1 Refer to REMOVING INSTALLING THE PRIMARY AND SECONDARY SHEAVES 9 Secondary sheave assembly 1 For installation reverse the removal procedure ...

Page 182: ...rimary sliding sheave Remove the parts in the order below 1 Primary pulley sheave cap 1 Refer to ASSEMBLING THE PRIMARY SHEAVE 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 183: ...dary sheave Remove the parts in the order below 1 Nut 1 Refer to DISASSEMBLING ASSEMBLING THE SECONDARY SHEAVE 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 184: ...THE SECONDARY SHEAVE 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 S...

Page 185: ... Replace 3 Check Primary sliding sheave Primary fixed sheave Cracks damage Replace CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave smooth operation Secondary sliding sheave smooth operation Scratches damage Replace as a set 2 Check Torque cam groove 1 Wear damage Replace 3 Check Guide pin 2 Wear damage Replace 4 Check Secondary sheave spring Damage Replace 5 Measure Secondary sheave s...

Page 186: ...ght and install Apply Yamaha Grizzly grease to the inner surface of the collar Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave 3 Install Spacer Slider 1 Primary pulley cam 2 Primary sliding sheave cap T R 3 Nm 0 3 m kg 2 2 ft lb ASSEMBLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals BEL RAY assembly...

Page 187: ...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 specified torque using the locknut wrench Remove the sheave spring compressor locknut wrench and sheave fixed block Sheave fixed block P N YM 04135 90890 04135 Locknut wrench P N 90890 01348 Sheave spring ...

Page 188: ...he gap between the secondary fixed and sliding 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 primary 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 ft...

Page 189: ... in the order below Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES 1 Cover 1 2 Clutch housing assembly 1 Refer to REMOVING INSTALLING THE CLUTCH 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 190: ... Q ty Remarks Disassembling the clutch housing Remove the parts in the order below 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For assembly reverse the disassembly procedure ...

Page 191: ...lace the one way clutch assembly and clutch housing as a set The one way clutch bearing 2 must be installed with the arrow mark side facing up Checking steps Install the one way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly When turning the clutch carrier assembly clockwise È the clutch carrier assembly should turn freely If not the one way c...

Page 192: ...Clutch carrier assembly Nut 1 NOTE Lubricate the nut with molybdenum disulfide oil 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...

Page 193: ... pins Gasket Clutch housing assembly NOTE Tighten the bolts in stages using a crisscross pattern After tightening the bolts check that the clutch housing assembly to counterclockwise rotates smoothly New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 194: ...ylinder head Refer to CYLINDER HEAD Cylinder and piston Refer to CYLINDER AND PISTON Recoil starter and rotor Refer to RECOIL STARTER AND A C MAGNETO 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 REMOVING INSTALLING THE OIL PUMP DRIVE GEAR 2 Oil pump driven gear 1 3 Timing chain guide 1 4...

Page 195: ... 8 Shift cam stopper 1 9 Low range switch 1 10 High range switch 1 11 Neutral switch 1 12 Reverse switch 1 13 Oil filler cap 1 14 Bearing cover gasket 1 1 15 Oil delivery pipe 1 16 Oil strainer cover O ring 1 1 17 Compression spring 1 18 Oil strainer 1 For installation reverse the removal procedure ...

Page 196: ...ve the parts in the order below 1 Shift lever cover gasket 1 1 Refer to INSTALLING THE SHIFT LEVER 2 Shift lever 1 O ring 1 1 3 Shift lever 2 assembly 1 4 Crankcase left 1 Refer to SEPARATING ASSEMBLING THE CRANKCASE 5 Dowel pin 2 6 Crankcase right 1 For installation reverse the removal procedure ...

Page 197: ...e crankcase bearing 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 198: ...tch holding tool 2 and loosen the oil pump drive gear nut Remove the clutch carrier assembly Clutch holding tool P N YM 91042 90890 04086 SEPARATING THE CRANKCASE 1 Separate Left 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 crisscross pattern È Left crankcase É...

Page 199: ...efully Make sure that the crankcase halves separate evenly Remove the dowel pins CHECKING THE TIMING CHAIN AND GUIDE 1 Check Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Check Intake side timing chain guide Wear damage Replace CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 1 Check Oil strainer 1 2 Check Oil delivery pipe Cracks damage Replace Clogged Blow ou...

Page 200: ... then rotate the inner race with a finger Roughness Replace ASSEMBLING THE CRANKCASE 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 torquing the crankcase h...

Page 201: ...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 INSTALLING THE SHIFT LEVER 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 202: ...w 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 Clutch holding tool P N YM 91042 90890 04086 T R 50 Nm 5 0 m kg 36 ft lb 3 Bend the lock washer tab ...

Page 203: ...kshaft and oil pump 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 REMOVING THE CRANKSHAFT INSTALLING THE CRANKSHAFT AND BALANCER 4 Crankshaft seal 2 5 Crankshaft 1 For installation reverse the removal procedure ...

Page 204: ... Order Job name Part name Q ty Remarks Disassembling the oil pump Remove the parts in the order below 1 Rotor cover 1 2 Pin 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 205: ...eparating tool 1 Crankcase separating tool P N YU 01135 A 90890 01135 CHECKING THE OIL PUMP 1 Check Oil pump driven gear Oil pump housing 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 ...

Page 206: ...Runout C Out of specification Replace the crankshaft 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 crankshaft Crank width 62 95 63 00 mm 2 4783 2 4803 in Big end side clearance 0 25 0 75 mm 0 0098 0 0295 in Li...

Page 207: ... 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 Spacer crankshaft 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 direc...

Page 208: ...emoving the transmission Remove the parts in the order below Crankcase separation Refer to CRANKCASE 1 Driven sprocket 1 2 Chain 1 3 Clutch dog 2 1 4 Shift fork L 1 5 Spring 1 6 Low wheel gear 1 7 Secondary shaft 1 8 Middle driven gear 1 9 Drive axle assembly 1 10 Guide bar 1 ...

Page 209: ...e Part name Q ty Remarks 11 Shift fork R 1 12 Spring 1 13 Shift cam 1 14 Stopper wheel 1 15 Clutch dog 1 1 16 High wheel gear 1 17 Middle drive gear 1 18 Stopper lever 1 19 Spacer O ring 1 1 For installation reverse the removal procedure ...

Page 210: ...ck 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 Check Spring Cracks damage Replace CHECKING THE SHIFT CAM 1 Check Shift cam grooves Scratches wear damage Replace ...

Page 211: ...tting wear Replace Mated dogs Rounded edges cracks missing portions Replace 3 Check Gear movement Unsmooth Repeat steps 1 and 2 or replace the defective parts 4 Check Circlip Bends looseness damage Replace CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 1 Check Gear teeth Blue discoloration pitting wear Replace 2 Check Gear movement Unsmooth Repeat steps 1 or replace the defective parts 3 Check C...

Page 212: ...r Replace the stopper wheel and stopper lever as a set Shaft 3 Bends damage wear Replace INSTALLING THE TRANSMISSION 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 facing towards the right side of the crankcase and the shift fork with the L mark facing towards the left ...

Page 213: ...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 214: ...below Crankcase separation Refer to CRANKCASE Transmission Refer to TRANSMISSION 1 Bearing housing assembly 1 2 Nut 1 Refer to REMOVING INSTALLING THE MIDDLE DRIVE SHAFT 3 Middle drive pinion gear 1 4 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM 5 Middle drive shaft 1 6 Bearing retainer 2 For installation reverse the removal procedure ...

Page 215: ...to CRANKCASE 1 Circlip 4 Refer to REMOVING INSTALLING THE MIDDLE DRIVEN SHAFT 2 Bearing 4 3 Universal joint 2 4 Universal joint yoke 2 5 Bearing housing O ring 1 1 6 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM 7 Middle drive pinion gear 1 Refer to REMOVING INSTALLING THE MIDDLE DRIVEN SHAFT 8 Bearing retainer 1 9 Damper cam 1 10 Spring 1 11 Gear coupling 1 ...

Page 216: ...4 78 ENG MIDDLE GEAR Order Job name Part name Q ty Remarks 12 Bearing retainer 1 13 Middle driven shaft 1 For installation reverse the removal procedure ...

Page 217: ...ive pinion gear Middle drive pinion gear Shim s REMOVING THE MIDDLE DRIVEN SHAFT 1 Remove 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 be ...

Page 218: ... 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 bearing 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 loosen t...

Page 219: ...ds To loosen the retainer turn it clockwise Ring nut wrench P N YM 38404 90890 01430 6 Remove Middle drive shaft 1 with bearing CHECKING THE PINION GEAR 1 Check Damper cam surfaces Wear scratches Replace damper cam and driven pinion gear as a set 2 Check Damper spring Damage cracks Replace 3 Check Gear teeth drive pinion gear 1 Gear teeth driven pinion gear 2 Pitting galling wear Replace ...

Page 220: ...ion middle drive and driven gear by using shims 1 and 2 with their respective thickness calculated from information marked on crankcase bearing housing and drive gear end 1 Shim thickness A 2 Shim thickness B To find shim thickness A use following formula Where a a numeral usually a decimal number on the bearing housing is either added to or subtracted from 10 5 b drive pinion gear to driven pinio...

Page 221: ... 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 thickness Hundredths Round value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle drive pinion gear shim Thickness mm 0 10 0 30 0 15 0 40 0 20 0 50 To find shim thickness B use the following formula Middle driven pinion gear sh...

Page 222: ...cimal number 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 57 mm B 76 03 59 02 79 40 95 79 0 05 0 57 6 Round off hundredths digit and select appro...

Page 223: ... 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 Attach the folded rag 2 Secure the bearing housing edge in the vise 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...

Page 224: ...s so that the tabs are positioned 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 Installation steps Install the opposite yoke into the U joint Apply wheel be...

Page 225: ...lip can be installed Install the circlips 2 into the groove of each bearing INSTALLING THE MIDDLE DRIVE SHAFT 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 130 Nm 13 0 m kg 94 ft lb MEASURING THE MIDDLE GEAR BACKLASH 1 Measure Gear lash Measurement steps Temporarily install the right crankcase ...

Page 226: ...h 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 227: ...COOL 5 ...

Page 228: ...R 5 1 CHECKING THE RADIATOR 5 3 INSTALLING THE RADIATOR 5 4 THERMOSTAT 5 5 CHECKING THE THERMOSTAT 5 6 INSTALLING THE THERMOSTAT 5 6 WATER PUMP 5 7 DISASSEMBLING THE WATER PUMP 5 9 CHECKING THE WATER PUMP 5 9 ASSEMBLING THE WATER PUMP 5 10 ...

Page 229: ...COOL ...

Page 230: ...IDE PANELS 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 CHANGING THE COOLANT 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 231: ...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 232: ...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 seconds 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 CHAPTER 9 Radiator cap opening pressure 93 7 122 6 kPa 0 937 1 226...

Page 233: ...ADIATOR INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recommended coolant Refer to CHANGING THE COOLANT in CHAPTER 3 2 Check Cooling system Leaks Repair or replace any faulty part ...

Page 234: ...rmostat 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 CHANGING THE COOLANT in CHAPTER 3 1 Radiator inlet hose 1 2 Thermostat cover 1 3 Thermostat 1 For installation reverse the removal procedure ...

Page 235: ...meter 3 Water 4 Container È Fully closed É Fully open NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace INSTALLING THE THERMOSTAT 1 Install Thermostat 1 Thermostat cover NOTE Install the thermostat with its breather hole a toward the projection b 2 Fill Cooling system with ...

Page 236: ...e side cover Refer to SEAT AND SIDE PANELS in CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Coolant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 O ring 1 4 Radiator outlet hose 1 5 Water pump breather hose 1 6 Water pump assembly 1 7 O ring 1 For installation reverse the removal procedure ...

Page 237: ...the water pump 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 238: ...the water pump seal from the inside 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 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller 3 Rubber damper 4 Rubber damper holder 5 Cracks damage wear Replace 2 Check Water pump outlet pi...

Page 239: ...socket 3 that matches its outside diameter New 2 Install Water pump seal 1 into the water pump housing 2 NOTE Before installing the water pump seal 1 apply tap water or coolant onto its outer surface CAUTION Never lubricate the water pump seal surface with oil or grease NOTE Install the water pump seal with the special tools È Push down Mechanical seal installer 3 P N YM 33221 90890 04078 Middle d...

Page 240: ... Rubber damper 1 Rubber damper holder 2 NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface CAUTION Make sure that the rubber damper and rubber damper holder are flush with the impeller New New ...

Page 241: ......

Page 242: ...CARB 6 ...

Page 243: ...CARB CHAPTER 6 CARBURETION CARBURETOR 6 1 CHECKING THE CARBURETOR 6 4 ASSEMBLING THE CARBURETOR 6 6 ADJUSTING THE FUEL LEVEL 6 7 ...

Page 244: ...CARB ...

Page 245: ...uel 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 Vacuum chamber breather hose 1 4 Carburetor assembly 1 5 Throttle valve cover 1 6 Throttle cable end 1 7 Throttle cable 2 NOTE After removing the carburetor assembly remove the throttle cable For installation reverse the removal procedure ...

Page 246: ...s in the order below 1 Float chamber 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 ASSEMBLING THE CARBURETOR C Needle valve set 1 ...

Page 247: ...r Job name Part name Q ty Remarks D Pilot jet 1 E Pilot screw set 1 Refer to DISASSEMBLING ASSEMBLING THE CARBURETOR F Main jet 1 G Needle jet 1 H Starter jet 1 I Pilot air jet 1 For assembly reverse the disassembly procedure ...

Page 248: ...or in a petroleum based solvent Do not use any caustic carburetor cleaning solution Blow out all of the passages and jets with compressed air 2 Check Float 1 Float tang 2 Damage Replace 3 Check 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 Check Piston valve 1 Scratches wear damage Replace Rubber diaph...

Page 249: ...ain 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 compressed 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 250: ...uretor in an upside down position Measure the distance from the mating surface of the float chamber gasket removed to the top of the float NOTE The float arm should be resting on the needle valve but not compressing it If the float height is not within the specification check the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by bending the...

Page 251: ...ally 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 Check 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 4 0 5 0 mm 0 16 0 20 in Above the float c...

Page 252: ......

Page 253: ...DRIV 7 ...

Page 254: ...NG THE UNIVERSAL JOINT 7 13 MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH 7 14 CHECKING THE DIFFERENTIAL GEAR OPERATION 7 16 REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT 7 17 REMOVING THE REAR AXLE 7 20 DISASSEMBLING THE FINAL DRIVE GEAR 7 20 REPLACING THE FINAL DRIVE ROLLER BEARING 7 21 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR 7 22 CHECKING THE REAR AXLE 7 26 CHECKING THE DRIVE SH...

Page 255: ...DRIV ...

Page 256: ...d a high pitched 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 1 Check Unusu...

Page 257: ...nd possible injury to the rider 2 Check 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 Check Oil leakage Checking 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 necessary to ...

Page 258: ... Feel for bearing damage NO Constant velocity joint bearings and differential 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 ADJUSTING THE REAR BRAKE in CHAPTER 3 YES Check the rear axle Feel for bearing damage NO Rear axle bearings and rear drive shaft bearings are probably not dama...

Page 259: ...ender 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 Brake master cylinder cover Refer to FRONT AND REAR BRAKES in CHAPTER 8 1 Constant velocity joint 2 2 Gear motor coupler on command four wheel drive switch and differential gear ...

Page 260: ... DRIV FRONT 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 For installation reverse the removal procedure ...

Page 261: ...g the constant velocity joint Remove the parts in the order below 1 Circlip 1 2 Boot band 2 Refer to ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT 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 262: ...der below 1 Gear motor O ring 1 1 NOTE Be sure not to disassemble the gear motor or remove the pinion gear 2 Circlip 2 Refer to REMOVING INSTALLING THE UNIVERSAL JOINT 3 Bearing 2 4 Universal joint 1 5 Universal joint yoke O ring 1 1 6 Stopper bolt shaft 1 1 7 Shift fork sliding gear 1 8 Shift fork 1 9 Differential gear case cover 1 0 Drive clutch 1 A Shim left ...

Page 263: ...Y JOINTS AND DIFFERENTIAL GEAR Order Job name Part name Q ty Remarks B Differential gear assembly 1 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 264: ...ghtly tap the yoke with a punch 2 Remove Universal joint yoke Use a universal joint holder 1 Universal joint holder P N YM 04062 90890 04062 REMOVING THE RING GEAR 1 Remove Ring gear 1 NOTE The ring gear and the differential gear cover should be fastened together Do not disassemble the differential gear assembly CAUTION The differential gears are assembled into a proper unit at the factory by mean...

Page 265: ...ce of double off set joint Pitting wear damage Replace CHECKING THE DIFFERENTIAL GEAR 1 Check Gear teeth Pitting galling wear Replace drive pinion gear and ring gear as a set Bearing Pitting damage Replace Oil seal O ring Damage Replace 2 Check Drive shaft splines Universal joints Front drive gear splines Wear damage Replace Spring Fatigue Replace Move the spring up and down 3 Check Front drive sh...

Page 266: ... the gear motor or remove the pinion gear È É ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT 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 Dust 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 b...

Page 267: ... the pinion gear 3 and operate it until the paint mark 4 on the gear is aligned with the paint mark 5 on the gear motor case CAUTION Do not use a 12 V battery to operate the pinion gear Insert 8 mm bolts 6 into the gear motor 7 and use them as a guide to set the motor on the differential gear assembly 8 so that the shift fork sliding gear 9 does not move CAUTION If the position of the shift fork s...

Page 268: ... INSTALLING THE UNIVERSAL JOINT 1 Install Universal joint Installation steps Install the opposite yoke into the U joint Apply wheel bearing grease to the bearings Install the bearing 1 onto the yoke CAUTION Check each bearing The needles can easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place Press...

Page 269: ...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 21 mm 0 83 in 5 Measure Gear lash Gently rotate the gear coupling from engagement to engagement NOTE Measure the gear lash at four positions Rotate the shaft 90 each time Gear lash measurement tool P N YM 01467 90890 01467 Differential gear lash 0 05...

Page 270: ...e right shim thickness by 0 1 mm 0 004 in for every 0 1 mm 0 004 in of left shim increase If it is necessary to reduce by more than 0 1 mm 0 004 in Increase right shim thickness by 0 1 mm 0 004 in for every 0 1 mm of left shim decreased Right only Too little gear lash Reduce shim thickness Too large gear lash Increase shim thickness Ring gear shim left and right Thickness mm 0 1 0 2 0 3 0 4 0 5 1 ...

Page 271: ...ear 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 differential gear assembly 5 Within specification Install the new cotter pin and wheel cap T R Front wheel starting torque differential gear preload New unit 17 25 Nm 1 7 2 5 m kg 12 18 ft lb...

Page 272: ...and drive shaft Remove 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 REMOVING INSTALLING THE REAR AXLE 3 Trailer hitch bracket 1 4 Final drive gear case breather hose 1 Disconnect 5 Final drive gear 1 6 Drive shaft 1 For installation reverse the removal procedure ...

Page 273: ...move 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 274: ...1 Refer to DISASSEMBLING ASSEMBLING THE FINAL DRIVE GEAR 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 REPLACING THE FINAL DRIVE ROLLER BEARING I Bearing 1 For assembly reverse the disassembly procedure ...

Page 275: ...ight DISASSEMBLING THE FINAL DRIVE GEAR 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...

Page 276: ...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 necessary 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 the d...

Page 277: ...numeral 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 d...

Page 278: ...l gear case either added to or subtracted from 45 d a numeral usually a decimal number on the outside of the ring gear bearing 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 constant 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 gear...

Page 279: ...owing thicknesses 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 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 not turn th...

Page 280: ...sher 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 0 1 1 1 2 1 3 1 35 1 4 1 45 1 5 1 55 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 ...

Page 281: ... 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 CHECKING THE REAR AXLE 1 Check Rear axle runout a Out of specification Replace WARNING Do not attempt to straighten a bent axle Ring gear stopper clearance 0 30 0 60 mm 0 012 ...

Page 282: ...ng are replaced be sure to adjust the shim of the final drive pinion gear and or ring gear 2 Check Gear teeth Pitting galling wear Replace the drive pinion gear and ring gear as a set Oil seals O rings Damage Replace 3 Check 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 pinion gear and or ...

Page 283: ...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 31 46 mm 1 24 in Gear lash measurement tool P N YM 01475 90890 01475 5 Measure Gear lash Gently rotate the gear coupling from engagement to engagement NOTE Measure the gear lash at four positions Rotate th...

Page 284: ...n Reduce the thrust washer thickness by 0 2 mm 0 008 in for every 0 2 mm 0 008 in 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 0 008 in 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 0 ...

Page 285: ...use a new bearing The final drive shaft bearing retainer has left hand threads Turn the retainer counterclockwise to tighten it 2 Adjust Final gear lash Refer to MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH Bearing retainer wrench P N YM 04050 90890 04050 T R 100 Nm 10 0 m kg 72 ft lb INSTALLING THE FINAL DRIVE GEAR 1 Lubricate Drive shaft Coupling gear O ring Oil seal Bearing 2 Install Drive sha...

Page 286: ... m kg 45 ft lb LT T R 63 Nm 6 3 m kg 45 ft lb 5 Install Dust cover Rear axle Installation steps Install the dust cover 1 onto the rear axle NOTE Adjust the length a to 210 1 mm 8 3 in when install the dust cover Install the rear axle with dust cover 2 Install the rear brake disc and rear wheel hub left Temporarily tighten the left axle nut 3 NOTE After tightening the rear axle nut 3 the position o...

Page 287: ......

Page 288: ...CHAS 8 ...

Page 289: ...ASTER CYLINDER 8 20 FRONT BRAKE CALIPER 8 22 REAR BRAKE CALIPER 8 24 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER 8 26 CHECKING THE FRONT AND REAR BRAKE CALIPER 8 26 ASSEMBLING THE FRONT AND REAR BRAKE CALIPER 8 27 INSTALLING THE FRONT BRAKE CALIPER 8 27 INSTALLING THE REAR BRAKE CALIPER 8 29 STEERING SYSTEM 8 30 HANDLEBAR 8 30 REMOVING THE REAR BRAKE SWITCH 8 31 CHECKING THE HANDLEBAR 8 31 INST...

Page 290: ...HE FRONT SHOCK ABSORBER 8 46 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 8 47 REAR SHOCK ABSORBER AND SWINGARM 8 48 REMOVING THE SWINGARM 8 50 CHECKING THE REAR SHOCK ABSORBER 8 50 CHECKING THE SWINGARM 8 51 CHECKING THE RUBBER BOOT 8 51 INSTALLING THE RUBBER BOOT 8 51 INSTALLING THE REAR AXLE HOUSING 8 52 ...

Page 291: ...G Securely support the machine so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE WHEEL 2 Wheel cap 1 Refer to INSTALLING THE WHEEL HUB 3 Cotter pin 1 4 Axle nut 1 5 Brake caliper assembly 1 NOTE Do not squeeze the brake lever when the brake caliper is off of the brake disc as the brake pads will be forced shut 6 Wheel hub 1 7 Brake disc 1 For installation reverse the...

Page 292: ... level surface WARNING Securely support the machine so there is no danger of it falling over 1 Rear wheel 2 Refer to INSTALLING THE WHEEL 2 Wheel cap 2 Refer to INSTALLING THE WHEEL HUB 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 9 Brake disc guard 1 For installation reverse the removal procedure ...

Page 293: ... 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 accident resulting in machine damage and possible operator injury CHECKING THE WHEEL HUB 1 Check Wheel hub 1 Cracks damage Replace Splines wheel hub 2 Wear damage Replace ...

Page 294: ...lace Brake disc maximum deflection 0 15 mm 0 006 in Brake disc minimum thickness 3 mm 0 12 in INSTALLING THE WHEEL HUB 1 Install Axle nut 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 T R 150 Nm 15 0 m kg 110 ft lb New INSTALLING THE WHEEL 1 Install Wheel NOTE T...

Page 295: ...wheel nuts 1 are used for both the front and rear wheels Install each nut with its tapered side towards the wheel 3 Tighten Nuts front wheel Nuts rear wheel NOTE Tighten the nuts in stages and in a crisscross pattern T R 64 Nm 6 4 m kg 46 ft lb T R 55 Nm 5 5 m kg 40 ft lb ...

Page 296: ...Remarks Removing the front brake pads Remove the parts in the order below Front wheel Refer to FRONT AND REAR WHEELS 1 Brake caliper mounting bolt 2 Refer to REPLACING THE FRONT BRAKE PAD 2 Brake pad holding bolt 2 3 Brake pad pad shim 2 1 4 Pad spring 1 For installation reverse the removal procedure ...

Page 297: ...he rear brake pads Remove the parts in the order below Rear wheel left Refer to FRONT AND REAR WHEELS 1 Brake caliper mounting bolt 2 Refer to REPLACING THE REAR BRAKE PAD 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 298: ...es or plastic parts as this may cause damage disconnect any hydraulic connection as this would require the entire brake system to be disassembled drained cleaned properly filled and bled after reassembly REPLACING THE FRONT BRAKE PAD 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 b...

Page 299: ...d shims 3 and a new brake pad spring Install the retaining bolts and brake caliper 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 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in CHAP...

Page 300: ...ake 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 hol...

Page 301: ... 3 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 4 Check Brake lever or brake pedal operation Soft or spongy feeling Bleed the rear brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 ...

Page 302: ...mmand four wheel drive switch and differential gear lock switch Refer to HANDLEBAR 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Brake lever 1 4 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER 5 Copper washer 2 6 Brake hose 1 7 Front brake light switch 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 For installation reverse the removal procedure...

Page 303: ...name Q ty Remarks Disassembling the front brake master cylinder Remove the parts in the order below 1 Brake master cylinder kit 1 Refer to ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 2 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 304: ... fender Refer to SEAT CARRIERS FENDERS 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 Union bolt 1 Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER 8 Copper washer 2 9 Brake hose 1 ...

Page 305: ...rake cable 1 Disconnect 11 Bracket 1 12 Brake master cylinder 1 13 Hose joint 1 14 Brake pedal 1 15 Select lever control cable 1 Disconnect 16 Rear brake light switch 1 17 Bracket 1 18 Bracket 1 19 Brake master cylinder bracket 1 For installation reverse the removal procedure ...

Page 306: ... name Q ty Remarks Disassembling the rear brake master cylinder Remove the parts in the order below 1 Brake master cylinder kit 1 Refer to ASSEMBLING THE REAR BRAKE MASTER CYLINDER 2 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 307: ...cylinder body Cracks damage Replace Brake fluid delivery passage brake master cylinder body Blockage Blow out with compressed air È Front É Rear È É 2 Check Front brake master cylinder reservoir 1 Front brake master cylinder reservoir diaphragm 2 Cracks damage Replace 3 Check Rear brake fluid reservoir 1 Rear brake fluid reservoir diaphragm 2 Cracks damage Replace ...

Page 308: ...e fluid DOT 4 EB702060 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Whenever a master cylinder is disassembled 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 clearance a is within the specified limits w...

Page 309: ...s etc Correct if necessary WARNING Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in CHAPTER 2 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 deteriorate the rubber seals causing lea...

Page 310: ... Brake fluid level Brake fluid level is under the LOWER level line Fill up Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 INSTALLING THE REAR BRAKE MASTER CYLINDER 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 essential t...

Page 311: ...e type of brake fluid mixing brake fluids may result in a harmful 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 BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHA...

Page 312: ... order below Brake fluid Drain Front wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CALIPER 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 313: ...arts 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 DISASSEMBLING ASSEMBLING THE FRONT AND REAR BRAKE CALIPER 7 Dust seal 1 8 Caliper piston seal 1 9 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 314: ...the parts in the order below Brake fluid Drain Rear wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE REAR BRAKE CALIPER 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 315: ...e 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 DISASSEMBLING ASSEMBLING THE FRONT AND REAR BRAKE CALIPER 6 Dust seal 1 7 Caliper piston seal 1 8 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 316: ...inder Remove the caliper piston seals EB702040 CHECKING THE FRONT AND REAR BRAKE CALIPER 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 replacement schedule Brake pads As required Piston seal dust seal Every two years Brake hoses Every two years Brake fluid Replace when br...

Page 317: ...rnal 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 É New New 2 Install Brake caliper piston 1 INSTALLING THE FRONT BRAKE CALIPER 1 Install Brake caliper assembly Brake caliper mounting bolt 1 Brake hose ...

Page 318: ...y brake 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 harmful 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 resul...

Page 319: ...uids 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 harmful 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 ...

Page 320: ...ear lock switch 1 Refer to INSTALLING THE MASTER CYLINDER ASSEMBLY 4 Master cylinder assembly bracket 1 1 5 Throttle lever assembly bracket 1 1 6 Rear brake switch 1 Refer to REMOVING THE REAR BRAKE SWITCH 7 Rear brake lever bracket 1 1 Refer to INSTALLING THE REAR BRAKE LEVER 8 Handlebar switch 1 9 Handlebar grip 2 10 Handlebar holder 2 Refer to INSTALLING THE HANDLEBAR 11 Handlebar 1 For install...

Page 321: ...lebar as this may dangerously weaken the handlebar INSTALLING THE HANDLEBAR 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 23 Nm 2 3 m kg 17 ft lb INSTALLING THE REAR BRAKE LEVER 1 Install Handleba...

Page 322: ...AS STEERING SYSTEM INSTALLING THE MASTER CYLINDER ASSEMBLY 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 323: ...rder 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 INSTALLING THE CABLE GUIDE 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 324: ...TEERING SYSTEM Order Job name Part name Q ty Remarks 11 Oil seal 1 12 Bearing retainer 1 Refer to REMOVING INSTALLING THE BEARING RETAINER 13 Bearing 1 14 Oil seal 1 For installation reverse the removal procedure ...

Page 325: ... weaken the stem 2 Check Oil seals 1 Steering stem bushings 2 Wear damage Replace INSTALLING THE BEARING RETAINER 1 Install Bearing retainer steering stem INSTALLING THE CABLE GUIDE 1 Install Cable guide Lock washer Bolts 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...

Page 326: ...he parts in the order below Front 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 INSTALLING THE TIE ROD 2 Brake disc guard 1 3 Brake hose holder bolt 1 4 Protector 1 5 Nut 1 6 Nut 1 7 O ring 1 8 Steering knuckle 1 Refer to REMOVING THE STEERING KNUCKLE ...

Page 327: ...7 CHAS STEERING SYSTEM Order Job name Part name Q ty Remarks 9 Oil seal 1 10 Oil seal 1 11 Bearing 2 12 Spacer 1 13 Circlip 1 14 Rubber boot 1 15 Ball joint 1 For installation reverse the removal procedure ...

Page 328: ... rod end Turns roughly Replace the tie rod end 2 Check Tie rod Bends damage Replace CHECKING THE STEERING KNUCKLE 1 Check Steering knuckle Damage pitting Replace 2 Check Ball joint Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint Replacement steps Clean the outside of the steering knuckle Remove the steering knuckle oil seal Remove the cir...

Page 329: ...in the short bolt 5 to remove the ball joint A from the steering knuckle Remove the ball joint remover installer Ball joint remover installer set P N YM 01474 90890 01474 Ball joint remover installer attachment set P N YM 01477 3 Body YM 01474 90890 01474 4 Long bolt YM 01474 90890 01474 5 Short bolt YM 01477 6 Remover washer YM 01477 7 Remover spacer YM 01477 8 Installer attachment YM 01477 9 Ins...

Page 330: ...to the new ball joint B Install a new rubber boot and new circlip NOTE Always use a new ball joint set Install a steering knuckle oil seal 3 Check Front wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly Replace Oil seals Damage Replace Replacement steps Clean the outside of the steering knuckle Remove the oil seals 1 Drive out the bearings 2 WARNING Eye protection is ...

Page 331: ...ade only with the outer race Install a new oil seal NOTE When installing the oil seals the seal side of the oil seal faces out INSTALLING THE TIE ROD 1 Install Tie rods left and right NOTE The tie rod which must be installed on the out side has grooves 1 T R 30 Nm 3 0 m kg 22 ft lb 2 Adjust Toe in Refer to ADJUSTING THE TOE IN in CHAPTER 3 STEERING SYSTEM ...

Page 332: ...Part name Q ty Remarks Removing the front arms and front shock absorber Remove the parts in the order below Engine skid plate 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 333: ... to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 5 Nut 1 6 Bolt nut 2 2 7 Front lower arm bushing 1 2 8 Nut bolt 2 2 9 Front shock absorber 1 10 Bolt nut 2 2 11 Front upper arm bushing 1 2 12 Circlip 1 13 Ball joint 1 For installation reverse the removal procedure ...

Page 334: ... the bushings Check the front arm vertical movement É by moving it up and down If the vertical movement is tight or rough or if there is binding check the bushings 2 Remove Front arms CHECKING THE FRONT ARM 1 Check Front arms Bends damage Replace 2 Check Bushings Wear damage Replace 3 Check Ball joint Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ...

Page 335: ...ile turning in the long bolt 4 to remove the ball joint 0 from the front lower arm Remove the ball joint remover installer Ball joint remover installer set P N YM 01474 90890 01474 Ball joint remover installer attachment set P N YM 01477 3 Body YM 01474 90890 01474 4 Long bolt YM 01474 90890 01474 5 Remover washer YM 01477 6 Remover spacer YM 01477 7 Installer attachment YM 01477 8 Installer space...

Page 336: ...all the new ball joint A into the front lower arm B Remove the ball joint remover installer Apply lithium soap base grease to the new ball joint A Install a new rubber boot and new circlip NOTE Always use a new ball joint set CHECKING THE FRONT SHOCK ABSORBER 1 Check Shock absorber rod Bends damage Replace the shock absorber assembly Shock absorber assembly Oil leaks Replace the shock absorber ass...

Page 337: ...te the bolts 3 with lithium soap based 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 310 mm 12 2 in T R Nut 6 45 Nm 4 5 m kg 32 ft lb T R Nut 7 30 Nm 3 0 m kg 22 ft lb T R Nut 4...

Page 338: ...the order below Rear wheel hubs brake disc Refer to FRONT AND REAR WHEELS Rear brake caliper brake hose Refer to FRONT AND REAR BRAKES 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 1 5 Trailer hitch bracket 1 6 Final drive gear case breather hose 1 7 Metal clamp 1 ...

Page 339: ...Order Job name Part name Q ty Remarks 8 Rear axle housing 1 Refer to INSTALLING THE REAR AXLE HOUSING 9 Nut bolt 2 2 Refer to REMOVING THE SWINGARM 10 Swingarm bushing 1 2 11 Spring rubber boot 1 1 For installation reverse the removal procedure ...

Page 340: ... Check the swingarm vertical movement É 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 82 Nm 8 2 m kg 59 ft lb CHECKING THE REAR SHOCK ABSORBER 1 Check Shock absorber Oil leaks Replace the shock absorber assembly Shock absorber rod Bends damage Replace the shock absorber assembly...

Page 341: ...Bends cracks damage Replace 2 Check Bushings 1 Wear damage Replace CHECKING THE RUBBER BOOT 1 Check Rubber boot 1 Damage Replace INSTALLING THE RUBBER BOOT 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 342: ... the swingarm and the final gear case Temporarily install the rear axle housing 1 and final gear case assembly 2 on the swingarm The bolts and nuts 3 5 should be temporarily tightened Install the rear axle with dust seal 6 from the left side of the machine Refer to REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT in CHAPTER 7 Tighten the bolts and nuts 3 5 in the specified order 3 Nut 4 4 Bolt 4 5 Bolt ...

Page 343: ...ELEC 9 ...

Page 344: ... TROUBLESHOOTING 9 10 ELECTRIC STARTING SYSTEM 9 15 CIRCUIT DIAGRAM 9 15 TROUBLESHOOTING 9 16 STARTER MOTOR 9 19 CHECKING THE STARTER MOTOR 9 20 ASSEMBLING THE STARTER MOTOR 9 21 CHARGING SYSTEM 9 22 CIRCUIT DIAGRAM 9 22 TROUBLESHOOTING 9 23 LIGHTING SYSTEM 9 25 CIRCUIT DIAGRAM 9 25 TROUBLESHOOTING 9 26 CHECKING THE LIGHTING SYSTEM 9 28 SIGNAL SYSTEM 9 30 CIRCUIT DIAGRAM 9 30 TROUBLESHOOTING 9 32 ...

Page 345: ... ELEC ...

Page 346: ...8 Four wheel drive relay 2 9 Four wheel drive relay 1 0 Main fuse A Starter relay B CDI unit C Rectifier regulator D Reverse switch E Neutral switch F High range switch G Low range switch H Speed sensor I Rear brake light switch J Gear motor K Thermo switch 2 L Fan M Headlight N Circuit breaker fan O Four wheel drive relay 3 P Ignition coil 1 2 3 4 5 6 7 8 9 0 A B C G F E D H I J K L M N O P ...

Page 347: ...s when checking it Pocket tester P N YU 03112 90890 03112 CHECKING 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 indicates the terminals with c...

Page 348: ...9 3 ELEC CHECKING THE SWITCH ...

Page 349: ...connection no continuity Correct or replace The coupler locations are circled L B Y G Br L B BLACK 1 4 5 D 6 2 3 R B R W PUSH Br L Y G B R W L B L G Br L Br R L R Sb Br Gy G R B R B L B 2WD 4WD LOCK L G L B L R Sb Gy Br G R B BLACK GRAY ON OFF R Br Br L Br B P P Br B B BLACK 7 B B BLACK 8 9 C B B B A 0 Br L Br R R ON OFF R R Br Br L PUSH OFF ...

Page 350: ...tch 4 On command four wheel drive switch and differential gear lock switch 5 Main switch 6 Rear brake light switch 7 Front brake light switch 8 Rear brake switch 9 Horn switch for Europe and Oceania 0 Reverse switch A Neutral switch B High range switch C Low range switch D Fuse ...

Page 351: ... shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb The majority of these bulbs can be removed from their respective socket by turning them counterclockwise Bulb C is used for turn signal and brake tail lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bul...

Page 352: ...ulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check Bulb for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to terminal 1 and the tester negative probe t...

Page 353: ...ulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester P N YU 03112 90890 03112 CHECKING THE BULBS AND BUL...

Page 354: ... W R L W L Y R B G W Y B G R Sb G L W B B R B Y B Y L Y R G Br R B R W B G L G R W L W L R Br Sb O C B O B W W B B B W B W W W W W W R R R R B W W W R B B PUSH _ R R B B B B B B R R R D W R W R D L W B R B R L W D A Br B Br B Br B B B W B W B W B A Sb Sb O R P B W L Y W B G R R G B G R R G B Y G B Y G B Y G B B Y Br R Br R L R B BLACK Br B Br R Br R L G B BLACK Br R L R B Y Br R B Br R L G Br B B ...

Page 355: ...el tank side panels 3 Front carrier 4 Front fender Use the following special tool s for troubleshooting 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 CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in C...

Page 356: ...rs Minimum spark gap 6 0 mm 0 24 in MEETS SPECIFICATION The ignition system is not faulty 5 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester Ω 1k to the spark plug cap For Europe and Oceania OUT OF SPECIFICATION OR NO SPARK 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition checker 1 as shown 2 Spark plug cap Turn the main switc...

Page 357: ...ICATION Connect the pocket tester Ω 1k to the ignition coil Tester lead Orange lead terminal Tester lead Spark plug lead 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 CHECKING THE SWITCH INCORRECT Replace the handlebar switch left MEETS SPECIFICATION...

Page 358: ...Ω at 20 C 68 F White Red White Green OUT OF SPECIFICATION Replace the pickup coil stator assembly 10 Charging rotor rotation direction detection coil resistance Disconnect the AC 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 MEETS SPECIFICATION Check...

Page 359: ...EC IGNITION SYSTEM C0NTINUITY CORRECT 11 Wiring connection Check the connections of the entire ignition system Refer to CIRCUIT DIAGRAM Replace the CDI unit POOR CONNECTION Properly connect the ignition system ...

Page 360: ...r Br W R W G R W G W R L W L Y R B G W Y B G R Sb G L W B B R B Y B Y L Y R G Br R B R W B G L G R W L W L R Br Sb O C B O B W W B B B W B W W W W W W R R R R B W W W R B B PUSH _ R R B B B B B B R R R D W R W R D L W B R B R L W D A Br B Br B Br B B B W B W B W B A Sb Sb O R P B W L Y W B G R R G B G R R G B Y G B Y G B Y G B B Y Br R Br R L R B BLACK Br B Br R Br R L G B BLACK Br R L R B Y Br R ...

Page 361: ...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 troubleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main ignition Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER ...

Page 362: ... lead may burn This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity DOES NOT TURN Repair or replace the starter motor 4 Starter relay Remove the starter relay from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the starter relay terminals CONTINUITY Battery terminal Blue White terminal 1 Battery terminal Blue Black terminal 2 T...

Page 363: ...gine stop switch Refer to CHECKING THE SWITCH INCORRECT Replace the handlebar switch left CORRECT 7 Start switch Refer to CHECKING THE SWITCH INCORRECT Replace the handlebar switch left EB803028 8 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM POOR CONNECTION Properly connect the starting system ...

Page 364: ...ts in the order below 1 Starter motor lead 1 2 Starter motor O ring 1 1 Disassembling the starter motor Remove the parts in the order below 1 Bracket 1 1 Refer to ASSEMBLING THE STARTER MOTOR 2 Washer kit 3 Bracket 2 bushing 1 4 Shims 5 Brush holder set 1 6 Armature coil 1 7 Yoke 1 For assembly reverse the disassembly procedure ...

Page 365: ...t using a 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 Check Armature coil insulation continuity Defects Replace the starter motor Checking steps Connect the pocket tester for the continuity check 1 and insulation check 2 Measure the armature resistances If the resistance is incorrect replace the ...

Page 366: ...rce Fatigue out of specification Replace the brush holder set Brush spring force 7 65 10 01 Nm 780 1 020 g 27 54 36 03 oz 7 Check O rings Wear damage Replace ASSEMBLING THE STARTER MOTOR 1 Install Brush holder set 1 NOTE Align the projection a on the brush seat 1 with the slot b on the yoke 2 Install Yoke Brackets NOTE Align the match marks a on the yoke with the match marks b on the brackets ...

Page 367: ...Br L R G L B G W G W L W Br Br W R W G R W G W R L W L Y R B G W Y B G R Sb G L W B B R B Y B Y L Y R G Br R B R W B G L G R W L W L R Br Sb O C B O B W W B B B W B W W W W W W R R R R B W W W R B B PUSH _ R R B B B B B B R R R D W R W R D L W B R B R L W D A Br B Br B Br B B B W B W B W B A Sb Sb O R P B W L Y W B G R R G B G R R G B Y G B Y G B Y G B B Y Br R Br R L R B BLACK Br B Br R Br R L G ...

Page 368: ...U 8036 A Engine tachometer P N 90890 03113 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY 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 369: ...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 41 0 61 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 370: ...G W L W Br Br W R W G R W G W R L W L Y R B G W Y B G R Sb G L W B B R B Y B Y L Y R G Br R B R W B G L G R W L W L R Br Sb O C B O B W W B B B W B W W W W W W R R R R B W W W R B B PUSH _ R R B B B B B B R R R D W R W R D L W B R B R L W D A Br B Br B Br B B B W B W B W B A Sb Sb O R P B W L Y W B G R R G B G R R G B Y G B Y G B Y G B B Y Br R Br R L R B BLACK Br B Br R Br R L G B BLACK Br R L R ...

Page 371: ...roubleshooting 1 Seat 2 Front carrier 3 Front fender panel Use the following special tool s for troubleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main headlight Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F ...

Page 372: ...o CHECKING THE SWITCH INCORRECT Light switch is faulty replace the handlebar switch left EB805013 CORRECT 5 Wiring connection Check the connections of the entire lighting system Refer to WIRING DIAGRAM Check the condition of each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYSTEM POOR CONNECTION Properly connect the lighting system ...

Page 373: ...C 20 V to the headlight couplers Tester lead Green terminal 1 or Yellow terminal 2 Tester lead Black terminal 3 È When the light switch is on É When the light switch is on È É MEETS SPECIFICATION Turn the main switch to ON Turn the light switch to or 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 circuit ...

Page 374: ...Voltage Connect the pocket tester 20 V to the bulb socket coupler Tester lead Blue lead 1 Tester lead Black lead 2 L Y B 1 2 MEETS SPECIFICATION Turn the main switch to ON Turn the light switch to or 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 repa...

Page 375: ... W W OFF ON OFF 2WD 4WD LOCK W G Br L R G L B G W G W L W Br Br W R W G R W G W R L W L Y R B G W Y B G R Sb G L W B B R B Y B Y L Y R G Br R B R W B G L G R W L W L R Br Sb O C B O B W W B B B W B W W W W W W R R R R B W W W R B B PUSH _ R R B B B B B B R R R D W R W R D L W B R B R L W D A Br B Br B Br B B B W B W B W B A Sb Sb O R P B W L Y W B G R R G B G R R G B Y G B Y G B Y G B B Y Br R Br ...

Page 376: ...ght J Reverse indicator light K Neutral indicator light L Park indicator light M High range indicator light N Low range indicator light O Low range switch P High range switch Q Neutral switch V On command four wheel drive switch and differential gear lock switch W Gear motor Z Ignition fuse f Signaling system fuse g Front brake light switch h Rear brake light switch i Tail brake light j Horn switc...

Page 377: ...hooting 1 Seat 2 Fuel tank 3 Air filter case 4 Front carrier 5 Front fender panel Use the following special tool s for troubleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main backup ignition signaling system Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Ope...

Page 378: ...ORRECT Replace the main switch EB806011 CORRECT 4 Wiring connections Check the connections of the entire signal system Refer to CIRCUIT DIAGRAM Check the condition of each of the signal system s circuits Refer to CHECKING THE SIGNAL SYSTEM POOR CONNECTION Properly connect the signal system ...

Page 379: ... CONTINUITY Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Pull in the brake lever or push down on the brake pedal Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The...

Page 380: ...r to CHECKING THE SWITCH NO CONTINUITY Replace the high range switch CONTINUITY 3 Low range switch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the low range switch CONTINUITY 4 Reverse switch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the reverse switch CONTINUITY 5 Four wheel drive switch Refer to CHECKING THE SWITCH Replace the meter assembly NO CONTINUITY Replace the four wheel d...

Page 381: ...eter 3 to record the temperatures Test step Coolant temperature Continuity Thermo switch 1 1 Less than 120 3 C 248 5 4 F NO 2 More than 120 3 C 248 5 4 F YES 3 More than 113 C 235 4 F YES 4 Less than 113 C 235 4 F NO Test steps 1 2 Heating phase Test steps 3 4 Cooling phase È The thermo switch 1 circuit is open and the coolant temperature warning light is off É The thermo switch 1 circuit is close...

Page 382: ...d MEETS SPECIFICATION HORN IS NOT SOUNDED Turn the main switch to ON Push the horn switch Check for voltage 12 V on the Pink lead at the horn terminal 3 Horn Disconnect the black lead at the horn terminal Connect a jumper lead 1 to the horn terminal and ground the jumper lead Turn the main switch to ON Push the horn switch Adjust or replace horn OUT OF SPECIFICATION The wiring circuit from the mai...

Page 383: ... Br Br W R W G R W G W R L W L Y R B G W Y B G R Sb G L W B B R B Y B Y L Y R G Br R B R W B G L G R W L W L R Br Sb O C B O B W W B B B W B W W W W W W R R R R B W W W R B B PUSH _ R R B B B B B B R R R D W R W R D L W B R B R L W D A Br B Br B Br B B B W B W B W B A Sb Sb O R P B W L Y W B G R R G B G R R G B Y G B Y G B Y G B B Y Br R Br R L R B BLACK Br B Br R Br R L G B BLACK Br R L R B Y Br ...

Page 384: ...ier 3 Front fender Use the following special tool s for troubleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or ...

Page 385: ...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 386: ... 8 5 4 F NO 2 More than 86 3 C 186 8 5 4 F YES 3 More than 80 3 C 176 5 4 F YES 4 Less than 80 3 C 176 5 4 F NO Test steps 1 2 Heating phase Test steps 3 4 Cooling phase È The thermo switch 2 circuit is open and the radiator fan is off É The thermo switch 2 circuit is closed and the radiator fan is on WARNING Handle the thermo switch 2 with special care Never subject it to a strong shock or allow ...

Page 387: ...LING SYSTEM C0NTINUITY EB803028 CORRECT 7 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM This circuit is not faulty POOR CONNECTION Properly connect the cooling system ...

Page 388: ... R B Y B Y L Y R G Br R B R W B G L G R W L W L R Br Sb O C B O B W W B B B W B W W W W W W R R R R B W W W R B B PUSH _ R R B B B B B B R R R D W R W R D L W B R B R L W D A Br B Br B Br B B B W B W B W B A Sb Sb O R P B W L Y W B G R R G B G R R G B Y G B Y G B Y G B B Y Br R Br R L R B BLACK Br B Br R Br R L G B BLACK Br R L R B Y Br R B Br R L G Br B B B B B B Br Sb L B L G Br B Y Sb L B B Y L...

Page 389: ... Remove the following part s before troubleshooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for troubleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main four wheel drive Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circui...

Page 390: ...d Brown Red terminal 5 Check the four wheel drive relay 1 for continuity NO CONTINUITY Replace the four wheel drive relay 1 CONTINUITY 5 Four wheel drive relay 2 Remove the four wheel drive relay 2 from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the four wheel drive relay 2 terminals Tester lead Black Yellow terminal 1 Tester lead Black terminal 2 Battery terminal Brown...

Page 391: ...ster lead Yellow Black terminal 2 Battery terminal Brown Red terminal 1 Battery terminal Yellow Black terminal 2 Tester lead Blue Red terminal 3 Tester lead Gray terminal 4 Check the four wheel drive relay 3 for continuity NO CONTINUITY Replace the four wheel drive relay 3 CORRECT 7 On command four wheel drive switch and differential gear lock switch Refer to CHECKING THE SWITCH INCORRECT Replace ...

Page 392: ...n gear 2 turns counterclockwise É Check that the pinion gear 2 turns clockwise 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 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR in CHAPTER 7 INCORRECT Replace the gear motor EB803028 CORRECT 9 Wiring connection Check the connections of the entire 2...

Page 393: ......

Page 394: ...TRBL SHTG 10 ...

Page 395: ...VE 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 FAULTY BRAKE 10 5 POOR BRAKING EFFECT 10 5 SHOCK ABSORBER MALFUNCTION 10 6 MALFUNCTION 10 6 UNS...

Page 396: ...TRBL SHTG ...

Page 397: ...lug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body CDI system Faulty CDI unit Faulty pickup coil Faulty charging rotor rotation direction 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...

Page 398: ...E 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 charging rotor rotation direction coil Faulty ignition coil Valve train ...

Page 399: ...uses 1 A pronounced hesitation or jerky movement during acceleration deceleration or sustained speed This must not be confused 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 re...

Page 400: ...per lever Shift fork Worn shift fork Shift cam Improper thrust play Worn 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 SL...

Page 401: ...tor 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 Cooling system Low coolant level Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin Damaged or faulty water pump Thermostat stays closed Clogged or damaged oil cooler Damaged hose Im...

Page 402: ...Deformed steering knuckles 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 LIGHTING SYSTEM HEADLIGHT DARK Improper bulb Too many electric accessories Hard charging broken charging coil and or faulty rectifier regulator Incorrect connection Improperly groun...

Page 403: ......

Page 404: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 405: ... B B BLACK BLACK Br Y Br B Br B 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M O P Q R S T U V W Y b d e i g j k h b a X Z c f N 1 A C magneto 2 Rectifier regulator 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 7 Starter relay 8 Starter motor 9 Reverse switch 0 CDI unit A Rear brake switch B Ignition coil C Spark plug D Speed sensor E Thermo switch 1 F Meter assembly G Multi function meter H Di...

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Yamaha YFM45FAR, Service Manual

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