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Yamaha YFM350FW, Service Manual

The Yamaha YFM350FW Service Manual is a comprehensive guide for all Yamaha YFM350FW owners. This invaluable manual covers maintenance, repairs, and troubleshooting of the Yamaha YFM350FW, providing detailed instructions and diagrams to ensure smooth operation. Download this manual for free from our website manualshive.com and unlock unparalleled expertise for your beloved ATV.

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Use 

Genuine YAMAHA

Parts And Accessories

LIT-11616-FM-37

YFM350FW

LIT-11616-FM-37

Service Manual

YAMAHA MOTOR CORPORATION, U.S.A.
PRINTED IN U.S.A.

Ser
vice Manual

YFM350FW

11616-FM-37_00_D  05/13/2002  3:02 PM  Page 1

[email protected]

www.midwestmanuals.com

www.midwestmanuals.com

Summary of Contents for YFM350FW

Page 1: ... Accessories LIT 11616 FM 37 YFM350FW LIT 11616 FM 37 Service Manual YAMAHA MOTOR CORPORATION U S A PRINTED IN U S A Service Manual YFM350FW 11616 FM 37_00_D 05 13 2002 3 02 PM Page 1 sales midwestmanuals com www midwestmanuals com www midwestmanuals com ...

Page 2: ...sales midwestmanuals com www midwestmanuals com YAMAHA sales mi anuails com www mldwestmanuals com LIT 11616 10 30 www midwestmanuals com ...

Page 3: ...d 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 followi...

Page 4: ... and marked with a corresponding symbol A circled number refers to an illustrated part j A circled lower case letter refers to an illustrated dimension or alignment mark An upper case letter in a box refers to other illustrated details An arrow mark after a given defect suggests the recommended course of action t In Chapter 3 Periodic Inspection and Adjustment it is usually the current sub section...

Page 5: ...hooting Illustrated symbols to are used to identify the specifications appearing in the text Filling fluid Lubricant Special tool Torque Wear limit clearance Engine speed O V A Illustrated symbols to l in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium s...

Page 6: ... ENGINE SERIAL NUMBER 1 MODEL LABEL 1 SPECIFICATIONS 2 GENERAL SPECIFICATIONS 2 MAINTENANCE SPECIFICATIONS 2 ENGINE 2 ELECTRiCAL 6 CABLE ROUTING 7 PERIODIC INSPECTION AND ADJUSTMENT 13 SEAT CARRIERS FENDERS AND FUEL TANK 13 REMOVAL 13 INSTALLATION 15 ELECTRiCAL 17 ELECTRICAL COMPONENTS 17 YFM350FWJ WIRING DIAGRAM www midwestmanuals com ...

Page 7: ... of the frame NOTE _______________________ The vehicle identification number is used to identify your machine and may be used to register your machine with a licensing authority in your state 1 ENGINE SERIAL NUMBER The engine serial number D is stamped into the right side of the engine MODEL LABEL The model label CD is affixed to the frame This information will be needed to order spare parts www m...

Page 8: ...ng Free length IN Limit Set length vaIve closed Compressed pressure installed EX IN EX IN EX IN EX YFM350FWJ 3HNX 1 940 mm 76 4 in 1 095 mm 43 1 in 1 130 mm 44 5 in 850 mm 33 5 in 1 210 mm 47 6 in 180 mm 7 1 in YFM350FWJ Chain Left 40 28 40 38 mm 1 586 1 590 in 40 26 mm 1 585 in 32 14 N 32 24 mm 1 265 1 269 in 32 11 mm 1 264 in 8 28 8 39 mm 0 326 0 330 in 8 26 mm 0 325 in 40 29 40 39 mm 1 586 1 59...

Page 9: ...t limit Direction of winding top view IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN YFM350FWJ 2 5 1 6 mm 2 5 06 in 2 5 1 6 mm 2 5 06 in Counterclockwise Counterclockwise n 43 27 mm 1 70 in 43 27 mm 1 70 in 41 27 mm 1 62 in 41 27 mm 1 62 in 36 6 mm 1 44 in 36 6 mm 1 44 in 22 99 26 59 kg 50 68 58 62 Ib 22 99 26 59 kg 50 68 58 62 Ib 2 5 1 6 mm 2 5 06 in 2 5 1 6 mm 2 5 06 in Clockwise EX Clockwise n 3 ...

Page 10: ...24 in 0 15 mm 0 0059 in 82 92 82 97 mm 3 265 3 267 in 5 5 mm 0 217 in 83 5 mm 3 29 in 84 0 mm 3 31 in 0 5 mm 0 02 in IN side 19 004 19 015 mm 0 7482 0 7486 in 18 991 19 000 mm 0 7477 0 7480 in Barrel B 1 2 mm 0 05 in T 3 3 mm 0 13 in Taper B 1 5 mm 0 06 in T 3 4 mm 0 13 in Expander B 2 8 mm 0 11 in T 2 8 mm 0 11 in 0 2 0 4 mm 0 008 0 016 in 0 2 0 4 mm 0 008 0 016 in 0 3 0 9 mm 0 012 0 035 in Top r...

Page 11: ... mm 0 08 in Wear limit 1 5 mm 0 06 in Clutch shoe spring free length 43 5 mm 1 71 in Clutch in revolution 1 750 1 950 r min Clutch stall revolution 2 900 3 200 r min Carburetor I D mark 3HN 00 Main jet M J 120 Main air jet M A J 0 8 Jet needle J N 5H26 3 Needle jet N J N 8 Pilot air jet P A J 1 1 0 Pilot air jet P A J 2 0 9 Pilot outlet P O 0 75 Pilot jet P J 45 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0...

Page 12: ...INDER ELECTRICAL Model YFM350FWJ C D I Magneto model manufacturer F3T43575 MITSUBISHI Pickup coil resistance color 459 561 n at 20 C 68 F Red White Source coil resistance color 270 330 n at 20 C 6BOF Brown Green C D 1 unit model manufacturer FBT32372 MITSUBISHI Ignition coil Model manufacturer F6T53573 MITSUBISHI Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 36 0 48 n at 20 C 6BOF Se...

Page 13: ...ose Throttle cable Terminal lead option j Indicator light lead Speedometer cable Speedometer light lead Front brake switch lead Handlebar switch lead CABLE ROUTING ISPECI U I Clip Backing plate Select lever control cable 2 Breather hose front differential Breather hose front brake Brake pipe Brake hose 3 7 www midwestmanuals com ...

Page 14: ... the handlebar I ru Insert the breather hose fuel tank into the hole of the handlebar cover g Fasten the speedometer light lead indicator light lead handlebar switch lead and front brake switch lead Q Pass the speedometer cable rear brake cable and throttle cable in the given order 1 Be sure the section of the breather hose front brake between the clips is as taut as the brake hose Install the bre...

Page 15: ...y j Battery positive lead Battery negative lead Terminal fuse option Breather hose battery 9 CABLE ROUTING 1SPEC1 0 1 Carburetor overflow hose COl magneto lead Neutral switch lead Select lever control cable 2 Oil hose 1 Breather hose final gear case Breather hose rear brake Carburetor air vent hose Throttle cable Oil hose 2 www midwestmanuals com ...

Page 16: ...se final gear case and carburetor air vent hose through the hole in the bracket rnl Fasten the wire harness neutral switch lead and COl magneto lead Fasten the starter motor lead Q Pass the breather hose rear brake through the guide f Pass the breather hose final gear case through the guide E E 10 www midwestmanuals com ...

Page 17: ... A CABLE ROUTING ISPECI 0 1 8J Align the white tape on the wire harness with the cross pipe With a plastic band fasten the wire harness to the frame at the point in front of the welding g Fasten the wire harness Q Pass the select lever control cable 1 through the guide III Pass the brake cable to the right of the starter motor Pass the rear brake cable over the fender stay Install the select lever...

Page 18: ...nt hose Taillight lead CABLE ROUTING ISPECI u I Insert the ends of the breather hose front differential into the frame pipe Fasten the wire harness at the point where the white tape is affixed to it g Fasten the wire harness and battery negative lead 1m Fasten the select lever control cable 2 III Insert the ends of the breather hoses front brake into the frame pipe 12 www midwestmanuals com ...

Page 19: ...achine on a level place 2 Remove Seat CD NOTE ______________________ Pull up the seat lock lever then remove by pulling up on the rear of the seat 3 Remove Front carrier CD 4 Remove Fuel tank cap D Fuel tank cover Rubber seat 5 lnstall Fuel tank cap D 6 Disconnect Main switch coupler D Headlight couplers 13 7 Remove Front fender 8 Left side Right side Front bumper www midwestmanuals com ...

Page 20: ...fuel cock lever to OFF 9 Disconnect Fuel hose CD NOTE ________________________ Place a rug on the engine to absorb any spilt fuel A WARNING Gasoline is highly flammable Avoid spilling fuel on the hot engine 10 Remove Fuel tank CD 11 Remove Rear carrier D 12 Remove Rear fender D 14 www midwestmanuals com ...

Page 21: ... Bolt rear bumper and frame 33 Nm 3 3 m kg 24 ft Ib Rear fender NOTE ________________________ Be sure the projection CD on the frame cor rectly engages with the hole into the rear fender stay 3 1nstall Rear carrier 15 4 1n5tall Bolt rear carrier and frame 33 Nm 3 3 m kg 24 ft Ib Nut rear carrier and rear bumper 9 Nm 0 9 m kg 6 5 ft Ib Front bumper Bolt front bumper and frame 23 Nm 2 3 m kg 17 ft I...

Page 22: ...nk breather hose CD into the handlebar protector hole 6 1nstall Front carrier 7 lnstall Seat Bolt front carrier and frame 33 Nm 3 3 m kg 24 ft Ib Bolt front carrier and front bumper 10 Nm 1 0 m kg 7 2 ft Ib NOTE _______________________ Insert the lobe CD on the seat front into the receptacle on the frame then push down the seat at the rear 16 www midwestmanuals com ...

Page 23: ...ry Starter relay J COl unit Neutral switch Reverse switch Main switch Reverse indicator light Neutral indicator light Oil temp indicator light 17 SPECIFICATIONS RESISTANCE IGNITION COIL PRIMARY 0 36 0 48 Q SECONDARY 5 44 7 36 kQ PICK UP COIL 459 561 Q SOURCE COIL 270 330 Q STATOR COIL 0 70 0 86 n A BATTERY B CAPACITY 12V 14AH C SPECIFIC GRAVITY 1 280 www midwestmanuals com ...

Page 24: ...oil Rectifier regulator Main switctl Main fuse 1 Battery Starter relay l Starter motor B W Black tWhite Br W Brown White GJL Green Blue GIY GreenlYellow L W Blue White Rtw RedM hite WIG White Green W L White Blue Y B Yellow Black Starting circuit cut off relay COl magneto source coil and pickup coil l COl unit Ignition coil Spark plug Oil temperature indicator light Thermo unit Diode Front brake s...

Page 25: ...sales midwestmanuals com www midwestmanuals com YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAIIWATA SHIZUOKA JAPAN PRINTED IN L www midwestmanuals com ...

Page 26: ...sales midwestmanuals com www midwestmanuals com YAMAHA sales mid i uru r r T lrY II LIT 11616 09 82 www midwestmanuals com ...

Page 27: ...ntinually striving to improve all models manufactured by Yamaha Modifications and significant changes in specifications or procedures will be for warded to all Authorized Yamaha dealers and will where applicable appear in future editions of this manual PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation A WARNING NOTE The Safety Alert Symbol means ATTENTION ...

Page 28: ...dure preceded by IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol An encircled numeral indicates a part name and an encircled alphabetical letter data or an alignment mark j the others being indicated by an alphabetical letter in a box A condition of a faulty component will precede an arrow symbol and the course of action required the symbol EXPLODED DIA...

Page 29: ...ine Carburetion Drive train j Chassis Electrical Troubleshooting Illustrated symbols to are used to iden tify the specifications appearing in the text Filling fluid Lubricant Special tool Tightening Wear limit clearance Engine speed Q V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and loca tion of lubrication point Apply engine oil Apply gear oil Apply molybdenum di...

Page 30: ...ENERAL SPECIFICATIONS 2 MAINTENANCE SPECIFICATIONS 3 ENGINE 3 CHASSIS 6 ELECTRICAL 7 CABLE ROUTING 8 PERIODIC INSPECTION AND ADJUSTMENT 13 CHASSIS 13 REAR BRAKE LEVER AND PEDAL ADJUSTMENT 13 REAR BRAKE SHOE INSPECTION 15 FRONT SHOCK ABSORBER ADJUSTMENT 16 REAR SHOCK ABSORBER ADJUSTMENT 16 CHASSIS 17 REAR BRAKE 17 REMOVAL 18 INSPECTION 19 INSTALLATION 20 www midwestmanuals com ...

Page 31: ...ntify your machine and may be used to register your machine with the licensing authority in your state Starting serial number JV43HNAO TA209101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the right side of the engine NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting serial number 3HN 209101 N...

Page 32: ...A222101 CDN Frame starting number 3HN 229101 EUR Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 348 cm3 Bore x stroke 83 0 x 64 5 mm 3 27 x 2 54 in Compression ratio 8 6 1 Compression pressure STD 850 kPa 8 5 kg cm2 121 psi at 350 r min Starting system Electric and recoil starter Brake Front brake Type Drum brake Operation Right hand ...

Page 33: ... valve closed IN EX Compressed pressure Installed Tilt limit IN EX IN EX YFM350FW H 82 97 83 02 mm 3 2665 3 2685 in 0 01 mm 0 0004 in 40 mm 1 57 in 83 15 mm 3 2736 in 39 9 mm 1 57 in 39 9 mm 1 57 in 37 9 mm 1 49 in 37 9 mm 1 49 in 33 6 mm 1 32 in 33 6 mm 1 32 in 10 7 12 3 kg 23 59 27 12 Ib 10 7 12 3 kg 23 59 27 12 Ib 2 5 1 6 mm 2 5 06 in 2 5 1 6 mm 2 5 06 in Counterclockwise Counterclockwise n 43 ...

Page 34: ...I A Runout limit C F Big end side clearance 0 Limit Big end radial clearance E Small end free play F Limit Clockwise Clockwise n YFM350FW H 0 04 0 06 mm 0 0016 0 0024 in 0 15 mm 0 0059 in 82 92 82 97 mm 3 265 3 267 in 5 5 mm 0 217 in 83 5 mm 3 29 in 84 0 mm 3 31 in 0 5 mm 0 02 in IN side 19 004 19 015 mm 0 7482 0 7486 in 18 990 18 995 mm 0 7476 0 7478 in 58 95 59 00 mm 2 321 2 323 in 0 06 mm 0 002...

Page 35: ...120 Main air jet M A J 0 8 Jet needle J N 5H26 3 Needle jet N J N 8 Pilot air jet P A J l 1 0 Pilot air jet P A J 2 0 9 Pilot outlet P O 0 75 Pilot jet P J 45 Bypass 1 B P l 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 1 0 Pilot screw P S 2 3 8 Valve seat size V S 2 5 Starter jet G S 1 75 Throttle valve size Th V 130 Float height F H 11 4 13 4 mm 0 45 0 53 in Fuel level F L 1 2 rnm 0 04 0 08 in Below the...

Page 36: ...r 2 5 mm 0 08 0 20 in cylinder piston Brake lever free play just before brake is actually applied 30mm 1 18in Rear brake lever brake pedal Brake lever free play at lever pivot 4 8 mm 0 16 0 31 in Brake pedal position 5 mm 0 20 in Brake pedal free play 20 30 mm 0 79 1 18 in Throttle cable Throttle cable free play 3 5 mm 0 12 0 20 in TIGHTENING TORQUE Parts to be tightened Parts Thread O ty Tighteni...

Page 37: ...stance color 270 330 n at 20 C 68 F Brown Green C D I unit model manufacturer F8T30576 MITSUBISHI Spark plug cap Type Resin type Resistance 10 kQ Charging system Type A C magneto generator Model manufacturer F3T43575 MITSUBISHI Nominal output 12 V 17 A at 3 000 r min Stator coil resistance color 0 70 0 86 n at 20 C 68 e F White White Rectifier Model manufacturer SH535 12 SHINDENGEN Capacity 20A Wi...

Page 38: ...nt brake breather hose Clip 8 Pass the throttle cable under the handlebar ID Insert the breather hose into the hole of the handlebar protector g Pass the speedometer cable rear brake cable and throttle cable in order from the inside 01 1 Q Pass the throttle cable under the brake hose Pass the bearing housing breather hose along the back of the brake hose Attach the clip to the brake hose grommet a...

Page 39: ... hose Leftside Carburetorbreather Band Select lever control cable 1 hose Select lever control cable 2 Differential gear case breather Differential gearcasebreather j Ground lead hose hose Positive lead Handlebar protector Final gearcase breather hose Final gear case breather hose Clampthe starter motorcable and Front brake breather hose Battery breather hose battery breather hose Q Pass the leads ...

Page 40: ...tmanuals com www midwestmanuals com CD Clamp Main switch Band Ignition coil Speedometer cable COl unit J Headlight CABLE ROUTING ISPECIu I Do not pinch the hoses when install the fuel tank 10 www midwestmanuals com ...

Page 41: ...y Neutral relay Reverse relay Band Carburetor breather hose J Fuse Select lever control cable 2 Speedometer cable Wireharness 6 5 CABLE ROUTING ISPECI U I Clamp the taillight lead ill Pass the taillight lead into the slit Connect the taillight leads in the lid of the taillight box 11 www midwestmanuals com ...

Page 42: ...r brake cable handlebar j Select lever control cable 2 Select lever control cable 1 CABLE ROUTING 1SPEC1 1 Pass the speedometer cable upperthe wire harness at back ofthe ignition coil rnl Pass the rear brake cable right side of the starter motor If Pass the rear brake cable upper the fender stay 12 www midwestmanuals com ...

Page 43: ...e rear brake 1 Check Brake pedal height 13 Out of specification Adjust Brake pedal height 2 Adjust 5 mm 0 2 in Below the footrest Brake pedal height Adjustment steps Loosen the locknut CD Turn the adjuster in or out until the specified pedal height is obtained Turning in Pedal height is upper Turning out Pedal height is lower Tighten the locknut A WARNING After adjusting the brake pedal height ad ...

Page 44: ... in 14 4 Adjust Free play rear brake lever Free play brake pedal Rear brake lever and brake pedal free play adjustment steps NOTE Before adjusting the free play pump the brake pedal 2 to 3 times Fully loosen the brake LEVER cable ad juster drum CD Turn the rear brake PEDAL rod adjuster until the brake pedal free play is within the specified limits Free play brake pedal 20 30 mm 0 8 AI 1 2 in Fully...

Page 45: ...urn the brake LEVER cable adjuster handlebar until the free play brake lever pivot is within the specified limits Free play brake lever pivot 4 8 mm 0 16 0 31 in Tighten the locknut handlebar A 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 any brake drag is no...

Page 46: ...ability 1 Adjust Spring preload 16 Turn the adjuster CDto increase or decrease the spring preload Front shock absorber preload Preload Standard Stiffer 00 7 Position A B C D E REAR SHOCK ABSORBER ADJUSTMENT 1 Adjust Spring preload Turn the adjuster CDto increase or decrease the spring preload NOTE The spring preload of the rear shock ab sorber can be adjusted to suit rider s prefer ence weight and...

Page 47: ...e shoe Dust seal J Camshaft Plain washer a ring CHASSIS Brake shoe plate Adjuster Pin Compression spring Wear indicator plate Camshaft lever Brake rod Brake pedal Brake cable 17 A BRAKE LINING WEAR LIMIT 2 mm 0 08 in 8 BRAKE DRUM WEAR LIMIT 161 mm 6 34 in C APPLY YAMAHA BRAKE GREASE PIN 90793 40003 D APPLY SEALANT QUICK GASKET OR YAMAHA BOND NO 1215 www midwestmanuals com ...

Page 48: ... the suitable stand under the frame 3 Remove Adjuster brake lever and pedal CD Pins Compression springs 4 Disconnect Brake cable brake lever Brake rod brake pedal 5 Remove Rear wheel left Rear brake drum left Refer to FRONT AND REAR WHEELS 6 Remove O ring CD Plain washer Brake shoe Bearing retainer Breather hose Brake shoe plate 7 Remove Spring CD Camshaft lever Wear indicator plate Camshaft Plain...

Page 49: ...placing the brake shoes replace the brake shoe springs at the same time 19 3 lnspect Brake shoe lining surface Glazed areas t Remove Use a coarse sand paper NOTE After using the sand paper clean of the pol ished particles with cloth 4 Measure Brake shoe lining thickness Out of specification t Replace CD Measuring points NOTE Replace the brake shoes as a set if either is found to be worn to the wea...

Page 50: ... lacquer thinner or solvent Scratches Use an emery cloth lightly and evenly polishing INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Lubricate Camshaft CD Pivot pin 1 1Lithium soap base grease i iijililll l ljiill li _______ Install the camshaft and the pivot pin with lightly greased Wipe off the excess grease 2 Install Wear indicator plate CD NOTE When installing the wear ...

Page 51: ...rm Sealant quick gasket PIN ACC 11001 01 Yamaha bond No 1215 PIN 90890 85505 5 lnstall Brake shoe plate CD Bearing retainer Breather hose Brake shoe Plain washer O ring Bolt brake shoe plate 28 Nm 2 8 m kg 20 ft Ib 6 Check Camshaft operation Unsmooth operation 7 Repair 7 Apply Yamaha brake grease D to the dust seal Yamaha brake grease PIN 90793 40003 a lnstall Rear brake drum Rear wheel Refer to F...

Page 52: ..._ BR_A_K_E ICHASI I 9 Connect 22 Brake rod brake lever CD Brake cable brake pedal 10 lnstall Compression springs Pins Adjusters brake lever and pedal 11 Adjust Rear brake pedal free play Rear brake lever free play Refer to REAR BRAKE LEVER AND PEDAL ADJUSTMENT www midwestmanuals com ...

Page 53: ...sales midwestmanuals com www midwestmanuals com YAMAHA sales mid Jr IIIi T lrT1II www lmidwe stmanU3 s colm LIT 11616 08 99 www midwestmanuals com ...

Page 54: ...ta and a special tool are framed in a box preceded by a relevant symbol An encircled numeral indicates a part name and an encircled alphabetical letter data or an alignment mark 0 the others being indicated by an alphabetical letter in a box A condition of a faulty component will precede an arrow symbol and the course of action required the symbol EXPLODED DIAGRAM Each chapter provides exploded di...

Page 55: ...d is continually striving to improve all models manufactured by Yamaha Modifications and significant changes in specifications or procedures will be for warded to all Authorized Yamaha dealers and will where applicable appear in future editions of this manual PARTICULARV IMPORTANT INFORMATION This material is distinguished by the following notation A WARNING NOTE The Safety Alert Symbol means ATTE...

Page 56: ...overhaul Carburetion Drive train j Chassis Electrical Troubleshooting Illustrated symbols to are used to iden tify the specifications appearing in the text Filling fluid Lubricant Special tool Tightening Wear limit clearance Engine speed Q V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and loca tion of lubrication point Apply engine oil Apply gear oil Apply molybden...

Page 57: ...MBER 1 SPECiFiCATIONS 2 GENERAL SPECIFICATIONS 2 MAINTENANCE SPECIFICATIONS 2 ENGINE 2 CHASSIS 3 ELECTRICAL 4 CABLE ROUTING 5 PERIODIC INSPECTION AND ADJUSTMENT 10 CHASSIS 10 SELECT LEVER CONTROL CABLE ADJUSTMENT 10 DRIVE TRAIN 12 DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 12 CHASSIS 13 FRONT SHOCK ABSORBER AND FRONT ARMS 13 www midwestmanuals com ...

Page 58: ...fy your machine and may be used to register your machine with the licensing authority in your state Starting serial number JY43HNAO RA149101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the right side of the engine NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting serial number 3HN 149101 1 NO...

Page 59: ...old tire Off road riding Front Rear MAINTENANCE SPECIFICATIONS ENGINE Model Piston ring Sectional sketch Top ring B 2nd ring I DB I T I Oil ring B I T 1 YFM350FWF 3HN JY43HNAO RA149101 3HN 149101 1 915 mm 75 4 in 1 095 mm 43 1 in 1 130 mm 44 5 in 850 mm 33 5 in 1 210 mm 47 6 in 180 mm 7 1 in 269 kg 593 Ib 3 500 mm 137 8 in Steel tube frame 2 5 0 15 mm 0 59 in 5 15 mm 0 20 0 59 in 840 mm 33 1 in 82...

Page 60: ...plate Thickness Type A 1 5 1 7 mm 0 059 0 067 in Type B 1 9 2 1 mm 0 075 0 083 in Quantity Type A 4 Type 118 2 Warp limit 0 2 mm 0 008 in Clutch spring Free length 47 8 mm 1 88 in Quantity 5 Wear limit 46 5 mm 1 83 in Clutch release method Outer push Clutch in revolution 1 850 2 150 r min Clutch stall revolution 3 050 3 450 r min CHASSIS Model YFM350FWF Front suspension Cushion stroke 67 5 mm 2 66...

Page 61: ...tightened Parts Thread Q ty Tightening torque Remarks name size Nm mekg ftelb Select lever body and crankcase cover left front Bolt M6 2 12 1 2 8 7 Select lever body and f crankcase cover left rear Bolt M6 1 12 1 2 8 7 Select lever body and select lever cover Bolt M6 3 10 1 0 7 2 Rink shaft and control cable locknut Nut M6 1 7 0 7 5 1 Control cable bracket Bolt M10 1 35 3 5 25 Select lever transfe...

Page 62: ...Pass the throttle cable under Q Front brake breather hose the brake hose Clips Pass the bea ri ng housi ng Pass the throttle cable under breather hose along the back the handlebar of the brake hose Insert the breather hose into the II Attach the cliptothe brake hose hole ofthe handlebar protector grommet as shown in the Pass the speedometer cable illustration rear brake cable and throttle cable in...

Page 63: ...ch lead Thermo switch 0 41 COl magneto lead Oil cooler hose Select lever control cable 1 Differential gear case breather hose Handlebar protector Clamp the starter motor cable and battery breather hose 6 Pass the final gear case breather hose into the holder g Pass the hoses into the holes Left side Carburetor breather hose Differential gear case breather hose Final gear case breather hose Front b...

Page 64: ...D Clamp 1 Main switch Band Ignition coil Speedometer cable CABLE ROUTING ISPECI ffI Front brake switch lead f Handlebar switch lead COl unit Auxiliary D C terminal Headlight 7 J Do not pinch the hoses when install the fuel tank www midwestmanuals com ...

Page 65: ...lay Neutral relay Reverse relay Band 6 5 CABLE ROUTING ISPEcl II Carburetor breather hose j Fuse Select lever control cable 2 Speedometer cable Wireharness 8 Clamp the taillight lead Pass the taillight lead into the slit g Connect the taillight leads in the lid of the taillight box www midwestmanuals com ...

Page 66: ...ear brake cable handlebar j Select lever control cable 2 Select lever control cable 1 9 CABLE ROUTING ISPECI yI Pass the speedometer cable upper the wire harness at back of the ignition coil Pass the rear brake cable right side of the starter motor Pass the rear brake cable upper the fender stay www midwestmanuals com ...

Page 67: ...Refer to REAR BRAKE LEVER AND PEDAL ADJUSTMENT section in chapter 2 Select lever control cables adjustment steps Control cable 2 Make sure that the select lever is LOW Adjust the control cable 2 so there is zero free play in the cable When the adjustment is correct slack in the return spring CD will be taken up NOTE In some cases it will be necessary to further adjust the cable with the locknuts a...

Page 68: ... cam 2 so the clevis pin slips easily through both the eyes and arm With the clevis pin removed carefully tighten the locknuts Verify that the clevis pin still slips through easily and with a silicone lubricant lightly lubricate the clevis pin and install it and the hitch pin Tighten the locknuts Locknuts control cable 1 25 Nm 2 5 m kg 18ft Ib Slide the dust bellows on the control cable in both di...

Page 69: ...r Collapsible collar Spacer Front drive gear Front drive gear shim Differential gear case Thrust washer 64 Nm 6 4 m kg 46 ft Ib A DIFFERENTIAL OIL Ring gear Differential gear assembly Ring gear shim Bearing housing ring gear Ring gear stopper Locknut TOTAL AMOUNT B 0 5 L 0 44 Imp qt 0 53 US qt GEAR LASH D 0 10 0 35 mm 0 004 0 014 in 23 Nm 2 3 m kg 17ft lb TYPE C SAE 80 API GL 4 HYPOID GEAR OIL STA...

Page 70: ...BER AND FRONT ARMS ICHASI dYOl CHASSIS FRONT SHOCK ABSORBER AND FRONT ARMS CD Bushing Front shock absorber Upper arm Lower arm Boot protector 45 Nm 4 5 m kg 32 ft Ib 45 Nm 4 5 m kg 32 ft Ib 45 Nm 4 5 m kg 32 ft Ib CD 48 Nm 4 8 m kg 35 ft Ib 13 www midwestmanuals com ...

Page 71: ...sales midwestmanuals com www midwestmanuals com YAMAHA TOR CO LTD PRINTED IN U S A www midwestmanuals com ...

Page 72: ...sales midwestmanuals com www midwestmanuals com _YAMAHA LIT 11616 07 58 sales mid wes www lmidwestmanuas com www midwestmanuals com ...

Page 73: ...tment Engine Carburetion Drive train j Chassis Electrical Troubleshooting Illustrated symbols to are usedto identify the specifications appearing in the text Filling fluid QJ Lubricant Special tool Tightening Wear limit clearance Engine speed a V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and location of lubrication point Apply licking agent LOCTITE Apply engine o...

Page 74: ...RTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation AWARNING NOTE MANUAL FORMAT The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED FailuretofollowWARNING instructions could resultin severe ordeathtothe machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be take...

Page 75: ...ON VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER SPECIFICATIONS 2 GENERAL SPECIFICATIONS 2 MAINTENANCE SPECIFICATIONS 2 CHASSIS 2 ELECTRiCAL 3 CABLE ROUTING 4 PERIODIC INSPECTION AND ADJUSTMENT 9 INTRODUCTION 9 PERIODIC MAINTENANCE LUBRICATION 9 YFM350FWB WIRING DIAGRAM www midwestmanuals com ...

Page 76: ...tarting Serial Number JV43HNWO MC048101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the right side of the engine OTE ________________________ The first three digits of these numbers are for model identifications the remaining digits arethe unit production number Starting Serial Number 3HN 048101 1 NOTE ________________________ Designs and specifications are subject to change w...

Page 77: ...and transfer gear oil with oil filter replacement Total Amount Rear Final Gear Case Total Amount Fuel Type Tank Capacity Reserve Amount MAINTENANCE SPECIFICATIONS CHASSIS Model Front Suspension Cushion Stroke Suspension Spring Free Length Limit Fitti ng Length Spring Rate Stroke K1 Optional Spring YFM350FWB 3HN6 JY43HNWO MC048101 3HN 048101 267 kg 589 Ib Yamalube 4 SAE10W30SE SF motor oil or SAE20...

Page 78: ...acturer MS5D 191 HITACHI Amperage Rating 100A Coil Winding Resistance Color 3 9 4 70 at 20 C 68 F R w L W Starting Circuit Cut off Relay Model Manufacturer ACA1211 9 MATSUSHITA Coil Winding Resistance 72 880 at 20 C 68 F Neutral Relay Model Manufacturer ACA1211 9 MATSUSHITA Coil Winding Resistance 72 88n at 20 C 68 F Reverse Relay Model Manufacturer ACA2211 3 MATSUSHITA Coil Winding Resistance 72 ...

Page 79: ...ABLE ROUTING SPECI ofl l Clip QD Brake pipe Breather hose front brake Clamp Indicator lights lead 00 Pass the cable under the handlebar throttle cable under the brake hose fi Insert the breather hose into the hole of the handlebar protector Q Pass the speedometer cable rear brake cable and throttle cable in order from the inside Q Pass the throttle cable under the brake hose I 8 11Ifl it i 9 4 www...

Page 80: ...ad breather hose Ground lead Breather hose front brake Final gear case breather hose Clip Battery breather hose Earth lead COl unit Carburetor over flow hose Handlebar protector 5 A Clamp the starter motor cable and battery breather hose I Pass the final gear case breather hose the clamp Q Pass the hoses into the holes Left side Carburetor breather hose Differential gear case breather hose Right s...

Page 81: ... CD Clamp Main switch Band Ignition coil Speedometer cable Front brake switch lead j Handlebar switch lead Earth lead COl unit COl unit Headlight g 6 CABLE ROUTING ISPECI ffl A Do not pinch the hoses when install the fuel tank www midwestmanuals com ...

Page 82: ...or Starting circuit cut off relay Neutral relay Reverse relay OIL TEMP indicator light checker Band J Carburetor breather hose Fuse Select lever control cable 2 CABLE ROUTING IAJ Clamp the taillight lead ru Pass the taillight lead into the slit 7 www midwestmanuals com ...

Page 83: ...lect lever control cable 1 Reverse lock release wire Rear brake cable Handlebar Select lever control cable 2 8 CABLE ROUTING ISPECI ffl A Pass the speedometer cable copper the wire harness at back of the ignition coil Pass the rear brake cable right side of the starter motor QJ Pass the rear brake cable upper the fender stay www midwestmanuals com ...

Page 84: ... 0 0 Fuelline Check fuel hose for cracks or damage Replace if necessary 0 0 0 Engine oil Replace Warm engine before draining Transfer gear oil 0 0 0 0 Engine oil filter Clean Replace if necessary 0 0 0 0 Engine oil strainer Clean 0 0 0 Final gear oill Check oillevelloilleakage Differential gear oil Replace every 12 months 0 0 Front brake Check operation fluid leakage See NOTE Correct if necessary ...

Page 85: ...ing the master cylinder or wheel cylinder replace the fluid Normally check the brake fluid level and add the fluid as required 2 On the inner parts of the master cylinder and wheel cylinder replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged Recommended brake fluid DOT 4 If DOT 4 is not available 3 can be used 10 www midwestmanuals com ...

Page 86: ...RSE indatorlfght GIV FlEE R h PUSH y GJV II J lI 0 11 0 Rectifior Rogul_ SurtiAll_it ClJI ff 1ov Noutn relov R_reIov I Sb G r GJ f Sb wta Br T iUight L L D ll LJ 8 t CJ t D 0 I I COLOR CODE B Black Y Yellow L Blue R Red G Green p Pink O Orange Br Brown Gy Gray Sb Skyblue W White B R Black Red B W Black White Y B Yellow Black LIW Blue White R W Red White G Y Green Yellow GIL Green Blue GfR Green Re...

Page 87: ... l II W1L NEUTRAL rn 1l f lI 8 indicator light J I 5b 5b r tI 1It 1 I REVERSE f n t 1 indicator light I O Gll OIY switch R O y Rear brake M G Y 0 11 COl magneto LtJFUse 9 I I 9 Taillight l L lI LJ s C c CJ COLOR CODE B Black Y Yellow L Blue R Red G Green N tr I J IReverse switch SWitch lfJ LfJ p Pink o Orange Sr Brown Gy Gray Sb Sky blue W White B R Black Red B w Black White Y B Yellow Black l W B...

Page 88: ...sales midwestmanuals com www midwestmanuals com YAMAHA sales mi anuails com www lmidwestmanu3 s com LIT 11616 07 02 3HN 28197 11 www midwestmanuals com ...

Page 89: ...LV IMPORTANT INFORMATION This material is distinguished by the following notation AWARNING NOTE MANUAL FORMAT The Safety Alerit Symbol means ATTENTION BECOME ALERTI YOUR SAFETYISINVOLVEDI Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must ...

Page 90: ... VEHICLE IDENTIFICATION NUMBER 1 ENGINE SERIAL NUMBER 1 SPECIFICATIONS 2 GENERAL SPECIFICAtiON 2 MAINTENANCE SPECIFICATION 2 ELECTRICAL 2 PERIODIC INSPECTION AND ADJUSTMENT 3 REAR BRAKE LEVE R AND PEDAL ADJUSTMENT 3 ELECTRICAL 6 YFM350FWA CIRCUIT DIAGRAM 6 YFM350FWA WIRING DIAGRAM www midwestmanuals com ...

Page 91: ...ame Starting Serial Number JY43HNWO LC023101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the right side of the engine NOTE _____________ The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting Serial Number 3HN 023101 NOTE _________________________ Designs and specifications are subject to change withou...

Page 92: ...Model COl Magneto Model Manufacturer Pickup Coil Resistance Color Source Coil Resistance Color COl Unit Model Manufacturer Ignition Coil Model Manufacturer Minimum Spark Gap Primary Winding Resistance Secondary Winding Resistance YFM350FWA 3HN JY43HNWO LC023101 3HN 023101 264 kg 582 Ib Tubeless AT25 x 8 12 DUNLOP KT951 B AT25 x 10 12 DUNLOP KT955B YFM350FWA F3T43573 MITSUBISHI 170 210U at 20 C 68 ...

Page 93: ...dal Height 5 mm 0 2 in Below the Footrest Top End Tighten the locknut 2 Adjust Free play Rear brake lever Free play Brake pedal Step for rear brake lever and brake pedal free play adjustment NOTE _________________________ Before adjusting the free plays pump the brake pedal 2 to 3 times Fully loosen the brake lever cable adjuster Handlebar CD Fully loosen both brake lever cable adjuster Caliper an...

Page 94: ...h the locknut Turn the brake pedal cable adjuster clock wise until the gap is within the specified limits Gap 0 1 mm 0 0 04 in Brake caliper lever Pin AWARNING After this adjustment is performed lift the front and rear wheels off the ground by the placing under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again elnspect t...

Page 95: ...ER AND PEDAL ADJUSTMENT 8 r11l iil1 5 Inspect the gap free play is within the specified limits at the handlebar lever and brake caliper lever If not perform the aforementioned step again Gap Free Play 4 5 mm 0 16 0 20 in Brake caliper lever www midwestmanuals com ...

Page 96: ...manuals com CIRCUIT DIAGRAM IELECI iiiiii I ELECTRICAL YFM350FWA CIRCUIT DIAGRAM B J B W t 0 B a B B BIW B J Br B W il Br r w Br R W Br 1 I Y B f B r r Br B 1 r Br __ GIL W B G Y I t y t Br fI G WIL Y G Y G Br B B 6 www midwestmanuals com ...

Page 97: ...Oil temperature indicator light checker Thermo switch COLOR CODE B Black B W Black White R Red R W Red White L Blue B R Black Red Y Yellow L W Blue White G Green G L Green Blue O Orange G Y Green Yellow W White G R Green Red Br Brown Y B Yellow Black P Pink W B White Black Gy Gray WIG White Green Sb Sky blue W L White Blue j Reverse switch Neutral relay Neutral switch LlGHTS Dimmer switch ijTailli...

Page 98: ... fl t t F indicator light I GIL n J U GIL GIV itch FR GIV Rear brake sw G v 11 0 Neutral relay Starting circuit I cut off relay Reverse relay Rectifier Regulator COl magneto L fJFUse I I I 1 Taillight L c J JI L D lI L o C U J I I b rhlReverse switch sWitch lfJ lfJ COLOR CODE B Black Y Yellow L Blue R Red G Green p Pink o Orange Br Brown Gy Gray Sb Sky blue W White BIR Black Red BIW BlacklWhite Y ...

Page 99: ...sales midwestmanuals com www midwestmanuals com YAMAHA TOR CO LTD PRINTED IN U S A www midwestmanuals com ...

Page 100: ...sales midwestmanuals com www midwestmanuals com _YAMAHA LIT 11616 06 66 saJes mi 1 A1 lJ TIrT1 www lmidwestmanu3 s com www midwestmanuals com ...

Page 101: ... MOTOR CO LTD HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation NOTE WARNING A NOTE provides key information to make procedures easier or clearer A CAUTION indicates special procedures that must be followed to avoid damage to the machine A WARNING indicates special procedures that must be followed to avoid injury to a machine operato...

Page 102: ...ATION j 1 VEHICLE IDENTIFICATION NUMBER 1 ENGINE SERIAL NUMBER 1 SPECIAL TOOLS 2 FOR CHASSIS SERVICE 2 CHASSIS 0 3 FRONT SRAKE 3 REMOVAL j i 4 INSTALLATION 4 REAR AXLE 5 INSTALLATION 5 APPENDICES 6 SPECI FICATIONS I j 6 GENERAL SPECIFICATIONS 6 MAINTeNANCE SPECIFICATIONS j B www midwestmanuals com ...

Page 103: ...rame Starting Serial Number JY43HNAO K000101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the right side of the engine NOTE _____________ The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting Serial Number 3HN 000101 NOTE __________________________ Designs and specifications are subject to change witho...

Page 104: ... com SPECIAL TOOLS I EF lcfeel SPECIAL TOOLS The following shows only the difference s from the YFM350FWT FOR CHASSIS SERVICE 1 Rear axle nut wrench PIN YM 37132 This tool is used to loosen and tighten the Nut Rear axle 2 www midwestmanuals com ...

Page 105: ...BRAKE CDBacking plate Pin Brake shoe Brake shoe set d Brake shoe Hol er Brake seal Brake drum l Blind Plu g Wh el cylinder Adjuster e _____ Iii Wheel cylinder 9 Lock spnn Cupset Piston Bleed s rew set j Brake pipe FRONT BRAKE FH I 3 www midwestmanuals com ...

Page 106: ...wise foreign materials will damage the brake seal with the resultant loss of the brake performance INSTALLATION The following shows only the difference s from the YFM350FWT 4 10 Inspect Brake seal CD Damage Replace 11 Apply Yamaha Brake Grease 90793 40003 To the seal on the backing plate 12 Install Brake drum NOTE _________________________ Before installing the brake drum arrange for each part to ...

Page 107: ...the inside nut with Rear Axle Nut Wrench to specification while holding the rear axle Rear Axle Nut Wrench YM 37132 Inside Nut First Tightening 55 Nm 5 5 m kg 40 ft lb Hold the inside nut CV and tighten the outside nut CD with Rear Axle Nut Wrench to specification Outside Nut 190 Nm 19 0 m kg 140 ft Ib Draw the line on inside and outside nut Hold the outside nut CD and tighten BACK the inside nut ...

Page 108: ...Level F L Float Height F H Engine Idling Speed Chassis Model Rear Suspension Cushion Stroke Suspension Spring Free Length Limit Fitting Length Spring Rate Stroke Kl K2 SPECIFICATIONS IAPPXI I APPENDICES YFM360FWW 3HN1 JY43HNAO KOO0101 3HN 000101 4 stroke Air cooled SOHC Single cylinder Forward inclined 348 cm3 83 0 x 64 5 mm 3 268 x 2 539 in 8 6 1 834 kPa 8 5 kg cm2 121 psi Electric starter YFM350...

Page 109: ...Nut M40 x 1 5 2 See NOTE NOTE ______________________________ 1 Apply LOCTITE to the thread portion of the rear axle 2 Finger tighten the inside nut while checking the ring gear engagement 3 Tighten the inside nut to 55 Nm 5 5 m kg 40 ft Ib while holding the rear axle 4 HOld the inside nut and tighten the outside nut to 190 Nm 19 0 m kg 140 ft Ib 5 Hold the outside nut and tighten back the inside n...

Page 110: ...sales midwestmanuals com www midwestmanuals com YAMAHA TOR CO LTD PRINTED IN U S A www midwestmanuals com ...

Page 111: ...nt if your model or year requires a supplement This manual is fully searchable just hold down the control key and the F key to search on any word If you bought this manual from any other seller they are reselling my work Please leave them negative feedback email me at sales midwestmanuals com Our goal is to be one of the BEST sellers on eBay and the internet by providing you with the BEST customer...

Page 112: ...westmanuals com www midwestmanuals com INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE CARBURETION DRIVE TRAIN CHASSIS ELECTRICAL APPENDICES ENG D DRIV iii ELEC APPX www midwestmanuals com ...

Page 113: ... Cooling system Carburetion Drive train j Chassis Electrical Appendices Illustrated symbols to are used to iden tify the specifications appearing Filling fluid CO Lubricant Tightening Wear limit clearance Engine speed n V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and location of lubrication point Apply locking agent LOCTITE Apply engine oil Apply gear oil Apply m...

Page 114: ...FORMATION 1 2 ALL REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 2 CI RCLIPS 1 3 SPECIAL TOOLS 1 3 FOR TUNE UP 1 3 FOR ENGINE SERViCE 1 4 FOR MIDDLE GEAR SERViCE 1 7 FOR FINAL GEAR SERVICE 1 8 FOR DIFFERENTIAL GEAR SERVICE 1 8 FOR CHASSIS SERVICE 1 9 FOR ELECTRICAL COMPONENTS 1 9 www midwestmanuals com ...

Page 115: ...may be used to register you r machine with the licensing autho rity in your state Starting Serial Number JV42HROO HC000101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the right side of the engine NOTE ___________________________ The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting Serial Number 2HR 0...

Page 116: ...ating parts and bearings during reassembly Apply grease to the oil seal lips LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates CD and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been pro perly tightened BEARINGS AND OIL SEALS 1 Install the bearing s CD and oil seal s with their manufacturer s marks ...

Page 117: ... See the sectional view Shaft SPECIAL TOOLS The proper special tools are necessary for com plete and accurate tune up and assembly Using the correct special tool will help prevent damage caused by the use of improper tools or impro vised techniques FOR TUNE UP 1 Inductive Tachometer PIN YU 08036 This tool is needed for detecting engine rpm 2 Inductive Timing Light PIN YM 33277 This tool is necessa...

Page 118: ...ool PIN YM 08035 This tool is necessary for adjusting the valve clearance FOR ENGINE SERVICE 1 Valve Spring Co pressor PIN YM 04019 This tool is needed to remove and install the valve assemblies 2 Slide Hammer Set PIN YU Ol083 These tools are used when removing the rocker arm shaft 3 Flywheel Puller PIN YM 01404 This tool is used to remove the CDI rotor 1 4 www midwestmanuals com ...

Page 119: ...alve Guide Reamer 7 0 mm PIN YM 01227 This tool is used to rebore the new valve guide 6 Valve Guide Installer 7 0 mm PIN YM Q4017 This tool is needed to install the valve guides properly 7 Valve Seat Cutter Set PIN YM 91043 This tool is needed to resurface the valve seat 8 Piston Pin Puller PIN YU 01304 This tool is used to remove the piston pin www midwestmanuals com ...

Page 120: ...t Quick Gasket PIN ACC 11001 05 01 This sealant bond is used for crankcase mating surfaces etc 11 Crankshaft Installer Set PIN YU 90050 These tools are used to install the crankshaft 12 Adapter 12 PIN YM 1383 CD Spacer PIN YM 91044 These tools are used to install the crankshaft 13 Middle Drive Shaft Nut Wrench PIN YM 04054 This tool is used to install the buffer boss 1 6 www midwestmanuals com ...

Page 121: ...ten the drive axle bearing retainer bolt 16 25 Torx Driver PIN YU 298434 This tool is used to loosen or tighten the shift cam segment securing bolt 17 Crankcase Separating Tool PIN YU 01135 CD Flywheel Puller Attachment PIN YM 01382 These tools are used when removing the crank shaft FOR MIDDLE GEAR SERVICE 1 Universal Joint Holder PIN YM 04062 CD Attachment PIN YM 33291 These tools are used to rem...

Page 122: ...sed to measure the gear lash for the middle gear and final gear FOR FINAL GEAR SERVICE 1 Final Drive Shaft Bearing Retainer Wrench PIN YM 33214 This tool is used to remove and install the final gear bearing retainer 2 Gear Lash Measurement Tool PIN YM 01230 This tool is used to measure the gear lash FOR DIFFERENTIAL GEAR SERVICE 1 Dial Gauge For Lever Type PIN YM 03110 This tool is used to measure...

Page 123: ...t 2 Damper Rod Holder PIN YM 01327 This tool is used to remove and install the bear ing retainer for the steering shaft holder bearing FOR ELECTRICAL COMPONENTS 1 Electro Tester PIN YU 33260 CD This instrument is necessary for checking the ignition system components 2 Pocket Tester PIN YU 33263 or PIN YU 03112 This instrument is invaluable for checking the eJectrical system www midwestmanuals com ...

Page 124: ...ID LEVEL INSPECTION 2 16 FRONT BRAKE LINING INSPECTION 2 17 FRONT BRAKE ADJUSTMENT 2 17 REAR BRAKE LEVER AND PEDAL ADJUSTMENT 2 20 REAR BRAKE PADS INSPECTION 2 22 CLUTCH ADJUSTMENT 2 22 SELECT LEVER CONTROL CABLE ADJUSTMENT 2 22 STEERING SYSTEM INSPECTION 2 24 REAR SHOCK ABSORBER ADJUSTMENT 2 25 CABLE INSPECTION AND LUBRICATION 2 26 LEVERS PEDAL ETC LUBRICATION 2 26 TIRES CHECK 2 26 WHEELS CHECK 2...

Page 125: ...el line Check fuel hose for cracks or damage 0 0 0 Replace if necessary Engine oil Replace Warm engine before draining 0 0 0 0 Transfer gear oil Engine oil filter Clean 0 0 0 Engine oil strainer Clean 0 0 0 Final gear oil Check oil level oil leakage 0 0 Differential gear oil Replace every 12 months Front brake Check operation fluid leakage See NOTE 0 0 0 0 0 Correct if necessary Rear brake Check o...

Page 126: ...assembiing the master cylinder or wheel cylinder replace the fluid Normally check the brake fluid level and add the fluid as required 2 On the inner parts of the master cylinder and wheel cylinder replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged Recommended brake fluid DOT 4 If DOT 4 is not available 3 can be used 2 2 www midwestmanuals com ...

Page 127: ... ___________________________ After removing the tank cover install the tank cap on the fuel tank WARNING GASOLINE IS HIGHLY FLAMMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the engine or exhaust system Never refuel in the vicinity of an open flame or while smoking GASOLINE CAN CAUSE INJURY If you should swallow some gasoline inhale excess gasoline vapors ...

Page 128: ...e clearance measurement steps Turn the starter pu lJey counterclockwise with recoil starter NOTE Valve clearance must be measured when the engine is cold to touch AI ign the liT mark CD on the flywheel with the stationary pointer on the crankcase cover When the liT mark is al igned with the stationary pointer the piston is at Top Dead Center TDC Measure the valve clearance using a Feeler Gauge Out...

Page 129: ...mm 0 006 0 008 in Hold the adjuster to prevent it from moving and thoroughly tighten the locknut Valve Clearance Adjusting Locknut 20 Nm 2 0 m kg 14 ft lb Measure the valve clearance If the clearance is incorrect repeat above steps until the proper clearance is obtained Installation When installing the tappet covers reverse the removal procedure Note the following points 1 Install Tappet cover Exh...

Page 130: ...e fuel tank breather hose CD into the handlebar protector hole CID Refer to CABLE ROUTING section 4 Install eSeat NOTE __________________________ Insert the lobes on the seat front into the re ceptacles on the frame then push down the seat at the rear IDLE SPEED ADJUSTMENT 1 Adjust eldle speed Warm up the engine and turn the throt tie stop screw CD to adjust Idle Speed 1 350 1 450 r min THROTTLE L...

Page 131: ...at the adjusters and locknuts CD on the carburetor side are fully tightened Loosen the locknut Turn the adjuster clockwise or counter clockwise until proper free play is attained Tighten the locknut SPEED LIMITER ADJUSTMENT The speed limiter keeps the carburetor throt tle from becoming full open even when the throttle grip is turned to a maximum Screw ing in the adjuster stops the engine speed fro...

Page 132: ...per throttle lever operation do not turn out the adjuster more than 12 mm 0 47 in Also adjust the throttle lever free play always to 3 5 mm 0 12 0 20 in FUEL LINE INSPECTION 1 Inspect Fuel hose CD Cracks Damage Replace AIR FILTER CLEANING NOTE __________________________ There is a check hose CD at the bottom of the air filter case If dust and or water collects in this hose clean the air filter ele...

Page 133: ...r use low flash point solvents such as gasoline to clean the air filter element Such solvent may lead to a fire or explosion 4 Inspect Element Damage Replace 5 Apply SAE 10W30 motor oil 6 Squeeze out the excess oil NOTE __________________________ The element should be wet but not dripping 7 Apply All purpose grease To the air filter seat S Install Air filter element To the element guide 9 Install ...

Page 134: ...k and inspect the oil level whether or not it is between maximum and minimum level If the level is lower add the oi I up to the proper level ENGINE OIL TRANSFER GEAR OIL RE PLACEMENT Engine Oil Transfer Gear Oil Replacement Without Oil Filter Change 1 Place the mac 1ine on a level place 2 Remove Engine guards Center and rear CD 3 Warm up the engine for several minutes and stop it 4 Place the oil p...

Page 135: ... forget to fit the a ring com pression spring and oil strainer 9 Fill Drain Plug Crankcase 32 Nm 3 2 m kg 23 ft lb Drain Plug Transfer Gear Oil 20 Nm 2 0 m kg 14 ft lb Engine Recommended Oil SAE 10W40 Type SE Motor Oil 0 10 30 50 70 gOOF SAE 10W30 type SE motor oil SAE 10W40 type SE motor oil Yamaha 4 cycle oillor I SAE 20W40 type SE motor oil 20W50 SAE 5W30 type SE motor oil 20 10 0 10 20 30 C Pe...

Page 136: ...en the oil gallery bolt CD in the cylinder head Start the engine and keep it idling until oil begins to seep from the oil gallery bolt If no oil comes out after one minute turn the engine off so it will not seize Restart the engine after solving the prob lem s and recheck the oil pressure Tighten the oil gallery bolt to specification Oil Gallery Bolt 7 Nm 0 7 m kg 5 1 ft lb Engine Oil Transfer Gea...

Page 137: ... Oil filter element Clean it with solvent 5 Inspect O rings CD Oil filter element Damage jo Replace 6 Install Component in above list Steps 3 2 7 Apply Sealant Quick Gasket ACC ll00l 05 01 To the thread portion of the filter cover bolts 8 Tighten Bolts Filter cover Bolt Change bolt Screw Clamp Bolts Filter Cover 10 Nm 1 0 m kg 7 2 ft lb a Bolts Change Pedal 10 Nm 1 0 m kg 7 2 ft lb Screw Clamp 7 N...

Page 138: ..._______________________ Insufficient compression pressure will result in performance loss 1 Measure Valve clearance Out of specification Adjust 2 Warm up the engine and stop it 3 Remove Spark plug 4 Measure Compression pressure Compression pressure measurement steps 1nstall the Compression Gauge CD YU 33223 Crank over the engine with the electric starter be sure the battery is fu lIy charged with ...

Page 139: ...1 Squ irt a few drops of oil into the affected cylinder 2 Measure the compression again Compression Pressure with oil introduced into cylinder Reading Diagnosis Higher than without oil Worn or damaged pistons Defective ring s valves Same as without oil cylinder head gasket or piston is possible Above maximum level Inspect cylinder head valve surfaces or piston crown for carbon deposit www midwestm...

Page 140: ...6 Install Components in above list Steps 1 3 and 2 NOTE Be careful not to clamp the fuel cock too tightly as this may unseat the O ring and gasket and lead to a fuel leak FRONT BRAKE FLUID LEVEL INSPECTION 1 Inspect Brake fluid level Master cylinder Level low Replenish fluid CD Lower level NOTE __________________________ Spilled fluid is cleaned up immediately to prevent painted surfaces or plasti...

Page 141: ...ove Rubber plug CD 2 Inspect Brake lining thickness Out of specification i Replace Brake Lining Thickness 4 mm 0 16 in Wear Limit 1 mm 0 04 in Measuring points NOTE __________________________ Replace the brake shoes as a set if either is found to be worn to the wear limit FRONT BRAKE ADJUSTMENT NOTE __________________________ Before adjusting the front brake the front brake lining should be inspec...

Page 142: ...nut Turn the adjuster CD until the brake lever free play is within the specified limits Free Play Just Before Adjuster Contacts Master Cylinder Piston iW 3 5 mm O 12 0 20 in Tighten the locknut 3 Check Free play Just before brake is actually apply Out of specification Adjust Free play Just before brake is actually apply checking steps Place the machine on level place Lift the front and rear wheels...

Page 143: ...the direction shown by the arrow until the front brake locks Turn back the adjuster CD THREE CLCKS and squeeze the brake lever several times Turn the wheel 180 0 and carry out the same adjustment on the other adjuster on the same wheel Make sure there is no brake drag Adjust the other front brake on the opposite wheel Recheck the front brake free play Proper lever free play is essential to avoid e...

Page 144: ...adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake 1 Adjust Pedal height Brake pedal height adjustment steps Loosen the locknut CD Turn the adjuster until the pedal height is within the specified limits Pedal Height 5 mm 0 2 in Below the Footrest Top End Tighten the locknut 2 Adjust Free play Rear brake lever Free play Brake pedal Step for rear brake lever and b...

Page 145: ...t lb When tightening the locknut hold the adjusting bolt with a spanner so that the adjusting bolt is not turned together with the locknut Turn the brake pedal cable adjuster clock wise until the gap is within the specified limits Gap 0 1 mm 0 0 04 in Brake caliper lever Pin WARNING After this adjustment is performed lift the front and rear wheels off the ground by the placing under the engine and...

Page 146: ...o use Replace pads as a set CLUTCH ADJUSTMENT 1 Adjust Free play Clutch free play adjustment steps Loosen the locknut CD Slowly turn the adjuster counterclock wise until resistance is felt Turn it 1 8 clockwise NOTE ________________________ Turn the adjuster counterclockwise to decrease the clutch free play and turn it clockwise to increase the free play Tighten the locknut Clutch Locknut 15 Nm 1 ...

Page 147: ...ust taken up NOTE ____________ In some cases it will be necessary to further adjust the cable with the locknuts arrange ment that holds the cable to its mount Verify that the select lever cannot be shifted to REVE RSE without operating the brake pedal While operating the brake pedal make sure the control cable has at least 5 mm 0 2 in travel Control Cable 1 Make sure that the select lever in LOW R...

Page 148: ...nd verify that the brake pedal must be pressed before REVE RSE can be engaged Make sure there is a positive action as another range is engaged Unsually a distinct Click can be heard if engagement is positive STEERING SYSTEM INSPECTION 1 Place the machine on a level place 2 Check Steering assembly bushir 1gs Move the handlebar up and down and or back and forth Excessive play Replace the steering sh...

Page 149: ...nd or wheel bearings REAR SHOCK ABSORBER ADJUSTMENT 1 Adjust Spring preload NOTE ___________________________ The spring preload of the rear shock absorber can be adjusted to suit rider s preferance weight and the course conditions Spring preload adjustment steps Adjust the spring preload with the spring seat CD using the water pump pliers Stiffer 7 Increase the spring preload Raise the spring seat...

Page 150: ...tor Oil LEVERS PEDAL ETC LUBRICATION 1 Lubricate Pivot points Yamaha Chain and Cable Lube or SAE 10W30 Motor Oil TIRES CHECK WARNING This model is equipped with low pressure tires It is important that they be inflated correctly and maintained at the proper pressures TI RE CHARACTERISTICS 1 Tire characteristics influence the handling of ATV s The tires listed below have been approved by Yamaha Moto...

Page 151: ...e load limits 110 kg 240 Ib Total weight of cargo trailer hitch vertical load rider and accessories 2 When using this machine under 16 km h 10 mi h this load limit can be increased to 150 kg 330 Ib 3 Front carrier If so equipped 15 kg 33 Ib 4 Rear carrier 45 kg 100 Ib 5 Storage box 2 kg 4 4 Ib 6 Trailer hitch Horizontal load 300 kg 660 Ib Total weight of trailer and cargo Vertical load 15 kg 33 Ib...

Page 152: ...y cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires 2 Inspect Tire surfaces Wear Damage Replace Tire Wear Limit Front and Rear 3 0 mm O 12 in WARNING It is dangerous to ride with a wornout tire When a tire wear is out of specification replace the tire immediately WHEELS CHECK...

Page 153: ... not to allow foreign material to enter the final gear case Tighten the oil filler cap Oil Filler Cap Final Gear Case 23 Nm 2 3 mo kg 17 ft lb FINAL GEAR OIL DIFFERENTIAL GEAR OIL REPLACEMENTS 1 Place the oil pans under the final gear case and differential gear case 2 Remove Oil filler caps Final gear case and differen tial gear case Drain plug Final gear case CD Drain plug Differential gear case ...

Page 154: ...qt 0 53 US qt Recommended Oil Final Gear Oil and Differential Gear Oil SAE 80 API GL 4 Hypoid Gear Oil If desired an SAE 80W90 Hypoid gear oil may be used for all conditions WARNING Take care not to allow foreign material to enter the final gear case and differential gear case 5 Install Oil filler caps Final gear case and differen tial gear case Oil Filler Caps Final Gear Case and Differential iii...

Page 155: ...icated on the flywheel Incorrect Check flywheel and or pick up assembly tightness and or damage Refer to CHAPTE R 7 ELECTR ICAL for further information BATTERY INSPECTION 1 Inspect e Battery flu id level Battery fluid level low Fill Fluid level should be between upper CD and lower CV level marks Normal tap water contains minerals wh ich are harmful to a battery therefore refill only with distilled...

Page 156: ...carrier Battery 3 Inspect Battery flu id specific gravity Out of specification Charge Charging Current 1 4 Amps 10 Hrs Specific Gravity 1 280 at 20 C 68 F 4 Install Battery 5 Connect Inspect Battery breather hose CD Be sure the hose is properly attached and routed Clamp the starter motor cable and battery breather hose When inspecting the battery be sure the breather hose is routed correctly If th...

Page 157: ...EA N G K or X24ES U N D For Canada DRSES L N G K 4 Measure Spark plug gap Out of specification Regap Use awi re gauge Spark Plug Gap 0 6 0 7 mm 0 024 0 028 in 5 Tighten Spark plug NOTE ___________________________ Before installing a spark plug clean the gasket surface and plug surface Spark Plug 17 5 Nm 1 75 m kg 12 5 ft lb NOTE __________________________ If a torque wrench is not available when y...

Page 158: ...clockwise to release bulb WARNING Keep flammable products or your hands away from the bulb while it is on it will be hot Do not touch the bulb until it cools down 3 Install eBulb New Secure the new bulb with the bulb holder 4 Install e Headlight cover HEADLIGHT BEAM ADJUSTMENT 1 Adjust e Headlight beam Vertically Vertical Adjustment Higher Turn the adjusting screw CD clockwise Lower Turn the adjus...

Page 159: ...stem damage and possibly a fire Description Amperage Quantity Main 30A 1 Reserve 30A 1 CIRCUIT BREAKER INSPECTION 1 Remove Rear fender 2 Inspect Circu it breaker CD Circuit breaker inspection steps Turn off the ignition switch and switch in the circuit in question Push in the breaker knob Wait 30 seconds before resetting the circu it breaker Turn on the switches and see if the electrical device op...

Page 160: ...HEAD AND CYLINDER 3 11 PISTON 3 14 CRANKCASE COVER LEFT 3 14 CDI ROTOR 3 15 CAM CHAIN AND OIL PIPE 3 15 CRANKCASE COVER RIGHT 3 16 CLUTCH 3 16 BALANCER DRIVE AND DRIVEN GEARS 3 18 OIL PUMP AND SHIFTER 3 18 CRANKCASE 3 19 TRANSMISSION AND CRANKSHAFT 3 20 INSPECTION AND REPAI R 3 22 ROCKER ARMS AND ROCKER ARM SHAFTS 3 22 CAMSHAFT 3 24 CAM CHAIN 3 25 CAM SPROCKET AND CAM DRIVE SPROCKET 3 25 CHAI N DA...

Page 161: ...ARINGS 3 45 CIRCLIPS AND WASHERS 3 45 ENGINE ASSEMBLY AND ADJUSTMENT 3 46 CRANKSHAFT AND TRANSMISSION 3 46 CRANKCASE 3 48 OIL PUMP AND SHIFTER 3 52 BALANCER DRIVE AND DRIVEN GEARS 3 53 CLUTCH 3 54 CRANKCASE COVER RIGHT 3 58 OIL PIPE AND CAM CHAIN 3 58 COl ROTOR 3 59 CRANKCASE COVER LEFT 3 59 PISTON 3 60 CYLINDER AND CYLINDER HEAD 3 60 RECOIL STARTER 3 67 REMOUNTING ENGINE 3 68 www midwestmanuals c...

Page 162: ...ng equipment Refer to CHAPTER 1 GENERAL INFOR MATION SPECIAL TOOLS section NOTE __________________________ When disassembling the engine keep mated parts together This includes gears cylinder piston and other parts that have been Ilmated through nor mal wear Mated parts must be reused as an assembly or replaced 3 During engine disassembly clean all parts and place them in trays in the order of dis...

Page 163: ...p Refer to CHAPTE R 2 VALVE CLEAR ANCE ADJUSTMENT section NOTE __________________________ After removing the tank cover install the tank cap on the fuel tank 2 Remove Select lever CD Front carrier If so equipped Front fender Fuel tank Refer to CHAPTER 6 CHASSIS STEER ING SYSTEM section 3 Remove Stays Front fender CD 3 2 www midwestmanuals com ...

Page 164: ...westmanuals com www midwestmanuals com I ENG 1 1 ENGINE REMOVAL REAR CARRIER AND REAR FENDER 1 Remove Rear carrier CD Rear bumper 2 Remove Rear fender CD 3 Remove Stays Rear fender CD 3 3 www midwestmanuals com ...

Page 165: ... Muffler protector WIRING AND HOSE 1 Disconnect Spark plug lead COl magneto leads CD REVERSE switch lead NEUTRAL switch lead Ground lead Thermo switch with switch lead Ventilation hose WARNING Handle the thermo switch with special care Never subject it to strong shock or allow it to be dropped Should it be dropped it must be replaced 3 4 www midwestmanuals com ...

Page 166: ...S 1 Remove Adjusters Brake lever and brake pedal CD 2 Remove Footrest Left CD Change pedal 3 Remove Speedometer cable CD Wire guide Reverse lock release wire 4 Loosen Locknut CD 5 Remove Spring Upper Select lever control cable 2 Spring Lower 6 Remove Footrest Right CD Brake pedal assembly www midwestmanuals com ...

Page 167: ...loff Take care not to lose these parts CARBURETOR 1 Remove Wire cylinder CD Refer to CHAPTER 4 CARBURETION WI RE CYLINDER section 2 Remove Carburetor joint CD Carburetor Air cleaner manifold NOTE ___________________________ Noting the presence location and routing or all pipes remove the carburetor Cover the carburetor with a clean rag to prevent dirt or foreign matter into the carburetor 3 Discon...

Page 168: ... FILTER 1 Remove Clamp Oil hoses CD 2 Remove Oil filter cover Outside CD Oil filter cover Inside Oi I filter element REAR DRIVE ASSEMBLY AND SWINGARM 1 Remove Bolt Rear shock absorber Top CD 2 Disconnect Breather hose Rear final gear housing 3 Block the front wheels and elevate the rear wheels by placing the suitable stand under the frame 4 Remove Rear wheels www midwestmanuals com ...

Page 169: ...Pivot shafts Swingarm 7 Remove Rear drive assembly and swingarm CD NOTE __________________________ When removing the swingarm 1 TiIt it to the left side 2 The drive shaft coupling gear and spring will falloff Take care not to lose these parts TRANSFER GEAR ASSEMBLY AND FRONT DRIVE SHAFT 1 Remove Engine guard Rear CD 3 8 www midwestmanuals com ...

Page 170: ...embly Slide the rubber boot Rear on the drive shaft the move the transfer gear assembly to backward and pu II it to outside NOTE __ When removing the middle gear case and transfer gear assembly the dowel pins and shims will fall off Take care not to lose these parts 4 Disconnect Front drive shaft Slide the rubber boot Front on the drive shaft and pull out the drive shaft to back ward NOTE ________...

Page 171: ...om ENGINE REMOVAL IENG 1 1 ENGINE REMOVAL 1 Remove Bolts Engine mounting Top CD Bolt Engine mounting Front Bolts Engine mounting Rear 2 Remove Front drive shaft protector CD Front drive shaft 3 Remove Engine To the left 3 10 www midwestmanuals com ...

Page 172: ... 2 Remove Cap CD Starter handle NOTE _________________________ Before untying knot pull out the rope long enough to make knot on the rope so that the rope is not pulled into the case 3 Remove Nut CD Plate Spring Drive pawl Pawl spring Sheave drum Coil spring j CYLINDER HEAD AND CYLINDER 1 Remove Spark plug Timing plug CD www midwestmanuals com ...

Page 173: ...ment steps Turn the starter pulley counterclockwise with wrench Align the liT mark CD on the flywheel with the stationary pointer on the crankcase cover When the T mark is aligned with the stationary pointer the piston is at Top Dead Center TDC NOTE ________________________ TDC on compression stroke check Both rocker arms must have avalve clearance when the cam sprocket match mark is aligned with ...

Page 174: ...____________________ Fasten safety wire to the cam chain to prevent it from fail ling into the crankcase When removing the cam sprocket it is not necessary to separate the cam chain 7 Remove Bolts Cylinder head CD Cylinder head NOTE __________________________ Loosen the bolts starting with the highest numbered one 8 Remove Gasket Cylinder head CD Dowel pins O ring Cam chain damper Exhaust 9 Remove...

Page 175: ...ole area If the piston pin groove is deburred and piston pin is still difficult to remove use Piston Pin Puller YU 01304 Do not use a hammer to drive the piston pin out CRANKCASE COVER LEFT 1 Remove Starter pulIey CD Use the Rotor Holder YU 01235 to hold the starter pulley NOTE __________________________ When removing the starter pulley the O ring will falloff Take care not to lose it 2 Remove era...

Page 176: ...up coil assembly COl ROTOR 1 Remove CDI rotor CD Use the Flywheel Puller YM 01404 2 Remove Woodruff key CD Starter idle gear 2 Bearing Plain washers Circlips Starter idle gear 1 Bearings f Shaft CAM CHAIN AND OIL PIPE 1 Remove Cam chain damper Intake CD Cam chain 2 Remove Oil pipe CD www midwestmanuals com ...

Page 177: ...sened Before removing the crankcase cover remove the dip stick CLUTCH Shift Guide 1 Remove Clutch lever spring CD Shift guide 1 Pawl holder Shift guide 2 Plain washers Bearing Shift shaft i Primary Clutch and Secondary Clutch 1 Straighten Lock washer tabs 2 Remove Nuts Primary clutch CD Use the Rotor Holder YU 01235 to hold the clutch shoe assembly 3 Remove Lock washer Clutch carrier assembly CD P...

Page 178: ...primary gear before removing the primary clutch assembly 4 Remove Push rod CD Bearing Clutch spring plate Clutch springs 5 Straighten Lock washer tabs Clutch boss 6 Remove Nut Clutch boss CD Use the Rotor Holder YU 01235 to hold the clutch boss Lock washer 7 Remove Clutch boss CD Friction plate Cut 1pc CID Clutch plates Thickness 1 6 mm 4 pes Friction plates Red 6 pes Clutch plates Thickness 2 0 m...

Page 179: ...e gear Buffer boss NOTE __________________________ The balancer drive gear has six springs and three pins Use care so that they do not fall out when removing the balancer drive gear Using the suitable bearing puller when remov ing the buffer boss Key Woodruff Outside Plain washer Key Woodruff Inside j Collar Oil pump drive gear Balancer driven gear Key Straight Collar OIL PUMP AND SHIFTER 1 Remove...

Page 180: ...rn each Remove them after all are loosened 3 Remove Crankcase Right Dowel pins Alternately tap on the engine mounting boss transmission shafts shift cam and crankshaft NOTE __________________________ When removing the crankcase Right the three plain washer CD will fall off Take care not to lose these parts Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap o...

Page 181: ...Inside Shift cam 1 Shift fork 2 Guide bar 1 Shorter NOTE _____________ Note the position of each part Pay particular at tention to the location and direction of shift forks 2 Remove Plain washer Reverse axle CD Reverse wheel gear 1 36T Reverse axle Balancer weight 3 Remove Plain washer Drive axle CD High pinion gear 23T 1 st wheel gear 38T Plain washer Drive axle Plain washer Idle axle High wheel ...

Page 182: ...n gear Middle drive gear Dog clutch Reverse wheel gear 2 J Guide bar 2 Shift fork 2 Shift fork 1 Shift cam 2 j NOTE __________________________ Note the position of each part Pay particular attention to the location and direction of shift forks 6 Remove Crankshaft Use the Crankcase Separating Tool YU 01135 Q and Flywheel Puller Attachment YU 01382 www midwestmanuals com ...

Page 183: ...ocknuts Adjusters 3 Straighten Lock washer tabs 4 Remove Bolts Camshaft CD Lock washer Retainer 5 Attach Slide Hammer Set CD YU 01083 6 Remove Rocker arm shafts 7 Remove Camshaft CD Camshaft bushing NOTE _____________ Screw in a suitable length of 10 mm bolt into the thread hole on the camshaft and pull out the camshaft 8 Remove Rocker arms Intake and exhaust 3 22 www midwestmanuals com ...

Page 184: ...t of specification Replace Rocker Arm Inside Diameter Limit 12 078 mm 0 4755 in Measure the outside diameter of the rocker arm shaft Out of specification Replace Rocker Arm Shaft Outside Diameter Limit 11 951 mm 0 4705 in Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Clearance is greater than 0 08 mm 0 0032 in Replace either or bot...

Page 185: ...es Use a Micrometer Out of specification Replace Cam Lobe Cam Lobe Limit A Limit B Intake 40 26 mm 32 11 mm 1 585 in 1 264 in Exhaust 40 25 mm 32 11 mm 1 585 in 1 264 in 5 Install Camshaft CD To the cylinder head NOTE ___________________________ The pin on the end of the camshaft must align with the timing mark on the cylinder head 6 Install Camshaft bushing NOTE ___________________________ The cu...

Page 186: ...n 7 Install Retainer CD Lock washer New V Bolts Camshaft Bolts Camshaft 8 Nm 0 8 m kg 5 8 ft lb 8 Bend the lock washer tabs CAM CHAIN 1 Inspect Cam chain CD Chain stretch Cracks Replace CAM SPROCKET AND CAM DRIVE SPROCK ET 1 Inspect Cam sprocket Cam drive sprocket Wear Damage Replace CHAIN DAMPERS 1 Inspect Cam chain damper Intake CD Cam chain damper Exhaust V Wear Replace www midwestmanuals com ...

Page 187: ...COVER 1 Inspect Tappet covers Intake and exhaust CD Side cover O rings Damage Replace CYLINDER HEAD 1 Attach Valve Spring Compressor CD YM 04019 2 Remove Valve retainers CD Valve spring seat Valve spring Oil seal Valve spring seat Valve NOTE __________________________ Deburr any deformed valve stem end Use an oil stone to smooth the stem end CD Deburr Valve stem 3 26 www midwestmanuals com ...

Page 188: ...ure Cylinder head warpage Out of specification Resurface Re place Cylinder Head Warp Limit Less than 0 03 mm 0 0012 in VALVE VALVE GUIDE AND VALVE SEAT Intake and Exhaust Valve 1 Check Valve face Stem end Wear Pitting Out of specification Re place Minimum Thickness Service Limit 0 8 mm 0 031 in Beveled 0 5 mm 0 020 in Minimum Length Service Limit 4 0 mm 0 157 in 2 Inspect Valve stem end Mushroom s...

Page 189: ...2 in 0 0039 in AJ VALVE STEM OUTSIDE DIAMET ER 8 VALVE GUIDE INSIDE DIAMETER 4 Measure Valve stem runout Out of specification Replace Maximum Runout 0 02 tom 0 0008 in Valve Guide NOTE __________________________ Always replace valve guide if valve is replaced Always replace oil seal if valve is removed 1 Remove Valve guide Use a Valve Guide Remover CD YM 01225 NOTE __________________________ Heat ...

Page 190: ... to obtain proper valve guide valve stem clearance Recut the valve seat Valve Seat 1 Inspect Valve seats Wear Pitting Valve replacement Resur face seat at 45 angle Clean valve seat if pitted or worn using the 45 Valve Seat Cutter YM 91043 CD When twist ing cutter keep an even downward pressure to prevent chatter marks Cut section as follows Section Cutter A 20 B 45 C 60 2 Measure Valve seat width ...

Page 191: ...ove just enough material to achieve satis factory seat Seat Width Standard 1 0 1 2 mm 0 039 0 047 in Wear Limit 1 6 mm 0 063 in Valve seat recutting steps are necessary if Valve seat is uniform around perimeter of valve face but too wide or not centered on valve face Valve Seat Cutter Set Desired result 20 cutter Use 45 cutter To center the seat or either to reduce its width 60 cutter Valve face i...

Page 192: ...er the seat and 45 cutter to increase its width Valve seat is too narrow and is located down near the bottom edge of the valve face see diagram lid Valve Seat Cutter Set Desired Result 60 cutter first To center the seat and Use 45 cutter to increase its width Valve Valve Seat Assembly Lapping 1 Apply Coarse lapping compound Small amount To valve face Molybdenum disulfide oil To valve stem 2 Positi...

Page 193: ...ke full seat contact indi cated by grey surface all around The valve face where bluing was removed Faulty contact Replace See procedure below 10 Apply Solvent Into each intake and exhaust port NOTE ___________________________ Pour solvent into intake and exhaust ports only after completion of all valve work and assembly of all head parts 11 Check Valve seals CD Leakage past valve seat Replace valv...

Page 194: ...g force Installed length Out of specification l Replace Valve Compressed Force Inner Spring 10 7 12 3 kg 23 6 27 1 Ib at 36 6 mm 1 32 in Outer Spring 24 0 25 6 kg 52 9 56 4 Ib at 36 6 mm 1 44 in CD Installed length Valve Installation 1 Lubricate Valve stem Oil seal High Quality Molybdenum Disulfide Motor Oil or Molybdenum Disulfide Grease 2 Install Valve CD Valve spring seat Oil seal Valve springs...

Page 195: ...ce measurement steps First pipe Measure the cylinder bore lie with the Cylinder Bore Gauge CD40 mm 1 57 in from the cylinder top NOTE _________________________ Measure the cylinder bore IIC in parallel to and at right angles to the crankshaft Then find the average of the measurements Cylinder Bore e Standard 82 97 83 02 mm 3 267 3 269 in X Y C 2 Wear Limit 83 10 mm 3 272 in If out of specification...

Page 196: ...arance Cylinder Bore c Piston Skirt Diameter P If out of specification rebore or replace the cylinder and replace the piston and piston ri ngs as a set Piston to cylinder Clearance 0 04 0 06 mm 0 0016 0 0024 in PISTON RING AND PISTON PIN Piston Ring 1 Measure Side clearance Use the Feeler Gauge CD Out of specification Replace piston and or rings Side Clearance Standard Limit Top 0 04 0 08 mm 0 12 ...

Page 197: ...0 9mm Ring 0 012 0 036 in Piston Ring Oversize Top and 2nd piston ring Oversize top and middle ring sizes are stamped on top of ring Oversize 2 0 50 mm 0 0197 in Oversize 4 1 00 mm 0 0394 in Oil control ring Expander spacer of bottom ring oiIcontrol ring is color coded to identify sizes Size Color Oversize 2 Blue Oversize 4 Yellow Piston Pin 1 Lubricate Piston pin Lightly 2 Install Piston pin CD I...

Page 198: ...t Drive gear CD Scratches Wear Damage Replace crank shaft 2 Inspect Driven gear CD Scratches Wear Damage Replace clutch housing assembly Idler gear Scratches Wear Damage Replace 3 Inspect Bearing CD Damage Replace Bolts Starter clutch Loose Replace with a new one and clinch the end of the bolt NOTE _________________________ The arrow mark on the starter clutch must face inward away from the COl ro...

Page 199: ...ace NOTE ______________ Replace the one way clutch assembly and clutch housing as a set Clutch Carrier 1 Inspect Clutch shoe Heat damage Replace 2 Measure Clutch shoe thickness Out of specification Replace Clutch Shoe Wear Limit 1 5 mm 0 06 in SECONDARY CLUTCH Clutch Housing 1 Inspect Dogs on the housing Cracks Wear Damage Deburr or replace Clutch housing bearing Chafing Wear Damage Replace 3 38 w...

Page 200: ...coring on the clutch plate splines will cause erratic operation Friction Plates 1 Inspect Friction plate Damage Wear Replace friction plate as a set 2 Measure Friction plate thickness Measure at all four points Out of specification Replace friction plate as a set Friction Plate Thickness Wear Limit 2 8 mm 0 110 in Clutch Plates 1 Measure CI utch plate warpage Use surface plate and Feeler Gauge CD ...

Page 201: ...prings as a set Clutch Spring Minimum Length 45 8 mm 1 80 in 3 Measure Cushion spring height Out of specification Replace Cushion Spring Height 3 15 3 45 mm 0 12 0 14 in OIL PUMP 1 Measure Housing CD Outer rotor CV clearance Use a Feeler Gauge Out of specification Replace oil pump assembly Side Clearance 0 04 0 09 mm 0 0016 0 0035 in 2 Measure Outer rotor CD 1 nner rotor CV clearance Use a Feeler ...

Page 202: ...t of specification Disassemble the crankshaft and replace worn parts then reassemble the crankshaft Big End Side Clearance Limit B 0 9 mm 0 035 in Runout c Use the V bl cks and Dial Gauge Out of specification Correct any mis alignment Runout Limit C1 0 02 mm O OOOS in C2 0 06 mm 0 0024 in Small end free play F Use the V blocks and Dial Gauge Out of specification Disassemble the crankshaft and repl...

Page 203: ...rankshaft CD and the crank pin oil passages must be properly interconnected with a tolerance of less than 1 mm 0 04 in The buffer boss and woodruff key should be replaced when removed them from the crank shaft TRANSMISSION Shift Fork 1 Inspect Sh ift forks On the gear and shift cam contact surfaces Wear Chafing Bends Damage Replace 2 Check Shift fork movement On its guide bar Unsmooth operation Re...

Page 204: ... Drive Axles 1 Measure Axle CD runout Use centering device and Dial Gauge Out of specification Replace Runout Limit 0 08 mm 0 0031 in Gears 1 Inspect Gears Mating dogs Cracks Damage Wear Replace 2 Check Gear movement Unsmooth operation Replace DECOMPRESSION CAM 1 Inspect Oil seal CD Spring Decompression cam Damage Wear Replace STARTER PULLEY AND RECOIL STARTER 1 Inspect Starter pu Iley Cracks Pitt...

Page 205: ...e CD Sheave drum Drive pawl Wear Damage I Replace Coil spring Pawl spring Spring Fatigue 0 Replace BALANCER DRIVE GEAR 1 Inspect Collar CD Plain washer Buffer boss Drive gear Springs Dowel pins Holding plate j Damage Wear Fatigue I Replace CRANKCASE 1 Inspect Case halves Bearing seat Damage I Replace 3 44 www midwestmanuals com ...

Page 206: ...idwestmanuals com I ENG IINSPECTION AND REPAIR 3 45 BEARINGS 1 Inspect Axle bearings Shift cam bearing Pitting Damage j Replace CIRCLIPS AND WASHERS 1 Inspect Circlips Washers Damage Looseness Bends j Replace www midwestmanuals com ...

Page 207: ...rankshaft To protect the crankshaft against scratches or to facilitate the operation of the installation apply the engine oil to each bearing 2 Install Reverse wheel gear 2 CD Plain washer Circlip Dog cIutch NOTE ______________ Before installing the middle drive gear j install the shift fork 1 and shift cam 2 Plain washer Circlip Holder Middle driven gear Shift fork 2 Middle driven gear Guide bar ...

Page 208: ...___ Oil each gear and bearing thoroughly 4 Install Main axle assembly CD Drive axle gear assembly 5 Install 5th wheel gear 24T CD 1st wheel gear 38T High wheel gear NOTE __________________________ Align the projected portion of the high wheel gear end with the groove in the hole of the crankcase 6 Install High pinion gear 23T CD Plain washer Drive axle Plain washer Idle axle www midwestmanuals com...

Page 209: ...ide bar 2 Longer NOTE __________________________ Each shift fork is identified by a number cast on its side All the numbers should face the left side 9 Check Transmission and shifter operation Unsmooth operation Repair NOTE ________________________ Oil each gear and bearing thoroughly CRANKCASE 1 Apply Sealant Quick Gasket CD ACC 11001 05 01 To the mating surfaces of both case halves 2 Install Dow...

Page 210: ...Crankcase NOTE __________________________ Tighten the bolt in stage using a crisscross pattern Bolts Crankcase 10 Nm 1 0 m kg 7 2 ft lb 5 Apply 4 stroke engine oil To the crank pin bearing and oil delivery hole 6 Check Crankshaft and transmission operation Unsmooth operation Repair 7_ Install Ball CD Spring Plain washer Bolt Shift cam 2 NOTE _____________ Apply grease to the ball and spring thorou...

Page 211: ...Left Oil pump driven gear Woodruff key Piston ring set Piston Bearing Woodruff key Crank Right Washer Crank pin Connecting rod A CRAN KSHAFT A 5S 95 59 00 mm 2 321 2 323 in B 0 35 0 S5 mm 0 014 0 033 in Cl 0 02 mm O OOOS in C2 0 06 mm 0 0024 in F 2 0 mm O OSin SIDE CLEARANCE LIMIT o END GAP LIMIT E TOP RING 0 12 mm 0 0047 in 0 5mm 0 020 in F F 2ND RING 0 12 mm 0 0047 in 0 5mm 0 020 in PISTON CLEAR...

Page 212: ...ar Plain washer ear 1 Reverse wheel g Circlip Reverse axle d en gear Middle n die driven gear j Holder Mid Middle drive gear Dog clutch 3 51 jj Dowel pm Middle drive axle j High wheel gear Idle axle OJI seal 23T iY on gear High pml 38T 1st wheel gear Drive axle 2nd wheel gear Main axle 5th pinion gear 3rd pinion gear 4th pinion gear fit 2nd pinion gear www midwestmanuals com ...

Page 213: ...to its original positon 3 Tighten Bolt Stopper lever Bolt Stopper Lever 4 Install 14 Nm 1 4 m kg 10 ft lb LOCTITE Plain washer CD Shift shaft NOTE ___________________________ Be sure the shift lever correctly engages the shift cam pins Be sure the stopper shaft is placed between the spring hooks 5 Install Oil pipe CD Gasket Oil pump Oil pump assembly Oil Pipe 16 Nm 1 6 m kg 11 ft lb Oil Pump 7 Nm ...

Page 214: ... away from the main bearing Be sure the woodruff key in the crankshaft should engage the keyway in the buffer boss 2 Attach Suitable tool Steel CD Middle Drive Shaft Nut Wrench YM 04054 3 Secure Buffer boss Tap on the wrench end with a steel hammer 4 Install Balancer drive gear CD NOTE ________ _________________ The balancer drive gear damper assembly is composed of six springs and three pins Inse...

Page 215: ...b of the lock washer engages the slot in the balancer shaft Nuts Driven gear Finger tighten the nut 7 Tighten Nut Driven gear CD NOTE _________________________ Place a folded rag between the teeth of the driven gear and drive gear to lock them Nut Balancer Driven Gear 60 Nm 6 0 m kg 43 ft lb 8 Bend the lock washer tabs CLUTCH Secondary Clutch and Primary Clutch 1 Install Collar CD Clutch housing T...

Page 216: ...s Cushion springs 2 pes Clutch plate Thickness 2 0 mm 2 pes Pressure plate Thrustwasher Clutch housing Collar Clutch carrier assembly Plain washer A CLUTCH SPRING MINIMUM LENGTH 45 B mm LBO in CLUTCH PLATE WARP LIMIT Bearing retainer One way bearing Clutch housing complete Plain washer B 0 2 mm O OOB in 8 Nm 0 8 m kg 5 8 ftolb C CLUTCH SHOE WEAR LIMIT 1 5 mm 0 06 in D FRICTION PLATE WEAR LIMIT 2 B...

Page 217: ...nately on the clutch boss starting with a friction plate and ending with a friction plate 3 Install Clutch boss CD To the pressure plate assembly NOTE ______________ Align the arrow marks on the clutch boss with the pressure plate assembly 4 Install Lock washer New Nut Clutch boss CD Use the Rotor Holder YU 01235 to hold the clutch boss Nut Clutch Boss 80 Nm 8 0 m kg 58 ft lb 5 Bend the lock washe...

Page 218: ...two notches machines into it to permit the primary drive gear behind the primary clutch to clear the secondary clutch Align one of these notches with the primary gear before installing the primary clutch assembly 8 Tighten Nut Primary clutch CD Use the Rotor Holder YU 01235 to hold the clutch shoe assembly Nut Primary Clutch 78 Nm 7 8 m kg 56 ft lb 9 Bend the lock washer tabs Shift Guide 1 Install...

Page 219: ... cover R ight CD NOTE ___________________________ The shift arm engages the shift guide 1 The pin of middle drive axle engages the groove of speedometer drive gear The crankshaft end engages the bearing of crankcase j 2 Tighten Bolts Crankcase cover NOTE ___________________________ Tighten the bolts in stage using a crisscross pattern Screws Crankcase Cover 10 Nm 1 0 m kg 7 2 ft lb OIL PIPE AND CA...

Page 220: ...ter idIe gear 2 j Woodruff key 2 Install CDI rotor NOTE ___________________________ Before installing the rotor clean the outside of the crankshaft and inside of the r otor After installing the rotor check the rotor rotation smoothly If not reinstall the key and rotor CRANKCASE COVER LEFT 1 Install Stator assembly CD Pickup coi I assembly Stator Assembly 7 Nm 0 7 m kg 5 1 ft lb 2 Install Dowel pin...

Page 221: ..._________ The arrow on the piston must point to the front of the engine Before installing the piston pin clip cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material into the crankcase Always use a new piston pin clip 2 Apply 4 stroke engine oil To the piston pin piston ring grooves and piston skirt areas CYLINDER AND CYLINDER HEAD 1 Install Piston...

Page 222: ...OIL RING LOWER RAIL OIL RING UPPER RAIL 2ND 4 Install a ring CD Dowel pins Gasket New Cylinder Bolts Cylinder NOTE ___________________________ Install the cylinder with one hand while com pressing the piston rings with the other hand Be careful not to damage the cam chain damper during installation Pass the cam chain through the cam chain _cavity Bolts Cylinder 10Nm 1 0m kg 7 2ft lb 5 Install Cam ...

Page 223: ...ust Cylinder head Bearing retainer f Lock washer Side cover Cylinder CYLINDER HEAD A WARP LIMIT 0 03 mm 0 0012 in B SPARK PLUG TYPE MAN UFACTU RER C D8EA N G K or X24ES U N D For Canada DR8ES L N G K SPARK PLUG GAP D 0 6 0 7 mm 0 024 0 028 in 10 Nm 1 0 mokg 7 2 ftolb 17 5 Nm 1 75 mokg 12 5 ftolb 0 1 0 mokgo7 2 ftolbJ I I a I s o 10 Nm 1 0 mokg 7 2 ft Ib 3 62 www midwestmanuals com ...

Page 224: ...Intake Bearing Camshaft Cam chain Cam sprocket Valve retainers j Valve spring seat Valve springs Oil seal Cam chain damper Exhaust j Valve spring seat VALVE CLEARANCE COLD INTAKE 0 06 0 10 mm A 0 002 0 004 in EXHAUST 0 16 0 20 mm 0 006 0 008 in VALVE SPRING LENGTH B LIMIT FREE INNER 37 9 mm 1 49 in OUTER 41 27 mm 1 62 in 25 Nm 2 5 m kg 18 ft Ib USE NEW ONE f 4r l t 7 1 t it a Uf II iii I t l 11 J ...

Page 225: ...haft to align the camshaft pin CD with the cylinder head match mark Turn the starter pulley until the liT mark is aligned with the stationary pointer on the crankcase Place the cam chain onto the cam chain sprocket I nstall the cam chain sprocket onto the camshaft and fi nger tighten the sprocket bolt NOTE _____________ Be sure the match mark on the cam chain sprocket is al igned with the match ma...

Page 226: ... the starter pulley Bolt Cam Chain Sprocket 60 Nm 6 0 m kg 43 ftolb 11 Install Gasket New CD Cam chain tensioner body Bolts Cam Chain Tensioner Body 10 Nm 1 0 mokg 7 2 ftolb 12 Install Spring CD Plain washer End plug End Plug Cam Chain Tensioner 25 Nm 2 5 m kg 18 ft lb 13 Adjust Valve clearance Refer to CHAPTER 2 VALVE CLEAR ANCE ADJUSTMENT section NOTE ___________________________ After adjusting ...

Page 227: ...ing Exhaust cover Tappet cover Exhaust CD O ring Intake cover Tappet cover Intake NOTE _____________ Install the tappet covers with its ridge facing upward Check the O rings for damage If damaged replace Tappet Cover 10 Nm 1 0 m kg 7 2 ft lb 15 Install O ring Side cover Side cover Cylinder head CD Side Cover Cylinder Head 10 Nm 1 0 m kg 7 2 ft lb 16 Install Timing plug CD Spark plug Spark Plug 17 ...

Page 228: ... rope into the drum slit 2 Install Starter spring CD Sheave drum assembly NOTE ___________________ Mesh the spring hook with the case slit then wind the spring clockwise into the case from larger to smaller diameter Mesh the sheave drum hook with the spring hook 3 Install Spring CD Friction plate Nut NOTE ________________________ Insert the spring hooks into the pawl side holes 4 Turn the sheave d...

Page 229: ... REMOUNTING ENGINE When remounting the engine reverse the removal procedure Note the following points 1 Install Engine From the left side 2 Apply Molbdenum disulfide grease To the drive shaft splines 3 Install Front drive shaft CD Front drive shaft protector NOTE __________________________ Before connecting the drive shaft do not forget to fit the spring seat and spring Insert the front drive shaf...

Page 230: ...ue them at this point After installing the rear drive assembly and swingarm tighten the mounting bolts securely 5 Install Transfer gear assembly D NOTE ___________________________ Before installing the transfer gear assembly 1 Insert the front drive shaft into the universal joint Transfer gear side properly and slide the rubber boot Rear on the drive shaft 2 Do not forget to fit the shims Finger t...

Page 231: ...er washer With clamp 8 Check Front drive shaft operation Front drive shaft operation checking steps Make sure that the machine is off the ground at the rear Lift the front of the machine off the ground too WARNING Securely support the machine so there is no danger of it falling over Turn the front wheels back and forth Check the front drive shaft operation If the operation is unsmooth reinstall th...

Page 232: ...fore installing the swingarm lubricate the following parts 1 Bearings 2 Oil seals 3 Collars 4 Pivot shaft Lithium Base Waterproof Wheel Bearing Grease Before installing the swingarm do not forget to fit the rear drive shaft CD and spring Insert the rear drive shaft into the universal joint properly When installing the swingarm tilt it to the left side 11 Install Rubber boot CD NOTE _______________...

Page 233: ... machine off the ground too WARNING Securely support the machine so there is no danger of it falling over Turn the front wheel back and forth Check the rear axle operation If the opera tion is unsmooth reinstall the swingarm properly 14 Tighten Bolts Engine mounting Pivot shaft Swingarm Locknuts Swingarm Bolts Rear shock absorber Nuts Rear wheels Refer to CHAPTE R 6 CHASSIS REAR SHOCK ABSORBER AND...

Page 234: ...filter cover Inside Oil filter cover Outside NOTE _____________ Before installing the oil filter element clean it with solvent Before installing the bolts Filter cover apply the Sealant Quick Gasket ACC 11001 05 01 to the thread portion of the bolts Bolts Oil Filter Cover 10 Nm 1 0 m kg 7 2 ft Ib 16 InstaII Clamp Oil hose CD Screw Oil Hose 7 Nm 0 7 m kg 5 1 ft Ib 17 InstaII Starter motor CD Starte...

Page 235: ...e carburetor joint Bolts Carburetor Joint 16 Nm 1 6 m kg 11 ft Ib Nuts Carburetor 8 Nm 0 8 m kg 5 8 ft lb 19 InstaII Wire cylinder CD Refer to CHAPTER 4 CARBURETION WIRE CYLINDER section 20 Check Throttle cable operation Unsmooth operation Repair 21 Adjust Throttle lever free play Out of specification Adjust Refer to CHAPTER 2 THROTTLE LEVER ADJUSTMENT section Throttle Lever Free Play 3 5 mm 0 12 ...

Page 236: ...dal apply the 4 cycle oil to the pivot on the frame When installing the brake pedal do not forget to fit the circlip Footrest Right 55 Nm 5 5 m kg 40 ft lb 24 Install Select lever control cable 2 CD Spring Upper Spring Lower Locknut NOTE _________________________ After connecting the cable 2 adjust the control cable Refer to CHAPTER 2 SELECT LEVER CONTROL CABLE ADJUSTMENT section 25 Install Speedo...

Page 237: ...shifting operation If there is unsmooth opera tion repair Change Pedal 10 Nm 1 0 m kg 7 2 ft lb Footrest Left 55 Nm 5 5 m kg 40 ft lb 27 Install Adjuster Brake lever and brake pedal CD NOTE ___________________________ After installing the adjusters adjust the brake lever and pedal free play Refer to CHAPTER 2 REAR BRAKE LEVER AND PEDAL AD JUSTMENT section 28 Connect Spark plug lead CDI magneto lea...

Page 238: ...strong shock or allow it to be dropped Should it be dropped it must be replaced Thermo Switch 20 Nm 2 0 m kg 14 ft lb 29 Install Muffler protector Exhaust pipe Muffler NOTE _________________________ Inspect the gasket CD Exhaust pipe and muffler If damaged replace Bolts Exhaust Pipe 12 Nm 1 2 m kg 8 7 ft lb Bolt Muffler and Exhaust Pipe 20 Nm 2 0 m kg 14 ft lb Bolts Muffler 27 Nm 2 7 m kg 19 ft lb...

Page 239: ... 32 Install Stays Front fender CD NOTE __________________________ Be sure the projection on the frame correctly engages with the hole into the stay 33 Install Fuel tank CD Front fender Front carrier If so equipped Select lever Refer to CHAPTE R 6 CHASSIS STEER ING SYSTEM section Front Carrier and Frame 20 Nm 2 0 mo kg 14 ftolb Front Carrier and Front Bumper 10 Nm 1 0 mokg 7 2 ftolb Screws Select L...

Page 240: ...e Oillea age 36 Check e NEUTRAL indicator light operation e REVERSE indicator light operation e OI L TEMP indicator light operation Poor operation 4 Repair 37 Check e Reverse lock release wire CD operation Reverse lock release wire operation checking steps e Pull the reverse lock release wire by hand e Put gear in reverse shift NOTE ________________________ Do not use the rear brake pedal at this ...

Page 241: ... ________ RBI I CHAPTER 4 CARBURETION CARBURETOR 4 1 SECTIONAL VIEW 4 2 REMOVAL 4 3 DISASSEMBLY 4w 3 INSPECTION 4 5 ASSEMBLY 4 6 INSTALLATION 4 8 ADJUSTMENT 4 8 WI RE CYLINDER 4 9 REMOVAL 4 9 INSPECTION 4 10 INSTALLATION 4 10 www midwestmanuals com ...

Page 242: ...seat Jet needle Needle valve j Pilot screw Float pin Piston valve Drian screw Pilot jet Main nozzle Mainjet Float 4 1 SPI CIFICATIONS MAIN JET M J 122 5 MAIN AIR JET M A J 0 8 JET NEEDLE J N 5H26 3 PI LOT JET P J 45 PILOT AIR JET P A J 1 1 0 P A J 2 0 9 PILOT SCREW 2 and 3 4 turns out FLOAT VALVE SEAT 2 5 ENGINE IDLE SPEED 1 350 1 450 r min FUEL LEVEL F L 1 0 2 0mm 0 04 0 08 in FLOAT HEIGHT F H 11...

Page 243: ...lot jet J Bypass hole PiIat screw Throttle valve q AJ c t rnJ Q Pilot air jet No 1 Pilot air jet No 2 Starter air bleed Starter bleed pipe Starter jet Starter plunger Fuel inlet Float Float valve set CARBURETOR cARsl I AJ AIR rnJ MIXTURE FUEL Q MAIN METERING SYSTE EJ STARTER SYSTEM J FLOAT SYSTEM 4 2 www midwestmanuals com ...

Page 244: ...er to engine removal section NOTE ____________________________ The following parts can be cleaned and inspected witho t disassembly Throttle stop screw set Starter plunger DISASSEMBLY 1 Remove Starter plunger assembly CD 2 Remove Carburetor cap CD Spring Connector Upper Gasket 3 Remove Connector Lower CD Needle holder Jet needIe Piston valve www midwestmanuals com ...

Page 245: ...ctor Throttle valve 5 Remove Cover Coasting enricher CD Spring Diaphragm Coasting enricher 6 Remove Float chamber cover CD eO ring 7 Remove Float pin CD Float Needle valve Main jet ring ePlate Valve seat O ring J 8 Remove eMain jet CD Main nozzle e Pjlot jet Pilot screw set eO ring 4 4 www midwestmanuals com ...

Page 246: ...etor in petroleum based solvent Do not use any caustic carburetor cleaning solution Blowout all passages and jets with com pressed air O rings Damage Replace 2 Inspect Floats Damage Replace 3 Inspect Needle valve CD Seat O ring Damage Wear Contamination Replace as a set 4 Inspect Piston valve CD Jet needle Connector Lower Connector Upper Damage Bends Wear Replace www midwestmanuals com ...

Page 247: ... 7 Check Free movement Piston valve Stick Replace Insert the piston valve into the carburetor body and check for free movement 8 Check Free movement Throttle valve Stick Replace carburetor assembly ASSEMBLY To assemble the carburetor reverse the dis assembly procedures Note the following points Before reassembling wash all parts in clean gasoline Always use a new gasket 4 6 www midwestmanuals com ...

Page 248: ... The float arm should be resting on the needle valve but not compressing the needle valve elf the float height is not within specification inspect the valve seat and needle valve elf either is worn replace them both elf both are fine adjust the float height by bending the float tang CD on the float e Recheck the float height 3 Install e Diaphragm Coasting enricher CD NOTE _________________________...

Page 249: ...sted 1 Measure Fuel level Out of specificaton Adjust Fuel level measurement and adjustment steps Place the machine on a level place Use a garage jack under the engine to ensure that the carburetor is positioned vertically Attach the Fuel Level Gauge CD YM 01312 A to the float chamber nozzle Loosen the drain screw and start the engine Place tube vertically next to the center of the mating line of t...

Page 250: ...e rubber band and slide the band 3 Open Cover Wire cylinder 4 Disconnect Throttle cable Throttle lever side CD Piston valve cable Carburetor side Throttle valve cable Carburetor side Before removing the piston valve cable and thro ttle valve cable make sure that the adjusters and locknuts on the carburetor side are fully tight ened If not the throttle does not operate pro perly 5 Remove Sliders Sp...

Page 251: ... Rubber boots Damage Replace 2 Check Slider operation Unsmooth operation Repair INSTALLATION 1 Apply Lithium base grease To the sliders and cable ends 2 Install Sliders CD Spring NOTE __________________________ Before installing the sliders do not forget to fit the spring 3 Connect Throttle cable Throttle lever side Piston valve cable Carburetor side Throttle valve cable Carburetor side 4 10 www m...

Page 252: ...le lever side into the rubber band Before installing the piston valve cable and thro ttle valve cable make sure that the adjusters and locknuts on the carburetor side are fully tighte ned If not the throttle does not operate pro perly 4 Install Cover Wire cylinder 5 Check Cable operation Unsmooth operation Repair 6 Hook the rubber band securely www midwestmanuals com ...

Page 253: ...5 23 DIFFERENTIAL GEAR OPERATION CHECK 5 25 TRANSFER GEAR 5 27 REMOVAL 5 28 DISASSEMBLY 5 28 INSPECTI ON 5 32 REASSEMBLY 5 33 INSTALLATION 5 39 ADJUSTM ENT 5 39 MIDDLE DRIVE AND DRIVEN GEARS POSITIONING 5 41 REAR AXLE REAR FINAL GEAR AND REAR DRIVE SHAFT 5 46 REMOVAL 5 48 DISASSEMBLY 5 51 INSPECTION 5 53 REASSEMBLY 5 54 INSTALLATION 5 56 MEASUREMENT AND AD JUSTMENT 5 59 REAR FINAL DRIVE GEAR AND R...

Page 254: ...o front and or rear wheel F Seizure due to lack of lubrication G Small foreign object lodged between moving parts NOTE Areas A B and C above may be extremely difficult to diagnose The symptoms are quite subtle and difficult to distinguish from normal machine operating noise If there is reason to believe these components are damaged remove the components for specific inspection 5 1 Inspection Notes...

Page 255: ... the rider 2 Inspect Drained oil Drain plug shows large amount of metal Particles Check bearing fur seizure NOTE _________________________ A small amount of metal particles in the oil is normal 3 Inspect Oil leakage Oil leakage inspection steps Clean the entire machine thoroughly then dry it Apply a leak localizing compound or dry powder spray to the shaft drive Road test the machine for the dista...

Page 256: ... Remove the rear axle Check for axle bearing damage IRemove the drive shaft components 5 3 Replace the wheel bearing Refer to CHAPTER 6 FRONT AND REAR WHEELS section Constant velocity joint bearings and differential gear bearings probably not damaged Repeat test or re move individual components Rear axle bearings and rear drive shaft bearings probably not damaged Repeat test or remove individual c...

Page 257: ...ible collar Spacer Front drive gear Front drive gear shim Differential gear case Thrust washer Ringgear Differential gear assembly 23 Nm 2 3 m kg 17 ft lb GEAR LASH Ring gear shim Bearing housing Ring gear Ring gear stopper Locknut D TOTAL AMOUNT B 0 10 0 35 mm 0 004 0 014 in 45 Nm 4 5 m kg 32 ftolb 0 5 L 0 44 Imp qt 0 53 US qt TYPE C SAE 80 API GL 4 HYPOID GEAR OIL E STARTING TORQUE 0 8 1 3 Nm 0 ...

Page 258: ...ww midwestmanuals com IDRIVI ra 1 DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS CD Circlip Double off set joint Snap ring Dust boot Boot band Joint shaft f Ball joint 5 5 B REAIR PARTS KITS A USE NEW ONE www midwestmanuals com ...

Page 259: ...CHASSIS STEERING SYSTEM section 2 Remove Front wheels Front wheel hubs Refer to CHAPTE R 6 CHASSIS FRaNT AN DREAR WH EE LS section 3 Remove Rear carrier Rear bumper Rear fender Exhaust pipe Muffler Starter motor CD Refer to CHAPTER 3 ENGINE OVER HAUL ENGINE REMOVAL section 4 Remove Clamp Oil hose CD Bolts OiI cooler 5 Remove Front shock absorbers Right and left CD Cotter pins Nuts Tie rod end Tie ...

Page 260: ...rm 7 Disconnect Ball joint ends Push down the lower arm and pull up the steering knuckle 8 Remove Engine protector Front CD Drain plugs Drain the oil completely 9 Remove Bolts Front drive shaft protector Front half Front drive shaft protector CD NOTE ____________________________ Do not remove the rear half protector CV com pletely at this point www midwestmanuals com ...

Page 261: ... and disconnect the drive shaft universal joint NOTE ________________________ When disconnecting the drive shaft the spring seat and spring will falloff Take care not to lose these parts Remove the gear case to the rear right side 12 Remove Front drive shaft CD Slide the rubber boot Rear on the drive shaft and pull out the drive shaft to forward Constant Velocity Joint 1 Remove Constant velocity j...

Page 262: ...nt in a press With a suitable diameter pipe beneath the yoke press the bearing 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 necessary to lightly tap the yoke with a punch 4 Attach Universal Joint Holder CD YM 04062 Attachement YM 33291 ...

Page 263: ...ver directly press the shaft end with a Hydraulic Press this will result in damage to the shaft thread Install the suitable socket on the shaft end to protect the thread from damage Press the shaft end and remove the spacer and collapsible collar 7 Remove 8 mm bolts Bearing housing Ring gear 10 mm bolts Bearing housing Ring gear NOTE __________________________ Working in a crisscross pattern loose...

Page 264: ... assembled into a proper unit at the factory by means of spe cialized equipment Do not attempt to dis assemble this unit Disassembly will result in the mulfunction of the unit Constant Velocity Joint 1 Remove Bands Double off set joint CD NOTE ___________________________ After removing the bands slide the dust boot Double off set joint to the ball Joint side 2 Remove Circlip CD NOTE ______________...

Page 265: ...D Dust boot Ball joint From the ball joint assembly INSPECTION Differential Gear 1 Inspect Gear teeth Pitting Galling Wear Replace front drive gear and ring gear as a set Bearing Pitting Damage Replace Oil seal O ring Damage Replace 2 Inspect Drive shaft splines Universal joints Front drive gear spline Wear Damage Replace Spring Fatigue Replace Move the spring up and down 5 12 www midwestmanuals c...

Page 266: ...tial gear assembly Insert the double off set joint into the differential gear and turn the gear back and forth Constant Velocity Joint 1 Inspect Double off set joint spline Ball joint spline Shaft spline Wear Damage Replace 2 Inspect Dust boots Cracks Damage Replace Always use new boot band 3 Inspect Balls and ball races Inner surface of double off set joint Pitting Damage Wear Replace 4 Check Fre...

Page 267: ...s New To the differential gear assembly Ring Gear 64 Nm 6 4 m kg 46 ft lb 3 Bend the lock washer tab along the bolt flats 4 Install Thrust washer CD Differential gear assembly with ring gear Ring gear shim s 5 Tighten 10 mm bolts Bearing housing Ring gear 8 mm bolts Bearing housing Ring gear NOTE ___________________________ Tighten the bolts in stage using a crisscross pattern 10 mm Bolts Bearing ...

Page 268: ...G Always use a new collapsible collar Fit the spacer and collapsible collar onto the front drive gear shaft Insert the front drive gear assembly into the bearing housing Clamp the front drive gear in a vise with soft jaws Do not clamp the bearing inner race Clamp the front drive gear with care at this point Install the hand made tool CD and nut Front drive gear Tighten the nut unti I the front dri...

Page 269: ...ment YM 33291 on the U joint Carefu lIy tighten the nut Front drive gear Iittle by little Remove the aforementioned special tools Measure the starting torque of the front drive gear with the small size torque wrench CD Front Drive Gear Starting Torque 0 8 1 3 Nm 0 08 0 13 m kg 0 60 0 94 ft lb Repeat tightening steps to establish the standard starting torque for the front drive gear Never exceed th...

Page 270: ...ach bearing The needles can easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place Press each bearing into the U joint using a suitable socket NOTE _________________________ Bearing must be inserted far enough into U joint so that circlip can be installed Install the circlips into the groove of each b...

Page 271: ... Refer to IIMEASUREMENT AND AD JUSTMENT section Constant Velocity Joint When reassembling the constant velocity joint Reverse the disassembly procedures Note the following points 1 Apply Molbdenum disulfide grease Into the ball joint assembly NOTE __________________________ Molbdenum disulfide grease is included in the repair kit 2 Install Dust boot Ball joint CD Bands Ball joint New NOTE ________...

Page 272: ...________ Before installing the ball bearing apply the molbdenum disulfide grease into the double off set joint Cover the double off set joint with the dust boot 5 Install Bands Double off set joint CD NOTE _________________________ After installing the bands bend the band ends securely Always use the new bands 6 Check Free play Thrust movement Refer to INSPECTION section INSTALLATION Constant Velo...

Page 273: ...sulfide grease To the drive shaft splines 2 Install Front drive shaft D NOTE __________________________ Insert the drive shaft into the universal joint properly and slide the rubber boot Rear 3 Install Differential gear case with constant velocity joints CD Differential gear case installa tion steps Insert the gear case from the rear right side Connect the drive shaft universal joint NOTE ________...

Page 274: ...e Shaft Protector 10 Nm 1 0 m kg 7 2 ft lb Drain Plugs 8 mm 16 Nm 1 6 m kg 11 ft lb Drain Plug 14 mm 23 Nm 2 3 m kg 17 ft lb Bolts Engine Guard Front 16 Nm 1 6 m kg 11 ft lb Differential gear case WARNIr lG Take care not to allow foreign material to enter the differential gear case Total Amount 0 5 L 0 44 Imp qt 0 53 US qt Recomended Oil 7 Install SAE 80 API GL 4 Hypoid Gear Oil If desired an SAE ...

Page 275: ...__________ Be sure to position the tie rod so that its white painted mark is right hand rod Be sure to position the front shock absorber holding bolts Upper and lower so that the bolt head face forward WARNING Always use a new cotter pin Nuts Tie rod End 25 Nm 2 5 m kg 18 ft lb Nuts Front Shock Absorber 45 Nm 4 5 m kg 32 ft lb 9 Tighten Bolts Oil cooler CD Screw Clamp Oil hose Bolts Oil Cooler 7 N...

Page 276: ... 0311 0 4 Measure Gear lash Gently rotate the constant velocity joint from engagement to engagement Over specified limit Adjust NOTE ___________________________ When rotating the joint do not turn the U joint Measure the gear lash at 4 positions Rotate the ring gear 90 each time Differential Gear Gear Lash 0 10 0 35 mm 0 004 0 014 in Differential Gear Gear Lash Adjustment 1 Remove 8 mm bolts Beari...

Page 277: ...e suitable shim s and thrust washer by the following chart Too little gear lash Reduce shim thickness Too large gear lash Increase shim thickness To Add or Reduce Ring Gear Shim Thickness Increase by more Reduce by more than 0 1 mm 0 004 in than 0 1 mm 0 004 in Reduce thrust washer thickness by 0 1 mm 0 004 in Reverse for every 0 1 mm of ring r procedure gear shim increase Ring Gear Shim Thrust Wa...

Page 278: ...k it 1 2 rotation Tighten the locknut Locknut Ring Gear Stopper 16 Nm 1 6 m kg 11 ft lb DIFFERENTIAL GEAR OPERATION CHECK 1 Block the rear wheels and elevate the front wheels by placing a suitable stand under the frame 2 Remove the wheel cap and cotter pin from the axle nut Right or left 3 Measure the starting torque of the front wheel i e differential gear preload with the torque wrench NOTE ____...

Page 279: ...Torque Differential Gear Preload iiiiiiiiIIIII New Unit 40 80 Nm 4 0 8 0 m kg 29 58 ft lb Minimum 10 Nm 1 0 mokg 7 2 ft lb 4 Out of the above specification replace the differential gear assembly 5 Within the above specification install the cotter pin and wheel cap WARNING Always use a new cotter pin 5 26 www midwestmanuals com ...

Page 280: ... Bearing housing assembly Shims Middle driven shaft For rear final gear Damper spring Damper cam 5 27 Middle driven gear Holder Retainers Idler gear 34T Middle driven shaft For differential gear Transfer driven gear 26T Middle drive gear Thrust shims Bearing retainers Middle drive shaft B STAKE 120 Nm 12 0 mokg 85 ftolb 4 MIDDLE GEAR LASH C 0 1 0 2 mm 0 004 0 008 in 23 Nm 2 3 mokg 17 ft Ib www mid...

Page 281: ... For Rear Final Gear 1 Remove Universal joint For rear final gear Universal joint removal steps Remove the circlips CD Place the U joint in a press With a suitable diameter pipe beneath the yoke press the bearing 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 necessary to lightly tap t...

Page 282: ...ddle driven shaft Place the middle driven shaft assembly onto a Hydraulic Press Never directly press the shaft end with a Hydraulic Press this will result in damage to the shaft thread Install the suitable socket on the shaft end to protect the thread from damage Press the shaft end and remove the collar and bearing housing 5 Attach Damper Spring Compressor CD YM 33286 Middle Drive Gear Holder YM ...

Page 283: ... all loosened 2 Remove Transfer gear case Rear NOTE __________________________ For this removal slits in the transfer gear case can be use as shown When removing the transfer gear case the dowel pins will fall off Take care not to lose these parts 3 Remove Transfer drive gear CD Idler gear 4 Remove Universal joint For differential gear Universal joint removal steps Remove the circlips CD Place the...

Page 284: ...aft For differential gear Washer Yoke Middle driven shaft assembly For differ ential gear Lightly tap the end of the shaft with soft hammer 7 Attach Damper Spring Compressor CD YM 33286 Middle Drive Gear Holder YM 33222 Onto the holder of transfer driven gear 8 Position Middle driven shaft assembly Onto a Hydraulic Press 9 Compress the damper spring on the holder 10 Remove Retainers CD Holder Damp...

Page 285: ... Bearing retainers Q Use 40 Torx Driver YM 04049 5 Remove Bearing G Shim CV INSPECTION Middle Driven Shafts 1 Inspect Damper cam surfaces Wear Scratches Replace damper and middle driven gear as a set 2 Inspect Damper spring Damage Cracks Replace 3 Inspect Gear teeth Middle gear Pitting Galling Wear Replace middle gear as a set Gear teeth Transfer gear Pitting Galling Wear Replace transfer gear as ...

Page 286: ...alling Wear Replace middle gear as a set Bearing Pitting Damage Replace REASSEMBLY Middle Drive Shaft 1 Install Shim CD Bearing 2 Install Bearing retainers CD Use 40 Torx Driver YM 04049 Bearing Retainer 25 Nm 2 5 m kg 18 ft Ib 3 Lock the screw head with drift punch 4 Install Middle drive axle CD Middle drive gear Nut Middle drive gear Secure the middle drive axle in a vice or other support 5 Lock...

Page 287: ...mpress the damper spring on the holder 6 Install Retainers Into the middle driven shaft groove 7 Install Middle driven shaft assembly To the transfer gear case NOTE __________________________ Before installing the middle driven shaft apply the lithium base grease to the oil seal Voke Washer Nut Middle drive shaft For differential gear To the middle driven shaft 8 Attach Universal Joint Holder VM 0...

Page 288: ...rth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place Press each bearing into the U joint using a suitable socket NOTE _______________________ Bearing must be inserted far enough into U joint so that circlip can be installed Install the circlips into the groove of each bearing 11 Install Idle gear CD Transfer drive gear 12 InstaII Transfer gear case Rear N...

Page 289: ...olybdenum disulfide grease To the middle drive shaft oil seal and O ring 2 Install Damper spring Q Damper cam Middle driven gear Holder To the middle drive shaft 3 Attach Damper Spring Compressor Q YM 33286 Middle Drive Gear Holder YM 33222 Onto the middle driven gear 4 Position Middle driven gear assembly Onto a Hydraulic Press 5 Compress the damper spring on the middle driven gear assembly 6 Ins...

Page 290: ...ft assembly onto a Hydraulic Press Never directly press the collar or bearing housing with a Hydraulic Press this will re sult in damage to them Install the hand made tool to protect the collar and bearing housing from damage Press the hand made tool and secure the collar and bearing housing 8 Install Middle driven shaft assembly NOTE __________________________ Before installing the middle driven ...

Page 291: ...oint Middle drive shaft For rear final gear Universal joint installation steps Install the opposite yoke into the U joint e Apply the wheel bearing grease to the bearings elnstall the bearing CD onto the yoke Check each bearing The needles can easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place Pre...

Page 292: ... Engine guard Rear Rear drive assembly with swingarm Rear fender Rear carrier Refer to CHAPTER 3 ENGINE OVER HAUL REMOUNTING ENGINE sec tion ADJUSTMENT Middle Gear Gear Lash Adjustment 1 Install Bolts Four On transfer gear case Finger tighten the bolts NOTE _________________________ Clearance between the crankcase and bearing housing should be about 2 mm Measure gap with Feeler Gauge CD 2 Remove B...

Page 293: ...______________ Check the gear lash at four positions Rotate the U joint 90 degrees each time and repeat the gear lash check 7 Tighten Bolt Four Tighten carefully one thread turn only Push in bearing housing and hold in position while tightening bearing housing bolts Do not overtighten bearing housing bolts or you may obtain too little gear lash and cause damage to gears If over tightened loosen th...

Page 294: ...measured shim thickness is 0 46 mm The chart instructs you however to round off the 6 to 5 Thus you should use 0 15 mm and 0 30 mm shims Shim sizes are supplied in the following thickness Middle Driven Gear Shim Thickness mm 0 10 0 15 0 20 0 30 0 40 11 Tighten Bolts Bearing housing Bolts Bearing Housing 25 Nm 2 5 m kg 18 ft lb 12 Measure Gear lash MIDDLE DRIVE AND DRIVEN GEAR POSI TIONING NOTE ___...

Page 295: ...sales midwestmanuals com www midwestmanuals com TRANSFER GEAR IORlvllD 1 1 Select Middle drive gear shim CD Middle driven gear shim 5 42 www midwestmanuals com ...

Page 296: ...im Thickness A Where a numeral usually a decimal number on the drive gear is either added to or substracted from 55 a numeral usually a decimal number on the crankcase is either added to or subtracted from 54 Example 1 If the drive gear is marked 11 03 is 55 03 2 If the crankcase is marked 45 is 54 45 A 55 03 54 45 0 S8 3 Therefore shim thickness is 0 S8 mm Shim sizes are supplied in following thi...

Page 297: ...l on bearing housing Le 124 20 a numeral usually a decimal number on the driven gear is either added to or substracted from 1 5 a numeral usually a decimal number on the driven gear is either added to or substracted from 49 5 a numeral usually a decimal number on the crankcase is either added to or substracted from 1 68 Example 1 If the bearing housing is marked 124 20 is 124 20 2 If the driven ge...

Page 298: ...ments round off hundredths digit and select appropriate shim s Hundredths Round value 0 1 2 0 3 4 5 6 7 5 8 9 10 In the example above the caIculated shim thickness is 0 87 mm The chart instructs you however to round off the 7 to 5 Thus you may choose either 1 pc 0 40 mm shim and 3 pcs 0 15 mm shims or 1 pc 0 40 mm shim 1 pc 0 30 mm shim and 1 pc 0 15 mm shim 5 45 www midwestmanuals com ...

Page 299: ... to the thread portion of the rear axle 2 Finger tighten the inside ring nut while checking the ring gear engagement 3 Tighten the inside ring nut to 30 Nm 3 0 mokg 22 ftolb while holding the rear axle 4 Hole the inside ring nut and tighten the outside ring nut to 190 Nm 19 0 mokg 140 ft lb 5 Hold the outside ring nut and tighten BACK the inside ring nut to 240 Nm 24 0 mokg 170 ftolb REAR AXLE RUN...

Page 300: ...ng Oil seal Bearing Drive pinion gear Final drive gear shim A FINAL GEAR OIL CAPACITY Bearing Bearing retainer O ring Oil seal Collar Coupling gear Spring Rear drive shaft Circlip Universal joint Bearing B 0 25 L 0 22 Imp qt 0 26 US qt C D TYPE SAE 80 API GL 4 HYPOID GEAR OIL GEAR LASH 0 1 0 2 mm 0 004 0 008 in IFI KINDS 10 23 Nm 2 3 mokg 17 ftolb I 23 Nm 2 3 mokg 17 ftolb F KINDS 6 100 Nm 10 0 mo...

Page 301: ...nd brake lever 2 Unhook the brake lever spring 3 Remove Rear final gear protector CD Trailer hitch bracket 4 Loosen Ring nuts Rear axle CD Use the Ring Nut Wrench NOTE ___________________________ Before loosening the ring nuts reinstall the rear wheel hub Left and rear wheel Left Use the rear wheel to hold the rear axle 5 Remove Rear wheel Left Rear wheel hub Left Ring nuts Rear axle 6 Remove Brak...

Page 302: ...Remove Caliper CD Brake disc 9 Remove Brake cover I nner CD 10 Remove Rear axle CD Tap the LEFT END axle Never directly tap the axle end with a hammer this will result in damage to the axle thread and spline Install the wheel boss and suitable socket on the axle end to protect the thread and spline from damage CD Axle thread Spline www midwestmanuals com ...

Page 303: ...riking tools Install the new bearing by reversing the previous steps NOTE ________________________ Use a socket that matches the outside diameter of the race of the bearing Do not strike the center race or balls of the bearing Contact should be made only with the outer race Install the oil seals New and hub dust covers CD Rear Final Gear 1 Remove Rear axle Refer to Rear Axle section 2 Remove Breat...

Page 304: ...TE __________________________ Before disassembling the rear final gear drain the oil completely 1 Remove 8 mm bolts Bearing housing 0mm bolts Bearing housing NOTE Working in a crisscross pattern loosen bolt 1 4 turn each Remove them after all loosened 2 Remove Bearing housing CD Shim s Thrust washer 3 Remove Coupling gear Bearing retainer Final drive shaft Use a Final Drive Shaft Bearing Retainer ...

Page 305: ...s or races after removal 5 Remove Oil seal CD Roller bearing Large Use a suitable press tool and an ap propriate support for the main housing 6 Remove Final drive shaft Roller bearing Small CD Roller bearing Small removal steps Heat the bare housing to 150 C 302 F Remove the roller bearing outer race with an appropriately shaped punch Remove the inner race from the final drive shaft NOTE _________...

Page 306: ...6 in 2 Inspect Oil seals Damage l Replace 3 Check Bearings Bearings allow play in the final gear housing and rear hub or rear axle turns roughly Replace Rear Final Gear 1 Inspect Gear teeth Pitting Galling Wear Replace drive pi nion gear and ring gear as a set Oil seal O ring Damage Replace 2 Inspect Roller bearing Damage 7 Replace NOTE __________________________ Reuse of roller bearing OK but Yam...

Page 307: ...e the following points 1 Install Roller bearing Small New Roller bearing Small installation steps Heat the bare bearing to 150 C 302 F I nstall the roller bearing outer race using the proper adapted Install the inner race onto the drive shaft 2 Install Oil seal New CD Roller bearing Large Use a suitable press tool and a press to install the above components into the main housing 3 Install Shims Re...

Page 308: ...housing NOTE ___________________________ Tighten the bolts in stage using a crisscross pattern 10 mm Bolts Bearing Housing 40 Nm 4 0 m kg 29 ft lb 8 mm Bolts Bearing Housing 23 Nm 2 3 m kg 17 ft lb 6 Check Gear lash Out of specification Adjust Refer to MEASUREMENT AND AD JUSTMENT section 7 Fill Rear final gear case WARNING Take care not to allow foreign material to enter the final gear case Oil Ca...

Page 309: ...talling the rear final gear reverse the removal procedure Note the following points 1 Apply Lithium bas grease Lightly grease to the oil seals and bearing 2 Apply Sealant Quick Gasket ACC 11 001 05 01 CD To the mating surfaces of both case halves 3 Tighten Nuts Rear final gear housing Bolts Rear final gear housing Nuts Rear Final Gear Housing 23 Nm 2 3 mokg 17 ft lb Bolts Rear Final Gear Housing 4...

Page 310: ...oval procedure Note the following points 1 Install Rear axle CD Tap the RIGHT END axle while cheking the ring gear engagement Never directly tap the axle end with a hammer this will result in damage to the axle thread CD and spline Install the wheel boss and suitable socket on the axle end to protect the thread and spline from damage 2 Tighten Nuts Caliper Nuts Cam holder NOTE ____________________...

Page 311: ...s Rear axle CD Ring nuts tightening steps NOTE ________________________ Before tightening the ring nuts apply the LOCTITE to the thread portion of the rear axle Finger tighten the inside ring nut while checking the ring gear engagement Tighten the inside ring nut with Ring Nut Wrench YU 33975 to specification while holding the rear axle Inside Ring Nut First Tightening 30 Nm 3 0 m kg 24 ft lb Hold...

Page 312: ... Final Gear Gear Lash Measurement 1 Secure the gear case in a vise or other su pport 2 Remove Drian plug Drian the oi I 3 Install A bolt of the specified size CD Into the drain plug hole Finger tighten the bolt until it holds the ring gear Otherwise the ring gear will be damaged 4 Attach Gear Lash Measurement Tool CD YM 01230 Dial Gauge YM 03097 Measuring point 5 Measure Gear lash Gently rotate th...

Page 313: ...r 3 Adjust Gear lash Gear lash adjustment steps Select the suitable shims and thrust washer by the following chart Too little gear lash 1 Reduce shim thickness Too large gear lash 1 Increase shim thickness To Add or Reduce Ring Gear Shim Thickness Increase by more Reduce by more than 0 1 mm 0 004 in than 0 1 mm 0 004 in l Reduce thrust washer thickness by 0 1 mm 0 004 in Reverse for every 0 1 mm o...

Page 314: ...section 2 Measure Ring gear stopper clearance Use the Feeler Gauge CD Out of specification Adjust Ring Gear Stopper Clearance 0 30 0 60 mm 0 012 0 024 in Ring gear stopper Ring gear 3 Install Bearing housing with ring gear Ring Gear Stopper Clearance Adjustment 1 Remove Ring gear CD Ring gear stopper Shim s Bearing housing A Left hand threads 2 Select Suitable shim s Thickness mm 0 10 0 20 0 40 Sh...

Page 315: ...him CD Ring gear shim Final drive ring gear shim selection steps Position final drive shaft gear and ring gear by using shims CD and with their re spective thicknesses calculated from infor mation marked on final gear case drive gear end and ring gear CDShim thickness Au Shim thickness B Thrust washer To find shim thickness Ii A use following formula Final Drive Gear Shim Thickness A Where a numer...

Page 316: ...e the calculated shim thickness is 0 51 mm The chart instructs you however to round off the 1 to O Thus you should use a 0 50 mm shim eTo find shim thickness liB use following formula Ring Gear Shim Thickness B CD Where numeral on gear case Le 45 23 numeral usually a decimal number on outside of ring gear bearing housing and added to 1 numeral usually a decimal number on inside of ring gear either...

Page 317: ...select appropriate shim s Hundredths Round value 0 1 2 o 3 4 5 6 7 5 8 9 10 In the example above the calculated shim thickness is 0 43 mm The chart instructs you however to round off the 3 to 5 Thus you should use a 0 45 mm shims 2 Install Shims Proper size as calculated Final drive pinion gear assembly Bearing retainer Final drive shaft Use a Final Drive Shaft Bearing Retainer Wrench CD YM 33214 ...

Page 318: ...m Bolts Bearing Housing 23 Nm 2 3 m kg 17 ft lb 10 mm Bolt Bearing Housing 40 Nm 4 0 m kg 29 ft lb NOTE _________________________ Do not turn the shaft drive and ring gear when measuring clearance with Plastigage Remove the ring gear assembly Measure the thrust clearance Calculate width of flattened Plastigage CD Ring Gear Thrust Clearance 0 1 0 2 mm 0 004 0 008 in If the correct clearance install...

Page 319: ...uals com REAR AXLE REAR FINAL GEAR AND REAR SHAFT DRIVE IORlvl fD 1 Repeat measurement steps until the ring gear thrust clearance is within the specified limits Ring Gear Thrust Clearance 0 1 0 2 mm 0 004 0 008 in 5 66 www midwestmanuals com ...

Page 320: ...VAL 6 19 INSPECTION 6 20 INSTALLATION 6 20 STEERING SYSTEM 6 22 REMOVAL 6 23 INSPECTION 6 26 INSTALLATION 6 27 STEERING KNUCKLES AND TIE ROD ENDS 6 30 REMOVAL 6 30 INSPECTION 6 31 INSTALLATION 6 32 ADJUSTME NT 6 34 FRONT SHOCK ABSORBER AND FRONT ARMS 6 36 REMOVAL 6 37 FREE PLAY INSPECTION 6 37 INSPECTION 6 38 INSTALLATION 6 38 REAR SHOCK ABSORBER AND SWINGARM 6 40 REMOVAL 6 41 FREE PLAY INSPECTION...

Page 321: ...rds the wheel USE NEW ONE 55 Nm 5 5 mokg 40 ft lb 150 Nm 15 mokg 110 ftolb Standard Minimum Maximum A B C 0 20 kPa 20 kPa 0 20 kg cm2 0 20 kg cm2 2 8 psi 2 8 psi 17 kPa 17 kPa 0 17 kg cm2 0 17 kg cm2 2 4 psi 2 4 psi 23 kPa 23 kPa 0 23 kg cm2 0 23 kg cm2 3 2 psi 3 2 psi TIRE SIZE FRONT AT25X8 12 REAR AT25X10 12 RIM SIZE FRONT 12XS 5AT REAR 12X8 0AT WHEEL RUNOUT LIMIT VERTICAL 2 mm 0 08 in LATE RAL ...

Page 322: ... elevate the front wheels by placing the suitable stand under the frame 4 Remove Nuts Front wheel Front wheel Front Wheel Hub Removal 1 Remove Wheel cap Cotter pin CD Axle nut Plain washer Brake drum Wheel hub NOTE __________________________ If the brake drum is difficult to removal turn the adjusters on both wheel cylinders in the direction opposite to the arrow Rear Wheel Removal Refer to Front ...

Page 323: ...D Dial gauge Rim Runout Limit Vertical 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in INSTALLATION When installing the front and rear wheels re serve the removal procedure Note the following points Front Wheel Hub Installation 1 Tighten Axle nut Front wheel Axle Nut Front Wheel 130 Nm 13 m kg 94 ft Ib 2 Install Cotter pin New CD NOTE _________________________ Do not loosen the axle nut after torque tighten...

Page 324: ... on the tire must point toward the rotating direction A of the wheel 2 Tighten Nuts Front wheel CD WARNING Tapered wheel nuts CD are used for both front and rear wheels Install the nut with its tapered side towards the wheel Nut Front Wheel 55 Nm 5 5 m 0 kg 40 ft lb Rear Wheel Hub Installation Refer to Front Wheel Hub Installation section 1 Tighten Axle nut Rear wheel Axle Nut Rear Wheel 150 Nm 15...

Page 325: ... midwestmanuals com www midwestmanuals com FHASIAI FRONT AND REAR WHEELS Rear Wheel Installation Refer to Front Wheel Installation section CD Arrow mark Rotating direction of wheel 6 5 www midwestmanuals com ...

Page 326: ...lip 0 USE NEW ONE b l I 0 4 9 Nm 0 9 m kg 6 5 ttolb 20 Nm 2 0 m kg 14 tt lb BRAKE FLUID A DOT 4 IF DOT 4 IS NOT AVAILABLE 3 CAN BE USED BRAKE LEVER FREE PLAY B JUST BEFORE ADJUSTER CONTACTS MASTER CYLINDER PISTON 3 5 mm 0 12 0 20 in BRAKE LEVER FREE PLAY C JUST BEFORE BRAKE IS ACTUALLY APPLY 25 30 mm 1 0 1 2 in 10 IUSE NEWO N_E_I_ _ L _ __ 25 Nm 2 5 mokg 18 ft lb L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ...

Page 327: ...ind plug j Adjuster Wheel cylinder Wheel cylinder Lock spring 10 Nm 1 0 m kg 7 2 ft Ib t P E USE NEW ONE Cupset Piston Bleed screw set Brake pipe APPLY LOCTITE HEAT RESISTANT USE NEW ONE A BRAKE LINING WEAR LIMIT 1 mm 0 04 in B BRAKE DRUM WEAR LIMIT 161 mm 6 34 in o APPLY LITHIUM BASE GREASE F APPLY LOCTITE HEAT RESISTANT 6 7 USE NEW ONE www midwestmanuals com ...

Page 328: ...id to contact painted surfaces plastic parts otherwise damage may occur Disconnect any hydraulic connection other wise the entire system must be disassembled drained cleaned and then properly filled and bled after reassembly Wheel Cylinder Disassembly 1 Remove Front wheel Front wheel hub Refer to FRONT AND REAR WHEELS section 2 Remove Holders Brake shoe CD Pins Brake shoe Brake shoes Springs Turn ...

Page 329: ...ylinder CD Piston seaI V Piston Dust seal NOTE __________________________ Identify each adjuster position very carefully so that it can be reinstalled in its original place Master Cylinder and Brake Hose Disassembly 1 Remove Front carrier If so equipped Front fender Refer to STEERING SYSTEM section 2 Disconnect Brake hose Upper with brake joint CD Brake pipe Upper V Brake hose Lower NOTE _________...

Page 330: ...Do not use solvents will cause seals to swell and distort Recommended Brake Component Replacement Schedule Brake shoes As required Piston seal dust seal Every two years Brake hoses Every four years Replace only when Brake fluid brakes are disassembled Replace whenever Brake pipes brake pipes are dis connecting 1 Inspect Brake Iining surface Glazed areas Remove Use a coarse sand paper NOTE ________...

Page 331: ... 3 Inspect Brake drum inner surface Fluid Oil Scratches l Remove Brake Use a rag soaked in lacquer Fluid Oil thinner or solvent Scratches Use a emery cloth Lightly and evenly polishing 4 Inspect Master cylinder kit Master cylinder body Brake hose Scratches Wear Replace 5 Inspect Cylinder bore Wheel cylinder Piston surfaces Wheel cylinder Adjuster Wheel cylinder Rust Scratches Damage Repair or re p...

Page 332: ...OT 4 If DOT 4 is not available 3 can be used Wheel Cylinder Reassembly When assembling the wheel cylinder reverse the disassembly procedure Note the following points 1 Apply Rubber grease To the part A Lithium base grease To the part ID Be careful not to apply too much grease to the part 00 and If grease gets on the brake lin ing the brake slippage will result 2 Install Adjuster Wheel Cylinder CD ...

Page 333: ...t it can be reinstalled in its ori ginal place To prevent confusion there is on ilL em bossed on each of the left hand wheel cylinders and an R embossed on each of the right hand wheel cylinders Install the wheel cylinders with the arrow facing outward Wheel Cylinder 4 Install 10 Nm 1 0 m kg 7 2 ft lb LOCTITE HEAT RESISTANT Backing plate CD NOTE _____________________________ The backing plate shou...

Page 334: ...the part A If grease gets on the brake lining the brake slippage will result 7 Install Brake shoes D Springs Pins Brake shoe Holders Brake shoe NOTE __________________________ Make sure that the above components are pro per positioned as shown Make sure that the pin is hitched on the holder Before installing the brake drum turn the ad juster on both wheel cylinders in the direction opposite to the...

Page 335: ... Install Collar CD Master cylinder Master cylinder cap NOTE ___________________________ Engage the receptacle on the collar with the lobe on the throttle lever assembly The up mark on the master cylinder bracket should be upward Master Cylinder Assembly 9 Nm 0 9 m kg 6 5 ft lb 3 Connect Brake hose Lower CD Brake pipe Upper New Brake hose Upper with brake joint NOTE __________________________ Befor...

Page 336: ...he air completely from the brake sys tem Refer to AI R BLEEDING section AIR BLEEDING WARNING Bleed the brake system if The system has been disassembled The brake hose or brake pipe have been loos ened or removed The brake fluid is very low The brake operation is faulty A dangerous loss of braking performance may occur if the brake system is not properly bled 1 Bleed Brake fluid Air bleeding steps ...

Page 337: ...he lever to travel towards its limit h Tighten the bleed screw when the lever li mit has been reached then release the lever Bleed Screw 6 Nm 0 6 m kg 4 3 ft lb i Repeat steps e to h until of the air bu bbles have been removed from the system NOTE ________________________ If bleeding is difficult it may be necessary to let the brake fluid system stabilize for a few hours Repeat the bleeding proced...

Page 338: ..._ RE A R B R AK EFHASIAI 2 Locknut Caliper Brak I Brake dl se e ever Oil seal Cam holder Cam j Backup plate Brake pads A 2BRAKE PAD WEAR LIMIT 0 mm O 08 in B RAKE DISC WEAR LIMIT 0 mm 0 12 in C OMASXIMUM DEFLECTION _ mm 0 02 in 16Nm 16 __ mokg 11 ftolb 6 18 www midwestmanuals com ...

Page 339: ...elevate the rear wheels by placing the suitable stand under the frame 3 Remove Rear wheel Left Rear wheel hub Left Adjusters Brake pedal and brake lever 4 Unhook the brake lever spring 5 Remove Brake cover Outer CD Cam holder with brake lever 6 Remove Caliper CD Brake disc 7 Remove Caliper pads CD Backup plate Oil seals Cam Cam holder Brake lever Locknut j Adjuster www midwestmanuals com ...

Page 340: ...brake pads as a set 2 Inspect Backup plate CD Cam Cam holder Rust Damage l Replace Oil seals Damage l Replace 3 Measure Brake disc thickness Brake disc deflection Out of specification l Replace CD Dial gauge Brake Disc Wear Limit 3 0 mm 0 12 in Brake Disc Maximum Deflection 0 5 mm 0 02 in INSTALLATION When installing the rear brake reserve the re moval procedure Note the following points 1 Install...

Page 341: ...pair 3 Tighten Nuts Caliper Nuts Cam holder NOTE _____________ Be sure to posiJ ion the cam holder so that the holder projection CD face backward Nuts Caliper 50 Nm 5 0 m kg 36 ft lb Nuts Cam Holder 9 Nm 0 9 m kg 6 5 ft lb 2 Install Adjusters Brake pedal and brake lever 3 Adjust Brake lever free play Brake pedal free play Refer to HAPTER 2 BRAKE LEVER AND PEDAL ADJUSTMENT section 4 Install Rear wh...

Page 342: ...ing shaft bushing Oil seal Steering shaft Steering knuckle Bearing Oil seal j Spacer Bearing retainer Collar TOE IN Tie rod Tie rod end 5 15 mm 0 20 0 59 in 20 Nm 2 0 mokg 14 ftolb 23 Nm 2 3 m kg 17 ft lbl I C USE NEW ONE 35 Nm 3 5 m kg 25 ft Ib 6 22 www midwestmanuals com ...

Page 343: ...e tank cap on the fuel tank Refer to CHAPTER 2 VALVE CLEARANCE ADJUSTMENT section 2 Remove HeadIight cover CD 3 Disconnect Headlight couplers CD After disconnecting the couplers insert the couplers to the fender hole NOTE ____ When disconnecting the couplers the grommet will fall off Take care not to lose this part 4 Disconnect Main switch coupler CD Auxiliary D C terminal leads www midwestmanuals...

Page 344: ..._T_E_ER_I_NG_SY_S_T_EM_EHASI AI 5 Remove Select lever CD 6 Remove Front carrier If so equipped CD Front fender 7 Disconnect Brake cable Rear brake CD Rear brake switch Handlebar switch coupers 8 Remove Bands Handlebar Handlebar switch 6 24 www midwestmanuals com ...

Page 345: ...r Throttle lever assembly 10 Disconnect Indicator leads CD Pull up the handlebar cover and discon nect the leads 11 Remove Handlebar holders Upper and lower CD Handlebar 12 Remove Meter assembly CD 13 Straighten Lock washer tabs 14 Remove Steering shaft bracket Steering shaft bushings CD Oil seals www midwestmanuals com ...

Page 346: ...CD Nuts Tie rod end CV Tie rod ends Steering shaft 17 Remove Oil seals CD Bearing retainer Use the Damper Rod Holder YM 01327 Bearing INSPECTION 1 Inspect Steeri ng shaft Bends Replace WARNING Do not attempt to straighten a bent shaft this may dangerously weaken the shaft 2 Inspect Oil seals CD Steering shaft bushings Wear Damage Replace 6 26 www midwestmanuals com ...

Page 347: ...wing points 1 Install Bearing CD Bearing retainer Use the Damper Rod Holder YM 01327 Oil seals NOTE _____________ Apply lithium base grease to the bearing and oil seals Bearing Retainer 40 Nm 4 0 m kg 29 ft lb 2 Install Steering shaft WARNING Make sure the brake hoses and pipes are pro perly routed and are not damaged or twisted 3 Tighten Nuts Tie rod end Nut Steering shaft Nuts Tie rod End 25 Nm ...

Page 348: ... Bracket 23 Nm 2 3 m kg 17 ft lb 7 Bend the lock washer tab along the bolt flats 8 Install Handlebar Handlebar holders Upper and lower NOTE ___________________________ Insert the projection CD of handlebar holder Lower into the steering shaft hole The upper handlebar holder should be installed with the punched mark forward Align the slit j of handlebar with the edge of handlebar holder Lower First...

Page 349: ...et should be upward 10 Install Front fender Front carrier If so equipped Front Carrier and Frame 20 Nm 2 0 m kg 14 ft Ib Front Carrier and Front Bumber 10 Nm 1 0 m kg 7 2 ft lb 11 InstaII Select lever CD Screws Select Lever 1 5 Nrn 0 15 m kg 1 1 ft Ib LOCTITE 12 Connect Headlight couplers CD NOTE ___________________________ Before connecting the couplers do not forget to fit the grommet 13 Adjust ...

Page 350: ...ct Brake hose CD Place the open hose end into a container and drain the brake fluid Completely wipe off any brake fluid adhering to any part of machine The brake fluid reacts chemically with paint plastics rubber materials etc 3 Remove Backing plate assembly CD 4 Remove Cotter pins CD Nuts Tie rod end Tie rod 5 Remove Cotter pins CD Nut Tie rod end Nuts Steering knucke Bolt Knuckle arm 6 30 www mi...

Page 351: ...heck Tie rod free play and movement Tie rod is exists free play Replace tie rod end Tie rod is turns roughly Replace tie rod end 2 Inspect Steering knuckle Damage Pitting Replace 3 Inspect Ball joints Damage Pitting Replace front arms Ball joint is exists free play Replace front arms Ball joint turns roughly Replace front arms 4 Inspect Wheel bearings Bearings allow play in the wheel hubs or wheel...

Page 352: ...ll the outside bearing first Do not strike the center race or balls of the bearing Contact should be made only with the outer race Install the new oil seal NOTE ________________________ When installing the oil seals sealed side of oil seal comes outside INSTALLATION When installing the tie rod reverse the removal procedure Note the following points 1 Apply Lithium base grease Lightly grease to the...

Page 353: ...4 5 mm 13 6 in A Right hand threads ill Left hand threads To steering shaft QJ To knuckle NOTE _________________________ The threads on both tie rod ends must be of the same length Tighten the locknuts Locknut Tie rod 30 Nm 3 0 m kg 22 ft lb 5 Install Tie rods Left and right NOTE __________________________ Be sure to position the tie rod so that its white painted mark CD is right hand rod 6 Tighte...

Page 354: ...any brake fluid adhering to any part of machine The brake fluid reacts chemically with paint plastics rubber materi als etc Insert the brake hose end into the hose holder on the backing plate WARNING Always use the new copper washer 10 Fill Master cylinder Brake Fluid V DOT 4 IF DOT 4 IS NOT AVAILABLE 3 CAN BE USED 11 Bleed the air completely from the brake sys tem Refer to FRONT BRAKE AIR BLEEDIN...

Page 355: ...Toe in 5 15 mm 0 20 0 59 in If the toe in is incorrect adjust the toe in 3 Adjust Toe in Refer to IITie rod assembly length adjust ment steps section WARNING Be sure that both tie rod are turned by the same amount If not the machine will go right or left even though the handlebar is positioned straight and it may lead to mis handling and accident After setting the toe in to specification run the m...

Page 356: ...w midwestmanuals com FRONT SHOCK ABSORBER AND FRONT ARMS CHASj I FRONT SHOCK ABSORBER AND FRONT ARMS CD Bushing Front shock absorber Upper arm Lower arm 43 Nm 4 3 m kg 31 ft Ib 45 Nm 4 5 m kg 32 ft Ib 6 36 www midwestmanuals com ...

Page 357: ... TIE ROD ENDS REMOVAL section 3 Remove Nuts Front shock absorber CD Bolts Front shock absorber Front shock absorber Nuts Upper arm Bolts Upper arm Upper arm Nuts Lower arm Bolts Lower arm Lower arm Bushings FREE PLAY INSPECTION 1 Remove Front wheels Front hubs Backing plate assemblies Tie rods Steering knuckles Front shock absorbers 2 Check Front arms Side play Side play l Replace bushings Move th...

Page 358: ...rber rod Bends Damage Replace the shock absorber assembly e Shock absorber assembly Oil leakes Replace the shock absorber assembly eSp ring Fatigue Replace the shock absorber assembly Move the spring up and down Front Arms Inspection 1 Inspect e Bushings CD Wear Damage Replace INSTALLATION When installing the front arms and shock absor ber reverse the removal procedure Note the following points 1 ...

Page 359: ...ace outward When tightening the nuts move up the front arms Forward 3 Tighten Nuts Front arm Nuts Front Arms 43 Nm 4 3 m kg 31 ft lb 4 Install Front shock absorber NOTE _________________________ Be sure to position the bolts Upper and lower D so that he bolt head face forward 5 Tighten Nuts Front shock absorber Nuts Front Shock Absorber 45 Nm 4 5 m kg 32 ft lb 6 Bleed the air completely from the b...

Page 360: ...ear shock absorber Thrust washer Locknut Pivot shaft Collar Oil seal l Taper roller bearing SWingarm Rubber boot A REAR SHOCK ABSORBER B STANDARD POSITION C C SOFTEST POSITION A c 0 E 0 STIFFEST POSITION E E SWINGARM FREE PLAY LIMIT SIDE 1 0 mm 0 04 in 130 Nm 13 0 mokg 94 ft lb 6 Nm 0 6 m kg 4 3 ft Ib 16 Nm 1 6 m kg 11 ft Ib 6 40 www midwestmanuals com ...

Page 361: ... to FRONT AND REAR WHEELS section Rear axle Refer to CHAPTER 5 DRIVE TRAIN REAR AXLE section 2 Remove Rear carrier Rear fender Exhaust pipe Muffler Refer to CHAPTER 3 ENGINE OVER HAUL ENGINE REMOVAL section 3 Remove Rear shock absorber CD 4 Remove Rubber boot CD 5 Remove Pivot shaft caps Locknuts Swingarm CD Pivot shafts Swingarm Breather hose www midwestmanuals com ...

Page 362: ... Rear axle Rear carrier Rear fender Exhaust pipe Muffler Rear shock absorber 2 Check Swingarm Side play Out of specification Replace taper roller bearings and collars Move the swingarm from side to side Swingarm Side Free Play Limit 1 0 mm 0 04 in 3 Check Swingarm Vertical movement Tightness Binding Rough spots Replace taper roller bearings and collars Move the swingarm up and down INSPECTION Rear...

Page 363: ...embly Move the spring up and down Swingarm Inspection 1 Wash the bearings in a solvent 2 Inspect Bearing Race Rollers CD Pitting Damage Replace Oil seals Collars Damage Replace 3 Inspect Rubber boot CD Damage Replace INSTALLATION When installing the rear wheels reverse the removal procedures Note the following points 1 Lubricate Bearing Oil seals Collars Pivot shafts Lithium Base Waterproof Wheel ...

Page 364: ...t into the universal joint properly 5 Install Pivot shafts Locknuts Swingarm NOTE ___ _ Finger tighten the pivot shafts and locknuts do not torque them at this point 6 Check Rear drive shaft operation Rear drive shaft operation checking steps Make sure that the machine is off the ground at the rear Place a suitable block under the swingarm Lift the front of the machine off the ground too WARNING S...

Page 365: ...haft Left 6 Nm 0 6 m kg 4 3 ft lb Locknut Left 130 Nm 13 0 m kg 94 ft lb 8 Check Swingarm Side play Swingarm Vertical movement Refer to FREE PLAY INSPECTION sec tion 9 Apply Lithium base grease To the bolt and pin Rear shock absorber 1O InstaII Rear shock absorbers NOTE __________________________ The rear shock absorber should be installed so that the spring seat CD on the shock absorber face down...

Page 366: ...G CIRCUIT OPERATION 7 12 STARTER MOTOR TEST 7 13 CHARGING SYSTEM 7 17 CIRCUIT DIAGRAM 7 17 TROUBLESHOOTING 7 19 IGNITION SYSTEM 7 21 CIRCUIT DIAGRAM 7 21 TROUBLESHOOTING 7 23 LIGHTING SYSTEM 7 27 CI RCUIT DIAGRAM 7 27 TROUBLESHOOTING 7 29 SIGNAL SYSTEM 7 33 CIRCUIT DIAGRAM 7 33 TROUBLESHOOTING 7 35 SWITCHES TEST 7 43 ACCESSORY SYSTEM 7 45 CIRCUIT DIAGRAM 7 45 TROUBLESHOOTING 7 47 www midwestmanual...

Page 367: ...IAGRAM ELECTRICAL YFM350FWT CIRCUIT DIAGRAM B J 0 B I B W B B Y G Y G B B 7 G Y B Y G B P ff p P_e__ Br CD Br R Br l B R W W Br W B a R W Br I B L Br Br W B Br Br G Br W l G R Sb G Y t 1 60 tORWAR R VERSE G Br L G Y I r LO HI B B B B B www midwestmanuals com ...

Page 368: ...01 L TEMP indicator light COLOR CODe B Black B W Black White R Red R W Red White L Blue B R Black Red Y Yellow L W Blue White G Green G L Green Blue O Orange G Y Green Yellow W White G R Green Red Br Brown Y B Yellow Black p Pink W B White Black Gy Gray W L White Blue Sb Sky blue Oil temperature indicator light checker Thermo relay Thermo switch Reverse switch Neutral relay Neutral switch LIGHTS D...

Page 369: ...j Reverse relay Battery Starter relay 7 3 Oil temperature indicator light checker Reverse switch Neutral switch Auxiliary D C terminal CDI unit Thermo relay Main switch Ignition coil SPECIFICATIONS IGNITION COIL PRIMARY SECONDARY PICK UP COl L SOURCE COIL CHARGING COIL RESISTANCE 0 72 0 9Sn 5 02 6 79kn lS0 220n 270 330n 0 70 0 86n A BATTERY B CAPACITY 12V 14AH C SPECIFIC GRAVITY 1 280 www midwestm...

Page 370: ...sales midwestmanuals com www midwestmanuals com IELECIIiiIELECTRICAL STARTING SYSTEM ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM B l j B R W I Br W B 7 5 www midwestmanuals com ...

Page 371: ...it in circuit diagram NOTE ____________________________ For the encircled numbers and color codes see page 7 2 Main switch Fuse j Battery START switch Starting circuit cut off relay Starter relay Starter motor NEUTRAL indicator light Reverse switch Neutral relay Neutral switch Rear brake switch ENGINE STOP switch CDI unit 7 6 www midwestmanuals com ...

Page 372: ...or is operated go to the next steps If not repair and or replace the starter motor Disconnect the starter relay coupler Red White and Blue White Connect the battery positive terminal CD and starter relay coupler Red White using the jumper lead Ground the starter relay coupler Blue White to the frame using the jumper lead Check the starter motor operation OK FAULTY FAULTY Battery is faulty Recharge...

Page 373: ...elay CD coupler Yellow Black Red White Red White and Blue White from the wire harness Connect the Pocket Tester YU 03112 and battery 12V to the relay coup ler Yellow Black Red White Red White and Blue White Check the relay for continuity 0 Continuity Good Condition o x o o Bad Condition x x x o X Discontinuity OQ on 3 OK FAULTY Starting circuit cut off relay is faulty Replace it 7 8 www midwestman...

Page 374: ... Black and Sky blue from the wire harness Connect the Pocket Tester YU 03112 and battery 12V to the relay coup ler Green Yellow Brown White Black and Sky blue Check the relay for continuity Good Condition Bad Condition Battery Connected o o x X Battery Disconnected 0 Continuity 7 9 x o x o X Discontinuity 00 on FAULTY Neutral relay is faulty Replace it www midwestmanuals com ...

Page 375: ... the reverse switch eConnect the positive lead of the Pocket Tester YU 03112 to the reverse switch lead eGround the negative lead of the Tester to the engine eMove the select lever toward FOR WARD or REVERSE and check the switch for continuity Select Lever Good Bad Position Condition Condition Reverse X 0 X X Forward 0 0 X 0 0 Continuity X Discontinuity GOOD CONDITION BAD CONDITION 7 10 www midwes...

Page 376: ... to the engine Shift the gear and check the switch for continuity Transmission Good Bad Position Condition Condition In neutral 0 0 X X In gear X 0 X 0 0 Continuity X Discontinuity 7 ENGINE STOP rear brake and main switches conduct test Check the IIENGINE STOP rear brake and main switches for continuity Refer to SIGNAL SYSTEM section OK 8 Check entire electrical starting system for connections Ref...

Page 377: ... Pull in the rear brake lever the brake switch is on NOTE __________________________ The starter motor can be operated irrespective of the engine stop switch OFF or IIRUN however the engine can be started if the engine stop switch is at IIRUN The starting circuit cut off relay prevents the starter from operating when the transmission is in gear or select lever is in reverse and rear brake lever is...

Page 378: ...CTRICAL STARTING SYSTEM STARTER MOTOR TEST CDO ring Brush set Armature Stator ARMATURE COIL A 0 011 0 013 2 BRUSH WEAR LIMIT B 8 5 mm 0 33 in COMMUTATOR WEAR LIMIT C 27 mm 1 0S in MICA UNDERCUT D O S mm 0 024 in 10 Nm 1 0 m kg 7 2 ft lb 7 13 www midwestmanuals com ...

Page 379: ...r motor Commutateur Wear Limit 27 mm 1 06 in 3 Measure Mica undercut Out of specification Scrape the mica to proper value use a hacksaw blade can be ground to fit Mica Undercut b 0 6 mm 0 024 in NOTE __________________________ The mica insulation of the commutator must be undercut to ensure proper operation of commutator 4 Inspect Armature coil insulation continuity Defects s Replace starter motor...

Page 380: ...arter motor 5 Measure e Brush length Out of specification Replace Brush length limit 8 5 mm 0 33 in 6 Measure e Brush spring pressure Fatigue Out of specification Replace as a set Brush Spring Pressure 650 950 g 22 9 33 4 oz 7 Inspect eBearing CD eOil seal eO rings Wear Damage Replace Installation 1 Install Starter motor NOTE ___________________________ Align the match marks CD on the bracket with...

Page 381: ...sales midwestmanuals com www midwestmanuals com IELECIIii ICHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 7 17 www midwestmanuals com ...

Page 382: ..._______C_H_A_R_G_IN_G_S_YS_T_E_M_IELECIIiiI Aforementioned circuit diagram shows charging circuit in circuit diagram NOTE _____________ For the encircled numbers and color codes see page 7 2 Fuse Rectifier with regulator CDI magneto j Battery www midwestmanuals com ...

Page 383: ...ttery condition Refer to CHAPTER 2 BATTERY INSPEC TION section OK 3 Charging voltage test Connect the Pocket Tester YU 03112 to the battery Start the engine and accelerate to about 5 000 r min Measure the charging voltage Ih 11 Charging Voltage oG l 14 15V at 5 000 r min CDPositive lead Pocket Tester Positive terminal Battery Negative lead Pocket Tester Negative terminal Battery FAULTY Fuse is fau...

Page 384: ...nect the Pocket Tester YU 03112 to the CD I matneto coupler Measure the charging coil resistance OUTOF SPECI FICATI ON Charging Coil Resistance White CD White 1 White CD White 1 III 1 Charging coil is faulty Replace stator assembly 0 70 0 86n at 20 C 68 F 5 Check entire charging system for con nections 1 __lIIb 1 Correct Refer to WI RI NG DIAGRAM section OK Rectifier Regulator is faulty Replace it...

Page 385: ...sales midwestmanuals com www midwestmanuals com IELECIIii IIGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM L O I 7 21 www midwestmanuals com ...

Page 386: ...rcuit diagram shows ignition circuit in circuit diagram IGNITION SYSTEM ELECIIii NOTE __________________________ For the encircled numbers and color codes see page 7 2 Main switch CDI magneto ENGINE STOP switch CDI unit Ignition coil Spark plug www midwestmanuals com ...

Page 387: ...1 Spark plug inspection Check the spark plug condition Refer to CHAPTER 2 SPARK PLUG IN SPECTI ON section OK 2 Ignition spark test With spark plug 7 23 Install the spark plug to the plug cap Ground the spark plug to the cylinder head Turn the main switch to ON and ENGINE STOP switch to IIRUN then shift the gear in neutral and set the panking brake Push the START switch Check the ignition spark con...

Page 388: ...efer to SIGNAL SYSTEM section OK 5 Ignition coil resistance test Disconnect the ignition coil lead Orange CD and spark plug lead Connect the Pocket Tester YU 03112 as shown Measure the primary and secondary coil resistances 1 1 11 Primary Coil Resistance IAl 00 0 72 0 g8n at 20 C 68 F Secondary Coil Resistance ID 5 02 6 79 kn at 20 C 68 F Spark plug and or plug cap is faulty Replace faulty part s ...

Page 389: ...d OUTOF SPECIFICATION 270 330n at 20 C 68 0 F Source coil is faulty JI p Rep ced ora embly OK 7 Pickup coil resistance test 7 25 Disconnect the pickup coil coupler Yellow CD Green Gray and Blue from the COl unit Connect the Pocket Tester YU 03112 to the pickup coiI coupler Measure the pickup coil resistance Pickup Coil Resistance Yellow CD Green Gray Blue 180 2200 at 20 C 68 F OUTOF SPECIFICATION ...

Page 390: ... www midwestmanuals com IGNITION SYSTEM IELECIIii I POOR CONNECTION 8 a heck entire ignition system for con r nections I _ I Correct Refer to WIRING DIAGRAM section OK ICOl unit is faulty Replace it 7 26 www midwestmanuals com ...

Page 391: ...sales midwestmanuals com www midwestmanuals com IELECIIiiILIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM Y G Y G B B 7 27 www midwestmanuals com ...

Page 392: ...am shows lighting circuit in circuit diagram LIGHTING SYSTEM IELECI iii I NOTE ___________________________ For the encircled numbers and color codes see page 7 2 Main switch Fuse j Battery LIGHTS Dimmer switch Taillight Headlight Left Headlight Right 7 28 www midwestmanuals com ...

Page 393: ... NOT EXIST ON CIRCUIT Connect the Pocket Tester YU 03112 _ to the bulb terminals as shown and 1 ___ lIIIIb Bulb is faulty check the bulb for continuity Replace it 2 Headlight bulb socket conduct check Install the bulb to the headlight socket Connect the Pocket Tester YU 03112 to the headlight coupler Black CD CONTINUITY DOES NOT EXIST ON CIRCUIT YeIlOW andGreen andcheckitl _____b Bulbsocket is fau...

Page 394: ...nd accelerate to about Ir Lighting system Headlight is good S ODO r min Measure the lighting voltage Lighting Voltage 14 15V at 5 000 r min 6 LIGHTS Dimmer switch conduct check FAULTY Check the LIGHTS Dimmer switch for continuity Refer to SIGNAL SYSTEM section LIGHTS Dimmer switch is faulty Replace faulty part s OK 7 Main switch conduct check FAULTY Check the main switch for continuity Main switch...

Page 395: ...ct check Install the bulb to taillight socket Disconnect the taillight coupler Blue CD and Black Connect the Pocket Tester YU 03112 to the taillight coupler as shown and check it for continuity NO CONTINUITY _b Bulb is faulty Replace it CONTINUITY DOES NOT EXIST ON CI RCUIT _b Bulb socket is faulty Replace it n CONTINUITY EXISTS ON BOTH CIRCUIT 3 Fuse inspection Check the fuse condition Refer to I...

Page 396: ...000 r min Measure the lighting voltage FAULTY Battery is fau Ity Recharge or replace battery LIGHTING VOLTAGE MEETS SPECIFICATION r Lightingsystem 11 2 11 Lighting Voltage _ Taillight is good e0 14 15V at 5 000 r min 6 Main switch conduct check Check the main switch for continuity Refer to SIGNAL SYSTEM section OK Main switch is faulty Replace it POOR CONNECTION 7 Check entire lighting system for ...

Page 397: ...sales midwestmanuals com www midwestmanuals com IELECIIii ISIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 7 33 www midwestmanuals com ...

Page 398: ...CIIii I NOTE ___________________________ For the encircled numbers and color codes see page 7 2 Main switch Fuse f Battery NEUTRAL indicator light REVERSE indicator light Reverse relay 01 L TEMP indicator light Oil temperature indicator checker Thermo relay Thermo switch Reverse switch Neutral relay Neutral switch www midwestmanuals com ...

Page 399: ...HTING SYSTEM section OK 2 NEUTRAL indicator light bulb socket conduct check FAU LTY Check the NEUTRAL indicator light U llllt bulb socket condition Refer to ilLIG HT TING SYSTEM section OK 3 Fuse inspection Check the fuse condition Refer to CHAPTER 2 FUSE INSPEC TION section OK 4 Battery inspection FAULTY FAULTY NEUTRAL indicator light bulb is faulty Replace it N EUTRAL indicator light bulb socket...

Page 400: ...uity Refer to ELECTRICAL STARTING SYSTEM section GOOD CONDITION 7 Neutral relay test Disconnect the neutral relay coupler Brown Green Yellow White Black and Sky blue Connect the neutral relay coupler White Black CD and Sky blue Wire harness side using the jumper lead Shift the gear in neutral LIGHTS Turn the main switch to liON and 1 I1 check the NEUTRAL indicator light condition FAULTY Neutral sw...

Page 401: ...SE indicator faulty Replace it FAULTY light bulb is Check the REVERSE indicator light I llltt REVERSE indicator light bulb bulb socket condition Refer to ilLIG HT socket is faulty Replace it ING SYSTEM section OK 3 Fuse inspection Check the fuse condition Refer to CHAPTER 2 FUSE INSPEC TION section OK 4 Battery inspection 7 37 Check the battery condition Refer to CHAPTE R 2 BATTE RY INSPEC TION se...

Page 402: ... switch for continuity Refer to ELECTRICAL STARTING SYSTEM section n GOOD V CONDITION CONDITION 7 Reverse relay test FAU LTY Disconnect the reverse relay CD coupler Green Yellow Brown Green Blue and 1 Black from the wire harness Connect the Pocket Tester YU 03112 and battery 12V to the relay coup ler Green Yellow Brown I Green Blue and Black Check the relay for continuity Good Bad Q o 0 Condition ...

Page 403: ...anuals com www midwestmanuals com IELECIIii ISIGNAL SYSTEM 00 on OK 8 Check entire signal system for connection Refer go WIRING DIAGRAM section 7 39 FAULTY tl c_o_r_re_c_t ____________________ www midwestmanuals com ...

Page 404: ...HTING SYSTEM section OK 2 110 IL Tl MP indicator light bulb socket conduct check Check the 01 l TEMP indicator light bulb socket condition Refer to ilLIGHT ING SYSTEM section OK 3 Fuse inspection Check the fuse condition Refer to CHAPTER 2 FUSE INSPEC TION section OK 4 Battery inspection Check the battery condition Refer to CHAPTER 2 BATTERY INSPEC TION section OK FAULTY FAULTY IIOIL TEMI indicato...

Page 405: ...r Disconnect the checker leads Black and Brown from the wire harness Connect the Pocket Tester YU 03112 and battery 12V CD to the checker leads Black and Brown Check the checker for continuity Just After Battery Connected Zeron Several Seconds After Battery Connected 0 NOTE _________________________ The time required for the checker resistance to rise is affected by anbient temperature varying fro...

Page 406: ...ELECIIiiiI FAULTY ler Green Red Brown White 1 _ Blue and Black Thermo switch is fau Ity Replace it Check the relay for continuity Good Bad Condition Condition Battery X X 0 0 Connected Battery 0 X 0 X Disconnected 0 Continuity X Discontinuity 00 On OK 8 Check entire 01 L TEMP indication sys tem for connection Refer to WI RING DIAGRAM section OK Thermo relay is faulty Replace it FAULTY I _ I_c_o_r_...

Page 407: ... ENGINE STOP switch CID LIGHTS Dimmer switch START switch Main Switch Switch Position B R OFF ON 0 Rear Brake Switch Switch Position B FREE PUSH ENGINE STOP Switch Switch Position B W RUN OFF Lead Color B R Lead Color G Y 0 Lead Color Br LIGHTS Dimmer Switch Lead Color Switch Position Br L G OFF LO HI liSTART Switch Lead Color Switch Position Br R W OFF ON Br 0 Y www midwestmanuals com ...

Page 408: ...sales midwestmanuals com www midwestmanuals com IELECIIii IACCESSORY SYSTEM ACCESSORY SYSTEM CIRCUIT DIAGRAM 7 45 www midwestmanuals com ...

Page 409: ... show accessory circuit in circuit diagram ACCESSORY SYSTEM IELECI iii I NOTE ___________________________ For the encircled numbers and color codes see page 7 2 CD Auxiliary DC terminal Circuit breaker Main switch Rectifier with regulator CD I magneto 7 46 www midwestmanuals com ...

Page 410: ...ERY INSPEC TION section J OK 3 Main switch conduct test Check the switch for continuity Refer to SIGNAL SYSTEM section OK 4 Output voltage test Connect the Pocket Tester YU 03112 to the auxiliary DC terminal leads Black Red CD and Black Start the engine and accelerate to about 5 000 r min Measure the out put voltage 11 11 Out Put Voltage 14 15V at 5 000 r min Positive lead Pocket Tester Negative l...

Page 411: ...oil resistance Charging coil is faulty Refer to CHARGING SYSTEM sec Replace stator assembly tion nRESISTANCE MEETS SPECI FICATIONS POOR 6 Check entire accessory system for connec cONNECT IO_N____________ t i_c_or_r_ec_t_ ____________________ tions Refer to WI RING DIAGRAM section OK Rectifier Regulator is faulty Replace it 7 48 www midwestmanuals com ...

Page 412: ...CHAPTER 8 APPENDICES SPECIFICATIONS 8 1 GENERAL SPECIFICATIONS 8 1 MAINTENANCE SPECIFICATIONS 8 3 GENERAL TORQUE SPECIFICATIONS 8 15 DEFINITION OF UNITS 8 15 LUBRICATION DIAGRAM 8 16 CABLE ROUTING 8 19 YFM350FWT WIRING DIAGRAM www midwestmanuals com ...

Page 413: ...20W50 SAE 5W30 type SE motor oil I I 20 10 0 10 20 30 C Final Gear Oil and Differential Gear Oil Oil Capacity Engine Oil Periodic Oil Change Total Amount Transfer Gear Case Rear Final Gear Case Total Amount Differential Gear Case Total Amount Air Filter 8 1 YFM350FWT 2HR JY42HROO HCOO0101 2HR 000101 1 885 mm 74 2 in 1 095 mm 43 1 in 1 110 mm 43 7 in 830 mm 32 7 in 1 210 mm 47 6 in 180 mm 7 1 in 26...

Page 414: ...d l speed reverse Operation Left foot operation Left hand operation Gear Ratio High range Low range 1st 38 13 x 23 24 x 24 23 2 923 38 13 x 27 20 x 24 23 4 116 2nd 34 18 x 23 24 x 24 23 1 889 34 18 x 27 20 x 24 23 2 670 3rd 30 22 x 23 24 x 24 23 1 364 30 22 x 27 20 x 24 23 1 921 4th 26 25 x 23 24 x 24 23 1 040 26 25 x 27 20 x 24 23 1 464 5th 24 29 x 23 24 x 24 23 0 828 24 29 x 27 20 x 24 23 1 166 ...

Page 415: ... mm 4 33 in Electrical Ignition System COl Generator System A C magneto generator Battery Type Capacity GM 14AZ 4A 12V 14AH Headlight Type Bulb Bulb Wattage x Quantity Headlight 12V 25W 25Wx 2 Taillight 12V 7 5W x 1 Indicator Light Wattage x Quantity NEUTRAL 12V 3 4W x 1 IIREVERSE 12V 3AW x 1 01 L TEMP 12V 3AW x 1 MAINTENANCE SPECIFICATIONS Engine Model YFM350FWT Cylinder Head Warp Limit 0 03 mm 0...

Page 416: ...585 in 32 14 32 24 mm 1 265 1 269 in 32 11 mm 1 264 in 8 28 8 40 mm 0 326 0 331 in 8 26 mm 0 325 in 40 28 40 38 mm 1 586 1 590 in 40 25 mm 1 585 in 32 14 32 24 mm 1 265 1 269 in 32 11 mm 1 264 in 8 28 8 40 mm 0 326 0 331 in 8 26 mm 0 325 in 0 03 mm 0 0012 in BF05M 90 Links Automatic 12 000 12 018 mm 0 4724 0 4731 in 12 078 mm 0 4755 in 11 981 11 991 mm 0 4717 0 4721 in 11 951 mm 0 4705 in 0 009 0 ...

Page 417: ...inding Top view 8 5 YFM350FWT 7 000 7 012 mm 0 2756 J 0 2761 in 7 03 mm 0 277 in 7 000 J 7 012 mm 0 2756 0 2761 in 7 03 mm 0 277 in 0 010 0 037 mm 0 0004 0 0015 in 0 08 mm 0 0031 in 0 030 0 057 mm 0 0012 0 0022 in 0 1 mm 0 0039 in 0 02 mm 0 0008 in 1 0 1 2 mm 0 039 0 047 in 1 6 mm 0 063 in 39 9 mm 1 57 in 37 9 mm 1 49 in 39 9 mm 1 57 in 37 9 mm 1 49 in 43 27 mm 1 70 in 41 27 mm 1 62 in 43 27 mm 1 ...

Page 418: ...ECI FICAliONS IAPPX YFM350FWT 82 92 82 97 mm 3 265 3 267 in 5 5 mm 0 22 in From bottom line of piston skirt 83 50 mm 3 287 in 84 00 mm 3 307 in 0 04 0 06 mm 0 0016 0 0024 in Barrel B 1 2 mm 0 05 in T 3 3 mm 0 13 in Taper B 1 5 mm 0 06 in T 3 4 mm 0 13 in Expander B 2 8 mm 0 11 in T 2 5 mm 0 10 in 0 2 0 4 mm 0 008 0 016 in 0 2 0 4 mm 0 008 0 016 in 0 3 0 9 mm 0 012 0 035 in 0 5 mm 0 020 in 0 5 mm 0...

Page 419: ...r Cam drum Decompression Device Type Manual Air Filter Oil Grade Oiled Filter Foam air filter oil or SAE 10W30 type SE motor oil Carbu retor Type Manufacturer Quantity BTM32SH MIKUNI 1 I D Mark 2HR 00 Main Jet M J 122 5 Main Air Jet M A J b0 8 Jet Needle clip Position J N 5H26 3 Needle Jet N J N 8 Pilot Air Jet P A J 1 1 0 P A J 2 0 9 Pilot Jet P J 45 Pilot Outlet P O b0 75 Pilot Screw P S 2 3 4 V...

Page 420: ...Model Rear Final Gear Gear Lash Ring Gear Stopper Clearance Differential Gear Gear Lash Lubrication Diagram r Pressure feed Splashed scavenge Oil Pan YFM350FWT 0 1 0 2 mm 0 004 0 008 in 0 30 0 60 mm 0 012 0 024 in 0 10 0 35 mm 0 004 0 014 in Oil Strainer Cam Shaft Cam Chain Area 8 8 www midwestmanuals com ...

Page 421: ...M6 2 12 1 2 8 7 Exhaust Pipe Protector Screw M6 4 B 0 8 5 B Crankcase Bolt M6 16 10 1 0 7 2 Crankcase Cover Left Bolt M6 12 10 1 0 7 2 Clutch Spring Bolt M6 5 B 0 8 5 B Clutch Boss Nut M16 1 BO B O 58 Use lock washer Primary Drive Gear Nut M16 1 78 7 8 56 Use lock washer Drive Sprocket Nut M20 2 75 7 5 54 Change Pedal Bolt M6 1 10 1 0 7 2 Cam Chain Tensioner End Plug Plug M12 1 25 2 5 lB Tensioner...

Page 422: ...1 Oil Cooler Hose Oil Hose Nut 2 35 3 5 25 Hose Clamp Screw M6 2 7 0 7 5 1 Crankcase Nut 2 35 3 5 25 Transfer Gear Case Bolt M6 9 10 1 0 7 2 Drain Plug Transfer Gear Case Plug MB 1 20 2 0 14 Filler Plug Transfer Gear Case Plug M14 1 23 2 3 17 Differential Gear Case and Frame Front Bolt M10 4 45 4 5 32 Rear Bolt MB 4 23 2 3 17 Drain Plug Plug M14 2 23 2 3 17 Differential Gear Case Plug MB 1 16 1 6 ...

Page 423: ... 2 17 3 66 in Swingarm Free Play Limit Side 1 0 mm 0 04 in Wheel Front Wheel Type Disc Wheel Rear Wheel Type Disc Wheel Front Rim Size Material 12 x 6 5AT Steel Rear Rim Size Material 12 x 8 0AT Steel Rin Runout Limit Vertical 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in Front Drum Brake Type Two leading Drum Inside Diameter 160 mm 6 30 in Limit 161 mm 6 34 in Lining Thickness 4 mm 0 16 in Limit 1 mm 0 0...

Page 424: ... 2 23 2 3 17 Front Carrier and Frame Bolt M8 x 1 25 2 20 2 0 14 Front Carrier and Front Bumper Bolt M6 x 1 0 2 10 1 0 7 2 Rear Bumper Bolt M8 x 1 25 4 33 3 3 24 Rear Carrier and Rear Bumper Bolt M6 x 1 0 2 9 0 9 6 5 Rear Carrier Bolt M8 x 1 25 2 33 3 3 24 Rear Axle and Nut Nut M16 x 1 5 2 150 15 0 110 Rear Axle and Ring Nut Ring nut M40 x 1 5 2 See NOTE Rear Disc Wheel and Wheel Collar Nut Ml0 x 1...

Page 425: ...SUBISH I Ignition Coil ModellManufacturer Minimum Spark Gap Primary Winding Resistance Secondary Winding Resistance Charging System Type A C Magneto Generator Charging Current Charging Coil Resistance Color Voltage Regulator Type Model Manufacture No Load Regulated Voltage 8 13 F6T50971 MITSUBISHI 6 mm 0 24 in 0 72 0 98n at 20 C 68 F 5 02 6 79 kn at 20 C 68 F A C magneto generator 9A or more at 1 ...

Page 426: ... Relay ModeliManufacturer Coil Winding Resistance Diode Thermo Relay ModeliManufacturer Coil Winding Resistance Diode Oil Temperature Switch Model Manufacturer Circuit Breaker Type MAIN D C TERMINAL Amperage for Individual Circuit Quantity Main MAIN Reserve MAl N Circuit Breaker YFM350FWT SH235 SHINDENGEN lSA 200V 12V 14AH 1 280 Constant mesh type DBSDV N IPPONDE NSO 0 7 kW 0 011 0 013n at 20 C 68...

Page 427: ...call for clean dry threads Components should be at room temperature IA L A Distance across flats B Outside thread diameter DEFINITION OF UNITS Unit Read mm millimeter cm centimeter kg kilogram N Newton Nm Newton meter m kg Meter ki logram Pa Pascal N mn Newton per millimeter L Liter cm3 Cubic centimeter r min Rotation per minute 8 15 A B Nut Bolt 10mm 6mm 12mm 8mm 14mm 10mm 17mm 12mm 19mm 14mm 22m...

Page 428: ...ww midwestmanuals com LUBRICATION DIAGRAMS CDCamshaft Oil cleaner Main axle Orive axle Crankshaft Oil filter VOilpump Idle axle Middle drive axle Oil cooler LUBRICATION DIAGRAMS IAPPXI I Thermo switch 8 16 www midwestmanuals com ...

Page 429: ...als com www midwestmanuals com IAPpxl I LUBRICATION DIAGRAMS i Camshaft VOil cleaner Main axle Orive axle Crankshaft 8 17 Oil filter VOil pump Idle axle Middle drive axle Oilcooler j Thermo switch www midwestmanuals com ...

Page 430: ...edometer cable Front brake switch lead Handlebar switch lead Indicator lights lead Brake pipe Pass the cable under the handlebar throttle 00 cable under the brake hose Insert the breather hose into the hole of the handlebar protector Pass the speedometer cable rear brake cable and throttle cable in order from the inside QJ Pass the throttle cable under the brake hose l5 liR l8 u aD 8 18 www midwes...

Page 431: ...1 f Ground lead Differential gear case Positive lead breather hose Final gear case breather hose j Handlebar protector Battery breather hose 8 19 8 Clamp the starter motor cable and battery breather hose Pass the final gear case breather hose the clamp Pass the hoses into the holes Left side Carburetor breather hose Differential gear case breather hose Right side Carburetor breather hose Q Pass th...

Page 432: ...Thermo relay Main switch Band Ignition coil Speedometer cable j Front brake switch lead Handlebar switch lead COl unit Auxiliary D C terminal f D Headlight CABLE ROUTING IAPPXI I A Do not pinch the hoses when install the fuel tank 8 20 www midwestmanuals com ...

Page 433: ... regulator Starting circuit cut off relay Neutral relay Reverse relay Oil temperature indicator light checker Band j Carburetor breather hose j 8 21 Circuit breaker Fuse Select lever control cable 2 8 Clamp the taillight lead Pass the taillight lead into the slit www midwestmanuals com ...

Page 434: ...ear brake cable Handlebar Select lever control cable 2 Select lever control cable 1 Reverse lock release wire CD CABLE ROUTING Pass the speedometer cable copper the wire harness at back of the ignition coil ijJ Pass the rear brake cable right side of the starter motor CJ Pass the rear brake cable upper the fender stay 8 22 www midwestmanuals com ...

Page 435: ... B 11 I 1 I L DD C JQ Y Oil TEMP indicatorl ght NEUTflAl indicator light REVERSE indicator light r n iI O S U W 1 fCJ JJ W L I I l I a Sb III l G L I I r R_l rok _ d Aux iary D C uorminal G jR t CJr Lj J B c Jc Jr B fiJ R R CDI Reverse twit COLOR CODE B Black Y Yellow L Blue R Red G Green P Pink O Orange Br Brown Gy Gray Sb Sky blue W White B R Black Red B W Black White Y B Yellow Black LIW Blue W...

Page 436: ...sales midwestmanuals com www midwestmanuals com YAMAHA 38 atv sales midwe nuals com LlT 11616 12 10 www midwestmanuals coml 4WU 28197 22 www midwestmanuals com ...

Page 437: ...l its models Modifications 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 A WARNING NOTE...

Page 438: ...edures are marked with bullets e Important information such as fluids special tools and torques are framed and marked with a corresponding symbol A circled number refers to an illustrated part j A circled lower case letter refers to an illustrated dimension or alignment mark An upper case letter in a box refers to other illustrated details An arrow mark after a given defect suggests the recommende...

Page 439: ...ooting Illustrated symbols to are used to identify the specifications appearing in the text Filling fluid Lubricant Special tool Torque Wear limit clearance Engine speed Q V A Illustrated symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium soap...

Page 440: ...S AND ADJUSTMENTS 10 CHASSIS 10 FRONT BRAKE PAD INSPECTION 10 AIR BLEEDING HYDRAULIC BRAKE SYSTEM 10 FRONT SHOCK ABSORBER ADJUSTMENT 11 REAR SHOCK ABSORBER ADJUSTMENT 12 CHASSIS 13 FRONT WHEEL 13 REMOVAL 14 FRONT BRAKE 15 BRAKE PAD REPLACEMENT 16 CALIPER DISASSEMBLY 18 MASTER CYLINDER DISASSEMBLY 19 INSPECTION AND REPAIR 20 CALIPER ASSEMBLY 23 MASTER CYLINDER ASSEMBLY 26 www midwestmanuals com ...

Page 441: ... weight With oil and full fuel tank 257 kg 567 Ib Chassis Frame type Steel tube frame Caster angle 4 Trail 21 mm 0 83 in Tread STD rear 820 mm 32 28 in Tread STD front 849 mm 33 43 in Toe in 5 15 mm 0 20 0 59 in Brake Front brake type Single disc brake operation Right hand operation Rear brake type Drum brake operation Left hand and right foot operation 1 www midwestmanuals com ...

Page 442: ...lutch release method Inner push cam push CHASSIS Model YFM350FWBL C Steering system Steering bearing type Ball and race bearing Front suspension Shock absorber travel 93 5 mm 36 8 in Fork spring free length 302 5 mm 11 91 in Spring rate K1 14 2 N mm 1 42 kg mm 81 08 Ib in Stroke K1 o 93 5 mm 0 3 68 in Optional spring No Rear suspension Shock absorber travel 99 mm 3 9 in Spring free length 250 mm 9...

Page 443: ...0 20 in Brake lever free play left 5 8 mm 0 20 0 31 in Brake pedal position 5 mm 0 20 in Brake pedal free play 20 30 mm 0 8 1 2 in Throttle lever free play 3 5 mm 0 12 0 20 in Tightening torques Part to be tightened Thread size Tightening torque Remarks Nm m kg ft lb Front wheel and wheel hub M10 64 6 4 46 Front axle and wheel hub M16 150 15 110 Front brake caliper and steering knuckle M8 30 3 0 2...

Page 444: ...ance Brush overall length Limit Spring force Commutator diameter Wear limit Mica undercut Starter relay Model manufacturer Amperage rating Coil winding resistance Thermostat switch Model manufacturer YFM350FWBL C F4T423 MITSUBISHI 459 561 nat 20 C 68 F White Green White Red 270 330 nat 20 C 68 F Brown Green F8T32372 MITSUBISHI 2JN YAMAHA 6 mm 0 24 in 0 18 0 28 nat 20 C 68 F 6 32 9 48 nat 20 C 68 F...

Page 445: ...brake switch Rear brake cable Accessory terminal Front brake hose Throttle cable Reverse control cable J Main switch lead Engine stop switch lead Handlebar switch lead CABLE ROUTING ISPECI 0 1 Brake pipe Breather hose differential gear case A B B 5 www midwestmanuals com ...

Page 446: ...he reverse control knob and main switch then con nect the leads on the inside of the handlebar cover 1m Insert the breather hose fuel tank into the hole in the handlebar cover 19 To the indicator light lead Q To the accessory terminal 6 CABLE ROUTING ISPECI U I A 8 8 www midwestmanuals com ...

Page 447: ... Fuel hose Rectifier regulator Starter circuit cut off relay J COl unit Starter relay Battery lead Breather hose final gear case Breather hose battery A B B CABLE ROUTING ISPECI U J Carburetor overflow hose COl magneto lead Starter motor lead Breather hose rear brake Carburetor air vent hose 16 D 7 www midwestmanuals com ...

Page 448: ...motor lead behind the COl unit bracket then connect it at a 90 angle to the starter relay Q Pass the ground lead between the battery bracket and the plastic tail box 16 A 8 8 CABLE ROUTING ISPECr I Fasten the ground lead with a left crankcase cover bolt fJ When installing the plastic band do not crush the breather hoses Pass the breather hose rear brake through the metal guide lBl Pass the breathe...

Page 449: ...ms should be positioned from right to left as listed 9 CABLE ROUTING ISPECI U I ill Fasten the rear brake breather hose and final gear case breather hose with a plastic band Fasten the rear brake breather hose final gear case breather hose and carburetor air vent hose with a plastic band f Pass the carburetor air vent hose rear brake breather hose and final gear case breather hose through the hole...

Page 450: ...ke system if The system has been disassembled A brake hose or brake pipe have been loosened or removed The brake fluid has been very low The brake operation has been faulty A loss of braking performance may occur if the brake system is not properly bled 1 Bleed Brake system Air bleeding steps a Add the proper brake fluid to the reser voir b Install the diaphragm Be careful not to spill any fluid o...

Page 451: ... is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the system have disap peared k Add brake fluid to the proper level Refer to BRAKE FLUID LEVEL INSPEC TION A WARNING Check the operation of the brake after bleeding the brake system FRONT SHOCK ABSORBER ADJUSTMENT A WARNING Always adjust both front shock absorber sp...

Page 452: ...ENT 1 Adjust Spring preload Turn the adjuster to increase or decrease the spring preload NOTE _______________________ The spring preload of the rear shock absorber can be adjusted to suit rider s preference weight and the course condi tions Standard position B Softest position A Stiffest position E www midwestmanuals com ...

Page 453: ...locity joint TIRE AIR PRESSURE Cold Tire Pressure Front Rear 13 25 kPa Standard 0 25 kg cm2 25 kPa 0 25 kg cm2 3 6 psi 3 6 psi 22 kPa Minimum 0 22 kg cm2 22 kPa 0 22 kg cm2 3 2 psi 3 2 psi 28 kPa Maximum 0 28 kg cm2 28 kPa 0 28 kg cm2 4 0 psi 4 0 psi A TIRE SIZE AT25 x 8 12 8 TIRE WEAR LIMIT 3 mm 0 12 in C RIM SIZE 12xS OAT RIM RUNOUT LIMIT 0 Radial 2 mm 0 08 in Lateral 2 mm 0 08 in 150 Nm 15 0 m ...

Page 454: ...e stand under the frame 2 Remove Nuts front wheel Front wheel 3 Remove Wheel cap Cotter pin CD Nut wheel hub Washer 4 Remove Front brake caliper CD NOTE Do not depress the brake lever when the wheel is off the machine otherwise the brake pads will be forced shut 5 Remove Front wheel hub CD with brake disc 6 Remove Front brake disc CD www midwestmanuals com ...

Page 455: ...sc A BRAKE FLUID TYPE DOT 4 B BRAKE PAD WEAR LIMIT 1 0 mm 0 04 in C BRAKE DISC WEAR LIMIT 3 0 mm 0 12 in 27 Nm 2 7 m kg 19 ft Ib Bleed screw Retaining bolt Brake caliper Padshim Brake pad Piston Piston seal Brake disc guard 27 Nm 2 7 m kg 19 ft Ib 30 Nm 3 0 m kg 22 ft Ib 6 Nm 0 6 m kg 4 3 ft Ib 18Nm 1 8m k 13ft lb 15 FRONT BRAKE HASI6Y61 27 Nm 2 7 m kg 19 ft Ib www midwestmanuals com ...

Page 456: ...es otherwise eye injury may occur Allow brake fluid to contact painted sur faces or plastic parts otherwise damage may occur Disconnect any hydraulic connection oth erwise the entire system must be disas sembled drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE _______________________ It is not necessary to disassemble the brake caliper and brake hose to...

Page 457: ...brake pad Pad spring Brake pads Installation steps Connect a suitable hose D tightly to the caliper bleed screw Then place the other end of this hose into an open con tainer Loosen the caliper bleed screw and push the pistons into the caliper with the finger Tighten the caliper bleed screw Caliper bleed screw 6 Nm 0 6 m kg 4 3 ft Ib Install the pad shim new onto the brake pad new NOTE ______ The a...

Page 458: ...e 10 Check Brake lever operation A soft or spongy feeling Bleed brake system Refer to AIR BLEEDING CALIPER DISASSEMBLV NOTE ________________________ Before disassembling the front brake cali per drain the brake hose master cylinder brake caliper and reservoir tank of their brake fluid 1 Remove Front wheel 2 Loosen Union bolt Retaining bolts Retaining bolt caliper bracket 3 Remove Front brake calip...

Page 459: ...caliper body from the bracket disconnect the dust boot from the guide shaft on the bracket 6 Remove Piston Piston seals D Removal steps Blow compressed air into the hose joint opening to force out the caliper piston from the caliper body Remove the piston seals A WARNING Never try to pry out the piston MASTER CYLINDER DISASSEMBLY NOTE Before disassembling the front brake mas ter cylinder drain the...

Page 460: ...er cap CD Diaphragm Master cylinder 3 Remove Dust boot CD Circlip Master cylinder kit Drain the excess fluid INSPECTION AND REPAIR Recommended brake component replacement schedule Brake pads As required Piston seal Every two years Brake hoses Every two years Brake fluid Replace only when brakes are disas sembled A WARNING All internal parts should be cleaned in new brake fluid only Do not use solv...

Page 461: ...y Blowout with compressed air A WARNING Replace the piston seal whenever the cali per is disassembled 2 lnspect Master cylinder Wear scratches Replace the master cyl inder assembly Master cylinder body Cracks damage Replace Oil delivery passage master cylinder body Blowout with compressed air 3 lnspect Master cylinder kit Scratches wear damage Replace as a set 4 lnspect Diaphragm Wear damage Repla...

Page 462: ...place the pads as a set if either is found to be worn to the wear limit I Wear limit 1 0 mm 0 04 in 7 1nspect Brake disc Galling damage Replace 8 Measure Brake disc deflection Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc s Maximum deflection 0 15 mm 0 006 in Brake disc thickness Out of specification Replace Minimum thickness 3 0 mm 0 12 in C...

Page 463: ... should be cleaned in new brake fluid only Internal parts should be lubricated with brake fluid when installed Recommended brake fluid V DOT 4 Replace the piston seals whenever a cali per is disassembled 1 lnstall Piston seals CD Piston A WARNING Always use new piston seals 2 1nstall Caliper bracket CD Caliper body NOTE ________________________ Apply the lithium soap base grease onto the caliper g...

Page 464: ...ches the projection on the brake caliper A WARNING Proper hose routing is essential to insure safe machine operation Refer to CABLE ROUTING Always use new copper washers 4 Remove Brake caliper 5 1nstall Pad spring Brake pads with pad shim Retaining bolts Front brake caliper Refer to BRAKE PAD REPLACEMENT Retaining bolt caliper bracket 28 Nm 2 8 m kg 20 ft Ib Retaining bolt 18 Nm 1 8 m kg 13 ft Ib ...

Page 465: ...e 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 perfor mance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock 7 Air bleed Brake system Refer t...

Page 466: ...T 4 Replace the piston seals and dust seals whenever a master cylinder is disassem bled 1 lnstall Master cylinder kit CD Circlip Dust boot 2 lnstall Master cylinder CD llg_1I1 Install the master cylinder holder with the UP mark facing upward Engage the indentations in the collar with the lobes on the throttle lever assembly and master cylinder Tighten first the upper bolt then the lower bolt Bolt ...

Page 467: ...t and correct if necessary A WARNING Proper hose routing is essential to insure safe machine operation Refer to CABLE ROUTING Always use new copper washers 4 1nstaII Spring CD Brake lever 5 Fill Reservoir tank Recommended brake fluid DOT 4 NOTE __________________________ If DOT 4 is not available 3 can be used llall Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fl...

Page 468: ...d to poor perfor mance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock 6 Air bleed Brake system Refer to AIR BLEEDING 7 lnspect Brake fluid level Fluid level is under LOWER level line Replenish Refer to BRAKE FLUID INSPECTION LOWER level line www midwestmanuals com ...

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