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Yamaha YFM4FAR, Service Manual

The Yamaha YFM4FAR Service manual is a comprehensive guide that enables users to efficiently maintain and troubleshoot their Yamaha YFM4FAR product. This manual is available for free download at manualshive.com, providing users with the necessary knowledge to optimize their Yamaha YFM4FAR experience effortlessly.

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SPEC

Front bumper and frame

M8

33

3.3

24

Front carrier and frame

M8

33

3.3

24

Front carrier and front bumper

M8

33

3.3

24

Rear carrier and frame

M8

33

3.3

24

Differential gear case filler bolt

M14

23

2.3

17

Differential gear case drain bolt

M10

10

1.0

7

Differential gear case and bearing housing

M8

25

2.5

18

Gear motor

M8

13

1.3

9.4

Final gear case oil filler bolt 

M14

23

2.3

17

Final gear case oil drain bolt

M14

23

2.3

17

Bearing retainer (drive pinion gear)

M65

100

10.0

72

Final gear case and bearing housing

M10

40

4.0

29

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 light switch bracket

M8

23

2.3

17

Rear brake light switch cover 

M6

7

0.7

5.1

Front brake caliper retaining bolt

M8

30

3.0

22

Air duct (front)

M6

7

0.7

5.1

Rear brake lever holder bracket

M6

7

0.7

5.1

Rear brake lever (bolt)

M6

7

0.7

5.1

Rear brake lever (nut)

M6

7

0.7

5.1

Brake camshaft lever

M6

9

0.9

6.5

Four-wheel drive switch

M10

20

2.0

14

Part to be tightened

Thread size

Tightening torque

Remarks

Nm

m·kg

ft·lb

MAINTENANCE SPECIFICATIONS

Summary of Contents for YFM4FAR

Page 1: ...YFM4FAR YFM400FAR 5TE2 AE1 SERVICE MANUAL ...

Page 2: ......

Page 3: ...FM400FAR SERVICE MANUAL 2002 by Yamaha Motor Co Ltd First edition April 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: ...FICATION NUMBER 1 1 MODEL LABEL 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL PROCEDURES 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING OF CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

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: ...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 14: ...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 15: ...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 16: ...0890 01084 Set YU 01083 A Slide hammer bolt M6 weight set These tools are used to remove the rocker arm shafts 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 guides 90890 04017 YM 04017 Valve guide installer 7 0 mm This tool is needed to install the va...

Page 17: ... 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 systems 90890 01352 YU 33984 Adapter This tool is used to check the cooling systems 90890 01348 YM 01348 Locknut wrench This tool is needed when removing or installing the seco...

Page 18: ...er cartridge 90890 01430 YM 38404 Ring nut wrench This tool is needed to removing and installing the middle driven shaft bearing retainers 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 joints YM 01477 Ball joint remover installer a...

Page 19: ...This 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 seals 90890 04050 YM 04050 ...

Page 20: ...aring retainers 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 21: ......

Page 22: ...SPEC 2 ...

Page 23: ...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 24: ...SPEC ...

Page 25: ...full fuel tank 265 kg 584 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 401 cm3 Bore stroke 84 5 71 5 mm 3 33 2 81 in Compression ratio 10 5 1 Standard compression pressure at sea level 1 400 kPa 14 0 kg cm2 203 psi at 750 r min Starting system Electric and recoil starter Lubrication system Wet sump Oil type or grade Engine oil...

Page 26: ...3 9 US gal 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 O...

Page 27: ...tion Suspension Front suspension Double wishbone Rear suspension Swingarm monocross Shock absorbers Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 160 mm 6 30 in Rear wheel travel 180 mm 7 09 in Electrical Ignition system D C C D I Generator system A C magneto Battery type YTX14AH For CDN and Europe YTX20L BS For Oceania Batte...

Page 28: ... 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 29: ...m 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 ...

Page 30: ... 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 31: ...ston offset 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 2 3 1 mm 0 04724 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 32: ...nkshaft 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 Clu...

Page 33: ...P 3 0 8 Pilot screw P S 2 1 2 turns out Valve seat size V S 2 0 Starter jet G S 1 75 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 cleara...

Page 34: ... centrifugal pump Reduction ratio 38 32 1 188 Thermostat Valve opening temperature 63 5 66 5 C 146 3 151 7 F Valve full open temperature 80 C 176 F Valve lift full open 3 mm 0 12 in Shaft drive Middle gear backlash 0 1 0 3 mm 0 004 0 012 in Final gear backlash 0 1 0 2 mm 0 004 0 008 in Differential gear backlash 0 10 0 50 mm 0 004 0 020 in Lubrication chart Item Standard Limit Oil Strainer Timing ...

Page 35: ...2 11 SPEC Cylinder head tightening sequence Item Standard Limit MAINTENANCE SPECIFICATIONS ...

Page 36: ...l 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 brack...

Page 37: ...Reverse switch M10 1 20 2 0 14 Stator 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 ...

Page 38: ...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 39: ...liper cylinder inside diameter 32 mm 1 26 in Brake fluid type DOT 4 Rear drum brake Type Leading trailing Brake drum inside diameter 160 mm 6 30 in 161 mm 6 34 in Lining thickness 4 0 mm 0 16 in 2 mm 0 08 in Brake lever and brake pedal Brake lever free play pivot front 0 mm 0 in rear 3 5 mm 0 12 0 20 in Brake pedal free play 20 30 mm 0 79 1 18 in Throttle lever free play 3 5 mm 0 12 0 20 in Item S...

Page 40: ... Front shock absorber and upper front arm M10 45 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 St...

Page 41: ...ng 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 light switch bracket M8 23 2 3 17 Rear brake light switch cover M6 7 0 7 5 1 Front brake caliper retaining bolt M8 30 3 0...

Page 42: ...nce 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 Resistance 10 kΩ Charging system Type A C magneto generator Model manufacturer F4T464 MITSUBISHI Nominal output 14 V 17 5 A at 5 000 r min Charging coil resistance color 0 46 0 62 Ω at 20 C 68 F White White Rectifier regulator Regulator type Semi conductor short circuit No load regulated v...

Page 43: ... C 68 F Electric fan Running rpm 3 500 r min Thermostat switch Thermostat switch cylinder head Model manufacturer 4BA DENSO Thermostat switch radiator Model manufacturer 5ND NIPPON THERMOSTAT Circuit breakers Type Fuse Amperage for individual circuit Main fuse 30 A 1 Headlight fuse 15 A 1 Ignition fuse 10 A 1 Auxiliary DC jack fuse 10 A 1 Four wheel drive fuse 3 A 1 Signaling system fuse 10 A 1 Re...

Page 44: ... 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 45: ...journal M Cylinder head 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 E Shift guide LS Shift cam lever M Clutch housing E One way bearing M Drive chain sprocket E Driven cam M Front drive shaft collar E Crankcase mating surface Sealant Quick Gasket...

Page 46: ...2 22 SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch radiator 3 Fan motor È To coolant reservoir COOLANT FLOW DIAGRAMS ...

Page 47: ...2 23 SPEC 1 Radiator 2 Thermostat È To coolant reservoir COOLANT FLOW DIAGRAMS ...

Page 48: ...2 24 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle OIL FLOW DIAGRAMS ...

Page 49: ...2 25 SPEC 1 Oil filter OIL FLOW DIAGRAMS ...

Page 50: ...2 26 SPEC 1 Oil pump 2 Oil strainer OIL FLOW DIAGRAMS ...

Page 51: ...n command four wheel drive 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 Horn switch lead For Europe and Oceania D On command four wheel drive switch lead CABLE ROUTING ...

Page 52: ...sten the starter cable handlebar switch lead horn switch lead for Europe and Oceania and rear brake switch lead behind the handlebar with a plastic band Ê Fasten the handlebar switch lead horn switch lead for Europe and Oceania and rear brake switch lead behind the handlebar with a plastic band CABLE ROUTING ...

Page 53: ...9 SPEC 1 Sub wire harness 2 Headlight lead 3 Auxiliary DC jack lead 4 Meter assembly coupler 5 Differential gear case breather hose 6 Coolant reservoir breather hose 7 Fan motor breather hose CABLE ROUTING ...

Page 54: ... hose 9 Sub wire harness 0 Differential gear case breather hose A Thermo switch radiator B Speedometer cable 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 radiator lead and fan motor breather hose with a plastic band CABLE ROUTING ...

Page 55: ...lead 6 Negative battery lead 7 Rear brake lever cable 8 Air filter case check hose 9 Water pump breather hose 0 Radiator outlet hose A Starter cable B Float chamber air vent hose C Cylinder head breather hose D Fuel hose E A C magneto lead F Gear position switch lead G Neutral switch H Reverse switch I Rectifier regulator CABLE ROUTING ...

Page 56: ...case breather hose rear brake breather hose rectifier regulator lead gear position switch 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 gear position switch lead A C magneto lead rectifier regulator lead and negative battery lead with a plastic band CABLE ROUTING ...

Page 57: ...ator inlet hose 3 Spark plug lead 4 Main switch 5 Wire harness 6 Rear brake light switch lead 7 Select lever control cable 8 Rear brake pedal cable È Fasten the radiator inlet hose and spark plug lead with a plastic band CABLE ROUTING ...

Page 58: ... 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 Rear brake breather hose 7 Starter cable 8 Rear brake lever cable CABLE ROUTING ...

Page 59: ...2 35 SPEC 1 Battery 2 Negative battery lead 3 Tail brake light lead 4 CDI unit 5 Positive battery lead È For CDN and Europe É For Oceania CABLE ROUTING ...

Page 60: ...2 36 SPEC 1 Rear brake pedal cable 2 Final drive gear case breather hose 3 Rear brake breather hose 4 Rear brake lever cable 5 Air filter case check hose CABLE ROUTING ...

Page 61: ...CHK ADJ 3 ...

Page 62: ...GING THE ENGINE OIL 3 24 CLEANING THE AIR FILTER 3 26 CHECKING THE COOLANT LEVEL 3 29 CHANGING THE COOLANT 3 30 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 3 33 CHECKING THE V BELT 3 33 CLEANING THE SPARK ARRESTER 3 34 CHASSIS 3 36 ADJUSTING THE REAR BRAKE 3 36 CHECKING THE FRONT BRAKE FLUID LEVEL 3 38 CHECKING THE FRONT BRAKE PADS 3 39 CHECKING THE REAR BRAKE SHOES 3 39 CHECKING THE BRAKE HOSE...

Page 63: ...NG THE TIRES 3 49 CHECKING THE WHEELS 3 52 CHECKING AND LUBRICATING THE CABLES 3 53 LUBRICATING THE LEVERS PEDAL ETC 3 53 ELECTRICAL 3 54 CHECKING THE BATTERY 3 54 CHECKING THE FUSES 3 59 ADJUSTING THE HEADLIGHT BEAMS 3 61 CHANGING THE HEADLIGHT BULB 3 61 ...

Page 64: ...4 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 Retighten if necessary Repl...

Page 65: ... 2 On the inner parts of the master cylinder and caliper replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Axle boots Check operation Replace if damaged Fittings and Fasteners Check all chassis fit...

Page 66: ...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 67: ...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 68: ...1 Auxiliary DC jack connector 2 Disconnect 12 Meter assembly coupler 3 Disconnect 13 Speedometer cable 1 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 69: ... 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 70: ...3 7 CHK ADJ SEAT CARRIERS FENDERS AND FUEL TANK Order Job name Part name Q ty Remarks 8 C D I unit 1 9 Wire harness 1 10 Rear fender 1 For installation reverse the removal procedure ...

Page 71: ...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 72: ...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 73: ...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 74: ... 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 75: ... 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 76: ...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 self powered tachometer or engine tachometer to the spark plug lead 4 Check Engine idling speed Out of specification Adjust Inductive self powered tachometer P N YU 8036 B Engine tachometer P N 90890 03113 Engine idling speed 1 450 1 550 r min ...

Page 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...d 3 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 pickup coil Install the timing plug Install the recoil starter Inductive self powered tachometer P N Y...

Page 84: ...oss of 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...

Page 85: ...e 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 1 400 kP...

Page 86: ... 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 Never remove the dipsti...

Page 87: ...er 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 4 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 88: ... 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 89: ... 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 T R Oil gallery bolt 7 Nm 0 7 m kg 5 1 ft lb CLEANING THE AIR FILTER NOTE T...

Page 90: ...ter element 2 Air filter element cap 3 Air filter element CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid wear and possible engine 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 91: ...sion 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 assembly Air filter case cover NOTE To prevent air leaks make sure that the sealing surface of the element matches t...

Page 92: ...roper level CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available 4 Start the engine warm it up for several minutes and then turn it off 5 Check Coolant level NOTE Be...

Page 93: ...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 94: ...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 95: ... 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 96: ... comes on momentarily Coolant temperature warning light does not come on Coolant temperature warning light comes on Coolant temperature and electrical circuit are OK Go ahead with riding Ask a Yamaha dealer to check the electrical circuit CHECKING THE V BELT 1 Remove Right footrest board Refer to FOOTREST BOARDS Crankcase cover right Refer to PRIMARY AND SECONDARY SHEAVES in CHAPTER 4 2 Check V be...

Page 97: ...d NOTE Tightening the bolts 1 will push the secondary sliding sheave away causing the gap between the secondary fixed and 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 ...

Page 98: ...not start the engine when removing the tailpipe from the muffler Remove the bolts 1 Remove the tailpipe 2 by pulling it out of the muffler 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 ...

Page 99: ...ake pedal free play 20 30 mm 0 80 1 18 in Rear brake lever free play 3 5 mm 0 12 0 20 in 2 Adjust Rear brake lever free play Rear brake pedal free play Adjustment steps Loosen the locknut handlebar 1 and fully screw in the brake lever cable adjuster handlebar 2 Fully loosen the brake lever cable adjusting nut drum 3 Turn the rear brake pedal cable adjusting nut 4 until the brake pedal free play is...

Page 100: ...dlebar 2 until the rear brake lever free play b 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 WARNING After this adjustment is performed lift the front and rear wheels off the ground by placing a block under the engine and spin the rear wheels to ensure there is no brake drag If a...

Page 101: ...s 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 significant...

Page 102: ...almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE in CHAPTER 8 3 Operate the brake lever 4 Install Front wheel Brake pad wear limit a 1 mm 0 04 in CHECKING THE REAR BRAKE SHOES 1 Operate the brake lever or brake pedal 2 Check Wear indicator 1 Reaches the wear limit line 2 Replace the brake shoes as a set Refer to REAR BRAKE in CHAPTER 8 ...

Page 103: ... FUEL TANK 2 Check NOTE Hold the machine in an upright position and apply the parking brake Front brake hoses 1 Cracks wear damage Replace Fluid leakage Replace any damaged hose Refer to FRONT BRAKE in CHAPTER 8 3 Check Brake hose clamps Loosen Tighten 4 Install Front fender Front carrier Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ...

Page 104: ...clear plastic hose 1 tightly to the caliper bleed screw 2 d Place the other end of the hose into a container e Slowly apply the brake lever several times f Pull the lever in and hold it g Loosen the bleed screw and allow the lever to travel towards its limit h Tighten the bleed screw when the lever limit has been reached then release the lever i Repeat steps e to h until all the air bubbles have d...

Page 105: ...rottle 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 Remove the rear brake light switch cover 1 Make sure the select lever is in NEUTRAL Adjust the control cable so there is zero free play in the cable When the adju...

Page 106: ...ocknuts 3 are tightened correctly If the operation of the select lever is incorrect adjust the select lever control cable 4 with the adjuster 5 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 brake light switch is operated by ...

Page 107: ...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 108: ...n plug gasket 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 109: ... is filled to the brim of the oil filler hole oil may 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 35 L 0 31 Imp qt 0 37 US qt Total amount 0 40 L 0 35 Imp qt 0 42 US qt Recommended oil SAE 80 API GL...

Page 110: ...nd 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 the ...

Page 111: ...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 112: ...ring 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 113: ...sure below the minimum specification could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 22 kPa 0 22 kg cm2 3 2 psi Rear 22 kPa 0 22 kg cm2 3 2 psi 3 Use no more than Front 250 kPa 2 5 kg cm2 36 psi Rear 250 kPa 2 5 kg cm2 36 psi when seating the tire beads Higher pressures may cause the tire to burst Inflate the tires slowly and carefully ...

Page 114: ...careful of the machine balance and stability when towing a trailer 1 Measure Tire pressure cold tire pressure Out of specification Adjust NOTE The low pressure tire gauge 1 is included as standard equipment If dust or the like is stuck to this gauge it will not provide the correct readings Therefore take two measurements of the tire s pressure and use the second reading Cold tire pressure Front Re...

Page 115: ... 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 Tire wear limit a Front and rear 3 0 mm 0 12 in CHECKING THE WHEELS 1 Check Wheel 1 Damage bends Replace NOTE Always balance the wheel when a tire or wheel has been changed or replaced WARNING Never attempt even small re...

Page 116: ...ace 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 cable 3 Apply Lithium soap based grease onto end of the cable Recommended lubricant Yamaha chain and cable lube or Engine oil LUBRICATING THE LEVERS PEDAL ETC 1 Lubricate the pivoting parts...

Page 117: ...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 118: ...at Battery holding bracket Battery lead cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Disconnect Battery leads CAUTION First disconnect the negative lead then disconnect the positive lead 3 Remove Battery 4 Check Battery condition Battery condition checking steps Connect a digital voltmeter to the battery terminals NOTE The charge state of an MF battery can be checked by measuring the open ...

Page 119: ...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 120: ...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 121: ...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 122: ...t the positive lead then connect the negative lead 8 Install Battery lead cover Battery holding bracket Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE FUSES 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 pocket tester to ...

Page 123: ...ition Install a new fuse of the proper amperage Turn on switches to verify operation of the related electrical devices If the fuse immediately blows again check the electrical circuit Description Current rating Quantity Main 30 A 1 Headlight 15 A 1 Ignition 10 A 1 Terminal Auxiliary DC jack 10 A 1 4WD Four wheel drive 3 A 1 Signaling system fuse 10 A 1 Reserve 30 A 1 Reserve 15 A 1 Reserve 10 A 1 ...

Page 124: ...er fuse may cause extensive damage to the electrical system a malfunction of the lighting and ignition systems and could possibly cause a fire 4 Install Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically Turn the adjuster 1 in or out Turning in Headlight beam raised Turning out Headlight beam lowered CHANGING THE HEADLIGHT BULB 1 Remo...

Page 125: ...ince it will be hot Do not touch the bulb until it cools down 3 Install Bulb Secure the new bulb with the headlight unit CAUTION 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 Inst...

Page 126: ...ENG 4 ...

Page 127: ... CHECKING THE CAMSHAFT 4 19 CHECKING THE ROCKER ARMS AND CAMSHAFT 4 19 CHECKING THE VALVES AND VALVE SPRINGS 4 21 INSTALLING THE VALVES AND VALVE SPRINGS 4 25 INSTALLING THE CAMSHAFT AND ROCKER ARMS 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 RINGS 4 30 CHECKING THE PISTON PIN 4 31 INSTALLING ...

Page 128: ... CRANKCASE BEARINGS 4 59 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 ...

Page 129: ...OVING THE MIDDLE DRIVE SHAFT 4 78 REMOVING THE MIDDLE DRIVEN SHAFT 4 78 CHECKING THE PINION GEARS 4 80 SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS 4 81 INSTALLING THE MIDDLE DRIVEN SHAFT 4 84 INSTALLING THE MIDDLE DRIVE SHAFT 4 86 MEASURING THE MIDDLE GEAR BACKLASH 4 86 ...

Page 130: ...ENG ...

Page 131: ... 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 bracket 1 4 Exhaust pipe gasket 1 1 5 Air duct assembly ...

Page 132: ...ob name Part name Q ty Remarks 6 Final drive gear case breather hose 1 7 Rear brake breather hose 1 8 Cylinder head breather hose 1 9 Vacuum chamber breather hose 1 10 Air filter case 1 For installation reverse the removal procedure ...

Page 133: ...ame Q ty Remarks Removing the select lever unit and coolant reservoir Remove the parts in the order below 1 Select lever shift rod 1 2 Select lever unit 1 3 Coolant reservoir breather hose 1 4 Coolant reservoir hose 1 5 Coolant reservoir 1 For installation reverse the removal procedure ...

Page 134: ... hose Refer to WATER PUMP in CHAPTER 5 1 Cylinder head breather hose 1 2 Spark plug lead 1 Disconnect 3 Thermo switch cylinder head 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 Engine ground lead 1 For installation reverse the removal procedure ...

Page 135: ...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 136: ...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 137: ...mounting bolt rear lower nut 8 NOTE Do not fully tighten the bolts and nuts 2 Tighten Engine mounting bolt front upper nut 2 Engine bracket bolt front upper 3 Engine mounting bolt front lower 5 Engine bracket bolt front lower 6 Engine mounting bolt rear upper nut 7 Engine mounting 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 ...

Page 138: ...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 mounting bolt upper nut 1 1 4 Engine bracket upper 1 ...

Page 139: ...Tappet cover O ring 2 2 8 Thermo switch cylinder head 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 140: ...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 141: ... a crisscross pattern loosen each 10 mm bolt 1 4 of a turn After all the bolts are loosened remove them CHECKING THE TAPPET COVERS 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 142: ...rust 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 patter...

Page 143: ...shaft 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 ch...

Page 144: ... 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 145: ...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 146: ...low 1 Intake manifold O ring 1 1 2 Thermo switch cylinder head 1 3 Oil check bolt 1 4 Lock washer bearing retainer 1 1 5 Camshaft 1 Refer to REMOVING INSTALLING THE CAMSHAFT AND ROCKER ARMS 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 VALVES AND VALVE SPRINGS 10 Valve spring retainer 2 11 Valve spring outer 2 ...

Page 147: ...der Job name Part name Q ty Remarks 12 Valve spring inner 2 Refer to REMOVING INSTALLING THE VALVES AND VALVE SPRINGS 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 148: ...mmer 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 VALVES AND VALVE SPRINGS 1 Check Valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVES AND VALVE SPRINGS Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that ...

Page 149: ...m 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 ARMS AND CAMSHAFT 1 Check Camshaft lobe contact surface 1 Valve adjusters 2 Blue discoloration pitt...

Page 150: ...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 151: ...placement 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 152: ...re Runout valve stem Out of specification Replace NOTE When installing a new valve always replace the guide When a valve is removed or replaced always replace the oil seal 6 Eliminate Carbon deposits from the valve face and valve seat 7 Check Valve seat 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 se...

Page 153: ...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 154: ...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 155: ...lve stem seal Valve Valve springs inner and outer Valve spring retainer 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 springs 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 Hitting...

Page 156: ...HAFT AND ROCKER ARMS 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 shafts 3 Install Camshaft 1 NOTE Install the camshaft pin hole a facing up ...

Page 157: ...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 158: ...t use a hammer to drive the piston pin out Piston pin puller set 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...

Page 159: ...place 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 spec...

Page 160: ...Measure Piston 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...

Page 161: ...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 162: ...ricate 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 o...

Page 163: ... 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 164: ...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 165: ...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 166: ...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 167: ... 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 A C MA...

Page 168: ...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 169: ...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 170: ...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 171: ...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 172: ...in the order below Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Rear fender Right footrest board Refer to FOOTREST BOARDS in CHAPTER 3 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 173: ... 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 174: ...imary sliding sheave Remove the parts in the order below 1 Primary sliding sheave cap 1 Refer to ASSEMBLING THE PRIMARY SHEAVE 2 Primary pulley slider 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 175: ...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 176: ...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 Sheav...

Page 177: ... 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 grooves 1 Wear damage Replace 3 Check Guide pins 2 Wear damage Replace 4 Check Secondary sheave spring Damage Replace 5 Measure Secondary sheave...

Page 178: ...ghts 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 Sliders 1 Primary pulley cam 2 Primary sliding sheave cap T R 3 Nm 0 3 m kg 2 2 ft lb ASSEMBLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals BEL RAY assemb...

Page 179: ...o the secondary sheave assembly Place the sheave fixed block in a vise and secure it Tighten the sheave spring compressor nut 1 and compress the spring Install the nut 2 and tighten it to the specified torque using the locknut wrench Remove the sheave spring compressor locknut wrench and sheave fixed block Sheave fixed block P N YM 04135 90890 04135 Locknut wrench P N YM 01348 90890 01348 Sheave s...

Page 180: ...e 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 YS 01880 A 90890 01701 T R 100 Nm 10 0 m kg 72 f...

Page 181: ... 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 182: ... 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 183: ...ace the one way clutch assembly and clutch housing as a set The one way clutch bearing 2 must be installed with the arrow marked 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 ...

Page 184: ...ch 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 a f...

Page 185: ... 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 186: ...nder 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 intake...

Page 187: ... Speed sensor 1 8 Shift cam stopper 1 9 Neutral switch 1 10 Reverse switch 1 11 Oil filler cap 1 12 Gear unit 1 13 Bearing cover gasket 1 1 14 Oil delivery pipe 1 15 Oil strainer cover O ring 1 1 16 Compression spring 1 17 Oil strainer 1 For installation reverse the removal procedure ...

Page 188: ... crankcase Remove the parts in the order below 1 Engine side cover bracket 1 Refer to INSTALLING THE SHIFT LEVER 2 Shift lever assembly 1 3 Crankcase left 1 Refer to SEPARATING ASSEMBLING THE CRANKCASE 4 Dowel pin 2 5 Crankcase right 1 For installation reverse the removal procedure ...

Page 189: ...e crankcase bearings 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 190: ...utch 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 ...

Page 191: ...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 192: ... 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 pins 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 ...

Page 193: ... Tighten the bolts in stages using a crisscross pattern È É T R 10 Nm 1 0 m kg 7 2 ft lb 5 Apply 4 stroke engine oil to the crank pin bearings and oil delivery hole 6 Check Crankshaft and transmission operation Unsmooth operation Repair INSTALLING THE SHIFT LEVER 1 Install Shift lever assembly 1 T R 14 Nm 1 4 m kg 10 ft lb ...

Page 194: ...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 3 Remove the clutch carrier assembly 3 Bend the lock washer tab 4 Clutch holding tool P N YM 91042 90890 04086 T R 50 Nm 5 0 m kg 36 ft lb ...

Page 195: ...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 196: ... 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 197: ...ool 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 20 mm 0 008...

Page 198: ...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 199: ...UTION Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier Crankshaft installer set 12 P N YU 90050 Buffer boss installer set 23 P N 90890 04088 Crankshaft installer bolt 1 P N 90890 01275 Adapter 11 3 P N YM 33279 Spacer crankshaft P N YM 90070 A 90890 04060 2 Install Crankshaft seal NOTE Install the crankshaft seals in the correct place and...

Page 200: ...emarks Removing the transmission Remove the parts in the order below Crankcase separation Refer to CRANKCASE 1 Driven sprocket 1 2 Chain 1 3 Guide bar 1 4 Shift fork 1 5 Clutch dog 1 6 Low wheel gear 1 7 Secondary shaft 1 8 Middle driven gear 1 9 Drive axle assembly 1 ...

Page 201: ...4 71 ENG TRANSMISSION Order Job name Part name Q ty Remarks 10 Shift cam 1 11 Middle drive gear 1 12 Spacer O ring 1 1 For installation reverse the removal procedure ...

Page 202: ...RNING 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 CHECKING THE SHIFT CAM 1 Check Shift cam groove Scratches wear damage Replace CHECKING THE TRANSMISSION 1 Measure Axle runout Use a centering device and a dial gauge Out of specification Replace the bent axle Runout limit drive axle 0 06 mm 0 ...

Page 203: ... defective parts 4 Check Circlips 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 Circlips Bends looseness damage Replace CHECKING THE CHAIN 1 Check Chain Cracks shift Replace the chain secondary shaft and driven sprocket as...

Page 204: ...hift fork with the L mark facing towards the left side of the crankcase Be sure that the shift fork guide pin is properly seated in the shift drum groove 2 Check Shift operation Unsmooth operation Repair NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely ...

Page 205: ...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 SHIMS 5 Middle drive shaft 1 6 Bearing retainer 2 For installation reverse the removal procedure ...

Page 206: ...to CRANKCASE 1 Circlip 2 Refer to REMOVING INSTALLING THE MIDDLE DRIVEN SHAFT 2 Bearing 2 3 Universal joint 1 4 Universal joint yoke 1 5 Bearing housing O ring 1 1 6 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS 7 Middle 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 207: ...4 77 ENG MIDDLE GEAR Order Job name Part name Q ty Remarks 12 Front drive shaft coupling 1 13 Bearing retainer 1 14 Middle driven shaft 1 For installation reverse the removal procedure ...

Page 208: ...ve pinion gear Middle drive pinion gear Shim s REMOVING THE MIDDLE DRIVEN SHAFT 1 Remove Universal joints 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 209: ...amage 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 Bearings 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 the b...

Page 210: ...oosen the bearing retainer turn it clockwise Ring nut wrench P N YM 38404 90890 01430 6 Remove Middle driven shaft 1 with bearing CHECKING THE PINION GEARS 1 Check Damper cam surfaces Wear scratches Replace damper cam and driven pinion gear as a set 2 Check Damper cam spring Damage cracks Replace 3 Check Gear teeth drive pinion gear 1 Gear teeth driven pinion gear 2 Pitting galling wear Replace ...

Page 211: ...ition 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 pin...

Page 212: ...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 thicknesses Hundredths Round value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle drive pinion gear shim Thickness mm 0 10 0 30 0 15 0 40 0 20 0 50 To find shim thickness B use the following formula Middle driven pinion gear s...

Page 213: ...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 214: ... ring nut wrench 2 CAUTION The middle driven shaft bearing retainer has left handed threads To tighten the bearing 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 8...

Page 215: ...shims 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 whee...

Page 216: ...U joint so that the circlip 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 a 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 instal...

Page 217: ... gear lash 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 with middle driven pinion gear shims and or middle drive pinion gear shims Gear lash measurement tool P N YM 01467 90890 01467 ...

Page 218: ......

Page 219: ...COOL 5 ...

Page 220: ...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 221: ...COOL ...

Page 222: ...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 223: ...TOR 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 radiator 1 For installation reverse the removal procedure ...

Page 224: ...ng pressure 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 93...

Page 225: ...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 226: ...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 227: ...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 228: ...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 229: ...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 230: ...eal 1 NOTE Tap out 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 Cracks damage wear Replace 2 Check Water pump outlet pipe Cracks damage wea...

Page 231: ...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 232: ... 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 233: ......

Page 234: ...CARB 6 ...

Page 235: ...CARB CHAPTER 6 CARBURETION CARBURETOR 6 1 CHECKING THE CARBURETOR 6 4 ASSEMBLING THE CARBURETOR 6 6 ADJUSTING THE FUEL LEVEL 6 7 ...

Page 236: ...CARB ...

Page 237: ...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 238: ...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 239: ...OR Order Job name Part name Q ty Remarks D Pilot jet 1 E Pilot screw set 1 Refer to 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 240: ...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 241: ...n jet 2 Needle jet 3 Pilot air jet 4 Pilot jet 5 Pilot screw set 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 242: ... carburetor 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 bendin...

Page 243: ...gauge 1 to the drain pipe 2 Loosen the drain screw 3 Hold the gauge vertically 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 R...

Page 244: ......

Page 245: ...DRIV 7 ...

Page 246: ...D ADJUSTING THE DIFFERENTIAL GEAR LASH 7 12 CHECKING THE DIFFERENTIAL GEAR OPERATION 7 14 REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT 7 15 REMOVING THE REAR AXLE 7 18 DISASSEMBLING THE FINAL DRIVE GEAR 7 18 REPLACING THE FINAL DRIVE ROLLER BEARINGS 7 19 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR 7 20 CHECKING THE REAR AXLE 7 24 CHECKING THE DRIVE SHAFT 7 25 CHECKING THE FINAL DRIVE GEAR ...

Page 247: ...DRIV ...

Page 248: ...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 249: ...nd possible injury to the rider 2 Check Drained oil Drained oil shows large amounts of metal particles Check the bearings 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 250: ...s 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 dam...

Page 251: ...ender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Differential gear oil Drain Refer to CHANGING THE DIFFERENTIAL GEAR OIL in CHAPTER 3 Steering knuckle Refer to STEERING SYSTEM in CHAPTER 8 Front arms lower Refer to FRONT ARMS AND FRONT SHOCK ABSORBERS in CHAPTER 8 Brake light switch cover Refer to FRONT BRAKE in CHAPTER 8 1 Constant velocity joint 2 2 Gear motor coupler four wheel d...

Page 252: ...NT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name Part name Q ty Remarks 4 Differential gear 1 5 Drive shaft 1 6 Compression spring 1 7 Coupling gear 1 For installation reverse the removal procedure ...

Page 253: ...g the constant velocity joints Remove the parts in the order below 1 Circlip 1 2 Boot band 2 Refer to ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint 1 7 Circlip 1 8 Ball bearing 1 9 Joint shaft assembly 1 For assembly reverse the disassembly procedure ...

Page 254: ...e the parts in the order below 1 Gear motor O ring 1 1 2 Four wheel drive switch 1 3 Dust seal 1 4 Circlip 1 5 Coupling gear bearing circlip 1 1 1 6 Stopper bolt shaft 1 1 7 Shift fork sliding gear 1 8 Shift fork 1 9 2WD 4WD shift sleeve 1 0 Differential gear case cover O ring 1 1 A Shim left B Differential gear assembly 1 ...

Page 255: ... CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name Part name Q ty Remarks C Shim right D Circlip bearing 1 1 E Drive pinion gear 1 F Differential gear case 1 For assembly reverse the disassembly procedure ...

Page 256: ...e factory by means of specialized equipment Do not attempt to disassemble this unit Disassembly will result in the malfunction of the unit CHECKING THE CONSTANT VELOCITY JOINTS 1 Check Double off set joint spline Ball joint spline Shaft spline Wear damage Replace 2 Check Dust boots Cracks damage Replace CAUTION Always use new boot bands 3 Check Balls and ball races Inner surface of double off set ...

Page 257: ...amage Replace Spring Fatigue Replace Move the spring up and down 3 Check Front drive shaft Bends Replace WARNING Do not attempt to straighten a bent shaft this may dangerously weaken the shaft ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS 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 ...

Page 258: ...EAR LASH 2 Install Gear motor Servomotor installation steps Make sure that the gear motor and shift fork sliding gear are in the 2WD position While aligning the gear motor stopper a with the differential gear case boss b mesh the pinion gear gear motor and shift fork sliding gear together Push the gear motor into the differential gear case Rotate the gear motor counterclockwise until it lines up w...

Page 259: ...e or another supporting device 2 Remove Drain plug Gasket 3 Install A bolt of the specified size 1 into the drain plug hole CAUTION Finger tighten the bolt until it holds the ring gear Otherwise the ring gear will be damaged 4 Attach Gear lash measurement tool 1 Dial gauge 2 a Measuring point is 25 mm 0 98 in 5 Measure Gear lash Gently rotate the gear coupling from engagement to engagement NOTE Me...

Page 260: ...ssary to increase by more than 0 05 mm 0 002 in Reduce right shim thickness by 0 1 mm 0 004 in for every 0 1 mm 0 004 in of left shim increase If it is necessary to reduce by more than 0 1 mm 0 004 in Increase right shim thickness by 0 1 mm 0 004 in for every 0 1 mm of left shim decrease Right only Too little gear lash Reduce shim thickness Too large gear lash Increase shim thickness Ring gear shi...

Page 261: ...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 262: ...der below Final gear oil Drain Refer to CHANGING THE FINAL GEAR OIL in CHAPTER 3 Rear wheel hubs Refer to FRONT AND REAR WHEELS in CHAPTER 8 Brake drum Refer to REAR BRAKE 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 rev...

Page 263: ...Remove 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 7 Oil seal bearing 1 1 8 Ring gear shim 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 264: ... 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 G Final drive gear case O ring 1 1 H Bearing oil seal 1 1 Refer to REPLACING THE FINAL DRIVE ROLLER BEARINGS I Bearing 1 For assembly reverse the disassembly procedure ...

Page 265: ...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 266: ... 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 ...

Page 267: ...meral 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 dig...

Page 268: ... 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 269: ...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 270: ...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 271: ... 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 272: ...sing 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 oil seals When the final drive pinion gear and or r...

Page 273: ...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 274: ...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 decrease 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 4...

Page 275: ...se 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 rings Oil seals Bearings 2 Install Drive s...

Page 276: ... 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 installing the dust cover Install the rear axle with dust cover 2 Install the rear brake drum and rear wheel hub left Temporarily tighten the left axle nut 3 NOTE After tightening the rear axle nut 3 the position ...

Page 277: ......

Page 278: ...CHAS 8 ...

Page 279: ...NT BRAKE CALIPERS 8 16 ASSEMBLING THE FRONT BRAKE CALIPERS 8 17 INSTALLING THE FRONT BRAKE CALIPERS 8 17 REAR BRAKE 8 19 REMOVING THE REAR BRAKE 8 23 CHECKING THE REAR BRAKE 8 24 INSTALLING THE REAR BRAKE 8 25 STEERING SYSTEM 8 28 HANDLEBAR 8 28 REMOVING THE REAR BRAKE SWITCH 8 29 CHECKING THE HANDLEBAR 8 29 INSTALLING THE HANDLEBAR 8 29 INSTALLING THE REAR BRAKE LEVER 8 29 INSTALLING THE MASTER C...

Page 280: ...THE FRONT SHOCK ABSORBER 8 44 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 8 45 REAR SHOCK ABSORBER AND SWINGARM 8 46 REMOVING THE SWINGARM 8 48 CHECKING THE REAR SHOCK ABSORBER 8 48 CHECKING THE SWINGARM 8 49 CHECKING THE RUBBER BOOT 8 49 INSTALLING THE RUBBER BOOT 8 49 INSTALLING THE REAR AXLE HOUSING 8 50 ...

Page 281: ... Securely support the machine so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE WHEELS 2 Wheel cap 1 Refer to INSTALLING THE WHEEL HUBS 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 th...

Page 282: ...rts in the order below Place the machine on a level surface WARNING Securely support the machine so there is no danger of it falling over 1 Wheel cap 2 2 Rear wheel 2 Refer to INSTALLING THE WHEELS 3 Cotter pin 2 Refer to INSTALLING THE WHEEL HUBS 4 Axle nut 2 5 Wheel hub 2 For installation reverse the removal procedure ...

Page 283: ... 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 HUBS 1 Check Wheel hub 1 Cracks damage Replace Splines wheel hub 2 Wear damage Replace ...

Page 284: ...ace Brake disc maximum deflection 0 15 mm 0 006 in Brake disc minimum thickness 3 mm 0 12 in INSTALLING THE WHEEL HUBS 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 WHEELS 1 Install Wheel NOTE ...

Page 285: ...heel 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 wheels Nuts rear wheels 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 286: ...moving 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 PADS 2 Brake pad holding bolt 2 3 Brake pad pad shim 2 1 4 Pad spring 1 For installation reverse the removal procedure ...

Page 287: ...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 PADS 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 brake ...

Page 288: ...3 and a new brake pad spring Install the holding 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 FRONT BRAKE FLUID LEVEL in CHAPTER ...

Page 289: ...he order below Brake fluid Drain 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 290: ...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 291: ...ody Blockage Blow out with compressed air 2 Check Front brake master cylinder reservoir 1 Front brake master cylinder reservoir diaphragm 2 Cracks damage Replace 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 a...

Page 292: ...cable wire harness leads 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 r...

Page 293: ...l significantly lower the boiling point of the brake fluid and may result in vapor lock 4 Air bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 5 Check Brake fluid level Brake fluid level is under the LOWER level line Fill up Refer to CHECKING THE FRONT BRAKE FLUID LEVEL in CHAPTER 3 ...

Page 294: ...r below Brake fluid Drain Front wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CALIPERS 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 295: ...rts 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 BRAKE CALIPERS 7 Dust seal 1 8 Caliper piston seal 1 9 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 296: ...r Remove the caliper piston seals EB702040 CHECKING THE FRONT BRAKE CALIPERS 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 brakes are dis...

Page 297: ...nents 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 New New 2 Install Brake caliper piston 1 INSTALLING THE FRONT BRAKE CALIPERS 1 Install Brake caliper assembly Brake caliper mounting bolts 1 Brake hose 2 Copper washers...

Page 298: ...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 result in vap...

Page 299: ...Q ty Remarks Removing the rear brake lever Remove the parts in the order below 1 Rear brake switch 1 2 Rear brake lever cable 1 3 Rear brake lever holder bracket 1 4 Rear brake lever holder 1 5 Rear brake lever 1 For installation reverse the removal procedure ...

Page 300: ...Removing the rear brake pedal Remove the parts in the order below 1 Rear brake light switch cover 1 2 Rear brake pedal cable 1 3 Brake pedal 1 4 Select lever control cable 1 5 Rear brake light switch 1 6 Bracket 1 For installation reverse the removal procedure ...

Page 301: ...ar brake drum Remove the parts in the order below Rear wheel left Refer to FRONT AND REAR WHEELS 1 Brake drum cover 1 2 Dust seal 1 3 Brake drum 1 4 Adjusting nut 2 5 Pin 2 6 Spring 2 7 Rear brake lever cable 1 8 Rear brake pedal cable 1 9 Brake shoe 2 10 Brake shoe spring 2 ...

Page 302: ... Job name Part name Q ty Remarks 11 Brake camshaft lever 1 12 Brake shoe wear indicator 1 13 Brake camshaft 1 14 O ring 2 15 Dust seal 1 16 Brake shoe plate 1 For installation reverse the removal procedure REAR BRAKE ...

Page 303: ...t Rear wheel hub left Refer to FRONT AND REAR WHEELS 2 Remove Brake drum cover 1 3 Remove Brake drum 1 4 Remove Adjusting nuts 1 Pins 2 Springs 3 5 Disconnect Rear brake lever cable 4 Rear brake pedal cable 5 6 Remove Brake shoes 1 Bearing retainer 2 Brake shoe plate 3 ...

Page 304: ...rake shoe plate 1 Pivot pin 2 Brake camshaft 3 Bends cracks damage Replace Dust seal 4 Wear damage Replace 3 Check Brake shoes 1 Brake shoe springs 2 Cracks damage Replace as a set NOTE When replacing the brake shoes replace the brake shoe springs at the same time 4 Check Brake shoe lining Glazed areas Repair Sand the glazed areas with coarse sandpa per NOTE After sanding the glazed areas clean th...

Page 305: ...0 mm 0 08 in 6 Measure Brake drum inside diameter a Out of specification Replace Brake drum inside diameter limit maximum 161 mm 6 34 in 7 Check Brake drum inner surface Oil deposits Clean Remove the oil with a rag soaked in lacquer thinner or solvent Scratches Repair Lightly and evenly polish the scratches with an emery cloth INSTALLING THE REAR BRAKE 1 Lubricate Brake camshaft 1 Pivot pin 2 Lith...

Page 306: ...e right end of the wear indicator scale 2 3 Install Brake camshaft lever 1 NOTE When installing the brake camshaft lever align the punch marks 3 on the brake camshaft lever and brake camshaft 4 Apply Sealant 4 onto the mating surfaces of swingarm 5 Install T R Bolt camshaft lever 9 Nm 0 9 m kg 6 5 ft lb Sealant Quick Gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 Brake shoe plate 1...

Page 307: ...1 Rear brake pedal cable 2 9 Install Springs 3 Pins 4 Adjusting nuts 5 Brake drum Brake drum cover 10 Install Rear wheel hub left Rear wheel left Refer to FRONT AND REAR WHEELS 11 Adjust Rear brake pedal free play Rear brake lever free play Refer to ADJUSTING THE REAR BRAKE in CHAPTER 3 T R Axle nut 150 Nm 15 m kg 110 ft lb Nut rear wheel 55 Nm 5 5 m kg 40 ft lb ...

Page 308: ... 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 installation reverse the...

Page 309: ...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 310: ...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 311: ...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 312: ...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 313: ...ly 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 tabs along a flat side of the bolts NOTE Pass the cables and hoses through the cable guide Refer to CABLE ROUTING in CHAPTER 2 Damper rod holder P N YM 0...

Page 314: ...the 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 RODS 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 KNUCKLES ...

Page 315: ...5 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 316: ... tie rod end Turns roughly Replace the tie rod end 2 Check Tie rods Bends damage Replace CHECKING THE STEERING KNUCKLES 1 Check Steering knuckles Damage pitting Replace 2 Check Ball joints 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...

Page 317: ...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 318: ...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 319: ...e only with the outer race Install the new oil seals NOTE When installing the oil seals the seal side of the oil seal faces out INSTALLING THE TIE RODS 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 320: ... Part name Q ty Remarks Removing the front arms and front shock absorbers Remove the parts in the order below Engine skid plate Refer to SEAT CARRIERS FENDERS AND FUEL TANK 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 321: ...r 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 322: ... 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 ARMS 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 323: ...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 324: ...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 325: ...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 326: ... Rear wheel hubs Refer to FRONT AND REAR WHEELS Rear brake drum Refer to REAR BRAKE Rear brake lever cable rear brake pedal cable Refer to REAR BRAKE 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 327: ...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 328: ... 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 bushings 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 assembl...

Page 329: ...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 330: ... 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 331: ...ELEC 9 ...

Page 332: ...8 TROUBLESHOOTING 9 9 ELECTRIC STARTING SYSTEM 9 14 CIRCUIT DIAGRAM 9 14 TROUBLESHOOTING 9 15 STARTER MOTOR 9 18 CHECKING THE STARTER MOTOR 9 19 ASSEMBLING THE STARTER MOTOR 9 20 CHARGING SYSTEM 9 21 CIRCUIT DIAGRAM 9 21 TROUBLESHOOTING 9 22 LIGHTING SYSTEM 9 24 CIRCUIT DIAGRAM 9 24 TROUBLESHOOTING 9 25 CHECKING THE LIGHTING SYSTEM 9 27 SIGNAL SYSTEM 9 31 CIRCUIT DIAGRAM 9 31 TROUBLESHOOTING 9 33 ...

Page 333: ... ELEC ...

Page 334: ...hermo switch cylinder head 5 Battery 6 Tail brake light 7 Fuse box 8 Main fuse 9 Starter relay 0 CDI unit A Rectifier regulator B Reverse switch C Neutral switch D Speed sensor E Rear brake light switch F Gear motor G Thermo switch radiator H Fan I Headlight J Circuit breaker fan K Ignition coil 1 2 3 4 5 6 7 8 9 0 A C B D E F G H I J K ...

Page 335: ...s when checking it Pocket tester P N YU 03112 C 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...

Page 336: ... lead terminals Poor connection no continuity Correct or replace The coupler locations are circled L B Y G Br L B BLACK 1 4 5 B 6 2 3 R B R W PUSH Br L Y G B R W Br L R L G B L B R B L B 2WD 4WD Br B P P Br B B BLACK 7 B B BLACK 8 9 B Y G Y Br G Y B Br Y GRAY Br L G L B B L R BROWN B A 0 Br L Br R R ON OFF R R Br Br L PUSH OFF ...

Page 337: ...itch 2 Engine stop switch 3 Start switch 4 On command four wheel drive 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 Neutral switch A Reverse switch B Fuses ...

Page 338: ... 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 tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bul...

Page 339: ...lb 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 to...

Page 340: ...lb 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 C 90890 03112 CHECKING THE BULBS AND BU...

Page 341: ... R S T BLACK BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G U U B G Y B Y G B G Y B Y G R B R W G W Sb Sb G W A L B B W O B W O BLACK A BLACK WIRE HARNESS SUB WIRE HARNESS 1 B WIRE HARNESS SUB WIRE HARNESS 2 BLACK C C C B BLACK WIRE HARNESS SUB WIRE HARNESS 1 W Sb B R B L B Br W B R B Sb W Br W L B W B B Y Br BLACK BLACK Br Y X B B Y Br BLACK BLACK L B B L GRAY GRAY W W A L B ...

Page 342: ...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 C 90890 03112 EB802011 CONTINUITY 1 Fuses main ignition Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuses EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY i...

Page 343: ...rs Minimum spark gap 6 0 mm 0 24 in MEETS SPECIFICATION The ignition system is not faulty 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 switch to ON Check the ignition spark gap a Crank the engine by pushing the starter switch and increase the spar...

Page 344: ...nge lead terminal Tester lead Ignition coil base Check that the primary coil has the specified resistance Primary coil resistance 0 18 0 28 Ω at 20 C 68 F BOTH MEET SPECIFICATION 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...

Page 345: ...1 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 Che...

Page 346: ...C IGNITION SYSTEM C0NTINUITY CORRECT 11 Wiring connections Check the connections of the entire ignition system Refer to CIRCUIT DIAGRAM Replace the CDI unit POOR CONNECTION Properly connect the ignition system ...

Page 347: ...Y L B Y R S T BLACK BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G U U B G Y B Y G B G Y B Y G R B R W G W Sb Sb G W A L B B W O B W O BLACK A BLACK WIRE HARNESS SUB WIRE HARNESS 1 B WIRE HARNESS SUB WIRE HARNESS 2 BLACK C C C B BLACK WIRE HARNESS SUB WIRE HARNESS 1 W Sb B R B L B Br W B R B Sb W Br W L B W B B Y Br BLACK BLACK Br Y X B B Y Br BLACK BLACK L B B L GRAY GRAY W W...

Page 348: ...eshooting 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 C 90890 03112 EB802011 CONTINUITY 1 Fuses main ignition Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPT...

Page 349: ... 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 350: ...ine stop switch Refer to CHECKING THE SWITCHES INCORRECT Replace the handlebar switch left CORRECT 7 Start switch Refer to CHECKING THE SWITCHES INCORRECT Replace the handlebar switch left EB803028 8 Wiring connections Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM POOR CONNECTION Properly connect the starting system ...

Page 351: ...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 352: ...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 353: ...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 354: ... L B Y L B L B G R Y L B Y R S T BLACK BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G U U B G Y B Y G B G Y B Y G R B R W G W Sb Sb G W A L B B W O B W O BLACK A BLACK WIRE HARNESS SUB WIRE HARNESS 1 B WIRE HARNESS SUB WIRE HARNESS 2 BLACK C C C B BLACK WIRE HARNESS SUB WIRE HARNESS 1 W Sb B R B L B Br W B R B Sb W Br W L B W B B Y Br BLACK BLACK Br Y X B B Y Br BLACK BLACK L ...

Page 355: ...P N YU 8036 B Engine tachometer P N 90890 03113 Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCHES 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 ...

Page 356: ...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 46 0 62 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 357: ...CK BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G U U B G Y B Y G B G Y B Y G R B R W G W Sb Sb G W A L B B W O B W O BLACK A BLACK WIRE HARNESS SUB WIRE HARNESS 1 B WIRE HARNESS SUB WIRE HARNESS 2 BLACK C C C B BLACK WIRE HARNESS SUB WIRE HARNESS 1 W Sb B R B L B Br W B R B Sb W Br W L B W B B Y Br BLACK BLACK Br Y X B B Y Br BLACK BLACK L B B L GRAY GRAY W W A L B L B A Sb S...

Page 358: ...ubleshooting 1 Seat 2 Front carrier 3 Front fender panel Use the following special tool s for troubleshooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main headlight Refer to CHECKING THE SWITCHES 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...

Page 359: ... CHECKING THE SWITCHES INCORRECT Light switch is faulty replace the handlebar switch left EB805013 CORRECT 5 Wiring connections 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 360: ...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 361: ...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 362: ...e bulb and or bulb socket 2 Voltage Connect the pocket tester 20 V to the bulb socket coupler Tester lead Blue terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Turn the light switch to or Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair it ...

Page 363: ...9 30 ELEC LIGHTING SYSTEM ...

Page 364: ...W R B Br G L B Y L B L B G R Y L B Y R S T BLACK BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G U U B G Y B Y G B G Y B Y G R B R W G W Sb Sb G W A L B B W O B W O BLACK A BLACK WIRE HARNESS SUB WIRE HARNESS 1 B WIRE HARNESS SUB WIRE HARNESS 2 BLACK C C C B BLACK WIRE HARNESS SUB WIRE HARNESS 1 W Sb B R B L B Br W B R B Sb W Br W L B W B B Y Br BLACK BLACK Br Y X B B Y Br BLAC...

Page 365: ...tor light H Thermo switch cylinder head I Four wheel drive fuse K Gear motor N Diode O Ignition fuse S Engine stop switch T Start switch V Signaling system fuse W Front brake light switch X Rear brake light switch Y Rear brake switch Z Tail brake light Reverse indicator light Neutral indicator light Horn switch For Europe and Oceania a Horn È For Europe and Oceania ...

Page 366: ...re troubleshooting 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 C 90890 03112 EB802011 CONTINUITY 1 Fuses main four wheel drive ignition signaling system Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING TH...

Page 367: ...CORRECT 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 368: ...O 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 Th...

Page 369: ...eutral switch Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the neutral switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead Sky blue terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket c...

Page 370: ...erse switch Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the reverse switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead Green Blue terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V Replace the CDI unit OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connect...

Page 371: ...inder head Connect the pocket tester Ω 1 to the thermo switch cylinder head 1 Immerse the thermo switch cylinder head in coolant 2 Check the thermo switch cylinder head for continuity While heating the coolant use a thermometer 3 to record the temperatures Test step Coolant temperature Continuity Thermo switch cylinder head 1 Less than 120 3 C 248 5 4 F NO 2 More than 120 3 C 248 5 4 F YES 3 More ...

Page 372: ...h cylinder head 8 Nm 0 8 m kg 5 8 ft lb Three bond sealock 10 BAD CONDITION Replace the thermo switch cylinder head 3 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Red Black terminal 1 Tester lead White Blue terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb s...

Page 373: ...Black terminal 1 Tester lead White Blue terminal 2 Continuity Tester lead White Blue terminal 2 Tester lead Blue Black terminal 1 No continuity NOTE When you switch the tester s positive and negative probes the readings in the left chart will be reversed INCORRECT Replace the diode CORRECT 5 Start switch Refer to CHECKING THE SWITCHES This circuit is not faulty INCORRECT Replace the handlebar swit...

Page 374: ...TY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC 20 V to the bulb socket lead Tester lead Brown Red terminal 1 Tester lead White terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair it ...

Page 375: ...Connect the pocket tester DC 20 V to the horn connector at the horn terminal Tester lead Pink lead 1 Tester lead Black lead 2 MEETS SPECIFICATION Turn the main switch to ON Push the horn switch For Europe and Oce ania Check for voltage 12 V on the Pink lead at the horn terminal Adjust or replace horn OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is fault...

Page 376: ... Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G U U B G Y B Y G B G Y B Y G R B R W G W Sb Sb G W A L B B W O B W O BLACK A BLACK WIRE HARNESS SUB WIRE HARNESS 1 B WIRE HARNESS SUB WIRE HARNESS 2 BLACK C C C B BLACK WIRE HARNESS SUB WIRE HARNESS 1 W Sb B R B L B Br W B R B Sb W Br W L B W B B Y Br BLACK BLACK Br Y X B B Y Br BLACK BLACK L B B L GRAY GRAY W W A L B L B A Sb Sb A Br W...

Page 377: ...rier 3 Front fender Use the following special tool s for troubleshooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCHES 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 Recharg...

Page 378: ...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 379: ... 186 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 radiator circuit is open and the radiator fan is off É The thermo switch radiator circuit is closed and the radiator fan is on WARNING Handle the thermo switch radiator with special care Never subject it to...

Page 380: ...ING SYSTEM C0NTINUITY EB803028 CORRECT 7 Wiring connections 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 381: ...K BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G U U B G Y B Y G B G Y B Y G R B R W G W Sb Sb G W A L B B W O B W O BLACK A BLACK WIRE HARNESS SUB WIRE HARNESS 1 B WIRE HARNESS SUB WIRE HARNESS 2 BLACK C C C B BLACK WIRE HARNESS SUB WIRE HARNESS 1 W Sb B R B L B Br W B R B Sb W Br W L B W B B Y Br BLACK BLACK Br Y X B B Y Br BLACK BLACK L B B L GRAY GRAY W W A L B L B A Sb Sb...

Page 382: ...Front carrier 3 Front fender Use the following special tool s for troubleshooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main four wheel drive Refer to CHECKING THE SWITCHES 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 th...

Page 383: ...ar motor from the differen tial gear case Connect the battery 12 V to the gear motor terminals 2WD 4WD Battery terminal Brown White terminal 1 Battery terminal Sky blue terminal 2 4WD 2WD Battery terminal Sky blue terminal 2 Battery terminal Blue Black terminal 3 Make sure that the drive gear shift fork sliding gear operates correctly NOTE When installing the differential gear case in the gear mot...

Page 384: ...ELECTING SYSTEM EB803028 CORRECT 6 Wiring connection Check the connections of the entire 2WD 4WD selecting system Refer to CIRCUIT DIAGRAM Replace the CDI unit POOR CONNECTION Properly connect the 2WD 4WD selecting system ...

Page 385: ......

Page 386: ...TRBL SHTG 10 ...

Page 387: ...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 388: ...TRBL SHTG ...

Page 389: ...heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body CDI system Faulty CDI unit Faulty pickup coil 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 Impro...

Page 390: ...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 391: ...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 392: ...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 393: ...tting 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 Improperly connected hose ...

Page 394: ...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 395: ......

Page 396: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 397: ... B Br B P B B Br OFF ON Br R Br L R R Br R Br L Y Br G Y Y B B Y Br B Y Sb G L R W R W c d e B R Br É GRAY GRAY 1 A C magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 CDI unit 9 Ignition coil 0 Spark plug A Reverse switch B Neutral switch C Circuit breaker fan motor D Thermo switch radiator E Fan motor F Coolant temperature warning light G Four wh...

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